Vol. III (B)
Vol. III (B)
Vol. III (B)
THIS PAGE IS A RECORD OF ALL SPECIFICATION REVISIONS. NORMALLY, REVISED SHEETS ONLY ATTACHED
EACH TIME THE SPECIFICATION IS CHANGED ONLY THE NEW OR REVISED ENTIRE SPECIFICATION RE-ISSUED
PAGES ARE ISSUED. ENTIRE SPECIFICATION REVISED
SPECIFICATION REV.
ECG ENGINEERING CONSULTANTS GROUP TABLE OF CONTENTS
KSA 000010 - 2970 1
CONTENTS
VOLUME I
(Not Included)
VOLUME II
DIVISION 0: INFORMATION
VOLUME III
TECHNICAL SPECIFICATIONS – PART A
Divisions 03 Concrete
Divisions 04 Masonry
Divisions 05 Metals
Divisions 09 Finishes
Division 10 Specialties
Division 22 Plumbing
Division 26 Electrical
Division 31 Earthwork
Division 33 Utilities
SPECIFICATION REV.
ECG ENGINEERING CONSULTANTS GROUP MEDIUM VOLTAGE CABLES
KSA 260513 - 2970 1
SECTION 260513
Page
PART 1 GENERAL 2
1.1 Related Documents 2
1.2 Summary 2
1.3 Submittals 2
1.4 Quality Assurance 3
1.5 Design Criteria 4
1.6 Shipment 5
1.7 Delivery, Storage And Handling 5
PART 2 PRODUCTS 5
2.1 Manufacturers 5
2.2 Construction Of Cables 6
2.3 Identification Of The Cable Phases And Marking 7
2.4 Multiple-Conductor Unarmoured Cables 8
2.5 Cable Supports And Fittings 8
2.6 Splice Kits 8
2.7 Solid Terminations 8
2.8 Cable Cleats 8
PART 3 EXECUTION 9
3.1 Installation 9
3.2 Inspection And Testing 12
3.3 Guarantee Tables 12
3.4 Field Testing 15
PART 1 GENERAL
1.2 SUMMARY
A This section covers the furnishing medium voltage cables, including armored and
unarmored multiple conductor power cables.
1.3 SUBMITTALS
A Submit the following in accordance with the requirements set forth at the Conditions
of Contract.
B Tendering Submittals: Contractor to fill-in the ECG compliance data sheet (when
attached to a section) and stamp it by the proposed supplier and by the proposed
electrical sub-contractor (or himself if no sub-contractor).
C If the Contractor is assuming two suppliers for one material item in his bid, two data
sheets should then be filled and stamped, as mentioned, for the same item.
1. Multi-core Cu/XLPE/PVC
E Each sample shall show full data embossed on the sheath and shall be prepared for
easy investigation and measuring purposes.
1. Conductor Resistance
2. Thickness of Armour
3. Ionization
4. High-Voltage
5. Flammability
6. Mechanical Integrity
7. Bending Test
8. High-Voltage Time Test
9. Dielectric Power Loss
10. Power-Factor Tests
11. Qualifications of Cable Splices
12. Dielectric Pothead Tests
A. Reference Standards
1. Governing Standards:
B. Installer’s Qualifications: The Contractor shall submit data showing that he has
successfully installed systems of the same type and design as specified herein, or
that the Contractor has a firm contractual agreement with a subcontractor having
not less than five years’ experience in the design and installation of such systems.
Data shall include names and location of at least two installations of such systems,
he or his referenced sub-contractors has installed. The references shall indicate type
and design of each system and certification that each system has been performed
satisfactorily in the manner intended for not less than three years.
A The Contractor manufacturers get approval from Authority Having Jurisdictions (SEC)
so as to finalize the respective 8.7/15 KV XLPE-Insulated medium voltage Cable
System.
B In designing the cable system for the specified cable route the following factors shall
be taken into account:
1.6 SHIPMENT
A Cable shall be shipped on reels such that the cable will be protected from mechanical
injury. Each end of each length of cable shall be hermetically sealed and securely
attached to the reel.
B Minimum reel drum diameter shall be 14 times the overall diameter of the cable. A
pulling eye shall be installed by the manufacturer for each length of cable supplied
for installation in ducts, manholes, and utility trenches.
A Delivery: All cables shall be delivered to site with seals intact and bearing the
Manufacturer's label indicating classification, size, description, length and grade. All
labels shall be retained and kept in a logbook to be available for inspection by the
Owner’s Representative.
B Storage: Cables shall be stored at normal temperatures and out of direct sunlight.
Cables not on purpose-built cable reels shall be coiled neatly, allowing for any
limitations of bend radius and protected against mechanical damage. Cable ends
shall be sealed to prevent ingress of moisture.
C Care shall be taken to ensure that all cables are adequately protected while stored
on site prior to erection. No damaged cable shall be used.
D Handling: Whenever possible, cranes shall be used with suitable spindle through the
center of the reel. In the absence of hosting equipment, temporary ramp shall be
provided to move cable reels to and from storage area. Cable reels that have been
dropped will be subject to rejection by the Owner’s Representative, because of
flatting of the cable inner layers. Drums shall be rolled in the direction of indicating
arrows.
PART 2 PRODUCTS
2.1 MANUFACTURERS
D. Medium voltage Cable 8.7/15 Cable (17.5 kV maximum between phases), XLPE -
insulated, for use on 13.8 KV system
B Conductors: The cable shall have single conductor of plain circular compacted
copper conductor Class 2, of concentric strand wires. The conductor shall be of
compacted circular shape.
1. The metallic screen shall consist of a layer of copper tape and/or layer of
annealed bare copper wires. Metallic screen shall be applied on 3 individual
screens, one on each core.
2. The screen size shall be as given below excluding copper tape.
3. Effective cross-sectional area of three individual metallic screens shall be such that
these (metallic screens) shall be suitable for withstanding the earth fault current
for 1 second duration unless otherwise agreed with the Engineer based on the
short circuit calculations.
G Copper Screen: on each core insulation screening, flat copper tapes shall be applied
helically and overlapped. The number of copper tapes and their percentage overlap,
for each core, shall be selected in such a way to obtain the effective cross-sectional
area of copper screen per phase
I Conductor of medium voltage cables shall withstand short circuit of 21 kA for cables
grade 8.7/15(17.5) kV unless otherwise indicating in the drawings.
J Filling and Inner Covering: The three cores shall be assembled together, the
interstice filled with non-hygroscopic; non–conductive material, which may be
extruded or not so, that the completed cable assembly is of substantial circular
cross-section.
K The inner covering wrapping the three cores together shall be of extruded corrosion
resistant material.
L The material is used for the filler and inner covering shall be suitable for the cable
operating temperature. The thickness of the inner covering shall be in accordance
with the attached table of dimensions.
M The material and dimensions of the steel tapes shall be in accordance with IEC 60502
standard.
N The tape armour shall be helically applied in two layers so that the outer tape is
approximately central to cover the gap of the inner tape. The gap between adjacent
turns of each tape shall not exceed 50% of the width of the tape.
O Current Carrying Capacity: The maximum continuous current carrying capacity and
maximum permissible conductor temperature shall be stated by the supplier. The
maximum continuous current carrying capacity shall be calculated in accordance
with the methods recommended in IEC publications no. 60287.
A Identification for phases shall be carried using colored plastic ribbon between the
semi-conducting layer and copper screen (RED, YELLOW, BLUE).
B The cable shall be marked throughout its length with the following items:
1. Voltage Rating
2. Size
3. Number of Conductors
4. Manufacturer’s Name
5. Cumulative Length
6. Year of Manufacture.
7. Compliance Standards
C Intervals of marking shall not exceed one meter and each mark shall serially indicate
the length of the cable remaining.
A Cable supports, related fittings, and accessories for use in corrosive underground
locations, such as manholes, shall be provided with a factory applied coating of
polyvinyl chloride of at least 0.51 millimeter thick. Polyvinyl chloride (PVC) coated
items shall have a uniform thickness and be free of blisters, breaks, and holidays.
PVC compound shall conform to IEC.
B Cable racks, cable tray supports and related fittings shall be IEC standard or heavy-
duty nonmetallic glass-reinforced nylon or polycarbonate.
A Approved connectors shall be provided for splices and terminal connections of all
copper conductors. The connector shall fit the conductor to which it shall be
connected, and the assembly shall have joint contact surfaces not less than 50%. (As
recommended in writing by the splicing kit manufacturer for specific sizes, ratings
and configuration of cable conductor and splices specified). Include all components
required for complete splice with detail instruction. Comply with IEC Code.
A Termination for medium voltage cable shall be in the switchgear or cable entrance
Compartment of transformers. Type of termination fitting shall be as required to
match conductor to equipment, built–up insulation and heat shrink stress cone as
manufactured by Raychem (or approved equal) for the type of cable specified.
A Cable Cleats shall be design and tested as per IEC 61914 and used to securing the
cables when installed at intervals along the length of the cables
B Where trays are not required metal rack with one or more pairs of cleats shall be
used to suit the formation of the cables.
D Where single core cables in trefoil or quadrature formation are not secured in cleats,
binders of approved material and construction shall be fitted around the formation
to prevent the cables separating under fault conditions. The binders shall consist of a
nonferrous strap secured around the cables by means of a bolted connection. The
spacing of binders shall be approved by the Engineer. Single core and multicore
cables shall be clamped to the racks with smooth finish split packing pieces of non-
inflammable material or cleats with bores of the correct size for the cable diameters.
PART 3 EXECUTION
3.1 INSTALLATION
B Cable shall be installed in underground duct banks; in conduit above and below
grade; inside buildings; by open wire method; on insulator hooks; on racks; in wall
and ceiling mounted cable trays and manholes; and by direct burial.
D Cables shall be secured with PVC coated, metallic or non-metallic cable clamps,
straps, hangers, or other approved supporting devices, ceilings, and in cable trays
mounted vertically, where tray bottom is in a vertical plane. When field cuts or other
damage occurs to the PVC coating, a liquid PVC patch shall be applied to maintain
the integrity of the coating. After the installation is complete, an inspection shall be
performed to ensure the absence of voids, pinholes, or cuts.
E Contractor shall ensure that all cable trays are properly secured and supported prior
to installing new armored cable. Contractor shall add new permanent and/or
temporary tray support devices as required to preclude cable tray failure during
cable pulling or after cable is installed.
I Duct Cleaning: Ducts shall be thoroughly cleaned before installation of power cables.
A standard flexible mandrel shall be pulled through each duct to loosen particles of
earth, sand, or foreign material in the line. Mandrel length shall be not less than
300-millimeter-long, and shall have a diameter 13 millimeter less than the inside
diameter of the duct. A brush with stiff bristles shall then be pulled through each
duct to remove the loosened particles. Brush diameter shall be the same as or
slightly larger than the diameter of the duct.
J Pulling Cables in Ducts and Manholes: Medium-voltage cables shall be pulled into
ducts with equipment designed for this purpose, including power-driven winch,
cable-feeding flexible tube guide, cable grips, and lubricants. A sufficient number of
trained personnel and equipment shall be employed to ensure the careful and
proper installation of the cable.
K Cable reel shall be set up at the side of the manhole and above the duct, allowing the
cable to enter through the opening without reverse bending. Flexible tube guide
shall be installed through the opening in a manner that will prevent the cable from
rubbing on the edges of any structural member.
L Cable shall be unreeled from the top of the reel. Payout shall be carefully controlled.
Cable to be pulled shall be attached through a swivel to the main pulling wire by
means of a pulling eye or suitable cable grip permitted only on cables less than 60-
meter-long and less than 50 millimeter in diameter.
M Woven-wire cable grips shall be used to grip the cable end when pulling small cables
and short straight lengths of heavier cables.
N Pulling eyes shall be attached to the cable conductors to prevent damage to the
cable structure.
O Pulling eyes and cable grips shall be used together for PVC sheathed cables to
prevent damage to the cable structure.
P Minimum bending radius shall be in accordance with NEC article 300.34 and IEEE
1185 as the following:
R Cables shall be pulled into ducts at a speed not to exceed 0.25 meter per second and
not in excess of maximum permissible pulling tension specified by the cable
manufacturer. Cable pulling using a vehicle shall not be permitted. Pulling operations
shall be stopped immediately with any indication of binding or obstruction and shall
not be resumed until such difficulty is corrected. Sufficient slack shall be provided
for free movement of cable due to expansion or contraction.
T Cables cut in the field shall have the cut ends immediately sealed to prevent
entrance of moisture. Unarmored cables shall be sealed with rubber tape wrapped
down to 75 millimeters from the cable end. Rubber tape shall be cover-wrapped
with polyvinyl chloride tape. Armored cables shall be sealed with wiping metal
making a firm bond with the end of the sheath or with a disk of lead fitted over the
end and wiped to the sheath.
U Direct Buried Installation: Cable direct buried, unless otherwise specified furnish a
bed of soft clean sand 100 mm depth at the bottom of trench, and the same over
cable. Install concrete tiles to the whole route of the cable with 50 mm thickness
and covering at least 200 mm over the outer edge of the cable from both sides.
V Then storing in backfilling with selected soil and reach to 95% compaction minimum.
Before reaching to the finished grade level by 300 mm, install warning tape, in both
English and Arabic, to cover the whole routes indicating “DANGER ELECTRICAL
CABLES”.
W In road crossing, install UPVC pipe embedded in concrete encasement and install
warning tape and install spare pipes not less than 25 % of the same size.
Z Use kits, which are compatible with conductor size, material and type and according
to the manufacturer’s recommendations.
AA Install terminations at ends of conductors and seal multi–conductor cable ends with
standard kits and glands.
A ENGINEER reserves its right to carry out inspection during fabrication stages and to
witness the testing of cables.
A The tenderer shall thoroughly fill the guarantee tables (technical particulars and
performance) for guidance.
B The cable length on each reel shall be as long as possible to minimize the number of
joints and as shown in the attached tables.
C All cable ends shall be firmly secured to the reel and shall be covered by heat-
shrinkable end caps.
D The cable drum shall be covered with wooden slabs of suitable thickness.
G Important Note
The factory laboratory must be equipped with all modern instruments and
equipment required to perform all routine and special tests of IEC 60502 with
the accuracies mentioned in IEC 60502
1. Offers from tenderers having no such laboratories shall not be considered
2. Dimensions shall be measured by digital and microscopic instruments.
1. The thickness of insulation at any place, may however be less than the
specified nominal value provided that the difference does not exceed 0.1 mm
+ 10% of the specified nominal value.
2. The dimension of the armour shall not fall below the specified nominal value
by more than 10%.
3. The measured smallest thickness of the PVC over sheath, at any point shall not
fall below 80% of the specified nominal value by more than 0.2 mm.
4. Guarantee Table (Similar data fills on typical manufacturer data sheets shall be
also accepted.
a. Technical Particulars
Maker’s Name:
1) Thickness of tape
2) Width of the tape
3) Percentage overlap of tape
4) Number of tapes
5) Effective cross-sectional area of screen per phase
6) Material of filling
7) Material of inner coverings
8) Minimum thickness of inner coverings
9) Material of armour tapes
10) Nominal thickness of armour tape
11) Minimum thickness of armour tape
I Performance
a. Conductor: KA
b. Screen/One Phase: KA
c. Screen for 3 Phase: KA
a. Continuous: °C
b. Emergency: °C
K We certify that the above mentioned data are guaranteed for the offered cable.
B The power frequency routine test voltage shall be 3.5 U0 values of single phase test
voltage for the standard rated voltage according to IEC 60502 and as given in the
following table:
C The partial discharge test shall be carried out in accordance with IEC 60885-3, except
that the sensitivity as defined in IEC 60885-3 and shall be 10 Pico-coulombs (P.C) or
better. The partial discharge test voltage shall be raised gradually to and held at 2 U0
for 10 seconds and then slowly reduced to 1.5 U0.
G Each power cable shall first be given a full dielectric-absorption test. Test shall be
applied for a long enough time to fully charge the cable. Readings shall be recorded
every 15 seconds during the first 3 minutes of test and at 1 minute intervals
thereafter. Test shall continue until three equal readings, 1 minute apart, are
obtained. Minimum reading shall be 200 mega ohms at an ambient temperature of
16 degrees C. Readings taken at other than 16 degrees C ambient temperatures
shall be corrected accordingly.
I Leakage current readings shall be recorded every 30 seconds during the first 2
minutes and every minute thereafter for the remainder of the test. When the
leakage current continues to increase after the first minute, the test shall be
immediately terminated and steps taken to find and correct the fault. When a
second test becomes necessary, this test procedure shall be repeated.
J Upon satisfactory completion of the high-potential test, the cable shall be given a
second dielectric-absorption test as before.
K Results of the second dielectric-absorption test shall agree with the first test and
shall indicate no evidence of permanent injury to the cable caused by the high-
potential test.
L Test data shall be recorded and shall include identification of cable and location,
mega ohm readings versus time, leakage current readings versus time, and cable
temperature versus time.
M Final acceptance shall depend upon the satisfactory performance of the cable under
test. No cable shall be energized until recorded test data have been accepted by the
Electrical Distribution Company and approved by the Engineer’s Representative.
SPECIFICATION REV.
ECG ENGINEERING CONSULTANTS GROUP LOW-VOLTAGE ELECTRICAL POWER
KSA CONDUCTORS AND CABLES 260519 – 2970 1
SECTION 260519
Page
PART 1 GENERAL 2
1.1 Related Documents 2
1.2 Summary 2
1.3 References 2
1.4 Submittals 3
1.5 Quality Assurance 4
1.6 Delivery, Storage, And Handling 4
1.7 Coordination 5
PART 2 PRODUCTS 6
2.1 Generally 6
2.2 System Characteristics 6
2.3 Lv Wires And Cables 450/750 V Grade 6
2.4 Lv Cables 600/1000 (1200) V Grade. 7
2.5 Performance And Design Requirements 7
2.6 Connectors (LV Power) 10
PART 3 EXECUTION 10
3.1 Inspection 10
3.2 Preparation 11
3.3 Installation 13
PART 1 GENERAL
A. Drawings and general provisions of the Contract, including General and Supplemen-
tary Conditions.
1.2 SUMMARY
A. This section covers the furnishing and installation of all insulated wires and cables in-
cluding control / (for power) cables voltages 600 volts nominal or lower; except wire
and cable for special applications, such as low-level circuits for analog signals, data
and supervisory control, Communication and Telemetering Systems.
B. Extent of electrical wire and cable work is indicated by Drawings and schedules.
C. Types of electrical wire, cable, and connectors specified in this section include the
following:
1.3 REFERENCES
1.4 SUBMITTALS
A. Submit the following in accordance with the requirements set forth at the Conditions
of Contract.
1. Tendering Submittals: Contractor to fill-in the compliance data sheet (when at-
tached to a section) and stamp it by the proposed supplier and by the pro-
posed electrical sub-contractor (or himself if no sub-contractor). If the Con-
tractor is assuming two suppliers for one material item in his bid, two data
sheets should then be filled and stamped, as mentioned, for the same item.
2. Drawings and Data: Descriptive literature, catalogs, cable list, drawings and
test reports for cable shall be submitted. Literature submitted should be
marked on a typical data sheet to clearly indicate any particular specification
paragraph for which the material applies.
3. Samples: In addition to complete specifications and descriptive literature, a
sample of selected sizes of each type of cable, termination, gland, identifica-
tion tag and warning tape shall be submitted for review before installation.
Each sample shall have the manufacturer's full surface printing identification
data engraved and shall be prepared for measuring and verification purposes.
The samples shall be retained until completion of the Contract. The Owner’s
Representative reserves the right to subject any of the samples submitted to
tests and will be in no way responsible for damage or breakage as a result of
any such tests.
4. Manufacturing Data and Test Reports: Showing dimensioned sketches, thick-
ness of insulation and sheath, factory tests, drum data and shipping details.
5. Shop and Construction Drawings: Submit drawings for approval including, but
not limited to, the following:
a. Exact routing layouts, sections and profiles of trays, feeder, sub feeder
cables and branch circuits, with indication of any equipment to show
and verify coordination between various trades.
b. Details of supports and fixings for buses, trays and cables.
c. Details of connections to transformers, switchboards, panelboards etc.
d. Details of terminations, splices and tapings where permitted, glands and
bushings at enclosures.
e. Number and size of conductors in conduit for all branch circuits in ac-
cordance with final conduit routing.
f. Cable sizing calculations.
g. Cable schedule.
h. Cable termination schedule.
B. Standards: Wires and cables are to comply with IEC or other equally approved stand-
ards and are to bear the mark of identification of the Standards to which they are
manufactured. Wires and cables not having this identification will be rejected.
C.
A. Deliver wires and cables properly packaged in factory packed or fabricated contain-
ers, wound on factory reels.
B. Store wires and cables in dry areas, and protect from weather, fumes, water, debris,
etc.
C. Handle wire and cable carefully to avoid abrading, puncturing and tearing wire and
cable insulation and sheathing. Ensure that dielectric resistance integrity of
wires/cables is maintained.
D. Before dispatch, the manufacturer shall cap the ends of all cables so as to form a seal
to prevent the ingress of water during transportation, storage and installation. The
cable shall be supplied on stout wooden drums, which shall be designed so as to pro-
tect the cable from damage.
E. The lagging batten shall be secured at least with 2 nails of each end in addition to
steel bonding straps. No drum shall contain more than 1 length of the cable.
F. The cable shall be tightly wrapped on the cable drum and no turn shall be left loose.
Both ends of the cable shall be adequately secured to the cable drum. Inner end of
the cable shall be suitably fixed / gripped to the cable drum so that it will not come
out during cable laying operation. The cable shall be wrapped on drums of suitable
diameter such that the radius of bend of the innermost layers is not less than the
minimum radius of bend stipulated in relevant BS/IEC for installation of the cable.
G. No space shall exist between the adjacent layers of the cable and between the drum
flange and the cable.
H. Cable shall be wrapped with black polyethylene sheet inside the wood covering of
the drum.
I. Central lifting hole of the cable drum shall be provided with a steel pipe. The pipe
shall be welded with steel plates at both ends and these plates shall be duly secured
Low-Voltage Electrical Power Conductors And Cables Section 260519
Riyadh Sedra 2 (Prj. 2970) Page 4 of 13
to the flanges of the cable drum with suitable size bolts. The pipe and the welded end
plates shall be of robust design to withstand the weight of the cable drum during un-
rolling.
J. Each drum shall bear a distinguishing number on the outside of the flanges and par-
ticulars of the cable, i.e. voltage, length, conductor size, cable type and gross weight
shall also be clearly visible. The direction for rolling shall be indicated by an arrow.
K. Immediately after the Works tests, both ends of every length of metal sheathed cable
shall be sealed by means of a metal cap fitted over the end and plumbed to the
sheath. All cables shall be sealed by enclosing the ends in approved caps, which shall
be tight fitting and adequately secured to prevent ingress of moisture.
L. The ends of factory lengths of cable shall be marked "A" and "Z", "A" being the end at
which the sequence of core numbers is clockwise and "Z" the end at which the se-
quence is anti-clockwise. The words "Running End "A"" or "Running End "Z"" shall be
marked on the flange and the direction for rolling shall be indicated by an arrow. The
method of drum marking shall be to the Purchaser's approval.
M. The cable end which is left projecting from the drum shall be adequately protected
against damage.
N. Cable drums shall be non-returnable and shall be made of timber, pressure impreg-
nated against fungal and insect attack or made of steel suitably protected against
corrosion. They shall be arranged to take a round spindle and be lagged with strong
closely-fitting battens of minimum 38 mm thickness.
O. All cables and accessories shall be carefully packed for transport and storage on Site
in such a manner that they are fully protected against all climatic conditions, particu-
lar attention being paid to the possibility of deterioration during transport to the Site
by sea or overland and to the conditions prevailing on the Site.
P. Wooden drums shall be suitably constructed to avoid problems due to shrinkage, rot
and attack by insects.
Q. Drums, carts, cases, etc., for maintenance spares shall be non-returnable. Cable
maintenance lengths and spare lengths shall be wound onto steel drums inspected
and tested by the Engineer before they are handed over to the Purchaser's stores.
Particulars of the cable (as stated above) shall be clearly marked.
1.7 COORDINATION
B. Revise locations and elevations from those indicated, as required to suit field condi-
tions and as approved by Engineer.
C. Ensure that cable twists, and crossings are avoided and sufficient bending radius is
maintained as per regulation.
2.1 GENERALLY
A. Conductors: Unless otherwise specified, cables and other feeders are to have copper
conductors. Cable conductors are to be stranded for sections 4 mm2 and above,
based on IEC 60228 Class 2. Signal and control cables are to have solid conductors
unless otherwise specified. Flexible cords are to have finely stranded conductors.
Conductors of single-core cables 25-mm2 and above are to be compacted.
B. Conductor sizes are to be metric. Conductors with cross-sectional area smaller than
specified will not be accepted.
D. Buried Cables: Cables buried directly in the ground are to be armored type, unless
otherwise indicated in particular Sections of the Specification.
E. Buried cables in high water content soil are to be watertight type, provided with wa-
ter blocking swell able tape above insulation as longitudinal water barrier, PE lami-
nated aluminum foil longitudinally applied with suitable overlap as radial water bar-
rier and an external outer sheath made of extruded black polyethylene compound.
F. Outdoor cables exposed to sunlight are to be provided with ultraviolet resistant PVC
sheath having 2.5% black carbon content.
C. Frequency: 60 H
A. Single Core PVC Insulated Cables and Wires 450/750 V grade: single conductor cables
for wiring in conduit are to have soft annealed copper stranded conductors, insulated
with flame retardant, moisture and heat resistant PVC according to IEC 60227 or BS
6004, suitable for wet locations and for conductor temperature of 70 deg. C.
B. Single Core PVC Insulated Cables with Flexible Copper Conductors 450/750 V grade:
Soft annealed Copper fine wires, bunched together in subunits or stranded bunched
groups into a main units, twisted and Sheathed which forms the flexible conduc-
tor. According to IEC 60227 or BS 6004. Shall be used where particular flexibility is
required for Electrical Panels connection and electrical apparatus they can be laid in
groups around steel sheets. Conductor temperature of 70 deg. C.
Low-Voltage Electrical Power Conductors And Cables Section 260519
Riyadh Sedra 2 (Prj. 2970) Page 6 of 13
2.4 LV CABLES 600/1000 (1200) V GRADE.
A Cables are produced Multi-Core PVC Insulated Cables (0.6/1 kV): soft annealed,
copper conductors, compacted, suitable filler and sheathed with PVC according to IEC
60502 , flame retardant, moisture and heat resistant, suitable for outdoor and indoor
installations in damp and wet locations. Conductor temperatures of 70 deg. C.
B Single Core XLPE Insulated Feeder Cables (0.6/1 kV): Single-core circular stranded,
annealed copper conductors, compacted, insulated with flame retardant, moisture
and heat resistant cross-linked polyethylene (XLPE) , according to IEC 60502 or BS
7889 suitable for wet locations and conductor temperatures of 90 deg. C. and PVC
over-sheath. Armored cables are to have taped bedding, single wire aluminum armor
and PVC over-sheath.
C Multi-Core XLPE Insulated Feeder Cables (0.6/1 kV): Single core annealed copper
conductors, compacted, XLPE insulated, for conductor temperature of 90 deg. C, laid
up and bedded with suitable non-hygroscopic material compatible with the
insulation and PVC over-sheathed, color black according to IEC 60502 or BS 5467.
Armored cables are to have single layer of galvanized steel wire or steel tape applied
helically over extruded PVC bedding (which may be an integral part of filling) and
over-sheathed with PVC, color black. PVC over-sheaths are to be type ST2 according
to IEC 60502.
D Armored cables are to have single layer of galvanized steel wire or steel tape
armored (as shown on the drawings) with PVC over-sheath. Cables are to comply
with IEC 60502 or BS 6346. Armored cables shall be used where mechanical damages
are expected.
A Cable Design Criteria: All cables shall conform to the applicable provisions of the IEC
and local standard.
B Each type of cable used throughout the installation shall be supplied by one
manufacturer only.
D Cable Types: The following types of wiring systems shall be used for power circuits
and controls.
F Cable Sizing and Selection: The applicable IEC or local regulations for Electrical
Installations shall be used as the basis for sizing cables and conductors.
G Minimum wire size shall be 4 mm2 for power circuits; 6 mm2 for current transformer
secondary circuits; 3 mm2 for potential transformer, digital signal, relaying, and
control circuits; 1.5 mm2 for annunciator circuits, analog signal and alarm circuits.
H Voltage drop on main distribution cables shall not exceed four percent from the
source to the farthest end of any sub-circuit.
I No cable shall be loaded to more than 80 percent of its current carrying capacity
after application of all the appropriate derating factors.
J The spacing of cables shall be as determined in the calculation of the derating factors
for the current carrying capacity of cables.
K When required, control cables shall be selected taking into account of the following:
L Cable sizes shall not be less than the minimum size specified herein. Minimum
cables sizes for circuits outgoing from main switchboards, distribution panel board,
and main distribution boards shall be in accordance with the schedule set forth in the
drawings and single line diagram, indicating the nominal cross section area of PVC
type cables.
N Cables for motors above 2 kW, shall be sized to conform to the Governing Standards,
so that the current ratings is not less than 125 percent of the full load current of the
motor and that the cable is not smaller than
a. Voltage rating
b. Size
c. Number of conductors
d. Manufacturer’s name
P Cables in Conduits and Trunking: All cables for lighting, small power, control and
auxiliary services, including low and extra low voltage services, shall be multistranded
single core (except for metal conduits shall be multicore) PVC, butyl, or silicone
insulated as required for 450/750 Volt grade as set forth in IEC and local specification
having stranded copper conductors. The minimum cable size shall be 1.5 mm2.
Q All cables shall be color coded in accordance with the relevant IEC and local
Standards.
R Marker sleeves shall be fitted to each end of cables and at suitable distances along its
length. Sleeves and markers shall be of the proprietary type manufactured for the
particular applications, and they shall be of the correct size to ensure a tight fit on
the cable. Where cables changed direction, or are routed through conduits, cables
identification sleeves shall be fitted.
S Cables shall be contained within a protective enclosure of a size not less than that
complying with IEC or local standards throughout its whole length.
T Cables installed in conduits, trunking shall be so grouped that the cables of all
phases, neutral and earth, are drawn into the same conduit. The lead and return
conductors shall always be drawn into the same conduit. Not less than three single
core cables shall be enclosed in any one conduit or trunking compartment.
U The grouping of cables fed from different distribution units shall not be permitted.
Also the grouping of cables of different service systems shall not be permitted.
V Where cables are installed in trunking, they shall be grouped in their respective
circuits or services and taped or bound by means of nylon cable straps at one-meter
intervals for purpose of identification.
W Flexible Cables: The use and type of flexible cables or cords shall suit the applications.
X Flexible cables and cores shall be used for pendant luminaires, adjustable lamps,
portable appliances and certain items of special equipment such as air conditioning
terminal units.
Z No flexible cable, other than that enclosed in conduits, shall be in excess of two
meters in length.
AA Heat Resistant Cables: Where indicated, flexible cables for use with heating
appliances or luminaires shall be heat resistant of at least 105°C.
BB Cable Support Systems: For above ground installations the method of fixing
PVC/XLPE insulated and PVC sheathed cables shall be either laid on cable trays or
ladder rack or clipped to the building structure by suitable cable clamp. All single
core unsheathed cables shall be run in a non-metal conduit or trunking system.
DD In the case of vertical cables, the clamps shall be so designed and of sufficient
number to grip the cable firmly to prevent creeping. No cable runs shall be without
fittings. All cable hangers and racks shall be submitted for inspection by the Owner’s
Representative prior to the installation of cables. Where cable routes are subject to
numerous changes in level and direction additional cable hangers shall be provided.
A. Connector - Type A-1: Pressure indent type, for terminating or making T-taps and
splices on conductors 10 mm2 and smaller. Connector is to be non-ferrous copper al-
loy applied to conductor by mechanical crimping pressure, with vinyl insulating
sleeves or phenolic insulating covers.
B. Connector - Type A-2: Bolted pressure split type for terminating or making T-taps and
splices on conductors 16 mm2 and larger. Connector is to be cast non-ferrous copper
alloy applied to conductor by clamping with minimum of two screws and provided
with phenolic insulating cover.
C. Connector - Type B-1: Pre-insulated, spring type, for branch circuit and fixture wiring.
Connector is to be steel encased spring with shell, insulated with vinyl cap and skirt,
type Scotchlok brand, as manufactured by Minnesota Mining & Mfg. Co. or 3M or
other equal and approved.
PART 3 EXECUTION
3.1 INSPECTION
A. The outside of each cable reel shall be carefully inspected and protruding nails, fas-
tenings, or other objects which might damage the cable shall be removed. A thor-
ough visual inspection for flaws, breaks, or abrasions in the cable sheath shall be
Low-Voltage Electrical Power Conductors And Cables Section 260519
Riyadh Sedra 2 (Prj. 2970) Page 10 of 13
made as the cable leaves the reel, and the pulling speed shall be slow enough to
permit this inspection. Damage to the sheath or finish of the cable shall be sufficient
cause for rejecting the cable. Cable damaged in any way during installation shall be
replaced by and at the expense of the Contractor.
3.2 PREPARATION
A. Cable Protection: Cables shall be carefully handled during installation to avoid dam-
age of any kind. They shall be unreeled or uncoiled slowly in order to prevent dam-
age to the insulation or sheath due to sudden bending. Repeated bending shall be
avoided. Sharp links shall be avoided in unreeling, uncoiling and pulling.
B. The pulling of cables into conduits or ducts shall be carried out with all possible care.
The cable reels or coils shall be positioned so that the cable may be trained into the
conduit or duct as directly as possible, with the minimum of changes of direction or
of bending. The cable end shall be provided with a suitable protector to guard against
damage to the insulation or sheath. Where several cables are contained in one con-
duit or duct, all cables shall be pulled-in together.
C. The pulling tension shall not exceed the maximum tension as recommended by the
cable manufacturer.
D. Before cables are pulled through ducts, the ducts shall be checked for cleanliness and
smoothness. Where ducting is longer than two meters, a cable wire mesh cable
stocking shall be used to attach the cable to the draw-in rope.
E. The cross-section of cables must be selected according To the expected load, voltage
drop, ambient temperature and installation conditions including appropriate group-
ing factors. The maximum Voltage drop from the Connection Point to the remote end
of any Final Circuit must not exceed 4%, except in special Cases where equipment has
been designed to operate under a greater voltage drop (such cases must be clearly
stated in the Electrical Installation design and approved by the Distribution Compa-
ny).
F. Long lengths of cable shall be laid using an adequate number of drum jacks, rollers
and other handling accessories. Make-shift-arrangements will not be acceptable.
Care shall be taken to break the rotation of the reel and cables shall not be dragged
over loose earth, concrete or any surface detrimental to the insulation. Cables shall
not be stretched but shall be adequately supported on rollers or manhandled into
position.
G. The minimum bending radius shall be not less than that recommended but the cable
manufacturer and contra twisting shall be avoided.
H. Spacing between cables shall be suitable for the derating factors applied to the cable
installation design.
I. Cables shall be installed using the loop-in principle, unless otherwise specified no
straight through or tee joints will be permitted.
J. Cable Routing: The general route of all cables shall be indicated on the drawings
and/or as directed by the Owner’s Representative if there are no drawings. The Con-
tractor shall include for all deviations required by the building structure and other
Low-Voltage Electrical Power Conductors And Cables Section 260519
Riyadh Sedra 2 (Prj. 2970) Page 11 of 13
services. The final routes of all cables shall be submitted to the Owner’s Representa-
tive before any work in connection with the cable installation is commenced.
L. Where cables are situated below floor level in sub-stations and switch rooms, they
shall be run either in formed concrete open ducts, PVC or under fire resisting access
flooring. No cables shall be buried directly in concrete flooring or foundations.
M. Where cables pass through holes in panels or other metalwork, they shall be protect-
ed by rubber grommets, compression glands or their equivalent.
N. Where cables are run vertically heavy gauge sheet metal guards shall be supplied and
fixed where there is a possibility that the cable could sustain mechanical damage.
P. Before commencing any part of the works, the Contractor shall submit for engineer
study and approval, drawings indicating conduit, trunking, ladders, trays and duct
sizes together with the proposed layout of the system.
Q. Whenever cables have to pass through walls or slabs, special fire insulation should be
applied. The insulation shall have the same fire class as the wall or slab penetration.
R. Both high, medium, low voltage and intrinsically safe cables shall be on separate ca-
ble runs.
S. All cable runs shall have minimum 30% spare space after all cables is installed.
T. Cable runs, supports and all its splices shall be conductive and be well earthed.
U. The main runs for cables between buildings shall be on the edge of the road, outside
the water ditch. If cables have to cross roads or concrete covers the cables must be
run in a drained cast ditch of concrete. The ditch must have covers that are to move.
V. Segregation: Cables of different voltages and duties shall be segregated and particu-
lar attention shall be paid to the avoidance of induced 'spikes' or ' electrical noise' on
adjacent circuits due to high currents and/or switches surges.
W. Grounding: All metal work which cannot be insulated as defined in the Governing
Standards and is associated with cable runs shall be bonded to earth or to the cable
armoring where this latter methods is approved.
X. Where steel wire armored cables are specified and the resistance of the armoring is
unsatisfactory, a supplementary earth (ground) cable shall be run with the affected
cable. This cable shall be sized to ensure compliance with the wiring regulations for
earthing.
A. Cable Installation: Cable shall be installed in accordance with IEC standards and local
code.
B. If single core cables are used they must not be installed separately through openings
of magnetic materials. They must be installed in 3 phase grouping to avoid current
heating”.
C. Cables for intrinsically safe circuits shall be routed on separate cable ladder or trays
or separated clearly from other cables. The tray shall be marked with a light blue
color.
D. Cables shall not be buried in solid or hard setting building finishes unless prior ap-
proval has been given by the Owner’s Representative. The Contractor shall ensure
that cables when run in building finishes are immediately protected against mechani-
cal or any other damage. The Contractor shall also be in attendance when finishes
are applied and shall ensure that no damage or displacement occurs.
E. Cables shall be installed parallel to the building lines and shall not be run diagonally
in floor or ceiling finishes.
F. Single cable passing through walls and floors shall be protected by means of tubular
PVC or steel sleeves of sufficient size to give minimum 13 mm clearance all round the
cable. Sleeves passing through floors shall extend above the floor level a minimum of
40 mm.
G. Where passing through walls the sleeve shall finish flush with the finished surface.
All sleeves shall be tightly packed with suitable fire resistant materials of an approved
type. All cables rising from floor level to equipment or in other locations where acci-
dental damage may occur shall be protected.
I. Cables shall be straightened and dressed neatly on the runs by approved methods.
All bends shall have an inside radius of not less than that recommended by the cable
manufacturer and in no case shall it be smaller than the bending radii shown in the
appropriate standards.
K. Cables shall be tagged at both ends, inside each panel, and every 15 m of the run.
Tag shall be metal type and shall read both the cable size and the target panels or
loads (From/To).
SPECIFICATION REV.
ECG ENGINEERING CONSULTANTS GROUP GROUNDING AND BONDING FOR
KSA ELECTRICAL SYSTEMS 260526- 2970 1
SECTION 260526
Page
PART 1 - GENERAL 2
1.1 Related Documents 2
1.2 Summary 2
1.3 Definitions 2
1.4 Submittals 3
1.5 Quality Assurance 5
PART 2 - PRODUCTS 5
2.1 Conductors 5
2.2 Connectors and Earthing Accessories 6
2.3 Earthing Electrodes 6
2.4 Soil Survey and Calculations 7
2.5 Fault Current and Duration 8
2.6 System Design 8
PART 3 - EXECUTION 11
3.1 Applications 11
3.2 Equipment Grounding 12
3.3 Installation 12
3.4 Connections 14
3.5 Field Quality Control 14
PART 1 - GENERAL
A. Drawings and general provisions of the Contract, including General and Supplemen-
tary Conditions and Division 01 Specification Sections, apply to this Section.
1.2 SUMMARY
A. This Section includes complete installations to earth every source of energy and to
provide protective earthing and equipotential bonding, based on the TN-S system ar-
rangement, including:
1. LV Panelboards
2. Main earthing terminals or bars in electrical, etc.
3. Exposed conductive parts of electrical equipment (light fittings, switches and
socket outlets, etc.).
4. Extraneous conductive parts (generators, Panelboards, etc.).
5. Building main ring system of electrodes and conductors.
1.3 DEFINITIONS
A. The words "earth" and "earthing" as used herein are synonymous with the words
"ground" and "grounding" and may be used interchangeably within this specification.
B. The words "ground ring" as used herein is synonymous with the words "ground loop"
and may be used interchangeably within this specification.
C. Earth: Conductive mass of the Earth whose electric potential at any point is conven-
tionally taken as zero.
D. Earth Electrode: Conductor or group of conductors in initial contact with, and provid-
ing electrical connection to, Earth.
F. Extraneous Conductive Part: Any conductive part not forming part of the electrical
installation such as structural metalwork of a building, metallic gas pipes, water
pipes, heating tubes etc. and non-electrical apparatus electrically connected to them
i.e. radiators, cooking ranges, metal sinks etc. and non-insulating floors and walls.
G. Protective Conductor: Conductor used for some measure of protection against elec-
tric shock and intended for connecting together any of the following parts:
H. Main Earthing Terminal or Bar: The terminal or bar provided for the connection of
protective conductors, including equipotential bonding and functional earthing con-
ductors if any to the means of earthing.
1.4 SUBMITTALS
A. Product Data and Sample: Submit for each type of product indicated including manu-
facturer’s catalogue sheets with catalogue numbers marked for the items furnished,
which shall include:
B. Qualification data for firms and persons specified in "Quality Assurance" Article to
demonstrate their capabilities and experience. Include lists of completed projects
with project names and its locations, Engineer/Consultant and Owner. The firm
should have at least two years of success full installation experience.
C. Field inspection reports indicating compliance with specified requirement and submit
written test reports to include the following:
1. Test procedures used and test conditions (Method statements for testing of
E. Shop Drawings: Submit drawings for approval including, but not limited to, the fol-
lowing:
F. As-Built Drawings: Scaled drawings, showing actual layout and specification of all
components of earthing system include the number of rods driven and their depths
at each location, indicate nature of soil, special earthing arrangements, date and par-
ticulars of additives to soil or in bore-holes if used, test conditions such as weather
and other phenomena that may effect on the tests and results obtained.
G. Compliance Sheet: Contractor to fill-in the compliance data sheet (when attached to
a section) and stamp it by the proposed supplier and by the proposed electrical sub-
contractor (or himself if no sub-contractor). If the Contractor is assuming two suppli-
ers for one material item in his bid, two data sheets should then be filled and
stamped, as mentioned, for the same item.
H. Operation and Maintenance Data: For grounding to include the following in emer-
gency, operation, and maintenance manuals:
PART 2 - PRODUCTS
2.1 CONDUCTORS
A. Insulated Conductors: Copper wire or cable PVC insulated in green and/or green-
yellow color for 400 V unless otherwise required by applicable Code and indicated on
the drawings.
1. Stranded Conductors: Soft drawn annealed bare copper with 98% conductivity
and shall conform ASTM B3 and/or BS EN 60228 and/or IEC 60228.The cross
section shall be 70 mm2 unless otherwise indicated on the drawings.
2. Flexible braided cable strap: Copper, 250 mm by 35 mm thick ground post
clamps. Clamps shall be of the anti-electrolysis type.
3. Grounding plates: Copper, minimum 600 mm by 600 mm by 3 mm thick.
C. All conductor fittings shall be manufactured from high strength copper alloys with
phosphor bronze nuts, bolts, washers and screws. All fittings shall be designed for the
specific application and shall not be permanently deformed when correctly installed.
D. When the reinforcing in concrete is used as a part of the earthing system the fittings
used to provide a connection point at the surface of the concrete shall be exothermi-
cally welded to a reinforcing bar. This fitting shall be provided with a bolted connec-
tion for an earthing conductor. The main bars in the reinforcing shall be welded to-
gether at intervals to ensure electrical continuity throughout the reinforcing.
E. No connections shall be made to reinforcing bars and other steelwork, which do not
form part of the earthing system and are completely encased in concrete.
A. Earth Electrode: The earth electrodes shall comprise a system of bare conductors
forming a loop/ring buried near the surface of the ground supplemented, by one or
more of the following electrodes:
B. Ground/Earth Rods: Copper-clad steel rods and shall not less than 20mm in diameter
by not less than 3000 mm in length per section and shall conform to the require-
ments of NFPA 70 and UL 467 and/or BS. Ground rods must be clean and smooth and
have a cone-shaped point on the first section and be die-stamped near the top.
C. Earth Pit: Precast, square or circular section concrete hand hole (minimum 450 mm
D. Earth pit with Sealing Kit: shall be installed within the building itself. The pit shall be
provided with a suitable sealing mechanism around the earth electrode.
The pit shall be of high performance lightweight polymer, corrosion resistance pres-
sure tested, compliant to BS EN 62305-3 standard and tested according to BS EN
50164-5. The sealing mechanism shall consist of high density polyethylene molding
flange and housing to accommodate the sealing kit and protective tube for the earth
rod.
E. Disconnecting links shall comprise a high conductivity copper PVC insulated link sup-
ported on two insulators mounted on a galvanized steel base for bolting to the sup-
porting structure. The two conductors shall be in direct contact with the link and shall
not be disturbed by the removal of the link. Links for mounting at ground level shall
be mounted on bolts embedded in a concrete base.
F. Disconnecting links mounted at ground level and the connections at the earth rods
shall be enclosed in concrete inspection pits, with concrete lids, installed flush with
the ground level.
G. Testing joints (Test links): Copper or copper alloy, with bolted end connections, dis-
connect able by use of a tool, and suitably sized for earthing conductors or earth bar
connection. Links are to be fixed to porcelain or other approved insulating supports.
Contact surfaces are to be tinned.
A. The Contractor shall carry out an earth resistivity survey on each site and report in
writing to the Engineer in accordance with the approved program. The report shall
detail the methods and instruments used and the results of the surveys. Based on the
results the Contractor shall include in the report his proposals for the resistivity to be
used in the design of the earthing system.
B. The value of resistivity to be used in the design of the earthing system shall be sub-
ject to the Engineer’s approval.
C. The surveys shall show the variation of resistivity across the site and with the depth
below the site. The Contractor shall consider if there is a need to model the resistivity
in two layers and if there is any advantage in the use of long rods. The surveys shall
also determine the depth and nature of any underlying rock, which may limit the
depth for driving earth rods or if boring will be necessary for installing earth rods.
D. The weather conditions prior to and at the time of the surveys shall be recorded in
the report and an assessment made of the seasonal variations in resistivity based on
meteorological data for the area. The program for the project should, as far as possi-
ble, time the resistivity surveys to take place during a dry season.
F. The report shall be approved by the Engineer before proceeding with the design of
the earthing system.
G. The calculations shall be submitted for approval prior to commencing the design of
the earthing systems.
A. The earthing system design calculation by the Contractor shall be based on earth
fault withstand current.
A. Design Calculations:
1. The design of the earth electrode systems shall be based on the approved
earth resistivity data and the system’s fault currents and their duration.
2. The design calculations shall be submitted to the approval of the Engineer and
shall be based on the methods given in the standards listed. The calculations
shall include the following parameters:
B. General Requirements
12. Main Equipotential Bonding: Main incoming and outgoing water pipes and any
other metallic service pipes are to be connected by main equipotential bond-
ing conductors to main earth terminal or bar. Bonding connections are to be as
short as practicable between point of entry/exit of services and main earthing
bar. Where meters are installed, bonding is to be made on the premise side of
the meter. Cross-sections of conductors are not to be less than half that of the
earthing conductor connected thereto, and minimum 6 mm2.
13. Identification: Connection of every earthing conductor to earthing electrode
and every bonding conductor to extraneous conducting parts is to be labeled
in accordance with the Regulations, as follows:
PART 3 - EXECUTION
3.1 APPLICATIONS
A. Conductors: Install solid conductor for 10 mm2 and smaller, and stranded conduc-
tors for 16 mm2 and larger, unless otherwise indicated on the drawings.
1. Bury at least 600 mm below grade at a distance not less than 1000mm and not
more than 3000 mm from the edge of walkways and not more than 3 meters
from the structure.
2. Duct-Bank Grounding Conductor: Bury 300 mm above duct bank when indi-
cated as part of duct-bank installation.
D. Grounding Resistance: The completed installation when a ground loop is not used
shall have a maximum total resistance to ground using the fall-of-potential method
described in IEEE 81 or equivalent method as per BS and/or IEC of 2 ohms, under
normally dry conditions. Use a ground loop when two of any three (3) ground rods,
driven not less than three meters into the ground, a minimum of three meters apart
and equally spaced around the perimeter, give a combined value exceeding 50 ohms
immediately after having been driven.
F. Make connections between ground conductors and grounds or ground loop and be-
tween ground loop and grounds electrically continuous. Where so indicated, provide
an alternate method for grounding electrodes in shallow soil by digging trenches ra-
dially from the building. A 70 mm2 bare copper cable (or as shown on the drawings)
arranged in a star pattern with the structure at the center for radial systems shall be
installed.
B. Road Lighting
1. Earthing Cables: separate protective earthing cables for lighting column circuits
are to be run with power circuit, terminated at LV supply position in lighting
control panel and looped into column earthing terminals. The last column is to
be bonded via an earthing bolt to a single 16 mm diameter copper covered
steel rod, 2.4 m long, driven into ground adjacent to column. Bonding is to be
16 mm2 stranded bare copper conductor.
2. Connections between rods and earthing conductors are to be made by the cad
weld process producing a fused joint. Bolted connections may be used for con-
nection to removable items of equipment only.
3.3 INSTALLATION
A. Coordination: All works below grade shall be thoroughly coordinated with all under-
ground services and structures. Grounding and bonding works must, in all circum-
stances prevent any dissimilar metal contact that will cause galvanic corrosion.
Bonding shall be made only after thorough inspection of metal parts to be bonded.
Grounding conductors shall be run with all three phase feeders, and all single and
three phase branch circuits.
B. Continuity: Ensure that complete earthing system is electrically continuous and me-
chanically secure.
C. Grounding Conductors: Route along shortest and straightest paths possible, unless
otherwise indicated or required by Code. Avoid obstructing access or placing con-
ductors where they may be subjected to strain, impact, or damage.
D. Ground Rods: Drive rods until tops are 50 mm below finished floor or final grade, un-
less otherwise indicated.
E. Test Pits: Install at least one test pit for each service, unless otherwise indicated on
the drawings. Set top of test pit flush with finished grade or floor.
F. Bonding Straps and Jumpers: Install in locations accessible for inspection and
maintenance, except where routed through short lengths of conduit.
1. Bonding to Structure: Bond straps directly to basic structure, taking care not
to penetrate any adjacent parts.
2. Bonding to Equipment Mounted on Vibration Isolation Hangers and Supports:
Install so vibration is not transmitted to rigidly mounted equipment.
3. Use exothermic-welded connectors for outdoor locations, but if a disconnect-
type connection is required as per the project specifications, use a bolted
clamp.
G. Bonding shall be provided where necessary to assure electrical continuity and the ca-
pacity to conduct safely any fault current likely to be imposed. Non-current-carrying
metal parts of service equipment shall be effectively bonded together.
I. Care shall be taken to ensure good ground continuity, in particular between the con-
duit system and equipment frames and enclosures. Where necessary, jumper wires
shall be installed.
K. Bonding Interior Metal Ducts: Bond metal air ducts to equipment grounding conduc-
tors of associated fans, blowers, electric heaters, and air cleaners. Install bonding
jumper to bond across flexible duct connections to achieve continuity.
3.4 CONNECTIONS
C. Where earth connections between dissimilar metals must be made, use bimetallic fit-
tings and protect by coating with moisture resisting bituminous paint or compound,
or by wrapping with protective tape to exclude moisture.
E. Tighten screws and bolts for grounding and bonding connectors and terminals ac-
cording to manufacturer's published torque-tightening values. If manufacturer's
torque values are not indicated, use those specified in applicable Standards.
F. Connection of earthing conductors to ground pit earth rods, shall utilize multiple
connectors as required. More than one cable shall not be connected through one
connector clamp unless specifically permitted.
A. Testing Agency: Owner or his representative will engage a qualified testing and in-
specting agency to perform field tests and inspections and prepare test reports.
B. Perform the following tests in addition to the tests required by IEC and/or BS and in-
spections and prepare test reports:
1. After installing grounding system but before permanent electrical circuits have
been energized, test for compliance with specifications and drawings require-
ments.
2. Test completed grounding system at each location where a maximum ground-
resistance level is specified, at service disconnect enclosure grounding termi-
nal. Make tests at ground rods before any conductors are connected.
a. Measure ground resistance not less than two full days after last trace
of precipitation and without soil being moistened by any means oth-
er than natural drainage or seepage and without chemical treatment
or other artificial means of reducing natural ground resistance.
C. Report measured ground resistances that exceed the maximum ground resistance
value required.
SPECIFICATION REV.
ECG ENGINEERING CONSULTANTS GROUP RACEWAY AND BOXES FOR ELECTRICAL
KSA SYSTEMS 260533 - 2970 1
SECTION 260533
Page
PART 1 GENERAL 2
1.1 Related Documents 2
1.2 Summary 2
1.3 References 2
1.4 Submittals 3
1.5 Quality Assurance 3
1.6 Coordination 3
PART 2 PRODUCTS 4
2.1 Manufacturers 4
2.2 General 4
2.3 Application Considerations 4
2.4 Intermediate Metal Conduit 5
2.5 Electrical Metallic Tubing (Emt) 5
2.6 Flexible Metal Conduit 5
2.7 Rigid Heavy Gauge Upvc Conduit 6
2.8 Under Groung Upvc Conduits 6
2.9 Flexible Pvc Conduit 6
2.10 Steel Conduit Accessories 7
2.11 Wiring And Cable Trunking 7
2.12 Weatherproof Wiring And Cable Trunking 8
2.13 Outlet Boxes, General 8
2.14 Metallic Outlet Boxes 8
2.15 Moulded Plastic Outlet Boxes 9
2.16 Underfloor Trunking 9
PART 3 EXECUTION 10
3.1 Examination 10
3.2 Equipment Installation Requirements 10
3.3 Installation And Wiring 10
3.4 Outlet Boxes 12
3.5 Junction, Pull 13
3.6 Grounding And Bonding 13
3.7 Connections 14
3.8 Empty Conduits 14
3.9 Protection 14
3.10 Cleaning 14
PART 1 GENERAL
A Drawings and general provisions of the Contract, including General and Supplemen-
tary Conditions and Division 01 Specification Sections, apply to this Section.
1.2 SUMMARY
A This section covers raceways, fittings, boxes, enclosures, and cabinets for electrical
wiring:
1. Raceways include all types of conduits, trunking and duct bank systems, such
as, Rigid PVC Conduit, Electrical Metallic tubing (EMC), Intermediate metal
conduit (IMC), Flexible Conduit, wire ways, Surface Raceways, galvanized
trunking, rigid PVC trunking, etc.
2. Boxes, enclosures, and cabinets include the following devices: floor boxes, pull-
ing and junction boxes, cabinets and hinged cover enclosures.
1.3 REFERENCES
1. All requirement and Standards Referenced in the latest version of SBC code
shall be part of the requirements for this Project. Where differences occur be-
tween the provision of SBC Code and Referenced Standards, the provisions of
SBC Code shall apply. Where related SASO Standards exist, they shall apply and
have precedence.
D. ASTM A 525- General Requirements for Steel Sheet, Zinc-Coated Galvanized by the
Hot-Dip Process.
C Shop Drawings showing components and wiring as to ensure clearances and access
provisions. Refer to cable sections (260513, 260519) for more details on cable laying,
segregation and bundling inside raceways, trunking and trays.
E Samples.
A Products specified in this section should comply with IEC & local regulations for com-
ponents and installation.
B Provide products specified in this section that are listed and labeled according to IEC
Standards.
D Material shall comply with the latest edition of the following standard:
1.6 COORDINATION
A Coordinate layout and installation of raceways and boxes with other construction el-
ements to ensure adequate heady room, working clearance, and access.
2.1 MANUFACTURERS
2.2 GENERAL
A Materials and equipment to be provided shall be new and essentially the standard
catalogued products of a manufacturer regularly engaged in the manufacture of the
products.
A The specified products for raceways, boxes, and cabinets shall be used as suitable to
the environment. The following table shall be a general guide and shows a complete
list of environments and permissible products.
Boxes, Enclosures,
No. Environment Raceways
Cabinets
7. Industrial location, general EMT, FMC, LFMC NEMA 12, 12K (IP 52)
C Notes
1. PVC conduits are permitted for installation above false ceiling, only if the area
above false ceiling is not used as return plenum. Metal conduits shall be used
instead if the area above false ceiling is used as return plenum.
2. Corrosion protection required for all metal conduits.
3. Fittings for purpose required for all conduits.
4. Aluminum materials not permitted.
A. Intermediate Metal Conduit (IMC): Rigid high grade mild strip welded steel, hot dip
galvanized over the entire length including factory made treads after cutting with or-
ganic corrosion resistant polymer inside coating and to US Federal Specification, UL
1242 and ANSI C80.6.
B. IMC Fittings: Generally Threaded fittings and connectors and terminations with rigid
coupling, concrete tight where required, and with red lead coated threads where site
cut. Factory made bands are to be provided where site bending is not possible.
A Welded steel, non-threaded type, galvanized externally and protected internally with
corrosion resistant enamel, and to U.S. Federal Specifications, UL 797 and ANSI
C80.3.
B EMT Fittings Generally: Thread less pressure type, galvanized or cadmium plated mal-
leable cast iron. Fittings used in corrosive atmospheres are to be specially treated.
Factory made bends are to be provided where site bending is not possible.
A Material: Steel, cold rolled and annealed, non-threaded type, formed from continu-
ous length of helically wound and interlocked strip steel, with fused zinc coating on
inside and outside, and to IEC 61386-1, BS EN 50086-1.
D Straight Connectors: One piece body, female end, having hinged clamp and deep
slotted machine screws for securing to conduit, male end having thread and locknut.
