MOH-MOWE Sewer PDF

Table of Contents
PART 1:
GENERAL REQUIREMENT
Page
1
SECTION 1.01 FORMAT AND REFERENCING .............................................. 1

1.01.1 FORMAT OF SPECIFICATIONS .......................................................... 1
1.01.2 REFERENCING ..................................................................................... 2
SECTION 1.02 ABBREVIATIONS AND DEFINITIONS OF TERMS ............. 3
1.02.1 ABBREVIATIONS .................................................................................... 3
1.02.2 DEFINITIONS .......................................................................................... 6
SECTION 1.03 SCOPE AND CONTROL OF WORKS ................................... 8
1.03.1 INTENT OF CONTRACT ........................................................................ 8
1.03.2 SILENCE OF SPECIFICATIONS ......................................................... 8
1.03.3 CONTRACTOR'S WORK AREAS ........................................................ 8
1.03.4 WATER SUPPLY ..................................................................................... 9
1.03.5 ELECTRICITY SUPPLY.......................................................................... 9
1.03.6 EXISTING UTILITIES AND OTHER OBSTRUCTIONS .................... 10
1.03.7 SIGN BOARDS .................................................................................... 14
1.03.8 SURVEYING EQUIPMENT .................................................................. 14
1.03.9 SETTING OUT OF WORKS ............................................................... 15
1.03.10 HAUL ROUTES FOR HEAVY VEHICLES ....................................... 16
1.03.11 SCAFFOLDING AND FALSEWORK .................................................. 17
1.03.12 USE OF EXPLOSIVES ..................................................................... 17
1.03.13 FIRE FIGHTING EQUIPMENT ......................................................... 18
1.03.14 PHOTOGRAPHIC RECORDS OF CONSTRUCTION .................... 18
1.03.15 SITE CLEANING AND FINAL CLEAN UP ........................................ 19
SECTION 1.04 TEMPORARY WORKS .......................................................... 20
1.04.1 SCOPE ................................................................................................. 20
1.04.2 DESIGN REQUIREMENTS ................................................................. 20
1.04.3 AGREEMENT OF PROPERTY OWNERS .......................................... 20
SECTION 1.05 CONTROL OF MATERIALS AND STANDARDS FOR
SAMPLING AND TESTING ............................................................... 21
1.05.1 STORAGE OF MATERIALS ............................................................... 21
1.05.2 HANDLING MATERIALS ...................................................................... 21
1.05.3 MATERIALS SUPPLIED BY EMPLOYER ........................................... 21
1.05.4 LOCAL MATERIAL SOURCES ............................................................ 21
1.05.5 SOURCES OF SUPPLY AND QUALITY REQUIREMENTS ............ 22
1.05.6 CERTIFICATES OF GUARANTEE AND PRODUCTION PLANT
INSPECTIONS ................................................................................. 22
1.05.7 SAMPLING AND TESTING PROCEDURES ..................................... 22
1.05.8 SAMPLING AND TESTING STANDARDS ........................................ 24
1.05.9 UNACCEPTABLE MATERIALS .......................................................... 25
SECTION 1.06 CONTRACTOR'S PLANT AND EQUIPMENT ...................... 26
TOC -i
Technical Specification For Sewer Network
1.06.1 GENERAL ............................................................................................. 26

1.06.2 CONTRACTOR'S SCHEDULE OF PLANT AND EQUIPMENT ...... 26
1.06.3 PROVISION AND USE OF PLANT AND EQUIPMENT ................. 26
SECTION 1.07 MEASUREMENT PROCEDURES ..................................... 27
-+1.07.1 GENERAL ......................................................................................... 27
1.07.2 MANUFACTURED ITEMS ................................................................ 27
1.07.3 FITTINGS AND ACCESSORIES ........................................................ 27
1.07.4 WEIGHT MEASUREMENTS ............................................................. 28
1.07.5 LINEAR AND AREA MEASUREMENTS ........................................... 28
1.07.6 VOLUME MEASUREMENTS IN VEHICLES ................................... 28
1.07.7 EARTHWORK VOLUME MEASUREMENTS .................................. 29
SECTION 1.08 TEMPORARY FACILITIES .................................................. 30
1.08.1 GENERALLY ........................................................................................ 30
1.08.2 TEMPORARY SITE FACILITIES ...................................................... 31
1.08.3 CONTRACTOR'S TEMPORARY BUILDINGS ................................ 32
1.08.4 TEMPORARY SERVICES ................................................................. 32
1.08.6 DIVERSION OF PUBLIC UTILITY SERVICES ............................... 33
SECTION 1.09 SAFETY PRECAUTION MEASURES ................................. 35
1.09.1 GENERAL ............................................................................................. 35
P AR T 2 :
E X C AV AT I O N AN D B AC K F I L L I N G ..............................36
SECTION 2.01 SCOPE ................................................................................. 36

SECTION 2.02 SITE CLEARING ................................................................... 37
2.02.1 CLEARING AND GRUBBING .................................................................. 37
2.02.2 REMOVAL OR REALIGNMENT OF OBSTRUCTION AND
UTILITIES .......................................................................................... 37
SECTION 2.03 EXCAVATION ...................................................................... 38
2.03.1 GENERAL ............................................................................................. 38
2.03.2 TOP SOIL ........................................................................................... 38
2.03.3 EXCAVATING ...................................................................................... 38
2.03.4 DISPOSAL OF MATERIALS ........................................................................41
2.03.6 ROAD EXCAVATION (FOR PREPARATION OF SERVICE ROADS
ALONG PIPELINES) ........................................................................ 43
2.03.7 EXCAVATION FOR STRUCTURES ................................................ 46
2.03.8 EXCAVATION FOR PIPE TRENCHES ............................................. 49
2.03.9 TECHNICAL SPECIFICATIONS OF THRUST BORING .....................52
SECTION 2.04 SOIL FILLING AND BACKFILLING FOR STRUCTURES 57
2.04.1 SCOPE .............................................................................................57
2.04.2 FILLING MATERIAL AND BORROW MATERIAL .........................57
2.04.3 BACKFILLING FOR STRUCTURES ...............................................58
2.04.4 EMBANKMENT CONSTRUCTION ................................................63
2.04.5 PIPE BEDDING MATERIAL AND BACKFILLING FOR PIPE
TRENCHES ....................................................................................... 70
SECTION 2.05 SUBGRADE CONSTRUCTION ......................................... 74
2.05.1 GENERAL ............................................................................................. 74
TOC -ii
2.05.2 MATERIALS .......................................................................................... 74

2.05.3 WORKMANSHIP .................................................................................. 75
SECTION 2.06 GABIONS ............................................................................... 77
2.06.1 GENERAL ............................................................................................. 77
2.06.2 MATERIALS .......................................................................................... 77
2.06.3 CONSTRUCTION ................................................................................. 78
SECTION 2.07 STONE PITCHING IN CONCRETE ..................................... 79
2.07.1 GENERAL ............................................................................................. 79
2.07.2 MATERIALS .......................................................................................... 79
2.07.3 PLACING ............................................................................................. 79
SECTION 2.08 GEOTEXTILES ...................................................................... 81
2.08.1 GENERAL ............................................................................................. 81
2.08.2 MATERIAL .......................................................................................... 81
2.08.3 WORKMANSHIP .................................................................................. 82
PART 3:
PAVEMENT AND ROADS SURFACE FINISHING . 83
SECTION 3.01 SCOPE .................................................................................. 83

SECTION 3.02 GRANULAR SUBBASE AND BASE COURSES ................. 84
3.02.1 GENERAL ............................................................................................. 84
3.02.2 MATERIALS .......................................................................................... 85
3.02.3 CONSTRUCTION ................................................................................. 87
SECTION 3.03 BITUMINOUS LAYERS ....................................................... 89
3.03.1 GENERAL ..................................................................................................... 89
3.03.2 MATERIALS AND REQUIREMENTS FOR BITUMINOUS
COURSES ......................................................................................... 89
3.03.3 CONSTRUCTION ....................................................................................... 93
SECTION 3.04 PAVEMENT REPAIRS AND TRENCH REINSTATEMENT
WORKS ............................................................................................96
3.04.1 GENERAL ..........................................................................................96
3.04.2 ASPHALTING ....................................................................................96
3.04.3 MATERIALS ......................................................................................97
3.04.4 CONSTRUCTION AND REPAIR WORKS ......................................97
SECTION 3.05 CURBS, GUTTERS, SIDEWALKS AND PAVED MEDIANS 100
3.05.1 GENERAL ............................................................................................... 100
3.05.2 MATERIALS AND PRECAST MANUFACTURE .............................. 100
3.05.3 CONSTRUCTION AND INSTALLATION ............................................ 102
SECTION 3.06 MAINTENANCE OF TRAFFIC AND DETOURS ................ 109
3.06.1 GENERAL ............................................................................................... 109
3.06.2 MAINTENANCE AND PROTECTION OF TRAFFIC ....................... 109
PART 4:
PIPE WORKS AND NETWORK ACCESSORIES . 112
SECTION 4.01 SCOPE ................................................................................... 112

SECTION 4.02 GENERAL REQUIREMENTS .............................................. 113
4.02.1 GENERAL ............................................................................................... 113
4.02.2 SEQUENCE OF CONSTRUCTION ..................................................... 113
TOC -iii
4.02.3 RIGHT OF WAY (ROW)...................................................................... 114

4.02.4 MATERIALS, PRODUCTS SUPPLY AND HANDLING .................. 115
SECTION 4.03 PIPES, FITTINGS AND ACCESSORIES .......................... 121
4.03.1 MATERIALS ......................................................................................... 121
4.03.2 CONSTRUCTION AND INSTALLATION ........................................... 131
4.03.3 PIPE WORK TESTING ...................................................................................134
SECTION 4.04 VALVES, HOUSE CONNECTIONS AND SUNDRY WORKS
140
4.04.1 GENERAL ............................................................................................ 140
4.04.2 VALVES .............................................................................................. 140
4.04.3 HOUSE CONNECTIONS FOR SEWER NETWORKS ..................... 143
4.04.4 JOINTING MATERIALS AND ADAPTORS ....................................... 144
4.04.5 VALVE ACCESSORIES ...................................................................... 147
4.04.7 RECORDS .........................................................................................................149
SECTION 4.05 BEDDING, SURROUND, HAUNCHING, ENCASEMENT
AND THRUST BLOCKS .................................................................. 153
4.05.1 GENERAL ............................................................................................ 153
4.05.2 MATERIALS ......................................................................................... 153
4.05.3 WORKMANSHIP ................................................................................. 153
SECTION 4.06 MANHOLES AND CHAMBERS ........................................... 155
4.06.1 GENERAL ............................................................................................ 155
4.06.2 MATERIALS ......................................................................................... 155
PART 5:
CONCRETE WORKS ................................................................. 164
SECTION 5.01 CONCRETE AND CONCRETE MIXES AND TESTING .... 164
5.01.1 GENERAL ........................................................................................ 164
5.01.2 MATERIALS .................................................................................... 164
5.01.3 DEFINITIONS .................................................................................. 178
5.01.4 CONCRETE STRENGTH REQUIREMENTS ......................................
5.01.5 COMPOSITION OF CONCRETE .......................................................
5.01.6 REQUIREMENTS FOR COMBINING MATERIALS ..........................
5.01.7
READY-MIXED CONCRETE AND CENTRAL MIXED CONCRETE
......................................................................................................... 18
SECTION 5.02 CONCRETE HANDLING, PLACING AND CURING ......... 193
5.02.1 GENERAL ........................................................................................193
5.02.2 MATERIALS ....................................................................................193
5.02.3 PLACING .......................................................................................193
5.02.4 COMPACTING ...............................................................................198
5.02.5 CURING .........................................................................................201
5.02.6 HOT WEATHER CONCRETING ..................................................204
5.02.7 COLD WEATHER CONCRETING .................................................207
5.02.8 NIGHT CONCRETING ....................................................................208
SECTION 5.03 STEEL REINFORCEMENT AND FIXING ..........................209
5.03.1 GENERAL ........................................................................................... 209

TOC -iv
5.03.2 MATERIALS ........................................................................................ 209

5.03.3 CONSTRUCTION ............................................................................... 210
SECTION 5.04 FORMS, FORMWORK AND FALSEWORK ...................... 214
5.04.1 GENERAL ........................................................................................214
5.04.2 DEFINITIONS ..................................................................................214
5.04.3 MATERIALS .....................................................................................215
5.04.4 DESIGN ...........................................................................................216
5.04.5 FINISHES .......................................................................................220
5.04.6 TOLERANCES ................................................................................222
5.04.7 CONSTRUCTION REQUIREMENTS ...........................................222
5.04.8 REMOVAL OF FORMWORK AND FALSEWORK ......................223
SECTION 5.05 PLAIN AND REINFORCED CONCRETE STRUCTURES 225
5.05.1 GENERALLY ...................................................................................... 225
5.05.2 MATERIALS ........................................................................................ 225
5.05.3 CONSTRUCTION ............................................................................... 226
SECTION 5.06 WATERPROOFING FOR STRUCTURES ....................... 231
5.06.1 GENERAL ........................................................................................... 231
5.06.2 MATERIALS ........................................................................................ 231
5.06.3 SURFACE PREPARATION ............................................................. 235
5.06.4 INSPECTION, DELIVERY AND STORAGE ................................... 235
5.06.5 CONSTRUCTION ............................................................................... 236
SECTION 5.07 JOINT SEALING AND JOINT FILLER ............................... 240
5.07.1 GENERAL ........................................................................................... 240
5.07.2 MATERIALS: JOINT SEALING COMPOUNDS .............................. 240
5.07.3 PREFORMED EXPANSION JOINT FILLER .................................. 243
5.07.4 CERTIFICATE OF GUARANTEE ...................................................... 243
5.07.5 CONSTRUCTION ............................................................................... 244
TOC -v
List of Tables
Page
PART 2 : EXCAVATION AND BACKFILLING
Table 2.1 : Soil Suitable for Embankment .................................................................. 63
Table 2.2 : Rock Suitable for Embankment ............................................................... 64
PART 3 : PAVEMENT AND ROADS SURFACE FINISHING

Table 3.1 : Job Mix Formula ....................................................................................... 92
Table 3.2 : Surface Tolerances ................................................................................. 92
Table 3.3 : Tests for Bituminous Pavements: Minimum Tests Required ..................... 95
PART 5 : CONCRETE WORKS

Table 5.1.1 : Limits of Gradation for Coarse Aggregates ...........................................172
Table 5.1.2 : Limits of Gradation for Combined Aggregates........................................173
Table 5.1.3 : Maximum Permitted Impurities in Non-Potable Water ............................176
Table 5.1.4 : Concrete Class and Design Mixes .........................................................180
Table 5.1.5 : Grading for No-Fines Concrete .............................................................181
Table 5.1.6 : Preliminary Tests for Stretch .................................................................182
Table 5.2.1 : Selection of Poker Diameter for Size of Pour .........................................200
Table 5.2.2 : Normal Curing Periods..........................................................................205
Table 5.4.1 : Permitted Hardwoods for Load-Bearing Wedges and Packing................215
Table 5.4.2 : Minimum Period Before Striking for Ordinary Structural Concrete
Made with Ordinary Portland Cement ...................................................224
TOC -vi
PART 1: General Requirement
P ART 1:
GENER AL REQUIREMENT
SECTION 1.01 FORMAT AND REFERENCING

1.01.1
A.
FORMAT OF SPECIFICATIONS
Part
A.1 This Specification is divided into Parts. Each Part is designated by a single or double
digit number followed by a title. (Part 1 General Requirements)
B.
Section
B.1 Each Part is divided into Sections. Each Section is designated by the Part number, a
decimal point and a 2-digit sequential number, followed by a title. (Section 1.01 Format and
Referencing)
C.
Subsection
C.1 Each Section is divided into Subsections. Each Subsection is designated by the Part
number, a decimal point and a 2-digit Section number, a decimal point and a single or double
digit number followed by a title. (1.01.1 Format of Specifications)
D.
Clause
D.1 Each Subsection may be divided into Clauses. Each Clause is designated by sequential
alphabetic letters and a decimal point. (D.)
E.
Item
E.1 Each Clause may be divided into items. Each Item is designated by the Clause letter, a
decimal point and a single or double digit sequential number, followed (if required) by a title in
lower case lettering. The text then normally follows on the same line (E. 1).
Page 1 of 244
1.01.2
REFERENCING
A.
The Specifications for Items in the Bills of Quantities are prescribed in the respective
Section/s corresponding to the type of Works involved.
B.
A l l the provisions of these Section/s shall be construed as Specifications for such

Items of Work, except in respect of those provisions clearly inapplicable in the context
in which they appear or unless they are waived or modified in the Contract Documents
or by Variation Orders.
C.
Specifications and Drawings may contain cross references to other Sections, Clauses,
Items, etc., which shall likewise be construed as Specifications for the Item of Work
involved.
D.
Any references in the Specification to Work or materials not required will be deemed
inapplicable.
Page 2 of 244
SECTION 1.02
1.02.1
A.
ABBREVIATIONS AND DEFINITIONS OF TERMS
ABBREVIATIONS
Interpretation
A.1 Wherever the following abbreviations of titles, terms and units of measurement are used in
the Specifications or on the Drawings, the intent and meaning shall be interpreted as described
hereunder.
B.
Titles and Terms
B.1 AASHTO - American Association of State Highway and Transportation Officials:
ABS
ACI
AISC
AISI
ANSI
API
ASTM
AV.
AWG
AWS
AWWA
Bit.
BS
BSSC
BST
CB
CBR
conc
CIE
DBSC
DIN
Equiv
FSS
hwy
ht
H:V
IEC
IEE
Acrylonitrile-Butadiene-Styrene
American Concrete Institute
American Institute of Steel Construction American Iron and Steel Institute
American National Standards Institute
American Petroleum Institute American Society for Testing and Materials
Average
American Wire guage
American Welding Society
American Water Works Association
bitumen/bituminous
British Standard
bituminous slurry seal coat bituminous surface treatment
circuit breaker
California Bearing Ratio concrete
Commission Internationale de l'Eclairage double bituminous seal coat
Deutsches Institute Fur Normalizieung equivalent
Federal Standard Specification (USA) highway
height
horizontal: vertical
International Electrical Commission
Institution of Electrical Engineers (UK)
Page 3 of 244
ISO
L.L.
L.S.
max
MCCB
min
MUTCD
NEC
NEMA
NJB
pav't
P.C.
PCC
PE
P.I.
P.L.
PTFE
PVC
qty
RC
RCP
rdwy
ROW
SBSC
S.G.
SI
Sta
SWG
TBSC
uPVC
VDE
wgt
GRP
DI
SASO
C.
Units of Measurement
:
:
:
:
International Organization for Standardization

liquid limit limit
lump sum :
maximum
molded case circuit breaker
minimum (or minute)
Manual on Uniform Traffic Control Devices
National Electrical Code (UK)
National Electrical Manufacturers' Association (USA) New Jersey
barrier
pavement
prime cost
Portland cement concrete
polyethylene plasticity
index
plastic limit Polytetrafluoroethylene
polyvinyl chloride
quantity
reinforced concrete
:
reinforced concrete pipe
: roadway
:
right-of-way
:
single bituminous seal coat
:
specific gravity
:
Systeme International D'Unites Station (location
along a survey line) standard wire gauge (UK)
triple bituminous seal coat
unplasticized polyvinyl chloride Verband
Deutscher Electrotechniker
weight
Class reinforced plastic
Ductile Iron
Saudi Arabia Standards Organization
C.1 Throughout the documentation units of measurement are referred to by symbols as follows:
-
Nr
mm
cm
m
:
:
: number
: millimeter/s
centimeter/s
meter/s
Page 4 of 244
lin.m
km
sq.mm :
sq.cm
sq.m
ha
cu.m
gm
kg
tonne
ml
ltr
Pa
N
kN
MN
A
mA
V
W
kW
C
Hz
rpm
km/h
sec
min
h
mS
dB
dBA
ppm
in.
ft
sq.in
sq.ft
cu.ft
lb.
psi
gal
gal(Imp)
mph
HP
USG
:
:
:
:
linear meter/s kilometer/s

square millimeter/s
square centimeter/s
square meter/s hectare/s
cubic meter/s gram/s
kilogram/s
metric ton (1,000 kg) milliliter/s
liter/s
Pascal/s
Newton/s
kilo Newtons mega Newtons amperes
milli amperes volt/s
Watt
kilowatt
Celsius (Centigrade)
Hertz (Frequency) revolutions per minute kilometers per
hour
seconds
minute/s (or minimum) hour/s
milli Siemens decibel/s
decibels absolute parts per million
inch/inches ( 1 in. = 25.4 mm) foot/feet (1ft = 0.3048 m) square
inch/inches
square foot/feet cubic foot/feet pound/s (weight) pounds
per square inch gallon/s (U.S.) gallon/s (Imperial)
miles per hour horsepower
American gage
:
:
:
:
Page 5 of 244
1.02.2
DEFINITIONS
A.
Wherever in the specification or in other Contract Documents any of the following
terms is used, the intent and meaning shall be interpreted as follows:
ACCEPTED - Accepted in writing by the Engineer (or by the Employer where

appropriate) as meeting the requirements of the Contract Documents and of any
authorized variations thereto. "Acceptance" means accepted in writing as
aforesaid. "Acceptable" means acceptable to the Engineer as aforesaid.
ADDENDUM/NOTICE - Amendment of or revision to any of the Contract