A Material: Rigid unplasticized polyvinyl chloride with high impact and high tempera-
ture resistance, flame retardant, non-hygroscopic and non-porous, to CEE 26, BS
4607 and BS EN 50086-1, IEC 61386-1, IEC 61386-21, DIN 49016 or other equal and
approved standards conforming to IEC 60423.
A UPVC conduits used for electrical low voltage and medium voltage Cables ducts shall
comply with DIN Standard 8061/8062 or BS 3506.
B Conduits installed in concrete encased duct bank shall be utility grade PVC type EP-
35.
A Sleeves Through Outside Walls: Cast iron, with end and intermediate integral flanges,
and internal diameter larger than diameter of through-conduit. Length is to corre-
spond to wall thickness. Space between sleeve and conduit is to be packed with
backer rod/oakum to within 50 mm of both faces of wall, remainder of sleeve packed
with plastic compound or lead, held in place by heavy escutcheon plates bolted at
both ends to flanged ends of sleeve. Alternatively, sleeves are to be O.Z/Gedney,
Type WSK or other equal and approved, with cable or conduit bolted pressure sealing
components.
B Supports and Hangers: Galvanized malleable cast iron straps or structural steel sec-
tions with hot dip galvanized bolts and nuts.
C Expansion Joint for Embedded Steel Conduits - Type A: Watertight, flexible conduit
with end fittings to receive fixed conduits. Length is to allow movement within range
of joint and is not to be less than 20 times diameter of conduit. Conduit is to be cov-
ered with thick rubber tubing with 5 mm minimum gap all around tube. Bonding
jumper with earth clamp is to be electrically connected both sides of joint.
D Expansion Joint for Exposed Steel Conduits - Type B: Sleeve with fittings to permit
telescoping of one conduit into sleeve. Movable conduit is to be fitted with water-
tight bushing. Joint is to be weatherproof, of galvanized malleable iron or steel.
Bonding jumper with earth clamp is to electrically connect both sides of joint. Expan-
sion fitting is to be O.Z/Gedney, Type DXX or other equal and approved.
E Expansion Joint for Exposed Steel Conduits - Type C: PVC sheathed flexible steel con-
duit terminating in pull boxes and securely fixed on each side of structural expansion
joint. Bonding jumper is to electrically connect both sides of joint.
F Tags: 50 mm diameter steel with indented lettering, rust inhibiting treatment and
baked enamel finish.
A Components are to include wire way base, clip-on covers, couplings, end plates, wall
flanges, panel to trunking rubber grommets, elbows, tees, adaptor plates and neces-
sary hangers, supports and accessories.
C PVC Trunking: To BS 4678 part 4 high impact, heavy duty, self-extinguishing, rigid PVC
with grooved double locking action of the clip-on cover. Design is to be approved by
Engineer before ordering materials. Trunking is to be capable of receiving functional
slot-in hangers and demountable separators to segregate wiring systems as needed.
A Type: Hot-dip galvanized sheet steel trunking of 1.5 mm thickness (minimum) with 1
mm thick cover to BS EN 50085-1 and BS EN 50085-2 for trunking and BS EN ISO 1461
for galvanizing.
B Construction: Trunking is to have outwardly turned flanges to receive cover, and in-
ternal sleeve coupling between sections, permitting cutting of trunking on site.
C Gaskets: Neoprene bonded cork gaskets are to be fitted throughout, between any
two attached surfaces.
D Screws: Removable flanged covers are to be secured with galvanized steel holding
screws.
A Surface or recessed boxes are to be suitable for type of related conduit or cable sys-
tem. Shapes and sizes of boxes are to be of compatible standards as switches and
socket outlets specified under Division 26 Section "Wiring Devices", and lighting fix-
tures selected and of various types and mounting methods required.
B Unused openings in outlet boxes are to be closed with molded caps or knock-out
closers manufactured for the purpose.
A Recessed and Concealed Boxes: Galvanized pressed steel, with knock-outs for easy
field installation. Special boxes are to be punched as required on Site.
B Exposed Surface Mounted Boxes: Galvanized cast iron with threaded hubs.
C Outdoor Surface or Recessed Boxes: Galvanized cast iron with threaded hubs and
PVC gaskets to ensure water tightness and with stainless steel or non-ferrous, corro-
sion resistant screws.
D Floor Boxes - Type A: Watertight, cast iron or cast metal alloy with corrosion resistant
finish, adjustable mounting, standard duty, round or square, factory drilled and
tapped for required conduit sizes, and with brass cover and flange with brushed fin-
ish free from markings other than required for mounting screws.
E Floor Boxes - Type B: non-standard size, flush floor mounted, cast metal alloy, with
watertight neoprene gasket and hinged cover for each service. Box to be ready with
factory drilled and tapped conduit entries and adjustable mounting fittings. Metal
barriers are to separate services for power and low current.
A Type: Boxes and covers used with PVC conduit systems are to be heavy gauge pres-
sure molded plastic, minimum 2 mm thick, self-extinguishing, with softening point
not less than 85 deg. C. Boxes are to have provision for securely terminating conduits
and are to be manufacturer's standard for required application.
B Fittings: Boxes are to have brass inset threads to receive cover screws and for mount-
ing devices or accessories, push-fit brass earth terminals, and steel insert clips to pro-
vide additional support for pendants or for heat conduction. Neoprene gaskets are to
be provided for weatherproof installations.
A Type: For installation in floor screed, laid on unfinished concrete floor, secured and
grouted flush with screed.
B Material: 3.3 m lengths of 2 mm thick (14 gauge) galvanized sheet steel, protected by
corrosion resistant coating on inside and outside surfaces. Single, double or triple
systems, as required. Dimensions are to be as required. Covers to be minimum 3 mm
thick. Galvanizing to be at least 270 gms/m2.
C Openings: Ducts are to have 32 mm openings spaced at 600 mm with screw plugs for
receiving initial or future installation of outlet boxes. Screw plugs are to be replaced
by brass ferrules, inserted and securely fastened by crimping tool, for installation of
pedestal type outlet boxes.
E Junction Boxes: Flush, cast iron, or galvanized sheet steel or die-cast metal protected
by corrosion resistant coating and suitable for double or triple duct systems, as
required. Openings are to be provided for ducts and conduits. Interior of boxes is to
be partitioned for two or three services; completely isolating each duct system and
providing straight cross-junctions. Leveling and anchoring of boxes is to be by adjust-
ing screws at four corners. Flush cover plates are to form smooth surface with floor-
ing.
G Supports are to be capable of adjustment for height and arranged for maintenance of
alignment and spacing of raceways during concreting.
H Recessed Service Fittings: Modular fittings that match with preset inserts and include
PART 3 EXECUTION
3.1 EXAMINATION
A Examine surfaces to install raceways, boxes enclosures and cabinets for compliance
with installation tolerances and other conditions affecting performance of the race-
way system. The Contractor shall not proceed with installation until unsatisfactory
conditions have been corrected.
A General: Provide all the equipment installation and wiring installation, including con-
nections as indicated, specified and required. Assure proper fits for all equipment
and materials in the space as shown on the Drawings. Conduits installed under-
ground shall be provided with preformed long radius PVC elbows encased in
concrete. Liquid-tight lengths of flexible conduit shall be used for connections to all
motors and equipment subject to vibration. Maximum conduit fill shall not exceed
40%.
A Conduits shall be concealed either within false ceiling plenums or embedded in slabs,
walls and floors. Conduits shall be installed in accordance with the requirements of
IEE Building Regulations. Conduit runs shall be determined by the Contractor and
agreed by the Engineer before commencing work. Exposed interior conduits shall
have supports spaced 1.00 m, 1.5 m, 2.00 m apart for conduits 20 mm, 25 mm, 32
mm, respectively, with at least one support between couplings and be installed paral-
lel or perpendicular to walls, structural members or intersections of vertical planes
and ceilings with right-angle turns to be made with symmetrical bends. Conduit shall
be supported on approved types of galvanized strap hangers, pipe straps or be se-
cured by means of expansion bolts on concrete, wood screws on wood or ma- chine
screws on metal surfaces. Conduit supports shall be provided on each side of conduit
bends or elbows and not more than 0.5 m on each side of each outlet. Field- formed
bends and offsets shall be avoided where possible, but where necessary shall be
made with an approved conduit-bending means. In case, the conduits to be in-
stalled are galvanized steel, the junction and pull (draw) boxes shall be galvanized
with galvanized locknuts and bushings and full number of threads projecting through
to permit the bushing to be drawn tight against the box to ensure good electrical
contact.
B A minimum clearance of 300 mm shall be maintained for conduits that are installed
C Sleeves and inserts shall be furnished and installed as required for electrical work.
D Open conduit ends shall be carefully closed during construction to prevent foreign
materials from entering the conduit. Conduits, which have been crushed or de-
formed in any way, shall not be installed; or if so deformed after installation, shall be
replaced. Where conduits cross building joints, furnish and install, expansion fittings
for contraction, expansion and settlement 300 mm long, on both sides. Heavy gauge
rigid PVC conduits running in the concrete slab shall be interconnected with flexible
PVC conduits through the expansion joints.
E Conduit buried in concrete shall have 35 mm depth of cover over its entire length.
H The length of thread (for galvanized steel conduits) at the ends shall suit the length of
the internal thread of the fitting or accessory. Excess length shall not be allowed.
I Fixings for surface mounted conduit boxes, accessory boxes and saddles to concrete,
brick, building blocks and similar materials shall be by means of cadmium-plated steel
screws and raw plugs.
J The ends of conduits shall be cut straight and the length of screw thread (for the
galvanized steel conduits) shall be sufficient only to allow the ends of the conduit to
butt solidly in all couplings and against the shoulders provided in conduit boxes.
K The ends of galvanized conduits shall be carefully reamered to remove all burrs or
sharp edges after the screw threads have been cut. All dirt, paint or oil on the
screwed threads of the conduit and accessories shall be carefully removed
immediately prior to erection.
L The number of running joints in conduit shall be kept to a minimum and where in-
stalled locknuts shall be used to secure the sockets.
M Where space permits their use, plain bends are preferred than elbows. Maximum
number of bends is 3 as total.
O All joints in an assembly of conduit shall be painted after assembly with two coats of
moisture resisting paint. Arrangements shall be made, where necessary to prevent
the collection of moisture in conduit fittings.
P Runs terminating in flexible conduit shall have the latter fitted with special adaptors
in accordance with the Manufacturer's recommendations to ensure a weatherproof
connection and where applicable, earth continuity.
Q Where equipment is provided with a plain entry only, the conduit shall be fixed by
R All conduits shall be swabbed through before wiring is commenced and cable shall
not be drawn into any section of the system until all conduits and draw boxes for that
particular section are fixed in position.
S Deep boxes or extension rings on standard circular conduit boxes shall be used where
necessary in order to bring the front face of each box flush with the surface of the
ceilings.
T Nails shall not be used for fastening the boxes installed in concrete slabs.
U The box shall be so constructed as to prevent contact between the conductors in the
box and the supporting screws.
V Flush-mounted boxes shall be cast in concrete walls or grouted into hollow masonry
walls. Metal boxes threaded to raceways in exposed installations shall be separately
supported. Boxes installed in concealed conduit or raceway systems shall be set flush
with the finished surfaces. The location of all boxes shall be easily accessible and any
interference with mechanical equipment or structural features shall be relocated as
directed by the Engineer.
W All circuit wires shall be tagged to indicate clearly the circuit number and panel
designation at each pull box or access point. Circuit wires in excess of 600 V shall
have voltage identification.
X Device plates shall be installed with all four edges in continuous contact with finished
wall surfaces without the use of mats or similar devices. Device plates shall be in-
stalled vertically with an alignment tolerance of 2 mm.
B Outlet boxes for similar equipment shall be mounted at uniform heights within the
Raceway And Boxes For Electrical Systems Section 260533
Riyadh Sedra 2 (Prj. 2970) Page 12 of 14
same or similar areas. Without any restrictions by Drawings or instructions on Site,
and except where they are located 250 mm above work benches or positioned to suit
a particular piece of equipment, switches and socket outlets shall be mounted at 1.25
m and 300 mm from finished floor level, respectively.
C All outlet boxes shall be securely fastened. Exposed outlet boxes shall be attached to
permanent inserts or lead anchors with machine screws.
D All unused openings in outlet boxes shall be closed with knockout closers
manufactured for such purpose.
E Blank plates for wall outlets shall be attached by a bridge with slots for horizontal
and vertical adjustment.
F Outlet boxes shall be of shape and dimension suitable for their application as used
with switches, socket outlets, and lighting fixtures of the various types and mounting
methods applicable.
A Junction and pull boxes shall be located where required to facilitate pulling of wires.
B Boxes of adequate capacity shall be provided at every junction of the conduit system
and as required by the "IEE Building Regulations".
D Concealed surfaces of hot dip galvanized steel junction, pull boxes shall be given a
heavy field application of emulsified asphalt prior to installation.
B Effectiveness of grounding shall not be dependent upon the continuity of the metal
and a separate earth conductor shall run throughout the conduit for this purpose.
D Sizes of installed earthing conductor shall not be less than those indicated in relevant
regulations, codes of practice etc.
A All conduit connections shall be made up tight to provide good electrical conductivity
throughout the entire length of the conduit run including flexible conduits.
A All empty conduits shall be provided with suitable nylon rope or other approved. Not
less than 250 mm of slack shall be left at each end of the conduit run. Empty
conduits shall be tagged at each accessible end with a plastic tag identifying the pur-
pose of the conduit and the location of the other end.
3.9 PROTECTION
A The contractor shall exercise the necessary precautions to prevent the lodgment of
dirt, plaster or trash in conduit, fittings and boxes during the course of installation. A
run of conduit, which has become clogged, shall be entirely freed of these
accumulations or shall be replaced. Open conduit ends shall be carefully closed dur-
ing construction to prevent foreign materials entering the conduit. Conduits, which
have been crushed or deformed in any way, shall not be installed; or if so deformed
after installation, shall be replaced.
3.10 CLEANING
SPECIFICATION REV.
ECG ENGINEERING CONSULTANTS GROUP
CABLE TRAYS FOR ELECTRICAL SYSTEMS
KSA 260536 - 2970 1
SECTION 260536
Page
PART 1 - GENERAL 2
1.1 Related Documents 2
1.2 Summary 2
1.3 Submittals 2
1.4 Quality Assurance 3
1.5 Sequencing And Scheduling 3
1.6 Delivery,Storage And Handlines 3
PART 2 - PRODCUTS 3
2.1 Materials And Finishes 3
2.2 Sizes And Configurations 4
2.3 Cable Tray Accessories 4
2.4 Fire Stopping 4
2.5 Wiring Signs 5
2.6 Perforation Engineering 5
2.7 Cable Saddles 5
2.8 End Caps 5
2.9 Source Quality Control 5
2.10 Cable Trunking 5
PART 3 - EXECUTION 6
3.1 General 6
3.2 Installation 6
3.3 Grounding 7
3.4 Warning Signs 7
3.5 Field Quality Control 7
3.6 Cleaning 8
3.7 Protection 8
PART 1 - GENERAL
A. Drawings and general provisions of the Contract, including General and Supplemen-
tary Conditions and Division 01 Specification Sections, apply to this Section.
1.2 SUMMARY
A. This Section covers cable trays and accessories as required by the contract.
B. Related Sections.
1.3 SUBMITTALS
C. Shop Drawings: To scale 1:50 detailing the installation of main cable trays, including
plans, sections, and attachment to other construction elements, to show the sup-
porting intervals and inside clearances as suitable to actual assigned cables and
weights as per selected manufacturer’s recommendations.
D. In general:
1. Where multi-core cables are installed in ventilated cable trays, the sum of the
diameters of all cables installed shall not exceed 90 percent of the cable tray
E. Coordination Drawings: Floor plans drawn to accurate scale. Show accurately scaled
cable tray layout and relationships between components and adjacent structural and
mechanical elements.
A. All cable tray and components shall be the product of a single manufacturer.
A. Contractor should coordinate layout and installation of cable trays with other trades
and installation. Revise location and elevations as required to suit field condition and
as approved by the Engineer.
A. Store indoors to prevent water or other foreign materials from staining or adhering
to cable tray.
PART 2 - PRODCUTS
A. Cable trays, fittings and accessories shall be post fabricated heavy gauge hot-dip gal-
vanized, manufactured from mild steel sheets of thickness not less than 2 mm for
above 400 mm width. Trays shall not present sharp edges, burrs or projections inju-
rious to the insulation or jackets of cables. Fixing brackets shall be hot-dip galva-
nized. Cable trays shall be epoxy coated externally and internally for corrosion pro-
tection.
B. All cable tray sections shall be close return flange type, legibly and durably marked to
show the manufacturer name or logo.
C. Successful manufacturer shall have his logo engraved or bossed to the tray and a
strengthen means along the tray width by forming smooth left and right corrugation
in its base (not just 4 shape).
A. Sizes and configuration shall be as per table below and comply with IEC Code. Cable
trays shall carry the installed cable weight with an allowance for future cable load of
about 25% of the existing cable plus the weight of a tradesman standing at mid span
on tray (about 80 kg) at the expected locations.
B. Ladder-Type Trays.
1. Width: 100 mm
2. 150 mm
3. 200 mm
4. 300 mm
5. 400 mm
6. 600 mm
7. 800 mm
8. Inside Depth: 100 mm
9. Cross-Rung Spacing: 300 mm
C. Perforated-Type Trays.
1. Width: 100 mm
2. 150 mm
3. 200 mm
4. 300 mm
5. 400 mm
6. 600 mm
7. 800 mm
8. Inside Depth: 100 mm
A. Cable tray fittings, bends, tips, etc., shall be supplied by the same cable tray manufac-
turer and from the same material and finishing as cable trays. Site fabricated acces-
sories shall not be accepted.
B. In selecting materials for use as fire stops, some important factors such as gas tight-
ness, poisonous gases or fumes developed during installation or during a fire, and
heat dissipation are to be considered. Spray coating of fire resisting material (30 min.
A. All visible cable trays shall have approved durable type conspicuously located warn-
ing signs reading "WARNING! NOT TO BE USED AS WALKWAY, LADDER, OR SUPPORT
FOR LADDERS OR PERSONNEL", and shall be readable at 8-meter distance. All warn-
ing signs shall be in Arabic / English. Sign's lettering shall be black on yellow back-
ground and 40 mm high.
A. The perforation details shall provide both adequate heat dissipation and adequate
strength or rigidity to the bottom and sides of cable trays.
A. Cable installed on trays shall be secured by means of PVC covered metal saddles.
Cable should be clamped to the tray at 3m intervals horizontally or 0.9m vertically.
A. Plastic end caps for cable trays and tray support shall be provided, to avoid personnel
injury.
A. Installation: Secure trunking of all sizes at intervals not exceeding 1200 mm. Joints
are not to overhang a fixing by more than 500 mm.
B. Trunking passing through walls and ceilings is to have the cover fixed solidly for 25
mm either side of walls and for 150 mm either side of floors and ceilings.
C. Vertical sections of trunking over 900 mm long are to have staggered insulated tie-off
studs to support weight of cables.
F. Earthing: Do not use metal trunking as earth continuity conductor. Provide protective
conductor in accordance
PART 3 - EXECUTION
3.1 GENERAL
A. Provide cable trays with the indicated types and sizes as per the approved shop
drawings, complete with manufacturer's recommended covers, fire barriers, strips,
dropouts, fittings, bolts, conduits adapters, hold-down devices, supports, connectors,
bonding jumpers, etc.
3.2 INSTALLATION
A. General: Cable trays shall be installed (level and plumb) as indicated and according
to manufacturer's written instructions and reference standard. Cable tray shall be
supported at not more than 1.5 m intervals, and/or in accordance with Manufactur-
er's instructions and Engineer's approval. Supports for horizontal elbow trays fittings
shall be placed within 0.2 m of each fitting extremity. Remove burrs and sharp edges
of cable trays. Unless otherwise indicated, cable tray supports shall be securely fas-
tened to the building structure.
1. Supports shall be designed to carry the greater of the calculated loads with an
allowance for future load about 25% of the existing weight plus a tradesman
standing at mid span on tray about 80 kg at the expected locations
2. Make connections to equipment with flanges fittings fastened to the tray and
to the equipment. Support the tray independently of fitting. Do not carry
the weight of the tray on the equipment enclosure.
3. Provide adequate supports for cables leaving or entering the tray individually
to prevent stress on cables.
4. Install expansion connectors in cable tray runs that exceed 30 m. Space con-
nectors and set gaps according to IEC.
5. Change in direction, elevation and cable tray connection shall be in accordance
with manufacturer's instruction and by standard fittings, of same manufactur-
er.
6. Locate cable tray above piping except as required for tray accessibility and
otherwise indicated and providing sufficient space to permit access for in-
stalling cables.
7. Cable trays for different systems (for power, communications and data pro-
cessing cables), and different insulation levels (600 V and 13.8 or 18kV) to be
installed separately.
3.3 GROUNDING
A. After installation of cable trays is completed, install warning signs in a visible location
on or near cable tray according to the engineer instructions.
3.6 CLEANING
3.7 PROTECTION
B. Repair damage to galvanized finishes with paint recommended by the tray Manufac-
turer.
SPECIFICATION REV.
ECG ENGINEERING CONSULTANTS GROUP MEDIUM-VOLTAGE OIL
KSA TRANSFORMERS 261201 - 2970 1
SECTION 261201
Page
PART 1 - GENERAL 2
1.1 Related Documents 2
1.2 Summary 2
1.3 Submittals 2
1.4 Warranty 3
1.5 Quality Assurance 3
1.6 Delivery, Storage, And Handling 4
1.7 Project Conditions 4
1.8 Coordination 4
PART 2 - PRODUCTS 4
2.1 Identification Devices 8
2.2 Source Quality Control 8
PART 3 - EXECUTION 9
3.1 Examination 9
3.2 Installation 9
3.3 Identification 9
3.4 Connections 9
3.5 Field Quality Control 10
3.6 System Validation 10
PART 1 - GENERAL
1.2 SUMMARY
A. This Section includes the oil type with medium-voltage primary 13.8 KV and low-
voltage secondary 400/230 V, 60 Hz.
B. The Contractor is responsible to supply and install the transformer (s) according to
the latest requirements of Saudi Electricity Company (SEC). This shall require from
the contractor’s manufacturer to obtain the approval (before delivering) for the type,
voltage, losses, etc. from SEC. Any additional requirements shall be considered
without any extra cost to the Contract.
1.3 SUBMITTALS
C. Coordination Drawings: Floor plans, drawn to scale, on which the following items are
shown and coordinated with each other, based on input from installers of the items
involved:
A. The Maintenance Period for the equipment and appurtenances shall begin when the
performance test on the equipment and appurtenances has been successfully
completed and preliminary accepted as stipulated in the Conditions of Contract.
F. Electrical Components, Devices, and Accessories: Listed and labeled as defined in IEC
and/or BS, by a testing agency acceptable to authorities having jurisdiction, and
marked for intended use.
A. Store transformers protected from weather and so condensation will not form on or
in units. Provide temporary heating according to manufacturer's written
instructions.
1.8 COORDINATION
A. Coordinate size and location of concrete bases. Cast anchor-bolt inserts into bases.
Concrete, reinforcement, and formwork requirements are specified in Division 03.
C. Coordinate installation a sump pit of sufficient size retains the liquid capacity of
transformer according to the mechanical drawings. The transformer room floor shall
be sloped to drain any transformer seepage to the sump pit.
PART 2 - PRODUCTS
B. Insulating Liquid: High quality mineral oil class 1, complying with IEC 60296.The
insulating oil shall contain an inhibitor to extend its oxidation life. Rating and
stipulated capacity shall be continuous Site-rated capacity under all encountered
environmental and climatic conditions. The oil shall be best quality mineral oil of high
breakdown strength, low viscosity, high resistance to oxidation and shall not
deteriorate under all loading condition.
J. Full-Capacity Voltage Taps (13.8 kV): Total fife taps, four nominal 2.5 percent taps, 2
above and 2 below rated primary voltage; with externally operable tap changer for
de-energized use and with position indicator and padlock hasp. The tape changer
shall be gang-operated and be capable of withstanding full transformer short circuit
current without damage. Tap changer shall have at any tap position indicator visible
from base level.
K. Maximum Losses: The indicated table below are the maximum acceptable values.
And according to SEC Requirements:
L. Permissible Overload: after thermal equilibrium has been rated at 75% of rated load,
the transformer shall be capable of sustaining the overload conditions listed in the
following table without the transformer winding hot spot temperature exceeding 140
deg C.
30 deg C 40 deg C
133 240 155
150 98 65
M. Cooling System: Class OA, self-cooled (ONAN) (for oil immersed transformers the
identification is expressed by a four letter code as following.
1. O (internal cooling medium): Mineral oil or synthetic insulating liquid with fire
pointless than or equal 300 deg. C.
2. N(Circulation mechanism): natural flow through cooling equipment and in
windings,
3. A(External cooling medium): Air
4. N (circulation mechanism for external cooling medium): Natural convection
P. Core: The cores of the transformer are made of grain-oriented magnetic, high
permeability cold-rolled silicon steel laminations with low losses. The lamination
should be insulated with suitable varnish or paint; solid insulation is not acceptable.
Design of the core shall be made to reduce the vibration and minimize noise level.
Q. Windings: Windings shall be of high grade electrolytic copper conductors with low loss
as per SEC and IEC requirements. the winding shall be clamped effectively so that
they withstand shocks and vibrations during transport and forces produced by the
most sever short circuit current. The winding shall be uniformly insulated using high
dielectric strength tapes having very good temperature stability and be firmly braced.
R. Noise Level: the noise level emitted by a transformer at full load shall not exceed 48
dB at measured distance of one meter. And measurement shall be accordance to IEC
60076-10
1. 25 times full load current for ratings of 50, 100, 200 and 300 kVA.
2. 20 times full load current for rating of 500 kVA.
3. 17 times full load current for ratings of 1000 and 1500 kVA.
U. Bushing: High and low voltage bushings shall be of highest quality glazed porcelain.
Suitable for rated voltage and current, indoor and outdoor installations. Bushings
shall generally comply with the requirements of IEC Standard 60137. The minimum
creepage distance shall not be less than 2 cm/KV for indoor and 4 cm/KV for outdoor
or according to SEC requirements. The MV bushings shall be labeled U, V, W by using
indelible black color paint. Phase identification by adhesive stickers is not acceptable.
V. Tank and Base: Transformer tank shall incorporate cooling fins. Final finish shall take
the form of sand blasting to bare metal, followed by at least two coats of suitable
primer and two final coats, medium grey color or any other color recommended by
the supplier. Transformer tank shall be welded steel construction, suitable for
vacuum filling (300 mm vacuum) oil and able to withstand all stresses during
transport and operation including full short circuit. The tank base shall be fitted with
oil drain and sampling valve. Gasketed joints for tank and cover, bushings and other
bolted attachments shall be so designed that gaskets shall not deteriorate due to
weathering.
Transformer base shall be designed to permit skidding in directions parallel to either
centerline.
1. MV Cable End Box: The transformer shall be fitted with suitable end
termination box with cable entry coming vertically from bottom/top according
to the approved workshop drawings. The box shall include cable clamps,
grounding connectors, and its size shall be adequate for terminating MV cables
with size as shown on the drawings. The box shall be single gasketed
removable bolted cover. The box shall be fitted with cables entries steel
knockouts suitable for cables. Loose rubber bushings shall be provided inside
of this box for these knockouts.
2. LV Cable End Box: The transformer shall be fitted with suitable LV cable end
box having non-magnetic material gland plate with appropriate size single
compression brass gland according to the cable size shown on the drawings
Y. Accessories: Grounding pads, lifting lugs, and provisions for jacking under base.
Transformers shall have a steel base and frame allowing use of pipe rollers in any
direction, and an insulated, low-voltage, neutral bushing with removable ground
strap. Include the following additional accessories:
A. Reference Standards:
C. The owner and/or his representative to be notified by the date of tests at least 14
days before date of the tests and indicate the tests approximate duration.
3.1 EXAMINATION
A. Inspect each transformer and related accessories for damage, defects and
completeness before installing.
B. Examine areas and conditions for compliance with requirements for medium-voltage
transformers.
D. Examine walls, floors, roofs, and concrete bases for suitable mounting conditions
where transformers will be installed.
E. Verify that ground connections are in place and that requirements in Division 26
Section "Grounding and Bonding for Electrical Systems" have been met.
F. Proceed with installation only after unsatisfactory conditions have been corrected.
3.2 INSTALLATION
3.3 IDENTIFICATION
A. Identify field-installed wiring and components and provide warning signs as specified
in Division 26 Section "Identification for Electrical Systems."
3.4 CONNECTIONS
B. Perform the following field tests and inspections and prepare test reports:
B. Simulate malfunctions to sound alarms. Check all systems thoroughly for correct
operation. Test equipment for this function shall be furnished by the Contractor.
C. Immediately correct all defects and malfunctions disclosed by tests. Use new parts
and materials as required and approved and retest. Provide a report certifying
completion and validation of each system.
SPECIFICATION REV.
ECG ENGINEERING CONSULTANTS GROUP RING MAIN UNIT
KSA 261301 - 2970 1
SECTION 261301
Page
PART 1 GENERAL 2
1.1 Related Documents 2
1.2 Summary 2
1.3 Submittals 2
1.4 Quality Assurance 3
1.5 Coordination 3
1.6 Delivery, Storage And Handling 4
1.7 Warranty 5
1.8 Instructions And Training On Operation And Maintenance 5
PART 2 PRODUCTS 5
2.1 Manufacturers 5
2.2 Performance And Design Requirements 5
2.3 Components 5
2.4 Accessories 9
2.5 Voltage Presence Indicators (Vpi) 9
2.6 Fault Passage Indicator 9
2.7 Fabrication 10
PART 3 EXECUTION 10
3.1 Installation 10
3.2 Field Quality Control 10
PART 1 GENERAL
1.2 SUMMARY
A This section covers Ring Main Unit which shall be furnished and installed as specified
herein and as indicated on the drawings.
B Equipment furnished and installed under this section shall be fabricated, assembled,
erected, and placed in proper operating condition in full conformity with the
drawings, specifications, engineering data, instructions, and recommendations of the
equipment manufacturer unless exceptions are noted by the Engineer.
D During tendering, the Contractor shall select one of the manufacturers whose is
capable of delivering Ring Main Unit which fulfill the requirement of Saudi Electric
company (SEC) and had previous approvals of similar types. By this awareness the
manufacture shall give the correct quotation for the required Equipment including
EDC requirements during tendering.
E Before delivery, the Contractor is responsible to obtain the approval for the
manufacturer, type, voltage, protection devices, meters, etc. from the Saudi
Electrical Company (SEC) whose additional requirements shall be considered even if
these requirements are not clearly mentioned in these specifications.
1.3 SUBMITTALS
A Drawings and Data: Complete drawings, details, and specifications covering the
equipment furnished under this section shall be submitted.
B Complete and accurate drawings of the equipment, including plan, front, and
sectional or side views, and base plans showing anchor bolt locations and base
details, shall be provided.
C Within 90 days after the Notice to Proceed, the Contractor shall furnish outline
drawings and dimensional data which fully describe the projected floor space
required for the equipment; the absolute minimum working space required at the
front, rear, and sides of the equipment; the equipment height; and the equipment
weight.
Ring Main Unit Section 261301
Riyadh Sedra 2 (Prj. 2970) Sheet 2 of 11
D Operations and Maintenance Manuals/Charts and Spare Parts Data: Complete
operations and maintenance manuals/charts including spare parts data and wiring
diagrams of all equipment furnished under this section.
C Manufacturer’s Experience: Each Ring Main Unit (RMU) shall be a product of RMU
manufacturer who has designed, fabricated, and furnished equipment of the type
and size specified which has been successfully installed for a period of not less than
five or ten years in KSA or Gulf Area.
D Shop Tests: All standard factory tests, including quality control tests, shall be
performed on the RMU. Four certified copies of test results shall be submitted to
the Owner Representative before the equipment is shipped.
1.5 COORDINATION
A All equipment specified under this section shall be furnished by or through a single
manufacturer who shall be responsible for the design, coordination, testing, and
satisfactory performance of all the components.
F Protective relay coordination curves for each relay provided as a part of the unit
substation assembly.
G Protective fuse curves for each current-limiting fuse provided as a part of the RMU
assembly.
H Within 28 days after the return of the initial equipment shop drawing submittal, the
equipment manufacturer shall provide the above information to the Contractor in
accordance with Section 26, Electrical Materials and Method.
A Delivery Schedule: Delivery schedule of the RMU shall be coordinated with the
Engineer and the Contractor. A copy of all correspondence and memoranda
regarding delivery of each RMU beyond point of manufacture to the construction
sites shall be submitted as required at the Conditions of Contract.
D In additions to the protection specified for prolonged storage, the packaging of spare
parts shall be prepared for export packing and shall be suitable for long-term storage
in a damp location. Each spare item shall be packed separately and shall be
completely identified on the outside of the container.
Spare parts list for normal operation and maintenance for 3 years recommended by
manufacture.
A The Maintenance Period for the equipment and appurtenances shall begin when the
performance test on the equipment and appurtenances has been successfully
completed and preliminary accepted as stipulated in the Conditions of Contract.
A Contractor shall provide instructions and training for the staff to be assigned in the
operation and maintenance of the equipment specified under this section. Training
and instructions shall be in accordance with the requirements set forth at the
Conditions of Contract.
PART 2 PRODUCTS
2.1 MANUFACTURERS
A System Characteristics: The system will be rated at 13.8 KV, 3-Phase, 60 Hz. The
approximate fault current shall be 500 MVA unless otherwise as shown on the
drawing.
1. Two SF6 Load break switches with earthing switch mechanically interlocked.
2. One SF6 Load break switch with ampere rating as indicated in the drawings for
feeding power transformer
3. Earth leakage indicator with Ferranti C.T.
4. Complete with bus bars and supporting insulators
5. Complete with copper earthing bar and there shall be a 25 mm2 earthing
copper braid install from each earthing switch to earthing bar
2.3 COMPONENTS
A RMU Enclosure: Enclosure shall be made of steel sheet 2.5 mm thick before paint
and treated against rust and provided with priming, intermediate and finishing coats
of electrostatic painting powder from inside and outside.
B Each switch shall be enclosed in a special compartment with its own door which have
device to prevent self-closing. The door shall be interlocked with the LBS such that it
can’t be opened unless the LBS is open. Door shall have a rubber sealing gasket.
D All bus bars shall be electrical copper of section not less than 400 mm2, mounted on
support insulators enough to withstand mechanical forces which may happen due to
short circuit 21 kA r.m.s. at 13.8 kV for 1 sec.
F Each switch compartment shall be equipped with suitable clamp or any other mean
for supporting and fixing the cable or end box.
H Each switch board shall be supplied with a delachable insulated operating handle ≥
650 mm.
J Detailed drawings and technical specifications shall be attached with the offer.
1. Load break switch and its mechanically interlocked earthing switch shall be
SF6 insulation.
M Specifications and tests shall comply with IEC 62271-103 for load break switch
(L.B.S.).
O The earthing switch shall be manual operated with mechanical lock which prevents
its switching while the main switch is on.
P When fuse LBS switches are used then two earthing switches shall be used. One
above fuse and one below fuse. All LBS shall be equipped with permanent voltage
presence lamps.
Q The rated short-time withstand current of the earthing switch shall be at least equal
to that assigned to the disconnector (L.B.S.)
S Cable L.B.S. shall also fulfill the conditions for isolating distance acc. To IEC 62271-
102 prescribed for isolators.
T At the side of the fused switch compartment shall be the outlet of 3 single or multi
core XLPE cables. That side shall be equipped with an insulating backelite plate with
three holes to pass the XLPE cables outside to the transformer. The level of this
backelite plate shall be ≥ 200 mm over the bottom, from outside, the place of the
backelite plate shall have a cover of the same sheet steel bolted with detachable
bolts. Depth of cover ≥ 22 cm.
U Contractor shall submit type tests certificates for the offered equipments according
to IEC.
V Routine tests shall be in accordance with IEC and shall be attended by Employer’s
representative(s).
W Earth Fault Indicators: 220 V, 60Hz, Automatic reset type complete with Ferranti
current transformer which will be erected around the cable sheath, according to the
specification.
Z A powder filled fuse-link shall not emit flame or powder although a minor emission
of flame from a striker is permissible, provided this does not cause breakdown or
significant electrical leakage to earth.
AA After the fuse has operated, the components of the fuse apart from these intended
to be replaced after each operation shall be in the original state. It shall be possible
to remove the fuse-link in one piece after operation.
BB Strikers shall comply with the requirements specified in Sub-clause 18.3 of IEC
60282-1.
EE Fuse Ratings:
FF Features Required:
1. The fuse links shall have the dimensions as per attached spec.
2. The fuse link contacts shall be silver plated.
3. The fuse link body shall be of porcelain.
4. On each fuse link the badge of the Employer shall be printed.
5. Each fuse link shall be equipped with a striker which complies with Sub-clause
18.13 of IEC 60282-1.
1. Current Transformers (CT's): Class 0.5 for metering and 5P10 for protection
n10.
2. Potential Transformers (PT's): Class 0.5 for the first core (metering) and class
3P for the second core (protection).
II All potential transformers shall be provided with current limiting fuses. Voltage
rating for the secondary winding shall be of ratios:
For metering and protection. the open delta winding shall be loaded by a resistor to
avoid Ferro resonance; the resistor is to be selected by the switchgear manufacturer.
JJ The thermal rating of the transformers shall be sufficient to provide the total current
required to operate the burdens on the secondaries without exceeding the rating of
transformer as indicated on nameplate. PT's (1 per phase) shall be installed either as
a unit drawout assembly or with an isolating switch in a separate compartment so
that the transformers, primary fuses and secondary circuits may be inspected and
tested in a completely de-energized condition.
KK CT's shall have mechanical and thermal rating equal to the rating of the circuit
breaker and LBS. Secondary rating shall be 5 amperes and primary ratings shall be as
shown on one-line diagram. Transformer shall be capable of carrying 120 percent of
rated current for one hour. Ground current sensing transformers shall have a one
ampere secondary current.
Ring Main Unit Section 261301
Riyadh Sedra 2 (Prj. 2970) Sheet 8 of 11
LL Control switches shall be the rotary enclosed type with positive means for
maintaining contact position.
2.4 ACCESSORIES
A Signage: Each RMU shall have engraved laminated nameplates screwed to the doors
of each individual compartment and wiring diagrams pasted inside each door.
B Each RMU shall be furnished with a sign marked “DANGER - HIGH VOLTAGE”. Letters
shall not be less than 25mm high, 6 mm stroke. Signs shall be laminated plastic, red
letters with a white background.
C All compartments with voltages from sources outside of the compartment shall have
a sign on the compartment door marked “CAUTION - THIS UNIT CONTAINS A
VOLTAGE FROM A SOURCE OUTSIDE OF THIS UNIT”. Letters shall be black on a high
visibility yellow background. Signs shall be adhesive backed vinyl approximately
75mm by 125mm.
A Each RMU function shall be equipped with a Voltage Presence Indicator (VPI) on the
front cover to indicate whether there is voltage in the cables.
C Cable connection bushings shall be equipped with capacitive dividers that will supply
low voltage power to the voltage presence lamps.
D The lamps shall be of high performance LED technology to insure high visibility and
long life duration. Three voltage sensing inlets shall be provided on each function to
allow checking the phase concordance.
E It shall be possible to replace the voltage presence indicator while unit remains
energized, guaranteeing the safety of people.
A Each of the two Incoming Load break switches shall be equipped with a fault Passage
indicator
B The voltage signal shall be taken from the Voltage Presence Indicator (VPI)
connected to capacitive divider in each load break switch cable bushing.
C The voltage detection device shall display the MV network voltage. It is not allowed
to use a voltage measuring tool to calibrate the device.
D The fault passage indicator function is used to detect and localize the faulty part of
the network.
F It shall indicate permanently the load currents of each phase and memories the maxi
meters of each phase.
H In order to guarantee a fault validation on cable with low load value, a validation by
voltage presence shall be provided.
2.7 FABRICATION
A Surface Preparation: Remove all casing projections, weld flux, or splatter by hand
scraping, hand impact tools, etc., followed by wire brushing or power grinding. Sharp
corners or sheared edges shall be dulled and radiused with power grinder to improve
paint adherence.
B Exposed grooved surfaces shall be finished smooth by filling and thoroughly cleaned
as required to provide a smooth uniform surface for painting.
C Shop Painting: Unless galvanized surfaces are provided, all ferrous metal surfaces
shall be painted with a prime coat and given two or more finish coats of paint.
PART 3 EXECUTION
3.1 INSTALLATION
A The RMU base assembly comprises the preformed concrete sump to which are fixed
2 opposing sheet steel support trays. The steel support trays, which overhang the
concrete sump, serve to support and secure RMU together with the external
extremities of the cable entry compartments.
A Test and Checks: The following minimum test and checks shall be performed before
energizing the substation.
B Megger terminals and buses for grounds after disconnecting devices sensitive to
megger voltage.
G Tests Certificate
1. Type test certificates shall be submitted with the offer (if not before
submission) including:
H OWNER may require its representative(s) to attend some or all of the routine tests
according to same above IEC publications.
SPECIFICATION REV.
ECG ENGINEERING CONSULTANTS GROUP LOW VOLTAGE SWITCHBOARDS
KSA 262413- 2970 1
SECTION 262413
Page
PART 1 GENERAL 2
1.1 Related Documents 2
1.2 Summary 2
1.3 Submittals 2
1.4 Quality Assurance 4
1.5 Delivery, Storage And Handling 4
1.6 Warranty And Product Quality 4
PART 2 PRODUCTS 5
2.1 Manufacturers 5
2.2 General 5
2.3 Switchgear 7
2.4 Incoming Supply And Outgoing Circuits 10
2.5 Circuit Breakers 11
2.6 Power Air Circuit Breakers (Pacbs) 12
2.7 Distribution Board For Outdoor Lighting 15
2.8 Instrumentation And Controls 15
2.9 Mcc Special Requirements 16
2.10 Surge Protection Device (Spd) 16
2.11 Factory Testing 16
2.12 Painting And Anticorrosion 17
PART 3 EXECUTION 17
3.1 Inspection 17
3.2 Preparation 17
3.3 Electrical Work 17
3.4 Mounting 18
3.5 Installation Supervision 18
3.6 Field Testing 18
3.7 System Validation 19
PART 1 GENERAL
B. The Contractor is responsible to supply and install the low voltage switchgear accord-
ing to the latest requirements of the Saudi Electricity Authority (SEC). This shall re-
quire from the contractor’s manufacturer to obtain the approval (before delivering)
for the type, voltage, form, etc. from Authority have jurisdiction.
1.2 SUMMARY
A. This section covers low voltage metal enclosed switchgear as indicated on the
Drawings and required by the Contract and shall include the following items:
1. Switchboard
2. Distribution Boards
B. Related Sections
1.3 SUBMITTALS
A. Submit the following in accordance with the Conditions of the Contract and Division-
1 Specification Sections.
5. Provide thermal stress limitation checks for all breakers and cables as per
manufacturer’s data
6. Short circuit calculations
7. Provide full discrimination and relay coordination studies for all breakers as
per manufacturer’s data according to the requirements shown on the single
line diagrams
Test Programs:
1. Plans, front, rear and side elevations, with indication of all face-mounted
equipment exact dimensions and weights.
2. Drawings of arrangement of equipment inside the board.
3. One-line schematic diagram of circuits.
4. Control circuit diagram, showing all auxiliary contacts remote control, if any,
and remote indication.
5. Indication of arrangement of main incoming feeders and outgoing feeders
(bus-bars or cables).
A. Reference Standards
1. The work and equipment of this section shall be designed, manufactured and
Design verification in accordance with the International Electro-Technical
Commission (IEC) or other approved equivalent International Standards.
2. International Electro-Technical Commission IEC 61439.
3. Electrical Regulations/Code Compliance: comply with applicable local
regulations/code requirements (SASO). This will have precedence over other
codes/standards nominated for the project, unless otherwise approved in
writing. Switchboard to be approved by SEC and manufacturer to be listed in
SEC vender list.
A. Shipments shall be securely packed for delivery and transit, protected against
excessive heat and humidity and waterproofed for protection against water damage.
When material must be bundled due to excessive size each bundle shall have a tag,
made of metal, securely tied on with heavy gauge wire. Purchaser's markings shall
be die-stamped on the tag.
B. Equipment, relays, and other components with moving or fragile parts shall be
properly blocked, tied or packed to prevent damage.
C. Any component shipped separately shall be clearly marked with description, use and
installation instructions.
D. All packages shall be marked with equipment tag number for identification when
shipped and when received at site.
F. Each shipping unit shall be equipped with shipping angles or lifting lugs for handling
by crane.
A. one year warranty after the date of Substantial Completion, for the low voltage
switchgear shall be provided, for the materials and manufacturing quality control.
B. Contractor shall agree to repair or replace the equipment that does not comply with
the requirements or fails in work.
2.1 MANUFACTURERS
2.2 GENERAL
A. Materials and equipment shall be new and completely assembled, wired and type
tested at the factory requiring only field installation and connection of power and
control circuits to place the equipment in service, except for multi-unit switchgear
which could be divided into shipping section after being completed and tested at the
factory.
B. All Switchboards shall be Type tested (Design Verified Assemblies) against short
circuit as a minimum as per the latest IEC 61439 and manufactured only by
manufacturer having ISO 9001 Certificates. The Manufacturer shall also submit test
certificates such as KEMA, ASTA or as issued by any other accredited testing
authority confirming the declared short circuit ratings of Switchboards and circuit
breakers
E. Index of protection for all distribution boards & panel boards shall be as follow:
F. Switchgear shall be metal enclosed, form (2b) as per IEC 61439, complete with
stationary structure, have complete bussing and front access apparatus described
herein.
G. Provide a dead hanged front panel behind the door of a distribution board, to allow
safe operation. This front panel shall carry the required tags of equipment to show
function of each breaker inside or any push-button, etc.
H. The Contractor shall make sure that the space for each switchboard is available in
accordance with the requirements for the installation and operation and
maintenance of the equipment as specified and supplied by the Manufacturer, and
as per IEC 61364, 61439. Any inaccuracy in the building shall be corrected as
required and directed by the Engineer, and at no extra charge to the Employer.
J. The switchgear shall contain equipment with ratings as indicated on the one-line
diagram, panel details, and in this Specification.
K. All equipment designated as "spare" shall be fully equipped with all of the necessary
items required to make the equipment operable by connecting to the outgoing
power and control leads.
L. Switchgear shall have additional "space" for at least 20% of its outgoings for future
extension. Equipment shall have a blank front cover and shall be equipped with
horizontal and/or vertical bussing complete with the necessary screens required and
circuit breaker cassette for the future addition of a circuit breaker suitable or a
combination of breakers within the space factor limits.
N. Switchgear shall be suitable for future extension on both ends. Unequipped space
units will be furnished only as required to balance the switchgear assembly.
O. All ratings shown on the one line diagrams are the required operational equipment
ratings at the ambient temperature.
P. The Contractor shall assume all responsibility for mechanical and electrical
coordination of equipment and devices required by the Drawings and Specifications.
Q. Interrupting capacities and short circuit ratings shown on the Drawings are for
guidance only; Contractor shall submit calculation for actual levels to the Engineer
for approval.
R. The prospected short circuit current (Isc) value indicated at each bus-bar on drawings
shall represent the maximum 3-phase symmetrical R.M.S. kA, and it is the rating that
all switchboard components (e.g. bus, bars, bolts, circuit breakers, etc. shall
withstand.
S. Buses shall be 99.8% electrolytic copper of sufficient size to limit temperature rise to
45C or an additional derating would be necessary.
V. Any switchboard column housing a number of circuit breakers summing more than
3000 Amp of name-plate ratings should be fitted with a top heat extraction fan and a
bottom ventilating louver fitted with a front filter to maintain the switchboard
protection degree.
W. The phase arrangement on 3-phases buses shall be R.S.T from front to back, left to
right, or top to bottom from the front of the switchboard.
Low Voltage Switchboards
Riyadh Sedra 2 (Prj. 2970) Section 262413
Page 6 of 19
X. All switchboard components shall be of the same manufacturer and must be tested
according to IEC standards. The assembly must be design verification and fully
coordinated. All design must be in accordance to temperature-rise type test.
Y. All switchboard doors shall have a key lock and indicating lamp for ON/OFF-READY, in
addition to the necessary equipment for security identification.
Z. All indicating lamps used in the switchboards should be semi-conductor LED diodes.
Use of neon or incandescent indicating lamps is not acceptable.
AA. All indicating lamps and pushbuttons should be chromatid metallic base and body.
BB. All panel access doors shall be provided with a master key for maintenance and
operation.
CC. The panel shall be designed to permit continuous operation of all components
mounted therein with panel ambient temperatures of up to 45C for indoor
installation and 50C for outdoor (with shade) installation.
DD. Main circuit breakers of the MDB shall be provided with smart interface module SIM
for ACB and MCCB circuit breakers as indicated on the drawings.
EE. Digital Power Meters with Modbus communication protocol for Main switch boards
shall be provided as required in single line diagram and according to the following:
1. Accuracy class 0.5, dual source, digital energy meters with provision for Time
of Day (TOD) tariff and Real Time Clock (RTC)
2. The meter shall be suitable for satisfactory continuous operation under the
following condition:
3. The meter shall be protected against malfunction due to the ingress of vermin.
4. All meters and equipment’s shall be complying with IEC and ISO standards:
2.3 SWITCHGEAR
A. The switchgear shell is composed of a rigid frame, the frame structure is assembled
with a C-shaped skeleton not less than 2 mm thick shaped in one time by a flexible
processing line, the inner part of the partition plate is also made of aluminum zinc
coated plate. All the metal structural parts of the cabinet are treated with anti-
corrosion.
C. Each low-voltage cabinet has a nameplate. The equipment nameplate shall be made
of stainless steel plate. All rating values shall be indicated on the nameplate at least
as specified in the standard. Each drawer unit is equipped with a circuit label marked
with circuit name, which shall be in Chinese and English.
D. The switchgear should have good ventilation and heat dissipation conditions and
sufficient temperature rise margin, such as the ventilation is equipped with louvers
or other vents, measures shall be taken to prevent water leakage and small animals
from entering, and relevant standards shall be complied with SEC Requirements.
E. Cabinet materials and cabinet structure should be able to prevent the generation of
fault arc. Once the fault arc occurs, it can be extinguished in a short time. The
structure of the switchgear compartment should be able to withstand the arc
generated by the three-phase short circuit or the pressure generated by the free gas
without causing damage, and should provide appropriate measures to eliminate the
gas.
F. The drawer type cabinet should be separated into three small rooms, i.e. main bus
bar room, electrical room and cable room. The compartment can meet the following
requirements:
1. The separation between functional units and compartments is clear and relia-
ble, so that the work of other units will not be affected by the failure of a unit
and the failure will be limited to a minimum range.
2. The openings between the compartments ensure that the gas generated by
the circuit breaker during short-circuit breaking does not affect the normal op-
eration of the functional units of the adjacent compartment.
G. Apparatus: All auxiliary equipment, transition sections, bus duct, and other necessary
components required for complete installation and proper operation, under TN-S
distribution system, although not specifically listed herein, shall be furnished and
included in the switchgear assembly.
H. All circuit breakers of the same type and rating shall be completely inter-changeable
between compartments and between units at different locations on the site.
I. All doors, panels and cubicles in general, shall be sealed with neoprene or equivalent
gaskets. Enclosure shall be dust and vermin proof. Provide a directory of circuits on
inside cable compartment.
J. Fuses (if applicable) shall be of the same manufacturer, dual elements current
limiting type.
M. All live conductors behind doors should be protected against accidental contact by
use of transparent plexi-glass sheet marked with an electrical shock warning label.
N. Fuses or miniature circuit breakers shall be provided so that relays, controls and
instruments may be isolated whilst other essential circuits are kept energized.
Accordingly, the control circuit should be divided into two separate circuits
(indicators circuit) and (circuit breakers control circuit).
O. Supply of any control shall be via a suitably sized control transformer (at least three
times the VA rating of all connected devices). Control circuits which are fed directly
from the busbar will not be accepted. The control transformer shall be protected at
its primary and secondary sides by HRC fuses of suitable size.
P. Main Bus: The main bus shall be made of 99.9% pure copper and shall be continuous
current ratings as indicated on the Drawings or shall be of equal rating to the
maximum setting of the protective device on the incoming side whichever is greater.
Q. Copper bus bars require tinning or silver plating at the lap joint. All copper rows are
tinned and bolted securely and tightly so that the bus bar temperature remains
essentially constant at the initial contact pressure around the bolt hole from the
standard rated ambient temperature to the rated full load temperature. The contact
surface temperature of the connector section is less than 70°C at full load under the
operating ambient temperature.
The bus-bars shall be insulated with a 1000 V electrostatic epoxy insulating paint to
limit the possibilities of internal short circuit. The bus-bar dropper shall be rated at
125 % of the current carried by the bus-bar
R. The creepage distance and electrical clearance between the live parts of the bus bar
and main circuit connections and their grounded metal components shall be not less
than 15 mm.
S. All bus-bars shall be fully rated and extend with the same size along the entire length
of the switchgear assembly.
T. All horizontal bussing shall have provisions for future extension on either end.
U. All main bus connections shall be tight and tin plated, corrosion-free and with
sufficient bolts to withstand the symmetrical fault currents indicated on the
Drawings.
V. The bus-bar supports shall be formed of high strength, low moisture absorbing, high
impact material with ample creepage distance between bus-bars. Bus-bars shall be
braced to withstand the symmetrical fault currents indicated. All busbar bracing
materials should be of a non-magnetic material.
X. Vertical Bus: All vertical bus-bars shall be of same material of main bus and shall
have sufficient capacity to supply all installed circuit breakers and each vertical
section shall have full height and depth, fire stop barriers of approved fire resistant
material.
Y. Vertical bus compartment shall be completely enclosed and isolated from other
components.
Z. All vertical bus connections shall be tight, corrosion free and be able to withstand the
symmetrical fault currents indicated.
AA. Neutral Bus: Neutral buses shall be sized for the same capacity of the main bus and
shall be of copper.
BB. The neutral bus shall be separate and isolated from the ground bus and completely
insulated from ground. A removable bus link shall be provided for grounding the
neutral bus as shown on Drawings.
CC. All neutral bus connections shall be tight and corrosion free.
DD. Ground Bus: A solid copper ground bus shall extend along the full length of the
switchgear and rigidly bolted to the switchgear lower part compartments, frame and
all sections of structure.
A. Source: Incoming supply shall be 400 volts, 3-phase, 5 wires, 60 Hz, with symmetrical
fault current level available at the incoming line terminals as indicated on Drawings.
B. The connections from the incoming line terminals to the main bus shall have the
same capacity as the main horizontal bus.
D. If the incoming power supply is shown as cables a removable metallic gland plate
with thickness of not less than 5 mm shall be fixed to the top or bottom or both sides
of the panel depending on the direction of the cables. A non-ferrous material must
be used in case of single core conductors. Pressure lugs shall be provided for the
termination of cables, whose sizes are as shown on the one line diagrams.
E. Outgoing Circuit by Cables: All outgoing feeder sizes shown on Drawings are
considered a minimum and the Contractor shall adjust to conform to the IEC 60364
Regulations after final equipment selection, same gland plates mentioned above will
be applicable.
A. Main incoming, bus tie circuit breakers shall be four-pole, single-throw, molded case
circuit breaker with continuous current ratings as shown on the one-line diagram and
wiring schedules.
B. All breakers above or equal to 1600A must be air-type or as indicated in the drawings
C. As a general rule All breakers above 1600A must be electrically motorized unless
otherwise indicated on drawings
D. Unless otherwise indicated all incoming and coupler breakers must be withdrawable
air type.
E. All automatic source change over (ATS) schemes must have mechanical interlocks in
addition to electrical interlocks.
F. Three (3) phase outgoing circuit breakers shall be Three (3) pole molded case, Three
(3) pole miniature circuit breakers or combined with residual current devices four (4)
pole as shown in the single line diagram or in panel schedules.
G. All four (4) pole circuit breakers must have neutral protection accordingly their trip
units should be able to sense the current on all four (4) poles. The trip unit should
allow a separate setting for the neutral pole to select one of three settings (neutral
unprotected), (neutral protected at 50% phase current) and (neutral protected at
100% of phase current).
H. Circuit breakers shall be selected in line with this specification at the point of
application in accordance with the drawings, allocated spaces and the "Regulations"
as applicable and shall be suitably graded for 660-volt line service.
I. Circuit breakers serving as generator incoming must be fitted with a generator class
trip unit capable of achieving low settings suitable to generator applications.
K. Each pole of the circuit-breaker shall have an inverse-time delay over current
protection for small overloads and an instantaneous magnetic overcurrent trip
element for operation under short circuit conditions. All poles shall be constructed
to open, trip or close simultaneously.
L. Circuit breakers shall be provided with quick-make, quick break switching mechanism
and positive trip-free operation so that contacts cannot be held closed against excess
currents under manual or automatic operation. Contacts shall be non-welding silver
alloy and shall be adequately protected with effective arc-quenching devices.
O. All miniature circuit breakers should have protection shoulders against accidental
contact with their terminals.
P. Frame sizes (or continuous current ratings) indicated shall be the minimum accepted
ratings based on a fully-rated interrupting duty (non-current-limiting) as shown on
the drawings. The trip current rating (amps) indicates the nominal rating at which the
thermal overload element operates.
Q. When tripped by either the thermal or magnetic elements, the handle shall
automatically assume a position midway between ON and OFF positions which
clearly indicates a "TRIPPED" position.
S. Non-interchangeable trip breakers shall have their covers sealed and breakers with
interchangeable trips shall have the trip unit sealed to prevent tampering.
T. All incoming and outgoing circuit breakers in the same switchboard shall be totally
selective at the prospected short circuit level.
U. Molded case circuit breakers shall have trip units that achieve full selective system
for overload, short circuit and instantaneous protection.
V. Circuit breakers of rating 250 Ampere and above shall have electronic trip unit.
X. Combination of circuit breakers and ground fault circuit interrupters shall be used
wherever specified with a fault indicator lamp. It shall be instantaneous trip with a10
mA, 30 mA and 100 mA sensitivity setting unless otherwise indicated.
Y. All circuit breakers shall be derated according to climatic conditions and operating
temperature as per manufacturer standards.
Z. All main circuit breakers to be provided with necessary accessories connection with
BMS system as required and specified in BMS schedules.
A. Type: Encased in high strength, high temperature resistant, molded plastic insulating
C. Control Power: For electrically charged circuit breaker and/or for shunt trip device,
where required, control power is to be 120V ac obtained from in-built MDB control
power transformer connected and fused on line-side of circuit breaker. Where shunt
trip and/or under voltage release are required, a sufficient capacitor trip device is to
be provided.
D. Rating: 4-pole, unless otherwise shown on the drawings. 750 V rated insulation volt-
age class, with continuous current rating (frame size) as per the approved design and
calculations, ranging between 1600 A and 5000 A (1600, 2000, 2500, 3000, 4000 and
5000 A), fully rated (100%) for service under worst site conditions. Breakers are to be
rated for a symmetrical RMS service short-circuit breaking capacity as per the ap-
proved design and calculations, to IEC 60947-2 sequence II (rated service short-circuit
breaking capacity) at specified voltage and frequency, meeting IEC60947-2, sequence
I, II, III and IV tests (for circuit breakers of utilization category B), tested in an enclo-
sure substantially the same as the enclosure in which they are to be installed.
E. Trip Unit: Totally enclosed, programmable, solid state device, interchangeable for
compatible frame sizes, pluggable into front of circuit breaker, tamper-proof and
with transparent, sealable cover. Trip unit is to measure sinusoidal and non–
sinusoidal current wave forms (fundamental to thirteenth harmonic) by continuously
sampling each phase throughout every cycle. Trip unit is to be direct acting trip de-
vice, current transformer operated, with flux transfer shunt trip that requires no ex-
ternal power. It is to have adjustable current setting (0.5 - 1.0 times trip unit rating)
with adjustable long-time delay, short-time pick-up and short-time delay, earth-fault
pick-up and time delay instantaneous over current pickup. Current setting range is to
be by means of replaceable trip-units within the maximum frame size rating. Once
removed, circuit breaker is to remain in the trip-free position. Short time delay is to
be adjustable in steps, 2 - 9 times current setting, with pre-settable or adjustable
time band having maximum delay of 0.3 to 0.5 seconds. Instantaneous trip is to be
adjustable in steps at least 2 – 13 times the trip Unit rating. Over-ride protection is to
allow full sensitivity up to interrupting capacity of Circuit Breaker.
G. Trip Unit Status Display: Shall indicate in words the status of normal breaker opera-
tion, long time over current pick up, instantaneous time over current trip, short time
over current trip, ground fault trip. Unit shall have integral resettable counter to
count long time, short time, instantaneous and ground fault trips.
H. Position Indicators: Positive with trip indication target. Target indicator is to be me-
chanical and is to give indication even when control power has been lost.
I. Trip unit shall have inputs from conventional potential transformers for every phase.
Current sensors transformers for every phase. Current sensors shall be encased in
epoxy filled plastic housing to protect against damage and moisture and shall be in-
tegrally mounted in breakers.
J. Neutral Current Transformer: Provide on the neutral conductor of each main, tie or
outgoing circuit having earth fault protection. Rating and characteristics of the neu-
tral current transformer are to be suitable for proper operation of the earth fault
protection system.
L. Auxiliary Contacts: Include N.O. and N.C. contacts on switchgear as required for re-
mote monitoring and control, plus 2 N.O. and 2 N.C. spare contacts.
M. Electrical Interlock: If electrical interlock is required between power air circuit break-
ers (as shown on the drawings), the mechanical closing button of the circuit breaker
is to be disabled in the connect position and an additional electrical push button is to
be provided for the closing of the circuit breaker through the breaker’s shunt close
coil. The electrical interlock is to be provided on both shunt trip and close coils of the
circuit breaker in order to perform simultaneous tripping and inhibit closing functions
on the interlocked breaker.
A. When the photoelectric lighting control and timer unit switches on the triple pole
contactor, the outgoing phase lighting circuits shall be energized.
B. Control switches, if any, shall be the rotary enclosed rear-mounting type with
positive means for maintaining contact position.
C. Ammeters mounted in the main incoming sections shall be moving-iron type having a
measuring range and shall be capable of withstanding twice the rated current for one
second without damage.
E. A voltmeter selector switch shall be mounted in the main incoming panel and shall
be of the rotary type with cam operated contacts. It shall have (7) positions "OFF",
R-S, S-T, T-R, R-N, S-N and T-N.
F. Current transformers (CTS) shall be of accuracy class 0.5 for measurements and shall
comply with IEC Recommendations 60185 and SEC requirements.
I. All remote push buttons, indicating lights and control services, as shown on the
schematic diagrams, shall be furnished and installed by the Contractor. Provisions
for connecting these remote devices to the switchgear shall be made by furnishing
terminal blocks or strips.
A. Frequency Converters: A quite large amount of the installed motors may be driven
by Frequency Converters.
B. If the total amount of Converters has any impact or not on the electrical supply
system must be considered and investigated. The Converters shall not have impact
on other electrical consumers in the network. It could be that special requirements
for electrical components must be considered. These are components as Circuit
Breakers and Capacitor Banks.
C. As a rule, shall be used on each Converter. Please follow the recommendation given
by the brand.
D. Cables shall be used. The earthing of the screen must be done with special
clamps/terminal made for screened cables. The motor cables shall not be laid
together with instrument cables.
A. Transient voltage suppressor – shall be provided at the incoming supply side of main
low voltage panel, as shown on the drawings. These should be as manufactured by
FURSE (UK), ESP or approved equivalent. The Contractor should select the proper
type recommended by the supplier and submit to the Engineer for approval
supported by calculations.
A. The switchgear shall be factory assembled and tested before shipping. Test reports
shall be furnished by the Contractor.
A. The Bidder shall make treatment and painting on the equipment surface according to
different operation conditions of the equipment, and illustrate the equipment sur-
face treatment method, painting scheme and construction technologies. Before
painting construction, the Bidder shall report to the Tenderer for approval, and be
responsible for clarifying the opinions of the Tenderer until they are passed; during
this process, the commercial price changes due to scheme change cannot be pro-
posed to the Tenderer. The submitted anticorrosion scheme shall contain equipment
name, surface treatment method, roughness after surface treatment of base materi-
al, selected supporting paint (including specific paint model, dry film thickness of
each paint layer and gross dry film thickness of paint), finish coat color (marked with
RAL color number), instruction to construction technology, etc.
B. Corrosion environment in the project according to the latest edition of (ISO 12944)
PART 3 EXECUTION
3.1 INSPECTION
A. Inspect each switchgear assembly and related accessories for damage, defects,
completeness and correct operation before installing. Inspect previously installed
related work and verify that it is ready for installation of instruments and equipment.
3.2 PREPARATION
A. Ensure that installation areas are clean and that construction operations are
completed prior to installing equipment. Maintain the areas in a broom-clean
condition during installation operations.
A. The Contractor shall perform all interconnecting wiring and grounding as indicated,
specified and required and shall include cables, conductors, terminals, connectors,
wire markers, conduits, conduit fittings, supports, hardware and all other required
materials.
B. Provide the electrical materials and complete all the required electrical installations
in accordance with the requirements specified in Section 260500 and as required by
Drawings.
A. The switchboards and Panelboards (both surface and flush types) shall be installed so
that the height of the top edge will not exceed 1.80 m from the finished floor.
Directories shall be typewritten in English and Arabic to indicate load served by each
circuit, and shall be mounted in a holder behind protective coating. Contractor shall
follow manufacturer's installation instructions.
B. Contractor shall submit to the Engineer for approval, an elevation mounting detail
and plan for each distribution board specially those mounted inside vertical service
ducts, also showing cable risers and racking to a scale of 1:10 or 1:50 before
installation.
A. Furnish the service of engineer especially trained and experienced in the installation
of the equipment to (1) supervise the installation in accordance with the approved
material and equipment manuals and (2) inspect, check, adjust as necessary in
accordance with the Specifications herein, until the installation and operation are
acceptable. Include all costs for services in the Contract Price.
A. Contractor shall prepare in full details and submit for approval, post installation, test
procedures attached with test forms for all L.V. panels.
D. The whole of the switchgear and control center shall be tested as integral units based
on the completeness of the circuits in the final manufactured form within the
Manufacturer's works. Witnessed tests shall comprise Routine Tests in accordance
with BS EN 61439 and/or IEC 61439 include but not limited to the following:
1. Primary injection tests to ensure correct ratio and polarity of CT's and to
demonstrate the correct operation of current operated protection relays and
direct acting coils over their full range of settings.
2. Operation and through current stability tests on balanced earth fault
protection relays by primary current injection.
3. Correct operation of sequencing and control circuits indications and alarms at
normal operating voltages by operation of local control switches and
simulation of operation of remote control circuits and all protection devices.
Low Voltage Switchboards
Riyadh Sedra 2 (Prj. 2970) Section 262413
Page 18 of 19
4. Circuit breakers shall be subject to routine tests together with checking of all
mechanical and electrical interlocks.
5. Type test certificates and performance test data for identical panel types shall
be made available.
6. Measure phase-to-phase and phase-to-ground insulations to meet
manufacturer's specified minimum resistance.
7. Check electrical continuity of circuits and for short circuits.
8. Coordinate tests with tests of generator and run them concurrently.
9. Demonstrate interlocking and operational functions for at least 3 times.
A. Provide the services of trained and field experienced Engineer(s) to validate each
Switchgear System to verify that each system is operational and performing its
intended functions as specified and detailed in the approved Post-Installation Test
Procedures. Validate each system by simulating inputs.
B. Immediately correct any and all defects and malfunctions disclosed by tests. Use
new parts and materials as required and approved and retest. Provide a report
certifying completion of validation of each system.
SPECIFICATION REV.
ECG ENGINEERING CONSULTANTS GROUP
PANELBOARDS
KSA 262416 - 2970 1
SECTION 262416
PANELBOARDS
Page
PART 1 GENERAL 2
1.1 Related Documents 2
1.2 Summary 2
1.3 Submittals 2
1.4 Quality Assurance 3
1.5 Coordination 3
1.6 Warranty 3
1.7 Factory Acceptance Test 3
1.8 Schedules 4
PART 2 PRODUCTS 4
2.1 Manufacturers 4
2.2 General Requirements 4
2.3 Panelboard Enclosures 5
2.4 Busbars 6
2.5 Molded Case Circuit Breakers (Mccbs) 6
2.6 Miniature Circuit Breakers (Mcbs) 8
2.7 Distribution Panelboards (Dp) 9
2.8 Final Branch Circuit, Power And Sub-Distribution Panelboards -
Generally 10
2.9 Final Branch Circuit, Power And Subdistribution Panelboards - Type
Mccb 10
2.10 Final Branch Panelboards - Type Mcb 11
2.11 Lighting Control Panel 12
PART 3 EXECUTION 12
3.1 Installation 12
3.2 Identification 13
3.3 Connections 13
3.4 Field Quality Control 13
PART 1 GENERAL
B. The Contractor shall execute the required work as per requirements of latest revision
of Saudi Building Codes.
1.2 SUMMARY
A. This section covers low voltage panel boards as indicated on the drawings and
required by the contract and shall include the following items:
1.3 SUBMITTALS
A. Equipment Data: Submit data for approval including, but not limited to, the
following:
1. Exact composition of each panel board, indicating Bus bar rating, frame and
trip ratings of circuit breakers.
2. Typical installation details of panel boards, indicating main feeder and branch
circuit conduit connections, terminal provisions, tags, labels, mounting
methods and materials used.
F. Panel board Schedules: For installation in panel boards submit final versions after
load balancing.
G. Panel board Schedules: For installation in panel boards. Submit final versions after
load balancing. As-Built (Record) Drawings before energization.
A. Comply with:
1.5 COORDINATION
A. Coordinate layout and installation of panel boards and components with other
construction that penetrates walls or is supported by them, including electrical and
other types of equipment, raceways, piping, and encumbrances to workspace
clearance requirements.
1.6 WARRANTY
A. Contractor shall submit manufacturer's type test certificates and routine test records
in accordance with the IEC 61439.
A. Schedules shall show the designation and required type of panel board using the
following criteria:
PART 2 PRODUCTS
2.1 MANUFACTURERS
B. Panel boards are to be totally enclosed, dead front type, protection code IP 31 for
indoor installations and IP 55 for outdoor & Wet Area installations, in accordance
with IEC 60529, and are to be factory designed and assembled.
H. Circuit Breaker Arrangement: Panel boards are to have one main incoming circuit
breaker or switch and the required number of branch circuit breakers, including
spare circuit breakers and spaces for future expansion. Three-phase panel boards are
to be designed for sequence phase connection of branch circuit devices.
I. In the event of an insulation fault, the fault current shall be limited to a safe value
and shall not result in a loss of power.
A. Type: General purpose type, suitable for relevant ambient conditions, flush or surface
mounted, comprising box, trim, or trim and door to approved manufacturer's
standards and sizes.
B. Construction: Box, trim and doors where required, are to be Electro-galvanized sheet
steel of gauges not less than specified and in accordance with the standards. Welded
joints are to be galvanized after manufacture. Gutter spaces are to conform to the
standards, adequate for the utilized cables/wires subject to the engineers’ approval
and in no case less than 100 mm on all sides. Enclosure is to have pre-designed
angles or threaded end studs to support and adjust mounting of interior panel board
assembly.
C. Trims are to cover and overlap front shield, covering all terminals and bus
compartments, to form a dead front panel. Trims are to be fixed to cabinet/box by
quarter-turn clamps engaging flange of box (use of screws engaging holes in flange of
box is not acceptable). Screws where used are to be oval-head, countersunk and
flush. Trims for flush mounted panel boards are to overlap box and front shields by at
least 20 mm. Trims for surface mounted panel boards are to be exactly sized to form
flush fit to box.
D. Doors are to have concealed hinges integral with trim, and flush combination cylinder
lock and catch. Doors over 1000 mm high are to have vault-type handle and multiple
point latch mechanism. Locks are to be keyed alike.
E. Finish: Inner and outer surfaces of cabinet/boxes, trims, doors etc. Are to be cleaned,
phosphatized, chrome passivated and treated with final thermosetting epoxy powder
modified by polyester resins providing high resistance to mechanical injury, heat, acid
and alkali solvents, grease, aging and corrosion and of standard gray color to the
approval of Engineer.
G. Outdoor enclosures are to be heavy duty sheet steel cabinets, minimum 2 mm thick,
2.4 BUSBARS
A. Type: One piece, 99% pure electrolytic copper, based on total maximum operating
temperature of 90 deg C at any point of the bus, at full continuous rating. Bolted or
clamped contact surfaces are to have maximum current density not exceeding
requirements of the approved standards. Aluminum is not to be used for bus bars or
panel board parts.
B. Design: Bus bars are to be shrouded/insulated and rigidly designed so that branch
circuit devices can be removed without disturbing adjacent units or changed without
additional machining, drilling or tapping. Busing is to be full size without reduction.
Busing and blank plates are to allow installation of future circuit devices.
C. Rating: Bus bar rating is to be at least equal to main-circuit breaker frame size. Where
no main circuit breaker is required, bus bars are to have main lugs or disconnect
switch, with nominal rating equal to 1.25 times the upstream circuit breaker trip
rating.
D. Short-circuit Duty: Bus bars are to carry at least 125% of the maximum short-circuit
level at point of application for one second, without showing any signs of
degradation.
F. Neutral bar is to be solid and fully insulated from cabinet or box. One solder-less box
type set-screw connector is to be provided for neutral wire of each branch circuit and
one bolted clamp-type connector or anti-turn lug with set-screw for main incoming
neutral wire. Neutral is to be fully sized and rated as for phase bus bars.
G. Earthing bar is to be copper, brazed to panel board cabinet, with bolted pressure
connector for main conductor and one set-screw-type tunnel terminal for each
outgoing conductor, to provide secure and reliable contact with all metal parts and
enclosure.
B. Circuit Breaker Trip Units: Unless otherwise specified, molded case circuit breakers of
final branch circuit panel boards (LPs), power panel boards (PPs ) and sub distribution
panel boards (SDPs) are to be thermal magnetic type, while molded case circuit
breakers of distribution panel boards (DPs) are to be thermal magnetic for frame
sizes up to 160 amperes and electronic type for higher frame sizes.
C. Thermal magnetic circuit breaker trip units: are to have bi-metallic inverse time delay
over- current element for small overloads and instantaneous magnetic over-current
trip element for operation under short-circuit conditions on each pole. Circuit
breakers rated 150/160 A are to have adjustable instantaneous trips.
E. Electronic trips units, applicable to circuit breakers 250 A frame size and larger, are to
be solid state with long time delay settings between 0.5 and 1.0 times maximum trip
rating, short time delay range of 3 to 10 times maximum trip rating with a maximum
clearing time of 0.2 seconds, and instantaneous protection adjustable from 5 to 10
times continuous rating. Solid state trip units are to be insensitive to changes in
ambient temperature between -20 and +55 deg C. Earth fault protection is to be built
into trip unit where specified, and is to be suitable for connection to external current
sensor. Push-to-trip button is to be provided on cover for testing the trip unit. Short
time over current protection is only required for circuit breakers 630A and above.
G. Trip current rating (amps) indicates nominal maximum rating at which overload
element is set to operate.
H. MCCBs for LPs, PPs, SDPs and DPs Type 2: Comply with IEC 60947-2 test sequences I,
II, utilization category A, and are to have rated ultimate short circuit breaking
capacities (sequence III) to meet the electrical requirements at the panel board
location, with preferred ratings.
I. MCCBs for DP Type 1: MCCBs rated 630 A and above are to have utilization category
B (with an intended short time withstand capability), and are to have rated service
short circuit breaking capacities (sequence II) with suitably selected frame sizes and
trip ranges to meet the electrical requirements at the distribution panel board, with
declared ratings as percentage (100%, 75% or 50%) of the ultimate ratings as quoted
by the circuit breaker manufacturer marked on the circuit breaker rating plate.
MCCBs below 630A are to have utilization category A with rated ultimate short circuit
breaking capacity (sequence III) to meet the electrical requirements at the panel
boards locations with preferred ratings in accordance with the below tables.
L. Sealing: Circuit breakers with non-interchangeable trip units are to be sealed. Circuit
breakers with interchangeable trip units are to have trip unit covers sealed to
prevent tampering.
N. Residual current operated earth leakage trip devices (RCDs) are provided as add-on
or built-in earth leakage accessories, where required. Protection against earth fault
current, in addition to over-current and short-circuit protection, is to be in
accordance with the Regulations. Trip current sensitivity on breakers for branch
circuits is to be as per the local Regulations. Circuit breakers are to include current
transformer with tripping coil assembly, test button and trip free mechanism to
ensure circuit breaker cannot be held closed against earth faults.
O. Current Limiting Circuit Breakers: Molded case type without fusible elements. When
operating within current limiting range, the I2t of let-through current is to be less
than 1/2 cycle wave of symmetrical protective short-circuit current as compatible
with breaker construction.
P. Current limiting circuit breakers are to have, on each pole, adjustable inverse time-
delay over-current characteristics for overload protection and instantaneous trip for
short-circuit protection. Operation of main contacts is to be based on Electro-
magnetic repulsion forces between contacts created by fault current. Ratings are
specified at rated voltage for an rms value of prospective short-circuit current.
A. Type: Thermal magnetic non-adjustable type, tested in accordance with IEC 60947-2.
1. 6 - 125A MCB :
2. 10 or 15 kA at 230/240 - 400/415 V A.C.
F. Ratings: Preferred rated currents are to be 6, 10, 15, 20, 25, 30, 40, 50, 60, 80, 100
and 125 A, calibrated at 45deg.c, available as 1, 2, 3 and 4-pole circuit breakers. De-
rating above 45 deg C is not to exceed 1% per deg C and loading is not to exceed 70%
of circuit breaker rating.
G. Residual current devices for earth leakage protective circuit breakers are to be add-
on devices, or built-in and integral with the standard circuit breaker. Non-adjustable
sensitivities of 30 mA, 100 mA and 300 mA are to be available for all ratings of 2-pole
and 4-pole circuit breakers.
H. Auxiliaries are to include alarm switch, auxiliary switch, shunt trip, under voltage trip
and similar units which are to be modular additions to the circuit breakers.
A. DP Type 1: Form 2b to IEC 61439-1, and have a minimum rated insulation voltage of
750V free standing, with doors, suitable for ratings of main breaker and bus bars
ranging from 630 A to 1250 A, 3-phase, 4-wire (or 3-wire where specifically
indicated), suitably and orderly arranged for any selected combination of branch
MCCBs ranging from 150/160 A to 1250 A frame size and short-circuit interrupting
ratings. Circuit breakers smaller than 250 A frame size, where indicated, may be
grouped on an integral sub-assembly mounted to main chassis.
B. DP Type 2: Form 1 to IEC 61439-1, and have a minimum rated insulation voltage of
690V. Panel board is to be recessed or surface mounted type complete with trim and
door, adjustable trim fixation for flush panels, and with ratings of main circuit
breaker and bus bars up to 400 A, 3-phase, 4-wire, with 2 or 3-pole branch circuit
breakers, 100 A or 150/160 A or 250 A frame size.
C. CIRCUIT BREAKERS for DP’s shall be fitted with a plug-in base type of modular
construction complete with its accessories; non draw-out type.
D. Construction: Sheet steel, for cabinet/box; suitable for mechanical impact resistance
of IK 10 to IEC 62262 for enclosures protection degree IP55 and higher and IK08 to
IEC 62262 for enclosures protection degree lower than IP55. Test certificates for
mechanical impact are to be submitted for approval; otherwise enclosure thickness is
not to be less than 2mm. Fronts are to be single or twin covers to shield circuit
breakers, terminals and live ends.
G. Circuit breakers are to be mounted in twin arrangement (except for larger circuit
breakers) and bolted rigidly to copper cross and center bus connectors.
B. Indoor Enclosure: Sheet steel, minimum 1 mm thick for box/cabinet and minimum 2
mm thick for front shield, trim and door. Fixings for flush trim are to be adjustable to
allow for misalignment between box and wall surface. Wiring spaces (gutters) are to
be at least 100 mm wide. Larger gutters are to be provided where tap-off insulated
split connectors are required. Knockouts are to be provided in top or bottom of
enclosures and are to provide a neat and uniform conduit/cable terminal
arrangement.
A. Type: Rated insulation voltage rating 690V as a minimum. Single-phase and neutral
(SPN) or 3-phase and neutral (TPN), with bolted 1, 2, or 3-pole MCCBs on branch
circuits and 2, 3 or 4-pole MCCB on main incoming.
B. Branch circuit breakers are to be 1, 2 or 3-pole, rated 100 A frame size, with trip
ratings between 15 A and 100 A, and compatible ICs, selected from normal (N), high-
break (H) or current-limiting (L) range.
D. Short-circuit Rating: Panel boards may only have integrated equipment (series) short-
circuit ratings in accordance with paragraph F of Article 2.2 "GENERAL
REQUIREMENTS" hereof.
E. Assembly: Busbars are to be rigidly fixed on molded insulators to back pan in vertical
arrangement. Branch circuit breakers are to be bolted in twin arrangement to rigid
copper cross and center bus connectors. Back pan assembly is to be removable and
fixed to four threaded stud’s integral with cabinet.
B. Internal Assembly: Comprise removable back plate or back pan of rigid construction,
attached to enclosure by four captive screws through keyhole fixings, and provided
with DIN rails in horizontal arrangement for SPN panels and in vertical arrangement
for TPN panels. Assembly is to be complete with neutral terminal block, earthing bar
and one piece insulated bolt-on/comb-type phase bus bar. Bus bars are to be single-
phase or 3-phase with spade connectors for fixing by tightening a single screw on
circuit breaker. Insulation is to be high thermal rating, capable of carrying maximum
short-circuit current for one second without overheating beyond acceptable limits
required by the Standards. Panel boards are to comply with IEC 61439-3.
C. Internal Assembly: Comprise removable back plate or back pan of rigid construction,
attached to enclosure by four captive screws through keyhole fixings, and provided
with bus bars in horizontal arrangement for SPN panels and in vertical arrangement
for TPN panels. Assembly is to be complete with neutral terminal block, earthing bar
and one-piece insulated phase bus bar. Bus bars are to be single-phase or 3-phase
with spade connectors for fixing by tightening a single screw on circuit breaker.
Insulation is to be high thermal rating, capable of carrying maximum short-circuit
current for one second without overheating beyond acceptable limits required by the
Standards.
D. SPN type panel boards are to be suitable for 240 V maximum service voltage, single-
phase and neutral, with MCBs on branch circuits and main incoming.
E. SPN type main circuit breaker is to be double-pole MCB, with or without earth
leakage device (RCD), as shown on the Schedules.
F. Single-pole and double-pole MCBs for 240 V service, are to have trip ratings between
6A and 125A, with ICs as required in the Schedules.
G. TPN type panel boards are to be suitable for up to 415 V A.C. maximum service
voltage, 3- phase and neutral, with MCBs on branch circuits and 3 or 4-pole MCB or
MCCB main incoming.
H. Triple-pole branch circuit breakers are to have trip ratings between 6A and 125A,
with IC as required in the Schedules.
I. TPN type panel board main circuit breakers are to be MCB or MCCB, 125A continuous
current rating, with trip range from 25 A to 125A, or 250 A MCCB with trip range 70 A
to 250 A, normal (N) or high-break (H) duty with/without RCD.
J. Short-circuit Rating: TPN panel boards may only have integrated equipment (series)
short-circuit ratings in accordance with clause paragraph F of Article 2.2 "GENERAL
REQUIREMENTS" hereof.
B. Provide with bush button and indication lamp only devices as scheduled, matching
the IEC type specified for the enclosure.
PART 3 EXECUTION
3.1 INSTALLATION
A. Fixing Generally:
B. Panel board Interiors: Do not install in cabinets until all conduit connections to
cabinet have been completed.
C. Wiring inside Panel boards: Neatly arranged, accessible and strapped to prevent
tension on circuit breaker terminals. Tap-off connections are to be split and bolted
type, fully insulated.
D. Trim: Fix plumb and square prior to painting. Fix trim for flush mounted cabinets
flush with wall surface finish.
E. Protection: Treat concealed surfaces of recessed cabinets with heavy field application
of waterproof compound prior to installation.
F. Mounting Heights: Top of trim 1880 mm above finished floor, unless otherwise
indicated.
G. Mounting: Plumb and rigid without distortion of box. Mount recessed panel boards
with fronts uniformly flush with wall finish.
H. Circuit Directory: Create a directory to indicate installed circuit loads after balancing
panel board loads. Obtain approval before installing. Use a computer or typewriter to
create directory; handwritten directories are not acceptable.
J. Provision for Future Circuits at Flush Panel boards: as approved by the engineer, stub
four empty conduits from panel board into accessible ceiling space or space
designated to be ceiling space in the future. Stub four empty conduits into raised
floor space or below slab not on grade.
K. Provide panel board key on a stainless steel chain alongside the panel, fixed securely
to the adjoining wall.
L. Operating Instructions: Frame and mount printed, basic operating instructions for
switchboards, including control and key interlocking sequences and emergency
procedures. Fabricate frame of finished wood or metal and cover instructions with
clear acrylic plastic. Mount on the front of switchboards, drawings, SLD, load
schedules etc. to be installed inside rigid folders in drawing compartment.
3.2 IDENTIFICATION
B. Panel board Nameplates: Label each panel board with engraved metal or laminated-
plastic nameplate mounted with corrosion-resistant screws.
3.3 CONNECTIONS
A. Generally: Carry out all tests, required by the governing codes and by the Engineer,
on Panel boards after installation, to verify compliance with the specifications and
standards. Inspect conditions within panel boards and verify insulation conditions by
use of a megger.
B. Inspect conditions within panel boards and verify insulation conditions by use of a
D. Routine tests on site are to be carried out, in accordance with the Standards, on all
panel boards assembled from standardized components of the manufacturer outside
the works of the manufacturer.
E. Testing: After installing panel boards and after electrical circuitry has been energized,
demonstrate product capability and compliance with requirements.
SPECIFICATION REV.
ECG ENGINEERING CONSULTANTS GROUP MOTOR CONTROL CENTERS
KSA 262419 – 2970 1
SECTION 262419
PART 1 - GENERAL 2
1.1 Related Documents 2
1.2 Summary 2
1.3 Submittals 2
1.4 Quality Assurance 3
1.5 Delivery, Storage, And Handling 3
1.6 Coordination 3
1.7 Factory Acceptance Test 4
1.8 Coordination 4
1.9 Warranty And Product Quality 4
PART 2 - PRODUCTS 4
2.1 Approved Manufacturers 4
2.2 Variable Speed Drives (Vsds) 4
2.3 Starters 8
2.4 Combination Starters Switch Disconnectors 10
2.5 Push Buttons 10
2.6 Relays 11
2.7 Circuit Protectors And Switches 11
2.8 Motor Control Center 12
2.9 Control Switches 14
PART 3 - EXECUTIONS 15
3.1 Applications 15
3.2 Installation 15
3.3 Identification 16
3.4 Control Wiring Installation 16
3.5 Earthing 17
3.6 Connections 17
3.7 Field Quality Control 17
3.8 Cleaning 18
3.9 Demonstration 18
PART 1 - GENERAL
1.2 SUMMARY
A. This Section includes variable speed drives, motor control centers and panels for use
on AC circuits.
1.3 SUBMITTALS
A. Technical Data: Include dimensions, ratings and data on features and components &
enclosures. Type test certifications are also to be included as required.
C. It should be noted that other comments like “noted “ or “partial compliance” are
unacceptable and will be interpreted as a non-compliance.
D. Shop and Installation Drawings: Submit for each motor control center prior to
ordering materials and equipment specified in this Section. Include dimensioned
plans, elevations, and component lists. Show ratings, including short time and short-
circuit ratings, and horizontal and vertical bus ampacities.
F. Submit certified protection relay coordination settings for review, along with certified
“As- built” connection drawings, before energization of equipment.
A. Source Limitations: Obtain motor control devices, variable speed drives and
enclosures/panels, through one source from a single manufacturer. MCC to be
approved by EDC and manufacturer to be listed in EDC's vender list.
C. All products shall be sourced either directly from the manufacturer or from the
manufacturer’s authorized dealer/agent.
A. Deliver in shipping splits of lengths that can be moved past obstructions in delivery
path as indicated.
1.6 COORDINATION
A. Coordinate features of controllers and accessory devices with pilot devices and
control circuits to which they connect.
B. Coordinate features, accessories, and functions of each motor controller with the
ratings and characteristics of the supply circuit, the motor, the required control
sequence, and the duty cycle of the motor and load.
Motor Control Centers Section 262419
Riyadh Sedra 2 (Prj. 2970) Page 3 of 18
1.7 FACTORY ACCEPTANCE TEST
A. Contractor shall submit manufacturer's type test certificates and routine test records
in accordance with the IEC 61439
1.8 COORDINATION
A. Coordinate features of controllers and accessory devices with pilot devices and
control circuits to which they connect.
B. Coordinate features, accessories, and functions of each motor controller with the
ratings and characteristics of the supply circuit, the motor, the required control
sequence, and the duty cycle of the motor and load.
A. one-year warranty after the date of Substantial Completion, for the low voltage
switchgear shall be provided, for the materials and manufacturing quality control.
B. Contractor shall agree to repair or replace the equipment that does not comply with
the requirements or fails in work
PART 2 - PRODUCTS
A. General:
1. This part of the Specification describes the general requirements for the
variable speed drives, the VSDs. The nominal values, the standard documents
and the drive's minimum performance are defined in this part. The VSD does
not include motors in this specification. The Specification uses the term motor
unit which means a combination of the VSD and the motor.
2. If the Project specific part of the Specification is in contradiction with the other
parts of the document, the Project specific document shall apply.
3. Requirements for the Manufacturer:
4. Local support:
5. General requirements:
a) The VSD shall be of the modern design, yet user friendly and be simple
to install commission and maintain. The VSD shall be able to start and
control the speed of a standard squirrel cage induction AC motor. The
VSDs shall be CE marked. The VSDs have to be built to comply with the
IEC standards.
b) The materials used in the VSD as a complete unit shall be recyclable,
non-toxic and flame retardant.
c) The VSD shall be a digitally controlled drive, using, at least, the pulse
width modulation (PWM) with flux vector control, a direct torque
control (DTC), or equivalent. It shall have IGBT's in the inverter section of
the throughout the power range, and it shall have the following
minimum specifications.
6. Operating conditions:
8. Main Protections: Over current, short circuit, input/output phase loss, motor
overload and under load, over/under-voltage, over speed, over temperature,
motor stall, other internal fault.
9. The VSD shall be able to give a 100 percent output current continuously in the
above-specified conditions. In order to ensure that the drive can provide the
required output current in the specified ambient conditions, the manufacturer
shall inform of the required de rating, if the ambient temperature given in the
Project specific Specification is higher than 50 deg. C or if the installation
altitude is more than 1000 m above the sea level. The de rating factor shall be
specified so that neither the lifetime of the VSD nor the unit's performance,
overload ability included, nor the reliability of the VSD shall suffer.
10. Storage conditions (in the protective package):
a) Power loss ride-through: The drive shall have a power loss ride-through
capability. This means that the drive controls should stay alive during a
power loss by means of the energy stored in the load. The ride through
time shall be the longer the higher the kinetic energy of the load is. The
motor shall be magnetized as long as there is kinetic energy in the
Motor Control Centers Section 262419
Riyadh Sedra 2 (Prj. 2970) Page 6 of 18
system.
b) Flying start: The drive shall have a built-in Flying Start feature. This
feature will allow a motor unit which is still rotating, to be restarted
without first stopping it. The VSD shall restart the motor from the
rotating speed and then reaccelerate to the speed indicated by the
speed reference signal. The Flying Start feature shall be available in both
directions, to be able to start the drive in the required direction
regardless of the rotation direction of the motor.
c) Critical speed jump-over: The VSD shall have programmable skip speeds
to jump over critical resonance speeds. If the speed reference is in the
critical speed area, it is ignored and the latest speed reference is
maintained. 3 programmable critical speeds at least shall be available.
d) Current/speed limiting: In case the acceleration or deceleration ramps
are too fast for the drive capacity, the drive shall be able to
automatically reduce the ramp to prevent tripping. Also, in case of
transient overloads the drive shall automatically reduce speed to
prevent an over current trip, if the drive capacity is not sufficient to
handle the load.
e) PID-controller the drive shall have a built-in PID-controller for control of
the customer process.
f) Restart in the event of a fault trip due to over voltage, over current or
loss of analog signal, the VSD shall be programmable to attempt an
automatic restart. For safety reasons, the maximum number of attempts
shall be five (selectable) within a short time. If the fault does not clear
after the attempts, the drive shall lock out.
14. Documents:
2.3 STARTERS
B. Motor Data: Obtain from equipment supplier before ordering any motor starter, or
check motor nameplate for full load current rating and allowable temperature rise in
order to select proper overload thermal element for motor starter.
D. Control voltage for starters and control circuits is not to exceed 110 V.
G. Auxiliary supply for controls other than from main power circuit, to be effectively
isolated by auxiliary contacts on main isolator.
I. Starter type A for single phase motors not exceeding ½ HP to be surface or flush
mounted, manual 2 pole toggle type, for non-reversing across the line starting, fitted
with 1 overload element.
K. Starter type C for 3 phase motors ratings higher than 10 HP and not exceeding 50 HP
to be star-delta or electronic “soft” starter type as applicable and shown on the
drawings, with 3 pole overload relay and low voltage protection, unless otherwise
required by local regulations. Harmonics produced by such starters shall be certified
to be within the relevant IEC limits
L. Starter type D for 3 phase motors over 50 HP to be soft starter or variable frequency
drive as applicable, with 3 pole overload relay and low voltage protection, unless
otherwise required by local regulations. Harmonics produced by such starters shall
be certified to be within the relevant IEC limits.
O. Contactors: Comply with IEC 60947-4, utilization category AC3 or AC4 as applicable,
and be 3 phase, 4 pole, magnetic type, 600 V rating, capable of interrupting at least
ten times rated current inductive or non-inductive loads under normal service
conditions and are to have replaceable main arcing contacts and arc quenching
devices. Contactors are to withstand, without welding or burning of contacts, an
inrush current of 20 times normal rating for 4 seconds upon closing and are to be
capable of closing on the heaviest short circuit of the system and withstand the short
circuit for period required by upstream short circuit protective device to operate. 3
N.O. (normally open) and 3 N.C. (normally closed) spare contacts are to be provided
on each contactor.
P. Contactors shall be of robust design and shall comply with IEC 60947: Part 4-1. They
R. All ammeters shall be available with “dead rider” Max. Demand indicators of the re-
settable type.
B. Switch Disconnector Operating Mechanism: Quick make, quick break, with external
operating handle mechanically interlocked with enclosure cover necessitating
disconnecting switch to be in OFF position for access to inside of enclosure. Means
are to be provided for by-passing interlocks. Position of isolating switch to be clearly
indicated on cover.
C. Short circuit protection gear to be HRC fused cartridges or molded case circuit
breakers of appropriate current rupturing capacity. Switch disconnectors are not
required if circuit breakers are used for the short circuit protection. In this case the
circuit breaker will perform the disconnection function.
B. Lock keys shall be suitably attached within easy access on a stainless steel chain fixed
to immovable surface with anchor-bolts.
C. All push buttons shall be of the non-retaining type with body of stainless steel and
button made of non-hygroscopic materials, non-swelling and fitted to avoid any
possibility of sticking.
A. Motor Circuit Protector: Molded case, magnetic break type with adjustable
instantaneous setting suitable for motor protection.
C. Main incoming switches to be equipped to provide earth fault under voltage and
phase sequence protection through shunt trip coil. Earth fault detection and
interruption to be time coordinated with those of main incoming breaker on main
distribution board.
D. All motors shall be provided with a safety disconnect switch, 1000V insulation class,
category AC23, non-fused, single throw, safety type, housed in separate metallic
enclosure IP 55 with arc quenching devices on each pole, and provided with padlock
and anti-corrosion lock.
E. When located outdoors, the switch disconnector enclosures shall be provided with
U.V resistant paint finish.
F. Switch disconnector handle and indicator markings shall be Red/yellow and is to have
provision for bypassing interlock by authorized and trained technicians. Position of
handle is to be positive and clearly indicated on cover. Locking of operating handle is
to be possible in open and closed positions. Where safety disconnect switch ratings
are required to be in excess of 250 Amps, provide “Emergency” push button stations
wired directly for trip.
G. Switch disconnectors shall comply with IEC 60664 and IEC 60947 and shall carry
KEMA or ASTA or UL certification. They shall be manufactured to environmentally
friendly and recyclable materials.
I. Control switches for electrically operated circuit breakers and motor operated
disconnectors shall be discrepancy type and arranged to operate clockwise when
closing the devices and anti-clockwise when opening them. There should be marking
for discrepancy indications. They shall be designed to prevent accidental operation,
which shall be effected by 2 independent movements.
Motor Control Centers Section 262419
Riyadh Sedra 2 (Prj. 2970) Page 11 of 18
J. The contacts of all switches and push buttons shall be strong and to have a positive
wiping action when operated.
K. All safety switches and emergency push buttons shall be clearly labeled as per
specification 260553 .
G. Bus bars to be adequately isolated and braced to sustain maximum possible short
circuit current which may be encountered at the proposed location. Type test
certification required by ASTA or KEMA.
I. Spare Positions: Fully equipped cells, ready for connection to motors, are to be
provided in adequate number.
J. Space Positions: if required to be fully equipped cells ready to receive control unit are
to be provided in adequate number.
L. Incoming line connections to be made with solder less terminal 4 bolt type clamps.
M. Mounting plates for the draw-out feeders shall be painted galvanized sheet steel and
of minimum 2m thickness, with necessary “lock-in-place” fixtures made of metal.
Draw-out shall imply no requirement of any cable disconnection requirements for
either power or control.
N. Control wiring and BMS wiring shall not be routed through power areas within the
BMS.
O. All terminal blocks for control and BMS wiring shall be of 500V insulation class, DIN
rail mounted and manufactured from non-toxic, color coded non-inflammable, self-
extinguishing material and shall contain nickel plated electrolytic copper terminals.
The terminal contacts shall be suitable to meet the “pull-out” forces as per IEC
60947-7-1. All terminals shall be clearly identified in respect of service usage,
designation and number.
Q. Current transformers provided in the MCC shall conform to IEC 61869-2, class H
insulation, accuracy class 1 as per IEC and secondary 5A, of suitable VA rating. The
Current transformers shall have type test certification from an internationally
accredited testing laboratory and shall be subject to 100 % routine tests as per the
IEC.
R. Certified and stamped Schematic and wiring diagrams to be firmly fixed within motor
control center, showing each component and cross- referenced with component
labels.
A. Float Switch: Level operated, stainless steel, heavy duty, bracket mounted type,
suitable for application in open tanks, complete with 178 mm spun copper float,
brass rod, two stops, floor mounting stand, lever and counterweight. Switch to have
oil tight and dust tight enclosure and 2 pole double throw silver contacts that open
on liquid rise.
B. Pressure Switch: Industrial, heavy-duty bellows actuated type, suitable for water
service, with contacts to close on falling pressure. Range to be 0.1 to 8 kg/cm².
Switch to be good for 1720 kPa operating pressure and to have 6 mm pipe tap
bottom connection. It is to have oil tight and dust tight enclosure, single pole double
throw contacts and setting adjustment.
C. Low Suction Pressure Switch: Industrial, sensitive, low range, diaphragm actuated
type, suitable for water service, with range of 2 to 20 kPa of falling pressure, preset
at factory to 3 kPa. Switch to be good for 690 kPa operating pressure and to have 6
mm pipe tap bottom connection. It is to have oil tight and dust tight enclosure,
single pole double throw contacts, range adjustment knob, sealing cap and range
locking nut.
D. Control Switches shall be operated by shrouded push buttons or have handles of the
spade type. Control, reversing, selector and test switches shall be mounted,
constructed and wired so as to facilitate the maintenance of contacts without the
necessity for disconnecting wiring. Control switches shall carry KEMA or ASTA or UL
certification.
F. Control switches for use in direct control schemes shall be rated for the substation
battery voltage.
G. All control switches shall be provided with identification labels, including labels to
Motor Control Centers Section 262419
Riyadh Sedra 2 (Prj. 2970) Page 14 of 18
give clear indication to the direction of each operation, for example, "open", "close",
"raise", "lower", etc.
PART 3 - EXECUTIONS
3.1 APPLICATIONS
D. Emergency disconnect switches or push buttons (as applicable) for all motors, within
3 meters of the equipment that it is meant to protect, located at a logically
convenient position where it is clearly identifiable.
3.2 INSTALLATION
B. Anchor each motor control center assembly to steel-channel sills 100 mm high,
arranged and sized according to manufacturer's written instructions. Attach by tack
welding or bolting. Level and grout sills flush with motor control center mounting
surface.
C. Fuses: Install correctly rated and clearly labeled fuses in each fusible switch as
indicated.
D. Power and Control Wiring: Run in separate conduits unless otherwise specified.
E. Rigid conduits are not to terminate in nor be fastened to a motor frame or base.
H. Flexible Conduits: Do not use in place of rigid conduits except at motor connections,
unless otherwise specified.
J. Conduits are not to cross pipe or vent shafts, ducts or openings. They are to be run a
minimum 100 mm away from pipes of non-electrical services.
K. Conduits: Install so that moisture can drain to lowest point. Provide screw plug at all
low points for draining.
L. Keys for MCCs and other panels to be provided on stainless steel chain alongside the
panel, fixed securely to immovable surface with anchor bolt.
M. All installations shall particularly comply with requirements of IEC 60204- “Safety of
machinery-Electrical equipment of machines”. Contractor is required to submit
specific certification to this effect before power energization.
3.3 IDENTIFICATION
C. Starters: Fix certified, detailed wiring diagram inside enclosure cover to clearly
indicate circuits.
D. Starters: Identify control and power wires either by distinctive colored insulation,
engraved tags or other approved method.
B. Protect circuits with high rupturing capacity fuses or circuit breakers. Auxiliary supply
for controls other than from main power circuit, to be effectively isolated by auxiliary
contacts on main isolator.
C. Provide bus bar mounted fuses where direct control connections are required.
E. Connect selector switches to bypass only the manual and automatic control devices
that have no safety functions when switch is in the hand position.
3.5 EARTHING
C. All MCCs shall be provided with a second earthing connection through the local
common earth bar located in the respective electrical/mechanical room.
3.6 CONNECTIONS
A. Tighten motor control center bus joint, electrical connector, and terminal bolts with a
torque-wrench, according to manufacturer's published torque-tightening values.
B. Ensure all covers and doors are in proper alignment and all equipment handles
functioning properly.
C. Testing: After installing motor control center and after electrical circuitry has been
energized, demonstrate product capability and compliance with requirements, as per
approved method statement.
E. Remove and replace malfunctioning units with new units, and retest.
F. Submit settings along with justification to support them both at overload and short
circuit.
Motor Control Centers Section 262419
Riyadh Sedra 2 (Prj. 2970) Page 17 of 18
G. Circuit Breakers: Coordinate earth fault detection and interruption with those of
main incoming breaker on main distribution panel, and submit settings.
H. Pressure Switches: Test after installation to ensure dependable operation and correct
setting.
3.8 CLEANING
A. Inspect interior and exterior of motor control centers before energization and
vacuum clean all dust and debris. Remove paint splatters and other spots, dirt, and
debris. Touch up scratches and mars of finish to match original finish. Clean devices
internally, using methods and materials recommended by manufacturer.
3.9 DEMONSTRATION
SPECIFICATION REV.
ECG ENGINEERING CONSULTANTS GROUP WIRING DEVICES AND
KSA DISCONNECTORS 262726 - 2970 1
SECTION 262726
Page
PART 1 GENERAL 2
1.1 Related Documents 2
1.2 Summary 2
1.3 Submittal 2
1.4 Quality Assurance 2
PART 2 PRODUCTS 3
2.1 Manufacturers 3
2.2 Wiring Devices 3
2.3 Touch-Up Paint 6
2.4 Floor Outlet Boxes 6
PART 3 EXECUTION 8
3.1 Installation 8
3.2 Grounding 9
3.3 Field Quality Control 9
PART 1 GENERAL
B. The Contractor shall execute the required work as per requirements of latest revision of
Saudi Building Codes.
1.2 SUMMARY
A. This Section shall cover various types of receptacles, receptacles with Ground Fault Circuit
Interrupter (GFCI), connectors, switches and finish plates.
B. Related Sections
1.3 SUBMITTAL
A. Submit the following according to the Conditions of the Contract and Division 1
Specification Sections:
B. Product Data: Data shall be submitted for each product specified in this section, with
catalog clippings and manufacturer’s technical specifications.
C. Samples: Provide three (3) samples for each device, which shall be used, and for all
relevant accessories (cover, plates). Color selection and technical features shall be
complied with the requirements of codes, interior decoration and Owner’s representative
acceptance.
D. Operation and Maintenance Data: Provide operation and maintenance data for materials
and products specified in this section.
E. Field Quality Control: Submit for Engineer’s approval quality control plan.
PART 2 PRODUCTS
2.1 MANUFACTURERS
A. General: Wiring devices shall comply fully with the relevant Local, and International
Standards.
B. All wiring devices must be suitable for 3-wire systems for single phase and 5-wire
systems for three phase i.e. earthing terminal must be provided in sockets plugs,
lighting switches, power socket, etc.
C. Boxes and Fittings: Boxes shall be provided with means to terminate conduits
securely.
1. For heavy-molded rigid PVC boxes shall be provided with brass insert threads
and fixed lugs to receive cover screws or galvanized steel with suitable marked
earth terminal for exposed and outdoor use.
2. For more details on boxes and fittings, refer to Section 260533.
E. Various samples shall be submitted for approval and/or selection by the Engineer.
1. Fixing screws shall be chromium plated, polished. Screw head shall suit the
plates.
2. Combination (multi-gang) plates shall be provided for grouped outlets and
devices as detailed on the Architectural or Electrical Drawings. Color shall be
selected by the Engineer for different typical areas without any cost
implication to the Contract.
3. Unless otherwise stated or specified in Volume 5 "Interior and Furnishing
Works", heavy-molded, break-resistant material, White-Ivory color, flush-
F. Convenience Socket Outlets: The Contractor shall supply a unified standard type socket
outlet for the whole project.
1. Socket outlets shall be rated 13/16 Amp and 250 Volts with two rounded poles
plus side earth and 20 mm spacing. The earth terminal of each socket shall be
effectively connected with the earth continuity conductor, phase and neutral
conductors to the respective terminals.
2. Socket outlets shall have a molded plastic or porcelain base and be designed
to fit the appropriate plate as required or as approved, before execution, by
the Engineer.
3. Contacts shall be self-adjusted and have a non-expanding size limiting entry, to
prevent permanent distortion.
4. Where duplex socket outlets are shown on Drawings, two of this type of
socket shall be mounted under one common plate.
5. Weatherproof socket outlets shall be mounted in the box specified with a
gasketed, weatherproof cast-metal cover plate, with individual cap over each
socket outlet opening and stainless steel mounting screws. Caps shall be
tightly closed with stainless steel springs when the socket outlet is not in use.
6. Where indicated on Drawings, receptacles shall be served by ground fault
circuit interrupters for personnel protection.
7. Application: Outlets for internal use shall generally be of the insulated pattern
ivory finish, or as specified in Volume 5 interior and furniture works. Color is
to be selected by Engineer. In utility and workshop areas metal clad enclosures
and finishes shall be used.
8. Outlets for exterior use shall be weatherproof pattern enclosed in Glass-fiber
Reinforced Plastic (GRP) or galvanized metal boxes.
9. Terminals for 250 V outlets shall each be capable of receiving and satisfactorily
connecting two (2) conductors (solid or stranded), each of 4 mm2 minimum.
10. Contact pressure with conductors shall preferably be by clamp plate rather
than by pinch screw.
11. Socket outlets for flush fitting shall be mounted in appropriate recessed box.
12. Socket outlets and their enclosures shall be complete with necessary terminals
for the connection of circuit protective conductors as required by the IEE
Regulations and IEC latest edition.
13. Boxes providing enclosure and/or mounting for socket outlets shall be PVC if
concealed, or galvanized steel if exposed complete with conduit entries.
G. GFCI RECEPTACLES: Shall be used in the wet areas with voltage and current ration as
indicated in the drawings
1. Internal Lighting Switches: Internal lighting switches shall comply with IEC
60669 and shall be complete with box, cover plate and fixing screws. At multi-
switch positions, the switches shall be contained in multi-gang boxes.
2. Wall mounted switches shall be suitable for use at a system voltage of 230 V
and continuously rated at 10/16 A. Each switch terminals shall be capable of
terminating two (2) conductors (solid or stranded), each of 3 mm2 minimum.
3. Generally where a number of switches are mounted adjacent to each other,
they shall be grouped in one box and share a common switch plate, except
those fed from different supply panels or different phases.
4. Switches shall not disconnect the grounded conductor of a circuit. A switch in
a wet location or outside of a building shall be enclosed in a weatherproof
enclosure.
5. Switches for internal use shall generally be of the insulated, ivory finish
pattern unless otherwise specified. In utility and workshop areas, metal clad
enclosures and finish shall be used. Lighting switches shall be mounted in a
galvanized metal or PVC box with conduit entry facilities suitable for flush or
surface mountings as appropriate. In all cases, a sample shall be approved by
the Engineer.
6. Lighting switches for external use and wet areas shall be weatherproof and
shall be enclosed in Plastic Glass-fiber Reinforced (GRP) or galvanized metal
boxes.
7. Lighting switches shall be provided with all necessary terminals to allow
connection of circuit protective conductors as required by the 16th edition of
the IEE Regulations or IEC latest edition.
8. Multi Pole Switches: Multi pole switches shall conform to the requirements of
IEC 60669 Standard where used for the connection of fixed appliances.
9. Switches shall be installed as shown on Drawings, and for height refer to
general notes.
10. All units shall be of similar style and finish to those specified for lighting
switches and socket outlets.
11. Primary connection terminals shall be capable of receiving and satisfactorily
connecting the following stranded conductors:
10 A 3x(1x2.5) mm2
20 A 3x(1 x 4) mm2
25 A 3x(1 x 6) mm2
A. The surface of all wiring devices shall be of the manufacturer's finish according to location
and the Engineer’s approval.
A. Provide corrosion resistant, hot-dip galvanized, zinc coated sheet steel floor outlet boxes
of the types, shapes, sizes and depths to suit each respective location and installation. The
floor outlet boxes shall be suitable for raised floor trunking or under floor ducting system
as required.
B. Depths of floor outlet boxes shall be sufficient to accommodate conduit entries from
sides and all kinds of wiring devices with plugs from the top.
C. Cover of floor outlet boxes shall be capable of closing completely after installation of
plugs and connecting devices inside the box. The cover shall be suitable for flush floor
D. Floor outlet boxes shall be waterproof when fully closed. Appropriate rubber grommet
for cable protection shall be available for cable outlets from the floor base. The
grommets shall have an automatic lock function that prevents the cables from
getting cut should traffic pass over the box. The trap shall be fully reversible to allow
for change of direction of cable exit without the need to remove the trap frame.
E. The floor outlet boxes shall have a fully flexible plate configuration within them to ensure
that difficult configurations are achieved with ease.
F. Service outlet boxes for raised floor trunking system shall comprise an electro-
galvanized steel base frame to be installed in the raised floor tile. A die cast zinc alloy
service outlet frame and trap shall be mounted in the base frame. The base unit,
service outlet frame and traps shall have an oven baked epoxy powder paint finish
for protection against rust and corrosion. Provide flexible conduit of minimum 3
meter length to connect the service outlet box to the raised floor trunking.
G. Provide service outlet boxes and junction boxes for under floor ducting system,
constructed from high pressure zinc alloy die casting base frame and fixed to heavy
gauge hot-dip galvanized steel base plate adequate in strength and performance.
These boxes shall comply with the following requirements:
1. The design of the base frame shall cast the whole unit in one piece without
any joints/fabrication to prevent corrosion and concrete slippage into the box
during casting of concrete or screeding. The boxes shall be constructed with
provisions for ducting or conduit access on all four sides. Unwanted entries
shall be blanked off with detachable side blanks. All exposed portion of the
boxes shall be epoxy coated.
2. Cover for service outlet boxes shall be made of high pressure zinc alloy die
casting provided with suitable hinges designed to enable the trap cover to
open through 180 degrees and giving access at all times to the power, data,
telephone and other outlets.
3. Covers for service and junction boxes shall be made of high pressure zinc alloy
die casting secured by counter sunk screws. The covers shall be provided with
recess to accept the same floor finish.
4. All boxes shall be adjustable in height, independent of the ducting system to
take account of difference in floor / screed thickness.
5. Adequate segregation shall be provided between service runs within junction
boxes by using cross-over bridges and rigid compartments.
6. Cables emerging from service outlet boxes shall be protected against damage
by means of nylon cable-exit grommets or equivalent and approved material
and shall be reversible to close position when not in use. The lifting handle and
cable grommets shall be provided in opposite sides of the trap cover to allow
easy access to lifting handle and to avoid damage of the cable insulation.
H. All floor outlet boxes shall be complete with waterproof gasket and circuit protective
conductors between the covers and the boxes.
PART 3 EXECUTION
3.1 INSTALLATION
A. General: Flush-mounted boxes shall be cast in concrete walls and grouted into brick
walls. Metal boxes threaded to raceways in exposed installations shall be separately
supported.
B. Boxes installed in concealed conduits or raceway systems shall be set flush with the
finished surfaces. The location of all boxes shall be easily accessible and any interference
with mechanical equipment or structural features shall be relocated as directed by the
Engineer without any additional cost.
C. Receptacles: The receptacles shall be located and installed as shown on the Drawings.
The location shall be easily accessible. Receptacles shall be so installed that the neutral
pin is always on the left side when viewed facing the installation.
D. Switches: Local wall switches near doors, shall be located at free side of doors as finally
hung, whether so indicated on Drawings or not.
E. A junction box shall be placed in the back of each wall mounted switch or socket outlet.
F. If thickness of wall does not permit such an installation, adjacent position shall be
accepted.
G. The switches shall be installed as shown on the approved Drawings. Where more than
one switch is shown for one indoor outlet box, the switches shall be installed under one
plate. Toggle switches for lighting, except for 2-way and 3-way switches shall be installed
so that the contacts are closed when the handle is in the up position.
H. Switches shall be mounted with the longer dimension vertical and operating handle in an
upward position when in the "ON" position.
I. Single pole switches shall switch the (phase) wire circuit. Neutral wire shall not run
through switches.
K. Device Plates: Device plates shall be installed with all four edges in continuous contact
with finished wall surfaces without the use of mats or similar devices. Device plates shall
be installed vertically with an alignment tolerance of 0.16 mm (1/16 inches).
1. Mark the locations of all service outlet boxes and junction boxes on the floor
slab as preapproved shop drawings, and review all practical aspects before
start of installation.
2. Cover junction boxes and service outlet boxes in under floor ducting system
with the disposable screeding lids, approximately levelled and tapped to
ensure no cement/mortar gets into the boxes during screeding.
3. Adjust floor outlet boxes so that closure plates are flush with the surface of
the floor tile, or the floor if carpeting is specified. Provide under floor duct
fittings and outlets or single flush outlets with waterproof covers, as indicated
on the drawings.
3.2 GROUNDING
A. Provide checking, adjusting and testing operations on the wiring devices installation
including the following:
SPECIFICATION REV.