Documents issued to Tenderers, and which is deemed to form part of the
Contract Documents.
APPROVED - Approved in writing by the Engineer, including subsequent

written approval or confirmation of previous verbal approval by the Engineer.
"Approval" means approval in writing as aforesaid.
CERTIFICATE OF GUARANTEE - A signed statement by a person having

legal authority to bind a company or supplier to its product, and which confirms
that the materials and test results conform to the standards of these
Specifications.
DIRECTED - Directed in writing by the Engineer, including subsequent written

direction or confirmation of previous verbal direction by the Engineer.
PRESPLITTING - Establishment of a free surface, or shear plane, in rock cuts,

by controlled use of explosives in specially aligned and closely spaced drill holes
along the slope line.
SHEATHING - Backfilling to the inside faces of structures such as retaining

walls and abutments, using proprietary filter cloth and porous blocks, or using
selected, free-draining material such as gravel or noncementitious sand, etc,
prior to placing and compacting normal backfill.
SOIL STABILIZATION - Procedure whereby cement, bitumen or lime is added

to soils (subgrade layer) or to granular materials (sub-base course) in order to
improve their load bearing capacity and their resistance to weathering and
displacement.
SUBGRADE - The top surface of embankment or excavated area on which the

pavement structure and shoulders are constructed. Also referred to as Subgrade
Surface or Subgrade Level.
Page 6 of 244
SUBGRADE LAYER - The top layer of material, of at least 200 mm compacted

thickness, immediately below the subgrade surface.
SUBSIDIARY WORKS - Works which are subsidiary to or necessary or essential to, or

in support of, or usual to, the execution and completion of other Works.
WORKING DRAWINGS - Shop drawings, steel bending schedules, stress sheets,

fabrication and erection drawings, falsework drawings, and any other supplementary
drawings or data which the Contractor is required to submit to the Engineer for approval,
generally before such Works commence.
Page 7 of 244
SECTION 1.03
1.03.1
SCOPE AND CONTROL OF WORKS
INTENT OF CONTRACT
A.
The intent of the Contract is to provide for the construction and completion in every
detail and subsequent maintenance of the Works described. The Contractor shall
furnish all labor, materials, tools, equipment, transportation, supplies and facilities and
shall carry out all Permanent and Temporary Works and all other items necessary for
proper completion of the Works in accordance with all requirements of the Contract
Documents.
B.
Where the Specifications or Drawings describe any portions of the Works in outline only,
and not in complete detail, the best general engineering practice shall prevail and only
first quality materials and workmanship shall be used.
1.03.2
SILENCE OF SPECIFICATIONS
A. The apparent silence of the Specifications, Drawings or other Contract Documents as to any
detail or the apparent omission from them of a detailed description concerning any Works or
requirements, shall be regarded as meaning that good engineering practice shall apply and
shall be to the approval of the Engineer.
1.03.3
CONTRACTOR'S WORK AREAS
A.
The Contractor shall make all necessary arrangements, including payment i f need be,
regarding any land outside the Site that may be needed as work areas. The Employer
will not acknowledge any liability in respect of such land. The Contractor shall also be
responsible for insuring that all roads and temporary facilities needed are sufficient to
divert traffic adequately.
B.
The Contractor shall locate and select sites outside the right-of-way for the use of his
plant, equipment, site offices, residences, Temporary Works or any other uses which
are essential during the execution of the Contract. The Contractor shall take the
necessary measures for using these sites and shall be responsible for all expenses that
may become due in return for such use. Prior to using any land owned by public or
private owner outside the Site, the Contractor shall obtain the approval of the concerned
Authorities and the Engineer.
Page 8 of 244
C.
The Contractor, i f so required by the Engineer, whether before or after completion of

the Works, shall remove his constructional plant and duly clean the site and shall,
wherever applicable, remedy all damage and pay all monies due to land owners in
return for using their land.
D.
It is the Contractor's responsibility to verify the stability of side slopes in cut areas by
specialized staff. The Contractor, at his own expense shall execute any required site
investigation prior to cutting in the relevant areas. The proposal of site investigation
program as well the final recommendation should be approved by the Engineer. No
direct payment shall be made for this work, all expenses should be included in the
Contractor's rates.
E.
The Contractor shall inspect the location and the surrounding areas and comprehend all
the details related to the type, nature, details, topography and existing services of the
location.
The Contractor shall acquire all the information related to risks, dangers, weather conditions
and any other related factors that may influence his tender, and no later consideration will be
made since these expenses should be added by the Contractor on the prices of works and other
items.
1.03.4
WATER SUPPLY
A. The Contractor shall be deemed to have executed adequate investigations relating to the
availability of water for the purpose of the Works and to have consulted and arranged with the
appropriate Authorities and taken into consideration all legal aspects. The Contractor shall be
responsible for the supply of sufficient clean, fresh water at all times during progress of the
Works, including making temporary arrangements for storing and distributing the water on the
Site.
1.03.5
ELECTRICITY SUPPLY
A. The Contractor shall make his own arrangements for the supply of all electrical power and
all lighting and electrical equipment required for execution of the Works, including supplies for
commissioning engineering services and Plant at required voltages. The Contractor shall also
make provisions to store and distribute electrical power and equipment on Site.
Page 9 of 244
B.
The Contractor shall provide and maintain adequate efficient lighting for all parts of the
Works for safety and security purposes required to facilitate proper execution of work
and to illuminate surfaces during finishing work and inspection. Without prejudice to
his liability under the General Conditions of Contract, the Contractor shall, with respect
to the supply of electricity for power or lighting, take all necessary precautions to
ensure the safety of his workmen and others.
C.
Permanent electric supply and lighting installations may be used for testing and
commissioning and to illuminate the Works, subject to the following conditions:
The Employer does not guarantee that it will be available.
The Contractor must take responsibility for the operation, maintenance and
supervision of the system, indemnify the Employer against all damage and pay
all costs and renew all used tubes and lamps.
The Contractor must indemnify the Employer against any reduction in the
manufacturer's guarantee periods for equipment etc. due to its use before
completion of the Works.
1.03.6
EXISTING UTILITIES AND OTHER OBSTRUCTIONS
A.
Categories of Obstructions
A.1
Obstructions shall be classified as follows:
B.
Existing private and public owned utilities, above and below ground, which are
required to be either protected, adjusted, relocated or removed.
Obstructions, above and below ground (other than utilities), which are required
to be taken down, dismantled, demolished or excavated, and removed, as
appropriate.
Existing Utilities
B.1 Utilities shall include, but not be limited to, existing water lines, gas lines, sewer lines,
wire lines, service connections, water and gas meters and valve boxes, light poles and masts,
pylons, cableways, signals, and all utility appurtenances within the limits of the proposed
construction.
Page 10 of 244
B.1.1 The Contractor shall submit all plans showing existing utilities under earth and their
relations with pipelines under construction.
B.1.2 The Employer/Engineer takes no responsibility as to the correctness, accuracy,

completeness or validity of information obtained from these Drawings and the Contractor shall
be fully responsible for his own interpretation and shall execute whatever additional
investigations are necessary to obtain the needed information at the Contractor's own
expense.
B.1.3 The costs of all related Works concerning verification and identification of existing
utilities including excavating any trial pits, detection means, mapping detailing of drawings and
co-ordination with respective Authorities shall be fully borne by the Contractor. Should any
relocation of existing utilities, not previously identified by the Contractor, be instructed, or
shown on the Drawings, these shall not constitute a change in the Scope of Work, and shall
give no grounds for extension to the Time for Completion or for other claims. The relocations,
however, will be paid for and valued in accordance with the Contract rates.
B.2 The necessary utility diversions may be specified or directed to be carried out by the
Contractor. Alternatively, the Employer may make arrangements for such works to be
executed by other parties.
B.3
The Contractor shall:
Take into account that the diversion works shall be carried out to the
requirements and approval of the Utility Owners and/or under their supervision,
and also where required by the Utility Owners, specialist diversion works shall
be carried out by accredited specialist Contractors.
Verify and identify the existing utilities by excavating trial pits and other
measures including detection means existing utilities. Coordinate with the
relevant Authorities and map these utilities and prepare detailed and accurate
existing utilities drawings identifying the utilities that are in service and those that
are dead or abandoned. Submit these existing utilities Drawings, that are
accurate and detailed giving location of utilities in plan and section with all
pertinent data of the respective utility, to the Engineer and to the Utility
Owners.
Work out and develop, in coordination with the Utility Owners and the
Engineer, the approved utilities diversion schemes that will be required to
enable the execution of the Works and also maintain continued utilities
services in the Area, and to the users.
Page 11 of 244
Provide superintendence for the execution of the utility diversions whether

they are carried out by the Contractor directly or by other parties employed by
the Contractor.
Provide accurate As-Built Drawings of all permanent utility diversions that are
executed under the Contract.
B.4 The Employer will, in consultation with the Engineer and Contractor, coordinate with all
Utility Owners to ensure prompt adjustment, relocation or removal of all affected utilities,
including any additional utilities that may be encountered during the Works. The Employer
and Engineer will facilitate, to the maximum extent practicable, the Contractor's Work
Program, in this respect.
B.5 The Contractor shall take into account, in his Program of Work, the time effort involved
in the follow-up and execution of Works pertaining to all utility adjustments, relocations and
removals. The Contractor shall schedule construction activities so as to avoid or minimize
any potential delays, inconvenience or damage to the Works that may result from utility
interference or the operations of adjustment, relocations and removals.
B.6 The Contractor shall follow up the execution of the utility diversions whether they are
carried out directly or by other parties employed by the Contractor or directly by the
Employer. The Contractor shall, in good time, inform the Employer and the Engineer.
B.7 The Contractor shall be responsible for safeguarding and protecting all utilities and
appurtenances encountered during the Works. The Contractor shall be responsible for the
costs of making good any damage arising out of its own negligence.
B.8 The execution of the utility diversions should be done by similar materials of equivalent
grade or strength as minimum to the materials of the existing utilities and as per the Engineer
approval and the utility owners requirements.
B.9 In case it is required to stop the water in the existing network while execution of the
utilities diversions or replacement of existing water pipeline, the Contractor should inform the
Engineer and coordinate with the water supply authorities in advance by 48 hours. I f the
water supply would stop for more than 48 hours, the Contractor should provide temporary
service for water supply on his own expenses, either using temporary pipelines or by water
tanker or any other way approved by the Engineer. In all cases, the Contractor should get
written license from the water supply authority including the required instructions.
Page 12 of 244
B.10 Execution of the water networks diversions should be done as per the water networks
specifications stipulated in Section (4) of these specifications. Testing, cleaning and
disinfection of the pipelines should be done according to Section (4-3-3) of these
specifications.
C.
Obstacles
C.1 Obstacles shall include, but not limited to existing buildings, walls, fences, gates, wells,
septic tanks, manholes, pits, pipes, culverts, roadways, sidewalks, signs and rubbish dumps,
whether or not shown on the Drawings.
C.2 At the commencement of the Contract, the Contractor shall examine the Site and
identify/verify all obstacles in the Site above or below ground, and shall record all such
information on suitable Site Drawings which shall be submitted to the Engineer within one
month of commencement date.
C.3 Existing Septic Tanks:

I f the pipelines or the house connections cross any existing septic tanks and it was not
possible to change the pipeline routing to avoid them, the Contractor should proceed to dry,
clean, demolish and backfill those tanks partially or fully.
Wherever possible, only the crossing part of the tank with the water pipeline that will be
demolished and backfilled and the rest of the tank should be separated by building a suitable
wall to make the tank in a good working condition. A l l precautions should be taken to keep
the existing system working and to pump the sewerage from the tanks and to dispose of the
sewage according to the local authorities instructions. The sewer water must not be allowed to
leak to the water pipelines trenches or the water system.
In case of partial or full demolish, the top slab should be removed either fully or partially and
the walls should be lowered at least by 1m below the ground level. Filling should be as per
the backfilling specifications in this document.
All of the above requirements should be applied to all existing tanks including those
constructed during this pipelines contract and those crossing the pipelines.
Harmful gases concentration should be monitored using special gas monitoring devices
before and during commencing of the work in septic tanks. A l l laborers entering to the tanks
must be provided with full safety tools and gas masks, etc. and the Contractor must provide all
first aid tools on site.
Page 13 of 244
C.4 Change of Pipeline Rooting Around Tanks:

When existing tank crosses the proposed pipeline, the pipeline routing should be changed i f
possible around the tank leaving a 50 cm clear distance between the tank walls and the
pipeline. Those pipelines should be covered by plain concrete as per the Engineer
recommendations.
The Contractor should prepare detailed drawings for the tank boundaries that cross the
pipeline, showing all the connection details that are required to relocate the pipe around the
tank. This drawing should be approved by the Engineer prior to construction.
1.03.7
SIGN BOARDS
A.
Nameboard: The Contractor shall provide suitably sized project nameboards, bearing
the names of the Employer and Engineer together with any corresponding logos, the
name of the project, the name of the Contractor and such other names and information as
the Engineer may request. The design and style of the nameboard shall be submitted to
the Engineer for approval prior to fabrication. Nameboards are to be written in English
and the local language and erected at suitable locations as directed by the Engineer.
Refer to Section 1.08.2 Item G for the nameboard details. As detailed in Section
1.08.2, Item E of the specifications.
B.
Each sign board shall be erected in a prominent, approved position. Sign boards shall
be maintained in good order at all times and sign boards and supports shall be
dismantled and removed from the site upon completion of the Works.
C.
All sign boards are to comply with the requirements of concerned authorities
(Municipality/ Ministry of Transport/Traffic Directorate).
1.03.8
SURVEYING EQUIPMENT
A.
The Contractor shall provide sufficient and suitable surveying instruments and other
equipment for his own use in setting out and leveling of the Works, and also to enable
the Engineer to check the setting out. Furthermore, the Contractor shall provide
sufficient chainmen and other assistance as the Engineer may require.
B.
The accuracy of survey instruments may be verified at any time by the Engineer and
any unsatisfactory instruments shall be promptly calibrated or removed and replaced by
the Contractor at its own expense.
Page 14 of 244
C. Upon completion of the Contract, all survey instruments shall remain the property of the
Contractor, unless a Pay Item for such instruments is included in the Bills of Quantities, in
which case the instruments shall become the property of the Employer.
1.03.9 SETTING OUT OF WORKS
A.
The Contractor shall, prior to any setting out, submit a planned method of operations
for setting out the Works to the Engineer for his approval. The plan shall include the
accuracy, positions of the various types of stakes, method of marking stakes, and
methods to be used for protecting stakes, etc. No survey work shall proceed without to
the Engineer's approval of the Contractor's plan.
B.
The Contractor shall give written notice to the Engineer at least 24 hours before he
intends to survey any portion of the Works. Such notice shall include the time, location
and type of Works to be set out.
C.
Before commencing Work on Site, the Contractor shall carry out a topographical
survey of the Site, as directed by the Engineer. This survey shall include such parts of
the Site as the Engineer may direct, to record the Site limits, dimensions, ground
levels, obstructions and other features and the survey shall establish base lines and
points for future setting out and also record the basis for re-measurement of excavation
and earthwork, where applicable. The Contractor shall set out the Works, inform the
Engineer when setting out is complete and obtain Engineer's approval before
proceeding with construction. The Contractor shall provide instruments and assistance
for checking the setting out if required by the Engineer. If, in the opinion of the
Engineer, modification of the lines or grade is required, before or after survey, the
Engineer will issue detailed instructions to the Contractor who shall revise the setting
out accordingly.
D.
Setting Out Utility Works shall be as shown on the Drawings or as instructed on Site.
Stake-out shall be revised if , in the opinion of the Engineer, modifications of line or
grade are required.
E.
The Contractor shall be responsible for preserving all existing stakes, marks and
monuments and if any construction stakes or marks are destroyed or disturbed, the
Contractor shall replace them at his own expense.
E.1 Record Drawings: The Contractor shall record details of all grid lines, existing ground
levels, setting-out stations, bench marks and profiles on the site setting-out drawing.
This drawing shall be retained on the Site throughout the duration of the Contract and
handed over to the Engineer upon completion of the Works.
Page 15 of 244
E.2 A l l dimensions and levels on the Drawings and the Site, shall be checked particularly the
correlation between components and the work in place. Materials and components shall not
be ordered, or work carried out, until discrepancies have been resolved with the Engineer.
E.3 Appearance and Fit: The Works shall be constructed to higher levels of accuracy than
those specified where it is necessary to achieve a desired appearance and also to ensure that
materials, elements, and components of the building fit together as designed. Wherever the
accuracy, fit or appearance of the work is likely to be critical, or difficult to achieve, the
Contractor shall obtain the Engineer's approval of proposals or of the partially finished work as
early as possible.
E.4 Non-Compliance: Work which fails to meet the specified levels of accuracy must not be
rectified before the Contractor submits and receives approval of proposed rectification works.
A l l additional costs resulting from these rectification works shall be borne by the Contractor.
1.03.10
HAUL ROUTES FOR HEAVY VEHICLES
A.
The Contractor shall prepare proposals for routes to be used by heavy vehicles
particularly for hauling fill materials. Routes shall where possible, avoid existing roads
and built-up areas. Signs shall be provided and maintained to direct construction traffic
to and from haul routes. Details of haul routes and signing shall be submitted to the
concerned in Traffic Directorate for approval within a period not exceeding one month
prior to the commencement of the Works in the relevant area and the signs shall be
erected prior to actual commencement of the Works.
B.
I f and where it is necessary for Contractor's plant or vehicles to cross public highways,
and where required by the Engineer, all such crossings shall be equipped with manually
controlled traffic lights.
D. Stationary vehicles, equipment, huts, stockpiles of materials, etc., shall be kept well clear
of crossing points so that persons using the highway and the haul road shall have
adequate sight distance at all times.
Page 16 of 244
1.03.11
SCAFFOLDING AND FALSEWORK
A. The Contractor shall provide scaffolding and falsework to facilitate carrying out construction
of the Works in the required sequence. Scaffolding and falsework shall be properly designed
and constructed specifically for the loads intended. Full details of the proposed arrangements
shall be submitted to the Engineer for his approval. Such approval, however, shall not relieve the
Contractor of his responsibility with regard to the adequacy of all scaffolding and falsework
used in the Works.
1.03.12
A.
USE OF EXPLOSIVES
Control Measures
A.1 The Contractor shall not use explosives without the express permission from the controlling
Authority. The Contractor shall abide by all rules and regulations of the concerned Authorities
regarding purchasing, transportation, storing, handling and using the explosive materials.
A.2 Explosives and detonators shall be stored in special buildings as approved by the
concerned Authorities. These secured buildings should be located and clearly marked English
and Arabic "DANGER - EXPLOSIVES" as approved by the concerned authorities. Explosives
and detonators shall be stored in separate buildings.
A.3
All possible precautions shall be taken against accidental fire or explosion, and to
ensure that the explosives and detonators are kept in proper and safe condition.
A.4 Explosives and detonators shall always be transported in separate vehicles and kept apart
until the last possible moment. Metallic tools shall not be used to open boxes of explosives.
B.
Blasting Procedures
B.1 Ensure that blasting shall only be carried out by experienced shot firers. Priming, charging,
stemming and shot firing shall be carried out with greatest regard for safety and in strict
accordance with the Rules and Regulations of the concerned Authorities. Adequate warning of
blasting shall always be given and all persons cleared from the area, before blasting takes
place.
Page 17 of 244
B.2 Ensure that police and other concerned Authorities shall be kept fully informed of the
blasting program so that they may be present when blasting takes place i f they so require.
B.3 Ensure that explosive charges are not excessive, charged boreholes are properly
protected, and proper precautions are taken for the safety of persons and property. Only the
Contractor shall be responsible of people and premises full protection.
C.
Explosives Inventory
C.1 The Contractor shall maintain an up-to-date inventory of all explosives and explosive
devices and shall submit a monthly report to the Engineer, detailing the use of all explosives by
date and location.
1.03.13
FIRE FIGHTING EQUIPMENT
A.
The Contractor shall take all necessary measures to prevent personal injury or death or
damage to the Works or other property and adequate, fully operational fire fighting
equipment shall be furnished and maintained by the Contractor whose workmen shall
be trained in the operation of such equipment.
B.
Fire fighting arrangements shall be made as required by the local Civil Defense
Department and provision of fire fighting facilities in all vulnerable areas and as
instructed by the Engineer.
C.
Adequate water for fire fighting shall be available and outlets located so as to be readily
accessible.
D.
A l l equipment shall be regularly tested and properly maintained.
1.03.14
PHOTOGRAPHIC RECORDS OF CONSTRUCTION
A. The Contractor shall submit each month good quality progress photographs of at least 5
different subjects as agreed by the Engineer. For each subject, the Contractor shall supply
progress photographs taken from approved locations stations but not less than 20 (twenty) at
monthly intervals and submit 3 color prints (gloss finish) not less than size 16cm x 20cm of each
negatives and color transparency.
Page 18 of 244
B.
Each print and transparency supplied, shall be titled and referenced to a suitable key
plan. Prints and negatives shall also be suitably cross referenced.
1.03.15
A.
SITE CLEANING AND FINAL CLEAN UP
Site Cleaning During Progress of Works
A.1 A l l parts of the Site, and adjacent roads affected by the Works, shall be maintained in a
clean and tidy condition during progress of the Works. All waste and surplus materials and
other rubbish resulting from the Works or otherwise, shall be cleared away to locations approved
by the Municipalities and Directorate at intervals as directed by the Engineer.
A.2 I f the Contractor fails to remove any surplus or waste materials from the Site within 3 days
after being instructed to do so by the Engineer, these materials may be removed by others at the
Contractor's expense.
B.
Final Clean Up on Completion
B.1 The entire Site shall be delivered up on completion of the Works, in a clean, neat and
presentable condition, all as specified hereunder and as described in the General Conditions of
Contract.
B.2 Spoil tips, borrow pits and deposited materials shall be trimmed and regularized to profiles
and levels as directed. Flow of water courses affected by the tips or pits shall be maintained
without interruption and any agreement concerning these sites, existing between the Employer
and the persons or Authorities concerned, shall be observed.
B.3 Temporary Markings coverings and protective wrappings shall be removed unless
otherwise instructed by the Engineer.
B.4 Partial Possession by Employer: Where the Works are to be completed in sections, and
any such section depends for its adequate functioning on work located elsewhere on the Site,
such other work shall be completed in time to permit sectional completion as required.
Page 19 of 244
SECTION 1.04 TEMPORARY WORKS
1.04.1
SCOPE
A.
The Contractor shall construct, as required, all temporary detour roads, temporary
bridges and culverts, and other facilities for his Works or for maintenance of traffic in
locations affected by his works.
B.
The Contractor shall construct and maintain all detour routes ensuring at all times that the
detour routes are signed, striped, lighted, maintained and furnished with all traffic control
devices as shown, directed and/or needed. These proposed detours must be submitted to
the Engineer for approval.
C.
Trench crossings are to be provided for free and safe passage of vehicles and
pedestrians over pipe and other trenches.
1.04.2
DESIGN REQUIREMENTS
A. Designs and detailed working drawings for proposed Temporary Works shall be submitted
for approval, prior to commencing such Works. The Contractor shall be held responsible for any
damage that may result from the Temporary Works.
1.04.3
AGREEMENT OF PROPERTY OWNERS
A. The Contractor shall obtain the agreement of the affected land owners and approval from
the Engineer prior to commencing Temporary Works. Such approval shall not in any way
relieve the Contractor of his responsibilities expressed in the General Conditions of Contract.
Page 20 of 244
SECTION 1.05 CONTROL OF MATERIALS AND STANDARDS FOR

SAMPLING AND TESTING
1.05.1
STORAGE OF MATERIALS
A.
Materials shall be so stored as to assure the preservation of their quality and suitability
for the Works. Stored materials, approved before storage, may again be inspected prior
to their use in the Works. Stored materials shall be located so as to facilitate their
prompt inspection.
B.
Where materials are stockpiled on Government or private property, such sites shall be
abandoned immediately upon consumption of all stockpiled materials and the natural
surface shall be restored as far as practicable to the original condition by the Contractor
and to the satisfaction of the Engineer.
1.05.2
HANDLING MATERIALS
A. A l l materials shall be handled in such manner as to preserve their quality and suitability for
the Works. Aggregates shall be transported to the Works in vehicles, which are constructed to
prevent loss or undue segregation of materials after loading and unloading.
1.05.3
MATERIALS SUPPLIED BY EMPLOYER
A. The Contractor shall be responsible for all materials furnished by the Employer and shall
make good any shortages or deficiencies, from any cause whatsoever, or any damage which
may occur, after delivery of such materials.
1.05.4
LOCAL MATERIAL SOURCES
A.
When material sources are not designated on the Drawings, or in other documents, the
Contractor shall be responsible for locating and providing suitable materials from
approved sources.
B.
Any information provided in the tender documents about sources of local materials is
considered as a guideline only and does not relieve the Contractor of his responsibility in
respect of investigation and supply of suitable materials as specified.
Page 21 of 244
C.
Materials, regardless of their source, shall not be incorporated in the Works until
approved by the Engineer.
1.05.5
SOURCES OF SUPPLY AND QUALITY REQUIREMENTS
A.
A l l materials, including manufactured articles, and machinery incorporated in the

Works, shall meet all specified quality requirements and be approved by the Engineer.
B.
The Contractor shall, before placing any purchase order for any materials intended for
incorporation in the Works, submit for approval a complete description of all such
materials, names of the firms from whom he proposes to purchase them and copies of
all test reports verifying conformity with the provisions of the Specifications. Materials
shall not be ordered without the approval of the Engineer. When directed by the
Engineer or otherwise specified, the Contractor shall submit suitable samples for
approval.
C.
The Engineer shall have the right to retest all materials which have been tested and
accepted at the source of supply after delivery to the Site and prior to incorporation into
the Works and to reject any such materials which are clearly defective or, when
retested, do not conform with the Specifications.
1.05.6
CERTIFICATES OF GUARANTEE AND PRODUCTION PLANT

INSPECTIONS
A.
A l l shipments of materials shall be accompanied by a Certificate of Origin and a

Manufacturer's Certificate of Guarantee or Test Certificate from an approved
independent qualified laboratory approved by the Engineer. A l l certified materials
delivered to the Site shall undergo additional laboratory testing i f required by the
Engineer.
B.
Issuance of an invalid or erroneous Certificate of Guarantee shall be just cause for

rejection of the materials without further testing.
1.05.7
A.
SAMPLING AND TESTING PROCEDURES
Sampling
A.1 Samples of all materials shall be submitted to the Engineer for inspection, testing and
acceptance before incorporation in the Works. All materials being used will be subject to
inspection, testing, or rejection at any time prior to such incorporation.
Page 22 of 244
A.2 Where untested and unaccepted materials have been used without approval of the
Engineer, such use shall be at the Contractor's risk.
B.
Source Tests
B.1 A l l source samples shall be taken by the Contractor in the presence of the Engineer, using
approved sampling procedures. A l l source approval tests shall be performed under the
supervision of the Engineer or, when so specified, by an independent laboratory approved by
the Engineer and engaged by the Contractor.
B.2 After approval of any source of materials, the Contractor shall produce from such source
only to the extent that materials produced are of substantially the same quality as the approved
samples.
B.3 The Engineer will periodically order retesting of previously approved sources to verify that
they continue to conform to the Specifications and may order retesting at the same or at a
different laboratory from the one performing the original source approval tests. I f retesting
indicates that a previously approved source no longer conforms with the Specifications, the
Contractor shall forthwith cease production from such source.
C.
Job Control Tests
C.1 Job control tests shall be performed by the Contractor prior to submitting any materials to
the Engineer for approval. The Contractor shall submit details to the Engineer of his job control
testing program.
C.2 The Engineer may declare the Contractor's job control testing program unacceptable i f
frequent rejections of submitted materials occur when subjected to the Project Control Tests.
D.
Project Control Tests
D.1 A l l Project Control samples shall be taken jointly by the Engineer and the Contractor. Tests
shall be performed in the Site Laboratory, or in situ as appropriate, under the supervision of the
Engineer.
Page 23 of 244
D.2 The Engineer may order retesting of any material i f there has been a significant delay in
the construction operations or i f he determines that the material has deteriorated since its
original acceptance. Material which does not conform with the Specifications will be rejected
and shall be removed from the Works and replaced or corrected by the Contractor. The
Engineer may order additional testing to ascertain the extent of unacceptable material.
E.
Check Tests
E.1 The Engineer may periodically order check tests to verify the accuracy of Project Control
testing and equipment. The Engineer may direct that check tests be performed by qualified
persons other than those normally responsible for Project Control testing, or he may direct that
the samples be sent to the Employer's Central laboratory or to an approved independent
laboratory for testing.
E.2 The Contractor shall provide the Engineer with all necessary Test Report forms and
expendable materials required to perform all required tests. Copies of all test results will be
issued to the Contractor.
1.05.8
A.
SAMPLING AND TESTING STANDARDS
Standards to be Supplied
A.1 The Contractor shall, at the commencement of the Contract, furnish for use on site by the
Engineer and the Contractor one complete set of the following standards. The set shall
become the property of the Contractor upon completion of the Works.
A.1.1 AASHTO Standard Specifications for Transportation Materials and Methods of Sampling
and Testing (Part I : Specifications, and Part I I : Tests).
A.1.2 ASTM Standards for Testing and Materials: Section 00 plus all Volumes in Sections 1 to
6 inclusive, plus Specifications, as required, from Sections 7 to 15 inclusive.
A.1.3 British Standards referred to in the Specification
A.1.4 SASO Standards.
Page 24 of 244
A.1.5 D I N
A.1.6 ISO
A.1.5 All other relevant Standards referred to in the Specifications.
B.
Precedence of Materials and Testing Specifications
B.1 A l l references to methods of testing or specifications of AASHTO, ASTM and others will
be deemed to refer to the latest methods of testing as specified in the Contract Documents.
B.2 Unless otherwise specified, AASHTO methods of sampling and testing shall be adopted
where available. In the case of absence of an appropriate AASHTO specification, the ASTM or
BS specification shall govern.
1.05.9
UNACCEPTABLE MATERIALS
A.
A l l materials not conforming to the requirements of the Specifications at the time they
are used will be rejected and shall be removed immediately from the Site unless
otherwise instructed by the Engineer.
B.
No rejected material, the defects of which have been corrected, shall be used until
approval has been given.
Page 25 of 244
SECTION 1.06
1.06.1
CONTRACTOR'S PLANT AND EQUIPMENT
GENERAL
A.
Plant and equipment used on the Works shall be of sufficient size and in such
mechanical condition as to meet the requirements of the Specifications and shall be
available for use when required by the Engineer. The Engineer may order removal and
replacement of unsatisfactory plant or equipment.
B.
Wherever plant or equipment of a particular size or type is specified, the Contractor may
request permission to use an alternative type in place of that specified. In such cases, the
Contractor shall furnish evidence to the Engineer, before approval is given, that the
production of the plant or equipment proposed is at least equal to that of the specified
type.
1.06.2
CONTRACTOR'S SCHEDULE OF PLANT AND EQUIPMENT
A. The Contractor shall submit together with his Tender, a detailed schedule of the numbers
and types of plant and equipment which he proposes to utilize on Site to carry out the Works.
The schedule shall contain full details for each item, including type, manufacturer, model,
identification number, year of manufacture, number of years in use, and, for all new and
previously used items, the manufacturer's brochures, catalogues and specifications.
1.06.3
PROVISION AND USE OF PLANT AND EQUIPMENT
A.
The Contractor shall furnish all plant and equipment listed in his Schedule and
necessary for construction of each phase of the Works. Such plant and equipment shall
be delivered to the Site, inspected, and approved by the Engineer prior to
commencement of the particular phase of the Works for which it is intended. Any plant
or equipment, or part thereof, which becomes excessively worn or defective shall be
promptly repaired or replaced, as required by the Engineer.
B.
The Contractor shall not remove from the Site any approved plant or equipment without
the permission of the Engineer.
Page 26 of 244
SECTION 1.07 MEASUREMENT PROCEDURES
1.07.1
GENERAL
A.
A l l Works shall be measured net and in accordance with of the General Conditions of
Contract. A l l units of measurement shall be in the Metric System, unless specified
otherwise.
B.
The method of measurement and computations to be used in determining quantities of

materials furnished and of Works performed shall be as defined in the Method of
Measurement.
C.
All field measurements of quantities for monthly certificates and for final payment shall
be made by the Contractor in the presence of the Engineer. Original copies of the field
measurement notes, signed by the Contractor, will be retained by the Engineer.
D.
I f the Contractor fails to measure any Pay Items, the Engineer may, at his discretion,
estimate quantities of such items for the monthly Payment Certificate or recommend
that no payment be made for the Items not measured and quantities not computed until
it is measured.
1.07.2
MANUFACTURED ITEMS
A. Whenever standard manufactured items are specified, such as fence wire, plates, rolled
shapes, pipe conduit, etc. and these items are identified by gauge, unit weight, section
dimensions, etc., such identifications shall be deemed to be nominal weights or dimensions.
Unless controlled by tolerances in cited specifications, manufacturing tolerances established by
the industries involved may be accepted by the Engineer at the recommendation of the
Concerned Authorities.
1.07.3
FITTINGS AND ACCESSORIES
A. When any Items are shown on the Drawings or specified as requiring miscellaneous fittings
and accessories for which no separate measurement is provided, the Pay Item will be deemed
to include for all such fittings and accessories.
Page 27 of 244
1.07.4
WEIGHT MEASUREMENTS
A. A l l materials which are to be measured or proportioned by weight shall be weighed on

accurate and approved scales by competent and qualified personnel, at locations designated or
1.07.5
LINEAR AND AREA MEASUREMENTS
A.
A l l items which are to be measured by linear meter shall be measured parallel to the
base or foundation upon which such items are placed, unless otherwise shown on the
Drawings.
B.
Unless otherwise specified, longitudinal measurements for area computations shall be

made horizontally and no deductions shall be made for fixtures with an area less than
one sq.m. Transverse measurements for area computations shall be the neat
dimensions shown on the Drawings or as ordered by the Engineer.
C.
No measurements shall be made of rolled down or sloping edges of bituminous

courses.
1.07.6
VOLUME MEASUREMENTS IN VEHICLES
A.
Materials to be measured by volume in the hauling vehicle shall be hauled in approved

type vehicles and measured therein at the point of delivery. Vehicles for this purpose
may be of any size or type approved by the Engineer, provided that the body is of such
shape that the actual contents may be readily and accurately determined. A l l vehicles
shall be loaded to their level capacity and the Engineer may require loads to be
releveled when the vehicles arrive at the point of delivery.
B.
When requested by the Contractor and i f approved by the Engineer, material specified
to be measured by the cu. m. may be weighed and such weights will be converted to cu.
m. for payment purposes. Factors for conversion from weight measurement to volume
measurement will be determined by mutual agreement between the Engineer and the
Contractor, i f no agreement is obtained, the factors will be determined by the Engineer
and shall be accepted by the Contractor.
Page 28 of 244
1.07.7
EARTHWORK VOLUME MEASUREMENTS
A.
The quantities of excavation paid for under the Contract unit prices shall be limited to
the lines shown on the Drawings and on approved cross sections. Excavation beyond
lines shown on approved cross sections shall not be paid for unless approved by the
Engineer. Excavation in excess of approved cross sections will be measured for
payment only in the case of unstable or unsuitable materials ordered by the Engineer to
be removed.
B.
The Engineer will adjust the angle of slopes for cuts and fills as the Works proceed and
make determinations of the appropriate slope angles following his evaluation of soil
conditions in case there is a change in the type of the soil. The actual slopes of the cuts
as constructed shall be measured and recorded by the Contractor. The Engineer will
check these records and, i f satisfactory, will approve the measurements as a basis for
payment.
C.
Within 60 days of the date of field survey, the Contractor shall submit to the Engineer for
his approval, plots of the original and final earthwork cross sections together with the
area and volumetric earthwork computations. The Contractor's cross sections shall be
on transparent cross section sheets for print reproductions. Al l sheets shall have a title
block and be of the size designated by the Engineer. On final approval of the
Contractor's cross sections, the Contractor shall submit the original transparencies and
3 prints of each such transparency.
D.
In case of any variations from the approved Drawings, the Contractor shall submit the
original and 2 copies of the plotted cross sections and profiles and the notes and
computations of his survey. The Contractor shall take cross sections at maximum 25 m
intervals along the centerline and at other locations i f directed by the Engineer. Upon
mutual agreement between the Engineer and the Contractor, the Contractor may submit
cross sections intermediate to these locations. The Engineer will indicate, on one copy,
his approval of the proposed lines of the Works or his revisions thereto and return such
copy to the Contractor. The Contractor shall resubmit for approval any cross sections the
Engineer may have revised.
E.
The Contractor may, as an alternate method of earthwork computation, request

approval to use an electronic computer. Such request shall include details of the
computer hardware, the earthwork software programs, the input and output, and a
complete summary of the methods and procedures to be used. The Contractor may use
an electronic computer for computations, only i f approved, and continuance of such
approval is contingent upon satisfactory results being achieved. I f results are not as
represented or are otherwise deemed unsatisfactory, the Contractor shall recompute the
earthwork quantities by the cross section method.
Page 29 of 244
SECTION 1.08
1.08.1
TEMPORARY FACILITIES
GENERALLY
A.
LOCATIONS: The Engineer's approval is to be obtained for the intended locations

sitting of all spoil heaps, Temporary Works and services.
B.
STANDARDS AND DETAILS: Temporary Works are to be constructed to recognised

standards and codes of practice so that they are fit for their purpose. Drawings and
details of proposed Temporary Works are to be provided by the Contractor if requested
by the Engineer.
C.
TEMPORARY WORKS and services are to be maintained, altered and adapted and
as necessary and cleared away on completion or when no longer required. Work
disturbed is to be made good.
D.
GENERAL: The Contractor shall provide all Temporary Works and services and
Contractor's Equipment and tools required for the efficient and safe execution of the
Works, including but not limited to:
Temporary roads, hard standings, sleeper tracks and the like.
Temporary fences, gates and barriers.
Temporary offices, stores, messrooms, latrines and compounds.
Scaffold, ladders, hoists, cranes and the like.
Temporary screens, chutes, coverings, roofs and rainwater pipes for protection
of the Works and personnel.
Transport and vehicles on and off Site.
Fixed and movable mechanical plant and equipment.
Small tools.
Temporary water and power supplies and site lighting.
Temporary drainage.
Page 30 of 244
1.08.2
TEMPORARY SITE FACILITIES
A.
ROADS: Permanent roads, hard standings and footpaths on the Site may be used
provided they are adequately maintained and thoroughly cleaned and made good after
use and left in unimpaired condition.
B.
DIVERSIONS: The Contractor shall in accordance with the specification of the Ministry
of Communication and with liaison with the Traffic Department:
Provide temporary detour roads, temporary bridges and culverts, and other
facilities to divert traffic through or around any part of the Works or for
maintenance of traffic in locations affected by his works that warrant such
Temporary Works. Location, standard, width, construction and maintenance of
detour routes shall be in accordance with Section 3.06 of the Specification,
approved by the Engineer, ensuring at all times that the routes, are signed,
striped, maintained and furnished with all traffic control devices as shown,
directed and/or needed.
Submit designs and detailed working Drawings of the proposed Temporary

Works for approval by the Engineer prior to commencement of the works. The
design live load for temporary bridges related to roads exposed to heavy vehicles
shall not be less than the design live load for permanent bridges, or as directed
by the Engineer.
Where measurements are required for continuously regulating and supervising

traffic, provide temporary roads and bridges for one-way traffic with a minimum
width of 3.5m. In all other cases the minimum width shall be 7m.
Phase the execution of temporary and Permanent Works to minimise the

disruption to traffic.
Submit a phased programme of Temporary Works one month before

commencement of any part of the works.
C. TRAFFIC DIVERSIONS: The Contractor shall provide temporary diversions, detour roads,
temporary bridges, culverts and similar facilities, whenever it is necessary to safely divert traffic
through or around any part of the Works. As per concerned authorities requirements for
locations design widths, construction and maintenance of diversion and detour routes, including
the provision of signs, pavement markings, lighting, traffic control and the like are to be
submitted to and approved by the Engineer prior to execution on Site.
Page 31 of 244
E.
FRENCH CROSSINGS are to be provided for free and safe passage of vehicles and
pedestrians over pipe and other trenches.
F.
TEMPORARY SITE FENCE: The Contractor shall provide suitable and secure
temporary site fencing and gates where necessary or as directed by the Engineer.
Design of the fencing and gates, including location, construction details, etc. is to be
submitted to the Engineer for approval prior to fabrication and erection.
G.
NAMEBOARD: The Contractor shall provide reflecting boards (150 x 150) cm at the
start and end point of the excavations. Those boards should include the project name,
project no., ministry name, Contractor name, and his local address and phone No. in
addition to the supervision Consultants. Boards specifications and locations should be
approved by the Client and the Engineer.
General nameboards for the whole project should be fixed at the specified locations by the
Engineer and in each district of the project area. Those boards should include the project name,
Client name, Contractor name, Contact nos, Consultant name and phone no. for the
supervision staff office. Boards will be of 4 separated slices each of (240 x 240) cm with
spaces of 20 cm between slices that are made of 3 mm thick aluminum and provided with back
grooves for fixing on the columns, so no holes should appear at the face side of the board.
Face slide should be covered with reflective blue layer and text in reflective white color.
Boards shall be fixed on two columns of hot galvanized (16 or 18) cm I beams and the clear
space from the ground to the bottom of the slices shall be 2.0 m and the columns should be
provided with movable hinge according to the MOT specifications and fixed to the ground by
concrete blocks as per the site conditions. A ll these details should be approved by the
Engineer prior to installation of boards.
1.08.3
CONTRACTOR'S TEMPORARY BUILDINGS
Complete according to Project - Project Specifications. To be completed by the design

consultant and the water authority.
1.08.4
A.
TEMPORARY SERVICES
WATER: The Contractor shall provide clean, fresh water for the Works and make
temporary arrangements for storing and distributing about the Site.
Page 32 of 244
B.
ELECTRICITY: The Contractor shall provide electric supply and all equipment for
lighting and power for the Works and make temporary arrangements for distributing
about the Site.
C.
POWER: The Contractor shall provide electric power for the Works, including supplies
for commissioning engineering services and Plant, at the required voltages.
D.
LIGHTING: The Contractor shall provide lighting for the Site and the Works for safety
and security of the Works and to facilitate proper execution of work and to illuminate
internal surfaces during finishing work and inspection. Spaces designed to be
artificially lit during daylight hours are to have temporary illumination similar to that
provided by the permanent installation.
E.
PERMANENT ELECTRIC SUPPLY AND LIGHTING INSTALLATION may be used for

testing and commissioning and to illuminate the Works, subject to the following
conditions:
The Employer does not guarantee that it will be available.
The Contractor must take responsibility for the operation, maintenance and
supervision of the system, indemnify the Employer against all damage and pay
all costs and renew all used tubes and lamps.
The Contractor must indemnify the Employer against reduction in

manufacturer's guarantee periods for equipment etc. due to its use before
completion of the Works.
F. TELEPHONES: The Contractor shall provide joint temporary telephone facilities for his
own and Subcontractors' use and for the use of those acting on behalf of the Engineer and
shall pay the cost of all calls except international calls made by those acting on behalf of the
Engineer.
1.08.6
DIVERSION OF PUBLIC UTILITY SERVICES
A. TEMPORARY DIVERSION OF EXISTING PUBLIC UTILITY SERVICES: Where execution

of the Works involves the temporary diversion of existing public utility services, the Contractor
shall perform such temporary diversion and shall maintain the flow or service as directed by
the Engineer. Unless otherwise stated, the costs of any such diversions are deemed to be
included in the Contract Price.
Page 33 of 244
B. PERMANENT DIVERSION OF EXISTING PUBLIC UTILITY SERVICES: Where the

Works require the permanent diversion of existing public utility services, either as shown on
the Drawings or directed by the Engineer, the diversion shall be carried out by the Contractor
and shall be paid for at the prices stated for such work in the Bill of Quantities.
Page 34 of 244
SECTION 1.09
1.09.1
SAFETY PRECAUTION MEASURES
GENERAL
A. Contractor shall take all necessary measures for public safety for all project components
according to the requirements of municipalities and other concerned authorities.
Page 35 of 244
PART 36: Excavation and Backfilling
P AR T 2 : E X C AV AT I O N AN D B AC K F I L L I N G
SECTION 2.01
SCOPE
A. The Work Covered in this Division Comprises: Clearing of the site, and excavation and
backfilling for roads, structures and trenches and protection work related to gabions, riprap,
stone pitching and geotextiles.
Page 36 of 244
SECTION 2.02
2.02.1
SITE CLEARING
CLEARING AND GRUBBING
A.
The Contractor shall remove and dispose of all vegetation, surface debris, stones and
rocks from areas where the Works are to be performed.
B.
When shown on drawings or directed by the Engineer, the Contractor shall remove and
dispose of pavement layers including asphalt and granular layer to the surface of the
subgrade. Moreover the ground surface under all structures shall be cleared of all
existing concrete foundations (if any) and stumps.
C.
Trees shall be removed carefully, stored and / or relocated as specified or as instructed
by the concerned Authorities and the Engineer.
2.02.2
REMOVAL OR REALIGNMENT OF OBSTRUCTION AND

UTILITIES
A.
The Contractor shall remove wholly or in part and dispose of all obstructions, buildings,
fences, abandoned pipelines and others, as indicated on drawings or as directed by the
Engineer.
B.
Where indicated on the Drawings, utilities are to be realigned or salvaged as directed by

the Engineer.
Page 37 of 244
SECTION 2.03
2.03.1
EXCAVATION
GENERAL
A.
Earth: naturally occurring, man made or placed material that can be removed manually
or by mechanical shovel, bulldozer or other mechanical equipment.
B.
Rock/Hard Materials: naturally occurring, man made or placed material of more than
one cubic meter that cannot be destroyed or removed by methods used for removal of
earth described in Clause A but requires the use of pneumatic tools, impact breakers or,
i f allowed, explosives for its removal.
C.
Materials and conditions: the Contractor shall assess the nature of the work and the
materials to be excavated, and shall take sole responsibility for his assessment of
materials and conditions.
D.
Ground-water level is to be established at the time the various excavations are carried
out.
2.03.2
TOP SOIL
A.
Topsoil: before beginning general excavations or filling, the Contractor shall excavate
topsoil from required areas and keep separate from excavated subsoil.
B.
The Contractor shall stockpile excavated topsoil required to carry out subsequent
top-soiling operations in temporary spoil heaps on the Site as instructed.
C.
Surplus Topsoil: The Contractor shall remove from the Site to a tip provided by the
Contractor
2.03.3
A.
EXCAVATING
General
A.1 All excavation shall be performed to the line, grades, cross section and sizes shown on the
drawings, or/and directed by the Engineer.
Page 38 of 244
A.2 Methods: The Contractor shall submit with the Tender details of proposed methods of
working which may cause nuisance, damage or danger to people and/or property.
A.3 Materials arising from excavations are to remain the property of the Employer unless
instructed to be removed from the Site as per the Engineer or the authorities instructions.
B.
Excavations for Adjacent Utilities
B.1 Underground services must be set out so that their excavations do not encroach below a
line drawn at an angle from the horizontal from the nearest lower edge of building foundations.
The angle shall be 45 degrees for dry stable soil or 30 degrees for wet clays or soils below
water table. I f this condition cannot be met obtain instructions before proceeding.
B.2 Where an excavation encroaches below a line drawn at an angle from the horizontal of 45
degrees for dry stable soil or 30 degrees for wet clays or soils below water table from the
nearest formation level of another higher excavation then all work within the lower excavation
and backfilling thereto must be completed before the higher excavation is made.
C. Excavated formations are to be inspected and approved before new work is laid on them.
The Contractor shall give 24 hours written notice of when excavations will be ready for
inspection. If , after inspection, surfaces become unsuitable due to water, frost or other causes,
excavate further and backfill with approved material all at the Contractor's expense. The
Contractor shall place concrete or other f ill as soon as possible after inspection.
D.
The bottom 200 mm thickness of excavation shall be removed by hand just prior to
placing concrete blinding or pipe laying.
E.
The Contractor shall level or grade and compact bottoms of excavations to Engineer's
approval.
F. Headings: The Contractor shall drive accurately to required line and gradient and provide
adequate support. Construct in approved lengths to size required to contain permanent work.
The Contractor shall obtain approval from the Engineer before commencing activities.
Page 39 of 244
G.
Support
G.1 Sides of Excavations: Responsibility for upholding sides of excavations rests with the
Contractor.
G.2 Earthwork Support: The Contractor shall use as necessary to support sides of excavations
and remove on completion unless otherwise instructed. In the event of any collapse occurring
while excavations are open this will be the Contractors full responsibility and he should
re-excavate and reinstate such excavations and other work affected at the Contractor's
expense and responsibility.
G.3 Steel Sheet Piling: The Contractor shall use as necessary to support sides of excavations
and remove on completion unless otherwise instructed.
G.4 Special Support: The Contractor shall use as necessary to uphold excavations against
sides of adjoining buildings, public footpaths, roads and the like and remove on completion
unless otherwise instructed.
G.5 Unstable Ground: The Contractor shall inform the Engineer without delay i f any newly
excavated face will not remain unsupported sufficiently long to allow the necessary earthwork
support to be inserted. I f the instability is likely to affect adjacent structures or roadways take
appropriate emergency action. Responsibility for preventing instability rests with the Contractor.
H. Waterways: Temporary diversion as necessary of ditches, field drains and other waterways
encountered during the excavations is to include reinstatement on completion. I f reinstatement
is not possible the Contractor shall obtain instructions.
I.
Existing watercourses which have been diverted and are to be filled must be cleared of
all vegetable growth and soft deposits before filling.
J.
Existing Foundations
J.1
Where old foundations, beds, drains etc. are encountered the Contractor shall obtain
instructions before proceeding.
J.2 Breaking out old foundations, beds, drains etc. is to include sealing off drain ends, removing
contaminated earth and disinfecting as necessary and according to the Engineer instructions.
Page 40 of 244
K.
Backfilling of excavations shall be as specified in other Sections of these

specifications.
L.
Unauthorised Excavations: The Contractor shall backfill and compact as instructed at

no expense to the Employer.
M.
Water: All excavations shall be kept free from water arising from any source at all
times. The discharge of any water from the excavations must not effect other parts of
the works or adjoining areas.
N.
Pumping: The Contractor shall not disturb material in and around excavations by
pumping operations.
O.
Sumps: The Contractor shall obtain approval of location of any sumps and f ill with
approved material when no longer required.
P.
Permanent drainage system is not to be used for disposal of water from excavations
without approval.
Q.
The Contractor shall keep all excavations adequately drained at all times. Damage to
any part of the work due to poor drainage facilities shall be repaired at the Contractor's
expense.
R.
All excavated slopes shall be cut to the slopes shown on the Drawings.
2.03.4
DISPOSAL OF MATERIALS
A.
No excavated material shall be wasted without written permission from the Engineer.
Suitable material from excavation shall be used for embankment construction or backfill,
as directed by the Engineer.
B.
Surplus Subsoil: The Contractor shall remove from the Site surplus excavated
materials not specified as to be spread and leveled or stockpiled to a tip provided by
the Contractor.
C.
Tip: The Contractor shall use only public dumpsites assigned by the concerned
authorities for disposal of surplus excavated material removed from the Site and pay all
tip fees.
Page 41 of 244
2.03.5
ROCK EXC AV ATIO N
A.
A l l blasting shall be carried out in such a manner as will produce the least possible
disturbance of the material left in place.
B.
A l l the necessary precautions shall be taken to ensure that the blasting shall not be
dangerous to people or property.
C.
Where necessary or directed, the Contractor shall provide heavy mesh blasting mats for
protection of persons, properties, and the Works. I f , in the opinion of the Authorities and
the Engineer, blasting would be dangerous to persons or adjacent structures, or is being
carried out in an unsafe or unacceptable manner, the Engineer may prohibit blasting
and order the rock to be excavated by other means.
D.
I f the flow of traffic is to be interrupted during blasting operations, the Contractor shall
secure approval of his schedule for such interruptions and his proposed methods for
safeguarding the public and property.
E.
A l l drilling and blasting shall be done in such a manner as will most nearly complete the
excavation to the required grade lines, and produce the least practicable disturbance of
the material to be left in place. Blasting by means of drill holes, tunnels, or any other
methods shall be entirely at the Contractor's risk.
F.
Unless otherwise approved by the Engineer, rock cuts higher than 3 m shall be formed
using pre-splitting. Prior to starting the pres-splitting operation the Contractor shall
submit a layout plan showing the location of drill-holes, type of explosive to be used and
sequence of firing. This plan does not absolve the Contractor of his responsibilities for
the safety of people and structures, or for producing a satisfactory stable rock face. No
extra cost is charged by the Contractor for using pre-splitting.
G.
A l l overbreaks, overhangs loose blocks or unstable parts of the cut face, and benches
shall be cleared and cleaned, to the satisfaction of the Engineer.
H.
Backfilling of overbreakage shall be carried out as directed, using approved soil or

crushed materials or other special aggregate or cyclopean concrete, as shown on the
Drawings or as directed by the Engineer. Undrained pockets shall not be left in the
surface of the rock.
Page 42 of 244
2.03.6
A.
ROAD EXCAVATION (FOR PREPARATION OF SERVICE ROADS