ECG ENGINEERING CONSULTANTS GROUP ENGINE GENERATORS
KSA 263213 - 2970 1
SECTION 263213
ENGINE GENERATORS
Page
PART 1 GENERAL 2
1.1 Related Documents 2
1.2 Summary 2
1.3 Submittals 2
1.4 Quality Assurance 4
1.5 Coordination 4
1.6 Project Conditions 4
1.7 Delivery, Storage And Handling 4
1.8 Spare Parts 5
1.9 Instructions And Training On Operation & Maintenance 5
1.10 Project Conditions 5
1.11 Coordination 6
1.12 Warranty 6
1.13 Maintenance Service 6
PART 2 PRODUCTS 6
2.1 Engine-Generator Set 6
2.2 Engine 8
2.3 Fuel Oil Storage 10
2.4 Control And Monitoring 10
2.5 Generator Overcurrent And Fault Protection 11
2.6 Generator, Exciter, And Voltage Regulator 12
2.7 Vibration Isolation Devices 12
2.8 Source Quality Control 13
PART 3 EXECUTION 13
3.1 Examination 13
3.2 Installation 13
3.3 Field Quality Control 14
3.4 Grounding 14
3.5 Connections 14
3.6 Identification 15
3.7 Demonstration 15
3.8 Equipment Schedule 15
PART 1 GENERAL
A. Drawings and general provisions of the Contract, including General and Supplemen-
tary Conditions and Division 01 Specification Sections, apply to this Section.
B. The Contractor shall execute the required work as per requirements of latest revision
of Saudi Building Codes and SASO Standards
1.2 SUMMARY
A. This section covers the equipment, installation and testing of diesel engine and driv-
en electric generator units. The engine generator unit/s shall be installed as indicated
on the drawings.
1. Division 26 transfer switches for transfer switches including sensors and relays
to initiate automatic starting and stopping signals for engine generators sets.
2. Division 26 “grounding and bonding”
3. Division 26 “Low voltage conductors and cable”
4. Division 26 “Cable tray”
5. Division 26 “Raceway and boxes”
1.3 SUBMITTALS
A. Drawings and Data: Complete descriptive and engineering data shall be submitted.
These data shall consist of drawings and photographs in sufficient detail that the con-
struction of the equipment is indicated, together with details, specifications, perfor-
mance curves, installation drawings, schematics, and wiring diagrams; and founda-
tion drawing showing location detail and size of anchor bolts. Data submitted shall
include the following:
1. Engine Data.
2. Generator Data.
a. Manufacturer.
b. Model.
c. Rated kVA.
d. Rated kW at 0.8 PF.
e. Voltage.
f. Temperature rise above 50 C ambient for Stator and Field.
g. Class of insulation.
a. Full load.
b. 3/4 load.
c. 1/2 load.
d. 1/4 load.
B. Test Reports: Copies of the manufacturer’s certified shop test record of the complete
engine driven generator. The engine-generator log test sheets and a performance re-
view report shall be signed by the engine tested and certified by the manufacturer.
The report shall include brief outlines of all test procedures and shall compare actual
test results to the requirements of these specifications by means of calculations,
graphs, or charts.
D. Operations and Maintenance Manuals/Charts and Spare Parts Data: Complete opera-
tions and maintenance manuals/Charts including spare parts data and wiring dia-
grams of all equipment furnished under this section.
A. References Standards.
1.5 COORDINATION
A. All equipment specified in this section shall be furnished through a single manufac-
turer who shall be responsible for the design, manufacture coordination, and proper
installation and operation of the entire system and as mentioned in section division
26 Section “Basic Electric materials & methods “.
A. Power Supply: The power supply for the engine-generator accessories will be
400Y/230 Volts AC, 60 Hz, three-phase, 5-wire or as may be required by manufactur-
er’s standard.
A. Manufacturer Date: The required manufacturing date of the package engine genera-
tor (s) shall be 6 – 8 months before the delivering date.
C. Packaging: In addition to the protection specified for prolonged storage, the packag-
ing of spare units and spare parts shall be similar to export packing and shall be suit-
able for long-term storage in a damp location. Each spare item shall be packed sepa-
rately and shall be completely identified on the outside of the container.
A. A list of all spare parts recommend by the manufacturer for 1000 operating hours
and required for adjustment, operation, and maintenance of the equipment shall be
submitted in accordance with the requirements set forth at the Conditions of Con-
tract.
B. In addition, all special tools required for adjustment, operation, and maintenance of
the equipment. plus the following spare parts shall be furnished with each unit:
A. Contractor shall provide instructions and training for the staff to be assigned in the
operation and maintenance of the equipment specified under this section. Training
and instructions shall be in accordance with the requirements set forth at the Condi-
tions of Contract.
1.11 COORDINATION
A. Coordinate size and location of concrete bases for package engine generators. Cast
anchor-bolt inserts into bases. Concrete, reinforcement, and formwork requirements
are specified in Division 03.
1.12 WARRANTY
PART 2 PRODUCTS
D. Generator-Set Performance: The diesel generator set should have performance class
G2 according to ISO 8528.
E. Steady state voltage, Steady state frequency, Voltage recover time, frequency recov-
er time, Maximum voltage Dip, Maximum frequency Dip shall comply with ISO 8528-
5 for performance class G2.
G. Noise reduction is to be achieved by silencer, sound attenuators for air inlet and out-
lets and sound absorbing wall lining. Achieve an overall Noise Rating of 85 dBA at 1 m
outside the room in any direction in accordance with ISO standards. Coordinate with
the Architectural works for the needed provisions and installations.
1. Over sizing generator compared with the rated power output of the engine
is permissible to meet specified performance.
10. Start Time: Comply with NFPA 110, Type 10, system requirements.
2.2 ENGINE
C. Maximum Piston Speed for Four-Cycle Engines: 2250 fpm (11.4 m/s).
1. Main Fuel Pump: Mounted on engine. Pump ensures adequate primary fuel
flow under starting and load conditions.
2. Relief-Bypass Valve: Automatically regulates pressure in fuel line and returns
excess fuel to source.
G. Comply with NFPA 110 requirements for Level 1 equipment for heater capacity.
I. Cooling System: Closed loop, liquid cooled, with radiator factory mounted on en-
gine-generator-set mounting frame and integral engine-driven coolant pump.
B. Day Tank: Comply with UL 142, freestanding, factory-fabricated fuel tank assem-
bly, with integral, float-controlled transfer pump and the following features:
C. Indicating and Protective Devices and Controls: As required by NFPA 110 for Lev-
el 1 or 2 system as required, and the following:
1. AC voltmeter.
2. AC ammeter.
3. AC frequency meter.
4. DC voltmeter (alternator battery charging).
5. Engine-coolant temperature gage.
6. Engine lubricating-oil pressure gage.
7. Running-time meter.
8. Ammeter-voltmeter, phase-selector switch.
9. Generator-voltage adjusting rheostat.
10. Fuel tank derangement alarm.
11. Fuel tank high-level shutdown of fuel supply alarm.
D. Supporting Items: Include sensors, transducers, terminals, relays, and other de-
vices and include wiring required to support specified items. Locate sensors and
other supporting items on engine or generator, unless otherwise required.
B. Ground-Fault Indication: Comply with NFPA 70, "Emergency System" signals for
ground- fault. Integrate ground-fault alarm indication with other generator-set
alarm indications.
B. Drive: Generator shaft shall be directly connected to engine shaft. Exciter shall be
rotated integrally with generator rotor.
E. Construction shall prevent mechanical, electrical, and thermal damage due to vi-
bration, over speed up to 125 percent of rating, and heat.
I. Windings: Two-thirds pitch stator winding and fully linked amortisseur winding.
A. Prototype Testing: Factory test engine-generator set using same engine model,
constructed of identical or equivalent components and equipped with identical
or equivalent accessories.
1. Tests: Comply with NFPA 110, Level 1 Energy Converters and with IEEE 115.
1. Test components and accessories furnished with installed unit that are not
identical to those on tested prototype to demonstrate compatibility and
reliability.
2. Full load run.
3. Maximum power.
4. Voltage regulation.
5. Transient and steady-state governing.
6. Single-step load pickup.
7. Safety shutdown.
8. Provide 14 days' advance notice of tests and opportunity for observation of
tests by Owner's representative.
9. Report factory test results within 10 days of completion of test.
PART 3 EXECUTION
3.1 EXAMINATION
A. Examine areas, equipment bases, and conditions, with Installer present, for com-
pliance with requirements for installation and other conditions affecting pack-
aged engine-generator performance.
C. Proceed with installation only after unsatisfactory conditions have been correct-
ed.
3.2 INSTALLATION
A. Field Supervision and Tests: The Contractor shall include a minimum of three 8
hour working days allowance for the services of a competent manufacturer's
technical representative to check the installation, make all necessary adjust-
ments and, in the presence of the Engineer, perform acceptance tests on the en-
gine-generator unit to determine whether the equipment conforms to specified
requirements for load capacity and starting duty.
B. As part of the field test, each of the automatic shutdown devices shall be made
to be operated and the respective values recorded at which the devices actually
stopped the engine. Any adjustments required shall be made in the devices to
make the operating values correspond to those recommended by the engine
manufacturer.
C. Before running the field test, submit a copy of the proposed log sheet on which
shall be recorded the load and all corresponding temperatures and pressures as
well as the total quantity of fuel consumed during the test. The test shall consist
of operations under a load bank at the specified power rating for four continuous
hours.
D. Readings shall be taken and recorded at 15-minute intervals over the four-hour
test period.
E. The Contractor shall furnish the fuel, lubricants, load bank, instruments and all
other devices necessary for the tests.
3.4 GROUNDING
3.5 CONNECTIONS
E. Connect fuel piping to engines with a gate valve and union and flexible connect-
or.
3.6 IDENTIFICATION
3.7 DEMONSTRATION
SPECIFICATION REV.
ECG ENGINEERING CONSULTANTS GROUP LOW VOLTAGE POWER FACTOR
KSA CORRECTION EQUIPMENT 263533- 2970 1
SECTION 263533
Page
PART 1 GENERAL 2
1.1 Related Documents 2
1.2 Summary 2
1.3 Submittals 2
1.4 Quality Assurance 2
1.5 Standard Products 3
1.6 Extra Materials 3
1.7 Substitution Of Materials And Methods 3
1.8 Safety Signs 3
1.9 Warranty And Product Quality 3
PART 2 PRODUCTS 4
2.1 Manufacturers 4
2.2 General Description 4
2.3 System Configuration 4
2.4 Identifications 6
2.5 Fault Current Considerations 6
2.6 Performance Requirements 6
2.7 Withstanding Transients 6
2.8 Bms Signal 7
PART 3 EXECUTION 7
3.1 Inspection 7
3.2 Installation 7
3.3 Field Quality Control 8
3.4 Maintenance 8
PART 1 GENERAL
B. The Contractor is responsible to supply and install the Power Factor Corrections
according to the latest requirements of the Saudi Electricity Company (SEC). This
shall require from the contractor’s manufacturer to obtain the approval (before
delivering) for the type, voltage, form, etc. from Authority have jurisdiction.
1.2 SUMMARY
A. This section specifies capacitor-type power factor correction equipment for use in
electrical power systems rated 600 Volts and less.
1.3 SUBMITTALS
A. Product Data: For products specified, include data on features, components, ratings
and performance.
C. Special Studies: For the effect of the following systems (actual selected sizes of the
project) on the capacitors:
1. Motors.
2. Generators.
D. Three (3) complete original sets of operation and maintenance manuals. Each set
shall include:
B. Standard catalogue items and IEC sizes, ratings, capacities and voltages shall be
given preference.
A. All access panels to the electrical equipment shall have appropriate warning labels.
A. one (1) year warranty after the date of Substantial Completion, for the power factor
correction equipment shall be provided, for the materials and manufacturing quality
control.
B. Contractor shall agree to repair or replace the equipment that does not comply with
the requirements or fails in work.
2.1 MANUFACTURERS
A. The system shall consist of a power factor correction unit(s) installed in its own
enclosure to achieve at least 0.93 power factor correction, IP 42, for indoor
installation, and shall be an integral part of low voltage panel board. System
includes a separately mounted current transformer sensing current in the power
circuit being corrected and providing input to the system controls. Capacitor shall
be of the dry type and shall be capable of withstanding twice its rated voltage for 10
seconds at rated frequency between terminals and container. Capacitor shall also
withstand 3 kV for 10 seconds, capacitor losses shall be less than 0.5 W/KVAR.
A. Capacitor Banks and associated components shall be suitably designed and selected
to ensure reliable and continuous operation at a maximum system Voltage of 440V
and at a maximum ambient temperature of 50°C.
B. The basic types of power factor correction equipment used to incorporate the
capacitor cells may include:
2.4 IDENTIFICATIONS
A. Each capacitor shall be provided with a permanent nameplate, which includes the
following:
A. Air-Core Type inductors and power bus work in the power factor correction units
shall withstand the mechanical forces that occur when the prospected short circuit
currents flow.
B. These currents shall be limited by the appropriate protective means, and the bracing
of these components shall withstand the peak asymmetrical symmetrical short-
circuit current (S.C.C.) of the system.
C. The switching device should be over sized (as mentioned below) to exceed the
capacitor nominal current as follows:
A. The controls shall continuously sense the power factor on the circuit being corrected
and when it differs from the target settings for more than 10 seconds, system shall
bring the corrected circuit power factor closer to the target setting.
B. The supply cables and the control and protection devices of selected capacitor bank
ratings shall be oversized to at least (1.3 x 1.15 = 1.5) times their current rating
(other than installation derating requirements)
PART 3 EXECUTION
3.1 INSPECTION
3.2 INSTALLATION
C. Mount the switchboard assembly on flush steel aligning channels elevated above
floor level by a concrete pad and as noted on Drawings. Provide aligning shims to
achieve level installation where channels cannot be provided.
D. Ensure that centralized automatic power factor capacitor assemblies are shipped in
sections which can be fitted through the available structures and openings available.
J. Provide control fuses, with five spare fuses for each rating.
A. Upon completion of installation of equipment and after circuitry has been energized,
test equipment to demonstrate compliance with requirements. When possible,
field-correct malfunctioning units, then retest to demonstrate compliance.
3.4 MAINTENANCE
A. All maintenance and inspection on the capacitor assembly shall be done with the
system disconnect device in the open position.
C. An annual inspection of the capacitor cell (before the handing over of the
installation) shall be done to identify failing capacitor cells (a bulged cover is the
symptom to watch for).
SPECIFICATION REV.
ECG ENGINEERING CONSULTANTS GROUP AUTOMATIC TRANSFER SWITCHES
KSA 263600 - 2970 1
SECTION 263600
Page
PART 1 GENERAL 2
1.1 Related Documents 2
1.2 Summary 2
1.3 Submittals 2
1.4 Quality Assurance 3
1.5 Warranty 3
1.6 Delivery, Storage And Handling 4
1.7 Instructions And Training On Operation And Maintenance 4
PART 2 PRODUCTS 4
2.1 Manufacturers 4
2.2 Automatic Transfer Switch (Ats) 4
2.3 Enclosure 6
2.4 Testing 7
PART 3 EXECUTION 8
3.1 Installation 8
3.2 Operational Testing 8
PART 1 GENERAL
A. Drawings and general provisions of the Contract, including General Conditions, Conditions
of Particular Application and Division-1 Specification Sections, apply to this Section.
1.2 SUMMARY
A. This section covers the furnishing, the installing, and the placing in operation of the
Automatic Transfer Switch.
1.3 SUBMITTALS
A. Drawings and Data: One line diagram of ATS assembly and elementary or schematic and
wiring diagram of the unit in plastic lamination permanently secured to the inside of the
front enclosure door. An interface equipment connection diagram showing all conduits
and wiring between the ATS all other related equipment. The one-line diagram shall show
interlocking provisions and cautionary notes, if any.
1. It shall also general arrangement and complete dimensional layout of the equipment.
2. Above drawings shall show components description, technical ratings of equipment
and materials.
B. Certificates: Test certificates shall be executed and submitted prior to final inspection and
acceptance in accordance with the requirements of NEMA/IEC standards. The certified
tests reports shall show date, time and duration of the overload, endurance and
temperature tests, and that the unit under test was not de-energized during the test
sequence. Three certified copies of each test certificate shall be submitted to the
Owner’s Representative.
C. Test Plan: Test plan and test procedures for the acceptance tests. The test plan and test
procedures shall explain in detail, step-by-step actions and expected results to
demonstrate compliance with the requirements specified. The procedure shall also
explain methods for simulating the necessary conditions of operation to demonstrate
system performance.
D. Acceptance Tests: Test reports in booklet form showing all field tests are performed to
adjust each component and to prove compliance with the specified performance criteria,
upon completion and testing of the installed system. The reports shall include the
manufacturer, model number, and serial number of test equipment used in each test.
Each report shall indicate the final position of controls and operating mode of the system.
B. Installer’s Qualifications: Contractor shall submit data showing that he has successfully
installed systems of the same type and design as specified herein, or that the Contractor
has a firm contractual agreement with a subcontractor having not less than ten years’
experience in the design and installations of such system. Data shall include names and
location of at least two installations he or his referenced subcontractors has installed such
systems. The references shall indicate type and design of each system and certification
that each systems has performed satisfactorily in the manner intended for not less than
three years.
1.5 WARRANTY
A. Contractor shall agree to repair or replace the equipment that does not comply with
the requirements or fails in work.
B. In addition to the protection specified for prolonged storage, the packaging of spare parts
(If Any) shall be prepared for export packing and shall be suitable for long-term storage in
a damp location. Each spare item shall be packed separately and shall be completely
identified on the outside of the container.
C. Instructions for the servicing of equipment while in long-term or prolonged storage shall
accompany each item of equipment. An enclosed instruction with each package shall be
noted on the exterior of the package and shall be in the Arabic and English languages.
D. Verification of Dimensions: The Contractor shall become familiar with the details of the
work and working conditions, shall verify dimensions in the field, and shall advise the
Owner’s Representative of any discrepancies before performing the work.
E. Spare Parts: All lists of all spare parts required for adjustment, operation, and
maintenance of the equipment for a period of three years from the date of the certificate
of completion shall be provided in accordance with the requirements of Section 01605,
General Equipment Stipulations.
A. Contractor shall provide instructions and training for the staff to be assigned in the
operation and maintenance of the equipment specified under this section. Training and
instructions shall be in accordance with the requirements set forth at the Conditions of
Contract.
PART 2 PRODUCTS
2.1 MANUFACTURERS
A. ATS shall be double throw, electrically operated, mechanically held, fully protected,
complete with voltage sensing relay. ATS is mechanically held and electrically operated
by a single solenoid mechanism energized from the source to which the load is to be
transferred. ATS shall be suitable for use in emergency or standby systems described in
B. Automatic Transfer Switch (ATS) shall have a continuous phase or main current rating
equal to or exceed the rating shown but, in no case, less than 125 percent of the full load
rating of the emergency power source, 400 Volts, 4P, 60 Hz and according to final short
circuits calculations approved by the Engineer.
D. Override Time Delay: Time delay to override monitored source deviation shall be
adjustable from 0.5 to 6 seconds and factory set at 1 second. The device shall detect and
respond to a sustained voltage drop of 30 percent of nominal voltage between any two
of the normal supply conductors, and initiate transfer action to the emergency source
and start the engine-driven generator set after the set time period. The pickup voltage
shall be adjustable between 90 to 100 percent of nominal and factory set 90 percent. The
dropout voltage shall be adjustable from 65 to 70 percent of the pickup value, and factory
set at 70 percent of nominal voltage.
E. Transfer Time Delay: Time delay before transfer to the emergency power source shall be
adjustable from 0.2 to 120 seconds and factory set at 10 seconds. The device shall
monitor the frequency and voltage of the emergency power source and transfer when
frequency and voltage is stabilized at or above 90 percent of rated values. The pickup
voltage shall be adjustable from 85 to 100 percent of nominal, and factory set at 90
percent. The pickup frequency shall be adjustable from 90 to 100 percent of nominal and
factory set at 90 percent.
F. Return Time Delay: Time delay before return transfer to the normal power source shall
be adjustable from 2 to 30 minutes and factory set at 30 minutes. The time delay shall be
automatically defeated upon loss or sustained under voltage of the emergency power
source, provided that the normal supply has been restored.
G. Auxiliary Contacts: Two normally opened and two normally closed auxiliary switches shall
operate when the transfer switch is connected with the normal power source, and two
normally opened and two normally closed switches shall operate when the transfer
switch is connected with the emergency power source.
H. Control Panel: The transfer switch shall be equipped with a microprocessor based control
panel. This panel will perform the operational and display functions of the transfer switch.
The panel digital display shall be accessible without opening the door of enclosure.
I. Supplemental Features: The ATS shall also be furnished with the following:
1. ATS Shall have a withstand and closing rating (WCR) according to OEM tables and the
manufacturer shall provide a suitable WCR values to the Engineer for review and
approval taking into consideration the delay setting of the upstream breaker due to
the selectivity study.
J. Motor Starter Control: Under-voltage and timing relays, including any auxiliary relays
required, shall be installed in the ATS enclosure to provide an adequate number and type
of properly rated contacts to control the operation of remote motor controllers or
starters shown. Devices and wiring in an external to the ATS shall cause motors to be de-
energized for an adjustable period of time before the operation of the ATS in either
direction and, subsequently, to cause motors connected to the ATS load bus to be
energized immediately after transfer at time intervals shown. The time range shall be
approximately from 1 to 15 seconds and factory set at 3 or 5 seconds.
L. Override Switch: The override switch shall by-pass automatic transfer controls so the
transfer switch will transfer and remain connected with the emergency power source,
regardless of the conditions of the normal power source. If the emergency source fails
and the normal source is available, the transfer switch shall automatically retransfer to
the normal source.
M. Green Indicating Lights: A green indicating light shall supervise the normal power source
and shall have a nameplate engraved NORMAL.
N. Red Indicating Lights: A red indicating light shall supervise the emergency power source
and shall have a nameplate engraved EMERGENCY.
2.3 ENCLOSURE
C. Finishing: Painting required for surfaces not otherwise specified and finish painting of
items only primed at the factory shall be as Manufacturer’s recommendations.
2.4 TESTING
A. Laboratory Testing: Testing shall be completed on the ATS to be supplied under these
specifications, or shall have been completed on a previous, randomly selected standard
production ATS unit having the same model number and capacity as the ATS specified.
Endurance and temperature tests shall be conducted in that sequence and within the
shortest practicable period of time on the same ATS without de-energization of that ATS
under test. The test sequence for the ATS listed below shall be followed. No deviation
will be granted that is less stringent. Approval will not be granted to deviate from the
endurance and temperature test sequence.
1. General
2. Normal Operation
3. Over voltage
4. Under voltage
5. Endurance
6. Temperature rise
7. Dielectric Voltage - Withstand
8. Contact Opening
9. Dielectric Voltage - Withstand (Repeated)
10. Withstand
11. Instrumentation and Calibration of High Capacity Circuits
12. Closings
13. Dielectric Voltage - Withstand (Repeated)
14. Strength of Insulating Base and Support
B. Factory Testing: In addition to other factory tests, each completely assembled ATS unit
shall be subjected to dielectric and operational tests, and withstand tests.
C. Withstand Test in Excess of UL 1008 Requirements: The ATS shall be tested and rated to
withstand an available fault or short-circuit current of 30 kA symmetrical minimum
interrupting capacity, or as shown on the drawings.
D. Dielectric Tests: Tests shall be performed in accordance with NEMA ICS 1. Wiring of each
control panel shall be subjected to voltage surge tests as stipulated in IEEE C37.90.1.
Impulse withstand rating tests shall be performed in accordance with the requirements of
NEMA ICS 1.
PART 3 EXECUTION
3.1 INSTALLATION
A. The ATS shall be installed as indicated and in accordance with approved Manufacturer's
instructions.
A. Following completion of the installation of each of the ATS, the Contractor shall perform
operational tests in accordance with the written instructions of the manufacturer after
having made proper adjustments and settings to demonstrate that each of the ATS
functions satisfactorily and as specified. The Contractor shall advise the Owner’s
Representative not less than 5 work days prior to the scheduled date or dates for
operational testing, and shall provide certified field test reports to the Owner’s
Representative within 2 calendar weeks following successful completion of the
operational tests. The test reports shall describe all adjustments and settings made and
all operational tests performed.
SPECIFICATION REV.
ECG ENGINEERING CONSULTANTS GROUP
LIGHTING
KSA 265100 - 2970 1
SECTION 265100
LIGHTING
Page
PART 1 GENERAL 2
1.1 Related Documents 2
1.2 Summary 2
1.3 Submittals 2
1.4 Quality Assurance 3
1.5 Delivery, Storage And Handling 4
1.6 Warranty 4
PART 2 PRODUCTS 5
2.1 Manufacturers 5
2.2 General 5
2.3 Lighting Fittings, General 6
2.4 Led (Light Emitting Diode) Lighting Fixtures 7
2.5 Lamps 8
2.6 Drivers 9
2.7 Emergency Lighting Power Unit 9
2.8 Exit Signs 10
2.9 Lamps 10
2.10 Landscape Lighting 11
PART 3 EXECUTION 11
3.1 General 11
3.2 Inspection 11
3.3 Installation 12
3.4 Installation Supervision 13
PART 1 GENERAL
1.2 SUMMARY
A This section covers partially the work of indoor lighting and ancillary fittings and the
work of outdoors lighting as required by the Contract and includes the following
items:
B Indoor lighting and ancillary fittings of service areas in all project locations are
covered under this section.
C Extent of lighting work and ancillary fittings covered by this section are indicated on
Drawings.
D Related Sections
E The following sections include requirements, which relate to work of this section:
1.3 SUBMITTALS
a. LED module Data: Trade, model, origin, type, wattage, lumen, color
rendering, color temperature, lifetime and efficacy.
b. Driver Data: Trade, model, origin, type, P.F, ignition time, approval
mark and number of lamps per ballast
B Detail layout shop drawings are coordinated with all other trades (architectural,
HVAC, fire alarm, firefighting, etc.) These drawings shall identify, but not limited to,
the following:
C Product Certificates.
1. Test report for LED of the luminaire according to IES LM-80, measuring the
lumen depreciation of solid-state lighting sources, such as LED packages,
modules and arrays.
2. Test report for luminaire according to IES LM-79, Electrical and Photometric
tests.
3. Test Report for luminaire according to LM82, Characterization of LED Light
Engines and LED Lamps for Electrical and Photometric Properties as a Function
of Temperature
4. Thermal management test report, in situ temperature measurement testing
(ISTMT) according to TM-21-11.
1. Submit sample for each type of lighting fixture specified in the lighting fixtures
schedule for approval.
2. Spare parts data
3. Detailed painting procedure to meet requirements
E Calculations as per proposed Vendor’s software to verify the design, layout, furniture
and code lux values.
A Reference Standards: The work to be performed under this section shall be in strict
compliance with the applicable regulations and standards.
D In case of conflict among the referenced standards and codes, the more stringent
provision will govern.
E In case of conflict among the specifications, drawings and BOQ, the more stringent
provision will govern.
A Materials and products shall be securely packed for delivery, with waterproofed type
providing protection against excessive heat, humidity and water damages.
1.6 WARRANTY
A. Contractor shall agree to repair or replace the materials that does not comply
with the requirements or fails in work.
2.1 MANUFACTURERS
2.2 GENERAL
A Provide all new lighting fittings, wall brackets, lamps, poles, auxiliary lighting units
and other fixtures and materials, including proper space, and complete the interior
lighting installations as shown on Drawings, specified and required.
C Luminaires have been selected to provide the illumination levels in accordance with
Lighting Handbook, IES. If the space envelope and/or furniture layout of any facility
is changed from Drawings, the Contractor shall adjust the lighting layout for that
space to maintain these standards.
F The Contractors shall produce upon request, the photometric data for any luminaire
specified or supplied.
G All luminaries shall be provided with a lamp compatible with the control gear used.
I All flexible cords shall be anchored at both ends such that the cord is free from
strain.
J Any plastics used in the luminaire shall be light and UV stable and shall be suitable
for their application.
K All sheet steel components shall be suitably pre-treated and electrostatically spray-
painted using acrylic polyester or epoxy powders.
M Louvers shall be restrained to prevent them from failing out of the body of the
luminaire under normal conditions and when relamping. Metal louvers shall be
earthed to the body of the luminaire or the earth terminal.
N Diffusers shall be restrained to prevent them from falling out of the body of the
luminaries under normal conditions and when relamping.
P All lights have on their packaging a description of what they are and a position
number which matches that in the project manual.
Q Exact specifications for heat technology and thickness, can be obtained personally
from the applicant.
R If the supplier or contractor should have doubts about the quality of any materials,
construction, equipment or installations from other companies particularly with
regard to accident, prevention, and if these things will affect what is defined in the
project manual, he shall immediately report this in writing.
T When submitting the tender, the bidder shall provide the following technical
specifications
U For the prototypes and the series lights in the form of a report:
V The lights shall be examined before delivered to ensure they are capable of the
required performance;
W After the award of the contract this shall be verified by laboratory testing. The client
reserves the right to have these tests carried out by an institution of his own
choosing
X For all areas, illuminance calculations and luminance distribution graphs conforming
to the applicable statutory requirements shall be presented and must be approved
(horizontal and vertical).
B Wiring: Connection to the Main Circuit Wiring Shall Be 3-Wire of A Minimum Core
Size of 3 Mm2, Earthing Shall Be Connected. The Wiring from Ceiling Rose Shall Be
Heat Resisting.
C The Contractor shall not order any lighting fitting until final approval of the type,
color and surface finish has been given by the Engineer.
A Provide LED lighting fixtures shall be in accordance with the Fixture Schedule.
B LED lighting fixtures and drivers shall be from the same manufacture and shall be
tested and certified as whole Luminaire.
F The LED luminaire shall be designed and suitably rated to ensure correct operation
and continuous trouble free service under the prevailing climatic conditions. The
luminaire shall be designed to withstand the effects of direct sun exposure during
the day and dusty weather conditions including the occasional sand storm. The
luminaire manufacturer shall guarantee the performance and life time claims of;
lumen maintenance and luminaire life of the luminaire under the stated climatic
conditions.
H LED fixtures shall be modular and allow for separate replacement of LED lamps and
drivers. User serviceable LED lamps and drivers shall be replaceable from the room
side.
I The classification of the risk group shall meet the requirements of IEC 62471 and The
LED binning shall be as defined by ANSI in the C78.377 standard - MacAdam color
ellipse.
J Housing:
K Lenses:
1. Reflectors and lenses must be designed so that they do not affect neither the
electrical (e.g. risk of short circuits in misplaced metal reflectors) nor the
mechanical stability of the LED (eg. by damaging the LED components).
2. Optical components, each according to the product and the field of
implementation, must be protected against damage by radiation (clouding of
the lens), mechanical stress, etc.
3. Solder Connections must be produced according to the data sheet and shall
not affect the function of the LED.
L Binning:
1. In the manufacturing process the LEDs and their component features are
subject to a relatively large dispersion in different areas. The selection of the
LEDs according to different finely scaled classes is called "binning".
2. A detailed list of the binnings and the associated data and diagrams of a LED
must be provided by the manufacturer in order to understand the
photometric and electro technical measurement values.
M Luminaires must be tested to IES LM-79, IES LM-80 and IES LM-82 standards, with
the results provided as required in the Submittals paragraph of this specification.
2.5 LAMPS
B LED lamps shall have a color temperature of 3500 degrees K, a CRI of 80 minimum,
and a lumen maintenance L70 rating of 50,000 hours minimum.
C LED lamps shall comply with NEMA SSL 4 “SSL Retrofit Lamps: Suggested Minimum
Performance Requirements”.
D Adequate spacing shall be left between wall and bracket-mounted lighting bulbs.
E The fixed wiring to a fitting shall terminate adjacent to the fitting in a conduit box.
Final connection to the fitting being carried out silicon rubber insulated pull through
flexible conduit.
F Final connections between fixed wiring systems and lighting fittings shall in all cases
be carried out in heat resisting flexible cables. Under no circumstances shall cables
insulated with general purpose PVC be used for final connections to any lighting
fittings.
G The flexible cables used for final connections shall be type selected for temperature
duty and current/mass supported in accordance with IEC Regulations, except that no
cable shall be less than 2.5 mm2 cross section.
C LED driver shall be Class 2 comply with UL1310 Standard for Safety which requires
the output voltage to pose no risk of fire or electric shock which makes secondary
circuit protection unnecessary.
E Drivers shall have a total individual Luminaire Harmonic Distortion (THD) of ≤20% in
accordance with ANSI C82.77
G Drivers shall be rated for the ambient temperature from -20°C to +50°C
I Electromagnetic Compliance of drivers shall comply with FCC Title 47 Part 15 Class A
M Drivers shall comply with the requirements of IEC 61000-4-5 for surge immunity, 6 kv
for outdoor lighting.
N Individually fused drivers shall have their fuses accessible from outside of the fixture
chassis.
O Luminaires shall be equipped with an LED driver(s) that accepts the voltage as
indicated on the "Luminaire (Lighting Fixture) Schedule". Individual driver(s) shall be
replaceable.
B All “Exit” signs and fire safety signs shall be of the pictogram type utilizing the
pictograms as give in IEC or DIN/VDE Standards. Where wording is incorporated on
the signs it shall be in accordance with IEC or DIN/VDE Standards.
D Self-energized signs (in respect of luminosity) shall comply with IEC or DIN/VDE
standards.
1. Lamps for AC Operation: LEDs, 70,000 hours minimum rated lamp life.
2. Self-Powered Exit Signs (Battery Type): Integral automatic charger in a self-
contained power pack with battery kit 3 hours unless otherwise indicated in
the drawings.
2.9 LAMPS
C LED Lamps: shall be designed for more than 50,000- operation hour at 50°C ambient.
Manufacturer shall provide data to demonstrate the hour lumen depreciation factor
at the minimum 50°C temperature. The method of calculation of lumen depreciation
for more than 50,000 hrs. shall be reviewed and declared consistent with their data
by the LED chip manufacturer and provided to the Engineer for approval.
E Garden Lighting fixture shall be with electrostatic painting with body of the
Aluminum – die cast, ingress protection IP65
F All fixtures installed in the Landscape Lighting System shall be suitable for outdoor
installation.
PART 3 EXECUTION
3.1 GENERAL
3.2 INSPECTION
A Inspect each assembly and related accessories for damage, defects and
completeness prior to installation.
B At early stage of the construction, inspect a sample area to verify that the Lux level is
as per approved calculation
A Where a conduit wiring system is specified for the wiring to totally enclose lighting
fittings such as bulkhead fittings etc., and the wiring passes through the fittings or
the fittings are mounted directly to a conduit box housing, the circuit wiring shall be
carried out in silicone rubber insulated cable enclosed in a separate conduit.
C Adequate spacing shall be left between wall and bracket-mounted lighting bulbs.
D The fixed wiring to a fitting shall terminate adjacent to the fitting in a conduit box.
Final connection to the fitting being carried out silicon rubber insulated pull through
flexible conduit.
E Final connections between fixed wiring systems and lighting fittings shall in all cases
be carried out in heat resisting flexible cables.
F Under no circumstances shall cables insulated with general purpose PVC be used for
final connections to any lighting fittings.
G The flexible cables used for final connections shall be type selected for temperature
duty and current/mass supported in accordance with IEC Regulations, except that no
cable shall be less than 2.5 mm2 cross section.
J The luminaire has to be mounted at the wall with a gap of 5mm below the bottom
edge of the wall.
K For maintenance it must be able to change the LED modules in the luminaire as easy
as possible without any additional maintenance tools. Therefore it is designed that
the LED modules can be taken off for easy maintenance.
L The luminaire housing is mounted at the wall with three distance cylinder. These
mounting cylinders are very important because the walls are not always straight.
Therefore it is necessary to have a gap Between the wall and luminaire. The final
leangth of the distance cylinder in the construction drawing of the manufacturer has
to be approved by the architect and lighting consultant.
M The distance from the LED-module to the light output holes (Φ10mm) in the
luminaire cover has to be exact 10mm.
N Final details and developments have to be done by the luminaire manufacturer and
to be approved by the client and the lighting specialist.
O Any design / construction drawings have to be coordinated and agreed with the
lighting specialist, engineer and client.
Q The operating devices for normal and emergency operation are located in the
luminaire housing. For each luminaire it is necessary to have operating devices for
normal and emergency operation as described under point 1.3.
R All required connection cables between the LED module and operating devices have
to be delivered with the luminaire and connected via appropriate plugs and have to
be pre wired and connected ready for installation.
S The luminaire manufacturer has to coordinate the control cable type from the
operating devices to the nearest electrical room with the lighting control system
supplier.
SPECIFICATION REV.
ECG ENGINEERING CONSULTANTS GROUP
EXTERIOR LIGHTING
KSA 265600 - 2970 1
SECTION 265600
EXTERIOR LIGHTING
Page
PART 1 - GENERAL 2
1.1 Related Documents 2
1.2 Summary 2
1.3 Definitions 2
1.4 Structural Analysis Criteria For Pole Selection 2
1.5 Submittals 3
1.6 Informational Submittals 3
1.7 Quality Assurance 4
1.8 Delivery, Storage, And Handling 4
1.9 Warranty 4
PART 2 - PRODUCTS 5
2.1 Manufacturers 5
2.2 General 5
2.3 Street Lighting Luminaire 6
2.4 Optional Photoelectric Relay 7
2.5 Required Data In Catalog 7
2.6 Luminaire Support Components 8
2.7 Lighting Poles 8
2.8 Decorative Poles 9
PART 3 - EXECUTION 9
3.1 General 9
3.2 Inspection 9
3.3 Pole Installation 9
3.4 Grounding 10
3.5 Field Quality Control 11
PART 1 - GENERAL
1.2 SUMMARY
1.3 DEFINITIONS
D. Pole: Luminaire support structure, including tower used for large area illumination.
A. Dead Load: Weight of luminaire and its horizontal and vertical supports, lowering
devices, and supporting structure, applied as stated in AASHTO LTS-4.
B. Wind Load: Pressure of wind on pole and luminaire, calculated and applied as per
IEC 2006 Edition -Exposure C, basic wind speed go mph
A. Product Data: For each luminaire, pole, and support component, arranged in order
of lighting unit designation. Include data on features, accessories, finishes, and the
following:
6. Photoelectric relays.
7. Ballasts, including energy-efficiency data.
8. Lamps, including life, output, and energy-efficiency data.
9. Materials, dimensions, and finishes of poles.
10. Means of attaching luminaires to supports, and indication that attachment is
suitable for components involved.
11. Anchor bolts for poles.
12. Manufactured pole foundations.
C. Shop Drawings: Include plans, elevations, sections, details, and attachments to other
work.
D. Samples: For products designated for sample submission in the Exterior Lighting
Device Schedule. Each Sample shall include lamps and ballasts.
B. Qualification Data: For qualified agencies providing photometric data for lighting
fixtures.
A. Store poles on decay-resistant-treated skids at least 12 inches (300 mm) above grade
and vegetation. Support poles to prevent distortion and arrange to provide free air
circulation.
B. Handle wood poles so they will not be damaged. Do not use pointed tools that can
indent pole surface more than 1/4 inch (6 mm) deep. Do not apply tools to section of
pole to be installed below ground line.
1.9 WARRANTY
1. Warranty Period for Luminaries: Five years from date of Substantial Comple-
tion.
2. Warranty Period for Metal Corrosion: Five years from date of Substantial
Completion.
3. Warranty Period for Color Retention: Five years from date of Substantial Com-
pletion.
4. Warranty Period for Poles: Repair or replace lighting poles and standards that
PART 2 - PRODUCTS
2.1 MANUFACTURERS
2.2 GENERAL
A. Comply with UL 1572, UL 1598 and listed for installation in wet locations. Comply
with IESNA RP-8 for parameters of lateral lighting distribution patterns and shall
meet ambient conditions of 50°C, 90% humidity.
D. Housing: Rigidly formed, weather and light-tight enclosure with integral control
gear.
E. Doors, Frames and Accessibility: Easily accessible and usable, self blocking, smooth,
free of light leakage, permits relamping without use of tools and without risk of
accidental falling of parts. Removable doors for cleaning or replacing lens. Designed
to disconnect ballast when door opens. Easy access to lamp, gear tray, tilt
adjustment and lamp adjustment.
F. Plastic Parts: High resistance to yellowing and other changes due to aging, exposure
to heat and UV radiation.
K. Seal Gasket: Use heat and aging-resistant, removable non glued, silicon resilient
gaskets to seal and cushion lenses and refractors in luminaire doors.
M. Luminaire Wiring: Use 105ºC moisture and heat-resistant silicon rubber wires,
A. General:
1. Luminaires must be tested to IES LM-79 and IES LM-80 standards, with the re-
sults provided as required in the Submittals paragraph of this specification.
2. IES LM-79 : Electrical and Photometric Measurements of Solid-State Lighting
Products
3. IES LM-80 : Measuring Lumen Maintenance of LED Light Source
4. Luminaire drive current value must be identical to that provided by test data
for luminaire.
5. LED components and sub components shall meet the new standard IES LM-84,
IES LM-85, IES TM-26 and IES TM-28.
1. Exterior LED luminaires supplied shall be complete with the proper Reflectors,
diffusers, house side shields, louvers, glassware, gaskets, pole arms, Collars,
shims, wiring, control, conduit, hardware, drivers, photo controls, and Other
appropriate devices, parts and accessories to be properly installed for an exte-
rior weatherproof lighting installation.
1. Poles for LED luminaires shall be as indicated on the Drawings with factory fin-
ish as shown in the "Luminaire (Lighting Fixture) Schedule". Poles shall be fac-
tory wrapped with heavy weatherproof paper for protection during handling
and shipping.
2. Contractor shall furnish hot-dipped galvanized anchor bolts, templates, ground
rods, conduit elbows, and base information, etc., for the installation of con-
crete bases as detailed on the Drawings.
3. Poles shall be of the height and with brackets, etc. as indicated in the drawings
"Luminaire (Lighting Fixture) Schedule".
D. (DRIVERS)
E. ILLUMINATION
1. Illumination values for roadways and sidewalks shall be set to achieve the rec-
ommended values of standard:
F. FOUNDATIONS
A. UL listed, factory mounted to the luminaire, single throw, designed and factory set to
turn the light unit on at 15 to 30 lux and OFF at 50 to 100 lux with 15-sec. minimum
time delay.
C. Polar diagrams
G. Inlet diameter
E. Anchor Bolts Nuts, and washers: Hot-dip galvanized after fabrication unless stainless
steel items are indicated.
G. Pole/Support Structure Bases: Anchor type with hold-down or anchor bolts, leveling
nuts, and bolt covers. The design strength of concrete for pole foundation shall be
3000-psig (20.7 M Pa), 28-day compressive strength.
B. Pole of area lighting shall withstand the weight of 4 luminaires (explosion proof type)
plus one person in operation and the resultant moment of these weights at the
indicated height and wind.
C. Pole Earthing: Provide a 12 mm welded threaded lug, for steel poles, accessible
through hand hole and listed for copper conductor connection.
D. Pole Finish: Grind welds and polish surfaces to a smooth, even finish.
A. Pole Material:
B. Mounting Provisions:
C. Fixture Brackets:
PART 3 - EXECUTION
3.1 GENERAL
3.2 INSPECTION
A. Inspect each assembly and related accessories for damage, defects and
completeness prior to installation.
A. Alignment: Align pole foundations and poles for optimum directional alignment of
luminaires and their mounting provisions on the pole.
D. Foundation-Mounted Poles: Mount pole with leveling nuts, and tighten top nuts to
torque level recommended by pole manufacturer.
1. Use anchor bolts and nuts selected to resist seismic forces defined for the ap-
plication and approved by manufacturer.
2. Grout void between pole base and foundation. Use non shrink or expanding
concrete grout firmly packed to fill space.
3. Install base covers unless otherwise required.
4. Use a short piece of 1/2-inch- (13-mm-) diameter pipe to make a drain hole
through grout. Arrange to drain condensation from interior of pole.
E. Embedded Poles with Tamped Earth Backfill: Set poles to depth below finished
grade, but not less than one-sixth of pole height.
1. Dig holes large enough to permit use of tampers in the full depth of hole.
2. Backfill in 6-inch (150-mm) layers and thoroughly tamp each layer so compac-
tion of backfill is equal to or greater than that of undisturbed earth.
F. Embedded Poles with Concrete Backfill: Set poles in augured holes to depth below
finished grade, but not less than one-sixth of pole height.
1. Make holes 6 inches (150 mm) in diameter larger than pole diameter.
2. Fill augured hole around pole with air-entrained concrete having a minimum
compressive strength of 3000 psi (20 MPa) at 28 days, and finish in a dome
above finished grade.
3. Use a short piece of 1/2-inch- (13-mm-) diameter pipe to make a drain hole
through concrete dome. Arrange to drain condensation from interior of pole.
4. Cure concrete a minimum of 72 hours before performing work on pole.
G. Poles and Pole Foundations Set in Concrete Paved Areas: Install poles with minimum
of 6- inch- (150-mm-) wide, unpaved gap between the pole or pole foundation and
the edge of adjacent concrete slab. Fill unpaved ring with pea gravel to a level 1 inch
(25 mm) below top of concrete slab.
H. Raise and set poles using web fabric slings (not chain or cable).
3.4 GROUNDING
A. Inspect each installed fixture for damage. Replace damaged fixtures and
components.
C. Illumination Tests:
SPECIFICATION REV.
ECG ENGINEERING CONSULTANTS GROUP FIRE-ALARM SYSTEM
KSA 283100 – 2970 1
SECTION 283100
FIRE-ALARM SYSTEM
Page
PART 1 GENERAL 2
1.1 Related Documents 2
1.2 Summary 2
1.3 Definitions 2
1.4 System Integration 2
1.5 Performance Requirements 3
1.6 Submittals 3
1.7 Quality Assurance 4
1.8 Reference Codes And Standards 5
1.9 Delivery, Storage And Handling 6
1.10 Software Service Agreement 6
1.11 Extra Materials 7
1.12 Coordination 7
1.13 Warranty 7
PART 2 PRODCUTS 8
2.1 Systems Operational Description 8
2.2 Interface Between The Bms And The Fire Alarm System 9
2.3 Fire-Alarm Control Unit (Main Fire Alarm Control Panel) 10
2.4 Sub-Fa Control Panels (S-Facp) 12
2.5 Repeater Panel 12
2.6 Manual Fire-Alarm Stations 13
2.7 System Detectors 13
2.8 Notification Appliances 14
2.9 Magnetic Door Holders 15
2.10 Addressable Interface Device 15
2.11 Fault Isolation Module 15
2.12 Automatic Telephone Dialer 16
2.13 System Printer 16
2.14 Device Guards 16
2.15 Wiring 16
PART 3 EXECUTION 17
3.1 Equipment Installation 17
3.2 Connections 18
3.3 Identification 19
3.4 Grounding 19
3.5 Field Quality Control 19
3.6 Training 21
PART 1 GENERAL
A. Drawings and general provisions of the Contract, including General and Supplemen-
tary Conditions and Division 01 Specification Sections, apply to this Section.
1.2 SUMMARY
A. Section Includes:
1.3 DEFINITIONS
A. System installer shall coordinate with Main Contractor to perform all system inte-
gration requirements.
B. Project Main Contractor should perform all required interfaces between all ELV/ICT
and related life safety and security systems in terms of software and hardware.
D. The Engineer has the right to approve and reject the documents after assessing the
integration procedures followed in addition to the system compliance with this
specification.
E. The Main Contractor is responsible for achieving all integration requirements men-
tioned throughout the documents (specs and drawings) for the project
F. Based on certain alarm or rule violation a POP UP screen should be shown immedi-
ately with the camera view responsible for the area of concern.
A. Seismic Performance: Fire-alarm control unit and raceways shall withstand the ef-
fects of earthquake motions determined according to [SEI/ASCE 7].
1. The term "withstand" means "the unit will remain in place without separation
of any parts from the device when subjected to the seismic forces specified
and the unit will be fully operational after the seismic event.
B. All the equipment shall operate reliably under the following environment condi-
tions:
1.6 SUBMITTALS
B. Shop Drawings: Provide shop drawings showing equipment, device locations and
connecting wiring of the systems, including riser diagrams. Shop drawings shall in-
clude, but not be limited to the following:
1. Complete pin to pin one-line riser diagram(s) showing all approved equip-
ment, size, type and number of all conductors, interconnection between the
system and all other related systems.
2. Installation details for detectors, manual stations raceways and all the other
components of the system. Installation details drawings shall show all acces-
sories used in installation such as back boxes, glands, washers, etc.
3. Exact location of every single component of the system in coordination with
all other adjacent works (Electromechanical, Arch., and Civil).
4. Signature of all involved engineers representing different disciplines (Electro-
mechanical, etc) to confirm their approval of such locations, installations and
coordination.
5. Voltage drop calculations for notification appliance circuits & DC lines.
6. Signal control module calculations.
7. Battery-size calculations.
8. Complete sequence of operations and functions of the system.
D. Maintenance Data: Submit maintenance data and spare parts list for each type of
Fire Alarm equipment installed, including furnished specialties and accessories. In-
clude this data, product data, and shop drawings in the maintenance manual in ac-
cordance with other relevant documentation.
E. Composite Coordinated drawings illustrating all MEP devices equipment that are
monitored and controlled by the fire alarm system.
F. Finalized Reflected ceiling drawings illustrating all works in the ceilings after finaliz-
ing the coordination process.
D. Source Limitations for Fire-Alarm System and Components: Obtain fire-alarm sys-
tem from single source from single manufacturer. Components shall be compatible
with, and operate as, an extension of the existing system.
A. All works shall be performed in strict accordance with the drawings, specifications
and stipulations of the Local Building and safety Codes, the National Fire Protection
Association (NFPA), International Electrical Commission (IEC) and other related in-
ternational standards:
C. The Cables used for Fire Alarm System shall meet the following standards:
BS Standards
1. IEC 60331-1 edition 1.0 (2002): Tests for Electric Cables under Fire Condi-
tions – Circuit Integrity
2. IEC 60754-1 edition 2.0 (1994): Tests on Gases Evolved during Combustion
of Material from Cables.
3. IEC 61034-1 edition 3.0 (2005-04): Measurement of Smoke Density of Cables
Burring under Defined Conditions.
4. IEC 60228 edition 3.0 (2004-11): Conductors of Insolated Cables.
5. IEC 60332 edition 3.0 (1993): Tests on Electric Cables under Fire Condi-
tions.
6. All fire alarm cables sizes shall meet the manufacturer requirements justified
by calculations and official documents.
7. All fire alarm cables must be fire resistant (105 C ° three hours) produce no
hazardous toxic gases at least 2.5 mm.
D. Equipment and installations shall comply with the latest revision of the current pro-
visions of the following codes and standards:
A. Deliver products in factory containers. Store in clean, dry, closed space in original
containers. Protect products from fumes. Handle very carefully to avoid shocks or
damage.
B. Inspection shall be performed in two stages, first time upon receiving the equip-
ment, devices and cables on site before storing and second time after installation
according to installation phases.
B. Upgrade Service: Update software to the latest version available at the Project
completion. Install and program software upgrades that become available within
two years from date of Substantial Completion. Upgrading software shall include
operating system. Upgrade shall include new or revised licenses for using of soft-
ware.
A. Furnish extra materials that match products installed and that are packaged with
protective covering for storage and identified with labels describing contents.
B. The Contractor shall provide the suggested spare parts for 5 years for approval.
Spare parts lists shall be submitted within the technical submittal, at the shop draw-
ings stage and close out documents.
1. Lamps for Strobe Units: Quantity equal to 3 percent of amount installed, but
not less than 1 unit.
2. Multi Detectors, Fire Detectors and Flame Detectors: Quantity equal to 5 per-
cent of amount of each type installed, but not less than 1 unit of each type.
3. Detector Bases: Quantity equal to 5 percent of amount of each type installed,
but not less than 1 unit of each type.
4. Keys and Tools: One extra set for access to lock and tamper proofed compo-
nents.
5. Audible and Visual Notification Appliances, Monitor modules, Controls and
Signal Control Modules: 3 percent of amount installed, but not less than 1
unit.
6. Manual Stations: Quantity equal to 5 percent of amount of each type in-
stalled, but not less than 1 unit.
7. FACP Power Supply: Quantity equal to one.
8. FACP Communication Card: Quantity equal to one.
9. FACP Loop Card Quantity equal to one unit.
10. FACP Power Card /Module Quantity equal to one unit.
1.12 COORDINATION
A. The Fire Alarm System supplier shall be responsible to coordinate and exchange in-
formation with the Suppliers of other systems and equipment which shall communi-
cate with, in order to achieve the required specified functions and achieve the civil
defense requirements. Contractor must coordinate with all other MEP disciplines to
perform all manual override and systems reset and return to normal operation, a
detailed document shall be submitted for the engineer’s approval.
1.13 WARRANTY
A. Contractor shall provide the Warranty certificates on which manufacturer and In-
staller confirm that they shall provide required maintenance / repair for the system
and all of its components including required spare parts and any other work re-
quired to keep the system working with the required performance within the speci-
fied warranty period (two years) without any extra cost.
1. Manual stations.
2. Heat detectors.
3. Multi Detetors
4. Verified automatic alarm operation of Multi detectors.
5. Automatic Sprinkler System Water Flow/Foam Flow.
6. Multi detectors in elevator shaft and pit.
7. Fire-extinguishing system operation.
8. Fire standpipe system.
C. Supervisory signal initiation shall be by one or more of the following devices and ac-
tions:
E. System Trouble and Supervisory Signal Actions: Initiate notification appliance and
annunciate at fire-alarm control unit and remote annunciators. Record the event on
system printer.
2.2 INTERFACE BETWEEN THE BMS AND THE FIRE ALARM SYSTEM
A. The Main Fire Alarm Panel shall have a data port to enable the transfer of infor-
mation to the Management level Network of the BMS. The communication shall be
uni-directional from the Main Fire Alarm Panel to the Management Level Network
only.
B. The start and end of any message shall be uniquely identified and the message shall
indicate time, date, and zone of incidence, also indicating whether the fire alarm
system return to normal of fire alarm fault. In the event of a fire, the fire alarm sys-
tem shall communicate a list of all equipment shut down and start by fire alarm sys-
tem.
C. There shall be no transfer of data from the Management Level Network of BMS to
the Fire Alarm System.
D. The Fire Alarm System shall automatically shut down all terminal that serve the zone
of incidence in the event of a fire alarm and the BMS shall automatically restart
equipment following a return to normal message from the fire alarm system.
E. All control functions of subsystems are soul responsibility of those systems control
panels such as fire fighting panels, MCC panels, elevator panels…etc. All other sub-
systems panels that are performing life safety controlling and monitoring functions
must be manufactured, installed, tested and approved according to related fire
codes and standards.
F. The Fire Alarm System shall be fully interfaced with the Building Management Sys-
tem (BMS) by means of software in addition to dry contacts to monitor various
points in the system. The BMS shall receive all events, actions and reports from the
FACP through the appropriate protocol. The protocol converter and software shall
be included with FACP, so as to be fully compatible with the BMS. All addressing in-
formation must be transferred between the systems and shown on Both Graphical
B. Alphanumeric Display and System Controls: Arranged for the interface between
human operator at fire-alarm control unit and addressable system components in-
cluding annunciation and supervision. Display alarm, supervisory and component
status messages, with the programming and control menu.
C. Circuits:
1. Initiating Device, Notification Appliance, and Signaling Line Circuits: NFPA 72,
Class A.
E. Smoke-Alarm Verification:
a. Activation of all actions required in case of fire shall be delayed for thir-
ty (30 seconds), which is software adjustable, for receiving the first sig-
nal from an alarm-initiating detector.
b. If an alarm signal from a second detector in same zone area or a second
alarm signal from the same detector is received within 30 seconds, a
confirmation is assured and the programmed actions shall take place.
c. If no second alarm signal is received or a sustained detection condition
exists within the first thirty (30) seconds, the system shall reset to nor-
mal.
F. Elevator Recall:
1. Multi detectors at the following locations shall initiate automatic elevator re-
call. Alarm-initiating devices, except those listed, shall not start elevator re-
call.
2. Elevator lobby detectors located on the designated recall floors shall be pro-
grammed to be transferred to the alternate recall floor.
3. Water-flow alarm connected to sprinkler in an elevator shaft and elevator
machine room shall shut down elevators associated with the location without
time delay.
a. Water-flow switch associated with the sprinkler in the elevator pit may
have a delay to allow elevators to move to the designated floor.
J. Primary Power: 24-V dc obtained from 230 Vac service and a power-supply module.
Initiating devices, notification appliances, signaling lines, trouble signals, supervisory
and digital alarm communicator transmitters shall be powered by 24-V dc source.
1. Alarm current draw of entire fire-alarm system shall not exceed 80 percent
(80%) of the power-supply module rating.
K. Secondary Power: 24-V dc supply system with batteries, automatic battery charger,
and automatic transfer switch.
A. Sub- panel operate in a network configuration with the M-FACP and can operate in-
dependently if communication seizes between them. S-FACP exchange data and
commands with the M-FACP and the other S-FACP panels of the system by means of
communication link connecting the M-FACP and the S-FACP.
B. The S-FACP panel shall include the necessary hardware and software required to
function as specified and according to the code requirements
A. General Requirements for Manual Fire-Alarm stations: Comply with related fire
codes. Boxes shall be finished in red with molded, raised-letter operating instruc-
tions in contrasting color; shall show visible indication of operation; and shall be
mounted on recessed outlet box. If indicated as surface mounted, provide manufac-
turer's surface back box. The word Fire shall appear on the front of the station.
1. The detector shall process and analyze information from each sensor sepa-
rately.
2. The multi sensor shall combine optical smoke detection, heat detection and
microprocessor control with analogue addressable communications.
3. Integrated Photoelectric Smoke sensor, and 135°F (+57°C) Fixed-Temperature
Heat Sensing Technologies.
4. The detector shall have non-volatile memory which permanently stores serial
number, type of device and automatically shall update the historic infor-
mation including hours of operation, last maintenance date, number of alarms
and troubles, time of last alarm and analog signal patterns for each sensing
element just before last alarm.
5. The detector shall be On-board microprocessor based.
6. Continuous self-diagnosis and storage of environmental and operational data
sensitivity check.
7. Auto-addressing.
8. Automatic device mapping by means each detector shall transmits wiring in-
formation regarding its location with respect to other devices on the circuit.
9. Built in isolator.
10. Special algorithm for optimum combination of optical and thermal character-
istic.