ALONG PIPELINES)
Scope
A.1 These Works shall consist of excavating material in cut sections of the road, including
water courses, ditches and wadi relocations (but excluding borrow pits and structural
excavation) all as and where shown on the Drawings, and hauling the excavated material either
to locations for road embankments or to stockpiles or to waste.
A.2 These Works shall also include any necessary excavations outside the ROW ordered by
the Engineer to safeguard and protect the Works. These may include diversion of existing water
courses, channels; excavation of materials obstructing or impairing the flow along stream
channels; and excavation of unstable materials which may slide or encroach into ditches or
onto the ROW. Disposal of all such excavated materials shall be as instructed by the Engineer.
B.
Classification of Road Excavation
B.1 Any information concerning properties of the soil which may be shown on the plans, in the
B i l l of Quantities, in supplementary reports, or as a result of discussion with the Engineer or
others shall be considered as gratis and shall not be a basis for the Contractor's determination
of his bid prices.
C.
Utilization of Excavated Materials
C.1 A l l materials removed from the excavation shall be used in the formation of the
embankment, subgrade, shoulder, and at such other places as directed, unless it is declared
unsuitable and ordered to be wasted by the Engineer.
C.2 Unsuitable material shall include:
Unstable materials incapable of being compacted to the specified density using

ordinary compaction methods at optimum moisture content for the equipment
being used for compaction.
Material too wet to be compacted and circumstance prevent suitable in-place

drying prior to incorporation into the work.
Materials which are otherwise embankment.
Page 43 of 244
C.3 No excavation material shall be wasted without written permission from the Engineer.
C.4 Excavated rock which is not immediately suitable for incorporation in the works can either
be broken down to acceptable sizes or wasted at Contractor's expense.
D.
Drainage of Excavation Areas
D.1
The Contractor shall schedule road excavation and embankment and drainage Works
so that they complement each other. I f the Contractor's earthwork progress exceeds the
progress of the drainage construction to the point where the road becomes a dam to cross
drainage, the Engineer may order the Contractor to open adequate waterways through the
highway at the locations where drainage structures are to be installed. Any damage to the
highway caused by water passing through these openings shall be repaired at the Contractor's
expense.
D.2
During construction, surfaces in excavation areas shall be adequately drained at all

times. Side ditches or gutters emptying from cut to embankment shall be so constructed
as to avoid damage to embankments by erosion.
D.3
Damage to the Works attributable to saturation or erosion through failure to provide

adequate drainage shall be repaired by the Contractor at his expense.
D.4
Whenever groundwater is encountered which may adversely affect construction, the

Contractor shall advise the Engineer who will evaluate the situation and order necessary
remedial measures to drain or extract water.
E.
Slopes, Subgrade and Ditches
E.1
A l l excavated slopes, subgrade and ditches shall be finished true to lines, grades and
cross sections as shown on the Drawings.
E.2
Slopes, except in massive rock or other material which require special treatment, shall
be trimmed to slopes not steeper than the specified slope angles and rounded at top
and bottom to a smooth profile to blend in with the adjacent terrain. Material shall not be
loosened beyond the specified slope lines. High cut areas shall continuously be
monitored by an engineering geologist or a geotechnical Engineer.
Page 44 of 244
E.3 In cuts where earth overlays a rock formation, slopes shall be benched in an approved
manner.
E.4 Ditches of all types shall be excavated and trimmed neatly in conformity with the specified
grades and cross sections. A l l projecting rock, stumps, roots or similar shall be removed.
Ditches include side ditches, furrow ditches, irrigation ditches, wadi relocations, etc.
E.5 The Engineer will periodically check all or any part of the Works, to determine
conformance to the correct lines, grades and elevations. Tolerances on finished subgrade
elevations and on elevations of the surface at the underside of the subgrade layer, shall be as
specified in Section 2.05 - "Subgrade Construction".
F.
Excavation of Unsuitable Material
F.1
Where excavation to finished grades and cross sections exposes unsuitable material in
the subgrade, slopes or ditch inverts, etc the Engineer may require the Contractor to
remove the unsuitable material and backfill the excavated areas using approved
material. The Contractor shall conduct his operations in such a way that necessary
cross section measurements are taken before such backfill is placed.
F.2
Unsuitable material shall be disposed of as directed. Wasted unsuitable material shall

not be deposited on any cropland.
F.3
When the Contractor is directed to excavate unsuitable material below the surface of the
original ground in f ill areas, other than that required for clearing and grubbing, the
depth to which unsuitable material shall be removed will be determined by the Engineer.
The Contractor shall schedule the excavation so that cross sections are taken before
and after material has been removed.
F.4
Unsuitable materials outside the ROW or ditch slopes which, in the opinion of the
Engineer, are potentially unstable and liable to slide or encroach into the ROW or into
the ditches, shall be excavated and disposed of as specified for unsuitable material,
unless it is approved for use as embankment fill.
F.5
Unsuitable and surplus materials disposed of elsewhere than within the ROW shall be
spread, leveled and shaped as directed so as to present a neat and tidy appearance. No
materials shall be disposed of in such a way as to adversely affect natural drainage
courses or to cause damage to the highway or adjacent public or private property.
Page 45 of 244
F.6 I f approved by concerned authorities land can be used for disposal to the maximum extent
practicable. I f private land is used for disposal, the Contractor shall secure the consent of the
landowner or tenant and, i f necessary, and at his expense, pay for the use of such land. The
use of cropland for disposal purposes will not be permitted.
2.03.7
A.
EXCAVATION FOR STRUCTURES
Scope
A.1 These Works shall consist of all excavation in any material for structures associated with
networks such as water tanks, pump houses, culverts, utility ducts and water underdrains; for
retaining walls of all types; and for other major and minor structures; and including all
necessary clearing and grubbing; bailing; drainage; pumping; sheeting; temporary shoring and
cribbing; construction of temporary cofferdams or cribs; and disposal of all excavated material
and backfilling with suitable approved material; all as and where shown on the Drawings.
A.2 These Works shall also include the removal of those portions of existing structures below
ground which would in any way obstruct or interfere with construction of new structures.
A.3 The Contractor will be deemed to be fully aware, at the time of tendering, as to the type
and nature of soils and rock that will be encountered in structural excavations.
B.
Excavation
B.1 The Contractor shall notify the Engineer a sufficient time in advance of the beginning of any
excavation for structures so that the Engineer may, where necessary, survey and record the
cross sectional elevations and measurements of the existing ground and existing structures
affected by the proposed structure. Any materials removed or excavated before these
measurements have been taken and approved by the Engineer will not be paid for.
B.2 The Contractor shall be solely responsible for the safety at all times of all foundation and
trench excavations whether supported or otherwise. Approval of the Contractor's support
system or omission of a support system for any excavations shall not absolve the Contractor
from his sole responsibility in this regard.
Page 46 of 244
B.3 The Contractor shall take all necessary precautions, including shoring or otherwise, to
protect employees in the excavation and on the ground above. The Engineer will not enter
excavated areas to approve the foundation and further Works until he deems the areas to be
safe.
B.4 In areas where the excavation is adjacent to public roads and walkways, the Contractor
shall erect all necessary barricades, barriers, enclosed walkways, and warning signs necessary
to restrict the exposure of the public to the excavation.
B.5 The sides of all foundation pits and trenches shallower than 1 .5m shall be vertical and
adequately supported at all times unless otherwise shown on the Drawings. Sides more than 1.5
m in depth shall be sloped at a stable slope or supported in an approved manner unless the
material through which the pit or trench is cut is deemed to be sufficiently self supporting and
not requiring support.
B.6 Pits and trenches shall be kept free from water until footing concrete has been placed or
pipes have been installed. The Contractor shall minimize, to the maximum extent practicable,
the length of time excavated areas are open. The Contractor will be held responsible for
damage due to weather, equipment, and other causes during periods when the excavations are
left open.
B.7 The Contractor shall schedule the Works so that no excavation is left in an exposed
condition for a period greater than 20 days unless otherwise approved.
B.8 In areas where the excavation is adjacent to public highways, roads and walkways,
excavation shall be scheduled such as not to be left in an exposed condition for more than 7 days
unless otherwise approved.
B.9 For excavation in material sensitive to moisture (stiff clays, marls, etc.) the excavation shall
be cleaned and concrete blinding layer cast immediately on completion of the excavation.
B.10 The Contractor must notify the Engineer of any sign of failure or cracks within or around
the excavation immediately when such signs are noticed.
C.
Temporary Support System
C.1 When a temporary support system is required to protect adjacent property or to protect the
public during construction, the Contractor's design for such support system shall be submitted to
the Engineer for approval prior to commencing its construction.
Page 47 of 244
C.2 A l l temporary support systems shall be designed with adequate factors of safety to serve
with minimal maintenance, for the duration of its intended use, and shall include adequate
safety provisions to protect the public from construction activities.
C.3 Notwithstanding any approval of temporary support systems, the Contractor shall be
solely responsible for the adequacy of their design, construction, maintenance and all
necessary safety precautions associated therewith.
D.
Excavation for Major Structures
D.1
The foundations for buildings, water tanks, pump houses and other major structures,
shall be excavated in accordance with the dimensions as shown on the Drawings and
shall be of sufficient size to permit the placing of the full width and lengths of the
footings.
D.2
The excavation shall be carried to the elevations shown on the Drawings or as

established by the Engineer. Borings and soil tests, made during design, and actual
investigation of the completed foundation excavation shall be utilized by the Engineer
to determine final depth. No concrete shall be placed prior to approval of the excavation
pit.
D.3
Unless shown otherwise on the Drawings, the bottom of all excavations shall be
covered with a 75 mm minimum depth of lean (blinding) concrete Class 110/25 to serve
as a working platform.
D.4
Foundation pits or trenches shall be of sufficient size and provide minimum sufficient
working space to permit construction of structures or structure footings of the full width
and length shown on the Drawings.
D.5
Where footings are to be constructed using formwork, the excavations shall generally
not extend more than 500 mm beyond the maximum dimension on each side of the
proposed footing unless additional working space is clearly required and approved, by
the Engineer. Any unauthorised overwidth of excavation beyond the lateral limits
shown on the drawings or approved by the Engineer shall be backfilled with selected f ill
or lean concrete as directed by the Engineer.
D.6
Where footings are to be located, in or adjacent to firm, original ground and where
formwork is not required or ordered, any unauthorized overdepth excavation below the
approved elevation of base of footing shall be backfilled with blinding concrete.
Page 48 of 244
D.7 Where excavation to rock foundation is required, the excavation shall proceed in such a
manner as to allow the solid rock to be exposed and prepared in horizontal beds or properly
serrated for receiving the concrete. A l l loose and disintegrated rock and thin strata shall be
removed.
D.8 All blasting necessary for foundation placement shall be performed prior to placing any
concrete. Blasting will not be permitted in the vicinity of concrete which has not cured for at
least 14 days. Blasting shall not affect concrete properties and integrity in any way.
D.9 When unstable material or other unsuitable material is encountered below foundation
elevation like swelling soil or others, the Contractor shall excavate such material and replace
it with suitable backfill material or concrete as directed by the Engineer.
D.10 I f temporary works are required for maintaining the excavation dry, the Contractor shall
be responsible for the design and execution of the works. The proposed design shall be
submitted to the Engineer for approval, however, such approval does not relieve the
Contractor for his sole responsibility in this regard.
2.03.8
EXCAVATION FOR PIPE TRENCHES
A.
Before excavating trenches for pipes in any road, the contractor shall acquire the
necessary permission from the Engineer and concerned authorities.
B.
During excavation, material suitable for backfilling (Section 2.04) shall be piled at
sufficient distance from the sides of the trench as to avoid overloading and prevent
cave in. A l l excavated material not required, or unsuitable for backfilling shall be
removed and carted away to an approved dumping area.
C.
Trenches shall be excavated to such depths as will permit the pipes to be laid at
elevations, slopes or depths of cover indicated on the drawings, and at uniform
slopes between indicated elevations.
D.
Where excavation depth exceeds the level indicated on the drawings and is not
authorized in writing by the Engineer, the Contractor shall bear the cost of the excess
excavation, backfill or concrete level make up of any type as instructed by the Engineer.
E.
Trenches shall be excavated with vertical sides between the level of the bottom of
the trench and an elevation 300 mm above the top of the pipe.
Page 49 of 244
F.
Unless otherwise indicated on the Drawings, trench widths will be as shown in the
following table:
Pipe diameter (mm)
< 150
Trench Width (mm)

Minimum
Maximum
650
950
200
700
1000
250
750
1050
300
850
1150
350
900
1200
400
950
1250
450
1050
1350
500
1100
1400
600
1250
1550
700
1350
1650
800
1500
1800
900
1600
1900
1000
1750
2050
1100
1900
2200
1200
2000
2300
1300
2150
2450
1400
2250
2550
1500
2400
2700
1600
2550
2850
1700
2650
2950
1800
2800
3100
1900
2900
3200
2000
3050
3350
2100
3200
3500
2200
3300
3600
2300
3450
3750
2400
3550
3850
The lowest trench width will be used for the calculation of quantities and payment for all
types of trenches and excavation in rocks. The contractor should have included in his
prices any extra expenses that will be needed for extra excavation beyond the trench
width, this is applied also for the pavement and road surface finishing works.
Page 50 of 244
G.
Where the above specified maximum trench widths are exceeded; the Contractor shall
bear the cost of increased pipe strength or additional pipe protection i f the Engineer
calls for such measures due to excavations being taken wider than specified.
H.
Excavation with battered sides shall not intrude into private property and shall respect
the statutory regulations relevant to the R.O.W. and property limits.
I.
When the pipe, culvert or duct are to be laid in embankments or other f ill areas, the
embankment or f ill area shall first be filled and compacted as specified to the
proposed finished grade or to a height of at least 300 mm above the crown of pipe
whichever is lower. The trench shall then be excavated as in undisturbed material.
J.
When pipes, culverts or ducts are to be laid under existing pavements, trenches shall
be excavated carefully and to minimum widths. Methods that will give straight and
vertical face shall be used. The pavement shall be kept at its original level and
condition.
K.
In combined trenches where one pipe is at a lower level than an adjacent pipe the
following shall be applied:
The whole trench shall have a depth related to the lower pipe and the thickness
of the bedding shall be increased to the upper pipe as necessary.
The lower pipe shall be backfilled with thoroughly compacted granular material
up to a level of 0.30 meters above the higher pipe.
L.
Excavation for the forming of the trench for beds shall be carried out immediately
before laying beds or pipes. Unstable material, rock projections, boulders and hard
spots shall be removed and replaced with approved well consolidated filling material,
that will be compacted as instructed. Local soft spots shall be hardened by tamping in
bedding material.
M.
The bottoms of trenches shall be accurately graded to provide uniform bearing and
support for the bottom quadrant of each section of the pipe. Bell holes shall be excavated
to the necessary size at each joint or coupling to eliminate point bearing. Any material
or block that may cause point bearing shall be removed.
N.
The Contractor shall report to the Engineer any unsuitable or weak ground material
that may found below the indicated excavation levels before executing any trimming of
the excavation, pipe laying, concreting, or other work. Where, in the judgment of the
Engineer the bottom of the trench is found unsuitable, such material shall be removed
to the width and depth ordered by the Engineer. The trench shall then be made up by
backfilling with approved material as specified herein after.
Page 51 of 244
O.
Where rock excavation is encountered, the trench shall be excavated to min. 200 mm
below pipe invert and replaced with granular material matching the specification in
Item (2.4.5) or concrete class 110/25, as directed by the Engineer. In case of soil, the
min. bedding should be 150 mm.
P.
Headings, when required, shall be accurately driven to required line and gradient and
adequate support shall be provided. Construction shall be carried out in approved
lengths and to size required to contain permanent work. Approval shall be obtained
before starting pipe laying or other work.
Q.
Generally, trench excavation, pipe laying, and trench backfilling for any particular
project section shall be completed in twenty (20) days. At any one time, the maximum
length of open trenches in the project shall not exceed 300 meters.
R.
The Contractor should give special care while excavating in paved areas, so the
excavation width not to exceed the specified width. The Contractor should use the
suitable mechanical machines to cut the pavement in straight lines and the edges should
be vertical. In addition, the Contractor should always use vehicles with suitable tires (Air
tire) that will not damage the road surface pavement.
2.03.9 Technical Specifications of Thrust Boring

A.
Scope of works
This section covers pipes and fittings installation through Thrust boring. The relevant sections
mentioned in the general specifications for the implementation of the drainage networks for
the Water directorate general in Riyadh shall be considered applicable by the present
agreement unless otherwise stated therein. Furthermore it is a must to comply with the entire
specifications and conditions related to the Ministry of Transport and Saudi Railway
Organization regarding the implementation of such works.
B.
The general drilling of the ground pits and tunnels
B.1 The implementation of ground pits and the installation of pipelines should be carried out
by jacking as approved by the engineer.
B.2 The perforations of the ground pits should be of practical dimensions enabling to proceed
in the structural works properly. The drilling works should be performed with extreme care
preventing earth settlement and sliding and following the design alignment and levels for the
external dimensions of pits not to be anywhere smaller than the dimensions mentioned in the
plans or determined by the engineer. The Contractor should use specialized manpower in the
drilling works of pits.
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B.3 The Contractor should supply and fix all the other temporary supports and other necessary
structures to ensure the safety of works and adjacent structures outside the permanent work
place to the engineers approval.
The contractor must provide communication means between the pits and the and the work areas
that should not be of same quality like the telephone communication and that, to the engineers
approval.
The contractor should supply and operate and maintain an appropriate lighting and ventilation
network for each pit and the commencement of the drill obtaining the engineers approval. The
electricity power supply should be adequate.
All equipment shall be installed and maintained inside and around pits according to the relevant
work regulations and as per the suitable practical application principles to the engineers
satisfaction.
B.4 The pits should have separate openings equipped with stairs in addition to other required
openings during the structural works. Each pit should be surrounded by closed fence of height
not less than 1,80 meter equipped with security red lights when working in the traffic areas.
When work is suspended for any reason, the sides of pits should be covered and supported by
wooden boards and covered with light mortar for safety reasons, unless the engineer decides to
take other measures.
The contractor should take these temporary works into account while preparing his prices. All
the temporary supports and structure for pits, should be removed when no more needed unless
otherwise directed by the engineer.
B.5 Before starting to request any trench excavation equipment or starting any work the
contractor should present detailed proposals for making access openings or the work openings
to the engineer.
B.6 The earth reinforcement must be of sheet steel supports or of similar approved fixed metal
ring supports.
The contractor may use precast concrete pieces for the ground reinforcement above the
permanent work place, i f the concrete pieces are used for support, they should be covered as
per the specifications and discarded or broken after the work completion.
Such work shall not be measured nor classified for payment.
Page 53 of 244
C.
Checking alignment and levels
C.1 Checking and adjustment of the alignment and levels should be done using laser. The
contractor should prepare and present his proposals for checking and adjustment of the
alignment and levels to the engineers representative for approval in an earlier phase in the
Contract.
C.2 When permanent works are done outside the overstepping boundaries allowed by the
present specifications, the contractor should remedy this situation according to the engineers
directives.
D.
Works for preventing water leakage
All works should not have water leakage upon the completion of works and should remain free of
water leakage until the expiry of the maintenance period.
The contractor should immediately repair the defects at the engineers satisfaction.
E.
Ground treatment
I f the contractor considers that special a ground treatment is required and necessary for
preventing settling and sliding during the construction he must request the authorization from
the engineer in this concern. When the contractor is given the authorization, he must carry out
works as mentioned in the specifications. Such authorization (or the refusal the authorization)
does not exempt the contractor from assuming the responsibility of securing works safety.
The treatment should be implemented in sequences suitable to work requirements and the
contractor should carry out testing according to the engineers directives to check their
efficiency during and after the treatment works.
The contractor should keep meticulous and detailed register for all the ground treatment
methods to the engineers satisfaction. He must submit everyday copy of such register to the
engineer when the ground treatment is carried out. In the cases where the engineer considers
that such technique is necessary and essential for the appropriate implementation of works he
will give the necessary instructions to the contractor. The payment for the ground treatment
should be included in the prices of the pipeline by thrust boring. The contractor should assume
the responsibility of the damages occurring from the ground treatment operations.
Page 54 of 244
F.
Noise restriction means and the electrical machinery.
F.1 In order to minimize as much as possible the disturbance emanating from the equipment
noise during the night, the contractor should operate the machinery with the electrical power
unless otherwise authorized by the engineer.
F.2 The operations above ground level during night work should be restricted to the minimum
practicable work and the contractor should take all the precautionary measures for preventing
unnecessary noise.
G.
Pipe Jacking
Before starting works, the contractor should submit to the engineer full details on his
suggested methods for obtaining the engineers approval, such details should include the
following information:
a)
Interjacking locations and the reinforcement of the starting points of excavation.
b)
Dimensions of the starting points of the tunnel excavation and the supporting
methods of the excavations.
c)
Dimensions and details of the retaining wall
d)
A l l the sizes of the operating equipment
e)
Locations of the drainage gutter and the methods of preserving works free of water
G.1
The pipes jacking starts from the reinforced starting point of excavation, which
should be dug in with suitable size to accommodate the reinforcement wall, the
jacking equipment and the appropriate work place.
G.2
Excavation should be carried out inside the protection installations, which should be
kept in all times close to the work level and must be adjusted for monitoring the
alignment and the level.
G.3
Reinforcement should be used for the loose non-steady open excavation when pipe
jacking works are suspended.
G.4
The pipe jacking is done through hydraulic pressure by using appropriate jacket
designed for the higher pressure and using ring supports for distributing the pipe
jacking forces. The pipe jacking system should allow testing from both the
surface location and the surface of excavation starting point.
Page 55 of 244
G.5 The pipe jacking stations located at the center of the trajectory should properly serve the
jacked pipes joints and the relevant connections. Connections should be hermetically closed
and anti-leakage when in service.
The contractor should take all the necessary steps for securing the safety of pipes and the
tunnel protective coating during jacking of pipes. I f damages occur due to the contractor works,
Contractor should carry out the necessary repair to the engineers satisfaction and he should
withdraw the damaged pipes and export it out of site i f instructed by the Engineer, without any
extra cost.
H.
Thrust Boring under the railways
The contractor shall assume responsibility of securing the review of the adequate procedures
and the compliance with the specifications of Ministry of Transport regarding the pipes crossing
under the railways.
The attention of the contractor should be drawn particularly to the requirements of the Railway
Saudi Arab Establishment. But all crossings should be placed according to the fifth and tenth
sections of the present guidelines of the Railway Engineering Consultant Association, a copy of
which is enclosed for the proper use of the supervisor and/or engineer.
Page 56 of 244
SECTION 2.04
2.04.1
SOIL FILLING AND BACKFILLING FOR STRUCTURES
SCOPE
A. This section covers general soil filling material and source, backfilling for structures,
embankment construction, backfilling for pipe trenches and all particular requirements related
to these works.
2.04.2
FILLING MATERIAL AND BORROW MATERIAL
A.
Filling material shall be approved and capable of being compacted as specified.
B.
Filling materials for foundations and general filling shall pass a three inch U.S.
standard sieve and the material passing a No. 4 U.S. standard sieve is to have a
maximum plasticity index of 6%. No piece is to have its largest dimension greater than
one-third the thickness of a compacted layer.
C.
Sampling: The Contractor shall submit 50 kg representative samples to an approved