11. Automatic localization of interruptions and short circuits.
12. Thermal only detection mode.
13. Environmental Compensation.
14. Day/Night Sensitivity Adjustment.
1. General Requirements for Heat Detectors: Comply with related fire codes.
B. Horns: Electric-vibrating-polarized type, 24-V dc; with provision for housing the op-
erating mechanism behind a grille. Comply with related fire codes. Horns shall pro-
duce a sound-pressure level up to 95 dBA, measured 3 m from the horn as per relat-
ed fire codes.
C. For Outdoor Audible Announcements shall be the same as indoor but with weather
proof housing with minimum IP55.
D. Visible Notification Appliances: Xenon strobe lights comply with related fire codes,
with clear or nominal white polycarbonate lens mounted on an aluminum faceplate.
The word "FIRE" is engraved in minimum (25-mm-) high letters on the lens.
A. Description: Units are equipped for wall or floor mounting as indicated and are
complete with matching doorplate.
A. Description: Microelectronic monitor module, NRTL listed for use in providing a sys-
tem address for alarm-initiating devices for wired applications with normally open
contacts.
B. Two (2) state alarm or supervisory signals shall be transformed by the MMs to ad-
dressable digital form to be processed by the system.
D. Each control module must have at least two independents outputs with two sub ad-
dresses
A. Description: Addressable fault isolation module shall be used in signal circuits to in-
dicate and isolate wiring faults.
B. Fault isolation modules shall be installed in order to help FACP to allocate break in
communication wiring.
C. Fault isolation shall be provided at riser and loop circuits at locations not exceeding
the maximum number of devices in between according to Manufacture’s require-
ments.
D. The minimum number of isolators allowed is one (1) for every fifteen (15) device in
A. The Automatic Telephone Dialer shall provide the system with automatic ability to
dial a remote fire fighting location and deliver pre-recorded emergency message
through a dedicated line, the message length shall be of 50 second at least.
B. Telephone dialer shall provide message test speaker and a message test switch.
C. The dialer shall be provided with battery backup operation and programming facili-
ty.
A. Printer shall be listed and labeled by an NRTL as an integral part of fire-alarm sys-
tem.
B. All Alarm, trouble, supervisory and command events shall be memorized by the sys-
tem and printed by the event printer (EP). The system shall bear sufficient memory
to store not less than 1000 events and print them on command.
A. Description: Welded wire mesh of size and shape for the manual station, Multi de-
tector, gong, or other device requiring protection.
2.15 WIRING
A. Wire and cable for fire alarm systems shall be UL listed and labeled as complying
with NFPA 70, Article 760 and meet the above general standard requirements.
B. Cable must be separated from any open conductors of power, or Class 1 circuits,
and shall not be placed in any conduit, junction box or raceway containing these
conductors.
C. All wire and cable shall be listed and/or approved by a recognized testing agency for
use with a Protective Signaling System
D. Embedded conduits shall be PVC and all surface conduits shall be EMT
E. The wiring which interconnects all addressable devices (detectors, etc.) with control
equipment shall be fire resistant ( 105 C ° three hours ) produce no hazardous toxic
gases LSZH . The Fire alarm system manufacturer requirements shall be considered ,
1.5 mm2 minimum copper cables constituting supervised Class A circuits of the ap-
F. Fire alarm wiring shall be UL approved, or equivalent, and shall be in full compliance
with the Codes and the requirements of the fire alarm equipment Manufacturer.
G. The wiring of high current devices shall be fire resistant ( 105 C ° three hours ) pro-
duce no hazardous toxic gases and according to the Manufacturer requirements,
the cross section area shall not be less than 2.5 mm2 and shall not cause more than
five percent (5%) voltage drop. DC calculations shall be provided.
H. All wiring shall be color coded and cabled. Junction boxes shall be red colored and
include wiring identification numbering.
I. Wires and cables shall provide sufficient resistance to the spread of fire (according
to NFPA) and generate no hazardous smoke to human life.
J. Wiring System shall include all indoor and outdoor wires and cables necessary for
complete fire alarm system. Including control and supervisory circuits, intercon-
necting with other related systems (HVAC, etc.). Outgoing and returning conduc-
tors.
PART 3 EXECUTION
B. Equipment Mounting: Install fire-alarm control unit on concrete base with tops of
cabinets not more than 1830 mm above the finished floor. Comply with require-
ments for concrete base specified in Division 03 Section.
C. Equipment Mounting: Install fire-alarm control unit on finished floor with tops of
cabinets not more than 1830 mm above the finished floor.
1. Comply with NFPA 72, "Smoke-Sensing Fire Detectors" Section in the "Initiat-
ing Devices" Chapter, for smoke-detector spacing.
2. Comply with NFPA 72, "Heat-Sensing Fire Detectors" Section in the "Initiating
Devices" Chapter, for heat-detector spacing.
3. Smooth ceiling spacing shall not exceed 9 m.
4. Spacing of detectors for irregular areas, for irregular ceiling construction, and
for high ceiling areas shall be determined according to Appendix A in NFPA 72.
5. HVAC: Locate detectors not closer than 1 m from air-supply diffuser or re-
turn-air opening.
6. Lighting Fixtures: Locate detectors not closer than 300 mm from any part of a
lighting fixture.
E. Heat Detectors in Elevator Shafts: Coordinate temperature rating and location with
sprinkler rating and location.
F. Single-Station Multi Detectors: Where more than one smoke alarm is installed with-
in a dwelling or suite, they shall be connected so that the operation of any smoke
alarm causes the alarm in all smoke alarms to sound.
G. Remote Status and Alarm Indicators: Install near each Multi detector and each
sprinkler water-flow switch and valve-tamper switch that is not readily visible from
normal viewing position.
H. Audible Alarm-Indicating Devices: Install not less than 150 mm below the ceiling.
Install bells and horns on flush-mounted back boxes with the device-operating
mechanism concealed behind a grille.
I. Visible Alarm-Indicating Devices: Install adjacent to each alarm bell or alarm horn
and at least 150 mm below the ceiling.
J. Device Location-Indicating Lights: Locate in public space near the device they moni-
tor.
K. Fire-Alarm Control Unit: Surface mounted, with tops of cabinets not more than
1830 mm above the finished floor.
L. Annunciator: Install with top of panel not more than 1830 mm above the finished
floor.
3.2 CONNECTIONS
A. For fire-protection systems related to doors in fire-rated walls and partitions and to
doors in smoke partitions, comply with requirements in Division 08 Section "Door
Hardware." Connect hardware and devices to fire-alarm system.
3.3 IDENTIFICATION
A. Identify system components, wiring, cabling, and terminals. Comply with require-
ments for identification specified in Division 26 Section "Identification for Electrical
Systems."
3.4 GROUNDING
A. Ground fire-alarm control unit and associated circuits; comply with IEEE 1100. In-
stall a ground wire from main service ground to fire-alarm control unit.
2. System Testing: Comply with "Test Methods" Table in the "Testing" Section of
the "Inspection, Testing and Maintenance" Chapter in NFPA 72.
3. Test audible appliances for the public operating mode according to manufac-
turer's written instructions. Perform the test using a portable sound-level
meter complying with Type 2 requirements in ANSI S1.4.
4. Test audible appliances for the private operating mode according to manufac-
turer's written instructions.
5. Test visible appliances for the public operating mode according to manufac-
turer's written instructions.
6. Factory-authorized service representative shall prepare the "Fire Alarm Sys-
tem Record of Completion" in the "Documentation" Section of the "Funda-
mentals of Fire Alarm Systems" Chapter in NFPA 72 and the "Inspection and
Testing Form" in the "Records" Section of the "Inspection, Testing and
Maintenance" Chapter in NFPA 72.
F. Fire-alarm system will be considered defective if it does not pass tests and inspec-
tions.
H. Maintenance Test and Inspection: Perform tests and inspections listed for weekly,
monthly, quarterly, and semiannual periods. Use forms developed for initial tests
and inspections.
I. Annual Test and Inspection: One year after date of Substantial Completion, test fire-
alarm system complying with visual and testing inspection requirements in NFPA 72.
Use forms developed for initial tests and inspections.
SPECIFICATION REV.
ECG ENGINEERING CONSULTANTS GROUP
EARTHWORK
KSA 312000 - 2970 1
SECTION 312000
EARTHWORK
Page
PART 1 GENERAL 2
1.1 Related Documents 2
1.2 Summary 2
1.3 Reference Standards 2
1.4 Related Sections 3
1.5 Submittals 3
1.6 Definitions 4
1.7 Project Conditions 5
1.8 Use Of Explosives 6
1.9 Contractor's Responsibility 6
PART 2 PRODUCTS 7
2.1 Soil Materials 7
2.2 Warning Tape 9
2.3 Water 10
2.4 Equipment 10
PART 3 EXECUTION 10
3.1 Open-Cut Excavation, General 10
3.2 Excavation For Structures 12
3.3 Approval Of Subgrade Bottom 13
3.4 Footing Subgrade 14
3.5 Backfilling Around Foundations 14
3.6 Soil Replacement Under Foundations And Above Water Level 15
3.7 Field Quality Control 15
3.8 Auxiliary Works 16
3.9 Tolerance Limits 16
3.10 Surface Finish 16
3.11 Disposal 17
PART 1 GENERAL
A. Drawings and general provisions of the Contract, including Contract Conditions and
Division 1 Specification Sections, apply to work of this section.
1.2 SUMMARY
A. Earth works including cut, fill and backfilling and grading works shall be performed in
compliance with Drawings, tests and the requirements of the project, and the
specifications of the American Society of Testing and Materials (ASTM) as noted
below:
ASTM No.
ASTM C131 Standard Test Method for Resistance to Degradation of Small Size
Coarse Aggregate by Abrasion and impact in the Los Angeles
Machine.
ASTM C136 Sieve Analysis of Fine and Coarse Aggregates
ASTM C142 Clay Lumps and Friable Particles in Aggregates
ASTM D421 Practice for Dry Preparation of Soil Samples for Particle Size Analysis
and Determination of Soil Constants
ASTM D422 Particle Size Analysis of Soils
ASTM D427 Shrinkage Factors of Soils
ASTM D512 Chloride Ion in Water
ASTM D516 Sulfate Ion in Water
ASTM D638 Tensile Properties of Plastics
ASTM D698 Moisture Density Relation of Soils and Soil Aggregate Mixtures
ASTM D854 Specific Gravity of Soils
ASTM D1293 pH of Water
ASTM D1556 Density of Soil in Place by the Sand-Cone Method
1.5 SUBMITTALS
A. Submit the following in accordance with Conditions of the Contract and Division-1
Specification Sections:
1. 2 kg samples sealed in airtight containers, of each proposed fill and backfill soil
material from on-site or borrow sources
2. 300 mm long of each type of plastic warning tape
3. 300 x 300 mm samples of drainage fabric
G. Detailed design of temporary side slopes and side support system (if any) for
approval.
1.6 DEFINITIONS
A. Borrow soil: Satisfactory soil imported from off-site for use as fill or backfill.
D. Rock Fill: Material composed of hard, sound, durable rock with only a small amount
of fine particles used for filling or back filling
E. Sub-base Course: Course placed between the subgrade and base course for hot-mix
asphalt pavement, or course placed between the subgrade and a cement concrete
pavement or a cement concrete or hot-mix asphalt walk.
F. Retain definitions that remain after this Section has been edited. Revise to suit office
or local earthwork practices.
G. Base Course: Course placed between the sub-base course and hot-mix asphalt
paving.
H. Bedding Course: Course placed over the excavated subgrade in a trench before
laying pipe.
I. Revise heading in first paragraph below to read "Capillary Water Barrier" or a similar
title if required.
J. Drainage Course: Course supporting the slab-on-grade that also minimizes upward
capillary flow of pore water.
B. A geotechnical report has been prepared for this project and is available. The
opinions expressed in this report, the design and drawings are those of the
geotechnical engineer and represent interpretations of the subsoil conditions, tests,
and results of analyses conducted by the geotechnical engineer.
C. The Contractor shall carry out his own site investigations and shall inform and satisfy
himself as to the character, quality and distribution of all material to be excavated,
filled, spoiled and borrowed. The Contractor shall be fully responsible for asserting
necessary information concerning permanent water-table, period of rainfall and all
matters affecting the excavation and foundation work.
D. The contractor is responsible to verify the required different levels before starting
construction works.
E. Before starting any construction works compacting the top surface is required to
assure the quality of compaction.
F. Topographic Survey: Do not assume accuracy of the existing benchmark, and run a
closing survey of the existing project area and take cross-sectional elevations and
levels of the works on the Site and submit the result to the Engineer for approval, as
quantities of excavation, earthwork etc., shall be measured from these levels as
agreed and signed by the Engineer.
A. Blasting and use of explosives is prohibited. Do not bring explosives onto Site or use
in work.
A. The methods of excavation which the Contractor desires to use shall be at the sole
discretion of the Contractor.
B. The Contractor shall perform all excavation and backfilling as required for all works
under this Contract. Excavations shall be carried out in all materials, by whatever
means necessary and shall be performed accurately to the lines, levels and grades
shown on Drawings.
C. Except where indicated on the Drawings to remain undisturbed, the Contractor shall
remove all unaccepted topsoil, plants, roots, vegetation, rubbish, rock, etc., from
areas lying within limits of structures and from area to receive fill, embankment,
surfacing, road construction, concrete or other constructions.
E. In the event of a fall occurring in any excavation the Contractor shall carry out at his
own expense and to the satisfaction of the Engineer any re-excavation reinstatement
or repairs which may become necessary as the result of such fall. Any voids caused
by a fall shall be filled and consolidated as directed by the Engineer.
F. Protection of Persons and Properties: The Contractor shall erect temporary fencing
or barricade open excavations occurring as part of this work and post with warning
lamps and take all necessary steps to prevent any entry of public to the vicinity of
open excavation. He shall protect structures and utilities from damage caused by
settlement, lateral movement, undermining, washout and other hazards created by
earthwork operations.
G. The Contractor shall restore and repair any damage or defects caused to adjacent
structures, utilities or properties without responsibilities or extra charge to the
Employer.
PART 2 PRODUCTS
A. General: Provide borrow soil materials when sufficient satisfactory soil materials are
not available from excavations.
B. Topsoil: Natural and cultivated surface-soil layer containing organic matter and sand,
silt and clay particles, friable, pervious, and black or darker shade of brown, gray or
red than underlying subsoil, reasonably free of subsoil, clay lumps, gravel, and other
objects more than (50mm) in diameter, and free of subsoil and weeds, roots, toxic
materials, or other non-soil materials.
D. Structural fill shall be used underneath the structures and under slab on grade.
E. The source of the Engineering fill shall be provided by the Contractor and approved
by the Engineer. The Contractor shall provide samples at specified intervals to
monitor the material, and to the Engineer satisfaction.
F. Engineering fill shall be used underneath the structures, roads, shoulders and paved
areas and under slab on grade as specified in the geotechnical report. the below
table could be followed for soil structural fill gradation:
Table 1
Table 2
Selected Fill
1. For depth from 3.0 m to 10.0 m (under buildings area) with max. Fines
percentage 20% and min. compaction percentage 85% (as stated in table 3).
2. For depth from 2.0 m to 10.0 m (under roads and parking area) with max. Fines
percentage 25% and min. compaction percentage 85%.
3. Landscape area and non-loaded area (non-structural fill) with max. Fines
percentage 25%, min. compaction percentage 85% and the maximum
thickness for each layer is 700 mm.
I. Maximum dry density and optimum moisture content shall be determined based on
Modified Proctor Test according to ASTM D 1557.
J. Backfilling material uses under buildings specifications and criteria are stated in the
following table:
Table 3
Table 4
L. Backfilling material uses under roads and parking areas specifications and criteria are
stated in the following table:
M. Bedding for Underground Utility Installation: Bedding shall be granular, well graded,
with all material passing 12.5 mm (1/2 inch) mesh screen and at least 90 percent
retained on 75 µm (No. 200) sieve as determined in accordance with ASTM D 422.
N. Trench Backfill (Within the Pipe Zone): Trench backfill shall contain no rocks or
stones larger than 25 mm in the greatest dimension and shall be free of vegetation,
trash, chunks of highly plastic clay, or other unsatisfactory- material. Trench backfill
placed under roadways or structures shall meet the requirements of engineering fill.
A. Acid- and alkali-resistant polyethylene film warning tape for marking and identifying
underground utilities 150 mm wide and 4 mils thick, continuously inscribed with a
description of the utility; colored as follows:
1. Red: Electric
2.3 WATER
A. Water used for soil compaction shall be clean and free from unusual proportions of
dissolved salt, organic matters and industrial contamination oils, acids or other
deleterious matter.
B. Water shall not contain chemical salts including sulfates (SO3) and chlorides (Cl) in a
percentage that shall increase the overall salts percentage for filling materials more
than 0.35%.
C. For the water used in compaction process, water sample from wells and/or any
source shall be tested to satisfy the previous limits.
2.4 EQUIPMENT
A. Use types of equipment that are most suitable for the work and of numbers, sizes
and capacities that can perform earthwork as specified within the time schedule.
Equipment for earthwork shall be operated in strict accordance to manufacturer's
instructions and recommendations and shall be always maintained by the Contractor
in such condition that they shall deliver manufacturer's rated capacities.
PART 3 EXECUTION
A. Should the Contractor through negligence or other fault excavate or fill beyond the
designated lines, he shall replace/remove such excavation/fill in an approved manner
and condition at his own expense with satisfactory soil materials and thoroughly
compact to a density equal to adjacent original ground.
B. Do not neglect to check for underground services, which may not initially appear to
be of interest. Protect utilities, structures, improvements, pavement from damage
caused by settlement due to lateral movement created by earthwork operations.
B. Survey points, benchmarks, boundary stones and the like shall be removed only with
the engineer’s written consent.
C. Removed boundary stones and marking shall be stored according to the engineer
instructions.
E. For all fill and cut over 1 m in height, sturdy stakes shall be placed at any changes of
direction of the ground but in all cases at intervals not greater than 30 m as directed
by the engineer.
F. Permanent slope (if any) to be kept in the sand it shall be stabilized by one of the
following means:
G. The quantity, type and capacity of the equipment provided, the work method
envisaged transportation and distribution of the excavated materials, location of
stock-piles, main storage areas as well as the approximate number of laborers, etc.
and the working schedule and any amendment to it during the construction period
shall require the engineer’s period approved.
L. The Contractor shall make his own estimate of the kind and extent of the various
materials and presence or absence of water which shall be encountered in the
excavation.
M. The final 150 mm depth of all excavations shall be taken out manually or otherwise if
accepted by the Engineer and the bottom levelled and rammed immediately prior to
placing structures.
O. Stockpile soil materials suitable for backfill at sufficient distance away from edge of
excavation and neatly pile in stock piles in a manner that shall not overload or cause
collapse of excavation sides. All unsuitable and surplus excavated materials shall be
immediately removed from site, loaded and transported to dumps approved by local
authorities.
P. Extend excavations a sufficient distance from structures for placing and removing
concrete formwork, for installing services and other construction, for inspection.
R. No back-throwing whatever shall be allowed and all materials shall be brought to the
surface and formed in heaps clear of excavation.
T. Over Excavation: If somewhere and for any reason excavations are executed beyond
the established lines and without the engineer’s previous approval, the Contractor
shall backfill with lean concrete or other approved materials, the volume
corresponding to the over excavation.
W. The excavation shall at all times be well drained, kept free from storm water,
percolating water or subsoil water.
X. The Contractor shall make good at his own expense any damage that may result from
his failure to keep the excavation free from water.
A. Excavation Limits for Structures: Banks shall be either shored or sloped at a safe
angle according to conditions and to the approval of the Engineer. If necessary
extend a reasonable sufficient distance from footing and foundations to permit
placing and removal of concrete form work, shoring, installation of services and other
constructions, for performing all works in the excavation and for inspection. No
compensation shall be paid to the Contractor in respect to excavation or backfilling of
extended distances.
B. If any part of an excavated area is in error or excavated wider than required, the
excess excavated distance shall be backfilled as directed by the Engineer and
compacted at the Contractor's charge.
A. When excavation has reached required subgrade elevations, the Engineer shall
inspect soil materials at these elevations for suitability as a foundation level for the
related construction, and he may instruct the Contractor to test the bearing capacity
of the soil at this level. Should the bottoms of excavation be found to be unsuitable
as bearing surfaces as a result of such tests, the Engineer may decide to continue
excavation until suitable bearing materials are encountered and replace with
compacted backfill. Additional excavation and replacement material shall be paid for,
according to Contract.
B. Excavated materials shall not be piled up along sides of excavations in a manner that
will overload or cause collapse of excavation sides.
C. Sub-soil from the excavation shall be selected for suitability for backfilling and
compaction, shall be free from any organic materials and shall not have big lumps. It
shall be placed directly in its final position or stacked on site as directed by the
Engineer in the vicinity of the work and those unsuitable for fill shall be removed
from site to a tip provided by the Contractor. All other filling materials shall be
imported.
D. Cleaning, grubling and removal of trash and debris from excavation shall be done
before backfilling works.
F. Compaction areas shall be kept separate and no layer shall be covered by another
until the proper density is obtained.
I. The soil used in backfilling shall be mixed with sufficient water to provide a moisture
content within a range of 2% from the optimum value. The mixing process shall be
completed out of backfill area then soil shall be spread in loose lifts and compacted
at designated locations. The moisture content shall be uniform throughout the
compacted layer. If the field quality testing as specified in Clause 3.9 revealed
moisture content out of the previously specified range, the soil shall be removed,
remixed and compacted again.
J. The Engineer, at his own discretion, may allow greater lift thickness not exceeding
350 mm thick if proper density and uniformity is obtained. Effective spreading
equipment shall be used on each lift to obtain uniform thickness prior to compacting.
As the compaction of each layer progresses, continuous levelling and manipulating
shall be required to assure uniform density. Water shall be added in order to obtain
the correct water content and the required density on stocked soil outside the
excavation. Construction equipment shall be routed uniformly over the entire
surface both in width and longitudinal extent of each layer before the next lift is
started. At the start of the work a field test shall be performed in the Site over an
adequate area not less than 100 m2 to determine the allowable thickness of layers
K. Pipes and reinforced concrete foundation members such as tie-beams laid on natural
ground shall be protected with a minimum of 1000 mm of tamped fill over the top
surface or according to Drawings before heavy equipment is allowed to pass over.
L. Backfill excavations shall start as promptly as work permits, but not until completion
of the following:
M. Pipes and reinforced concrete foundation members such as tie beams laid on natural
ground shall be protected with a minimum of 1000 mm of tamped fill over the top
surface or according to Drawings before heavy equipment are allowed to pass over.
R. After installation of pipes and cables according to specifications and all related tests
are performed and approved by Engineer.
A. Unless otherwise indicated on Drawings, the subgrade under footings and tie-beams
shall be prepared in the following sequence:
1. Excavate under footing and tie-beams down to the required depth from
existing ground surface.
2. Clean bottom of excavation from the loose surface soil skin and compact the
soil using suitable compaction equipment.
A. Use selected fill materials as specified in Clause 2.1 and compact mechanically or by
manual tamping to 90% of maximum dry density according to ASTM D 1556 at
optimum moisture content during excavation.
A. Allow testing agency to inspect and test each subgrade and each fill layer.
B. Compaction and field density tests of in-place soil or the fill shall be made at each
location directed by the Engineer at the rate of one (1) test every 250 m2 for each
compacted layer according to ASTM D1556.
C. One plate loading test/1000 m2, with minimum of two tests for each plot, shall be
carried out at foundation level of natural granular soil or the top of the replacement
layer (if existing), or as directed by the Engineer.
In case of the existence of replacement soil with thickness equal to or bigger than
1.50 m, then the same number of tests shall be carried out at the middle of the layer
The test shall be carried out dry and soaked to check the soil collapsibility as per the
ASTM and shall satisfy the following:
1. The steel plate diameter at least 450 mm.
2. The stress of the test should be not less than three times the net allowable
bearing capacity at the foundation level.
3. The submergence is to occur at stress equals the net allowable bearing
capacity at the foundation level.
4. The value of deformation modulus, Es should be not less than 500 Kg/cm2
D. Field density tests shall be performed in accordance with AASHTO T-191 (sand cone
method). The Contractor shall perform the following tests at locations as directed by
the Engineer:
1. Laboratory test for Maximum Dry Density (MDD), Optimum moisture content,
for each layer.
2. Field density and California Bearing Ratio (CBR), for each layer as required by
the Engineer.
3. The areas shall be rejected if the resulting test results do not satisfy specified
requirements.
4. The Contractor shall be responsible for making good all settlement of filling
that may occur at/to the end of the Defect Liability Period.
A. Unless otherwise specified, all and any kind of works, materials, services, safety
measures, etc. as well as, and if so requested by the Engineer, all tests and samples
required for the completion of the work shall be for the responsibility of the
Contractor. The auxiliary works comprises, but not limited to the following:
A. The tolerance limits for the permanent finished earthworks will be as follows:
A. The top surface area shall be of dense and level without any protruding rock
fragments in excess of 50 mm, recesses of soft spots to the satisfaction of the
engineer.
A. Remove, only by night, surplus satisfactory soil and waste material including
unsatisfactory soil, trash, debris, and legally dispose of it off to the public disposal
areas.
THIS PAGE IS A RECORD OF ALL SPECIFICATION REVISIONS. NORMALLY, REVISED SHEETS ONLY ATTACHED
EACH TIME THE SPECIFICATION IS CHANGED ONLY THE NEW OR ENTIRE SPECIFICATION RE-ISSUED
REVISED PAGES ARE ISSUED. ENTIRE SPECIFICATION REVISED
SPECIFICATION REV.
ECG ENGINEERING CONSULTANTS GROUP WATER UTILITIES
KSA 331000 - 2970 1
SECTION 331000
WATER UTILITIES
PAGE
PART 1 GENERAL 2
1.1 Related Documents 2
1.2 Description Of Work 2
1.3 Reference Standards 2
1.4 Submittals 3
1.5 Quality Control 4
1.6 Quality Assurance 5
1.7 Delivery, Storage, And Handling 6
PART 2 PRODUCTS 9
2.1 Warning Tapes 9
2.2 Geo-Textile 10
2.3 Pipes, Fittings And Accessories 10
2.4 Valves 25
2.5 Floating Valve (For Water Tank) 33
2.6 Float Control Modulated Valve (For Water Tanks) 33
2.7 Globe Valves 35
2.8 Ball Valves 35
2.9 Stop Valves (For Water Tanks) 35
2.10 Drain Cocks (For Water Tanks) 35
2.11 Nuts And Bolts With Washers 35
2.12 Flexible - Coupling And Flange Adaptors 35
2.13 Dismantling Joints 36
2.14 Water Meter For House Connections 37
2.15 Valve Chambers 41
2.16 Fire Hydrant 44
PART 3 EXECUTION 45
3.1 General 45
3.2 Pipes, Fittings And Accessories 45
3.3 Valves Installation 53
3.2 Valve Chamber 57
3.3 Valve Chamber Step Irons & Ladders 60
3.4 Valve Chamber Frames And Covers 61
3.5 Tests 61
3.6 Fire Hydrants 61
3.7 Cleaning And Disinfection 62
PART 1 GENERAL
A. Drawings and general provisions of the Contract, including General and Supplementary
Conditions and Division 01 Specification Sections, apply to this Section.
B. RELATED Sections
A. This section covers water pressure pipes, valves as indicated on the drawings and spec-
ified here in addition to all types of potable water structure such as valve chambers as
required by the Contract. Extent of these structures is indicated on Drawings.
B. The Contractor shall provide equipment, materials, transportation, storing, safety tools
and labor required for proper construction of the water networks.
A. Pipes, fittings and accessories shall be performed in strict accordance with the stipula-
tions of the National Water Company (NWC) Latest Edition, the British Standard Speci-
fications (BS) or the American Standards (ASTM) as noted herein below or other equiv-
alent approved Standards and Sound Practice.
A. GENERAL:
BS No.
1. BS 6437 Polyethylene pipes (type 50) in metric diameters for general purpose
Water Supply Networks Section 331000
Riyadh Sedra 2 (Prj. 2970) Page 2 of 66
American Society for Testing and Materials
3. ASTM F894 Specification for Polyethylene (PE) Large Diameter Profile Wall
Sewer and Drain Pipe.
4. ASTM D3035 Standard Spec for PE Pipe (DR-PR) Based on Controlled Out-
side Diameter
5. ASTM D3261 Butt Heat Fusion PE Fittings for PE Pipe & Tubing
In the event of conflict between various codes and standards the most stringent condi-
tions shall apply.
1.4 SUBMITTALS
A. Submit the following in accordance with Conditions of the Contract and Division-1
Specification Sections:
1. Pipes
2. Valve
A. Testing
a. Unless otherwise specified, the Contractor shall be responsible for all test-
ing laboratory services in connection with concrete materials and mix de-
signs, the design of asphalt mixtures, gradation tests for embedment, fill,
backfill materials, and all other tests and engineering data required for the
Engineer's review of materials and equipment proposed to be used in the
Work. The Contractor shall obtain the Engineer's acceptance of the test-
ing laboratory before having services performed, and shall pay all costs for
services.
A. Codes and Standards: Reference to the standards of any technical society, organiza-
tion, or association, or to codes of local authorities, shall mean the latest standard,
code, specification, or tentative standard adopted and published at the date of taking
tender, unless specifically stated otherwise.
B. In the absence of a specified referenced code or standard, the Contractor may propose
other recognized international codes and standards, and in such a case the Contractor
shall demonstrate to the satisfaction of the Engineer, suitability and equivalence of the
substitute codes and standards as well as provide proof of previous successful use.
D. Where the specific date or issue of the standard is not included with the reference to
the standard, the latest edition, including all amendments published and available on
the first published date of the Invitation to Tender, shall apply.
E. Where two or more standards are specified to establish quality, the product and
workmanship shall conform to or surpass the requirements of both. In case of conflict
between referenced standards, the more stringent shall apply.
F. Where both a standard and a brand name are specified for a product in the Contract
Documents, the proprietary product named shall conform to or surpass the require-
ments of the specified reference standard.
G. The listing of a trade name in the Contract Documents shall not be construed as war-
ranting that such product conforms to the respective reference standard.
H. Copies of applicable referenced standards have not been bound in this Contract Docu-
ment. Where copies of standards are needed by the Contractor for superintendence
and quality control of the work, Contractor shall obtain a copy or copies directly from
the publication source and maintain in an orderly manner at the jobsite, available to
the Contractor's personnel, subcontractors, Employer, and Engineer.
I. Contractors shall clearly identify and submit for approval any requests to use products
1. Quality of Materials.
2. Offsite Inspection
1. The marking information and sequence shall comply with ISO 4427 (clause 8
marking). All pipes and fittings, including test samples shall be clearly and per-
manently marked using indent printing in a color that contrasts with the pipe.
2. All pipes shall be indelibly marked at maximum intervals of 1m The marking shall
indicate at least the following information:
3. The word "water" shall also be included if the pipe is intended for potable water.
Water Supply Networks Section 331000
Riyadh Sedra 2 (Prj. 2970) Page 6 of 66
4. The maximum quantity of pipe to have the same coil/length number is one silo
(coiled pipe) or one bundle (straight lengths). The maximum combined length of
pipe in the silo or bundle with the same coil/length number shall not exceed the
maximum allowable coil length.
5. When pipe material is boxed, the coil number shall be clearly marked on the out-
side edge of the box or silo. Invoices and packing lists shall include the date of
manufacture and coil/length numbers for all material in the shipment
6. The fittings shall be packaged in bulk or individually protected were necessary in
order to prevent deterioration and contamination. The package shall have at
least one label with manufacturer name, type and dimension of the fittings and
number of units.
7. All compression fittings packed individually by transparent protective bags indi-
cating its type and size.
8. All compression fittings packed in cartoon boxes.
9. If only one type of product packed, all cartoon boxes shall have a label showing
the manufacturer identification, the description of the product, the drawing of
the product, the relevant size and the quantity.
B. Shipping
a. Delivery
Delivery of the plastic pipes and fittings to site shall be no later than six
months after the stamped manufacture date.
b. Weathering
c. Tie-Downs
Tie-downs shall be at least 100 mm wide and be clean and free from sand,
gravel and other such materials. For straight length pipe (up to 12 m), a
minimum of 6 tie-downs are required.
d. Pallets
The pallets shall be suitable for transporting the material from the place of
manufacture to the designated receiving location without causing any
damage to the pipe. The pallets shall not contain any broken planks or ex-
tremities that may damage the coiled pipe or straight lengths. They shall
be durable enough to prevent loose pallet nails from gouging the bottom
coil/straight length.
e. Overhang
The pipes shall be loaded so as not to overhang the vehicle by more than
Water Supply Networks Section 331000
Riyadh Sedra 2 (Prj. 2970) Page 7 of 66
one meter. The vehicle shall have side supports at centers of no more than
2m and the inner upright surface shall be flat with no sharp edges.
f. Stacking
Different sizes are best stacked separately. If this is not practical, then
stack with the largest pipes at the base. Pipes shall not be nested for long
periods and stacks shall not exceed seven layers or 2m in height.
When socketed pipes are stacked, the bottom layer of sockets shall be
prevented from being in direct contact with the ground, either by excavat-
ing under the socket, or by use of transverse supports.
Alternate layers shall have the sockets protruding from, and opposite to,
the previous layer. In warm climates, stacks shall be limited to 1m in
height and be shaded from direct sunlight.
C. Trucking
1. Loose pipes are hand-loaded and care shall be taken before loading to check the
vehicle's load carrying area for nails and other projections. The pipes must be
evenly supported throughout their length, but where this is not possible, timber
supports of at least 75 mm bearing width shall be placed no more than 2 m
apart. When loading socket and spigot pipes, place the sockets at alternate ends
of each layer, and allow the sockets to protrude so that the pipes are evenly
supported.
2. When a mixed load of pipes (i.e. varying diameters) is to be transported, the
larger, thicker walled and thus heavier pipes shall be placed at the bottom of the
load with the small diameters on top.
3. Fittings shall be supplied in cardboard boxes or plastic bags. The complete load
shall be correctly secured prior to commencement of the journey.
4. When loose pipes have been transported one inside the other, always remove
the inner pipe first.
5. Pipes shall not be dropped or dragged.
D. Banding
E. Vendor Documentation
1. The CONTRACTOR shall furnish following vendor data as a minimum, with the
bid:
a. Catalogues / Brochures.
b. Dimensional details of pipes and fittings.
c. Detailed material specifications.
d. Manufacturer's drawings, showing fittings dimensions.
e. Complete details of testing facilities available at manufacturer's works.
Water Supply Networks Section 331000
Riyadh Sedra 2 (Prj. 2970) Page 8 of 66
f. Local agent name and address.
PART 2 PRODUCTS
Service protection tapes shall be installed above all water pipelines and pressure
mains constructed or exposed under this contract excluding individual service connec-
tions.
Tapes shall be durable and detectable by electro-magnetic means using low output
generator equipment. They shall remain legible and color-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 com-
posite laminate consisting of: -
Chemical resistance:-
The tape shall be remaining legible and color fast in all soil conditions at PH 2.5 to
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.
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 meters.
Water Supply Networks Section 331000
Riyadh Sedra 2 (Prj. 2970) Page 9 of 66
Tapes shall be color coded as follows, with black text as indicated. The sign and
styles of the text shall be approved by the Engineer.
Water : Blue
CAUTION : Water Pressure Mains Below
Municipality logo shall be printed in black between the spaces of repeated mes-
sages.
2.2 GEO-TEXTILE
A UPVC pipes and fittings (and preferable for pipes up to 400 mm)
1. General
The material from which pipe, fitting and accessories is produced shall consist
of substantially unplasticized polyvinyl chloride. Only those additives that are
needed may be used for the manufacture of the polymer, and for its conver-
sion into sound, durable extrusions or molding of good surface finish, me-
chanical strength and opacity.
UPVC pipes shall not be deteriorated or broken down under the effect of bac-
teria or other micro-organisms.
2. Classification of Pipes:
Pipes shall be manufactured in accordance with Table (1) of ES No. 484, Class (5) capa-
ble to withstand a working pressure of 16 kg/cm2.
3. Dimensions:
Pipe shall conform to the outside diameters, inside diameter and wall thick-
ness specified by the above mentioned standard. Pipes shall be accepted
within the following limits:
Thickness ± 30 %
Diameter ± 2.5%
Length ± 1%
Weight ± 5%
4. Lengths:
Pipes shall be of such kind that can be cut to length using fine tooth wood
saw or hacksaw and of an end which can be chamfered with one of the spe-
cial hard tools developed for shaping plastics.
a. General Properties:
Water Supply Networks Section 331000
Riyadh Sedra 2 (Prj. 2970) Page 11 of 66
UPVC pipes shall be manufactured by extrusion and shall have low specific gravity.
b. Appearance:
c. Specific Gravity:
- Specific gravity of pipes shall not be less than 1380 kg/m3 and not more
than 1425 kg/m3.
d. Heat Reversion:
e. Opacity:
- The pipe shall be full opacity and when tested the wall of the pipe shall not
transmit more than 0.2% of the visible light falling on to it.
- Expansion shall be 1 mm change in length at 22°C for each 5°C rise or fall in
temperature allowance for every 1 meter length of pipe when operating at
temperature above ambient.
7. Chemical Characteristics:
a. Water Absorption:
- Pipes shall be tested for water absorption, a sample shall be completely im-
mersed in water for 24 hours at 100° C, this test shall meet the requirements
of the Standard Specifications of the country of origin.
b. Resistance to Acetone:
- Pipes shall conform with the requirements to toxic substances which shall
ensure that the recommendations of the World Health Organization 1963
concerning toxic contaminants of drinking water are not exceeded.
8. Mechanical Characteristics:
a. Extruded pipes shall have high mechanical characteristics and shall fulfill the fol-
lowing requirements:
b. Tensile strength : 3.5 kgf/mm2, minimum
c. Modulus of elasticity : 197 kgf/mm2, minimum
d. Impact strength : 3.55 kgf/cm at notch, minimum
e. Deflection temperature under load: minimum: 0.1856 kgf/mm2: 55° C mini-
mum.
9. Marking:
a. All pipes shall be indelibly marked at interval of not greater than 3m or as speci-
fied in the origin Standards.
a. Manufacturer’s Name
b. Nominal Size
c. Class Pressure Rating
d. Identification Code
10. Jointing
a. Solvent Cement:
- Solvent cement joints are acceptable only up to size DN 50mm as per the
applicable code of practice for the fittings. The solvent cement shall be of
non-toxic quality suitable for drinking water service. Fittings shall conform to
BS 4346 Part 1/BS EN 1452.
b. Push-on Joints:
- Pipes shall be laid with a gap between the end of the spigot and the base of
the socket. This gap shall not be less than 10 mm or greater than (1/3) one
third of the straight draw of the pipe joint.
c. Rubber Rings:
11. Lubricant
- Shall be the type recommended by manufacture for use with the employed
pipes and no substitute is allowed.
12. Certification
1. General:
a. Ductile iron pipe and fittings shall be installed with push-on joints (socket and
spigot) for the buried portion of pipes, and flanged joints inside reinforced con-
crete pipe (sleeve) under the taxiway. Pipes and fittings shall have inside ce-
ment mortar lining and seal coat suitable for installation and service in water
(according to type of service) and a bituminous varnish outside coating. Pipe
shall be centrifugally cast (spun) in metal moulds, fabricated of heavy grade
best quality machine able ductile iron. Castings shall be produced under ade-
quate quality control and shall be sound, true to pattern and showing no im-
perfection, which may affect their use. Fittings and accessories shall be cast in
metal moulds.
b. Each length of pipe and each fitting shall be plainly marked with the manufac-
turer's trade name or initials or registered trademark by which he can readily
be identified and with letters to indicate the classification of pipe. The marking
shall also indicate the nominal diameter of pipe in millimeters. The marking
may be cast, stenciled or otherwise applied on the pipe so as to be clear and
legible at the time of installation. The marking shall be cast on fittings and shall
be located away from spigot and so as not to interfere with proper joining up-
on installation.
c. Where flanged-pipes are used, flanges shall be machined on the back to pro-
vide a flat surface for bolt heads and nuts. After machining, flanges shall be
flat and normal to the bore for the pipe to within 0.125 mm over the flange di-
Water Supply Networks Section 331000
Riyadh Sedra 2 (Prj. 2970) Page 14 of 66
ameter.
2. Heat treatment:
a. After casting, ductile iron pipe and fittings shall be subject to a suitable heat
treatment to give them the required mechanical characteristics.
3. Wall thickness:
a. Pipes and fittings shall be of wall thickness as specified in ISO 2531, accord-
ing to the following classes:
Type Class
1) Pipes K9
2) All Fittings except Tees K12
3) Tees K14
4. Internal coating:
a. Clean Water
1) All pipes and fittings shall be internally lined with Cement mortar
according to ISO 4179 and BS EN 545. Cement shall be sulphate re-
sistant conforming to ES No. 583 and sand shall be inert, hard,
strong and stable fine aggregate free from opaline, felspar, mica,
fool’s gold, siliceous magnesium, limestone or other deleterious
matters and conforming to ES NO. 1108. Sand shall also be free
from organic impurities and clay-bearing substances. Drinking wa-
ter or water whose composition is acceptable for drinking except for
bacteriological requirements shall be used for mixing.
2) The mortar shall be thoroughly mixed to a consistency, which pro-
duces a dense and homogeneous lining. Prior to applying mortar,
the inner surface shall be checked for the presence of any foreign
bodies, loose scale, or any other material which may be detrimental
to the adherence of lining to the metal. Any metal protrusions shall
be removed. Lining mortar shall be centrifugally cast inside the pipe
so that the inner surface of pipe and fittings, except for joint, shall
be entirely covered with mortar free from visible air bubbles or any
cavities and shall be of uniform maximum density at all points. Cast
lining shall be properly cured. Thickness of lining shall be as de-
fined in Decree 149, 1994, or 6 mm minimum. Hardened lining shall
be of uniformly smooth surface, of no flaky areas, crumbles, waves
or grooves. Single superficial cracks resulting from manufacture of
width up to 0.8 mm shall be acceptable.
3) Thickness of lining shall be tested as per DIN 1164. Each pipe shall
be inspected for the appearance of the surface conditions and fin-
ishing of ends.
b. Dirty water
1) All pipes and fittings shall be internally High alumina cement lined
5. Outside protection:
6. Allowable tolerances:
a. Straightness: Deviation shall not exceed 1.25 mm per each meter length of
pipe measured from pipe axis.
b. Masses: Tolerance shall not exceed + 5%. Pipe of weights exceeding max-
imum limits mentioned before can be accepted provided conformance
with specifications in all other requirements.
c. Lengths: Tolerance shall not exceed - 50 mm for pipe.
d. Thickness: Tolerance shall not exceed minus 1.3 mm plus 0.001 nominal
diameter of pipe. No limit for plus tolerance.
7. Gaskets:
8. Joints:
a. Flexible joints:
3) Rubber ring joints shall be of a type that will not deteriorate under
local conditions either during storage or during operation. The rub-
ber gasket shall be of EPDM elastomer or equivalent in accordance
with ISO 4633 suitable for drinking water supply and waste water.
4) 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 nec-
essary accessories. Where retainer glands are specified they shall be
supplied with bolts and/or other necessary accessories.
b. Flanged joints:
1) Flange ended pipes and fittings shall only be used when connecting
to valves or other special fittings as approved by ENGINEER.
2) The flanges shall be raised faced and integrally cast or welded on.
Screwed on flanges or glued on flanges are not acceptable. Rotata-
ble flanges may be used for pipes and fittings up to DN 600.
3) The dimensions and drilling of the flanges shall be to ISO 7005-2 or
EN 1092-2. However in case connections have to be made to other
systems based on other standards contractor is responsible to veri-
fy. 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.
4) 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 as per pipe system
requirement. The dimensions of the flange gaskets shall be to ISO
7483.
5) The nuts, bolts, washers shall be of steel having minimum tensile
strength of 400 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.
c. Restrained Joints
9. Polyethylene Sleeves
a. Protective polyethylene sleeves shall be used with all D.I. pipes and fittings
to be installed in buried condition and shall be in accordance with ISO
8180. The polyethylene sleeve manufacturer shall be ISO 9001: 2000 Qual-
ity Management System certified. The polyethylene sleeve shall be black,
resistant to the effect of ultra violet light; the minimum nominal thickness
of the sleeve shall be not less than 200µm microns with a maximum minus
tolerance of 10%. The material shall be made from a polymer with a melt
flow index as measured according to BS 2782, of 10 or less and a density in
the range of 0.910 to 0.935 g/ml. The sleeve shall be free from pinholes,
gels, undispersed raw materials and particles of foreign matter. The film
may not contain more than 5% by weight of material other than polyeth-
ylene. Polyethylene sleeving shall be stored in cool dry store away from di-
rect sunlight or excessive heat. Rolls shall be supplied individually packed
in black polyethylene sacks and clearly marked according to ISO 8150
clause.
1. General
2. Pressure Pipelines
a. Materials used for the manufacture of polyethylene pipe and fittings shall
be made from a PE 3408 high density polyethylene resin compound meet-
ing cell classification 345434C per ASTM D3350; and meeting Type lll,
Class C, Category 5, Grade P34 per ASTM D1238.
b. High Density Polyethylene (HDPE) pipe shall comply with AWWA Specifica-
tions C906.
c. If rework compounds are required, only those generated in the Manufac-
3. Fittings
a. General:
c. Fabricated Fittings
d. Thermoformed Fittings
4. Jointing
a. General
1. PE pipe or fittings are joined to each other by heat fusion or with mechan-
ical fittings. PE pipe may be joined to other pipe materials by means of
compression fittings, flanges, or other qualified types of manufactured
transition fittings. There are many types and styles of fittings available
from which the user may choose. Each offers its particular advantages and
limitations for each joining situation the user may encounter. Contact with
the various manufacturers is advisable for guidance in proper applications
and styles available for joining as described herein below:-
b. Thermal Heat Fusion Methods
c. Butt Fusion
d. Saddle/Conventional Fusion
e. Socket Fusion
1. There are many styles and varieties of “Bolt Type” couplings available to
join PE to PE or other types of pipe such as PVC, steel and cast iron in
sizes from 1¼” IPS and larger. As with the mechanical compression fit-
tings, these couplings work on the general principle of compressing an
elastomeric gasket around each pipe end to be joined, to form a seal.
2. The gasket, when compressed against the outside of the pipe by tighten-
ing the bolts, produces a pressure seal. These couplings may or may not
incorporate a grip ring, as illustrated, that provides pullout resistance
sufficient to exceed the yield strength of the PE pipe. When PE pipe is
pressurized, it expands a little and shortens slightly due to Poisson’s ef-
fect. In a run of PE pipe, the cumulative shortening may be enough to
cause separation of unrestrained mechanical joints that are in-line with
the PE pipe. This can be a particular concern where transitioning from PE
pipe to Ductile Iron pipe. Joint separation can be prevented by installing
external joint restraints (gripping devices or flex restraints; Additional
restraint mechanisms are available to supplement the pull resistance of
these types of fittings if needed.
g. Flanged Connections
2.4 VALVES
1. GATE VALVES
- All valves employed shall be suitable for water application and internally
epoxy coated.
- Valve Design: Non-Rising stem valves shall be used.
- Pressure and Temperature Ratings: As specified hereinafter.
- Sizes: Same size as pipe, unless otherwise indicated on Drawings.
- Class 125, cast, bronze body and union bonnet conforming to ASTM B62;
with threaded ends, "Teflon" impregnated packing and two-piece packing
gland assembly, solid wedge type gate-high tensile forged bronze spindle
engaging a gunmetal nut at the top of the gate, malleable iron spindle caps
and hand wheels.
1. Type:
- The valve shall be designed for no leakage under flow from either direction
at a differential pressure across the gate of 10.1 times the rated working
pressure. The valve shall be capable of being operated under the maximum
unbalanced pressure that may occur.
- Buried Valves shall have flanged ends, whereas valves inside different struc-
tures shall be flanged.
- When connected to Ductile Iron Pipes, Flanged and socketed ends shall con-
form to ISO 2531.
- The valve Body, Bonnet, and wedge body shall be Ductile Iron to DIN 1693
– GGG 40/50.
- The wedge shall be completely encapsulated with an EPDM rubber. The
rubber coating thickness shall be a minimum of 2 mm on the flow surfaces
and 4 mm on sealing surfaces.
- The stem (spindle) shall be Stainless steel 316 L to DIN 17400 - 1.4028. The
stem nut shall be of resistant Brass, CZ 132 to BS 2872 forged integral with
the wedge. Pins, clamps, screws and other means of attachment are not
acceptable.
- All Sealing rings of the bonnet and the stem shall be of EPDM with outside
plastic bearings.
- The Bonnet bolts shall be of Stainless steel 1.4401. Nuts, bolts, and
washers for Flanges shall be of high tensile steel, hot dipped galvanized to
BS 729.
- The valve Body and Bonnet shall be internally and externally coated with
non- toxic fusion bonded epoxy powder coat with a minimum dry film
thickness of 250 micron.
Working pressure:
3. Extension Spindle:
- The extension spindle shall be in one piece i. e. the main spindle shall be extend-
ed without connecting coupling. Alternatively, extension spindle with connecting
coupling shall be supplied.
- The height of extension spindle shall be such that spindle cap is 300mm from
surface box. The size and material of extension spindle shall be as per manufac-
turer recommendation and to ensure by manufacturer / tenderer that it can
withstand heavy torque during operation. The connecting coupling joining to
main spindle and extension spindle shall be attached by nut bolt of stainless
steel grade 316 and passing through. The spindle cap on the extension spindle
shall be as per dimension shown in BS 5163. The spindle cap shall be attached to
extension spindle by nut bolt of stainless steel grade 316 and passing through
extensional spindle and cap. Round supporting plate shall be welded to exten-
sion spindle at 100 mm below spindle cap and dia. of round supporting plate
shall be 5 mm less than internal dia. of PVC pipe. This is required to keep exten-
sion spindle in the center of PVC pipe. Extension spindle, connecting coupling
and spindle cap shall be epoxy coated in blue color. The following marking shall
be provided on top of round plate: Name Of Manufacturer, Contract No. and
Date of Manufacturing.
4. Extra Coating:
- Since valve is to be buried fully below ground, extra protection is required over
epoxy coating. Only epoxy coating is not acceptable.
- Mastic or tape filler or molding putty, if required, shall be applied by hand press-
ing to fill the angled / concave section so that exterior surface shall be smooth
and free of projection.
- Over the wrapping, self-adhesive thin plastic outer wrap shall be applied.
a. Type:
- Dual orifice vented valve, to allow automatic air venting as the network is being
filled with water, permanent degassing and rapid air ingress when network has
been emptied to avoid vacuum conditions.
- The Valve shall be equipped with isolating valve to allow maintenance of the air
valve without shutting off the main.
- Unless otherwise stated, the size of the valve shall be selected according to the
following schedule:
Pipeline Bore (mm) 200 300 350 450 600 900 1000*
Air Valve size (mm) 40 50 60 75 100 150 200
- The valve Body, Cover, float chamber, and baffle body shall be Ductile Iron to DIN
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1693 – GGG 40/50.
- Floating Balls shall be of Stainless Steel 13% chromium or light alloy coated
with EPDM.
- Spindle, Guides, Seats, bushing screws, and other internals shall be of Stain-
less Steel 316 L to DIN 17400 - 1.4401.
- Nuts, bolts, and washers for Flanges shall be of high tensile steel, hot dipped
galvanized to BS 729.
- The valve Body and cover shall be internally and externally coated with non-
toxic fusion bonded epoxy powder coat with a minimum dry film thickness of
250 micron.
A. Type:
- Valves shall be of the manually operated type, metal seated, with self-
lubricating bearing brushes.
- The body parts shall be circular and the diameter shall not be less than the
nominal pipe diameter. The valve shall be closed by clockwise movement of
the hand wheel and with direction of operation clearly casted on the hand
wheel. All valves shall be provided with extension spindles
- The valve shall have a local integral open/closed indicator to indicate the
valve position as a percentage.
- The valve body, disk, and bearing cover shall be ductile iron to din 1693 –
ggg 40/50.
- The Disk shaft shall be of Stainless steel 316 L to DIN 17400 - 1.4028.
- Nuts, bolts, and washers for Flanges shall be of high tensile steel, hot dipped
galvanized to BS 729.
- The valve Body shall be internally and externally coated with non- toxic fusion
bonded epoxy powder coat with a minimum dry film thickness of 250 micron.
Working pressure :
For transmission line 30 bars
For distribution network 16 bars
Test pressure equals 1.5 working pressure
a. General:
- Butterfly valves with motor actuators are used as a control valve at the inlet of the
water tank. The valve is connected to level control switches inside the tank to
control inlet flow.
- The motor operated butterfly valves shall consist of a butterfly valve as specified
in article 2.5 above coupled with 380/220 V, AC, 50 Hz motor actuator complete
with integral motor starter.
- The motor actuator for valves shall be of a standard, well tested and proven de-
sign 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.
- The actuators shall be suitable for use on a nominal 380V, 3 phases, or 220 V, 1
phase 50 Hz power supply and are to incorporate motor integral reversing starter,
local control facilities and terminals for remote control and indication connections.
- The actuator shall include a device to ensure that motor runs with the correct ro-
tation 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.
b. Actuator sizing:
- The actuator shall be sized to guarantee valve closure at the specified differen-
tial pressure. The safety margin of motor power available for seating and un-
seating the valve shall be sufficient to ensure torque switch trip at maximum
valve torque with the supply voltage 10 % below nominal. The operating speed
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shall be such to give valve closing and opening at approximately 10 inches per
minute.
c. Motor:
- The electric motor shall be 3 phase squirrel cage, class f insulated, with a time rat-
ing of 15 minutes at 40º C or twice the valve stroking time, whichever is longer, at
an average load of at least 3 % of maximum valve torque.
d. Gearing:
- 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.
Working pressure :
- The altitude valves shall be of the globe type and shall comply with the general
requirements of the specifications. The valve must be capable of bubble tight
sealing against 16 bar operating pressure unless mentioned otherwise. The end
flanges shall be rated and drilled in accordance with the standards indicated in
the Data Sheet.
- The altitude valves shall be of the straight through type. The operation of the
float operated pilot valve shall be through a chamber, which is separated with a
plunger from the body. The altitude valves shall be fitted with external hydraulic
relay system designed to automatically close the valve at reservoir high level and
reopen the valve at pre-set minimum level. The valve shall be suitable for drop
tight shut off by having full-face sealing.
- The relay control system shall consist of a three way float operated pilot valve,
orifice and strainer block, pilot control valves and interconnecting small bore pip-
ing. The float operated pilot valve shall be manufactured completely in 316 stain-
less steel.
- The orifice/strainer unit shall have a body and internals of stainless steel. The pi-
lot control valves and control piping shall be constructed in 316 stainless steel.
- The altitude valve shall be designed such that the hydraulic relay system can be
inspected, maintained or replaced without isolating the supply.
- The pressure setting shall be capable of being adjusted on site by turning the pi-
lot valve screw. The opening and closing speeds shall also be field adjustable by
adjusting the flow regulation screw.
- The minimum upstream pressure from the valve must exceed 0.4 bars. The dis-
tance between the main valve and the pilot valve should not exceed 50 m for
proper functioning of the valve.
- The globe valve shall be designed to provide the necessary loss of head and shall
operate smoothly without hunting.
- The valve shall be coated to a minimum dry film thickness of 300 microns (at any
point) internally with non-toxic fusion bonded epoxy coating system and exter-
nally with fusion bonded epoxy coating system. The maximum dry film thickness
shall be as per paint manufacturer recommendations.
a. Type:
- Float valves shall be of the elbow type, installed at the end of the inlet pipe, totally
closed when the float is at the end of its travel.
- The valve shall have flanged end conforming to ISO2531, and shall be able to con-
nect an extension pipe to its outlet
a. General:
b. Standard equipment:
d. Installation
- Globe valves 50 mm and smaller class 125; body and screwed bonnet of ASTM b
62 cast bronze, with threaded ends, replaceable composition disc, copper-silicon
alloy stem, bronze packing gland, "Teflon" impregnated packing and malleable
iron hand wheel.
2.8 BALL VALVES
- ball valves 25 mm and smaller: rated for 10 bars; two-piece construction; with
bronze body conforming to ASTM b 62, standard (or regular) port, chrome-
plated brass ball, replaceable "Teflon" or "TFE" seats and seals, blowout-proof
stem, and vinyl-covered steel handle with threaded ends.
- ball valves 35 mm to 50 mm: rated for 10 bars; 3-piece construction; with
bronze body conforming to ASTM b 62, conventional port, chrome-plated brass
ball, replaceable "Teflon" or "TFE" seats and seals, blowout proof stem and vinyl-
covered steel handle with threaded ends.
2.9 STOP VALVES (FOR WATER TANKS)
- Stop valves shall be screw down pattern, with chrome plated gunmetal bodies
and screwed connections.
2.10 DRAIN COCKS (FOR WATER TANKS)
- Drain cocks shall be plug type with hose union connector, loose key and gun-
metal body.
2.11 NUTS AND BOLTS WITH WASHERS
- Nuts & bolts with washers shall be of AISI type 316 Stainless Steel complying
with ASTM A276 or equivalent. The grade shall be embossed on bolts. They shall
be supplied with two stainless steel grade 316 standard washers. Unless other-
wise indicated on the drawings, all stainless steel (whether nut bolts or any other
items) shall be Type 316 with a mill finish
2.12 FLEXIBLE - COUPLING AND FLANGE ADAPTORS
- Where flexible couplings are required, they shall be of the tied or restrained
type, flexible couplings or equal. The supplier shall follow the manufacturer’s
Recommendations as to the methods and equipment to be used in assembling
the joints. In particular, the supplier shall ensure that rubber rings are correctly
positioned and free of twists. The rubber rings and any recommended lubricants
should be obtained only from the coupling manufacturer.
- Flexible couplings and flange adaptors shall be capable of withstanding the test
pressure appropriate to the pipes for which they are supplied.
Details of couplings for incorporation in the works shall be submitted to the Engi-
neer for approval
Dismantling joints shall be installed at selected locations within the piping of the
pump station and in the valve chambers along the pipeline as shown on the detailed
drawing to facilitate future removal of valves and other equipment for servic-
ing/replacement.
The dismantling joints shall be of the tied/restrained type having the following spec-
ifications:
Gasket: EPDM
OR
1. Water Meters
1. General
i. The flow meter shall be inherently bi-directional, and should total forward
and reverse flow separately.
j. Inter-connection between meters and signal converters shall be by cable
furnished by the manufacturer at no extra cost.
k. Magnetic flow meter shall incorporate a detector to constantly monitor
whether the pipe is full and all electronics, electrodes, sensors and cable
connections are operating correctly. Any fault shall be indicated immedi-
ately via a relay to any remote device, such as alarm, or signal or to the
motor actuator of a valve or pump to open or close as directed by the En-
gineer.
l. The flow meter shall incorporate a feature allowing a menu selection and
program changes to be made from outside the housing via hall-effect sen-
sors. It shall not be necessary to remove covers, panels or fasteners to ac-
complish calibration or program changes. The meter software shall incor-
porate a password, preventing inadvertent program changes. A hand-held
programmer is not acceptable.
1) Low flow cut-off, field adjustable from 0-9% of the full scale.
2) Current damping to modulate peaks and troughs for the 4-20mA
output signal in the event the output signals are spasmodically re-
ceived.
3) Noise suppression to cut-off the inaccuracy in magnetic field and
current due to noise created by the liquid flow.
4) Display damping to steady the reading of the flow rate and total.
5) Totalized flow and programmed configuration shall be maintained
in memory for up to 10 years.
2. Construction
a. The magnetic flow meters shall be of short-form type. Meters shall be de-
signed with end connections of NP 16 flanges. Field coils shall be either
completely encapsulated in the meter lining material or the meter tube
shall be 304 stainless steel with a suitable liner.
c. Sensor of shell-type enclosure with gaskets in between the shells is not ac-
ceptable.
3. Grounding
a. The flow meter shall be equipped with built-in grounding electrodes of the
same materials as the sensing electrode. In addition, each magnetic flow
meter shall be provided with two (2) numbers full-bore stainless steel
grounding rings installed at both ends of the sensor thus providing a
grounding circuit for each magnetic meter.
4. Manufacturer
b. The manufacturer of the flow meters shall confirm the particular applica-
tion of the flow meters for the intended use and shall provide a warranty
of minimum 5 years based on a replacement basis including labor and ma-
terial at no extra cost.
5. Rating:
1. Aggregate
a. Fine Aggregate
- The grading of fine aggregate shall be within the limits of Table (5) BS 882.
- Fine aggregate shall be of such uniformity that the fineness modulus as de-
fined in AASHTO M6 or (ASTM C125) shall not vary more than 0.20 either way
from the fineness modulus of the representative samples used in the mix de-
sign.
- The sand equivalent for fine aggregate (AASHTO T176) shall be a minimum of
70.
- The water absorption of fine aggregates (ASTM C128) or (AASHTO T84) shall
not exceed 2 percent.
b. Coarse Aggregate
2. Cement
3. Water
- Water for concrete, mortar and curing shall comply with BS 3148.
- All water used in concrete & mortar shall be clear, fresh water free from oil,
acids, alkali, sugar, vegetable substances, or any other contaminating agent.
- If required by the Engineer, Contractor shall provide water quality test re-
sults.
- Non-potable water shall not be used in concrete unless written approval to
do so is granted by the Engineer.
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4. Concrete Blocks
- Concrete blocks shall be hard, durable, sound, clean, well defined edges and
free from cracks, flaws or other defects. They shall comply with the require-
ments of ASTM C140.
- All mortar shall consist of one part masonry cement to three parts loose sand
complying with the following requirements.
- Sand complying with ASTM C144, grading and coloring suitable for type of
masonry and as approved by the Engineer.
- Sulphate Resisting Portland Cement shall comply with the requirements of BS
4027 or ASTM C150 type V.
- Water Complying with water for Concrete Mixes and curing, of the Specifica-
tions Section 03300 "Cast-in-Place Concrete"
5. Reinforcing
- Valve Chambers Covers and Frames: 600 x 600 mm opening ductile iron kite
marked to BS EN124 Class C250 with mesh type safety grid and two (2) slot
head stainless steel countersunk screws, (25) tone test load, warm applied
black bitumen coat to BS 3416 and special coats for protecting covers in sani-
tary manholes.
- The cover should be equipped with an integrated lifting and locking handle.
The handle should be fixed to the frame with an integrated hinge allowing
- The cover to be freely removed from the frame at suitable opening angle.
The cover should be also equipped with a safety mechanism to maintain the
cover safety locked when opened at suitable vertical angle.
- Step ironing rising main valve chambers shall be galvanized malleable cast iron, shall
conform to BS 1247, and shall be of general purpose type.
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- The tail length shall be 230 mm unless the well into which the tail is to be cast is
less than 290 mm thick.
- Step irons in house connection chambers shall be galvanized malleable cast iron and
epoxy coated in accordance with BS 1247, and shall be of general purpose type.
- The tail length shall be 230 mm unless the w all into which the tail is cast is less than
290 mm thick.
a. Steel ladders
Galvanized steel ladders shall be to the form and dimensions shown on the Draw-
ings, and as specified below:
b. GRP Ladders:
a) GRP material for ladders shall be fabricated from structural quality fiberglass
shapes with chemical and ultraviolet resistance. Resin shall be all vinyl ester.
Glass shall be all ECR and GRP thickness shall be a minimum 5 mm. The top
surface shall be provided with a non-slip silica sand finish. The structural
components shall have Class I fire retardance, with an ASTM E84 flame
spread rating of 25 maximum. Fiberglass components shall have an ultimate
tensile strength of 20 7 MPa, an ultimate compressive strength of 207 MPa, a
modulus of elasticity of 20.7 GPa, and a Barcol hardness of 50.
b) All cut or trimmed edges of the GRP ladder and braces shall be flow coated
with an approved vinyl ester resin. Glass fibres shall not be exposed.
9. Protective Coating:
- Mortar shall consist of one (1) part of cement to two (2) parts of sand, by volume.
1. Fire hydrants shall meet or exceed the latest revisions of ANSI/AWWA standard
C502 and shall be UL listed and FM approved.
2. Fire hydrants shall be rated for 250 psig operating pressure and 500 psig test
pressure.
3. Fire hydrants shall be 4.25” valve opening and shall be of the compression type,
opening against the pressure and closing with the pressure.
4. The operating nut shall be ductile iron and also serve as a weather shield. The op
nut shall be pinned to a bronze revolving nut that engages the stem. An anti-
friction washer shall be in place above the revolving nut thrust collar and below
the bronze hold down nut. The hold nut shall have an Allen head locking screw.
The hydrant bonnet shall have a directional arrow cast on it. Bonnet lubrication
shall be grease.
5. The bonnet shall be attached to the upper barrel using the bayonet connection
and then secured by stainless steel screw.
6. Fire hydrant nozzles shall thread counterclockwise into the upper barrel and uti-
lize the O-ring seals. A suitable nozzle lock shall be in place to prevent inadvert-
ent nozzle removal. The Nozzle shall be as specified as follows:
7. Hydrant shall be a “Traffic- Model” having upper and lower barriers joined at the
ground line by breakable flange providing 360o rotation of upper barrel for
proper nozzle facing the flange shall employ two stainless steel bolts and nuts for
easy repair.
8. The operating stem shall be 1.25” diameter steel (excluding threaded or ma-
chined areas) and be connected by a stainless steel safety coupling. Screw pins,
bolts, or fasteners used in conjunction with the stem couplings steel. The top of
the lower stem shall be recessed 2” below the safety flange to prevent water
hammer in the event of a “drive over”.
9. The lower barrel shall be an integrally cast unit. The use of threaded on or me-
chanically attached flanges is deemed unacceptable. The ground line shall be
cast on the lower barrel.
10. An O-ring bronze seat ring shall be threaded into a bronze drain ring and have
two drain holes allowed drainage of the hydrant. To control drainage the drain
valve shall be an integral part of the one-piece bronze upper valve plate. They
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shall operate without the use of springs, toggles, levers or other intricate syn-
chronizing mechanisms.
11. The shoe inlet size and connection type shall be as specified (Flanged, MJ, etc…).
12. The interior of the shoe including the lower valve plate shall have a protective
coating that meets the requirements of AWWA C550.
13. Hydrants shall be warranted by the manufacturer against defects in materials or
workmanship for a period of ten (10) years from the date of manufacture. The
manufacturing facility for the hydrant must have current ISO certification.
14. Material:
15. Rating:
16. Accessories: Each hydrant shall be equipped with, buried gate valve with surface
box and extension tube, and horizontal ductile iron pipe connected to the main
pipe. All the above mentioned accessories with all mechanical components
needed for installation as indicated on drawings shall not be measured or paid
for , but shall be considered as a subsidiary obligation of the respective items of
the Bill of Quantities
PART 3 EXECUTION
3.1 GENERAL
- All pipe work, fittings are to be installed in strict accordance with the manufacturer
instructions and in accordance with this specification. The excavation, pipe bed-
ding and back filling shall comply with Section 31 30 00 “Earthwork”
a. The Contractor shall undertake a survey of the routes of all the pipelines
prior to the commencement of construction work, and shall provide the
Engineer with at least two copies of the results of the survey which shall
be in the same format as the tender drawings, together with the Con-
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tractor’s proposals for the pipeline gradient and invert level, location of
air valves, washouts, bends (including co-ordinates),..etc. The survey
shall also show the location, dimensions and level of underground exist-
ing services or obstructions in the pipeline route and shall conform to
the following:
Soil investigation
1. Soil testing
The Contractor is required to dig trial pits and carry out in-situ and
laboratory soil tests at intervals along the route of the pipelines lo-
cated as directed by the Engineer but not exceeding 500m. The tests
shall be carried out at a sufficient distance ahead of pipe laying that
construction is not held up...
The Contractor shall carry out laboratory soil tests on selected mate-
rial removed from each trial pit to determine its suitability for trench
back-fill. The tests shall include particle size distribution, Waterberg
limits and dry density moisture content relationship.
Where the Engineer considers excavated material to be unsuitable
for use as trench backfill, the Contractor shall carry out soil tests on
the material he proposes to import to determine its suitability. If the
Contractor proposes a change in back-fill or fill material, all tests
shall be repeated for the new material.
The Contractor shall also prepare a survey of the soil resistivity along
each pipeline route at intervals not exceeding 500m and determined
at the depth of the underside of the pipe and at the depth of the top
2. Resistivity survey
The resistivity survey report for each section of pipeline shall be pre-
sented to the engineer at the same time as the conventional survey
drawings.
3. Interaction testing
B. Excavation
- The Engineer shall provide the Contractor with benchmark, base line and points
of reference to be used by the Contractor in laying out the work. From the
benchmark, base line and points of reference the Contractor shall do his own
layout. The Contractor shall notify the Engineer if for any reason these bench-
marks, base line and pints of reference are disturbed, lost or destroyed. The Con-
tractor shall be charged the cost necessary to replace and relocate all bench
marks, base line and points of reference so disturbed, lost or destroyed.
- The Contractor shall be responsible for true and proper laying out of the work
and for the correctness of position, levels, dimensions and alignment of all parts
of the work and for the provision of all necessary survey instruments, equip-
ment, labor, stakes, templates, batter boards, material and supplies necessary
for the laying out of the work and maintenance thereof.
- If at any time during the progress of the work any error shall appear or arise in
the position, levels, dimensions or alignment of any part of the work the Con-
tractor shall, at his own expense, rectify such error to the satisfaction of the En-
gineer.
- The checking of any layout or of any line or level by the Engineer shall in no way
relieve the Contractor of his responsibility for the correctness thereof.
D. Pipe Distribution
- Distribute material on the job no faster than it can be used to good advantage.
Unload pipe, which cannot be physically lifted by workers from the trucks, by a
forklift or other approved means. Do not drop pipe of any size from the bed of
week’s supply of material in advance of laying, unless otherwise approved by the
Engineer.
- Inspect all pipe and fittings prior to lowering into trench to ensure no cracked,
broken or otherwise defective materials are being used. Clean ends of pipe thor-
oughly. Remove foreign matter and dirt from inside of pipe and keep clean dur-
ing and after laying.
- Pipe and accessories that are chipped cracked or contain other imperfection or
do not meet the test requirements shall be marked with a permanent marking as
rejected and shall be promptly removed from the Site.
- Use proper implements, tools and facilities for the safe and proper protection of
the work. Lower pipe into the trench in such a manner as to avoid any physical
damage to it. Remove all damaged pipe from the Site. Do not drop or dump pipe
into trench under any circumstances.
- Warning tapes shall be laid above all utility pipes. Tapes shall be durable and de-
tectable by electro-magnetic means using low output generator equipment.
They shall remain legible and color fast in all soil conditions at pH values of 2.5 to
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11.0 inclusive.
- The tapes shall be flexible and subject to the Engineer’s approval. Width of the
tape shall be at least 6” (150 mm).
- Tapes shall have different colors for different utilities and with black text in Ara-
bic and English as “CAUTION WATER PRESSURE MAIN BELOW” for water mains,
etc. The text on the tape shall be permanent ink bounded to resist prolonged
chemical attack by corrosive acids and alkaline with message repeated at a max-
imum interval of two (2) meters.
- The tape shall be laid continuous over pipelines and at joints there shall be a
minimum of one (1) meter overlapping. Tape shall be terminated inside valve
boxes to allow clipping of detector equipment to the tape.
- Warning tape shall not be separately measured or paid for, but shall be consid-
ered as a subsidiary obligation under the respective items included in the Bill of
Quantities.
1. General:
A. INSPECTION
- For satisfactory material and product performance, system designs and installa-
tion methods rely on appropriate, properly made connections. An inadequate or
improperly made field joint may cause installation delays, may disable or impair
system operations, or may create hazardous conditions.
- Joining and connection methods will vary depending upon requirements for in-
ternal or external pressure, leak tightness, restraint against longitudinal move-
ment (thrust load capacity), application and operation conditions, construction
and installation requirements, and the products being joined.
- Before using a joining or connection method, the limitations of the joining or
connection method must be taken into account. Where a joining or connection
method is suitable, the manufacturer’s joining procedures, tools and compo-
nents required to construct and install joints in accordance with manufacturer’s
recommendations should always be used.
- The Spigot and socket to be joined shall be carefully examined for any damage
which would impair the jointing procedure. Particular attention shall be paid to
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the spigot chamfer and to the sealing ring. The pipes shall be chamfered to a
depth of half the wall thickness and at an inclination angle of 150 to the pipe ax-
is.
- If pipes are cut on site they shall be cut square to the pipe axis with a fine
toothed saw and chamfered to half the pipe wall thickness with a coarse file or
surform tool.
- The chamfered spigot shall clean and free from swarf and burrs. The sealing ring
shall be correctly seated in the insert ring. The sealing portion of the ring must
be free from damage of any sort. Joints containing damaged or incorrectly fitted
rings must not be used.
- The spigot insertion depths shall be measured as the depth from the mouth to
the shoulder of the socket. Pipes shall be supplied with the spigot insertion
depth marked on the spigot end. The spigots of cut pipes shall be marked simi-
larly using an indelible crayon. If an allowance for expansion is required (e.g.
where changes in operating temperatures are anticipated), this shall be deduct-
ed from the spigot insertion depth.
- The spigot and socket shall be thoroughly cleaned. All grease, dirt, swarf and
other foreign matter shall be removed from the sealing areas. The spigot end
and triple seal portion of the sealing ring shall be roughly lubricated with the lub-
ricant. The spigot shall be lubricated to the full insertion depth and around its
complete circumference, paying particular attention to the chamfer area. The
triple seal shall be lubricated around its complete circumference. The guiding
principle shall be applied for a liberal quality of lubricant to avoid 'dry' areas on
the sealing surfaces.
- Immediately after lubrication, the spigot shall be brought into contact with the
socket. The spigot pipe and parent joint shall be accurately aligned so that the
axes of the pipes are precisely in line. The spigot shall be hand fed into the sock-
et until resistance from the inner sealing section is felt. Correct alignment at this
stage is essential to ensure that the rubber sealing ring is not pinched or torn.
- The joint can now be completed by one of the methods described below:
a. Leverage Method
- Sizes up to DN 200 mm, can normally be joined by applying leverage with a crow
bar at the following socket end. A stout timber shall be inserted between the
crow bar and the pipe socket to prevent damage to the latter. The leverage shall
be applied in a steady, continuous manner until the spigot insertion depth mark
coincides with the mouth of the socket being jointed. If any undue resistance is
felt and the spigot cannot be levered, the joint shall be disassembled and exam-
ined to determine possible cause (e.g. lack of lubrication and prinched or
trapped sealing ring). The procedure shall then be repeated as described previ-
ously.
b. Joint Clamps
For sizes above DN 200mm specially designed joined clamps shall be used with
UPVC Pressure Pipes. These are particularly useful where bends are to be installed
in the pipeline.
The clamps shall be positioned so that one clamp is adjacent to the socket shoulder
and the other close to, but not overlapping the depth insertion mark.
The spigot shall be correctly aligned as described above and drawn into the socket
until the spigot insertion depth mark coincides with the mouth of the socket being
jointed. No further pulling shall take place.
The clamps incorporate protective pads to prevent gouging and scratching of the
pipe surface. The clamps must not be used without the protective pads.
B. ANCHORAGE
- Anchorage lugs shall be provided for socket and spigot fittings and socket clamps
and tie rods used where there is a possibility of pulling the joint under pressure.
Concrete thrust blocks shall be used in lieu of the above where socket and spigot
pipe is used below ground. The Contractor shall submit, for the Engineer’s ap-
proval, working drawings and information demonstrating the adequacy of anchor-
age systems other than thrust blocks or other systems shown on the Contract
Drawings.
- Tests and inspections performed during construction may include damage In-
spections, butt fusion joint quality tests, soil tests, pipe deflection tests for ID
controlled products such as extruded profile wall pipe, or pressure leak tests.
2. Damage Inspections
- Damage such as cuts, scrapes, gouges, tears, cracks, punctures, and the like may
occur during handling and installation. Damage may affect joint integrity or seal-
ing, or may compromise pipeline performance. The following guidelines may be
used to assess surface damage significance.
- For UPVC pipelines, damage should not exceed about 10% of the minimum wall
thickness required for the pipeline’s operating pressure or the minimum wall
thickness required to meet structural design requirements. Excessive damage
generally requires removing the damaged section or reinforcement with a full
encirclement repair clamp..
- Damage such as punctures and tears will generally require cutting the pipe to
remove the damaged section and replacement with undamaged pipe. Small
punctures may occasionally be repaired with patching saddles that are saddle
fused or electrofused over the puncture.
3. Soil Tests
- During buried pipe installation, work should be checked throughout the construction
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period by an inspector who is thoroughly familiar with the jobsite, contract specifi-
cations, materials, and installation procedures. Inspections should reasonably en-
sure that signify cant factors such as trench depth, grade, pipe foundation (if re-
quired), quality and compaction of embedment backfill, and safety are in compli-
ance with contract specifications and other requirements. To evaluate soil stabil-
ity, density and compaction, appropriate ASTM tests may be required in the con-
tract specifications.
- To properly size the mandrel, the allowable vertical diameter of the pipe must be
established. It is necessary to account for pipe ID manufacturing tolerances and
any ovality that may occur during shipping. Pipe base ID dimensions and toler-
ances should be obtained from the manufacturer.
A. General
1. Valves shall be suitable for continuous operation as well as for intermittent op-
eration. All ferrous parts of the valves shall be coated, except for the finished or
bearing surfaces. The type of the internal and external coating shall be as speci-
fied on the respective data sheets for each type of valve.
2. Valves, strainers and other devices mounted in underground pipelines shall be
installed in reinforced concrete chambers complete with all accessories and pro-
tection systems as per the project specifications and drawings.
3. Valves, strainers and other devices shall be adequately supported independently
of the pipes to which they connect to prevent the pipe having to bear the weight
of the valve.
4. The valves shall be supplied complete with all the required joint accessories, ap-
proved gaskets, bolts, nuts and washers etc. for both flanges of each valve. All
Water Supply Networks Section 331000
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valves shall have the name of the manufacturer, working pressure, diameter and
cast number on the body.
5. All valves to be supplied shall correspond to internationally accepted standards
as applicable in the relevant parts of this document. Any other equivalent na-
tional or international standard shall be considered subject to submission of ac-
ceptable comparison statement. The CONTRACTOR shall attach to his offer the
English text of Standards as applicable.
6. The valves must be accompanied with a certificate guaranteeing their water
tightness and satisfactory operation for a period of not less than 10 years.
7. Contractors shall provide Material Certificates issued by the Manufacturers in
accordance with the requirements of EN 10204 and any other requirements is-
sued by the Client.
8. Contractor shall ensure that all material in contact with potable water shall not
adversely affect the potable water quality requirement of Regulation & Supervi-
sion Bureau Regulation which refers to WHO.
9. Butterfly valves of 1000 mm diameter and larger shall be of double eccentric ex-
ecution according to ISO 5752 series 14 and the flanges shall be in accordance
with the relevant ISO/BS/DIN standards.
b. EXAMINATION
- CLIENT/ENGINEER and/or third party Inspection Authority reserve the right for
stage inspection of material, manufacturing process, testing, etc. by their author-
ized representatives. Such inspection shall not relieve the CONTRACTOR of the
responsibility for suitable design and workmanship.
- Each individual component of the valve (body, disk, shaft etc.) shall be subjected
to heat treatments and tests (including NDT) as required by the specific applica-
ble material specification.
- The material certificate indicating above details shall be inspected and certified
by CLIENT/ENGINEER's inspectors prior to starting shop tests of the valve.
- The program for the tests shall be prepared by the CONTRACTOR and shall be
subject to CLIENT/ENGINEER approval.
- The below mentioned certificate requirements shall apply to the quality Control
Plan.
Certificate of compliance for Valve body, disk/wedge, and shaft shall be issued
for the following criteria in accordance to EN 10204 - Type 2.2 - For mass pro-
duced valves and Type 3.1 for Butterfly, Control Valves and other valves which
are not mass produced.
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Heat treatment after coating (if required)
Chemical analysis
Physical properties
Certification of compliance for the following tests shall be issued by the manu-
facturer according to EN 10204 – Type 3.1
Functional tests
Strength test for the body
Leak test for the disk /seat
Rubber lining checks after vulcanization
Coating thickness checks (internally & externally)
Dimensional checks
The above certificates shall be reviewed and certified by the respective inspection
authority.
The Rubber lining checks after vulcanization shall include the following:
Visual inspection
Adhesion test
Dielectric test
Shore D hardness test
Thickness test by electronic device
Non Toxicity Certificate for material in contact with potable water
- The CONTRACTOR/MANUFACTURER shall make suitable provisions for testing and
inform CLIENT/ENGINEER sufficiently (at least one month) in advance to enable
their representatives to witness the test. If witnessing of any tests is not satisfacto-
ry and a retest is required, the cost of the witnessed retests shall be borne by the
CONTRACTOR.
- MANUFACTURER shall ensure that all the applicable codes and standards are
available at their works for CLIENT/ENGINEER's reference during their visit to
manufacturer's works for shop inspection/tests.
- Testing shall be carried out in accordance with applicable codes and standards for
the particular valves. Besides mechanical operation tests, each valve shall be sub-
jected to hydrostatic body pressure/leakage test of 1.5 times the design pressure
and a disc strength/ leakage test of 1.1 (hydrostatic) times the design pressure be-
fore leaving the manufacturer's works. Tests shall be witnessed by
CLIENT/ENGINEER as specified and each valve shall be accompanied by manufac-
turer's test certificates.
- 5% of each size and type of valves supplied (butterfly, gate, non-return and air
valves) or a minimum of 1 No. of each size and type whichever is greater shall be
made available to CLIENT/ENGINEER witness testing. If the test on any valve fails,
the percentage of valves to be tested will be raised to 10%. Flow control valves,
Water Supply Networks Section 331000
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pressure sustaining valves, pressure reducing valves & altitude valves shall be
100% witness tested by CLIENT/ENGINEER.
- If any defect is detected during the tests before completion or during the warranty
period, the faulty equipment shall then be rectified immediately by the
VENDOR/CONTRACTOR at his expense. If the fault cannot be rectified, the
VENDOR/CONTRACTOR must then replace the defective equipment which must al-
so be proven to be free from defect.
- The test certificates, material certificates and mill certificates shall be entered into
the manufacturing data record books, as an ongoing procedure and must not be
left until the end of the manufacturing program.
- The manufacturing data record books including the witnessed tests documents
shall be submitted to CLIENT/ENGINEER prior to the dispatch of the materials.
3. INSTALLATION
- Locate valves for easy access and provide separate support where necessary.
Install valves in horizontal piping with stem at or above the center of the pipe.
- Install valves in a position to allow full stem movement.
- Install swing check valves for proper direction of flow with hinge pin level.
- Locate flow meter as recommended by manufacturer with respect to other piping
components to ensure flow meter will meet specified accuracy.
- Flanged Connections: Align flange surfaces parallel. Assemble joints by sequenc-
ing bolt tightening to make initial contact of flanges and gaskets as flat and parallel
as possible. Use suitable lubricants on bolt threads. Tighten bolts gradually and
uniformly using a torque wrench.
- All exposed bolts nuts shall be heavily coated with 2 coats of bituminous paint.
- All valves shall be equipped with dismantling joint to enable removal and installa-
tion of flanged valves as shown on Drawings. Dismantling joint shall be DI and suit-
able for valves pressure rating.
- Install buried gate valve complete with valve box and install valves inside valve
chambers complete with hand wheels.
- Wrap buried valves, flanged joints, mechanical joints, flanged pipe spools with
thrust collars, and adapters with polyethylene material, complete the wrap prior
to placing concrete anchor blocks. Repair polyethylene material damaged during
construction.
4. Cleaning of valves:
- Clean mill scale, grease and protective coatings from exterior of valves and prepare
valves to receive finish painting or insulation.
- Install valve chambers in places indicated on drawings as per Standard specifications.
All buried valves shall be provided with a surface service box for operation.
5. Testing valves:
- After piping systems have been tested and put into service, but before final adjust-
ing and balancing, inspect valves for leaks. Adjust or replace packing to stop leaks;
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replace valve if leak persists.
All dirt, chips, sawdust, nails, and other foreign materials shall be completely re-
moved from forms before any concrete deposited therein. Forms previously used
shall be thoroughly cleaned of all dirt, mortar and foreign material before being re-
used. Before concrete is placed in forms, all inside surfaces of the forms shall be
thoroughly coated with commercial quality form oil or other equivalent coating
which will permit the ready release of the forms and will not discolor the concrete.
Forms may be removed at the convenience of the Contractor and with the prior ap-
proval of the Engineer after the concrete has hardened. The concrete surfaces ex-
posed by removing forms shall be protected from damage.
All concrete shall be used while fresh and before it has taken an initial set. Re-
tampering of partially hardened concrete with additional water will not be permit-
ted. A surface on which concrete is to be placed shall be thoroughly moistened with
water immediately before placing concrete.
Mixed concrete, after being deposited, shall be consolidated until all voids are filled
and free mortar just appears on the surface. The concrete shall be placed as nearly
as possible in its final position and the use of vibrators for shifting of the mass of
fresh concrete will not be permitted. Fresh concrete shall not be permitted to fall
from a height greater than 2 meters without the use of adjustable length pipes of
"elephant trunks", double belting may be used in lieu of adjustable pipes or "ele-
phant trunks".
All concrete shall be compacted by means of high frequency internal vibrators with-
in 15 minutes after it is deposited in the forms. The vibrators shall not be attached
to or held against the forms or the reinforcing steel. The location, manner and dura-
tion of the application of the vibrators shall be such as to secure maximum consoli-
dation of the concrete without causing segregation of the mortar and coarse aggre-
gate, and without causing water to flush to the surface. Fresh concrete shall be
spread in horizontal layers in so far as practicable and the thickness of the layers
shall not be greater than can be satisfactorily consolidated with the vibrators. If ad-
ditional concrete is to be placed, care shall be taken to remove all laitance and to
roughen the surfaces of the concrete to ensure that fresh concrete is deposited up-
on sound concrete surfaces. Layers of concrete shall not be tapered off in wedge-
shaped slopes, but shall be placed with square ends and level tops.
Joints in the concrete due to stopping work shall be avoided as far as possible. Such
joints, when necessary, shall be constructed as directed by the Engineer.
Construction joints shall be made only where located on the plans, shown in the
Construction joints shall be made without keys, except when keys are shown on the
plans.
All newly placed concrete shall be cured in accordance with the following provi-
sions. The concrete shall be kept continuously wet by the application of water for a
minimum period of 7 days after the concrete has been placed. Cotton mats, rugs,
carpets or sand blankets may be used as a curing medium to retain the moisture but
not prevent evaporation.
The moisture from the nozzle shall not be applied under pressure directly upon the
concrete and shall not be allowed to accumulate on the concrete in a quantity suffi-
cient to cause a flow or ash the surface.
After concrete has attained the required characteristic strength and all surfaces
have been finished and accepted by the Engineer, apply protective coating as per
the requirements of section “Division 7 " Corrosion Protection And Odor Control"
Unless otherwise indicated, top surfaces of walls supporting cover slabs shall be to
true line and level and painted with two coats of approved bituminous paint as a
bond breaker.
All valve chambers shall be backfilled to crown of pipe level or as directed by the
Engineer with concrete grade SRC 20 against undisturbed ground to resist thrust.
Backfill around all piping and valve chamber will be in accordance with the applica-
ble requirements of Section 02310 "Earthwork".
Where pipes pass through a concrete wall or structure they shall unless otherwise
shown on the Drawings project from the external face of the structure by 300 mm
for pipes with nominal bore of 500mm or less and by 600mm for pipes with nominal
bores in excess of 600mm and the surface of such pipes shall be prepared to the
approval of the Engineer to ensure a satisfactory bond between pipes and concrete
forming the wall. A puddle or thrust flange shall be incorporated on each pipe pass-
ing through a wall as shown on the drawings.
Any excavation beneath the formation line of a pipe trench adjacent to a structure
shall be backfilled to the formation line of the pipe trench with concrete grade SRC
20. The concrete shall extend at least 500mm beyond the extremities of the pipe on
each side.
TANKING
All underground external concrete surfaces shall be tanked, with the tanking ex-
tending 150 mm above finished ground level.
Tanking of all external faces of concrete shall be carried out by wrapping with a pre-
formed strong impervious self-adhesive laminated bitumen/ polythene membrane
which shall be capable of withstanding cracking of the substrate up to a crack width
of 0.6 millimeters and shall be subject to the approval of the Engineer's
All surfaces shall be dry and dust free and surfaces painted with a coat of primer as
recommended and supplied by the same manufacturer as the membrane. The
membrane shall have a 75 mm minimum overlap at the joints. The concrete blind-
ing shall be extended outside the wall line by at least 100 mm to enable overlapping
and fixing of the membrane.
The tanking membrane shall be applied in two layers and laps shall be staggered
from one layer to the next.
Horizontal tanking applied over the concrete blinding shall as soon as practicable af-
ter laying be protected from damage by the application overall of a 50mm screed of
Concrete Grade SRC 20.
Tanking to all other surfaces up to finished ground level shall be protected with a
12mm minimum thickness of bitumen bonded cork board which shall be subject to
the approval of the Engineer's Representative. The protective board shall be placed
against the tanking and held in position by temporary struts or other means while
the backfilling is being placed care being taken to prevent loose stones damaging
the membrane or the protective board. Tanking above finished ground level shall be
protected by an aluminum flashing as indicated on the drawings.
All application details for the tanking membrane shall be in accordance with the
membrane manufacturer's details.
General
The wall that supports access rungs or ladder shall be 90 degrees vertical from the
floor of structure to manhole cover.
Install steps and ladders per the manufacturer’s recommendations. Steps and lad-
ders shall not move or flex when used. All loose steps and ladders shall be replaced
by the Contractor.
Step Iron
Steps shall be thoroughly cleaned and given a protective coal tar epoxy coating. The
cleaning shall be done by suitable means to ensure that the surfaces to be coated
are free from foreign matters. After the steps have been cleaned, rinsed and dried,
apply the coating and allow drying before installing in concrete.
Installation of step irons shall not begin until concrete receiving them has attained
its sufficient strength. Embedment into walls shall be as recommended by the man-
ufacturer; non-shrink cement formulation shall be used for pointing.
Steps shall be located to provide a continuous vertical ladder from the valve cham-
ber rim to the top surface of the bottom slab at intervals of 300 mm, plus or minus
40 mm and shall be installed in a manner to be capable of withstanding a force of
160 kg applied on the step at any place and in any direction with no permanent de-
formation.
Steel Ladders
When supported horizontally over a span of 1.0 m with the climbing face uppermost
and with a load of 1000 N applied at the center of the span, the ladder shall not de-
flect more than 15 mm at the point of application of the load and shall show no
permanent deflection after removal of the load. Each ladder fixing shall be capable
of withstanding shear and pull - out loads of 5000 N
Safety cages shall be provided where indicated and where the distance between
landings exceeds 3500 mm. These shall be constructed of three vertical flat sec-
tions, minimum size 50 mm by 8 mm supported by flat hoops with a diameter of
750 mm. The hoops shall be at a maximum of 900 mm centers and the first hoop
shall be 2400 mm above lowest platform level. No single hoop shall be used
All welds shall be ground flush and smoothed and ladders hot - dip galvanized after
fabrication. Connections to concrete or masonry walls shall be secure with accu-
rately positioned stainless steel anchor bolts. Ladders shall be mounted to produce
a finished appearance that is plumb, straight and true to dimensions.
c. GRP ladders
1) GRP ladders shall be of an approved pattern and purpose made to suit the depth
of each location and shall be installed as shown on the Drawings. They shall be
white (or near white) in colour and shall be formed from a laminate of ‘ECR’ type
chopped strand mat and vinylester resin throughout, having a mould face one side
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and a finish of a tissue and final resin flow coat on the other, (after the hardwood
inserts). For full support hardwood stiffeners shall be provided inside both the
rungs and the side rails as a former, and shall be fully covered with GRP laminate.
2) The wall thickness of the laminate shall be not less than 5 mm at any point and
there shall be no sharp edges. The support fixing brackets shall be GRP continuous-
ly moulded with the main lamination and they shall be not more than 500 mm apart
(every 2 steps/rungs). The rungs shall be 250 mm apart with the upper face finished
with a non -slip surface.
3) The support fixing brackets shall be put through the liner wall, and be designed
to be totally encapsulated by concrete. The ladder brackets shall be laminated to
the outside of the liner.
5) When supported horizontally over a span of 1.0 m with the climbing face up-
permost and with a load of 1000 N applied at the centre of the span the ladder shall
not deflect more than 15 mm at the point of application of the load and shall show
no permanent deflection after removal of the load. Each ladder fixing shall be ca-
pable of withstanding shear and pull -out loads of 5000 N.
Install frames and covers on top of valve chambers to positively prevent all infiltration
of surface or ground water into valve chambers. Frames shall be set in a bed of mortar
with the mortar carried over the flange of the ring. Set frames so tops of covers are
flush with surface of adjoining finish pavement surface. Elsewhere-set 50 mm above
ground surface, unless otherwise shown or directed. Employ bricks conforming to this
specification built with cement sand mortar, to adjust cover level as required.
3.5 TESTS
The structures shall be filled with water to ground level, the underside of the cover
slab, or to give a head over the pipeline of 2 m whichever is the less. After a period to
the approval of the Engineer to allow for absorption of water by the structure, there
shall be no discernible loss of water over a period of 30 minutes as measured by a ver-
nier gauge or other approved device
A Set center of each hydrant not less than 600 mm no more than 1800 mm back of edge
of road or face of curb. Fire apparatus connection shall face road with center of nozzle
450 mm above finished grade. Set barrel flange not more than 50 mm above finished
grade.
B Set each hydrant on a slab of stone or concrete not less than 100 mm thick and 375
mm square. The service line to the hydrant, between the tee and the shoe of the hy-
drant, shall be fully restrained.
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C Set bases in not less than 0.4 cubic meter of crushed rock or gravel placed entirely be-
low hydrant drainage device.
Applicable procedures for disinfecting new and repaired potable water mains are pre-
sented in standards such as ANSI/AWWA C651 that uses liquid chlorine, sodium hypo-
chlorite, or calcium hypochlorite to chemically disinfect the main.
Disinfecting solutions containing chlorine should not exceed 12% active chlorine, be-
cause greater concentration can chemically attack and degrade plastic pipe.
Cleaning
Pipelines operating at low flow rates (around 2 ft/sec or less) may allow solids to settle
in the pipe invert. Plastic pipe has a smooth, non-wetting surface that resists the ad-
herence of sedimentation deposits. If the pipeline is occasionally subject to higher flow
rates, much of the sedimentation will be flushed from the system during these peak
flows. If cleaning is required, sedimentation deposits can usually be flushed from the
system with high pressure water.
Water-jet cleaning is available from commercial services. It usually employs high pres-
sure water sprays from a nozzle that is drawn through the pipe system with a cable.
Pressure piping systems may be cleaned with the water-jet process, or may be pigged.
Pigging involves forcing a resilient plastic plug (soft pig) through the pipeline. Soft pigs
must be used with Plastic pipe. Scraping finger type or bucket type pigs may severely
damage a Plastic pipe and must not be used.
Usually, hydrostatic or pneumatic pressure is applied behind the pig to move it down
the pipeline. Pigging should employ a pig launcher and a pig catcher.
The main flow is into the tee branch and out through a run outlet. The opposite tee run
outlet is used to launch the pig. The pig is fitted into the opposite tee run; then the run
behind the pig is pressurized to move the pig into the pipeline and downstream. In the
removable pipe spool, the pig is loaded into the spool, the spool is installed into the
pipeline, and then the pig is forced downstream. (Note – Fully pressure rated wyes
suitable for pig launching are generally not available.)
A pig may discharge from the pipeline with considerable velocity and force. The pig
catcher is a basket or other device at the end of the line to safely receive or catch the
pig when it discharges from the pipeline.
Testing
The intent of leak testing is to find unacceptable joint leakage in pressure or no pres-
sure piping systems. If leaks exist, they may manifest themselves by leakage or rupture.
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Leak tests of pressure systems generally involve filling the system or a section of the
system with a liquid or gaseous fluid and applying internal pressure to determine re-
sistance to leakage. Leak tests of non-pressure systems typically involve testing sec-
tions of the system or individual joints using end plugs or bulkheads to determine re-
sistance to leakage.
Conduct tests before backfilling over pipes to allow for inspection and conduct initial
service leak test
Where any section of pipe is provided with concrete reaction blocking (thrust block),
do not make the pressure test until at least seven (7) days have elapsed after the con-
crete thrust blocking is casted.
Duration: The duration of each pressure test shall be sixty (60) minutes minimum, un-
less otherwise directed by the Engineer.
Even at relatively low internal pressures, leak testing with a pressurized internal fluid
can generate very high forces that can be dangerous or even fatal if suddenly released
by the failure of a joint or a system component or a testing component.
Always take safety precautions when conducting pressurized fluid leak tests.
Restrain pipe, components and test equipment against movement in the event
of failure.
Joints may be exposed for leakage inspection provided that restraint is main-
tained.
Keep persons not involved in testing a safe distance away while testing is being
conducted.
Liquids such as water are preferred as test fluids because less energy is released if
something in the test section fails catastrophically. During a pressure leak test, energy
(internal pressure) is applied to stress the test section. If the test fluid is an incompress-
ible liquid such as water, the energy applied to pressurize the liquid transfers primarily
to the pipe and components in the test section. However, if the test fluid is a compress-
ible gas, energy is applied to compress the gas as well as to stress the piping section. If
a catastrophic failure occurs during a pressurized liquid leak test, the overall applied
energy is much lower, and energy dissipation is rapid.
However, if catastrophic failure occurs during a pressurized gas test, energy release is
many times greater, much more forceful and longer duration
Hydrostatic pressure leak tests of plastic pressure piping systems should be con-
ducted in accordance with ASTM F 2164. The preferred hydrostatic testing liquid
is clean water. Other non-hazardous liquids may be acceptable
Pressure System Leak Testing – Pneumatic testing should not be considered un-
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less one of the following conditions exists:
Expel all air from the pipe. Apply and maintain the specified test pressure by continu-
ous pumping if necessary for the entire test period. The test pressure shall be calculat-
ed for the point of lowest elevation or as directed by the Engineer. The pump suction
shall be in a barrel or similar device, or metered so that the amount of water required
maintaining the test pressure may be measured accurately.
Leakage shall be defined as the quantity of water necessary to hold the specified test
pressure for the duration of the test period. No pipe installation shall be accepted if the
leakage is greater than 0.90 liter per mm of pipe diameter per kilometer of pipe length
per day.
Correction of Excessive Leakage: Should any test of pipe laid reveal leakage greater
than that allowed, locate and repair or replace the defective joints or pipe until the
leakage of a subsequent test is within the specified allowance. Repairing and replacing
of defective joints or pipes shall be conducted in a manner approved by the Engineer at
no additional cost to the Employer.
Subsequent Failure
Infiltration of groundwater in an amount greater than 18.5 liters per day per millimeter
of pipe diameter per kilometer of pipeline, following a successful test as specified, shall
be considered as evidence that the original test was in error or that subsequent failure
of the pipeline has occurred. The Contractor shall correct such failures in a manner ap-
proved by the Engineer at no additional cost to the Employer.
Final Inspection
Facilitate the final inspection of the pipe system and ensure access to the work by the
Engineer. Notify the Engineer when any portion of the work is ready for final inspection
and witness the inspection.
The Engineer reserves the right to employ any means to accomplish the final inspection
including the use of television inspection equipment.
The Contractor shall provide necessary lamps, ropes, bulkheads, plugs, temporary
Water Supply Networks Section 331000
Riyadh Sedra 2 (Prj. 2970) Page 64 of 66
pumping, ventilation equipment, ladders and other equipment to allow the Engineer to
properly and safely inspect the work.
BACKFILLING
Backfilling shall normally be carried out using selected excavated materials similar to
the in situ materials in which the trench or structure is being constructed. Where the
Engineer's Representative designates the excavated material as unsuitable, suitable
material shall be imported, at no extra cost.
Material for backfilling may be selected from any part of the site and methods of selec-
tion may include sieving to remove large particles or methods of hand or machine sort-
ing.
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.
Cohesive Soils
Cohesive soils shall be placed in layers not greater than 150mm thick (compacted
thickness) and compacted such that throughout each layer placed the dry density is not
less than 95% of the in situ dry density of the soil prior to excavation when tested in
accordance with relevant BS specification.
The placement moisture of the soil shall be within the range 2% below to 1% above the
natural in situ moisture content of the soil before excavation. It is to be noted that the
cohesive soils or hard materials from excavations shall be broken down to suitable siz-
es to be used for, backfilling, of the top two layers for stability or as per Engineer’s in-
structions at no extra cost.
Granular Soils
Granular soils shall be placed in layers not greater than 150mm thick (compacted
thickness) and compacted such that throughout each layer placed the dry density is not
less than 95% of that obtained in the vibrating hammer compaction test when the test
is carried out on the same soil at the same moisture content in accordance with rele-
vant BS specification.
Unless otherwise directed the moisture content shall be maintained and if necessary
adjusted by approved means to fall within the range plus 1.5% to minus 3% of opti-
mum moisture content determined in the vibrating hammer compaction test.
For free draining granular soils that have no clearly defined optimum moisture content,
compaction shall be carried out to achieve a relative density of not less than 95%. Dur-
ing compaction the soil shall be made as wet as practicable.
The Contractor shall provide at his own cost the services of approved and backfilled soil
properties and shall maintain with a copy to the Engineer, a daily log of tests carried
out.
All back fills shall be carried out in layers of 150 mm thick. In-situ soil compaction tests
shall be carried out for pipe line trenches at the rate of one test per 100mtrs of trench
length for each layer of 150mm thick, starting from 450 mm above the crown of the
pipe. Deep test shall not be carried out as the test location may not be representative.
Also, the Contractor shall continue backfilling the next upper layer only if the test result
for the previous layer is available and found to have passed as per the requirements. In
addition to the pipeline trench backfilling and testing the chambers pits and pits form-
ing at the sides of the Thrust blocks shall backfilled in accordance with the relevant
specifications and tested for compaction for every 150 mm thick layers of backfills. The
initial layer to be tested shall be the excavated formation level for the Thrust Block or
chamber pits, which shall be tested prior to placing the structure. The remaining in-situ
soil compaction tests to be carried out as the backfilling progresses layer by layer.
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 excavation. This new drain shall be of similar pipes of the same di-
ameter as those in the existing drain. Before any further backfilling is done the Con-
tractor shall notify the owner or occupier to enable him to see the reinstated land
drain. The replacement drain shall be surrounded with pipe bedding material to a min-
imum thickness of 150mm before further backfilling.
Site Tests
After installation and before commissioning, the CONTRACTOR shall carry out site
tests, to be witnessed by ENGINEER representatives as well as valves manufacturer's
representative.
Test certificates shall be issued immediately after site testing and copies of the same
should be incorporated in the O&M manuals.
Any problems/defects detected during these tests shall be promptly remedied / recti-
fied by the CONTRACTOR/Manufacturer at no additional cost to ENGINEER.
THIS PAGE IS A RECORD OF ALL SPECIFICATION REVISIONS. REVISED SHEETS ONLY ATTACHED
NORMALLY, EACH TIME THE SPECIFICATION IS CHANGED ONLY THE ENTIRE SPECIFICATION RE-ISSUED
NEW OR REVISED PAGES ARE ISSUED. ENTIRE SPECIFICATION REVISED
SPECIFICATION REV.
ECG ENGINEERING CONSULTANTS GROUP SANITARY SEWERAGE UTILITIES
KSA 333000 – 2970 1
SECTION 333000
Page
PART 1 GENERAL 2
1.1 Related Documents 2
1.2 Description Of Work 2
1.3 Reference Standards 2
1.4 Submittals 9
1.5 Quality Assurance 9
1.6 Delivery, Storage, And Handling 10
PART 2 PRODUCTS 13
2.1 Warning Tapes 13
2.2 Geotextile 15
2.3 Pipe And Fittings 15
2.4 Anchorage 34
2.5 Grout 35
2.6 Sewage Structures 35
PART 3 EXECUTION 40
3.1 General 40
3.2 Joints 43
3.3 Pipe Laying 44
3.4 Manholes And Special Structures 48
3.5 Building Service Lines 55
3.6 Inspection Of Sewers 55
3.7 Testing 55
PART 1 GENERAL
B. Related Sections:
A This section covers gravity pipes, pressure pipes work for the conveyance of
wastewater as indicated on Drawings and specified here in addition to all types of
sewage structure such as manholes, slow down chambers and inspection chambers
as required by the Contract. Extent of these structures is indicated on Drawings.
A The work shall be performed in strict accordance with the stipulations of the
National Water Company (NWC) Latest Edition, the British Standard Specifications
(BS) or the American Standards (ASTM) as noted herein below or other equivalent
approved Standards and Sound Practice.
ISO NO.
ISO 4633 Rubber seals-Joint rings for water supply, drainage and sewerage
pipelines -- Specification for materials
ISO 4435 Unplasticized poly (vinyl chloride) (PVC-U) pipes and fittings for
buried drainage and sewerage systems – Specifications
ASTM NO.
ASTM D 2583 Indentation hardness of rigid plastics by means of a Barcol
Impresser.
ASTM D 638 Standard Test Method for tensile properties of Plastics.
D2466 Specifications for Poly Vinyl Chloride (PVC) plastic Pipe Fittings,
Schedule 40
D3034 Standard specifications for type PSM (PVC) sewer pipe and
fittings.
AWWA C908 2001 PVC self-tapping saddle trees for use on PVC pipe
(revision of ANSI/AWWA C908-97)
AWWA C909 Standard for Molecularly Oriented Polyvinyl Chloride (PVCO)
Pressure Pipe, 4 In. Through 24 In. (100 mm Through 600
mm), for Wastewater Service
ASTM NO.
AWWA C 950 Glass Fiber Reinforced Thermosetting Resin Pressure Pipe.
AWWA M 45 Manual of water supply practiced. Fiber glass pipe design.
BS 65 - 1991 Vitrified clay pipes, fittings and ducts, also flexible mechanical
joints for use solely with surface water pipes and fittings
BS EN 295-5:1994 Vitrified clay pipes and fittings and pipe joints for drains and
sewers.
ASTM NO.
ASTM C 425 Specification for Compression Joints for Vitrified Clay Pipes and
Fittings.
ASTM C 700 Specification for Vitrified Clay Pipes Extra Strength, Standard
Strength and Perforated
ASTM C 479 Standard Specification for Vitrified Clay Liner Plates
BS No.
ASTM NO.
A82 Specification for Steel Wire, Plain, for Concrete Reinforcement
A185 Specification for Steel Welded Wire, Fabric, Plain, for Concrete
Reinforcement
C618 Specification for Fly Ash and Raw or Calcined Natural Pozzolan
for Use as a Mineral Admixture in Concrete
ASTM NO.
IS0 4633, Rubber Seals - Joint Rings For Water Supply, Drainage and
Sewage Pipelines - Specification for Materials.
AWWA 651 Disinfecting water mains
ASTM D 2412 Standard Test Method for Determination of External loading
characteristics of Plastic pipe by Parallel plate loading.
ASTM D 2290 Standard Test Method for Apparent Tensile Strength of ring or
tubular plastics and reinforced plastics by Split Disk Method.
ASTM D 2584 Standard Test Method for Ignition Loss of cured Reinforced
Resins.
ASTM D 3517 Specification for Fiberglass Pressure Pipe
ASTM NO.
ASTM D 3261 Butt Heat Fusion PE Fittings for PE Pipe & Tubing
Outside Diameter
ASTM F 894 Specification for Polyethylene (PE) Large Diameter Profile Wall
Sewer and Drain Pipe.
ISO No.
BS No.
BS 8005 Sewerage Guide to New Sewerage Construction
BS 5750 Quality assurance in productions and installation
BS 5911 Specification For Inspection chamber and street gullies
BS EN 124 Manhole Covers, Road Gully Grating and Frames
BS 1247 Manhole Step Irons
A Submit the following in accordance with Conditions of the Contract and Division-1
Specification Sections:
C Pipes
D Sewage Structure
1. Detailed design and calculations for different types of sewage structures and
sewage chambers.
2. Shop drawings for all types of cast-in-situ concrete structures and chambers
3. Materials list, original catalogue, certificate of origin and manufacturer's data
sheet of the ductile iron frames, covers, steps, grout, waterproofing of the
manhole outside and plastic liner inside the manholes.
4. Representative samples of the ductile iron frames, covers and steps.
5. Method statement of the manholes construction.
6. Shop drawings of the ductile iron frames and covers installation.
7. Shop drawings of the manhole steps installation.
8. Record drawings of the manholes.
A. Products Criteria
1. Multiple Units: When two or more units of the same type or class of materials
or equipment are required, these units shall be products of one manufacturer
2. Nameplates: Nameplate bearing manufacturer's name, or identifiable
trademark, including model number, securely affixed in a conspicuous place on
equipment, or name or trademark, including model number cast integrally
with equipment, stamped, or otherwise permanently marked on each item of
E Inspection
1. Comply with the rules and regulations of the National Water Company having
jurisdiction over the connection to Public Sanitary Sewer lines and the
extension, and/or modifications to Public Utility Systems.
2. Inspection and Test by the Manufacturer: Pipe and fittings shall be thoroughly
inspected by the manufacturer before delivery. The manufacturer shall make
all tests as specified herein and the results of the tests shall be furnished to
the Contractor upon request in accordance with mutually acceptable
arrangements. The manufacturer may use his own or other suitable facilities
for the performance of the inspection and test requirements specified herein.
On the sample pieces selected for inspection, the inside diameter of the spigot
end shall be checked by suitable gauges. Fittings shall be suitably inspected for
soundness and brittleness.
3. Inspection and Test by the Contractor: Inspection and tests may be made at
the manufacturer plant or at other suitable facilities. If made at the place of
manufacture, the manufacturer shall provide, without charge, all reasonable
facilities to be determined that the material is in accordance with this
specification.
4. Contractor's Responsibility: The Contractor shall furnish materials, equipment,
transportation services and skilled experienced. Laborers necessary to
complete the work as indicated or as required. The Contractor shall be
responsible to complete the work in accordance with the Specifications and
Drawings including details related to this section and necessary works for
complying with requirements contained therein. Contractor shall grantee and
be responsible for keeping all other existing utilities working in healthy
conditions. Any damage –caused by the contractor- to the existing utilities
shall be repaired on the contractor cost. Moreover, contractor shall be
claimed accordingly.
F Testing:
1. Materials and installed work may require testing and retesting at any time
during the progress of work. Tests, including retesting of rejected materials or
installed work, shall be done at the Contractor's expense.
G Rejection:
A General
a. Nominal diameter
b. Name or trade mark of manufacturer
c. Serial number
d. Class of pipe, pressure rating in compliance with referenced standards
e. Date of manufacture
f. Type of service
g. Details on fittings such as angle of change and taper
2. The acceptability of the pipes and fittings on delivery to the Site will be based
on the results of tests carried out by one or more of the following:
B During transport
1. Pipes and fittings shall be well secured and adequately supported along their
length
2. Bolsters and binding of approved type shall be used
3. Nesting of pipes (placing a smaller pipe inside a larger) may be permitted for
pipes of certain materials and size provided that methods statements
demonstrate that effective precautions will be taken to protect all pipe
surfaces and coatings from damage
4. No pipe shall overhang the end of a vehicle
5. Pipes and fittings of plastic materials shall be covered.
1. All pipes, fittings and materials shall be stored in accordance with the
approved manufacturer’s recommendations and the following:
a. Pipes may be stored in the open on a flat level area and raised
above the ground on timber bearers so that the lowest point
of any pipe or fitting is not less than 150 mm above the ground
b. Timber bearers not less than 200 mm wide and 75 mm thick to
be provide d at 4 m intervals maximum
c. If on pallets or crated, on the pallets or in their crates until
required
d. If not on pallets or not crated, stacked one above the other as
follows:
e. In accordance with the manufacturer’s recommendations but
not to a greater number of tiers than the following:
a. If spigot and socket, stacked so that successive pipe layers have sockets
protruding at opposite ends of the stack
b. With pipes of different sizes and thickness stacked separately
c. With maximum height of stacked pipes not exceeding 2m, or
that recommended by the supplier if less than 2 m.
d. Plastic pipes will be stored under cover and not exposed to the
sunlight.
a. Under cover
5. Pipes and fittings shall be protected in storage to the approval of the Engineer
by means of an impermeable membrane which shall cover the pipes and
fittings and separate them from the ground on which they are supported. The
membrane shall be strong and durable in the prevailing climate conditions.
6. Pipes and fittings shall be subject to visual inspections after off-loading at site
and before installation.
7. The following procedures shall be followed for dealing with damaged pipes
and fittings:
PART 2 PRODUCTS
A Service protection tapes shall be installed above all sewage pipelines and pressure
mains constructed or exposed under this contract excluding individual service
connections.
B Tapes shall be durable and detectable by electro-magnetic means using low output
generator equipment. They shall remain legible and color-fast in all soil conditions at
pH values of 2.5 to 11.0 inclusive.
C The tape shall be 150 mm wide and 250 micron thick and produced as a strong
composite laminate consisting of: -
D The thickness of the tape (250 micron / 1000 gauge) shall be measured in
accordance with BS 2782: Part 6. Method 630 A.
1) MD : 450%
2) TD : 550%
2. Chemical resistance:
a. The tape shall be remaining legible and color 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.
a. 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 meters. Tapes shall be color coded as follows,
with black text as indicated. The sign and styles of the text shall be
approved by the Engineer
1) Sewers: Yellow
2) CAUTION: Sewer Below
3) Sewage pressure mains: Yellow
4) CAUTION: Sewage Pressure Main Below
1. General
a. The material from which pipe, fitting and accessories is produced shall
consist of substantially unplasticized polyvinyl chloride. Only those
additives that are needed may be used for the manufacture of the
polymer, and for its conversion into sound, durable extrusions or
molding of good surface finish, mechanical strength and opacity.
b. UPVC pipes shall not be deteriorated or broken down under the effect
of bacteria or other micro-organisms.
c. Shall be as uniform as commercially practical in color, opacity, density
and other physical properties.
d. The pipes, fittings and accessories shall have a registered certification
mark on, or in relation to a product, as an assurance that the goods have
been produced under the scheme of supervision control and testing in
accordance with the certification mark scheme. Fittings and accessories
shall comply with ASTM D 2466.
e. Shall be recommended as conduits for the conveyance of potable water
2. Properties:
f. Chemical Characteristics:
g. Mechanical Characteristics:
h. Marking:
a) Manufacturer’s Name
b) Nominal Size
c) Class Pressure Rating
d) Identification Code
i. Jointing
j. Lubricant
k. Certification
B GLASS REINFORCED PLASTIC PIPES (GRP) (according project condition and preferred
from diameter 700 to 900 mm)
1. General
2. Reinforcement:
a. The glass used for the manufacture of the reinforcement shall be one of
3. Wall construction
a. Inner layer
b. Structural layer
c. 2Outer layer
d. Appearance
a. Flexible joint
b. Rigid joint
a. Categories
1) The nominal size (DN) of pipes and fittings shall conform to the
appropriate Tables in Clause 5 BS 14364. If a thermoplastics liner
is present, its internal diameter shall be declared by the
manufacturer. The tolerance on the diameter shall be as specified
in Clause 5 BS 14364.
c. Nominal stiffness
500 2500
630 4000
1000 5000
1250 8000
2000 10000
Nominal pressure
(PN)
1 12.5
1) Stiffness shall be minimum 5000 N/m2 for all pipes but for pipes
to be used in pumping stations and valve chambers the stiffness
shall be minimum 10,000 N/m2 and pipes for use in micro-
tunneling or similar jacking operations the stiffness shall be
minimum 50,000 N/m2 unless enclosed in concrete.
1) Test certificates for all type tests and other tests specified in this
Clause shall be submitted to the Engineer.
2) The results of type tests appropriate to the proposed pipes and
fittings shall be used to determine the properties of pipes. Each
type test shall have been carried out on pipes or fittings
representative of the pipes to be used. The following type tests
shall be conducted at the manufacturer’s works in accordance
with the requirements of BS 5480 Part 2 except as noted, and the
tests shall be carried out at 25°C.