laboratory for tests as follows and submit results for approval:
For Soils with Less than 50% Fines: Sieve analysis and compaction.
For Soils with More than 50% Fines: Sieve analysis, Atteberg Limits and
Compaction.
D.
Approval: Sources and types of materials and moisture contents at which they may be
placed and compacted are to be those approved after receipt of laboratory test results.
E.
I f suitable filling or backfill material is not available from material excavated on the
project site, the Contractor shall be responsible for locating suitable borrow and
arranging for the excavation of suitable material with the land owner.
F.
Borrow pits are to be excavated in a uniform manner, neatly trimmed and graded and
left in an approved condition.
G.
The borrow material shall fulfill the requirements specified for the intended use. No
borrow material shall be brought to the site unless it has been approved by the
Engineer.
Page 57 of 244
H.
Testing Fill From Borrow Pits: The Contractor shall sample and test in accordance
with ASTM D1557 to determine the optimum amount of water to be used with f ill
material to obtain maximum dry density. Tests are to be conducted for every borrow
pit and for every type of f ill material encountered.
I.
The Engineer will periodically require testing of borrow materials to verify that no
change in quality has occurred since the original approval.
J.
Field density tests on compacted soils are to be made at an average of one test per
100 m of area. Minimum density required on soils when made in accordance with
ASTM D2167 'Rubber Balloon Method', ASTM D1556 'Sand-Cone Method' or ASTM
D2922 "Nuclear Method" is to be:
For Backfill Under Roads, Parking Areas and Paved Areas up to 500 mm: 95% of
maximum dry density
For Backfill Deeper than 500 mm Under Same Areas as last Described: 95% of
maximum dry density
Elsewhere Such as Landscaped Areas: 90% of maximum dry density.
K.
Selected Fill: Excavated material conforming to the specification for Filling material
and Borrow material, Clause B above.
2.04.3
BACKFILLING FOR STRUCTURES
A.
General Requirements
A.1
The Contractor shall obtain approval for his proposed method and rate of placing of
backfill, before backfilling commences.
A.2
Excavated material or material from other sources for use as backfilling shall conform
to the below requirements:
The supplied material shall not contain any organic or harmful material e.g: tree,
leaves, roots, and residues.
The supplied material shall conform to classification types: A-1-a, A-1-b, A-2-4,
according to MRDTM 210 (Directorate of Material and Research at the MOC).
The California Bearing Ratio shall not be less than 25% when tested according to
MRDTM 213.
Page 58 of 244
The maximum dry density shall not be less than 95% when tested according to
Directorate of Material and Research at the MOC.
The material shall be well graded passing sieve no. 3 (75 mm sieve) and shall contain
fine material for proper compaction.
A.3 Backfill materials shall be uniformly graded granular material, capable of being
compacted to the specified compaction level, and having adequate permeability to permit free
drainage through it. Backfill material shall also conform to the following:
Minimum D10 value
1 mm
Maximum Plasticity Index
10 per cent
Requirement for bridges, culverts etc. specified in subsequent sections.
A.4 Backfill material shall not be placed against any structure until approval is given. Unless
otherwise shown on the Drawings. Structures shall be backfilled to the same requirements as
specified for the adjacent embankment.
A.5 Backfill shall be placed in level layers for the full width of the excavated area until the
elevation of the original ground or surrounding embankment is reached. Backfill next to walls,
between columns or in other confined areas, shall be compacted by approved hand or portable
equipment.
A.6 Each successive layer of backfill shall contain only sufficient material to ensure proper
compaction and in no case shall any layer be greater than 300 mm thickness (before
compaction). The moisture content of the backfill material shall be uniform and within the
moisture range designated.
A.7 Water shall be drained from the areas to be backfilled wherever practicable. In cases
where, in the opinion of the Engineer, it is not practicable to drain the areas to be backfilled,
the initial backfill material shall consist of crushed, open graded material conforming to the
following gradation:
ASTM Sieve
Size
3/8"
No. 4
No. 30
No. 200
Percentage Passing
100
< 85
< 45
<5
Such material may be deposited below the standing water level without compaction. Above the
water level normal laying and compaction will be used.
Page 59 of 244
A.8 Additional water to be added during placement of backfill material to achieve required
compaction shall be fresh water or brackish water approved by the Engineer.
A.9 Minimum tests required during backfilling operations to verify material are:
One Proctor test for each structure (or for each 100 m2).
One Gradation of Materials when materials changed.
One Plasticity Index and field density for 50% of the layers and for each footing
and abutment (or for each 500 m2) as per instruction of the Engineer.
B.
Workmanship
B.1
Unsuitable Materials: The Contractor shall remove from the Site imported filling
materials deemed unsuitable by the Engineer.
B.2
Surplus: The Contractor shall remove surplus imported filling materials from the Site.
B.3
The Contractor shall place filling using approved methods to required dimensions,
levels, lines and profiles and to permit water to drain freely.
B.4
Earthmoving Equipment: The Contractor shall do not use for compaction except where
approved.
B.5
Heavy Steel or Pneumatic Rollers: Special precautions shall be taken to safeguard

existing structures when steel or pneumatic rollers are used. These shall not be used
when compacting backfill to pipe trenches.
B.6
Compaction Equipment: Backfilling shall be compacted by approved compaction

equipment suited to the type of material. Compaction around foundation walls, culverts
and small restricted areas shall be carried out by mechanical vibratory plates, tampers
or hydraulic compactors.
B.7
Moisture Content: Each layer of filling shall be moistened or dried to reach the correct
moisture content for the required dry density. The Contractor shall spread and
compact each layer to at least 95% of maximum dry density, unless otherwise specified,
all as determined by ASTM D1557. Each compacted layer shall be tested and approved
prior to placing subsequent layers.
Page 60 of 244
C.
Placing and Compacting Fill
C.1 Structures shall not be subject to the pressures of backfilling or to live loads until the
28-day strength of the concrete has been reached, unless a shorter period is approved in special
circumstances where the load is sufficiently small as not to constitute a risk of any damage to
the structure in the opinion of the Engineer. I f approved this period may be extended i f
subnormal curing conditions exist.
C.2 Surfaces to receive filling shall be cleared and all vegetation removed off Site before
filling is placed. Soil surfaces are to be scarified and re-compacted to at least 95% of maximum
dry density as determined by ASTM 1557. Compaction shall be to a depth of at least 200 mm
below ground surface. Hard or smooth surfaces shall be roughened before filling is placed.
Existing road surfaces and the like shall be broken up and removed or used as part of fill.
C.3 Soil filling generally shall be selected f ill spread and leveled in 300 mm maximum layers
each well consolidated with a suitable mechanical rammer.
C.4 The Contractor shall deposit soil filling in a manner not to endanger the partly finished
structure or sub-structure either by direct pressure or indirectly by overloading banks
contiguous to the operation or in any other manner.
C.5 Minor up filling and local adjustment of levels shall be selected f ill spread and leveled in
150 mm maximum layers each well consolidated by suitable mechanical means.
C.6 Benching: Where difference in level between adjacent areas of filling exceeds 600 mm
the Contractor shall cut into edge of higher filling to form benches having a minimum width of
600 mm and a height equivalent to the depth of a layer of compacted filling.
C.7 Benching: The Contractor shall spread and compact new filling to ensure maximum
continuity with previous filling.
C.8 Protection of formation:
Construction traffic shall not be allowed on completed filling until the level has
been raised not less than 150 mm above formation level by properly
compacted temporary protective filling
Temporary protective filling shall be removed from the Site before beginning
permanent construction
Stockpiling materials on newly filled areas shall not be done without
permission.
Page 61 of 244
D.
Backfilling for Bridges, Underpasses, Overpasses and Miscellaneous

Structures
D.1 Backfill placed around culverts, abutments and piers, shall be deposited on both sides to
approximately the same elevation at the same time. Special care shall be taken to prevent any
wedging action against the structure and slopes bounding the excavation shall be stepped,
where necessary, to prevent such wedge action occurring.
D.2 A l l backfill intended to support falsework loads, including temporary fills and pier backfill,
shall be designed for the minimum support required. As a minimum, such material shall be
AASHTO M 145, Class A-1-a, A-1-b or A-2-4, compacted to 90% AASHTO T 180 maximum
density.
D.3 Backfill material for bridge abutments and approach embankments within 20 m of any
part of the substructure shall be AASHTO M 145, Class A-1-a, A-1-b or A-2-4 compacted to
95% AASHTO T 180 maximum density up to the underside of the subgrade layer. The 200 mm
minimum thickness of subgrade layer shall consist of approved subgrade material placed and
compacted to 100% maximum density as specified under Section 2.05 - "Subgrade
Construction". The backfill shall be completed to the level of the original ground or to the top
elevation of any adjacent embankment.
D.4 Backfill around retaining walls shall be completed to the level of the original ground line
and to such heights above original ground line or to the levels as shown on the Drawings. Care
shall be exercised to prevent forward movement of the wall.
D.5 Unless shown otherwise on the Drawings, when special permeable backfill (sheathing) is
to be placed against the back faces of abutments, retaining walls or wing walls, it shall
consist of a continuous covering of approved type proprietary filter cloth protected by a
continuous wall of 200 mm minimum thickness precast, porous (no-fines) concrete blocks laid
in stretcher bond with dry joints. Prior to construction of the block wall, the proposed
underdrain system indicated on the drawings shall be laid along the base of the wall under the
sheathing.
D.6 The Contractor shall complete the backfill around box culverts to the level of the original
ground line and to the full width of excavation area. I f the top of culvert extends above the
original ground line the Contractor shall continue the backfill to the top of culvert and for a
width of 3 m on each side of the culvert for the full width of highway embankment. I f the
embankment is in place at the time of backfilling, the Contractor shall backfill around the
culvert to the top of embankment.
Page 62 of 244
D.7 Miscellaneous structures shall be backfilled in accordance with the methods specified.
Compaction of backfill when structures are outside the roadway right-of-way or in approach
roads, minor roads or similar areas, shall be to 90% of maximum density as determined by
AASHTO T 180 (Method D).
2.04.4
A.
EMBANKMENT CONSTRUCTION
Scope
A.1 These Works shall consist of constructing road embankments, including preparation of
the areas upon which they are to be placed; placing and compacting approved material within
areas where unsuitable material has been removed; and placing and compacting approved
embankment material in holes, pits and other depressions within the right-of-way area, all in
accordance with the lines, grades and cross sections shown on the Drawings.
B.
Materials
B.1 Material of classes A-1, A-2-4, A-2-5 or A3 "when confined" groups as in AAHSTO M145
and complying with Table 2.1 shall be used when available, except for rock f ill
embankments. I f material of this character is not available then materials from A-2-6, A-2-7,
A-4, A-5, groups (AASHTO M145) may be used provided it complies with Table 2.1; however,
special attention should be given to the construction.
Table 2.1: Soil Suitable for Embankment
123456-
Maximum dry density not less than 1.7 (AASHTO T-180D)

Organic matter not more than 5% (AASHTO T-267)
No use of A-6, A-7 soil (AASHTO M-145)
Maximum size not more than 1/2 of the layer thickness
Plasticity Index (PI) less than 20%
4 day soaked C.B.R. should not be less than 8% (AASHTO T-193)
when compacted at 100% maximum dry density i n accordance with
AASHTO T-180 Method D
B.2 The 200 mm depth of embankment subgrade layer immediately below the bottom of sub
base shall consist of selected subgrade material having a 4-day soaked CBR of at least 20%
when tested in accordance with AASHTO T 193 and with a gradation and P.I. as specified
under Section 2.05 - "Subgrade Construction".
Page 63 of 244
B.3 The 600 mm depth of embankment immediately below the subgrade layer shall consist of
material having a 4-day soaked C.B.R of at least 15% when compacted to 95% maximum dry
density in accordance with AASHTO T-180D and tested in accordance with AASHTO T-193
with a P.I. not more than 15%. I f rockfill is used for the bottom 400 mm depth then these
requirements shall apply to the top 200 mm below the subgrade layer.
B.4 In areas subject to flooding and prolonged inundation of the embankment, such as at bridge
and culvert sites, the material used in embankment, unless rock, shall conform to AASHTO M
145, Class A-1-a, A-1-b, A-2-4.
B.5 Where embankments are to be constructed using material classified as A3 (AASHTO M

145) or other material subject to side slope erosion or requiring confinement for stabilization
purposes, the embankment plating or confining layer shall be constructed using AASHTO M
145 Class A-1-a, A-1-b, or A-2-4 materials or as otherwise approved.
B.6 The material used in rockfill embankments shall consist predominantly of rock fragments of
such size that the material can be placed in layers of the thickness prescribed conforming to the
requirements stated in Table 2.2.
Table 2.2: Rock Suitable for Embankment
123-
Maximum particle size
300 mm or 1/2 or proposed loose layer

thickness whichever is less
Passing 0.42mm (Sieve No. 40) 25% maximum
Uniformity coefficient, Cu ..
6 minimum, where Cu = D60/D10
D60 = the Particle size at which 60% passes
D10 = the Particle size at which 10% passes
B.7 Rockfill material shall be obtained from roadway or tunnel excavation and shall be sound,
dense, hard and durable rock capable of being spread and compacted as specified. Individual
pieces are to be clean and angular. I t shall be the Contractor's responsibility to excavate
material from rock cuts, whether by blasting or other manner, so that all excavated materials
are of suitable size.
B.8 When suitable materials of widely divergent characteristics are drawn from different
sources, such materials may, i f approved, be mixed to meet the embankment requirements.
Rock and other materials shall be incorporated in such manner as to avoid segregation and an
accumulation of boulders, etc at the toe of embankment slopes.
B.9
Logs, trees, stumps, weeds, heavy grass, frozen soil, vegetable matter or other u
ndesirable and noncompactible materials shall not be placed in embankments.
Page 64 of 244
B.10 Rocks, broken concrete or other solid materials larger than 100 mm in any dimension
shall not be used as f ill material in areas where piling works are to be carried out.
C. Workmanship
C.1 Prior to placing embankment material on any area, it shall have been cleared and grubbed
as specified in Sub-Section 2.02.1 - "Clearing and Grubbing", and the foundation prepared as
specified herein.
C.2 Equipment used for foundation preparation and for placing, spreading and compacting
embankment materials shall be of approved types and furnished in sufficient numbers for the
purposes intended. Provision and use of such equipment shall conform with the relevant
requirements set in these specification and with the Contractor's approved Work Program.
C.3 Draglines shall not be used to construct embankment unless approval is given and only
when special procedures are adopted to keep the layers uniform and the embankment properly
graded and well-drained at all times.
C.4 Surfaces of embankment layers shall be kept properly shaped and drained at all times. The
Contractor shall utilize a sufficient number of motor graders or tractors to level and maintain the
surface of each layer of embankment during all placing and compacting operations.
C.5 Rockfill shall not be used in the top 200 mm of the embankment below the subgrade.
Water must be added as required, and with the approval of the Engineer, to achieve maximum
compaction.
C.6 Whenever feasible, trucks, scrapers, tractors, loaders and other heavy hauling equipment
shall be routed over the embankment in such a manner as will contribute effectively to
compaction of the f ill material.
C.7 Where an embankment is to be constructed over an area previously occupied by a building

basement, cellar, irrigation canal, well, any previous excavation, or adjacent to structures, and
where the proper use of normal compaction equipment is not practicable, the embankment
shall be constructed and compacted in accordance with the backfilling requirements of the
relevant sub-sections herein before, until the use of normal compaction equipment is practicable.
Layers shall not exceed 200 mm thickness (after compaction) and shall be compacted to the
degree of compaction specified for the embankment.
Page 65 of 244
C.8 Each embankment layer shall be tested and approved prior to placing the following layer in
accordance with Subsection D "Testing" here below.
C.9 The Engineer may at any time order suspension of delivery of materials to the
embankment Sites until previously delivered materials have been properly placed and
preceding layers are leveled and uniformly compacted to the specified density.
C.10 Unacceptable material placed in any embankment shall be removed and disposed of by the
Contractor at his expense.
C.11 The Contractor shall be responsible for the stability of all embankments and shall replace
all embankment sections which, in the opinion of the Engineer, have been damaged or displaced
due to carelessness or neglect on the part of the Contractor, or due to normally occurring natural
causes, such as storms, and not attributable to the unavoidable movement of the natural ground
upon which the embankment is constructed.
C.12 All embankment side slopes shall be neatly finished true to the lines and not steeper than
the slope angles as shown on the Drawings. The bottom (toe) of side slopes shall be graded to
a well rounded, smooth profile to blend in with the adjacent terrain.
C.13 The side slopes of rockfill embankments shall be thoroughly blanketted with A-1, A-2-4
material, and compacted to the satisfaction of the Engineer.
C.14 The Engineer may permit the Contractor to utilize suitable surplus material at his own
expense to widen embankments or flatten slopes, etc within the right-of-way. Surplus material
used in such manner shall be compacted to 90 per cent of maximum density, but this shall not
be measured for payment. When widening embankments, the Contractor shall bear the cost of
modifying the culverts and any protection work necessary.
C.15 Rockfill shall not be used within 5m of a structural element (next to bridge abutments
footings, etc)
C.16 Rockfill shall not be used for 600mm on top and bottom of Box and Pipe Culverts.
Subgrade material shall be used in these areas up to width excavated for structures.
C.17 I f shown on the Drawings, or as required by the Engineer, a trial embankment shall be
constructed. The trial section shall be at least 2 lanes wide by 100 m long at approved locations
at or adjacent to the Site. Compaction and other equipment used, shall be as specified and
listed in the Contractor Equipment Schedule and approved Programme of work.
Page 66 of 244
C.18 I f the original surface upon which embankment is to be placed is an existing roadbed, the
surface shall be plowed, scarified, or otherwise broken up regardless of the height of the
embankment to be placed thereon.
C.19 Unacceptable material placed in any embankment shall be removed and disposed of by the
Contractor at his expense.
C.20 Where embankment is to be placed and compacted on hillsides or where new

embankment is to be compacted against existing embankments or where embankment is built
part width at a time, the slopes steeper than 3:1 (H:V) when measured at right angles to the
highway centerline shall be continuously benched as the embankment is brought up in layers.
Benching shall be of sufficient width to permit operation of spreading and compaction
equipment, and in any case not less than 2 m wide except where insufficient width is available
between existing and new embankments. Each horizontal cut shall begin at the intersection of
the original ground and the vertical sides of the previous cuts. The vertical face of each bench
shall not be less than 1 m in height and not exceed 2 m. Authorized benching shall be
measured as highway excavation.
C.21 Where embankment is to be placed and compacted on wadi slopes, the entire slope area
shall be graded and trimmed to remove any vertical faces and overhangs. The final graded
slope shall not be steeper than 1.5:1 (H:V). The slope shall then be continuously benched as
the embankment is brought up in layers, all as described above for embankment on hillsides.
C.22 Rockfill shall not be placed on any slopes steeper than 1:1. A l l slopes steeper than 1:1
shall therefore be regraded to a slope of 1:1 or shallower and all vertical faces and overhangs
removed.
C.23 Roadway embankment consisting of soil or granular material shall be placed in horizontal
layers not exceeding 250 mm thickness (before compaction), shall be compacted as specified
and shall be approved prior to placing the next layer. The thickness of the first layer over areas of
Class A-3 dune sand may exceed 250 mm in order to bridge these areas. Approximately uniform
thickness of each layer shall be achieved prior to compaction. As the compaction of each layer
progresses, continuous leveling and working of the material shall be carried out to ensure
uniform density. The correct moisture content shall be maintained at all times.
C.24 Where embankments are to be constructed to a height in excess of 1.5 m above top of
original ground level the Engineer may approve layer thickness up to 300 mm (before
compaction) i f the Contractor's equipment and the nature of the material result in the required
density throughout the layer thickness.
Page 67 of 244
C.25 When the moisture content of the embankment material does not fall within the required
moisture range, (optimum moisture 2%) water shall be added and thoroughly mixed into the
soil by approved methods or the material shall be aerated, whichever is necessary to adjust the
material to the required moisture content.
C.26 When water is added to embankment material, the amount added shall be sufficient to
provide a moisture content within the required range plus a reasonable additional amount to
compensate for evaporation and other unavoidable losses. Water added in excess of this
amount shall be removed by aereation or other approved means at the Contractor's expense.
Satisfactory methods and sufficient equipment shall be used for the furnishing and handling of
the water in a manner that will minimize loss due to evaporation or waste.
C.27 Embankments that consist of rock-soil material with sufficient soil to make rolling feasible,
shall be placed and compacted in an approved manner and to the required degree of
compaction. Water shall be added as and when directed to assist in the compaction of such
materials.
C.28 In the case of embankments which are to be formed of approved rock-soil material
containing an appreciable quantity (normally not exceeding 30% greater than 80mm) of rock
fragments and which cannot be placed in layers of the thickness prescribed without crushing,
pulverizing, or otherwise breaking down the fragments, the embankment may be constructed in
layers not exceeding in thickness twice the average size of the largest rock fragments and in
any case not exceeding 600 mm (before compaction).
C.29 Rockfill materials shall be placed in such a manner that the larger rocks are well
distributed and the voids are filled to the maximum practical extent by smaller particles, each
layer shall be bladed into a neat and homogeneous mass prior to compaction. Any rocks found
protruding from the leveled surface shall be removed and replaced by smaller particles. Initial
breakdown compaction shall be performed with heavy bulldozers. The top level of each layer
must be surveyed before and after compaction and approved by the Engineer before the next
layer is placed. Oversize rock pieces may be used in high rockfill embankments to a level 3
metres below subgrade.
D.
Testing
D.1 The Engineer shall test the compaction of embankment materials in accordance with these
Specifications to ensure that adequate compaction or consolidation has been achieved. A l l
such tests shall be fully documented by the Contractor, in an approved manner.
Page 68 of 244
D.2 In the case of cohesionless, free draining rock-soil materials, where maximum density
tests fail to produce a well defined moisture - density relationship, the relative density test
shall be used, alternatively an electronic compaction meter or any other approved test
equipment shall be provided by the Contractor and used to determine the degree of
compaction achieved.
D.3 To determine the degree of compaction for embankment consisting of rock f ill, average
differential settlement values shall also be determined from surveys of an adequate number of
grid point elevations as and when directed, at the commencement of, during and after
embankment construction.
D.4 I f it is required to determine the modulus of soil reaction by the Plate Bearing test, this
shall be undertaken using the method given in AASHTO T222-81 (1986).
E.
Standards of Compaction for Soil and Granular Materials
E.1
The following compaction standards shall apply to embankment materials other than
predominantly rock materials. The "maximum density" of soil type materials shall be the
modified maximum density determined in accordance with AASHTO T 180 (Method D). The
"relative density" shall be the relative density determined in accordance with ASTM D4254,
which identifies the state of compactness of the material with respect to its loosest and
densest state. The relative density shall be the standard to which the field density is referred
for comparison in the case of cohesionless, free draining granular materials.
E.2
Soil type materials shall be compacted to at least 90% modified maximum density for
the full depth of embankment. The 600 mm of embankment material immediately below the
subgrade layer shall be compacted to at least 95% modified maximum density. Moisture
content shall be within plus or minus 2% of optimum at the time of compaction.
E.3
Cohesionless, free draining granular materials (of 75 mm maximum size and with not
more than 15% passing 0.075 mm (No. 200) sieve) shall be compacted to at least 70% of
relative density for the full depth of embankment. The 600 mm depth of such material
immediately below the subgrade layer shall be compacted to at least 75% of relative density.
Page 69 of 244
E.4 Minimum soil tests required during the construction of subgrade and/or embankment are:
2.04.5
A.
One sample for CBR, classification (AASHTO M145), and laboratory (Moisture
- density) or relative density compaction from each source prior to use. Each
sample shall represent not more than 5,000 cu m.
One sample for classification representing not more than 3,000 cubic meters of
the material in use.
For every completed layer, one field density shall be determined for each 1500
sq.m or 100 linear meters whichever is less. Testing shall be in accordance
with ASTM D1556 or ASTM D2167.
PIPE BEDDING MATERIAL AND BACKFILLING FOR PIPE