Impact resistance
Long-term hoop tensile
External pressure resistance ASTM D2924
Strain corrosion test ASTM D3681
1. General:
3. Properties:
1) Pipe shall internally coat with 3 layers (coat) of coal tar epoxy
with thickness not less 450 micron after drying. No solvent
allowed.
2) Pipe shall internally coated with thin layers (coats) of poly
chloride vinyl plastic with thickness not less than 2 mm after
drying and shall be fixed on the total perimeter of the pipe 360
with T-LOCK system.
3) Outside Protection: Pipe and fittings shall be externally coated
with 2 coats of a hygienically harmless factory applied bituminous
varnish (PF4) with thickness not less than 3 5 0 micron after
drying, no solvent is allowed.
4. Materials:
5. Reinforcement:
1) The length of the joint as used herein means the inside length of
the bell or the outside length of the spigot from the shoulder to
the end of the pipe section the bell ends shall contain
circumferential reinforcement. This reinforcement shall be an
extension of the outer cage or a single wall cage. Whichever is
less, or may be a separate cage of at least the same area per
meter with longitudinal. If a separate cage is used, the cage shall
Extend into the pipe with the last circumferential wire at least 25
mm past the inside shoulder where the pipe barrel meets the bell
of the joint, where bells require reinforcement, the maximum end
cover on the last circumferential shall be 38 mm.
6. Permissible Variations:
b. Thickness: The wall thickness shall not vary more than shown in the
design or specified wall by more than 5% or 5 mm, whichever is greater.
c. Length of Pipe: The under run in length of a section of pipe shall not be
more than 10 mm/m with a maximum of 13 nun in any length of pipe.
d. Leng1h of Two Opposite Sides: Variations in the laying length of two
opposite sides of the pipe shall not be more than 6 mm for all sizes
through 600-mm internal diameter, and not more than 10 mm/m of
internal diameter for all sizes larger with a maximum of 16 mm in any
length of pipe through 2100-mm internal diameter, and a maximum of
19 nun for 2250-mm internal diameter or larger.
e. Position or Area of Reinforcement: The maximum variation in the
position of the reinforcement shall be ±10 % of the wall thickness or ±13
mm, whichever is greater, shall the cover the circumferential
reinforcement be less than 6 mm as measured to the end of the spigot
or 13 mm as measured to any other surface. The preceding minimum
cover limitations do not apply to mating surfaces of non-rubber gasket
joints or gasket grooves in rubber gasket joints. If convoluted
reinforcement is used, the convoluted circumferential end wire may be
at the, end surface of the joint providing the alternate convolutions
have at least 25 mm cover from the end surface of the joint.
f. Product Marking: The following information shall be legibly marked on
each section of pipe:
D (VC) Vitrified Clay Pipe, Extra Strength (according project condition) preferred for
1. General
a. Clay, free clay, shale, and surface clay are as defined in ASTM Definitions
C 43.
b. Vitrified clay pipe shall be manufactured from free clay, shale, surface
clay, or a combination of these materials that, when formed into pipe
and fired to suitable temperatures, yields a product that is strong,
durable, and serviceable, free of objectionable defects, and conforms to
tills specification.
2. Physical Properties
a. Bearing Strength
b. Absorption:
. Up to 7
and
including
1 (25)
Over 1 (25) and including 1 ½ 9
(38)
Over 1 ½ (38) and including 2 12
(51)
Over 2 (51) and including 2 ½ 15
(64)
Over 2 ½ (64) and including 3 18
(76)
Over 3 (76) 21
d. Acid Resistance:
f. Straightness
1) Pipe shall not deviate from straight by more than 1/16 in./ft. (5
mm/m) of length when the maximum offset is measured from the
concave side of the pipe.
2) Measurements shall be taken by placing a straightedge on the
concave side of the pipe's full length of the barrel, being sure not
to include spigot joint material or socket, and measuring the
maximum distance between the straightedge and concave side of
the pipe.
g. Glaze
1) Pipe of nominal sizes from 3 to 18 in. (76 to 450 mm) shall have
no blister with a dimension exceeding 3 in. (75 mm), and no
blister or pimple shall project more than 1/8 in. (3 mm) above the
surface of the pipe.
2) Pipe of nominal sizes over 18 in. (450 mm) shall have no blister
exceeding 2 in/ft. (166 mm/m) of internal diameter, and no blister
or pimple shall above the surface of the pipe more than 1/8 in.
/ft. (10 mm/m) of internal diameter.
j. Finish of Ends
. in mm min
3 to 6 75-150 1
8 and 10 200-250 2
12 to 36 300-900 3
3) Scoring may be eliminated when it is conducive to the proper
application of the joint to be used.
k. Fittings
l. Inspection
2.4 ANCHORAGE
A. Anchorage lugs shall be provided for socket and spigot fittings and socket clamps and
tie rods used where there is a possibility of pulling the joint under pressure.
Concrete thrust blocks shall be used in lieu of the above where socket and spigot
pipe is used below ground. The Contractor shall submit, for the Engineer’s approval,
working drawings and information demonstrating the adequacy of anchorage
systems other than thrust blocks or other systems shown on the Contract Drawings.
1. Material
a. Fine Aggregate
1) The grading of fine aggregate shall be within the limits of Table (5)
BS 882.
2) Fine aggregate shall be of such uniformity that the fineness
modulus as defined in AASHTO M6 or (ASTM C125) shall not vary
more than 0.20 either way from the fineness modulus of the
representative samples used in the mix design.
3) The sand equivalent for fine aggregate (AASHTO T176) shall be a
minimum of 70.
4) The water absorption of fine aggregates (ASTM C128) or (AASHTO
T84) shall not exceed 2 percent.
b. Coarse Aggregate
c. Cement
d. Water
e. Concrete
f. Concrete Blocks
1. General
1) Sealant Materials
1. All manhole drop connections shall be outside drop. Outside drops shall be
provided with same pipe material and classification as sewer main as indicated
in the standard drawings.
2. Y connection shall be provided with same pipe material as sewer main and
with the same pipe classification as indicated in the standard drawings
1. Step Iron
2. Steel Ladders
1. Manholes
a. Ductile iron kite marked to BS EN124 Class D400 solid top circular
hinged access cover and frame , opposite cover parts block at 90, the
covers are removable from the frame horizontally or vertically after
removing the metal safety pins. Circular frame over all flanged with
anchoring holes that can be used to fix the frame.
b. The cover should be freely removed from the frame at suitable opening
angle. The cover should be also equipped with a safety mechanism to
maintain the cover safely locked when opened at suitable vertical angle.
c. Warm applied black bitumen coat (paint) to BS 3416 and special coats
for protecting covers.
d. All covers shall be non-rock preventing noise and vibration.
e. Clear opening dimensions shall be as indicated on drawings.
f. Each cover should be badged with:
2. Inspection Chamber
a. Ductile iron kite marked to BS EN124 Class D400 when located under
the road and Class C 250 when located under the landscape area solid
top circular hinged access cover and frame , opposite cover parts block
at 90, the covers are removable from the frame horizontally or
vertically after removing the metal safety pins. Circular frame over all
flanged with anchoring holes that can be used to fix the frame.
b. The cover should be freely removed from the frame at suitable opening
angle. The cover should be also equipped with a safety mechanism to
maintain the cover safely locked when opened at suitable vertical angle.
c. Warm applied black bitumen coat (paint) to BS 3416 and special coats
3. Soakaway
a. Ductile iron kite marked to BS EN124 Class C250 solid top circular
hinged access cover and frame , opposite cover parts block at 90, the
covers are removable from the frame horizontally or vertically after
removing the metal safety pins. Circular frame over all flanged with
anchoring holes that can be used to fix the frame.
b. The cover should be freely removed from the frame at suitable opening
angle. The cover should be also equipped with a safety mechanism to
maintain the cover safely locked when opened at suitable vertical angle.
c. Warm applied black bitumen coat (paint) to BS 3416 and special coats
for protecting covers.
d. All covers shall be non-rock preventing noise and vibration.
e. Clear opening dimensions shall be as indicated on drawings.
f. Each cover should be badged with:
F. Protective Coating:
PART 3 EXECUTION
3.1 GENERAL
1. The Employer may employ the services of a specialist firm to assist the
Engineer as he may require in any matter connected with pipes, and fitting
including the inspection of materials and workmanship and the witnessing of
tests at any stage during the execution and maintenance of the Works.
2. Such independent tests may be carried out at any stage during the execution
and maintenance of the Works, but they shall not relieve the Contractor of his
obligations under the Contract.
3. To the extent ordered by the Engineer, the Contractor shall provide labor,
plant, tools and materials (but not special testing equipment) for direct
assistance to the specialist firm in their inspection and independent testing
and for any further work, investigations, and repairs which the Engineer
considers necessary as a result of such inspection or testing.
4. The provision of labour, plant and materials a s aforesaid shall be an obligation
of the Contractor where in the Engineer’s opinion the inspection test or
1. Where designated in the Project Specification, the Contractor shall carry out a
soil corrosivity study along the route of proposed ferrous pipelines as directed
by the Engineer and mark the results on the pipeline layout plans.
2. Soil resistivity’s shall be undertaken using a low resistance, null -balance earth
tester and a four pin array, or any other equipment approved by the Engineer.
Readings shall be recorded in ohm-cm and shall be taken at 1.0 m incremental
depths to a depth 1 m below the pipeline invert levels. Readings shall be
taken at a spacing along the route of the proposed pipelines as required to
reflect the changing soil conditions, but in no case shall the spacing exceed 500
m.
3. Soil samples shall be taken as directed by the Engineer along the route of the
proposed pipelines at a maximum spacing of 500 m. Soil samples shall be
tested for sulphates, sulphides, chlorides, pH, moisture content, and
carbonates.
1. All sewers shall be laid accurately to the lines, and levels gradients shown on
the approved drawings so that the pipeline is straight between successive
manholes in the vertical and horizontal planes.
2. Pressure pipelines shall be laid accurately to the lines levels and depths shown
on the approved drawings. Where changes of direction are required,
deflections shall be made in accordance with the manufacturer’s
recommendations.
1. The Contractor shall supply all necessary tools for cutting, chamfering, jointing,
and testing and for any other requirement for satisfactory installing the
pipelines.
1. Pipes and fittings including any sheathing, inside linings and outside coatings,
shall be inspected by the Contractor immediately before and after installation,
and damage or other imperfection shall be repaired by the Contractor as
directed by the Engineer before installation and in accordance with the
following:
a. Material required for the repair of pipe, sheathing, linings and coatings
shall be obtained by the Contractor and shall be used in accordance
with the manufacturers recommendations
b. Without relieving the Contractor of any of his obligations, the Engineer
may inspect and test the pipe and appurtenances by any appropriate
means, and damage discovered by such inspection shall be repaired by
the Contractor
F. Dewatering
1. For the purpose of reducing the angular deflections at pipe joints, and for
closure sections, the Contractor will be permitted to install pipe sections of
less than standard length. Closing lengths and short sections of pipes of all
types shall be fabricated and installed by the Contractor as found necessary at
Site. Where closing pieces are required, the Contractor shall make all
necessary measurements and shall be responsible for the correctness thereof.
The Contractor shall be responsible for taking the measurements required to
determine the lengths of cut portions of pipes for insertion as closing lengths
in pipelines.
H. Cutting of Pipes
1. Where pipes are required to be cut on the Site the cutting shall be done by the
Contractor in accordance with the manufacturer’s recommendations and in a
manner approved by the Engineer.
2. The pipe and methods of jointing shall be such that the locations of fittings
and lengths of pipe can be adjusted to suit Site conditions.
3. Cutting of reinforced concrete pipes will not be allowed. Special lengths of
pipes shall be manufactured for closures as required. Other pipes such as GRP,
ductile iron, vitrified clay, MDPE, HDPE, PVC-U and cast iron pipes shall only be
cut if approved by the Engineer.
4. The cutting of vitrified clay pipes, MDPE, HDPE, PVC-U, and ductile iron pipes
for inserting specials, fittings or closure pieces shall be carried out as follows:
I. Stringing of Pipes
1. After excavations have been completed to the designated levels and, trench
formation compacted, the Contractor shall issue a formal notice to the
Engineer that the trench formation is ready between designated points for
inspection. The Engineer will without unreasonable delay inspect the said
trench formation, unless he considers it unnecessary and advises the
Contractor accordingly. Any rejection of trench formation will be confirmed in
writing by the Engineer.
3.2 JOINTS
1. Immediately before assembling each joint incorporating a rubber ring seal, the
rubber shall be inspected for cracks, every part of the ring being deformed by
hand to about l50 mm radius. If under this deformation any cracks are either
revealed or initiated the ring shall be rejected, cut through completely to
prevent inadvertent use, and the matter reported forthwith to the Engineer. If
more than three successive rings inspected in this way are rejected the
Contractor shall on the instruction of the Engineer stop all pipe jointing until
the cause of the defect has been proved and remedied to his satisfaction.
2. The rubber ring shall be placed in the groove on the socket or spigot ring. The
groove shall be free of deleterious material; e.g., dirt, moisture, oil, and
grease. The inside surface of the socket shall be lubricated with a compound
recommended by the manufacturer which will facilitate the telescoping of the
joint. The spigot end of the pipe shall then be inserted into the socket of the
adjoining pipe using a suitable tool to push the spigot into the socket. The
position of the pipe and the gasket in the joint shall then be checked using a
feeler gauge to demonstrate proper jointing. When joints are not properly
made, pipes shall be adjusted, or removed and rejointed as necessary to
ensure proper jointing. Care shall be taken to avoid twisting or cutting the ring
when jointing the pipe.
B. Mechanical Joints
C. Anchorage
1. Anchorage lugs shall be provided for socket and spigot fittings and socket
clamps and tie rods used where there is a possibility of pulling the joint under
pressure. Concrete thrust blocks shall be used in lieu of the above where
socket and spigot pipe is used below ground. The Contractor shall submit, for
the Engineer’s approval, working drawings and information demonstrating the
adequacy of anchorage systems other than thrust blocks or other systems
shown on the Contract Drawings.
A. General
1. Except as otherwise specified in this Clause, pipe bedding shall conform to the
requirements specified in 31 00 00 EARTHWORK. The Contractor shall, after
excavating the trench and preparing the proper bedding, furnish all necessary
facilities for properly lowering and placing sections of the pipe in the trench
without damage and shall properly install the pipe.
2. Each pipe shall be carefully lowered onto its prepared bed by means of
appropriate slings and tackle. A recess shall be left in the prepared bed to
permit the sling to be withdrawn. If the prepared bed is damaged, the pipe
shall be raised and the bed made good before pipe laying is continued.
3. No pipe shall be rolled into place for lowering into the trench except over
suitable timber planking free from roughness likely to damage any coatings.
4. The section of pipe shall be fitted together correctly and shall be laid true to
line and grade in accordance with the bench marks established by the
Contractor. The bench marks shall be approved by the Engineer.
5. The full length of the barrel of the pipe shall have a uniform bearing upon the
bedding material and if the pipe has a projecting socket, suitable excavation
shall be made to receive the socket which shall not bear on the subgrade.
6. Pipes shall be laid with the class identification marks or the jointing marks
shown by the manufacturer in the uppermost position. Pipe sections shall be
so laid and fitted together that the pipeline will have a smooth and uniform
interior. The pipeline shall be clean and unobstructed at the time of its
installation and shall be true to the required line and levels.
7. Spigot and socket pipes shall generally be laid upgrade without break from
structure to structure and with the socket end upgrade. Back laying may be
permitted as deemed necessary and approved by the Engineer.
8. Whenever work ceases on any pipeline the unfinished end of the pipeline shall
be securely closed with tight fitting plug or cover.
9. Before any pipe is lowered into place, the bedding shall be prepared and well
1. In trench pipes with flexible joints except where concrete bed, bed and
surround or protection is required shall be laid on a well compacted bed of
granular material extending for the full width of the trench and with sufficient
material at the sides to permit the pipes to be worked into the granular
material and firmly supported to true line and level. Sufficient space should be
left to enable the joints to be made tested and inspected but the Contractor
shall ensure that at least three quarters of the pipe length is fully supported.
After the pipeline has been tested and approved by the Engineer the trench
shall be carefully filled to 300 mm above the crown of the pipe with granular
material in accordance with the bedding requirements specified in Part 2 of
this Section and as shown on the Drawings.
E. WYE Branches
1. Location: In general, wye branches shall be placed in the main sewer opposite
each lot or property to which a house service may be extended.
2. Existing Sewers: Where a wye branch is to be installed in an existing sewer, the
CONTRACTOR will be permitted to tap the sewer pipe and install the wye as
directed by the ENGINEER. Wyes shall only be installed on the type of pipe for
which they were designed. Wyes shall be approved by the ENGINEER.
3. Wyes shall be of the same material, strength, and joint as the sewer main
pipe.
4. Where the wye branch is not designed for use with PVC service pipe,
appropriate adapters shall be used to connect the lateral to the wye branch.
F. RISER PIPE:
1. Where the cover on the wye branch is in excess of twelve feet below average
ground surface, a 45 degree bend and sufficient riser pipe (also installed at a
45 degree slope) shall be added to terminate at a depth of twelve feet below
the ground surface, provided the property being served will not require
additional depth.
G. CLOSURES
1. Where no riser pipe or lateral is installed with the wye branches, the outlet of
H. WYE POLES:
1. A wye pole shall be placed at the end of each wye branch, riser, or house
service, as the case may be, extending to a point 6 inches below the end of the
pipe to hold it firmly in position during backfilling. If the wye pole is pulled out,
bent, or broken, the CONTRACTOR shall, at no cost replace or straighten the
pole. The wye pole shall be adjacent to the end of the pipe but not above it or
against it.
2. Material: Wye poles shall be not less than a standard 2 x 4 and shall extend a
minimum of 3 feet above the finished grade. The material used for wye poles
shall be in good condition and shall be straight, sound and free from large or
loose knots
I. Backfilling
J. Deflection at Joints
1. The Contractor shall construct anchor and thrust blocks at every bend and
junction on pressure pipelines and where otherwise shown on the Contract
Drawings or instructed by the Engineer. Each thrust block shall to have a
sufficient bearing area and shall be placed to safely transmit thrust to the
surrounding original ground. If soft, spongy, unstable or similar material is
encountered upon which the thrust block is to bear this unsuitable material
shall be removed and replaced with Grade 20 SRC mass concrete as directed
by the Engineer.
2. Thrust blocks shall be in-situ concrete, cast on undisturbed soil, and unless
otherwise designated, shall be constructed of Grade 25 SRC concrete. Thrust
M. Cleanliness of Pipelines
1. Pipelines and manholes shall at all times be kept free of all silt1 mortar1 debris
and other obstructions. When work is not in progress the open ends of the
pipeline shall be securely plugged with an approved watertight plug or stopper
firmly fixed to resist unauthorized removal. Claw type plugs or any type liable
to damage the pipe shall not be used. All such stoppers1 plugs or caps shall be
provided with a vent incorporating a valve for the purpose of testing whether
the pipeline is under pressure or vacuum and to enable pressures to be
equalized before its removal.
2. The Contractor shall clear the inside of each fitting and pipe length
immediately before jointing and shall swab all fittings and pipe lengths to
remove all dirt1 sand or other matter that may clog the pipeline or
contaminate the fluid to be transported in the pipeline. After j ointing1 the
interior of the pipes shall be freed from any dirt, stones or other matter that
may have entered them. For this purpose, a rubber disc, brush, or other
suitable implement that will not harm the internal lining of the pipe shall be
pulled through the pipe after jointing.
N. Marker Tape
1. All trenches for pressure pipelines, shall be marked with a high quality acid and
alkali - resistant red non bio-degradable plastic tape with a minimum width of
150 mm placed during backfilling 300 mm below finished surface or as
directed by the Engineer.
A. General
1. The Contractor shall construct all manholes, chambers, and special structures
including transition chambers and outfall structures as indicated on the
drawings and herein specified.
2. Manholes, chambers, Soakaway and special structures shall conform in shape,
size, dimensions, materials, and other respects to the details indicated on the
1. Examination
2. Placement
D. soakaways
1. The Contractor shall complete and submit to the Engineer for approval a
standard record sheet of every property connection.
2. The Contractor shall carry out a survey of existing facilities and prepare
individual sketch plans at 1:500 scale for each property for which a sewerage
connection is required. These shall show existing plot boundaries, location of
property and location of all affecting services including septic tanks. These
shall be marked up to show the details of the proposed service connection and
shall be submitted to the Engineer for approval. No service connection work
shall begin before approval to the proposed layout has been received in
writing from the Engineer.
3. In special cases only, an inspection chamber may serve more than one service
connection. Locations of inspection chambers and the layout of service
connections shall be as approved by the Engineer.
4. Service connections shall be laid at sufficient depths to allow for adequate
gradient being continued throughout the properly drainage system without
the pipelines becoming too shallow for adequate cover to be provided over
the pipe.
1. Service connections shall be laid up to the property boundary and an end cap
with a marker post shall be provided at the termination of each service
connections. The Contractor shall produce accurate records of the exact
locations of all service connections.
1. Steps shall be thoroughly cleaned and given a protective coal tar epoxy
coating. The cleaning shall be done by suitable means to ensure that the
surfaces to be coated are free from foreign matters. After the steps have
been cleaned, rinsed and dried, apply the coating and allow drying before
installing in concrete.
2. Installation of steps shall not begin until concrete receiving them has attained
its sufficient strength. Embedment into walls shall be as recommended by the
manufacturer; no shrink cement formulation shall be used for pointing.
3. Steps shall be located to provide a continuous vertical distance from the
manhole rim to the top surface of the bottom slab at intervals of 300 mm, plus
or minus 40 mm and shall be installed in a manner to be capable of
withstanding a force of 160 kgs applied on the step at any place and in any
direction with no permanent deformation.
a. Slope of invert bench: 1 inch per foot minimum; 1-1/2 inches per foot
maximum
b. Depth of bench to invert:
c. Invert slope through manhole: 0.10 foot drop across manhole with
smooth transition of invert through manhole, unless otherwise
indicated on Construction Drawing.
2. Form invert channels with concrete if not integral with manhole base section.
3. For direction changes of mains, construct channels tangent to mains with
maximum possible radius of curvature. Provide curves for side inlets and
smooth invert fillets for flow transition between pipe inverts.
1. Manhole covers shall be ductile iron and comply with EN 124. Production
facilities shall be quality assessed in accordance with ISO 9000 or EN 29002 BS
5750).
2. Manhole covers for sewerage, surface water and treated sewage effluent
systems shall have the following words embossed in both English and Arabic,
respectively:
A. Install sanitary sewer service lines to point of connection within approximately 1500
mm outside of buildings where service is required and make connections. Coordinate
the invert and location of the service line with the Contractor installing the building
lines.
B. Connections of service line to building piping shall be made after the new sanitary
sewer system has been constructed, tested, and accepted for operation by the
Resident Engineer. The Contractor shall install all temporary caps or plugs required
for testing.
C. When building services have not been installed at the time when the sanitary sewer
system is complete, provide temporary plugs or caps at the ends of all service lines.
Mark the location and depth of the service lines with continuous warning tape
placed 300 mm above service lines
A. Inspect and obtain the Resident Engineer's approval. Thoroughly flush out before
inspection. Lamp test between structures and show full bore indicating sewer is true
to line and grade. Lips at joints on the inside of gravity sewer lines are not
acceptable.
3.7 TESTING
A. General
1. The Contractor shall submit for the Engineer’s approval details of his proposed
methods and program for testing (including details of test equipment) and
shall arrange for all test to be witnessed by the Engineer or other person
appointed by the Engineer. Test equipment shall be approved by the Engineer
and calibration certificates when requested by the Engineer shall be
submitted. The Contractor shall provide all equipment necessary for carrying
out testing and cleaning including pumps, gauges, piped connections, stop
ends, and all other temporary works. All water required for testing and
cleaning the pipelines shall be from a source approved by the Engineer.
2. Pipelines shall be adequately restrained before being put under test except as
hereinafter detailed. No testing will be permitted until seven days after thrust
blocks and other holding down works have been completed. Trenches may
not be left open at joints before testing pipelines except as permitted by the
Engineer who may lay down certain restricting conditions. In addition to any
tests of individual joints or other interim tests which may be designated
elsewhere, the Contractor shall submit all parts of the pipelines to a final test.
3. All pipelines shall be tested between manholes or valve chambers not
exceeding 400 m.
4. On completion of testing the section of pipeline shall be properly sealed to
prevent the intrusion of any extraneous matter, until connected to the
pipeline network. The seal should be fitted with a valued vent to allow
B. Air 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 100 mm water
gauge is indicated on a manometer connected to the system. After the
internal pressure of 100 mm water gauge is obtained, 5 min shall be allowed
for the air temperature to stabilize within the pipe
3. Air may be added to restore the pressure to 100 mm water gauge. During a
further period of 5 min, the pressure shall not fall below 75 mm water gauge
without further pumping.
C. Water Test
D. Infiltration Test
1. The upper ends of the sewer and service connections shall be closed
sufficiently to prevent the entry of water and pumping of groundwater shall be
discontinued until the groundwater surface reaches its natural level before
beginning the infiltration test
2. The dewatering system shall be stopped, but not be removed until the
infiltration test has been successfully completed or as otherwise permitted by
the Engineer
3. The infiltration shall not exceed 6 liters per millimeter diameter per kilo meter
per day of the portion of sewer being tested, including the length of service
connection entering that section
4. The total length tested in one section shall not exceed 400 m in length. This
length is dependent upon the type of deflection measuring equipment
proposed by the Contractor if flexible pipes are used
1. The pipeline shall be tested between valve chambers or into sections not
exceeding 400 m in length approved otherwise by the Engineer. The section
tests shall be carried out as follows:
a. Each pipeline or section thereof shall be filled with water and all air
removed as far as possible
b. The pressure shall then be raised by pumping in water until the test
pressure is reached and shall be maintained at this level by further
pumping until it is steady
c. Pumping shall then be stopped and the time taken for the observed
pressure to fall by 1.0 m shall be recorded
d. Pumping shall then be resumed and the quantity of water pumped in
order to restore the test pressure shall be recorded
e. If after three hours the test pressure has not fallen by 1.0 m, pumping
shall be resumed at that stage, the time being recorded as three hours
f. The rates of loss shall then be calculated as the recorded quantity
divided by the recorded time
g. The test pump and gauge shall be connected to the pipeline at a
location other than the highest point in the pipeline to facilitate release
of air from the highest point
h. The test pressure shall be such that the entire pipeline or section being
tested is subjected to 1.5 times the working pressure, 1.25 times the
maximum surge pressure or 800 kPa, whichever is the greatest
i. The loss shall not exceed 0.02 liters per mm diameter per kilo meter per
24 hours for each 0.1 MPa of head applied
j. If the pipeline fails to pass the test, the faults shall be located and
repaired and the pipeline retested until it passes the pressure test. All
exposed pipe, fittings, valves and joints shall be visually inspected
during the tests.
2. When all sections have been joined together after completion of section
testing, unless otherwise directed by the Engineer, the entire pipeline shall
than be subjected to final test as follows:
a. All joints between individual test sections shall be left uncovered during
this final test
b. The final test shall be carried out using the same procedure as the
section test
c. In all cases of water tests, where the measured leakage rate exceeds
the allowable, the Contractor shall, at his own expense, make all
necessary repairs and carryout additional testing until a satisfactory
result is obtained
d. Before pressure testing is started the Contractor shall recheck pipes and
valves for cleanliness and shall recheck the operation of all valves. The
1. 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. The structure shall be filled with
fresh water and shall stand for a period of three days, to allow for absorption.
The structure shall be considered satisfactory if, subsequent to this period,
there shall be no fall in level over a period of 24 hours (after making the
allowance for rainfall and evaporation) and there shall be no visible leaks, or
damp surface areas.
2. This shall be carried out before any backfilling and before the application of
any external concrete protection has taken place. Any damages revealed as a
result of such tests shall be made good to the satisfaction of the Engineer.
SPECIFICATION REV.
ECG ENGINEERING CONSULTANTS GROUP STROM WATER COLLECTION
KSA NETWORKS 334100- 2970 1
SECTION 334100
Page
PART 1 GENERAL 2
1.1 Related Documents 2
1.2 Description Of Work 2
1.3 Reference Standards 2
1.4 Submittals 8
1.5 Quality Assurance 9
1.6 Delivery, Storage, And Handling 10
PART 2 PRODUCTS 13
2.1 Warning Tapes 13
2.2 Geotextile 14
2.3 Pipe And Fittings 14
2.4 Anchorage 22
2.5 Grout 23
2.6 Storm Drainage Structures 23
2.7 Nonpressure-Type Pipe Couplings 29
2.8 Flap Valve 30
2.9 Pitching-Stone Fabrication 31
2.10 High Density Polyethylene Liner (Hdpe) 32
2.11 Pipe Outlets 35
PART 3 EXECUTION 35
3.1 General 35
3.2 Joints 38
3.3 Pipe Laying 39
3.4 Manholes And Special Structures 47
3.5 Testing 54
3.6 Riprap 57
3.7 Storm Water Inlet And Outlet Installation 58
PART 1 GENERAL
A Drawings and general provisions of the Contract, including General and Supplemen-
tary Conditions and Division 01 Specification Sections, apply to this Section.
B Related Sections:
A This section covers gravity pipes, pressure pipes work for the conveyance of storm
water as indicated on Drawings and specified here in addition to all types of storm
structure such as manholes, slow down chambers, catch basins, soak away and in-
spection chambers as required by the Contract. Extent of these structures is indicat-
ed on Drawings.
B The Contractor shall provide equipment, materials, transportation and labor required
for proper construction of the structures
A The work shall be performed in strict accordance with the stipulations of the National
Water Company (NWC) Latest Edition, British Standard Specifications (BS) and the
American Standards (ASTM) as noted herein below or other equivalent approved
Standards and Sound Practice.
ISO NO.
ISO 4633 Rubber seals-Joint rings for water supply, drainage and sewerage
pipelines -- Specification for materials
ISO 4435 Unplasticized poly (vinyl chloride) (PVC-U) pipes and fittings for
buried drainage and sewerage systems – Specifications
ASTM NO.
ASTM D 2583 Indentation hardness of rigid plastics by means of a Barcol Im-
presser.
ASTM D 638 Standard Test Method for tensile properties of Plastics.
D2466 Specifications for Poly Vinyl Chloride (PVC) plastic Pipe Fittings,
Schedule 40
D1784 Standard specification for rigid Poly Vinyl Chloride (PVC) com-
pounds and chlorinated poly Vinyl Chloride (CPVC)
D3034 Standard specifications for type PSM (PVC) sewer pipe and fit-
tings.
AWWA C908 2001 PVC self-tapping saddle trees for use on PVC pipe (revi-
sion of ANSI/AWWA C908-97)
AWWA C909 Standard for Molecularly Oriented Polyvinyl Chloride (PVCO)
Pressure Pipe, 4 In. Through 24 In. (100 mm Through 600
mm), for Wastewater Service
ASTM NO.
AWWA C 950 Glass Fiber Reinforced Thermosetting Resin Pressure Pipe.
AWWA M 45 Manual of water supply practiced. Fiber glass pipe design.
BS 65 - 1991 Vitrified clay pipes, fittings and ducts, also flexible mechanical
joints for use solely with surface water pipes and fittings
BS EN 295-5:1994 Vitrified clay pipes and fittings and pipe joints for drains and
sewers.
ASTM NO.
ASTM C 425 Specification for Compression Joints for Vitrified Clay Pipes and
Fittings.
ASTM C 700 Specification for Vitrified Clay Pipes Extra Strength, Standard
Strength and Perforated
BS No.
ASTM NO.
A82 Specification for Steel Wire, Plain, for Concrete Reinforcement
A185 Specification for Steel Welded Wire, Fabric, Plain, for Concrete
Reinforcement
A497 Specification for Steel WELDED wire Fabric, Deformed for Con-
crete Reinforcement
A615/A615 Specification for Deformed and Plain Billet-Steel Bars for Con-
crete Reinforcement
C14M Specification for Concrete Sewer, Storm Drain, and Culvert Pipe
(Metric)
C618 Specification for Fly Ash and Raw or Calcined Natural Pozzolan
for Use as a Mineral Admixture in Concrete
ASTM NO.
IS0 4633, Rubber Seals - Joint Rings For Water Supply, Drainage and
Sewage Pipelines - Specification for Materials.
AWWA 651 Disinfecting water mains
ASTM D 2412 Standard Test Method for Determination of External loading
characteristics of Plastic pipe by Parallel plate loading.
ASTM D 2290 Standard Test Method for Apparent Tensile Strength of ring or
tubular plastics and reinforced plastics by Split Disk Method.
ASTM D 2584 Standard Test Method for Ignition Loss of cured Reinforced
Resins.
ASTM D 3517 Specification for Fiberglass Pressure Pipe
ASTM NO.
ASTM D1599 Standard Test Method for Resistance to Short-Time Hydraulic Pres-
sure of Plastic Pipe, Tubing, and Fittings
ASTM D2412 Determination for External Loading Characteristics of Plastic Pipe by
Parallel Plate Loading
ASTM D2657 Standard Practice for Heat Fusion Joining of Polyolefin Pipe and Fit-
tings
ASTM D 3350 Standard Specification for PE Pipe & Fittings Materials
ASTM D 3261 Butt Heat Fusion PE Fittings for PE Pipe & Tubing
Outside Diameter
ASTM F 894 Specification for Polyethylene (PE) Large Diameter Profile Wall
Sewer and Drain Pipe.
ISO No.
BS No.
BS 8005 Sewerage Guide to New Sewerage Construction
BS 5750 Quality assurance in productions and installation
BS 5911 Specification For Inspection chamber and street gullies
BS EN 124 Manhole Covers, Road Gully Grating and Frames
BS 1247 Manhole Step Irons
1.4 SUBMITTALS
A Pipes
1. Material technical specifications list and manufacturer’s data of the pipes in-
clude its jointing material (rubber gaskets), fittings/ accessories, bedding ma-
terial and geo-textiles.
2. Material Certificates of compliance.
3. Materials Sample.
4. Method statement of pipelines construction.
Storm Utility Drainage Piping Section 334100
Riyadh Sedra 2 (Prj. 2970) (Prj.1856) Page 8 of 58
5. Shop drawings.
6. Record drawings.
7. Maintenance data.
8. Certificates of origin.
B Storm Structure
1. Detailed design and calculations for different types of storm water structures
and storm water chambers.
2. Shop drawings for all types of cast-in-situ concrete structures and chambers
3. Materials list, original catalogue, certificate of origin and manufacturer's data
sheet of the ductile iron frames, covers, steps, grout, waterproofing of the
storm water structure.
4. Representative samples of the ductile iron frames, covers and steps.
5. Method statement of the storm water structure.
6. Shop drawings of the ductile iron frames and covers installation.
7. Shop drawings of the steps installation.
8. Record drawings of each structure.
A Products Criteria
1. Multiple Units: When two or more units of the same type or class of materials
or equipment are required, these units shall be products of one manufacturer
2. Nameplates: Nameplate bearing manufacturer's name, or identifiable trade-
mark, including model number, securely affixed in a conspicuous place on
equipment, or name or trademark, including model number cast integrally
with equipment, stamped, or otherwise permanently marked on each item of
equipment.
3. Comply with the rules and regulations of the National Water Company having
jurisdiction over the connection to Public Sanitary Sewer lines and the exten-
sion, and/or modifications to Public Utility Systems.
B Inspection
1. Inspection and Test by the Manufacturer: Pipe and fittings shall be thoroughly
inspected by the manufacturer before delivery. The manufacturer shall make
all tests as specified herein and the results of the tests shall be furnished to
the Contractor upon request in accordance with mutually acceptable ar-
rangements. The manufacturer may use his own or other suitable facilities for
the performance of the inspection and test requirements specified herein. On
the sample pieces selected for inspection, the inside diameter of the spigot
end shall be checked by suitable gauges. Fittings shall be suitably inspected for
soundness and brittleness.
2. Inspection and Test by the Contractor: Inspection and tests may be made at
the manufacturer plant or at other suitable facilities. If made at the place of
manufacture, the manufacturer shall provide, without charge, all reasonable
facilities to be determined that the material is in accordance with this specifi-
cation.
3. Contractor's Responsibility: The Contractor shall furnish materials, equipment,
Storm Utility Drainage Piping Section 334100
Riyadh Sedra 2 (Prj. 2970) (Prj.1856) Page 9 of 58
transportation services and skilled experienced. Laborers necessary to com-
plete the work as indicated or as required. The Contractor shall be responsible
to complete the work in accordance with the Specifications and Drawings in-
cluding details related to this section and necessary works for complying with
requirements contained therein. Contractor shall grantee and be responsible
for keeping all other existing utilities working in healthy conditions. Any dam-
age –caused by the contractor- to the existing utilities shall be repaired on the
contractor cost. Moreover, contractor shall be claimed accordingly.
C Testing:
1. Materials and installed work may require testing and retesting at any time dur-
ing the progress of work. Tests, including retesting of rejected materials or in-
stalled work, shall be done at the Contractor's expense.
D Rejection:
A Each pipe, fitting and special appurtenance shall be marked with permanent identifi-
cation which shall include but not necessarily limited to the following:
1. Nominal diameter
2. Name or trade mark of manufacturer
3. Serial number
4. Class of pipe, pressure rating in compliance with referenced standards
5. Date of manufacture
6. Type of service
7. Details on fittings such as angle of change and taper
B The acceptability of the pipes and fittings on delivery to the Site will be based on the
results of tests carried out by one or more of the following:
C The Engineer shall be permitted at all reasonable times to visit places of manufacture
to witness tests.
D Transport, handling and storage of pipes and fittings shall be carried out as follows:
E During transport
1. All pipes, fittings and materials shall be stored in accordance with the ap-
proved manufacturer’s recommendations and the following:
a. Pipes may be stored in the open on a flat level area and raised above the
ground on timber bearers so that the lowest point of any pipe or fitting
is not less than 150 mm above the ground
b. Timber bearers not less than 200 mm wide and 75 mm thick to be pro-
vide d at 4 m intervals maximum
c. If on pallets or crated, on the pallets or in their crates until required
d. If not on pallets or not crated, stacked one above the other as follows:
e. In accordance with the manufacturer’s recommendations but not to a
greater number of tiers than the following:
2. Suitable protective packing shall be placed between tiers to the approval of the
Engineer
3. Wrapped pipes shall not be stacked
a. If spigot and sock et, stacked so that successive pipe layers have sockets
protruding at opposite ends of the stack
b. With pipes of different sizes and thickness stacked separately
c. With maximum height of stacked pipes not exceeding 2m, or that rec-
ommended by the supplier if less than 2 m.
d. Plastic pipes will be stored under cover and not exposed to the sunlight.
a. Under cover
b. Rubber ring gaskets shall
5. Pipes and fittings shall be protected in storage to the approval of the Engineer
by means of an impermeable membrane which shall cover the pipes and fit-
tings and separate them from the ground on which they are supported. The
membrane shall be strong and durable in the prevailing climate conditions.
6. Pipes and fittings shall be subject to visual inspections after off-loading at site
and before installation.
7. The following procedures shall be followed for dealing with damaged pipes
and fittings:
A Service protection tapes shall be installed above all Storm pipelines and pressure
mains constructed or exposed under this contract excluding individual service con-
nections.
B Tapes shall be durable and detectable by electro-magnetic means using low output
generator equipment. They shall remain legible and color-fast in all soil conditions at
pH values of 2.5 to 11.0 inclusive.
C The tape shall be 150 mm wide and 250 micron thick and produced as a strong com-
posite laminate consisting of: -
D The thickness of the tape (250 micron / 1000 gauge) shall be measured in accordance
with BS 2782: Part 6. Method 630 A.
a. MD : 450%
b. TD : 550%
a. The tape shall be remaining legible and color 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 pre-
sent in sub soil and water, oil, 5% Acetic Acid, 5% NaOH and Alcohol mix,
if any.
a. Text in Arabic and English indicating the protected services lying below
Storm Utility Drainage Piping Section 334100
Riyadh Sedra 2 (Prj. 2970) (Prj.1856) Page 13 of 58
the tape shall be permanent ink bonded to resist prolonged chemical at-
tack by corrosive acids and alkalis with the message repeated at a maxi-
mum interval of two meters. Tapes shall be color coded as follows, with
black text as indicated. The sign and styles of the text shall be approved
by the Engineer
2.2 GEOTEXTILE
2. The equivalent opening size for the non-woven fabric used shall be 70 to 100
U.S. Std. Sieve (ESD) in accordance with ASTM D422 and the Corps of Engi-
neers Classification CW-02215-77. The water flow rate shall be a minimum of
194 I/sec/m2 as determined by ASTM D737 and the coefficient of permeability
shall be a minimum of 0.30 cm/sec.
3. The grab tensile strength shall be a minimum of 90 kg (200 lbs) and the grab
tensile elongation shall be a minimum of 60 percent as measured by ASTM
D1682.
4. The burst strength as measured by the Diaphragm Method of ASTM D3786
shall be a minimum of 25 kg/cm2 (360 psi). The minimum trapezoid tear
strength shall be 34 kg (75 lbs) in accordance with ASTM D1117.
5. The puncture resistance of the geo textile measured with 8 mm hemispherical
tip in accordance with Method ASTM D3787 shall be a minimum of 43 kg (95
lbs).
6. The material shall be resistant to rot, mildew, aging, rodents, and insects. The
geo-textile shall withstand the abuses of placement by men and equipment
without tearing or being punctured.
7. Geo textile shall be inert to acids and alkalis within a pH range of 3 to 13.
8. The geo textile shall be resistant to ultraviolet light exposure based on testing
in accordance with ASTM D4355.
1. General
a. The material from which pipe, fitting and accessories is produced shall
consist of substantially un-plasticized polyvinyl chloride. Only those ad-
ditives that are needed may be used for the manufacture of the poly-
mer, and for its conversion into sound, durable extrusions or molding of
Storm Utility Drainage Piping Section 334100
Riyadh Sedra 2 (Prj. 2970) (Prj.1856) Page 14 of 58
good surface finish, mechanical strength and opacity.
b. UPVC pipes shall not be deteriorated or broken down under the effect of
bacteria or other micro-organisms.
c. Shall be as uniform as commercially practical in color, opacity, density
and other physical properties.
d. The pipes, fittings and accessories shall have a registered certification
mark on, or in relation to a product, as an assurance that the goods have
been produced under the scheme of supervision control and testing in
accordance with the certification mark scheme. Fittings and accessories
shall comply with ASTM D 2466.
e. Shall be recommended as conduits for the conveyance of potable water
or other liquids as specified.
f. Shall have chemical inertness and exceptionally smooth internal surface
preventing the formation of deposits and ensuring better flow rate.
g. Shall have long service life, resistance to chemicals and excellent corro-
sion resistance.
h. Shall be of great mechanical resistance to external and internal loadings.
i. Shall have the property of absorption of linear expansion or contraction,
thereby preventing eventual pipe distortions.
j. Shall have absolute tightness at the jointing points regardless of whether
there is an over or under-pressure in the network.
k. Properties of pipes shall meet the requirements of the physical, chemi-
cal and mechanical characteristics as mentioned hereinafter.
2. Properties:
f. Chemical Characteristics:
g. Mechanical Characteristics:
3. Marking:
1) Manufacturer’s Name
2) Nominal Size
3) Class Pressure Rating
Storm Utility Drainage Piping Section 334100
Riyadh Sedra 2 (Prj. 2970) (Prj.1856) Page 16 of 58
4) Identification Code
4. Jointing
5. Lubricant
a. Shall be the type recommended by manufacture for use with the em-
ployed pipes and no substitute is allowed.
6. Certification
B GLASS REINFORCED PLASTIC PIPES (GRP) (according project condition and preferred
for diameter greater than 315 mm)
1. General
2. Reinforcement:
a. The glass used for the manufacture of the reinforcement shall be one of
the following types:
3. Wall construction
a. Inner layer
b. Structural layer
c. Outer layer
1) The design of the outer layer of the pipe shall take into account
the environment in which the pipe is to be used. This layer shall
be formed of a thermosetting resin with or without aggregates or
fillers and with or without a reinforcement of glass or synthetic
filaments.
Storm Utility Drainage Piping Section 334100
Riyadh Sedra 2 (Prj. 2970) (Prj.1856) Page 18 of 58
2) The of use special constructions is permitted when the pipe is ex-
pected to be exposed to extreme climatic, environmental or
ground conditions, for example provision for the inclusion of pig-
ments or inhibitors for extreme climatic conditions or fire retarda-
tion.
d. Appearance
a. Flexible joint
b. Rigid joint
1) Which does not allow relative movement between the pipes being
joined, these types of joint are:
a. Categories
b. Nominal size
1) The nominal size (DN) of pipes and fittings shall conform to the
appropriate Tables in Clause 5 BS 14364. If a thermoplastics liner
is present, its internal diameter shall be declared by the manufac-
turer. The tolerance on the diameter shall be as specified in
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Riyadh Sedra 2 (Prj. 2970) (Prj.1856) Page 19 of 58
Clause 5 BS 14364.
c. Nominal stiffness
500 2500
630 4000
1000 5000
1250 8000
2000 10000
e. Pipes of nominal stiffness less than SN 1000 are not intended for laying
directly in the ground.
g. Nominal pressure
Nominal pressure
(PN)
1 12.5
2.5 16
4 20
6 25
10 32
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Riyadh Sedra 2 (Prj. 2970) (Prj.1856) Page 20 of 58
NOTE: Components marked PN1 are non-pressure (gravity) components.
3) Stiffness shall be minimum 5000 N/m2 for all pipes but for pipes
to be used in pumping stations and valve chambers the stiffness
shall be minimum 10,000 N/m2 and pipes for use in micro-
tunneling or similar jacking operations the stiffness shall be mini-
mum 50,000 N/m2 unless enclosed in concrete.
1) Test certificates for all type tests and other tests specified in this
Clause shall be submitted to the Engineer.
2) The results of type tests appropriate to the proposed pipes and
fittings shall be used to determine the properties of pipes. Each
type test shall have been carried out on pipes or fittings repre-
sentative of the pipes to be used. The following type tests shall be
conducted at the manufacturer’s works in accordance with the
requirements of BS 5480 Part 2 except as noted, and the tests
shall be carried out at 25°C.
Impact resistance
Long-term hoop tensile
External pressure resistance ASTM D2924
Strain corrosion test ASTM D3681
2.4 ANCHORAGE
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Riyadh Sedra 2 (Prj. 2970) (Prj.1856) Page 22 of 58
A. Anchorage lugs shall be provided for socket and spigot fittings and socket clamps and
tie rods used where there is a possibility of pulling the joint under pressure. Con-
crete thrust blocks shall be used in lieu of the above where socket and spigot pipe is
used below ground. The Contractor shall submit, for the Engineer’s approval, work-
ing drawings and information demonstrating the adequacy of anchorage systems
other than thrust blocks or other systems shown on the Contract Drawings.
2.5 GROUT
1. Material:
a. Fine Aggregate
b. Coarse Aggregate
d. Water
1) Water for concrete, mortar and curing shall comply with BS 3148.
2) All water used in concrete & mortar shall be clear, fresh water free
from oil, acids, alkali, sugar, vegetable substances, or any other con-
taminating agent.
3) If required by the Engineer, Contractor shall provide water quality test
results.
4) Non-potable water shall not be used in concrete unless written ap-
proval to do so is granted by the Engineer.
e. Concrete:
f. Concrete Blocks
2) All mortar shall consist of one part masonry cement to three parts
loose sand complying with the following requirements:
a. Sand complying with ASTM C144, grading and coloring suitable for
type of masonry and as approved by the Engineer.
3) Black annealed wire used as reinforcing steel, but not including tie
wire, in structures as shown on the plans, shall be commercial quality
black annealed wire of the gauge
1. General:
2. Sealant Materials:
1. All manhole drop connections shall be outside drop. Outside drops shall be
provided with same pipe material and classification as main pipe lines as indi-
cated in the standard drawings.
2. Y connection shall be provided with same pipe material as main pipe lines and
with the same pipe classification as indicated in the standard drawings
D Step Irons
1. Step Iron
2. Steel Ladders
3. GRP Ladders
a. GRP material for ladders shall be fabricated from structural quality fiber-
glass shapes with chemical and ultraviolet resistance. Resin shall be all
vinyl ester. Glass shall be all ECR and GRP thickness shall be a minimum
5 mm. The top surface shall be provided with a non-slip silica sand fin-
ish. The structural components shall have Class I fire retardance, with an
ASTM E84 flame spread rating of 25 maximum. Fiberglass components
shall have an ultimate tensile strength of 20 7 MPa, an ultimate com-
pressive strength of 207 MPa, a modulus of elasticity of 20.7 GPa, and a
Barcol hardness of 50.
b. All cut or trimmed edges of the GRP ladder and braces shall be flow
coated with an approved vinyl ester resin. Glass fibres shall not be ex-
posed.
1. Manholes:
a. Ductile iron kite marked to BS EN124 Class D400 solid top circular
hinged access cover and frame , opposite cover parts block at 90, the
covers are removable from the frame horizontally or vertically after re-
moving the metal safety pins. Circular frame over all flanged with an-
choring holes that can be used to fix the frame.
b. The cover should be freely removed from the frame at suitable opening
angle. The cover should be also equipped with a safety mechanism to
maintain the cover safely locked when opened at suitable vertical angle.
c. Warm applied black bitumen coat (paint) to BS 3416 and special coats
for protecting covers.
d. All covers shall be non-rock preventing noise and vibration.
e. Clear opening dimensions shall be as indicated on drawings.
f. Each cover should be badged with:
2. Soakaway
a. Ductile iron kite marked to BS EN124 Class C250 solid top circular
hinged access cover and frame , opposite cover parts block at 90, the
covers are removable from the frame horizontally or vertically after re-
moving the metal safety pins. Circular frame over all flanged with an-
choring holes that can be used to fix the frame.
b. The cover should be freely removed from the frame at suitable opening
angle. The cover should be also equipped with a safety mechanism to
maintain the cover safely locked when opened at suitable vertical angle.
c. Warm applied black bitumen coat (paint) to BS 3416 and special coats
Storm Utility Drainage Piping Section 334100
Riyadh Sedra 2 (Prj. 2970) (Prj.1856) Page 27 of 58
for protecting covers.
d. All covers shall be non-rock preventing noise and vibration.
e. Clear opening dimensions shall be as indicated on drawings.
f. Each cover should be badged with:
3. Catch Basin
a. Catch Basin Grating Cover and Frame: Ductile iron kite marked to BS
EN124 Class C 250 Hinged grate inlet type, grating should be of the sin-
gle type without cover. The grating should be fixed to the overall
flanged frame using suitable hinges. The hinges system should allow for
free removing of the grating from frame.
c. Warm applied black bitumen coat (paint) to BS 3416 and special coats
for protecting covers.
d. The cover should be freely removed from the frame
e. Warm applied black bitumen coat (paint) to BS 3416 and special coats
for protecting covers.
a. Ductile iron kite marked to BS EN124 Class D400 grating top circular
hinged access cover and frame , opposite cover parts block at 90, the
covers are removable from the frame horizontally or vertically after re-
moving the metal safety pins. Circular frame over all flanged with an-
choring holes that can be used to fix the frame.
b. The cover should be freely removed from the frame at suitable opening
angle. The cover should be also equipped with a safety mechanism to
maintain the cover safely locked when opened at suitable vertical angle.
c. Warm applied black bitumen coat (paint) to BS 3416 and special coats
for protecting covers.
d. All covers shall be non-rock preventing noise and vibration.
e. Clear opening dimensions shall be as indicated on drawings.
F Protective Coating:
B Sleeve Materials:
C Unshielded Flexible Couplings: Elastomeric sleeve with stainless-steel shear ring and
corrosion-resistant-metal tension band and tightening mechanism on each end.
D Shielded Flexible Couplings: ASTM C 1460, elastomeric or rubber sleeve with full-
length, corrosion-resistant outer shield and corrosion-resistant-metal tension band
and tightening mechanism on each end.
E Ring-Type Flexible Couplings: Elastomeric compression seal with dimensions to fit in-
side bell of larger pipe and for spigot of smaller pipe to fit inside ring.
a. Manufacturer's name
b. Product identification
c. Thickness
d. Roll number
e. Roll dimensions
a. Thickness
b. Density
c. Tensile properties
d. Tear resistance
e. Carbon black content
f. Carbon black dispersion.
H Conformance Testing:
a. Thickness
b. Density
c. Tensile properties
d. Tear resistance
e. Carbon black content
2. These conformance tests shall be performed in accordance with the above ta-
ble.
3. All conformance test results shall be reviewed by Engineer and accepted or re-
jected, prior to the placement of the geo-membrane. All test results shall
meet, or exceed, the property values listed in the above table. In case of fail-
ing test results, the manufacturer may request that another sample be retest-
ed by the independent laboratory with manufacturer's technical representa-
tive present during the testing procedures. This retesting shall be paid for by
the manufacturer. The manufacturer may also have the sample retested at
two different laboratories approved by the Owner. If both laboratories report
passing results, the material shall be accepted. If both laboratories do not re-
port passing results, all geo-membrane material from the lot representing the
failing sample will be considered out of specification and rejected.
A General
1. Flap valves of GRP designed for ease of installation due to their low weight but
with exceptional mechanical strength and durability
2. GRP Flap Valves shall comply with the following:-
3. The design of the valve body shall be such that there is adequate clearance
around the back of the door to minimize jamming by rags and debris. Stops
shall be provided to limit the back lift of the disc and shall be positioned to
prevent fouling.
B Material Specification
1. The CONTRACTOR may propose alternative types of check valves with all nec-
essary data to demonstrate an advantage to ENGINEER. The alternative pro-
posal will be evaluated during tender evaluation
A Riprap Slope protection: Stone for loose and grouted riprap shall consist of field
stones furnished in broad flat shapes to the maximum extent practicable and as indi-
cated in the design.
B All stone shall be hard, sound, durable, and highly resistant to weathering and shall
be suitable as protection material for the intended purpose.
C Samples of the stone material proposed for use in the Works shall be submitted to
the Ministry representative for approval prior to its use in the Work.
D The minimum apparent specific gravity shall be 2.5 and the maximum absorption
shall be 6% when tested in accordance with AASHTO T 85. The stone shall have an
abrasion loss not greater than 45% when tested in accordance with AASHTO T 96.
E Unless otherwise specified and approved by the Ministry representative, the weight
of stone for the various classes of riprap shall be as follows:
G Stones for wire fabric enclosed riprap and for gabions, shall conform to Class A grada-
tion.
H Stone for loose riprap shall be quarried, fractured, or otherwise predominantly angu-
lar. Stone for other riprap and gabions may be rounded (boulders) or angular.
A General
a. Properties
5. The geo-membrane rolls shall meet the minimum properties as per manufac-
turer recommendation and below table
Test
2
Property Unit Method Minimum
Thickness
1
Thickness mm avg. ASTM D5199 1.52 (60 mil)
Storm Utility Drainage Piping Section 334100
Riyadh Sedra 2 (Prj. 2970) (Prj.1856) Page 32 of 58
1
Thickness mm min. ASTM D5199 1.37 (54 mil)
1
(Each Direction) ASTM D638
3. Elongation
at Yield % min. 13
4. Elongation
at Break % min. 150
Dimensional
Stability % max. ASTM D1204 +2.0
1 hour @ 1080
Environmental
1
Stress Crack Hours min. ASTM D5297 1500
Carbon Black
Content % range ASTM D4218 2.0 to 3.0
Carbon Black
1
Dispersion N/A rating ASTM D5596 A1, A2, or B1
1) This value represents the minimum acceptable test value for a roll
as tested according to Manufacturing Quality Control Manual.
b. Other Materials
a) Manufacturer's name
b) Product identification
c) Thickness
d) Roll number
e) Roll dimensions
a) Thickness
b) Density
c) Tensile properties
d) Tear resistance
e) Carbon black content
f) Carbon black dispersion.
d. Conformance Testing
a) Thickness
b) Density
c) Tensile properties
d) Tear resistance
e) Carbon black content
A Head Walls: Cast-in-place reinforced concrete, with apron and tapered sides as indi-
cated in the drawing and as per Division 03 Concrete.
B Riprap Basins: Broken, irregular size and shape, graded stone according to NSSGA's
"Quarried Stone for Erosion and Sediment Control."
D Filter Stone: According to NSSGA's "Quarried Stone for Erosion and Sediment Con-
trol," No. FS-2, No. 4 screen opening, average-size, graded stone.
E Energy Dissipaters: According to NSSGA's "Quarried Stone for Erosion and Sediment
Control," No. A-1, 2700-kg average weight armor stone, unless otherwise indicated
PART 3 EXECUTION
3.1 GENERAL
1. The Employer may employ the services of a specialist firm to assist the Engi-
neer as he may require in any matter connected with pipes, and fitting includ-
ing the inspection of materials and workmanship and the witnessing of tests at
any stage during the execution and maintenance of the Works.
2. Such independent tests may be carried out at any stage during the execution
and maintenance of the Works, but they shall not relieve the Contractor of his
obligations under the Contract.
3. To the extent ordered by the Engineer, the Contractor shall provide labour,
plant, tools and materials (but not special testing equipment) for direct assis-
tance to the specialist firm in their inspection and independent testing and for
any further work, investigations, and repairs which the Engineer considers
necessary as a result of such inspection or testing.
4. The provision of labor, plant and materials a s aforesaid shall be an obligation
of the Contractor where in the Engineer’s opinion the inspection test or fur-
Storm Utility Drainage Piping Section 334100
Riyadh Sedra 2 (Prj. 2970) (Prj.1856) Page 35 of 58
ther investigation shows that materials and workmanship provided by the
Contractor do not comply with the designated requirements.
1. Where designated in the Project Specification, the Contractor shall carry out a
soil corrosivity study along the route of proposed ferrous pipelines as directed
by the Engineer and mark the results on the pipeline layout plans.
2. Soil resistivities shall be undertaken using a low resistance, null -balance earth
tester and a four pin array, or any other equipment approved by the Engineer.