TRENCHES
Granular Bedding and Backfill materials
A.1 Backfilling above pipe crest shall be with clean granular Class A-3 in layers 30 cm thick
and shall pass sieve No.(4) 4.75 mm, and be retained by sieve no. (200) 0.075mm.
A.2 Granular material for pipe bedding shall be composed of 14 mm maximum size natural
gravel, crushed gravel or crushed rock, free from dirt, clay, roots, organics and other
deleterious material mixed with sufficient sand to fill the voids, about 30 to 35% by volume.
A.3 Granular bedding shall conform to the following:

% By Weight Passing
Standard Sieve size
(mm)
19.0
4.76
1.19
0.300
0.177
0.075
(3/4 in)
(No. 4)
(No. 16)
(No. 50)
(No. 80)
(No. 200)
for rigid pipes

PE pipes
(DI or Concrete etc.)
100
25- 100
10-75
5-30
3-10
0-5
100
25-75
10-30
3-10
0-5
A.4 For GRP pipes bedding shall be of graded crushed stone 2.83-8 mm or as recommended
by Manufacturer.
Page 70 of 244
A.5 Sand bedding and f ill up to 300 mm minimum above crown of the pipe shall be
non-plastic, natural well graded sand having hard, strong, durable angular particles. It shall be
clean and free from extraneous materials, clay balls, organic matter or other detrimental
material. The amount of fines passing sieve No. 200 shall not exceed 15% or according to the
standard specifications (ASTM C33).
A.6
Backfill over a pipe shall consist of two different layers: Initial or selected backfill and
main backfill
A.7 Backfill in contact with the pipes and up to 300 mm minimum above crown of the pipe
shall be selected material
A.8 Selected f ill material shall comply with group type GW, GP, GM, BC, SW, SP, SM, SL in
compliance with ASTM D 2487.
A.9 Selected fill material shall not contain ashes, cinder, refuse, rubbish, organic material, or
the like. The material shall be capable of being compacted without the use of heavy rammers.
A.10 The main backfill (for the remainder of the trench) shall be done with suitable material
either from material removed in the course of excavating the trench, or imported from approved
borrow pit. In either case the backfill material shall conform to paragraph B of section 2.04.2
herein before.
A.11 Pipelines should be covered by plain concrete i f the top cover is less than 1 m or for deep
pipelines as per the manufacturer recommendations.
B.
Workmanship: Backfilling
B.1
Trenches shall not be backfilled at joints until after that section of the pipeline has
successfully passed the specified tests required
B.2
Selected backfill or surround up to a level of 300 mm above top of the pipe, shall be
placed and hand compacted in 150 mm layers. The backfill shall be brought up evenly
on both sides of the pipe for the full length of the pipe. Care shall be taken to ensure
thorough compaction of the f ill under the haunches of the pipe.
Page 71 of 244
B.3 For GRP pipe initial backfill shall be compacted to 95% relative density or as
recommended by manufacturers.
B.4 Main backfill shall be placed and well compacted in layers not exceeding 300 mm thick
before compaction. Heavy compactors shall not be used until there is 600 mm cover over
pipes.
B.5 Compaction of each layer shall be according to Section 2.04.2 paragraph J herein
before.
B.6 Heavy steel or pneumatic rollers shall not be used for compacting backfill to pipe
trenches. Special precautions shall be taken to safeguard existing structures when steel or
pneumatic rollers are used.
B.7 Compaction equipment shall be suited to the type of material and shall be subject to
approval. Compaction around foundation walls, culverts and small restricted areas shall be
carried out by mechanical vibratory plates, tampers or hydraulic compactors.
B.8 Backfilling trenches for pipes with concrete beds and or surrounds shall not start before
24 hours after placing the concrete. Heavy compactors shall not be used and traffic shall not
be allowed before the elapse of 72 hours after placing the concrete.
B.9 When the material is too wet from rain or excessive application of water, no compaction
shall be done. In this case the work shall be suspended until the previously placed and new
materials have dried sufficiently to permit proper compaction. Other measures shall be taken
i f necessary to obtain proper compaction.
B.10 Temporary crossing are to be provided over trenches to prevent construction traffic
damaging pipes after backfilling.
B.11 The top 500 mm of pipe trenches below road pavement layers shall be filled with
crushed aggregate base course material compacted to 95% of maximum dry density.
B.12 I f authorized by the Engineer, the main backfill may be consolidated using
water-jetting, puddling, or tamping as directed.
Page 72 of 244
C.
Restoration of surfaces
C.1 Restoration of asphalt, concrete, gravel pavements and the likes shall be of materials and
thickness to match the existing pavement. A l l works, workmanship material shall be in
accordance with concerned authorities specifications (Directorate, Municipality, Ministry of
transport) and Engineer direction.
C.2 Restoration of pavement shall be done according to the existing pavement quality and level
to ensure that new pavement is matching to provide uniform surface with the existing profile.
C.3 Grassed areas shall be restored by spreading, after backfilling, approved fertile soil over
affected area. Seeding, fertilizers and water shall be applied until grass is restored to its former
condition.
C.4 Surface grading shall be carried out to restore all un-surfaced areas and any adjoining
areas disturbed to provide a level, smooth surface.
C.5 The Contractor shall proceed with restoration of surfaces as soon after completion of other
work as is practicable, but in no case more than 10 days after backfilling of trenches and other
excavated areas. Restoration shall be completed within 20 days from the start of restoration or
as approved by the concerned authorities.
Page 73 of 244
SECTION 2.05
2.05.1
SUBGRADE CONSTRUCTION
GENERAL
A.
These Works shall consist of furnishing materials, constructing the sub-grade layer
and preparing the sub-grade surface ready to receive the pavement structure and
shoulders, all as and where shown on the Drawings.
B.
Sub-grade layer is the 200 mm minimum depth of selected material immediately below
the sub-grade surface, or as defined in the drawings or directed by the Engineer.
2.05.2
MATERIALS
A.
The supplied material shall not contain any organic or harmful material e.g: tree,
leaves, roots, and residues.
B.
The supplied material shall conform to classification types: A-1-a, A-1-b, A-2-4,
according to MRDTM 210 (Directorate of Material and Research at the MOC).
C.
Unless otherwise shown on the Drawings, sub-grade material shall consist of selected
material having a 4-day soaked CBR of not less than 25% when tested in accordance
with AASHTO T 193 when compacted at 100% of modified proctor AASHTO (T-180)
and having a maximum P.I. of 12% unless otherwise noted. Sub-grade gradation shall
be reasonably smooth without gap grading. All material shall pass 75 mm sieve and not
more than 18% shall pass 0.075 mm (No. 200) sieve.
D.
The maximum dry density shall not be less than 95% when tested according to
Directorate of Material and Research at the MOC.
E.
The material shall be well graded passing sieve no. 3 (75 mm sieve) and shall contain
fine material for proper compaction.
F.
Minimum tests required on subgrade are indicated in sub-Section 2.04.4

"Embankment Construction".
Page 74 of 244
2.05.3
A.
WORKMANSHIP
Subgrade in Cut
A.1 Where the subgrade is located in rock, the sub-grade, unless shown otherwise on the
Drawings, shall be undercut to a depth of 200 mm by drilling or blasting as directed. No rock
shall project more than 50 mm above the undercut surface elevation. The sub-grade layer shall
then be constructed using approved sub-grade material, as specified for sub-grade in
embankment.
A.2 Where the subgrade is on in-situ soil that is of a quality and CBR value at least equal to
those specified for sub-grade, the 200 mm depth of such material immediately below top of
sub-grade shall be scarified and all roots, sod, vegetable and other undesirable matter and
stones larger than 75 mm in any dimension shall be removed. The material shall then be brought
to a uniform moisture content within the specified range and compacted to 100% AASHTO T 180
(Method D) maximum density.
A.3 Where the subgrade is on in-situ soil which is unsuitable for retention as the sub-grade
layer, such material immediately below the top of subgrade layer shall be sub-excavated to a
depth of 200 mm, hauled away and disposed off unless approved for use as embankment fill.
The subgrade layer shall then be constructed using approved subgrade material, as specified
for subgrade in embankment. I f the material below subgrade layer does not satisfy the
requirement of top 600 mm, it shall be excavated for further 200 mm and replaced by suitable
material to satisfy the requirements of subgrade.
A.4 The underlying natural material shall be scarified, leveled and rolled. The surface of the
natural soil shall be approved by the Engineer before placement of suitable material.
B.
Subgrade in Embankment
B.1 The 200 mm minimum depth of embankment immediately below top of subgrade shall
consist of selected, approved sub-grade material. The material shall be spread in one layer over
the full width of the top of embankment, brought to a uniform moisture content within the
specified range and compacted to 100% AASHTO T 180 (Method D) medium density.
Page 75 of 244
C.
Surface Tolerances
C.1 A l l finished elevations, lines and grades shall be in accordance with the details shown on
the Drawings. Each cross section shall be checked at maximum intervals of 25 m, at each
change in cross slope and elsewhere as directed.
C.2 The tolerances on elevations of finished sub-grade, top of embankment under the
sub-grade layer and sub-excavated (undercut) surface shall be as follows:
Surface
Finished Sub-grade:
Soil
Rock (if approved)
Top of Embankment or Sub-excavated Surface:
Tolerance
+10 or -30 mm +50 or -50 mm +10
or -30mm
For agricultural roads, tolerances on elevations are allowed to be as follows:
Surface
Finished Sub-grade:
Soil
Rock (if approved)
Top of Embankment or Sub-excavated Surface:
Tolerance
+20 or -30 mm +50 or -50 mm +20
or -30mm
C.3 When the finished subgrade surface is tested with a 4 m long straightedge placed parallel
to, or at right angles to the centerline, the maximum depression of the surface from the testing by
straight edge shall be 30 mm.
D.
Maintenance of Finished Subgrade
D.1 The finished and approved sub-grade shall be continuously maintained in a smooth, well
compacted and properly drained condition until the sub-base (or base) course is constructed.
Reapproval of the subgrade will be required i f the overlying course is not constructed within 14
days of sub-grade completion or i f the subgrade layer is damaged by traffic or any other causes
prior to the placement of the sub-base layer.
Page 76 of 244
SECTION 2.06
2.06.1
GABIONS
GENERAL
A. The work shall include the supply of all material, preparation of gabions and their installation
as indicated on the Drawings or as instructed by the Engineer. Such works will be constructed
for protection in valleys and flooding areas.
2.06.2
MATERIALS
A.
Gabions shall consist of approved type galvanized steel wire mesh baskets (or other
approved types such as heavy-duty plastic mesh) filled with selected rocks before
installation.
B.
Galvanized steel wire mesh shall conform to ASTM A 390 Class 3, or equivalent and
with the requirements shown on the Drawings. The wire mesh shall be twisted to form
hexagonal or rectangular openings of uniform size. The maximum nominal opening size
shall be 100 mm. Mesh shall be constructed so as to resist pulling apart at any of the
twists or connections forming the mesh when a single wire strand in a section is cut.
C.
Baskets shall be furnished in one or more sizes that can be assembled to provide the
minimum dimensions, stability, and structural integrity of the installation specified. Sizes
of gabion baskets will normally be 2 m long by 1 m wide by 0.5 m to 1 m high.
Non-standard sizes shall be provided to suit the particular installation, as shown on the
Drawings.
D.
Baskets shall be fabricated in such a manner that the sides, ends, lid, and diaphragms
can be assembled on Site into rectangular baskets of the specified sizes. Gabion
baskets shall be of single unit construction. Long gabions assembled with diaphragms
between adjacent baskets, for use as foundation mattresses, etc., may not require lids.
E.
Base, lid, ends and sides shall be either woven into a single unit or one edge of these
members connected to the base section of the gabion in such a manner that strength and
flexibility at the point of connection is at least equal to that of the mesh.
Page 77 of 244
F.
A l l perimeter edges of the mesh forming the basket shall be securely clip bound or
selvedged so that the joints formed by tying the selvedges have at least the same strength
as the body of the mesh.
G.
Perimeter (edge), tie, and connection wires shall conform to ASTM A 641, Class 3,
Medium Temper, and the minimum diameters shown on the Drawings.
H.
Riprap material for filling of gabion baskets shall consist of rocks conforming to Riprap
Class A size, clean, strong, durable and highly resistant to weathering. Dimensions
shall range from 250 mm to approximately 125 mm diameters. Not more that 5% shall
be smaller than 100 mm.
2.06.3
CONSTRUCTION
A.
The surfaces upon which gabions and similar slope protection works are to be placed
shall be excavated and compacted to the required grades and lines and a footing
trench where specified, shall be excavated along the toe of the slopes, all as shown on
the Drawings or as directed. Subgrade or base shall be firm or compacted as directed.
B.
Each gabion basket shall be assembled by binding together all vertical edges with wire
ties on approximately 150 mm spacing or by use of a continuous piece of connecting
wire stitched around the vertical edges with a coil every 100 mm.
C.
Empty gabion units shall be installed to line and grade as shown on the Drawings.
Wire ties or connecting wire shall be used to join the units together in the same manner
as described for assembling. Internal tie wires shall be uniformly spaced and securely
fastened in each cell of the structure. A standard fence stretcher, chain fall, or iron rod
may be used to stretch the wire baskets and hold alignment.
D.
The gabions shall be filled with riprap as specified, placed by hand or machine to
assure alignment and avoid bulges with minimum voids. Alternate placing of rock and
connection wires shall be performed until the gabion is filled. After filling with riprap,
the lid shall be bent over until it meets the sides and edges, and shall be secured to the
sides, ends, and diaphragms with wire ties or connecting wire in the manner described
for assembling.
Page 78 of 244
SECTION 2.07
2.07.1
STONE PITCHING IN CONCRETE
GENERAL
A.
These works will be constructed in valleys and flooding areas.
B.
Stone pitching shall consist of broken stones, placed as indicated on the Drawings or in
locations as directed by the Engineer.
C.
Stone pitching shall be constructed to the shape and dimensions shown on the
Drawings in accordance with the provisions of the specification or as directed by the
Engineer.
D.
Stone pitching shall be classified as stone pitching in concrete and shall have a
thickness of 200 mm, unless otherwise indicated on the Drawings.
2.07.2
A.
MATERIALS
Rock
A.1 The stones for this work shall be durable, angular field or quarry stones of approved
quality, sound, hard, free from seam and other structural defects and shall have a specific
gravity of not less than 2.40. At least 60% of the stone pitching shall consist of pieces having a
weight of not less than 15 kg and of the remaining 40% no piece shall have a weight of less
than 7 kg. The thickness of each layer shall be achieved by the thickness of one rock piece.
The thickness of the rock piece shall be within 50mm from the specified layer thickness,
measured at the thinnest section of the rock piece.
B.
Concrete
B.1
Concrete used for filling shall be of the same class as blinding concrete.
2.07.3
PLACING
A. Ground surface to be protected by stone pitching shall be thoroughly compacted to the

approval of the Engineer and covered with 50 mm blinding concrete prior to placing of the rock.
Page 79 of 244
B.
Rock shall be placed starting with the lowest point of slopes.
C.
Approval of the Engineer is required for rock laying prior to pouring concrete. The rock
shall then be flushed with water to provide adequate bonding with concrete. Concrete
paring shall start with the lowest point of the area to be protected. Where more than one
layer of stone pitching is specified, or in keys, a layer of 50 mm blinding concrete shall
be placed below the first layer and between consecutive layers.
D.
The finished surface of the concrete shall be flush with the top of the surrounding stone
pieces.
Page 80 of 244
SECTION 2.08
2.08.1
GEOTEXTILES
GENERAL
A.
Geotextiles are used for protection and containment of the granular bedding and the
first dump layer around GRP pipes in the presence of water table in the trench.
B.
The work include the supply and installation of geotextile fabric as indicated on the
Drawings.
2.08.2
A.
MATERIAL
Drainage Fabric
A.1 Non-woven geotextile, specifically manufactured as a drainage geotextile; made from

polyolefins, polyesters, or polyamides; and with the following minimum properties determined
according to ASTM D 4759 and referenced standard test methods:
-
B.
Grab Tensile Strength:

Tear Strength:
Puncture Resistance:
Water Flow Rate:
Apparent Opening Size:
490 N (ASTM D 4632)

178 N (ASTM D 4533)
222 N (ASTM D 4833)
100 l/sec/m2 (ASTM D 4491)
0.3 mm (ASTM D 4751)
Separation Fabric
B.1 Woven geotextile, specifically manufactured for use as a separation geotextile; made
from polyolefins, polyesters, or polyamides; and with the following minimum properties
determined according to ASTM D 4759 and referenced standard test methods:
-
Grab Tensile Strength:

Tear Strength:
Puncture Resistance:
Water Flow Rate:
Apparent Opening Size:
890 N (ASTM D 4632)

333 N (ASTM D 4533)
400 N (ASTM D 4833)
2.7 l/sec/m2 (ASTM D 4491)
0.6 mm (ASTM D 4751)
Page 81 of 244
2.08.3
WORKMANSHIP
A. Store and handle geotextiles in accordance with ASTM D 4873. Place and install in
accordance with manufacturers written instructions and as follows, to the approval of the
Engineer.
Overlaps shall not, in any case, be less than 25 mm
Place bedding layer as soon as possible after placement of the geotextile, in

accordance with approved methods, to thickness shown on Drawings
Remove and replace any geotextile damaged or punctured either before, during
or after laying.
Page 82 of 244
PART 3: Pavement and Roads Surface Finishing
PART 3: PAVEMENT AND ROADS SURFACE FINISHING
SECTION 3.01
SCOPE
A. These works cover the supply of materials and construction of all components of the
roadwork specified in this Project. The roadwork components include: sub-base and base
courses, bituminous materials, pavement repairs and trench reinstatement and maintenance of
traffic and detours.
Page 83 of 244
SECTION 3.02
3.02.1
A.
GRANULAR SUBBASE AND BASE COURSES
GENERAL
Contractors Responsibility
A.1 The Contractor shall locate sources of material, ensure adequate supply and ensure
compliance with the Specifications.
A.2 The Contractor shall obtain and test, in an approved laboratory, samples from sources
and stockpiles which are in compliance with the Specifications.
A.3 Samples provided by the Contractor shall satisfy all specified test requirements. The
Contractor shall permit the Engineer to inspect any and all materials used or to be used, at
any time during or after their preparation, or while being used during progress of the Works.
Unsatisfactory materials, whether in place or not, shall be removed promptly from the Site.
The Contractor shall furnish all necessary labor, transport, tools and equipment required by
the Engineer for such inspection.
A.4 The Contractor shall ensure that screening plants or crushing and screening plants shall
not be put into operation prior to their approval. If, after any plant is put into operation, it fails
to perform as intended, the Contractor shall either rectify the defects in the existing plant to the
satisfaction of the Engineer, or shall provide alternative approved plant.
A.5 Approval of the crushing and screening plants and other equipment shall in no way relieve
the Contractor of his responsibilities in respect of producing granular materials and aggregates
which conform to the Specifications and in the quantities required for the completion of the
Works on time.
A.6 The Contractor shall conduct necessary tests in the Field Laboratory in the presence of
the Engineer and the Contractors Materials Engineer.
Page 84 of 244
A.7 Processed materials shall be tested and approved before being stockpiled on Site or
incorporated in the works and may be inspected and tested at any time during their preparation,
storage and use. Questionable materials, awaiting testing and approval, shall not be unloaded
and mixed with materials previously approved. I f the grading and quality of any materials
delivered to the Site does not conform to the grading and quality of the established control
samples, the Engineer will reject such materials.
A.8 Samples shall satisfy all specified test requirements. The Contractor shall permit the
Engineer to inspect any and all materials used or to be used. At any time during or after their
preparation, or while being used during progress of the Works. Unsatisfactory materials,
whether in place or not, shall be removed promptly from the site. The Contractor shall furnish all
necessary labor, transport, tools and equipment required by the Engineer for such inspections.
A.9 The contractor shall construct in accordance with the concerned authorities specification.
3.02.2
MATERIALS
A.
Subbase shall consist of naturally occurring gravel and sand, screened or crushed to
obtain the specified gradation.
B.
Base course shall consist of crushed gravel, crushed stone or sand with screenings as
required to obtain the specified gradation.
C.
The supplied material shall not contain any organic or harmful material e.g: tree, leaves,
roots, and residues.
D.
Material for subbase and base course shall conform to classification types: A-1-a, A-1-b
according to AASHTO classification system.
E.
Gravel, crushed gravel and crushed stone shall consist of hard, durable particles, free
from dirt, organic matters, shale and other deleterious materials, and shall not contain
more than 8% of clay lumps and friable particles. The fine material shall pass sieve no.
4 (4.75 mm) and shall consist of natural sand or crushed fine materials.
Page 85 of 244
F.
Physical and chemical properties of granular materials used for subbase and base
courses shall conform to the requirements specified as follows:
F.1
Gradation: Subbase and Base shall conform to the following gradation in accordance
with AASHTO T-27.
Sieve Designation
50
37.5
25
19
9.5
4.75
2.00
0.425
0.075
F.2
mm(2 inch)
mm(1 inch)
mm(1 inch)
mm(3/4 inch)
mm(3/8 inch)
mm(No.4)
mm(No.10)
mm(No.40)
mm(No.200)
Percent by weight passing

Subbase
Base
100
90-100
100
55-85
70 - 95
50-80
55-85
40-70
30-60
30-60
20-50
10-20
10-25
0-15
2-10
Other Requirements for Subbase and base are indicated in the following table:
Test/Designation
Clay Content AASHTO T.88
Fines Content AASHTO T.27
Subbase
max 5%
-
Base
max 5%
Los Angeles abrasion AASHTO T.96
< 50%
passing No.200
shall be less than
halfpassing No.40
< 45%
C.B.R ASTM D1883

(4 day soaked sample compacted @
100% Modified proctor)
Soundness AASHTO T.104
(Max. loss in weight after 5 cycles)
30%
80%
Fine aggregate AASHTO

T.89, T.90
Percentage of material with at least
one fractured face
In Sodium
Sulphate: 12%
In Magnesium
Sulphate: 18%
In Sodium
Sulphate: 12%
In Magnesium
Sulphate: 18%
For passing No.40 For passing No.40

LL 30%, PI 6% LL 25%, PI 6%
90%
F.3 I f it is found necessary to add fine material in order to improve gradation requirements,
this material shall pass sieve 0.425 mm (no. 40) and shall be mixed with the crushed material
in the quarry and not in the project site.
Page 86 of 244
F.4 The percent passing no. 200 sieve (0.075 mm) shall not be more than half the percent
passing sieve no. 40 (0.025 mm).
3.02.3
A.
CONSTRUCTION
Mixing and Spreading
A.1 The Contractor shall thoroughly mix aggregate and water to uniform moisture content.
A.2 The Contractor shall spread materials on prepared subgrade or subbase in uniform
layers not exceeding the following thickness before compaction:
For subbase
For base
300 mm
250 mm
A.3 All segregated material shall be removed and replaced with well-graded material
A.4 The Contractor shall compact each layer to the following density requirements:
Subbase
Base
100% of maximum density AASHTO T.180

100% of maximum density AASHTO T.180
A.5 Each layer shall be completely compacted and approved prior to delivery of materials for
the following layer.
B.
Tolerance
B.1 The Contractor shall conform to lines, grade and cross sections as shown on the
Drawings.
B.2 Tolerances on elevations for final layer at 20 m intervals and intermediate points as
follows:
-
Subbase:
Base:
+10 mm to - 20 mm
+10 mm to - 15 mm.
Page 87 of 244
B.3
For agricultural roads, tolerances on elevations shall be as follows:
Subbase:
Base:
+20 mm to - 20 mm
+15 mm to - 15 mm.
B.4 The Contractor shall remove defective sections and replace to correct tolerances.
B.5 The Contractor shall maintain finished course in good condition until succeeding layer is
placed.
C.
Testing
C.1 The Contractor shall carry out in-situ testing as directed by concerned authorities
(Municipality/Ministry of Transport) and Engineer or as per the listed-below:
Required Tests
1. Proctor
Test for every 500 LM for each layer or as

per specifications of the concerned
authorities (Municipality / Governamate /
Ministry of Transport)
2. Gradation of Materials
When materials changed or whenever

instructed by the Engineer
"
"
"
"
"
"
Test for every 2000 sq.m. and for every layer
3. Plasticity Index
4. C.B.R
5. Abrasion
6. Sand equivalent
7. Clay lumps and friable particles
8. Field Density
9. Thickness
D.
Repetition Required for all Tests
Compaction
D.1 Compaction shall be tested in accordance with AASHTO T 191 or AASHTO T 205. If
there is a delay between the construction of any layer and the following layer, i f necessary
and required by the Engineer the compaction of the lower layer may be re-verified to ensure
that it has not loosened due to traffic, passage of construction equipment, adverse weather
conditions or otherwise.
Page 88 of 244
SECTION 3.03
3.03.1
A.
BITUMINOUS LAYERS
GENERAL
Responsibility
A.1 The Contractor shall locate adequate sources and supply of material conforming with the
specifications.
A.2 The Contractor shall obtain the approval of the Engineer.
A.3 The Contractor shall sample and test all materials in an approved laboratory for
compliance with the specification.
A.4 The Contractor shall ensure crushing, screening and sampling materials shall be as
specified in section 3.02.1.
A.5 The Contractor shall construct as per specification of the concerned authorities
(Municipality / Ministry of Transport).
3.03.2
MATERIALS AND REQUIREMENTS FOR BITUMINOUS

COURSES
A.
Materials
A.1
The materials specified for use in construction of pavement layers include:
Coarse and fine mineral aggregate and filler.