Readings shall be recorded in ohm-cm and shall be taken at 1.0 m incremental
depths to a depth 1 m below the pipeline invert levels. Readings shall be tak-
en at spacing along the route of the proposed pipelines as required to reflect
the changing soil conditions, but in no case shall the spacing exceed 500 m.
3. Soil samples shall be taken as directed by the Engineer along the route of the
proposed pipelines at a maximum spacing of 500 m. Soil samples shall be
tested for sulphates, sulphides, chlorides, pH, moisture content, and car-
bonates.
1. All storm pipe lines shall be laid accurately to the lines, and levels gradients
shown on the approved drawings so that the pipeline is straight between suc-
cessive manholes in the vertical and horizontal planes.
2. Pressure pipelines shall be laid accurately to the lines levels and depths shown
on the approved drawings. Where changes of direction are required, deflec-
tions shall be made in accordance with the manufacturer’s recommendations.
1. The Contractor shall supply all necessary tools for cutting, chamfering, jointing,
and testing and for any other requirement for satisfactory installing the pipe-
lines.
1. Pipes and fittings including any sheathing, inside linings and outside coatings,
shall be inspected by the Contractor immediately before and after installation,
and damage or other imperfection shall be repaired by the Contractor as di-
rected by the Engineer before installation and in accordance with the follow-
ing:
a. Material required for the repair of pipe, sheathing, linings and coatings
shall be obtained by the Contractor and shall be used in accordance with
the manufacturers recommendations
b. Without relieving the Contractor of any of his obligations, the Engineer
may inspect and test the pipe and appurtenances by any appropriate
means, and damage discovered by such inspection shall be repaired by
the Contractor
c. The Contractor shall remove from Site any pipe or appurtenance which
in the opinion of the Engineer is so damaged as to be unfit for incorpora-
tion in the Works. The obtaining of replacements for damaged pipes
Storm Utility Drainage Piping Section 334100
Riyadh Sedra 2 (Prj. 2970) (Prj.1856) Page 36 of 58
and fittings to the approval of the Engineer shall be an obligation of the
Contractor.
F Dewatering
1. For the purpose of reducing the angular deflections at pipe joints, and for clo-
sure sections, the Contractor will be permitted to install pipe sections of less
than standard length. Closing lengths and short sections of pipes of all types
shall be fabricated and installed by the Contractor as found necessary at Site.
Where closing pieces are required, the Contractor shall make all necessary
measurements and shall be responsible for the correctness thereof. The Con-
tractor shall be responsible for taking the measurements required to deter-
mine the lengths of cut portions of pipes for insertion as closing lengths in
pipelines.
H Cutting of Pipes
1. Where pipes are required to be cut on the Site the cutting shall be done by the
Contractor in accordance with the manufacturer’s recommendations and in a
manner approved by the Engineer.
2. The pipe and methods of jointing shall be such that the locations of fittings
and lengths of pipe can be adjusted to suit Site conditions.
3. Cutting of reinforced concrete pipes will not be allowed. Special lengths of
pipes shall be manufactured for closures as required. Other pipes such as
GRP, ductile iron, vitrified clay, MDPE, HDPE, PVC-U and cast iron pipes shall
only be cut if approved by the Engineer.
4. The cutting of vitrified clay pipes, MDPE, HDPE, PVC-U, and ductile iron pipes
for inserting specials, fittings or closure pieces shall be carried out as follows:
I Stringing of Pipes
1. After excavations have been completed to the designated levels and, trench
formation compacted, the Contractor shall issue a formal notice to the Engi-
neer that the trench formation is ready between designated points for inspec-
tion. The Engineer will without unreasonable delay inspect the said trench
formation, unless he considers it unnecessary and advises the Contractor ac-
cordingly. Any rejection of trench formation will be confirmed in writing by
the Engineer.
3.2 JOINTS
1. Immediately before assembling each joint incorporating a rubber ring seal, the
rubber shall be inspected for cracks, every part of the ring being deformed by
hand to about l50 mm radius. If under this deformation any cracks are either
revealed or initiated the ring shall be rejected, cut through completely to pre-
vent inadvertent use, or the matter reported forthwith to the Engineer. If
more than three successive rings inspected in this way are rejected the Con-
tractor shall on the instruction of the Engineer stop all pipe jointing until the
cause of the defect has been proved and remedied to his satisfaction.
2. The rubber ring shall be placed in the groove on the socket or spigot ring. The
groove shall be free of deleterious material; e.g., dirt, moisture, oil, and
grease. The inside surface of the socket shall be lubricated with a compound
recommended by the manufacturer which will facilitate the telescoping of the
joint. The spigot end of the pipe shall then be inserted into the socket of the
adjoining pipe using a suitable tool to push the spigot into the socket. The po-
sition of the pipe and the gasket in the joint shall then be checked using a
feeler gauge to demonstrate proper jointing. When joints are not properly
made, pipes shall be adjusted, or removed and rejointed as necessary to en-
sure proper jointing. Care shall be taken to avoid twisting or cutting the ring
when jointing the pipe.
B Mechanical Joints:
1. Anchorage lugs shall be provided for socket and spigot fittings and socket
clamps and tie rods used where there is a possibility of pulling the joint under
pressure. Concrete thrust blocks shall be used in lieu of the above where
socket and spigot pipe is used below ground. The Contractor shall submit, for
the Engineer’s approval, working drawings and information demonstrating the
adequacy of anchorage systems other than thrust blocks or other systems
shown on the Contract Drawings.
A General
1. Except as otherwise specified in this Clause, pipe bedding shall conform to the
requirements specified in 31 00 00 EARTHWORK. The Contractor shall, after
excavating the trench and preparing the proper bedding, furnish all necessary
facilities for properly lowering and placing sections of the pipe in the trench
without damage and shall properly install the pipe.
2. Each pipe shall be carefully lowered onto its prepared bed by means of appro-
priate slings and tackle. A recess shall be left in the prepared bed to permit
the sling to be withdrawn. If the prepared bed is damaged, the pipe shall be
raised and the bed made good before pipe laying is continued.
3. No pipe shall be rolled into place for lowering into the trench except over suit-
able timber planking free from roughness likely to damage any coatings.
4. The section of pipe shall be fitted together correctly and shall be laid true to
line and grade in accordance with the bench marks established by the Con-
tractor. The bench marks shall be approved by the Engineer.
5. The full length of the barrel of the pipe shall have a uniform bearing upon the
bedding material and if the pipe has a projecting socket, suitable excavation
shall be made to receive the socket which shall not bear on the subgrade.
6. Pipes shall be laid with the class identification marks or the jointing marks
shown by the manufacturer in the uppermost position. Pipe sections shall be
so laid and fitted together that the pipeline will have a smooth and uniform in-
terior. The pipeline shall be clean and unobstructed at the time of its installa-
tion and shall be true to the required line and levels.
7. Spigot and socket pipes shall generally be laid upgrade without break from
structure to structure and with the socket end upgrade. Back laying may be
permitted as deemed necessary and approved by the Engineer.
8. Whenever work ceases on any pipeline the unfinished end of the pipeline shall
be securely closed with tight fitting plug or cover.
9. Before any pipe is lowered into place, the bedding shall be prepared and well
compacted so that each length of pipe shall have a firm and uniform bearing
over the entire length of the barrel.
10. Pipes shall be laid in straight lines, both in the horizontal and vertical planes,
between manholes or, where directed in the case of pressure pipelines and
larger diameter pipes to regular curves. The placement of pipes shall comply
with the following requirements:
11. Each pipe shall be plumbed to its correct line and directly and accurately sight-
ed by means of a laser positioning system or boning rods and sight rails fixed
to secure posts which shall be set up and maintained at each end of the sewer
Storm Utility Drainage Piping Section 334100
Riyadh Sedra 2 (Prj. 2970) (Prj.1856) Page 39 of 58
to be laid and not more than 20 m apart. Sight rails shall be clearly painted in
contrasting colors and be not less than l50 mm deep, straight and level
12. Boning rods shall be of robust construction clearly painted and accurately
made to the various lengths required, the lower end being provided with a flat
edged shoe of sufficient projection to rest on the invert of the pipes as laid.
The boning rod shall be complete with a vertical spirit level
13. Boning rods and sight rails shall not be removed until the pipeline has been
checked and approved by the Engineer
14. Alternative methods of locating and leveling pipelines may be allowed subject
to the approval of the Engineer
15. Any pipe which is not in true alignment, both vertically and horizontally, or
shows any undue settlement after laying, shall be taken up and relaid correct-
ly by the Contractor
16. All adjustments in line and grade shall be made by scraping away or filling and
tamping in under the barrel of the pipe and not by wedging or blocking
17. The trench shall be kept completely dry
18. In no case shall pipes be jointed before being lowered into position
19. The gasket should be positioned and lubricated.
1. This clause does not apply to GRP pipes for which laying requirements are giv-
en in this Section.
2. All operations involving the laying, bedding, jointing, backfilling etc. of pipes of
plastic materials shall be strictly in accordance with the manufacturer’s rec-
ommendations subject to the approval of the Engineer.
3. The pipes shall be laid and bedded in granular bedding material except where
concrete bedding or protection is required. The granular material shall extend
from not less than l50 millimeters beneath the pipes to l50 millimeters above
the crown of the pipes or as approved by the Engineer. Subsequent filling of
the pipe trench shall be carried out as detailed in this Section of the Specifica-
tion.
1. In trench pipes with flexible joints except where concrete bed, bed and sur-
round or protection is required shall be laid on a well compacted bed of granu-
lar material extending for the full width of the trench and with sufficient mate-
rial at the sides to permit the pipes to be worked into the granular material
and firmly supported to true line and level. Sufficient space should be left to
enable the joints to be made tested and inspected but the Contractor shall en-
sure that at least three quarters of the pipe length is fully supported. After the
pipeline has been tested and approved by the Engineer the trench shall be
carefully filled to 300 mm above the crown of the pipe with granular material
in accordance with the bedding requirements specified in Part 2 of this Section
and as shown on the Drawings.
1. If any defective pipe is discovered after it has been laid, it shall be removed
and replaced with a sound pipe in a satisfactory manner by the Contractor, at
his own expense. All pipe and fittings shall be thoroughly cleaned before lay-
Storm Utility Drainage Piping Section 334100
Riyadh Sedra 2 (Prj. 2970) (Prj.1856) Page 40 of 58
ing, shall be kept clean until they are used in the work, and when laid, shall
conform to the lines and grades required. PVC pipe and fittings shall be in-
stalled in accordance with requirements of the manufacturer except as other-
wise provide herein. As soon as the excavation is complete to normal grade of
the bottom of the trench, sand shall be placed as shown on the drawings,
compacted and graded to provide firm, uniform and continuous support for
the pipe. Bell holes shall be excavated so that only the barrel of the pipe
bears upon the bedding. The pipe shall be laid accurately to the lines and
grades indicated on the Drawings. Blocking under the pipe will not be permit-
ted. Sand shall be placed evenly on each side of the pipe to mid-diameter and
hand tools shall be used to force the sand bedding material under the
haunches of the pipe and into the bell holes to give firm continuous support
for the pipe. Sand shall then be placed to 300 mm above the top of the pipe.
The initial 900 mm of backfill above the bedding material shall be placed in
300 mm layers and carefully compacted. Generally the compaction shall be
done evenly on each side of the pipe and compaction equipment shall not be
operated directly over the pipe until sufficient backfill has been placed to en-
sure that such compaction equipment will not have a damaging effect on the
pipe. Equipment used in compacting the initial 900mm of backfill shall be ap-
proved by the pipe manufacturer's representative prior to use.
2. All pipe shall be sound and clean before laying. When laying is not in progress,
including lunchtime, the open ends of the pipe shall be closed by watertight
plug or other approved means. Good alignment shall be preserved in laying.
The deflection at joints shall not exceed that recommended by manufacturer.
3. When cutting pipe is required, the cutting shall be done by machine, leaving a
smooth cut at right angles to the axis of the pipe. Cut ends of pipe to be used
with a bell shall be beveled to conform to the manufactured spigot end.
4. Buried PVC pressure pipe shall be snaked along the trench to provide for ex-
pansion and contraction in accordance with manufacturer's recommenda-
tions.
5. The 100 mm PVC perforated pipe shall be installed in a trench with aggregate
filter media to a minimum depth of 500 mm. The aggregate filter media shall
have a minimum of 300 mm in thickness under the pipe and 100 mm over the
top of the pipe. Aggregate filter media shall have no fines smaller than 20 mm
and shall be covered with filter fabric before backfilling with soil.
6. Jointing PVC Pipe
7. Push-on type joints shall be made in strict accordance with the manufacturer's
instructions. Pipe shall be laid with bell ends looking upstream. A rubber gas-
ket shall be inserted in the groove of the bell end of the pipe, and the joint
surfaces cleaned and lubricated. The plain end of the pipe to be entered shall
then be inserted in alignment with the bell of the pipe to which it is to be
joined, and pushed home with a come-along or by other means. Check that
the reference mark on the spigot end is flush with the end of the bell.
a. Laying of Reinforced Concrete Pipes
Horizontal Alignment
All pipes + 50 mm
11. Some settlement of the pipe is expected during backfill operations; however,
the Contractor shall take the steps necessary to limit the total settlement from
the installed elevation to a maximum of 3 percent of the internal pipe diame-
ter. Differential settlements shall be limited such that the joints remain sealed,
the pipe or manhole is not damaged and the pipe installation is capable of
meeting the testing requirements specified herein.
12. Crushed stone shall be placed and compacted to give complete vertical and
lateral support for the lower section of the pipe as indicated on the Drawings.
A depression shall be left in the supporting bedding at the joint to prevent con-
tamination of the rubber gasket immediately before being forced home. Be-
fore the pipe is lowered into the trench, the spigot and bell shall be cleaned
and free from dirt. Gasket spigot and bell shall be lubricated by a vegetable
lubricant which is not soluble in water, furnished by the pipe manufacturer,
and harmless to the rubber gasket. The pipe shall be properly aligned in the
trench to avoid any possibility of contact with the side of the trench and foul-
ing the gasket. As soon as the spigot is centered in the bell of the bell of the
previously laid pipe, it shall be forced home with jacks or come-along. After
the gasket is compressed and before the pipe is brought fully home, each gas-
ket shall be carefully checked for proper position around the full circumference
of the joint. Steel inserts shall be used to prevent the pipe from going home
until the feeler gauge is used to check the final position of the gasket. The
jacks or come-along shall be anchored sufficiently back along the pipeline (a
minimum of 5 lengths) so that the pulling force will not dislodge the pieces of
pipe already in place. Only a jack or come-along shall be employed to force the
pipe home smoothly and evenly and hold the pipe while backfilling is in pro-
gress. Under no circumstances shall crowbars be used nor shall any of the mo-
tor driven equipment be used.
13. As soon as the pipe is in place and before the come-along is released, crushed
stone backfill shall be placed as indicated on the Drawings and packed carefully
by hand under the haunch of pipe for the length of pipe. Not until this backfill
is placed shall the come -along be released. If any motion at joints can be de-
tected, a greater amount of backfill shall be placed before pressure is released.
When pipe laying is not in progress, the open ends of the pipe shall be closed
by a watertight plug, bulkhead or other approved means. Precautions shall be
taken during this period to prevent flotation of the pipe.
Storm Utility Drainage Piping Section 334100
Riyadh Sedra 2 (Prj. 2970) (Prj.1856) Page 42 of 58
14. Carefully regulate equipment and construction operations such that the load-
ing of the pipe does not exceed the loads for which the pipe is designed and
manufactured. Any pipe damaged during construction operations shall
promptly and satisfactorily be repaired or replaced at the Contractor's ex-
pense.
15. The interior joints of all pipes shall be filled with non-shrinking grout after the
backfilling and testing is completed. Grout shall consist of one part by volume
of cement, 1-1/2 parts by volume of sand, conforming to ASTM C33 and 1/4
part by volume of EMBECO metallic aggregate or equal. The mixture shall have
a dry, crumbly consistency and shall be pounded into place and toweled to
make a smooth joint.
1. Where shown on the Drawings or directed by the Engineer, pipe shall be en-
cased, haunches or backfilled with concrete.
6. WYE Branches:
7. Riser Pipe:
a. Where the cover on the wye branch is in excess of twelve feet below av-
erage ground surface, a 45 degree bend and sufficient riser pipe (also in-
stalled at a 45 degree slope) shall be added to terminate at a depth of
twelve feet below the ground surface, provided the property being
served will not require additional depth.
8. Closures
a. Where no riser pipe or lateral is installed with the wye branches, the
outlet of each wye branch shall be securely sealed with a restrained wa-
ter tight closure that can be later removed without damage to the out-
Storm Utility Drainage Piping Section 334100
Riyadh Sedra 2 (Prj. 2970) (Prj.1856) Page 44 of 58
let.
b. PVC: All closures at the ends of PVC wye branches, risers or service lat-
erals shall be made by installing a length of PVC pipe to the wye branch,
riser or service lateral and solvent cementing PVC cap to the spigot end.
A sufficient length of pipe should be installed to permit removal of the
closure and extending the line in the future. Mechanical plugs shall not
be permitted.
c. All closures shall be capable of passing the storm piping leakage test(s).
9. WYE Poles
a. A wye pole shall be placed at the end of each wye branch, riser, or house
service, as the case may be, extending to a point 6 inches below the end
of the pipe to hold it firmly in position during backfilling. If the wye pole
is pulled out, bent, or broken, the CONTRACTOR shall, at no cost replace
or straighten the pole. The wye pole shall be adjacent to the end of the
pipe but not above it or against it.
b. Material: Wye poles shall be not less than a standard 2 x 4 and shall ex-
tend a minimum of 3 feet above the finished grade. The material used
for wye poles shall be in good condition and shall be straight, sound and
free from large or loose knots
H Backfilling
11. The protection and filling of headings shall be of Grade 20 SRC concrete.
12. Where concrete slab protection to GRP and PVC-U pipelines is required such
protection shall extend a minimum of 200 mm either side of the pipe trench.
The slab shall be of reinforced concrete as shown on the Drawings.
I Deflection at Joints
J Cleanliness of Pipelines
1. Pipelines and manholes shall at all times be kept free of all silt1 mortar1 debris
and other obstructions. When work is not in progress the open ends of the
pipeline shall be securely plugged with an approved watertight plug or stopper
firmly fixed to resist unauthorized removal. Claw type plugs or any type liable
to damage the pipe shall not be used. All such stoppers1 plugs or caps shall be
provided with a vent incorporating a valve for the purpose of testing whether
Storm Utility Drainage Piping Section 334100
Riyadh Sedra 2 (Prj. 2970) (Prj.1856) Page 46 of 58
the pipeline is under pressure or vacuum and to enable pressures to be equal-
ized before its removal.
2. The Contractor shall clear the inside of each fitting and pipe length immediate-
ly before jointing and shall swab all fittings and pipe lengths to remove all
dirt1 sand or other matter that may clog the pipeline or contaminate the fluid
to be transported in the pipeline. After j ointing1 the interior of the pipes
shall be freed from any dirt, stones or other matter that may have entered
them. For this purpose, a rubber disc, brush, or other suitable implement that
will not harm the internal lining of the pipe shall be pulled through the pipe af-
ter jointing.
K Marker Tape
1. All trenches for pressure pipelines, shall be marked with a high quality acid and
alkali - resistant red non bio-degradable plastic tape with a minimum width of
150 mm placed during backfilling 300 mm below finished surface or as di-
rected by the Engineer.
2. All tapes shall be clearly marked in black lettering with “STORM WATER” All
non-ferrous pipelines shall have marker tape with tracer wire.
A General
1. The Contractor shall construct all chambers and special structures as indicated
on the drawings and herein specified.
2. Soakaway, catch basin and special structures shall conform in shape, size, di-
mensions, materials, and other respects to the details indicated on the draw-
ings or as ordered by the Engineer.
1. All Soakaway, chambers, catch basin and special structures shall have rein-
forced-concrete bases as detailed on the drawings. Bases for storm-sewers
less than 600 mm and bases for chambers may be recast or cast in place at the
Contractor's option and as approved by the Engineer. For precast reinforced-
concrete manhole bases, openings for pipes if any 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.
2. Soakaway, chambers and catch basin cover slabs shall be cast in place rein-
forced concrete as marked on the drawings. The ductile iron frames and co-
vers for chambers shall be brought to grade by the number of courses of con-
crete blocks shown on the drawings or as instructed by the Engineer and a re-
inforced concrete frame into which the ductile iron frame is embedded.
3. The ductile iron frames, grates and covers shall be to the BS EN 124 standard
frame, grate and cover as indicated on the drawings and hereinafter specified
in this Section.
4. Catch Basin walls shall be plain Class A concrete formed to the shape and
thickness shown on the drawings by the use of sound formwork material to
give a fair faced finish.
Storm Utility Drainage Piping Section 334100
Riyadh Sedra 2 (Prj. 2970) (Prj.1856) Page 47 of 58
5. PVC/GRP lining to internal wall /or with a brush-applied bituminous emulsion
as indicated in the drawing. Lining shall incorporate lugs molded onto the out-
side face at 500 mm centers to allow bonding to the concrete surround. The
lining shall have adequate strength to withstand handling, and shall not buckle
or distort during pouring of the concrete surround. Internal bracing may be
used during pouring of the concrete surround. Internal bracing may be used
during pouring to maintain circularity and verticality.
6. The external (buried) surfaces shall be protected in accordance with Corrosion
Protection and Odor Control Section either with water-proof membrane with
protection board or with a brush-applied bituminous emulsion as indicated in
the drawing.
7. Pipes entering and leaving manholes, chambers and special structures shall be
laid soffit to soffit unless otherwise shown on the drawings.
8. All construction joints to chambers and special structures shall be perfectly
watertight. Water stop across joints in structures as specified shall be provid-
ed where detailed in the drawings or as directed. Joints shall be fully scrab-
bled.
9. Chambers shall be completely constructed as the Works progress and as each
one is reached by the pipe work. Frames and covers shall be placed immedi-
ately after the completion of the manhole and chamber.
10. Soakaways for storm drainage shall be constructed with concrete masonry
bricks.
11. Vertical joints between the bricks shall be left open and shall not receive any
mortar and shall be according to the dimensions shown in drawings.
12. The soakaway shall be surrounded with a graveller hard core backfill to pre-
vent clogging.
13. The filter shall be protected by a non-woven geotextile membrane of 1.0 mm
minimum thickness as shown on drawings. The membrane shall be of best
quality as per Terram or equivalent.
14. Catch basin shall be according to dimensions and details in Drawings.
15. Catch basin cover slabs shall be surmounted by ductile cast iron grating
top/solid top covers and frames of the quality specified; frame will be rested
on RC slab.
16. Unless otherwise indicated on drawings one cast iron trap shall be installed at
each pipe outlet for the catch basin.
1. Examination:
2. Placement:
D Soakaways
1. Soakaways shall be constructed using precast concrete rings. Concrete
works shall comply with the requirements (concrete section) of the speci-
fication. Concrete shall be grade C40 for the precast concrete rings and the
cover slab, using Moderately Sulphate Resisting Portland Cement.
2. The cover slab shall be of the dimensions and contain the reinforcement as
shown on the drawings .
3. The structural concrete shall be designed for durability and shall include as
a minimum the following specification:
5. The precast concrete rings shall be at least 150 mm thick and shall have
three evenly spaced lifting points.
6. No permanently embedded metal parts shall be left with a cover less than
40 mm from the surface. The precast rings shall be constructed with 50
mm diameter holes at 400 mm centres in rows spaced 300 mm apart. The
holes shall be alternately offset.
9. The granular material shall be laid in tamps in 150 mm layers and shall
nowhere be less than 225 mm in width.
10. The granular material shall be clean crushed rock from a source approved
by the Engineer.
11. The nominal size shall be 75 mm. The material passing a 0.075mm sieve
shall not exceed 5%.
12. ductile iron covers and frames shall be to BS EN 124 of the designated
loading class B 125.
13. Filter fabric material lining to the outside of the soakaway excavation shall
be Terram, grade 1000 The placing and laying of the material shall be in
accordance with the manufacturer’s instructions and
14. The geotextile material shall not be left exposed to the sun for a period
greater than 7 days before burying.
1. The Contractor shall complete and submit to the Engineer for approval a
standard record sheet of every property connection.
2. The Contractor shall carry out a survey of existing facilities and prepare indi-
vidual sketch plans at 1:500 scale for each property for which a sewerage or
storm connection is required. These shall show existing plot boundaries, loca-
tion of property and location of all affecting services. These shall be marked
1. Service connections shall be laid up to the property boundary and an end cap
with a marker post shall be provided at the termination of each service con-
nections. The Contractor shall produce accurate records of the exact locations
of all service connections.
1. Steps shall be thoroughly cleaned and given a protective coal tar epoxy coat-
ing. The cleaning shall be done by suitable means to ensure that the surfaces
to be coated are free from foreign matters. After the steps have been cleaned,
rinsed and dried, apply the coating and allow drying before installing in con-
crete.
2. Installation of steps shall not begin until concrete receiving them has attained
its sufficient strength. Embedment into walls shall be as recommended by the
manufacturer; no shrink cement formulation shall be used for pointing.
3. Steps shall be located to provide a continuous vertical distance from the man-
hole rim to the top surface of the bottom slab at intervals of 300 mm, plus or
minus 40 mm and shall be installed in a manner to be capable of withstanding
a force of 160 kgs applied on the step at any place and in any direction with no
permanent deformation.
4. GRP ladders of an approved pattern as specified may be purpose made to suit
the depth of each manhole. Fixings for ladders shall be approved stainless
steel stud anchors. Fixing holes shall be grouted with epoxy mortar and sealed
as above. Rungs or treads shall be ribbed to provide a non-slip surface.
a. Slope of invert bench: 1 inch per foot minimum; 1-1/2 inches per foot
maximum
b. Depth of bench to invert:
3. For direction changes of mains, construct channels tangent to mains with max-
imum possible radius of curvature. Provide curves for side inlets and smooth
invert fillets for flow transition between pipe inverts.
1. Chambers covers shall be ductile iron and comply with EN 124. Production fa-
cilities shall be quality assessed in accordance with ISO 9000 or EN 29002 BS
5750).
2. Manhole covers for storm, surface water and treated storm effluent systems
shall have the following words embossed in both English and Arabic, respec-
tively:
3. Surface water: Drainage Surface Water
4. The size of lettering shall be approved by the Engineer.
5. The Contractor shall supply one pair of manhole keys or prying and lifting bar,
as appropriate with each 30 covers provided with a minimum of one tool for
each type cover. Keys and prying and lifting bars shall be of approved appro-
priate design to match the different cover configurations. Keyways in man-
hole covers shall be of the closed type.
6. Install frames and covers on top of drainage structure to positively prevent all
infiltration of surface or ground water into manholes. Frames shall be set in a
bed of mortar with the mortar carried over the flange of the ring. Set frames
so tops of covers are flush with surface of adjoining finish pavement surface.
Elsewhere set 50 mm above ground surface, unless otherwise shown or di-
rected.
7. The covers in paved areas shall be accurately set on precast concrete brick-
work to the level and slopes of the roads or pavements, to adjust cover level
as required.
8. The covers in landscape area areas shall be accurately set on precast concrete
brickwork to the level above the landscape by at least 100 mm above the
landscape level.
J Deflection at Joints:
K Cleanliness of Pipelines:
1. Pipelines and manholes shall at all times be kept free of all silt1 mortar1 debris
Storm Utility Drainage Piping Section 334100
Riyadh Sedra 2 (Prj. 2970) (Prj.1856) Page 53 of 58
and other obstructions. When work is not in progress the open ends of the
pipeline shall be securely plugged with an approved watertight plug or stopper
firmly fixed to resist un authorized removal. Claw type plugs or any type liable
to damage the pipe shall not be used. All such stoppers1 plugs or caps shall be
provided with a vent incorporating a valve for the purpose of testing whether
the pipeline is under pressure or vacuum and to enable pressures to be equal-
ized before its removal.
2. The Contractor shall clear the inside of each fitting and pipe length immediate-
ly before jointing and shall swab all fittings and pipe lengths to remove all dirt1
sand or other matter that may clog the pipeline or contaminate the fluid to be
transported in the pipeline. After j ointing1 the interior of the pipes shall be
freed from any dirt, stones or other matter that may have entered them. For
this purpose, a rubber disc, brush, or other suitable implement that will not
harm the internal lining of the pipe shall be pulled through the pipe after joint-
ing.
L Marker Tape:
1. All trenches for pressure pipelines, shall be marked with a high quality acid and
alkali - resistant red non bio-degradable plastic tape with a minimum width of
150 mm placed during backfilling 300 mm below finished surface or as directed
by the Engineer.
2. All tapes shall be clearly marked in black lettering with “STORM WATER” All
non-ferrous pipelines shall have marker tape with tracer wire.
3.5 TESTING
A General
1. The Contractor shall submit for the Engineer’s approval details of his proposed
methods and program for testing (including details of test equipment) and
shall arrange for all test to be witnessed by the Engineer or other person ap-
pointed by the Engineer. Test equipment shall be approved by the Engineer
and calibration certificates when requested by the Engineer shall be submit-
ted. The Contractor shall provide all equipment necessary for carrying out
testing and cleaning including pumps, gauges, piped connections, stop ends,
and all other temporary works. All water required for testing and cleaning the
pipelines shall be from a source approved by the Engineer.
2. Pipelines shall be adequately restrained before being put under test except as
hereinafter detailed. No testing will be permitted until seven days after thrust
blocks and other holding down works have been completed. Trenches may
not be left open at joints before testing pipelines except as permitted by the
Engineer who may lay down certain restricting conditions. In addition to any
tests of individual joints or other interim tests which may be designated else-
where, the Contractor shall submit all parts of the pipelines to a final test.
3. All pipelines shall be tested between manholes or valve chambers not exceed-
ing 400 m.
4. On completion of testing the section of pipeline shall be properly sealed to
prevent the intrusion of any extraneous matter, until connected to the pipe-
line network. The seal should be fitted with a valued vent to allow equaliza-
tion of pressure before removal.
Storm Utility Drainage Piping Section 334100
Riyadh Sedra 2 (Prj. 2970) (Prj.1856) Page 54 of 58
5. All flexible pipelines shall be tested for deflection as per this specification.
6. Storm water Pipelines
B Air 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 100 mm water
gauge is indicated on a manometer connected to the system. After the inter-
nal pressure of 100 mm water gauge is obtained, 5 min shall be allowed for
the air temperature to stabilize within the pipe
3. Air may be added to restore the pressure to 100 mm water gauge. During a
further period of 5 min, the pressure shall not fall below 75 mm water gauge
without further pumping.
C Water Test
1. All the joints of the pipeline shall be able to withstand a pressure of a mini-
mum 5 m head of water, above the crown of pipe at the highest point of pipe-
line without leakage. A layer of embedding soil equal to the diameter of pipe
shall be laid over the pipe to prevent the lifting of pipe while applying test
pressure. However, all the joints shall be left open for the purpose of inspec-
tion for leakage if any. All branches and open ends shall be closed with stop-
pers, secured with longitudinal braces/ thrust block, before testing begins.
2. Water shall be filled from the lowest point and air allowed to escape through
an air vent fixed for the purpose at the high points of the pipeline section un-
der test. The diameter of air vent shall be about one and ha lf times the diam-
eter of water inlet pipe to allow easy escape of air. No entrapped air shall re-
main in the pipeline while testing.
3. A pressure of 5 m head of water shall be maintained for one hour to allow ini-
tial absorption of water. After that the test pressure shall be maintained for 15
min and water added shall be measured. If water consumption in 15 min does
not exceed 0.1 l/m 2 of wetted inner pipe surface and if there are no visible
leakage through joints, the pipeline shall be treated as passed.
1. The upper ends of the storm and service connections shall be closed sufficient-
ly to prevent the entry of water and pumping of groundwater shall be discon-
tinued until the groundwater surface reaches its natural level before begin-
ning the infiltration test
2. The dewatering system shall be stopped, but not be removed until the infiltra-
tion test has been successfully completed or as otherwise permitted by the
Engineer
3. The infiltration shall not exceed 6 liters per millimeter diameter per kilo meter
per day of the portion of storm being tested, including the length of service
connection entering that section
4. The total length tested in one section shall not exceed 400 m in length. This
length is dependent upon the type of deflection measuring equipment pro-
posed by the Contractor if flexible pipes are used
5. No gravity pipeline will be accepted if the total infiltration exceeds the above
mentioned limit and joints will not be accepted if during an internal inspec-
tion, any infiltration is visible.
1. The pipeline shall be tested between valve chambers or into sections not ex-
ceeding 400 m in length approved otherwise by the Engineer. The section
tests shall be carried out as follows:
a. Each pipeline or section thereof shall be filled with water and all air re-
moved as far as possible
b. The pressure shall then be raised by pumping in water until the test
pressure is reached and shall be maintained at this level by further
pumping until it is steady
c. Pumping shall then be stopped and the time taken for the observed
pressure to fall by 1.0 m shall be recorded
d. Pumping shall then be resumed and the quantity of water pumped in
order to restore the test pressure shall be recorded
e. If after three hours the test pressure has not fallen by 1.0 m, pumping
shall be resumed at that stage, the time being recorded as three hours
f. The rates of loss shall then be calculated as the recorded quantity divid-
ed by the recorded time
g. The test pump and gauge shall be connected to the pipeline at a location
other than the highest point in the pipeline to facilitate release of air
from the highest point
h. The test pressure shall be such that the entire pipeline or section being
tested is subjected to 1.5 times the working pressure, 1.25 times the
maximum surge pressure or 800 kPa, whichever is the greatest
i. The loss shall not exceed 0.02 liters per mm diameter per kilo meter per
24 hours for each 0.1 MPa of head applied
j. If the pipeline fails to pass the test, the faults shall be located and re-
paired and the pipeline retested until it passes the pressure test. All ex-
posed pipe, fittings, valves and joints shall be visually inspected during
the tests.
a. All joints between individual test sections shall be left uncovered during
this final test
b. The final test shall be carried out using the same procedure as the sec-
tion test
c. In all cases of water tests, where the measured leakage rate exceeds the
allowable, the Contractor shall, at his own expense, make all necessary
repairs and carryout additional testing until a satisfactory result is ob-
tained
d. Before pressure testing is started the Contractor shall recheck pipes and
valves for cleanliness and shall recheck the operation of all valves. The
“open” ends of the pipeline or sections thereof) shall normally be
stopped off by blank flanges or cap ends additionally secured where
necessary by temporary struts and wedges. All anchor and thrust blocks
shall have been completed and all pipe straps and other devices intend-
ed to prevent the movement of pipes shall have been securely fastened
e. Since valves cannot be guaranteed to be perfectly drop-tight, testing
against closed valves which are connected to an existing system shall be
prohibited; testing against other closed valves (including air valves) not
so connected, may be attempted if desired, provided the valves are suit-
ably anchored against thrust. No claims whatsoever will be entertained
on account of leaking valves, or any other difficulties in closing off
lengths of pipework for testing, which shall be entirely an obligation of
the Contractor
f. On successful completion of the final test, the exposed joints shall be
covered and the trench backfilled
1. All water retaining structures shall be visually inspected to confirm that there
is no infiltration. Where it is required by the Engineer, water retaining struc-
tures shall be tested for water tightness. The structure shall be filled with
fresh water and shall stand for a period of three days, to allow for absorption.
The structure shall be considered satisfactory if, subsequent to this period,
there shall be no fall in level over a period of 24 hours (after making the al-
lowance for rainfall and evaporation) and there shall be no visible leaks, or
damp surface areas.
2. This shall be carried out before any backfilling and before the application of
any external concrete protection has taken place. Any damages revealed as a
result of such tests shall be made good to the satisfaction of the Engineer.
3.6 RIPRAP
A Graded stone bedding shall be placed, graded, and compacted to the thickness
shown on the drawings, to obtain a continuous uninterrupted bed within the limits
required for riprap.
B Light and heavy riprap shall be placed on the prepared bed to the thickness shown on
Storm Utility Drainage Piping Section 334100
Riyadh Sedra 2 (Prj. 2970) (Prj.1856) Page 57 of 58
the drawings. Spaces between stones shall be filled with spalls of suitable size to
construct a solid, stable slope, free from voids and defects which might not protect
the earth slopes against erosion.”
C Riprap shall be placed at locations indicated on the Drawings and other areas as di-
rected by the Engineer.
A Construct inlet head walls, aprons, and sides of reinforced concrete, as indicated in
the drawing and as per Division 03 Concrete
C Install outlets that spill onto grade, anchored with concrete, where indicated as indi-
cated on the drawings
D Install outlets that spill onto grade, with flared end sections that match pipe, where
indicated.
SPECIFICATION REV.
ECG ENGINEERING CONSULTANTS GROUP OVERHEAD ELECTRIC CRANES
KSA 412215.10- 2970 1
SECTION 412215.10
PART 1 - GENERAL 2
1.1 Summary 2
1.2 Submittals 2
1.3 References 3
1.4 Quality Assurance 5
1.5 Testing And Inspection 5
1.6 Delivery And Storage 6
1.7 Field Measurements 6
1.8 Stability 6
PART 2 - PRODUCTS 7
2.1 Materials 7
2.2 Structural Materials 7
2.3 Mechanical Equipment 9
2.4 Electrical Components 12
PART 3 – EXECUTION 16
3.1 Erection 16
3.2 Acceptance Testing 17
3.3 Schematic Diagrams 19
3.4 Manufacturer’s Field Service Representative 19
3.5 Field Training 19
3.6 Spare Parts 19
3.7 Acceptance 20
3.8 Equipment Schedule 20
PART 1 - GENERAL
1.1 SUMMARY
C. Crane Terminology
1. Top-running bridge is a bridge gantry, which travels on the top surface of rails
of a fixed runway structure.
2. Top-running Trolley is a trolley which travels on the top surfaces of rails of the
bridge girder(s).
1.2 SUBMITTALS
A. Product Data
B. Shop Drawings
a. Acceptance Testing: Test reports in booklet form showing all field tests
performed to adjust each component and all field tests performed to prove
compliance with the specified performance criteria, upon completion and
testing of the installed system. The report shall include the information as
required by paragraph ACCEPTANCE TESTING.
b. Operation and Maintenance Data: Operation and Maintenance Manuals six
copies of operation and six copies of maintenance manuals for the equipment
furnished. One complete set prior to performance testing and the remainder
upon acceptance. Operation manuals shall detail the step-by-step procedures
required for system startup, operation and shutdown. Operation manuals shall
include the manufacturer's name, model number, parts list, and brief
description of all equipment and basic operating features. Maintenance
manuals shall list routine maintenance procedures, possible breakdowns and
repairs, and troubleshooting guides. Maintenance manuals shall include piping
and equipment layout and simplified wiring and control diagrams of the
system as installed. Operation and maintenance manuals shall be approved
prior to the field-training course.
1.3 REFERENCES
A. The publications listed below form a part of this specification to the extent
referenced. The publications are referred to within the text by the basic designation
only.
AGMA 6009 (2000a) Standard for Gear motor shaft Mounted and Screw
Conveyor Drives
AGMA 6010 1997f) Standard for Spur, Helical, Herringbone, and Sevel
Enclosed Drives
AWS D14.1/D14.1M (2005) Welding Industrial and Mill Cranes and Other
Material Handling Equipment
ASME B30.17 (2006) Overhead and Gantry Cranes (Top Running Bridge,
Single Girder, Under hung Hoists)
ASME B30.2 (2005) Overhead and Gantry Cranes (Top Running Bridge,
Single or Multiple Girder, Top Running Trolley Hoist)
ASME HST-1 (1999; R 2004) Performance Standard for Electric Chain Hoists
ASME HST-5 (1999; R 2004) Performance Standard for Air Chain Hoists
ASME HST-6 (1999; R 2004) Performance Standard for Air Wire Rope Hoists
ASTM A 325 (2006) Standard Specification for Structural Bolts, Steel, Heat
Treated, 120/105 ksi Minimum Tensile Strength
CIAA 74 (2004) Top Running and Under Running Single Girder Electric
Overhead Cranes Utilizing Under Running Trolley Hoist, No. 74
NEMA ICS 6 (1993; R 2006) Standard for Industrial Controls and Systems
Enclosures
NEMA 14G 1 (2006; Errata 2007) Standard for Motors and Generators
UL 489 (2002; Rev thru Jun 2006) Standard for Molded-Case Circuit
Breakers, Molded-Case Switches and Circuit-Breaker Enclosures
B. Inspection of Steel Castings: Load carrying steel castings shall be visually inspected
and tested using the magnetic-particle inspection method. Allowable degree of
discontinuities shall be referenced to ASTM E125, and shall be related to service
loads and stresses, critical configuration, location and type. Methods of repairing the
discontinuities shall be subject to review by the Contracting Officer.
1. Classification
D. Rated Capacity and Speeds: Rated capacity of cranes shall be (2) metric tons or as
per design drawings. Lower load block or assembly of hook, swivel bearing sheaves,
pins and frame suspended by the hoisting ropes shall not be considered part of the
rated capacity. Rated speeds in meters/second for the hoist and trolley at the rated
load shall be as follows:
Rated Speeds
A. Equipment delivered and placed in storage shall be stored with protection from the
weather, humidity and temperature variations, dirt and dust, and other
contaminants Protect bearings and couplings against damage.
A. Before performing any work, Contractor shall become familiar with all details of the
work, verify all dimensions in the field, and submit a letter describing the results of
this verification including discrepancies to the Contracting Officer and crane
manufacturer.
1.8 STABILITY
A. The gantry crane shall have a minimum factor of safety of 1.25 against overturning
under each condition of loading stated in paragraph 3.3.2.4 of CMAA 70.
Counterweights shall be provided if necessary to obtain the required stability.
2.1 MATERIALS
C. Use of Asbestos Products: Materials and products required for designing and
manufacturing cranes shall not contain asbestos.
D. Capacity Plates: Two capacity plates indicating the crane capacity in metric tons and
tons are required, one secured to each side of bridge. Each capacity plate shall be
fabricated of a steel backing plate and exterior quality/fade-resistant stick-on labels
with letters large enough to be easily read from the floor. Capacity plates shall be
placed in a location visible to pendant operator's position after the crane has been
installed.
E. Safety Warnings: Readable warning labels shall be affixed to each lift block or control
pendant in a readable position in accordance with? ASME B30.16, ASME B30.2 and
ASME B30.17. The Contractor shall submit these safety warnings, diagrams and other
framed instructions for display as indicated by the Contractin Officer.
1. The word "WARNING" or other legend shall be designed to bring the label to
the attention of the operator. Warning labels shall be durable type and display
the following information concerning safe-operating procedures: Cautionary
language against lifting more than the rated load; operating the hoist when the
hook is not centered under the hoist; operating hoist with twisted, kinked or
damaged rope; operating damaged or malfunctioning hoist; operating a rope
hoist with a rope that is not properly seated in its hoist drum groove; lifting
people; lifting loads over people; and removing or obscuring the warning label.
2. To avoid operation of crane in the wrong direction, the words "FORWARD" and
"REVERSE" and accompanying directional arrows shall be affixed in a location
on the trolley and bridge which are visible and readable to the operator from
pendant station. The words "FORWARD" and "REVERSE" shall agree with the
markings on control pendant. Directional arrows shall not be indicated on
control pendant.
A. Bolts, Nuts and Washers: High-strength bolted connections shall utilize SAE Grade 5
bolts with corresponding lockwashers, nuts, etc., conforming to requirements of AISC
B. Girders: Bridge girders shall be wide flange beams, standard I-Beams, reinforced
beams or sections fabricated from rolled plates and shapes.
C. Bridge Rails: Trolley runway rails, crane girders and other sections shall be straight
and true. When loaded with motor driven cranes the deflection of rails shall not
exceed 1/800 of the span. The deflection shall be calculated with the worst case of
two loaded bridge cranes located adjacent each other. Rail joints shall be flush and
true without misalignment of running tread and shall be designed to minimize
vibration. The gap between adjacent rail ends and the vertical misalignment of
running treads shall not exceed 1.588 mm. The bridge rail shall be leveled to a plus-
or-minus 3 mm at all rail support joints. Bridge rail shall be fastened to wide flange
or offset near web plate for welded box sections complete with welded clips. Bridge
rail joints shall be bolted using standard joint bars. Rail joints shall be staggered. A
positive stop shall be provided at bridge rail ends to prevent creep.
D. End Ties and Bridge Girder End Connections: Welded steel box sections shall be used
for end ties, full depth diaphragms shall be provided at girder connections and
jacking points. Horizontal gusset plates shall be provided at the elevation of top and
bottom end tie flanges for connection to girder ends. End connections shall be made
with high-strength bolts. Body-bound bolts fitted in drilled and reamed holes shall be
used to maintain the crane square.
E. Bridge End Trucks: End trucks shall be the rotating or fixed axle type fabricated of
structural tubes or from structural steel to provide a rigid box section structure.
Jacking pads shall be provided for removal of wheel assemblies.
F. Trolley Frame: Trolley frame shall consist of two structural steel side frames or trucks
welded together with one or more structural steel load girts to form a one-piece unit.
Pads shall be provided for the use of jacks or wedges when changing truck wheels. All
trolley yokes and load bars shall be of drop forged, cast or rolled steel.
G. Stops and Bumpers: Crane runways and bridge girders shall be fitted with structural
steel end stops. Bridge end trucks and trolley frames shall be fitted with shock-
absorbing, spring type bumpers capable of decelerating and stopping the bridge
and/or trolley within the limits stated by OSHA and MHI CMAA. Trolley end stops
shall be of sufficient strength to withstand the impact of a fully loaded trolley moving
at 50 percent of maximum rated travel speed. When two bridge cranes are on the
same runway, one crane shall be fitted with shock-absorbing bumpers on each end of
each end-truck, and the other crane shall have shock-absorbing bumpers as per
above on one end only of each end-truck, which is the opposite end of the adjacent
crane. The other end of the end-truck shall be fitted with a structural steel stop to
engage the bumpers of the adjacent crane. Bridge bumper stops shall be provided as
specified in Section 05 12 00 STRUCTURAL STEEL. Stops shall be located to permit
maximum bridge and trolley travel.
H. Footwalks
A. Drives
B. Load Blocks
1. Main and Auxiliary Hoist Load Blocks: Load blocks shall be of welded steel
construction. Load blocks shall be provided with hot-rolled or forged steel
fixed crosshead separate from the sheave pin with swivel mounting for forged
steel hook. Each lubrication fitting for sheave pins shall be an independent
type recessed within the sheave pin or adequately guarded to prevent
damage. The pitch diameter of the sheaves shall be not less than 16 times the
rope diameter. Sheaves shall be supported by roller type bearings on steel
sheave pins. Provisions for external lubrication shall be provided to allow
pressure relief and purging of old grease. Sheave blocks shall be constructed to
provide maximum personnel safety and to prevent the hoist rope from leaving
the sheaves under normal operating condition.
2. Hook Assembly: Hooks shall be single barbed and shall be made of forged steel
complying with ASTM A 668/A 668M. Hook dimensions shall be as shown.
Hooks shall be fitted with safety latches designed to preclude inadvertent
displacement of slings from the hook saddle. Painting or welding shall not be
performed on the hook. Hook nut shall be secured with a removable type set
screw or other similar fastener, but shall not be welded. Hooks shall be
designed and commercially rated with safety factors in accordance with MHI
CMAA. The hook shall be free to rotate through 360 degrees when supporting
the rated load.
3. Hoisting Ropes: Hoisting ropes shall be regular lay, performed, uncoated,
improved plow steel, 6 by 37 construction, with independent wire rope core.
Ropes shall be suited to meet the service requirements. Rope socketing or U-
bolt clip connections shall be made in accordance with clip or rope
manufacturer's recommendation, and shall be equal to or greater than the
rope strength. Hoisting ropes shall be the rated capacity load plus the load
block weight divided by the number of rope parts, and shall not exceed 20
7. Brakes: Brakes shall be of the shoe, disc, or conical type with thermal capacity
suitable for class and service specified in this section. Shoe, disc, and conical
brakes shall be spring-set and electrically-released by a continuously rated
direct acting magnet. Brakes shall be self-aligning and provide for easy
adjustment for torque setting and lining wear. Brake lining material shall be
asbestos free. Brake wheels shall be cast iron conforming to ASTM A 159 or
shall be the manufacturer's standard high-strength ductile cast-iron, provided
that the material exhibits wear characteristics in the form of powdered wear
particles and is resistant to heat-checking. Disc brakes shall be totally enclosed
and have multiple discs with stationary releasing magnets. Brake torque shall
be easily adjustable over a 2:1 torque range.
A. General Requirements: Motors shall be designed specifically for crane and hoist
duty. Drain holes shall be provided at low points near each end. Inspection and
service covers shall be provided with gaskets. Hardware shall be corrosion-resistant.
Motors shall conform to the requirements of NFPA 70, NEMA MG 1 and UL 1004.
Motor heaters shall be energized when mainline contactor is de-energized, and
water heaters shall be de-energized when mainline contactor is de-energized. Motors
15 lÑ 20 HP and larger shall be provided with a suitable heater to prevent
condensation during long periods of inactivity. One thermal sensitive device
embedded in hoist motor windings shall be provided. Device and associated circuitry
shall serve as an alarm activating an amber signal or pilot light visible to control
stations when motor temperatures become excessive. Set point shall be set below
the Class B insulation temperature limit. Thermal-sensitive device and associated
circuits shall be self-restoring (automatic reset). Two-speed, two-winding motors
with a solid-state control will not be allowed for creep-speed use.
C. Motor Enclosures
D. Hoist Motor Insulation and Time Rating: Hoist motors shall be provided with
insulation which has a Class H rating based on an l25-degree C motor temperature
rise above 40 degrees C ambient, with frame size selection based on continuous
ratings.
E. Bridge and Trolley Motor Insulation and Time Rating: Bridge and trolley drive mtors
shall be provided with an insulation which has a Class H rating based on 125 degrees
C motor temperature rise above 40 degree C ambient with frame size selection based
on continuous rating.
F. Electric Brakes
A. Control System: A separate controller shall be provided for each motor, a duplex
type for 2-motor bridge drives and a quadraplex type for 4-motor bridge drives on ac
central cranes. When 2-motor bridge drives are furnished and dc magnetic control is
required, dc series-connected motors shall be provided. When 4-motor bridge drives
are furnished and dc magnetic control is required, dc series-parallel connected
motors shall be provided. Overload protection shall be in conformance with
requirements of NEMA ICS 2 and NFPA 70. When contractors are used for starting,
stopping and reversing, contractors shall be mechanically and electrically interlocked.
1. Control Panels: Control Panels shall be fabricated of solid sheet steel designed
and constructed to conform to requirements of NEMA ICS 6 type at or above 0
degrees C shall be provided in each static crane control panel. Control panel
heaters shall be energized when mainline contractor is de-energized, and shall
be de-energized when mainline contactor is energized to prevent anti-
condensation. Control panel doors shall be hinged, equipped with gaskets and
fitted with key-lock handle design, complete with a single key to open all locks.
2. Main Hoist Control
a. Hoist motor control system shall provide two speeds in each direction
with of an electrically-operated, full-magnetic, across-the-line reversing
type starter. Electrical and mechanical interlocks shall be used to
prevent the operation of high speeds and low speeds.
b. Hoist control system shall provide reversing, constant potential dc, five-
speed, dynamic lowering, variable-resistance, do magnetic control of do
series wound hoist drive motors. Full-load lowering speed shall not
exceed the following percentages of rated full-load hoisting speeds: 30
percent on first point; 205 percent on fifth speed point. First point
hoisting shall provide not more than 30 percent of rated-motor speed at
no-load motor torque, and zero speed (plus 5 percent, minus 0 percent
of rated speed) at not less than G0 percent of rated-motor torque.
Emergency dynamic speed at no-load motor torque. Emergency dynamic
a. Bridge and trolley main control systems shall provide two speeds in each
direction with an electrically-operated, full- magnetic, across-the-line
reversing type starter. Centrifugal switches shall be used in control
circuit to prevent the plugging of trolley or bridge drive motors; each
switch shall be arranged to set the associated drive's brake while
attempts are made to plug. The ridge and trolley main control system
shall be provided with reduced voltage starting for all speed points.
b. Bridge and trolley main control systems shall be dc magnetic control
type, five-speed, reversing, plugging type.
a. POWER-OFF
b. POWER-ON.
c. Hoist-up.
d. Hoist-down.
e. Trolley-left.
f. Trolley-right.
6. Light Indicators: Pilot lights shall meet heavy-duty requirements of NEMA ICS
2. One amber pilot light to indicate excessive hoist motor temperature shall be
provided on pendant station. A blue pilot light shall be provided to indicate
that the main contactor is energized, and a white pilot light to indicate that
power is available on the load side of crane disconnect switch. A bright red
mushroom head shall be provided with the POWER-OFF pushbutton. A 2-
position selector switch shall be provided to select between normal and micro-
drive. A single green pilot light shall be provided to indicate all micro-drive
1. Hoist Upper Limit-Switches: Two limit-switches shall be provided for each hoist.
A rotating-type adjustable geared-control circuit interrupt limit-switch shall
provide hoist-up limiting. A secondary hoist-upper-limit shall be provided with a
weight-operated power circuit limit-switch to prevent the hoist from raising
beyond the safe limit. The secondary limit-switch shall operate to interrupt
power to all hoist motor conductors, set the hoist holding brakes and directly
open all “raise” power circuits
2. Bridge and Trolley Travel Limit-Switches: Runway (track-type) limit-switches
shall be provided for crane bridge and trolley motions to stop the bridge and
trolley motions, respectively. Limit-switch actuators shall be installed on
building and trolley frame to actuate the limit-switches and stop the crane
bridge or trolley prior to contacting the trolley frame bumpers. Trip
mechanism for trolley motion shall be located on crane runway to trip the
switch before the bumper contacts the stop. Trip mechanism for bridge motion
shall be located on crane runway to trip switch before bumper contacts the
stop. When the switch is tripped, the switch shall permit opposite travel in the
direction of stop and then automatically reset.
A. Wiring: Wiring shall comply with Article 610 of NFPA 70. Wires shall be numbered or
tagged at connection points. Splices shall be made in boxes or panels on terminals
boards or standoff insulators. Motor loop, branch circuit and brake conductor
selection shall be based on NFPA 70 for 90 degree C conductor rating on indoor
cranes, and for 75 degree C conductor rating on outdoor cranes. Conductors in the
vicinity of resistors and conductors connected to resistors shall be Type 5RML.
PART 3 - EXECUTION
3.1 ERECTION
A. General: Contractor shall provide all personnel necessary to conduct the required
testing which shall include but not be limited to crane operators, riggers, rigging gear
and test weights. Testing shall be performed in the presence of Contracting Officer or
his designated representative. Contractor shall notify Contracting Officer 7 days prior
to testing operations. Contractor shall operate all equipment and make all necessary
corrections and adjustments prior to the testing operations witnessed by Contracting
Officer. A representative of the Contractor responsible for procuring and installing
hoist equipment shall be present to direct the field testing. Test loads shall be
compact and permit a minimum of 50 percent of vertical lift. Test loads shall be
minus 0 percent to plus 5 percent of the required weight and shall be verified prior to
testing. Operational testing shall not be performed until after building interior has
been painted. Three copies of all test reports shall be furnished to Contracting
officer.
2. No-Load Testing
3. Load Test
a. Hoist Static Load Test: Holding brakes and hoisting components shall be
tested by raising the test load approximately 300 mm 1 foot and
manually releasing one of the holding brakes. Load shall be held for 10
minutes. First holding brake shall be reapplied and second holding brake
released. Load shall be held for 10 minutes. Any lowering that may occur
indicates a malfunction of brakes or lowering components.
b. Dynamic Load Test: Test load shall be raised and lowered through the
full range operating in each speed. Machinery shall be completely
stopped at least once in each direction to ensure proper brake
operation.
c. Hoist Mechanical Load Brake: With test load raised approximately 1.5 m
5 feet and with the hoist controller in the neutral position, holding brake
shall be released. Mechanical load brake shall be capable of holding the
test load. With holding brake in released position, test load shall be
lowered first point and the controller shall be returned to OFF position
as the test load lowers. Mechanical load brake shall prevent the test
load from accelerating.
d. Hoist Loss of Power Test: After raising test load to approximately 2.5 m 8
feet, slowly lowering the test load, the main power source and control
pushbutton shall be released verifying that the test load will not lower
and that both brakes will set. Test shall be repeated using micro-drive
controls.
e. Trolley Dynamic Load Test: While operating the trolley the full distance
of bridge rails in each direction with test load on the hook (one cycle),
proper functioning of all primary drive and speed control points and
proper brake action shall be tested.
f. Bridge Dynamic Load Test: With test load on hook, bridge shall be
operated for the full length of runway in both directions with trolley at
each extreme end of bridge. Proper functioning of all primary drive
speed control points and brake action shall be verified. Binding of the
bridge end trucks shall indicate malfunction.
A. Trolley and Bridge Loss of Power Test: A test load of 100 to 105 percent of rated load
shall be raised clear of any obstructions on operating floor. Starting at a safe distance
from walls or other obstructions, a slow speed shall be selected using the trolley and
bridge primary drive. While maintaining a safe distance to obstructions, the main
power source shall be disconnected and brakes shall be verified to have set and that
the equipment stops within the distance recommended by manufacturer.
D. Grounding Test: Hoist shall be tested to determine that the hoist, including hook and
pendant, are grounded to building during all phases of hoist operation. The
grounding of bridge and trolley shall be tested with approximately 10 percent of
rated load on hook. Grounding shall be tested between hoist hook and the
structure's grounding system.
A. Contractor shall conduct a training course for e operating staff. Training period shall
consist of a total of hours at normal working time and shall start after the system is
functionally completed but prior to final acceptance. Course instructions shall cover
pertinent points involved in operating, starting, stopping, and servicing the
equipment, including all major elements of the Operation and Maintenance Manuals.
Course instructions shall demonstrate all routine maintenance operations such as
lubrication, general inspection; Contracting Officer shall be given at least 2 weeks
advance notice of field training.
A. Final acceptance of crane system will not be given until Contractor has successfully
completed all testing operations, corrected all material and equipment defects,
made all proper operation adjustments, and removed paint or over spray on wire
rope, hook and electrical collector bars.
CRANE SCHEDULE
Capacity (Ton) 2
Span (M). 10
Quantity Required 1