Bitumen products including penetration graded bitumen and cutback bitumen.
A.2
Physical and chemical properties of all materials used in the bituminous mixes and/or
bituminous layer construction shall conform to the requirements outlined in sub-sections B, C
and D below.
Page 89 of 244
B.
Aggregates for paving layer
B.1 Aggregate shall be clean, hard, durable and sound and shall consist of crushed stone, of
uniform quality and free from decomposed rock organic matter or shale. Combined aggregate
grading for bituminous mixes including mineral filler shall conform to the requirements
indicated in the table below:
Sieve Designation
Percent by weight passing
Binder Course
100
75-90
65-80
55-65
35-80
20-35
7-20
5-25
3-7
1" (25.0 mm)

" (19.0 mm)
" (12.5 mm)
3/8" (9.5 mm)
No. 4 (4.75 mm)
No. 10 (2.00 mm)
No. 40 (0.425 mm)
No. 80 (0.180 mm)
No. 200 (0.075 mm)
Wearing Course
--100
90-100
78-83
46-60
30-42
14-25
8-16
3-7
B.2 Other Aggregate Requirements:
Percentage by weight of friable particles, clay lumps, organic material and

shale shall not exceed 1% as determined by AASHTO T-112.
Aggregate shall not contain more than 1% gypsum and 5% chert.
The plasticity index of material passing 0.425mm should not exceed 4%.
90% of crushed particles retained on No. 4 sieve (4.75 mm) shall have at least
2 or more fractured faces.
Flakiness index and elongation index tested in accordance with B.S. 812 shall
be within the following maximum limits:
Wearing Course
Flakiness Index
Elongation Index
Binder Course
30 30
25
25
Added mineral filler shall be fine particles of limestone or cement in

accordance with ASTM D-242. It shall be dry and free from organic material or
clay.
Loss in weight of aggregate after 500 revolutions shall not exceed 35%
when tested in accordance with AASHTO T-96.
Page 90 of 244
C.
Soundness, when tested in accordance with AASHTO T-104 for aggregate

retained on No 4 sieve (4.75 mm) shall not show signs of disintegration, and the
loss in weight after 5 cycles shall not exceed 10% for the sodium sulphate tests
and 12% for the magnesium sulphate test.
When tested for resistance to water damage in accordance with ASHTO T. 283,
the retained strength should be greater than 80%.
Combined mineral aggregate shall have a sand equivalence value not less than
50 when tested in accordance with AASHTO T-176.
Aggregates shall be washed i f directed to remove any clay lumps, adherent dust
and other deleterious materials.
Bitumen Products
C.1 Provide adequate transport and storage facilities for bitumen, and protect from temperature
under -5C or over + 60 C.
C.2 Sampling of bitumen shall be in accordance with AASHTO T-40.
C.3 Binder and wearing courses shall be plant mixes in accordance with an established Job
Mix Formula (J.M.F)
C.4 The J.M.F. shall be established by the Contractor and approved by the Engineer. The mix
design procedures shall be in accordance with the Marshall method procedure given in the
Asphalt Institute Manual, M.S-2.
C.5 The J.M.F. shall be re-established i f the source of aggregate, filler or bitumen is changed.
C.6 Unless otherwise specified the bitumen for binder and wearing courses shall be 60/70
penetration graded bitumen and shall conform generally to the requirement of AASHTO M20.
Page 91 of 244
C.7 The J.M.F. shall conform to table 3.1

Table 3.1: Job Mix Formula
Number of blows at each end of compacted specimen

Stability (Marshall) (Kg)
Flow (Marshall) (mm)
Percent Air Voids
Percent Voids in Mineral Aggregate (V.M.A.)
Percent Voids filled with bitumen (V.F.B.)
Loss of Marshall Stability (AAHTO T 165)
Filler Bitumen Ratio
Bitumen content, percent by weight of total mix.*
Binder Course
Wearing Course
75
1000
2-4
4-7
14
50 - 70
max 25%
0.6 - 1.5
3.5 - 4.5
75
1000
2-4
4-6
15
50 - 75
max 25%
0.6 - 1.4
3.5 - 4.5
* the optimum bitumen content shall be determined during the design mix procedure. (the given values are
tentative).
C.8 The maximum variations of the project mix from the approved J.M.F. are as shown in
table 3.2:
Table 3.2: Surface Tolerances
Sieve Designation (square openings)
9.5 mm (3/8 in.) and above
4.75 mm (No. 4)
2.00 mm (No. 10)
0.425 mm (No. 40)
0.18 mm (No. 80)
0.075 mm (No. 200)
Bitumen Content
Specified Tolerances
+ or -5.0%
+ or - 4.0%
+ or -4.0%
+ or -4.0%
+ or -4.0%
+ or -1.0%
to be recommended by the Engineer based on
trials conducted by the Contractor.
Temperature of Mix on discharge
+ or -50C
Any deviation from these limits shall be made only with the approval of the Engineer.
For agricultural roads the specified gradation tolerances above can be increased by 2%.
D.
Bituminous Prime and Tack Coats
D.1 Works shall consist of furnishing and applying MC cutback bitumen prime coat to a
previously constructed subgrade, sub-base, aggregate base course, or road shoulders, and
furnishing and applying RC cutback bitumen as a tack coat to a previously constructed
bituminous binder or wearing surface to provide bond for a superimposed bituminous course;
all as and where shown on the Drawings.
Page 92 of 244
D.2 Unless otherwise specified MC-70 shall be used for prime coat. Properties to conform
with AASHTO M82.
D.3 Tack coat shall be RC-70 in accordance with AASHTO M-8 1.
D.4 Surface for application to be sufficiently dry for Tack coat, and sufficiently moist for prime
coat. Ambient temperature to be more than 10C and no rain, dust or strong wind.
D.5
Spraying temperature shall be for RC-70 40 - 75C. and for MC-70: 45 - 60C.
D.6
Unless otherwise directed by the Engineer. The following rates of applications shall
be used.
-
Prime coat
0.75 - 2.0 liters/ sq.m
Tack coat
0.3 - 0.6 Kg/ sq.m
D.7 Prime coat shall be cured for 3 days or as directed by the Engineer.
D.8 Tack coat shall be allowed to dry to a suitable tacky condition before succeeding asphalt
layer is placed.
D.9 Traffic shall not be permitted on surfaces after they have been cleaned and prepared for
prime or tack coat application.
3.03.3
A.
CONSTRUCTION
Surface Preparation
A.1 When the bituminous mix is to be placed upon a granular subgrade subbase or base
course, the surface shall have been primed and approved by the Engineer.
Page 93 of 244
A.2 When the bituminous mix is to be placed upon an existing bituminous surface, the
surface shall be cleaned of all foreign material and broomed free of dust; to the approval of the
Engineer. If required on the Drawings a tack coat shall be applied prior to placing the new
layer.
B.
Delivery Spreading and Finishing
B.1 The maximum temperature of the bituminous mix at the mixing plant shall be 170C
when 60 / 70 penetration bitumen is used. The application temperature shall be between
145C and 165C.
B.2 The mix shall be laid by means of a paver, and rolled and compacted to not less than
97% of the average daily Marshall bulk density.
B.3
Unless otherwise directed, the schedule of testing shall be as shown in table 3.3.
B.4 The thickness of pavement surface layer equal to the initial pavement layer thickness
with a maximum thickness of 15 cm and with a minimum value of 8 cm and as per the
concerned authorities (Municipality / Government / Ministry of Transport)
C.
Tolerances
C.1 Elevation of finished course at intervals not exceeding 10 m shall be maximum 10mm
(or 15 mm for agricultural roads).
C.2 When tested with a 3 m long straightedge, parallel to and perpendicular to the
centerline, the maximum deviation between any two contact points shall not exceed 8 mm for
the binder course, and 5 mm for the wearing course (or 10 mm for binder course and 7 mm
for wearing course in case of an agricultural road).
Page 94 of 244
Table 3.3: TESTS FOR BITUMINOUS PAVEMENTS

Minimum Tests required.
(A)
Tests at Source
of material
Work item
3-1
Materials used in
Asphalt mix
(at Batching
plant)
1.
2.
3.
4.
5.
6.
3-2
Materials used in
Asphalt mix (from
hot bins)
3-3
Asphalt mix
design each layer
(At batching
plant)
1.
2.
3.
4.
5.
1.
2.
Frequency for all

tests mentioned
under (A)
Specific gravity and

water absorption
Abrasion test
Chert content
Clay lumps and
Friable materials
Flaky and elongated
Particles.
Soundness
Gradation
Specific gravity and
water absorption.
Plasticity index
Sand equivalent
Stripping with
asphalt
Complete mix design in accordance with

American Asphalt
Institute (MS2)
Loss of stability
3-4
Asphalt for each
layer
At Batching plant
1. Stability
2. Flow
3. Extraction (binder
content and
gradation)
4. Air voids
5. Voids in mineral
aggregates
6. Daily Marshall
density
7. Loss of Stability
Frequency for all

tests mentioned
under (B)
Test for each

source
When materials
quality changes
As requested
Test for each

source
When materials
quality changes
As requested
For each job mix

When materials
quality changes.
When results are
not consistent
with the mix
design results.
As requested
Test each 3
working days
Tests for each
batching plant
As requested
Once a week
As requested
(B)
Tests at road
Site
Behind spreader
1. Stability
2. Flow
3. Extraction
(binder content
& gradation)
4. Air voids
5. Voids in mineral
aggregates.
6. Daily Marshall
density
7. Road density and
thickness (after
final compaction)
Test for each

working day
Test for each
batch
As requested
Test for each

200 lin.m, per
lane and for
each layer
As requested
C.3 The combination of permitted tolerances in the levels of the bituminous courses shall not
result in a reduction of thickness of 10 mm from the specified thickness nor a reduction in the
final wearing course by more than 5 mm from that specified.
C.4 Thickness of each bituminous course shall be determined by taking core samples, as
directed by the Engineer.
Page 95 of 244
SECTION 3.04
3.04.1
A.
PAVEMENT REPAIRS AND TRENCH REINSTATEMENT

WORKS
GENERAL
Scope
A.1 Pavement repair and trench reinstatement Works shall consist of removing defective
bituminous pavement, preparing surfaces (after having properly backfilled all trenches and
potholes) to receive repairs, furnishing materials, placing and finishing new pavement, as and
where shown on the Drawings or as directed by the Engineer and the concerned authorities
(Municipality / Governmate / Ministry of Transport).
3.04.2
ASPHALTING
Pavement type A
Pavement type A shall be considered as asphaltic pavement for main roads with a total
thickness for base and pavement layers exceeding 15 cm in addition to a granular layer
below base with thickness greater than 15 cm.
Pavement type B
Pavement type B shall be considered as asphaltic pavement for collection roads with a
total thickness for asphalt of 10 to 15 cm in addition to a granular thickness below base with
thickness exceeding 15 cm.
Pavement type C
Pavement type C shall be considered as asphaltic pavement for roads that are not main or
collection roads and where asphalting is not of type A or B.
Page 96 of 244
3.04.3
A.
MATERIALS
General
A.1 A l l pavement materials shall conform with the relevant requirements and concerned
authorities mentioned in Section 3.02.2 - "Materials" and Section 3.03.2 - "Materials and
Requirements for Bituminous Layers".
A.2 Subgrade materials shall conform with the relevant requirements of Section 2.05 "Subgrade Construction" and requirements of concerned authorities.
3.04.4
CONSTRUCTION AND REPAIR WORKS
A.
Preparation of Pavement
A.1
Cracks in bituminous pavement that, in the opinion of the Engineer, do not require
reconstruction shall be prepared by wire brushing and blowing out with compressed air.
A.2
Defective bituminous pavement which, in the opinion of the Engineer, requires

reconstruction shall be cut back to good material using pneumatic cutting tools.
Excavation of pavement layers for trenching shall also be initiated with pneumatic tools
or asphalt saws and later completed with regular excavating equipment. The cut edges
shall be square or rectangular and in line with the direction of traffic. The depth of cut
shall be determined by the Engineer and may include asphaltic layers, base and
sub-base layers and subgrade layers (in the case of failed pavement, excavation shall
include a minimum of 300 mm of subgrade material). A l l excavated materials shall be
removed and disposed of off-site. When the bottom of the excavation consists of earth
or granular material it shall be thoroughly compacted using mechanical compactors to the
satisfaction of the Engineer. Excavated bituminous surfaces shall be thoroughly cleaned
and wire brushed prior to receiving repair materials.
A.3
Utility trench reinstatements in bituminous pavement shall be prepared in the same way
as defective bituminous pavement. Excavation shall include a minimum of 300 mm of
subgrade material.
Page 97 of 244
A.4 I f cracks are present in asphalt layer due to trench excavation works for sewage and water
network, the Contractor shall reinstate the defects present as below:
The crack and longitudinal and transverse joints shall be cleaned by a brush and by air.
The cracks shall then be filled with bitumen binder after which crushed sand shall be
spread above this binder.
I f settlement is obtained in the existing asphalt then the Contractor shall identify these
locations which shall be saw-cut in a square or rectangular shape with the suitable
equipment and shall then be reinstated as it was before failure.
B.
Placing and Finishing Repair Materials
B.1. Cracks of 3 mm width or wider shall be filled with clean, coarse sand then saturated with
1:1 diluted emulsified bitumen or as directed by the Engineer. Cracks of less than 3 mm shall
be filled with emulsified bitumen or as directed by the Engineer. Cracks shall be filled to the
road surface. Any excess bitumen shall be removed with a squeegee and the bitumen surface
shall be sprinkled liberally with coarse sand.
B.2 Excavations below subgrade level shall be filled to a level specified by the Engineer with
subgrade material in layers not exceeding 150 mm and compacted using mechanical
compactors to conform with the requirements of Section 2.05 - "Subgrade Construction" and to
the satisfaction of the Engineer.
B.3 Sub-base and/or base course, i f required, shall be placed in layers not exceeding 150 mm
and compacted using mechanical compactors. They shall comply with the relevant
requirements of Section 3.02.3 or as directed by the Engineer.
B.4 Prior to receiving bituminous material the excavations shall be thoroughly cleaned.
Subgrade, sub-base or base course material shall be primed with a light coating of MC cutback
bitumen and existing bituminous surfaces shall be lightly painted with RC cutback bitumen, all
in accordance with the requirements of Section 3.03.3.
B.5 The excavation shall be filled with bituminous pavement materials placed in layers not
exceeding 70 mm and compacted using vibratory compactors. Unless ordered to the contrary
by the Engineer, the top layer shall be compacted by steel wheeled roller, first compacting the
150 mm strips adjacent to the traffic edges, then rolling in the direction of traffic.
Page 98 of 244
B.6 New utility trenches shall be backfilled according to Section 2.04 and to the details shown
on the Drawings, or ordered, including any surrounds, haunching or protective materials.

Construction of subgrade and pavement shall be as for pavement repairs.
B.7 No excavated areas shall remain open overnight.
C.
Surface Tolerances
C.1
Levels shall be checked by straight edge in relation to the adjacent existing pavement.
C.2
Surface tolerances for bituminous layers shall conform with the relevant requirements of
Section 3.03.3.
C.3
Any deficiency in the wearing course surface shall be corrected by cutting out and
replacing.
Page 99 of 244
SECTION 3.05
3.05.1
A.
CURBS, GUTTERS, SIDEWALKS AND PAVED MEDIANS
GENERAL
Scope
A.1 These Works shall consist of furnishing materials and constructing concrete/limestone
curbs, gutters, curb-and-gutter combinations and concrete/limestone paving to sidewalks and
medians, using in situ concrete construction precast concrete units or limestone units, as and
where shown on the Drawings. The shapes and installation details of curbs and gutters,
sidewalks, and medians shall be coordinated with the concerned Authorities. Preparation and
construction methods shall comply with the requirements of the concerned authorities
(Municipality / Governmate / Ministry of Transport) or as per the Engineers direction.
3.05.2
A.
MATERIALS AND PRECAST MANUFACTURE
Concrete
A.1 Portland cement concrete shall be Class 2 10/20 for all in situ and precast concrete, except
base course and backing concrete which shall be Class 170/60. A l l concrete shall conform with
the relevant requirements of Section 5.01 - "Concrete and Concrete Mixes and Testing" and
shall be produced by an approved commercial ready-mix plant.
B.
Mortar
B.1 Mortar shall consist of cement and fine aggregate having the same proportions as used in
the concrete construction and shall conform with all relevant requirements of Section 5.01 "Concrete and Concrete Mixes and Testing".
C.
Reinforcement
C.1 Reinforcing steel shall conform with the requirements of Section 5.03 - "Steel
Reinforcement and Fixing".
Page 100 of 244
D.
Precast Concrete Units
D.1 A l l precast units shall be manufactured to the dimensions shown on the Drawings.
Manufacturing tolerances shall be 3 mm in any one dimension. End and edge faces shall be
perpendicular to the base.
D.2 Each precast curb or gutter unit shall normally be 0.5 m in length and this length shall be
reduced to 0.25 m or as directed, where units are to be installed along curves of less than 10 m
radius.
D.3 For horizontal curves of radius less than 10 m, curb and gutter units shall be manufactured
to the radius shown and in such circumstances where straight elements or portions of straight
elements shall not be used. Bullnoses and curved faces shall be of constant radius with a
smooth change from radius to plain face.
D.4 Unless shown otherwise on the Drawings, precast concrete tiles (paving slabs) shall be
400 mm by 400 mm by 40 mm thickness with 5 mm edge bevel. The tile face shall be grooved
in squares of a size agreed by the Engineer as appropriate to the tile dimensions. Coloring of
the top layer, where required, shall be achieved using mineral oxides.
D.5 Surfaces of precast units that will be exposed to view after installation, shall be true and
even, with a dense finish of uniform texture and color, free from cracks, holes, fins, staining or
other blemishes or defects. Units failing to meet these requirements will be rejected. Surfaces
that will not be exposed to view after installation shall have all fins and irregular projections
removed and all cavities, minor honeycombing and other defects made good with mortar after
the units have been saturated with water for at least 3 hours.
D.6 Precast units shall be cast upside down in approved steel molds under conditions of
controlled temperature and humidity. The units shall be steam cured or any other method
approved by the Engineer until the concrete attains the full specified 28-day strength.
D.7 The Contractor shall submit for approval, samples of each of the proposed units together
with the manufacturer's certificates and details of the method of manufacture and materials to
be used. The Engineer's approval of the samples will not be considered final and the Engineer
may reject any precast units delivered to the Site which do not meet the required standards or
specifications and requirements of concerned Authorities.
Page 101 of 244
E.
Limestone
E.1 Approved best quality limestone shall be obtained from one strata from one quarry,
delivered in one shipment, free from vents, cracks, fissures, discoloration or other defects which
adversely affect strength, durability or appearance, thoroughly seasoned, dressed and worked
before delivery to site, and to the sizes shown on the Drawings, cut square and true with clean
edges.
F.
Preformed Expansion Joint Filler
F.1 Preformed expansion joint filler shall conform to AASHTO M 33.
G.
Epoxy Adhesive
G.1 Epoxy adhesive (for use in attaching precast units to existing concrete pavement surfaces)
shall be a two component epoxy of high viscosity and rapid setting characteristics, conforming
to AASHTO M237, Class II.
H.
Ducts
H.1 Ducts (if required under sidewalks or medians) shall consist of uPVC plastic pipe
conforming to DIN 8061 and DIN 8062 or SAS 14 or approved equal. I f jacking is required, duct
shall be approved galvanized steel tube.
I.
Bedding
I.1
Bedding material shall conform to the relevant requirements of Section 3.02 - "Granular
Sub-base and Base Courses" for Class A or Class B granular material.
3.05.3
A.
CONSTRUCTION AND INSTALLATION

Cast In Situ Curbs and Gutters
A.1 The subgrade shall be excavated to the grades and sections shown on the Drawings. I f
the section is not indicated, the width to be excavated shall be 300 mm each side of the outside
edges of the curb or gutter. The subgrade shall be of approved uniform _____ density.
Page 102 of 244
The subgrade foundation shall be excavated to a minimum depth of 150 mm and the material
replaced with bedding material which shall be compacted to at least 95% AASHTO T180
maximum density. A l l foundations shall be rolled or compacted to provide a smooth surface
and shall be approved before placing concrete.
A.2 For stationary side form construction, forms for curb or gutter shall be of approved steel
type. A l l forms shall be sufficiently strong and rigid and securely staked and braced to obtain a
finished product correct to the dimensions, lines and grades required. Forms shall be cleaned
and oiled before each use. Forms may be removed as soon as practicable after concreting,
provided no damage results to the curb or gutter and in any case not until 24 hours after
completion of concreting.
A.3 For slip-form construction, curb or gutter may be constructed by use of approved slip-form
or extrusion equipment. The completed curb or gutter shall be true to shape, grade, and line,
and the concrete shall be dense and of the required surface texture.
A.4 Concrete shall be placed upon the previously prepared and moistened subgrade and shall
be consolidated with an approved type internal vibrator. The surface shall be shaped by use of
a steel screed to produce the section shown on the Drawings. The edges shall be rounded with
edgers to form the required radius, which i f not shown on the Drawings shall be 5 mm.
A.5 Contraction and construction joints of the required types shall be constructed at the
intervals and locations shown on the Drawings. Adjacent to flexible base or surface courses,
weaker plane contraction joints in curbs or gutters may be constructed by sawing through the
curb to a depth of not less than 30 mm below the surface of the gutter, or they may be formed
by inserting a suitable removable metal template in the fresh concrete, or by other approved
methods. Sealing of the joints will not be required unless shown on the Drawings.
A.6 Exposed surfaces shall be finished full width with a trowel and edger. The top face of curbs
or gutters shall receive a light brush finish. Forms for the roadway face of curbs and the top
surface of gutters shall be removed 24 hours after concrete has been placed and finishing of the
surfaces shall be carried out, provided the alignment tolerances and other requirements have
been met.
A.7 Tolerances on tangent sections of curb and gutter shall be tested using a 4 m straightedge.
The finished surface of concrete shall not deviate from the straightedge between any 2 contact
points by more than 5 mm. Curved sections shall be true to the specified radius plus or minus 5
mm and all joints shall be flush and neat in appearance.
Page 103 of 244
A.8 A l l fins and irregular projections shall be removed and cavities produced by form ties and
all other small holes, honeycomb spots, broken corners or edges and other defects shall be
rectified. After saturating with water for a period of not less than 3 hours, the surfaces shall be
carefully pointed and made true with mortar. Al l construction and expansion joints shall be
left carefully tooled and free of all mortar and concrete. Joint filler shall be left exposed for its
full length with clean and true edges. The resulting surfaces shall be true and uniform.
A.9 A rubbed finish shall then be carried out to surfaces that will be exposed to view after
completion of construction. Before rubbing, the concrete shall be kept saturated with water for
at least 3 hours. Sufficient time shall have elapsed before the wetting down to allow the
mortar used in the pointing of holes and defects to set. Surfaces shall by rubbed with a medium
carborundum stone, using mortar on its face. Rubbing shall remove all remaining form marks,
projections and irregularities, and result in a uniform surface. The final finish shall involve
rubbing with a fine carborundum stone and water until the entire surface is of a smooth
texture and uniform color. After the surface has dried, loose powder shall be removed and the
surface shall be left clean and free from unacceptable flaws or imperfections.
A.10 Curbs and gutters shall be moist cured until stripped and finished, and then membrane
cured in accordance with the relevant requirements of Section 5.02 - "Concrete Handling,
Placing and Curing". Curing compound shall be applied immediately following completion of
rubbed finish.
A.11 The area adjacent to completed and accepted curbs and gutters shall be backfilled with
approved material to the top edges of the curbs or gutters or to the elevations shown on the
Drawings. Backfill shall be placed and compacted to 95% AASHTO T180 maximum density.
B.
Precast Concrete/Limestone Curbs and Gutters
B.1
Subgrade for the concrete base shall be constructed as for in situ curbs and gutters.
B.2
Forms for the concrete base shall be approved wood or steel. A l l forms shall be
sufficiently strong and rigid and securely staked and braced to obtain a finished
product correct to the dimensions, lines and grade required. Forms shall be cleaned
and oiled before each use. I f approved, forms for the concrete base may be omitted and
the concrete placed directly against undisturbed excavated faces.
Page 104 of 244
B.3 Base course concrete shall be placed, compacted and shaped to the sections shown on
the Drawings. Concrete shall be compacted with an approved internal type vibrator or if
approved, by hand spudding and tamping. Edges shall be rounded if necessary by the use of
wood molding or by the use of an edger as applicable. The concrete base shall be finished to a
true and even surface with a wood float. Concrete shall be membrane or water cured for at
least 7 days before precast units are placed thereon.
B.4 Precast concrete units shall be soaked in water immediately before installation. Units shall
be set accurately in position in mortar on the concrete base. Joints between precast units shall
not be mortared unless otherwise shown on the Drawings. Units shall be closely spaced and
every 10 m run shall be provided with an expansion joint.
B.5 Where curbs or gutters are installed on existing concrete pavement using epoxy resin
adhesive, automatic devices for mixing epoxy adhesive shall be equipped so that the separate
components are delivered to the mixing head at the specified volume. The lines feeding the
mixing head shall be equipped with suitable valves that will allow samples to be taken for
checking the ratio of each component. The machine shall be capable of metering the amount
of adhesive required to secure each curb or gutter.
B.6 After curbs have been installed, steel forms shall be erected and concrete backing, i f
required, shall be placed as shown on the Drawings. Pavement courses shall not be laid
against curbs until the concrete backing has membrane or water cured for at least 14 days.
B.7 The tolerances on alignment of completed precast units shall be as specified for in situ
concrete construction.
B.8
Backfilling shall be carried out as specified for in situ curbs and gutters.
C.
In Situ Concrete Paving
C.1
Excavation shall be carried out to the required depth and to a width that will permit the
installation and bracing of the forms. The foundation shall be shaped and compacted to an even
surface conforming to the sections shown on the Drawings. All soft and yielding material shall
be removed and replaced with approved material.
C.2
Bedding material shall be placed in layers not exceeding 100 mm in depth and each
layer shall be compacted to 95% AASHTO T180 maximum density. The total bedding course
thickness shall be as shown on the Drawings, or i f not shown, 100 mm minimum thickness.
Page 105 of 244
C.3 Forms shall be of steel, wood, or other approved material and shall extend for the full
depth of the concrete. Al l forms shall be straight, free from warp, and of sufficient strength to
resist the pressure of the concrete without displacement. Bracing and staking of forms shall be
such that the forms remain in both horizontal and vertical alignment until their removal. A l l
forms shall be cleaned and oiled before concrete is placed.
C.4 The foundation shall be thoroughly moistened immediately prior to the placing concrete.
Concrete shall be deposited in one course in such a manner as to prevent segregation and
shall be consolidated by vibrators. The surface shall be finished with a wooden float and light
brooming. No plastering of the surface will be permitted. A l l outside edges of the concrete
tiles and all joints shall be edged with a 5 mm radius edging tool.
C.5 Forms may be removed only when there is no risk of damage to the concrete and in any
case not until at least 24 hours after completion of concreting.
C.6 The smoothness of paved areas shall be tested using a 4 m straightedge. The finished
surface of concrete shall not deviate from the straightedge between any two contact points
by more than 5 mm. Sections of defective paving shall be removed and replaced as directed,
at the Contractor's expense.
C.7 Expansion joints shall be of the dimensions specified and shall be filled with approved,
pre-molded expansion joint filler. The area being paved shall be divided into sections by
weakened plane joints formed by a jointing tool or other acceptable means as directed. These
joints shall extend into the concrete 0.20 to 0.25 times the depth and shall be approximately 3
mm wide. Joints shall match as nearly as possible adjacent joints in curb or pavements.
Weakened plane joints may be sawn in lieu of forming with a jointing tool.
C.8 Construction joints shall be formed around all appurtenances such as valve chambers,
utility poles, etc., extending into and through the side-walk or median. Pre-molded expansion
joint filler of 10 mm thickness shall be installed in these joints. Expansion joint filler of the
thickness indicated shall be installed between concrete construction and any adjacent fixed
structures such as buildings or bridges, etc. The expansion joint material shall extend for the
full depth of the concrete.
C.9 Concrete shall be cured by membrane curing in accordance with the requirements of
Section 5.02 "Concrete Handling, Placing and Curing".
Page 106 of 244
D.
Precast Concrete Tiles (Paving Slabs)
D.1 Excavation and the placing of bedding material shall be as specified for in situ concrete
paving. The surface of the completed bedding shall be dampened and base course concrete
shall be placed and finished to the thickness as shown on the Drawings or if not shown, 40 mm
minimum thickness.
D.2 The base course concrete shall be water or membrane cured as specified for in situ
concrete paving, for not less than 7 days before placing precast tiles.
D.3 Immediately prior to tile laying, the concrete base course shall be dampened and the
concrete tiles shall be immersed in water. Tiles shall then be laid true to line and grade on a 10
mm to 20 mm thickness of mortar. Joints shall be 3 mm wide.
D.4 The tolerance on smoothness of precast concrete tiled areas and removal and replacement
of defective tiling, shall be as specified for in situ concrete paving.
D.5 Tiles shall be cleaned 24 to 36 hours after laying and joints shall be mortared using, i f
approved, a plasticizer in the mortar to improve workability and to enable the mortar to be
readily smoothed and finished. As soon as the mortar has partially set, all mortar material shall
be raked from the top 3 mm depth of the joint, using a grooving tool to produce a smooth
circular section.
D.6 When the mortar is sufficiently set, the surface shall be sprinkled with water and covered
with plastic or nylon sheets during the curing period. The sheets shall be left in place until final
hardening of the mortar, or as directed. A l l foreign matter, wood, concrete, mortar lumps, etc.,
shall then be removed and the surface cleaned of staining, discoloration and other blemishes.
D.7 In cases where tiles are required to be cut at the boundaries of tiled areas, or due to the
presence of obstacles, poles, hydrants, etc., or in the construction of the driveways or side
roads, the Contractor shall cut the tiles or substitute in situ concrete of at least the same quality
as the tile concrete. The Engineer will decide, after trials, on the method to be adopted. Cutting
of tiles or substitution of in situ concrete shall be kept to a minimum. The Contractor shall
complete the areas using uncut precast tiles to the maximum extent practicable.
Page 107 of 244
D.8 The method of construction and sequence of operations, for areas constructed using
precast tiles, shall be the same as for areas constructed using in situ concrete. The Contractor
shall ensure that the final appearance of such surfaces, regardless of the method of construction,
is substantially the same for both types of construction.
D.9 Where a sidewalk crosses the entrance to a shop or a house, etc., which is higher than the
sidewalk, the Contractor shall construct steps, formed by a curb and a complete or partial tile.
Steps shall be backfilled with concrete of the same quality as specified for concrete base
course.
D.10 Steps shall be constructed wherever the difference in elevation between the entrance and
the sidewalk is more than 250 mm. The Contractor shall submit for approval, prior to
commencing any sidewalk construction, a list of locations where steps will be required, together
with design details for their construction.
Page 108 of 244
SECTION 3.06
3.06.1
A.
MAINTENANCE OF TRAFFIC AND DETOURS
GENERAL
Scope
A.1 These Works shall consist of supplying all materials and equipment, constructing detour
roads, bridges and culverts where necessary; and installing, operating and maintaining all
required temporary lighting, signing, signals, pavement marking, barriers and other safety
measures; all for the proper maintenance of vehicular and pedestrian traffic through and
around the Site of the Works during the Contract Period.
A.2 Temporary works shall conform with the general requirements of Section 1.04
"Temporary Works" and as specified by the concerned Authorities (Traffic Directorate
/Municipality/Governmate/ Ministry of transport).
3.06.2
MAINTENANCE AND PROTECTION OF TRAFFIC
A.
General
A.1
The Contractor shall ensure the free movement of vehicular and pedestrian traffic and
shall maintain all highways including temporary detours and accesses in a clear and
safe condition free from obstructions. Adequate access to the Site shall be maintained
at all times to ensure that traffic on existing roads is not impeded unnecessarily by
traffic turning into the Site.
A.2
In order to facilitate movement of traffic through or around construction and when and
wherever required by the Engineer, the Contractor shall furnish, erect and maintain
signs, traffic barricades and other facilities necessary for safe and efficient direction
and handling of traffic at specified locations in or around the Site and as per
specification of the concerned authorities and Engineer.
A.3
The Contractor shall, i f required by the Engineer, provide flashing signal lights by
night and provide sturdy barricades for the protection of workmen engaged on traffic
control.
Page 109 of 244
A.4 The Contractor shall, whenever necessary, provide flagmen at specified locations with
the sole task of directing traffic through or around the Site and shall provide and erect within or
near the Site any "warning" or "directional" signs the Engineer may require.
A.5 A l l barriers, traffic signs, signals and other such devices shall be erected, maintained
and removed when necessary, as directed by the Engineer and concerned authorities.
A.6 Whenever it becomes necessary to operate one-way traffic along any stretch of road in or
around the Site, the Contractor shall, for the purpose of maintaining traffic, provide a single
traffic lane not less than 3.5 m wide and shall keep it open to traffic.
A.7 Where, in the opinion of the Engineer, construction of a detour is inappropriate, new
construction may be limited to half the road width at a time.
A.8 The Contractor shall submit for approval, details of the layout, pavement construction,
drainage, lighting, signing and marking of any detours that he proposes. He shall give the
Engineer at least 7 days notice of such proposals.
A.9 The standard of lighting levels and uniformity for each detour shall be at least equivalent
to that existing on the road that it replaces. In addition to lighting of detours, the Contractor
shall provide and maintain illumination of all temporary traffic signs during the hours of
darkness.
A.10 Any obstruction associated with detours, including ramps, variations of lane widths, siting
of warning signs, etc., shall be marked by the use of cones, flashing beacons and warning
lamps, appropriate to the location concerned.
A.11 Detours shall be constructed in advance of the Works which interfere with the existing
highway or access and shall be regularly maintained in a condition acceptable to the Engineer
for as long as required.
A.12 Before any detour is opened, the Contractor shall obtain approval from the Engineer.
The diversion of traffic on the day on which the detour is initially put into operation shall be
carried out with the assistance and coordination of the Police Department.
Page 110 of 244
A.13 A l l works under this section shall comply with the requirements of the Ministry of
Communication and traffic directorate and the concerned authorities.
A.14 The Contractor should install sufficient number of metal plates as bridges to cross the
excavations for pipelines according to the Engineer instructions and in coordination with the
citizens as per one bridge for each house. The shopping stores should be considered. A l l
required roads diversions should be paved.
Enough coordination should be done with the citizens to facilitate their movement during the
construction by printed notification prepared as per the requirements of the water authority in
the project area and sticked on each house.
Page 111 of 244
PART 4: Pipe Works and Network Accessories
PART 4:
PIPE WORKS AND NETWORK ACCESSORIES
SECTION 4.01
SCOPE
A. The works cover the supply of materials, installation, testing and commissioning of all pipes,
fittings, valves, and appurtenances related to wastewater collection works and sewer force
mains.
Page 112 of 244
SECTION 4.02
4.02.1
A.
GENERAL REQUIREMENTS
GENERAL
Scope
A.1 This section outlines the sequence of construction works, aspects related to the right of
way (ROW) and the general requirements for supply and handling of equipments and materials.
4.02.2
SEQUENCE OF CONSTRUCTION
A. The Contractor shall adhere to the sequence of construction as set out below unless a
justified request for modifying this sequence is approved by the Engineer at least two weeks
prior to commencement of work on the affected section of the network:
Stake out pipe alignments.
Clear and grade the right of way.
Conduct field surveys.
Carry out exploratory trenching across existing roads to verify location, depth,
size and type of existing utilities.
Prepare and submit for approval composite Shop Drawings for all utilities
showing alignment, ground elevation, trench invert elevation, pipe size, class
and length, station and size of fittings, valves, manholes and inspection
chambers, inlets, appurtenances and structures to be demolished and reinstated
(curbstone, rails, culverts, etc.). Cross sections showing location and inverts of
existing pipes and those proposed shall be prepared. Pipes, structures and other
utilities to be removed or relocated shall be indicated on the Shop Drawings. The
Contract Drawings shall be modified wherever required to produce the detailed
Shop Drawings.
Relocate, demolish and reinstate existing utilities interfering with pipeline

alignments.
Remove pavement layers, excavate trenches, place bedding all as required.
Page 113 of 244
4.02.3
A.
Lay and join pipes, fittings, appurtenances, inspection chambers, manholes,

etc
Place primary backfill material.
Perform required air, hydraulic or other required testing.
Install required house connections and or connections to existing utilities as

required.
Place final backfill.
Restore or reinstate surfaces and structures as required.
Carry out final surface works road surfacing curb stone, backing walls, side
walk tiling, etc
Dispose of surplus materials.
RIGHT OF WAY (ROW)
Extent
A.1
A l l utilities services shall be installed in the right-of-way of existing or proposed roads

as shown on the Drawings.
B.
Clearing and Grading
B.1
The ROW shall be used for both access to works sites and for service roads for the
pipelines.
B.2
In case the pipe lines run outside existing roads, the ROW shall be cleared and graded
to the required slopes; road cross-sections and all drains, shall be as indicated on the
Drawings.
B.3
Road surfacing / resurfacing works shall commence only after completion of pipe
installation and construction of all required works.
Page 114 of 244
4.02.4
A.
MATERIALS, PRODUCTS SUPPLY AND HANDLING
Structural Materials
A.1 Concrete shall conform to the requirements specified in Section 5.01 "Concrete and
Concrete Mixes and Testing".
A.2 Reinforcement shall conform to the requirements specified in Section 5.03 "Steel
B.
Products supply requirements
B.1 Manufacturer's certificate: Materials shall be supplied with a certificate for each delivery.
The certificate shall clearly state that products comply with the specified Standards and have
been factory tested accordingly.
B.2 Marking: Unless otherwise specified in the relevant Standard products shall have legibly
cast, stamped or indelibly painted on, the following marks, as appropriate:
Manufacturer's name, initials and identification mark.

Nominal diameter.
Class designation.
Initials and number of relevant Standard.
Length of pipe i f shorter than standard length.
Angle of bends in degrees.
Date of manufacture.
B.3 Special tests: Whenever required by the Engineer, the Contractor shall supply and
transport samples of materials selected by the Engineer to a testing laboratory. The number of
samples shall not exceed 0.5% of total supplied. However, at least one sample from each class,
diameter and manufacturer shall be tested. Failure of any sample shall be followed by a second
and if necessary a third test from the same batch regardless of whether the limits on number of
tests has been exceeded or not. A third test failure shall result in all material from that
manufacturer being rejected and replaced by material from a different manufacturer, subject to
approval and satisfactory tests. Laboratory test report in an approved form must be provided.
Page 115 of 244
C.
Products handling
C.1 General
C.1.1 Manufacturer's recommendations on handling, repairing, laying, jointing, anchoring,

testing and other works for pipes and fittings shall be strictly followed.
C.1.2 For loading and unloading, the Contractor shall use cranes, hoists or skidways as
directed by the Engineer. Use of hooks, spreader beams, ropes, band or wire slings etc. shall
be as recommended by the manufacturer of each type of pipe and as approved by the Engineer.
C.1.3 Pipes shall be stacked on horizontal surfaces. Pipes shall not be stored on their
sockets or jointing fairlings. End pipes in bottom row shall be secured by chocks. The
allowable height of stacks shall be to the manufacturer's instructions.
C.1.4 Material and equipment shall be handled with care whenever moved by hand, skidways
or hoists and any damage incurred shall result in the material being rejected.
C.1.5 The Contractor shall provide safe storage for the material. The interior surfaces of
pipes, fittings etc. shall be kept free from dirt and foreign matter. Shade for materials shall be
provided as required by manufacturer's instructions and to the Engineer's approval.
C.1.6 Cutting hacksaws, manually operated wheel cutters or pipe cutting machines shall be
used as per manufacturer's instructions. I f , in the opinion of the Engineer, special precautions
are to be taken to eliminate airborne particles, methods and equipment shall be used as directed
by the Engineer. Ends shall be prepared according to type of joint used and as per
manufacturer's recommendations. Care shall be taken to avoid any damage to the lining. Minor
damage may be repaired on site as directed by the Engineer.
C.1.7 The Contractor shall repair damaged coating, sheathing or lining in accordance with the
Specification and manufacturer's instructions. Material used for repair work shall be
compatible with that originally used. A l l repair works shall be approved by the Engineer
before incorporating materials into the work.
C.1.8 Bricks and cast iron frames and covers of manholes and chambers and all other
construction materials shall be loaded and unloaded by fitting with hoists or skidding so as to
avoid shock or damage. No hooks shall be used inside pipe. Under no circumstances shall
such materials be dropped. Pipe handled on skidways shall not be skidded or rolled against the
other pipe or other materials already on the ground.
Page 116 of 244
C.1.9 A l l materials shall be delivered and distributed at the site by the Contractor. In
distributing the material at the site of the work, each pipe shall be unloaded opposite or at the
nearest possible place where it is to be laid in the trench.
C.1.10 A space of suitable width, clear of any spoil materials shall be left all along the trench
so that no pipes shall be placed on excavated material.
C.2 GRP Pipes and Fittings
For handling GRP pipes, fittings and rubber ring gaskets, instructions of the manufacturer shall
be strictly adhered to GRP pipes and fittings shall be suitably wedged or braced to prevent
damage during shipment and transportation and rubber rings gaskets and lubricants shall be
packed in suitable containers.
The allowable stack height is 2.5 meters. When storing the pipes directly on ground, the
ground shall be free of stones and materials causing any damage.
While lifting, the supports shall be pliable straps or ropes and shall not be steel cables or chains
unless sufficient padding is provided to protect pipes surfaces. Pipes shall never be dropped.
C.3 uPVC Pipes and HDPE Pipes and Fittings

Manufacturers instructions shall be strictly adhered to while handling uPVC pipes and fittings.
Extreme care shall be taken when handling uPVC pipes and fittings.
The pipes shall be loaded using enough supports to avoid any sort of bending, distortion,
damage, scratches to the barrel or ends or any part of pipes and fittings. When off loading,
pipes shall be lowered taking all precautions to avoid bending, distortion, damage, scratches
and never be dropped to the ground. Pipes shall be given adequate and enough supports while
stacking. Pipes shall never be stacked in large piles or under direct sun light to avoid ultraviolet
degradation and manufacturers instructions shall be strictly adhered to. Any pipe with ends
prepared for jointing shall be stacked in layers with sockets placed at alternate ends of the
stack and with the sockets protruding to avoid unstable stacks.
For long term storage, pipes shall be stored in pipe racks providing continuous support under
a shed with insulated roof and shall never be kept under sunlight to avoid ultraviolet
degradation.
Also while loading pipes and fittings, care must be taken to avoid their coming into contact with
any sharp corners such angle irons, sharp steel sheets, loose nail-heads. While in transit,
pipes shall be well secured over their entire length. While off-loading, care shall be taken that
pipes and fittings do not fall one upon another or to any hard or uneven surfaces. uPVC pipes
and fittings shall be transported to the site in special pile rack type containerized units to
facilitate loading, unloading, onsite storage, retrieval and protection of pipes and fittings from
sunlight and ultraviolet radiations.
Page 117 of 244
C.4 Reinforced Cement Concrete (RCC) Pipe and Vitrified Clay (VC) Pipe
For handling RCC and VC pipes, the instruction of the respective manufacturer shall be
strictly adhered to. RCC and VC pipes shall be handled with great care while transporting to the
site and while installing. Each pipe shall be properly wedged to stop any movement, which may
cause damage to the bell and spigot or tongue and groove ends of the pipes.
Each pipe shall be carefully inspected before being laid and no cracked or defective pipe shall
be used. Chipping of the bell and spigot or tongue and groove pipe ends, which in the
Engineers opinion may cause defective joints, shall be avoided. A l l cracked and defective
pipes shall be rejected.
C.5
Ductile Iron Pipes and Fittings
A l l ductile iron pipes and fittings shall be handled and stored strictly according to the
instructions of manufacturer.
Pipes, fittings, valves, hydrants, cast iron frames and covers and all other construction
materials shall be loaded and unloaded by lifting with hoists or skidding so as to avoid shock
or damage. No hooks shall be used inside the pipe. Under no circumstances shall such
materials be dropped. Pipe handled on skidways shall not be skidded or rolled against pipe or
other materials already on the ground.
In distributing the material at the site of the work, each pipe shall be unloaded opposite or near
the place where it is to be laid in the trench.
Pipe shall be so handled that coating and lining will not be damaged. If , however, any part of
the coating or lining is damaged, the repair shall be made by the Contractor at his expense
according to manufacturers specifications or in a manner satisfactory to the Engineer, or be
replaced as determined by the Engineer.
C.6
Rubber Ring Gaskets
A l l gaskets for vitrified clay (VC), unplasticised polyvinyl chloride (uPVC), Glass fiber
reinforced concrete (RC) pipes and fittings shall be handled and stored strictly according to
their respective manufacturers instructions.
For storage of gaskets, the storage temperature is to be between + 5C and + 25C. If stored at
low temperatures and taken out for immediate use, their temperature must be brought to
approximately 30C prior to their use. The gaskets are to be protected from direct sunlight and a
strong artificial light with ultraviolet content. The gaskets must be protected from the
surrounding air either by wrapping them up or storing them in hermetically sealed boxes.
Page 118 of 244
D.
Materials and Equipment Furnished by the Contractor
D.1 The Contractor shall furnish all materials and equipment that will be incorporated in the
works and all other materials and equipment needed during construction. He shall also furnish
such constructional plant and equipment as in the opinion of the Engineer, is necessary and
adequate to perform all work within the scheduled time for completion.
D.2 The tenderer shall state in the schedule provided in the trade name of materials and
equipment he intends to incorporate in the works as well as the name of the manufacturer and
his full address. The Contractor shall be bound to use the same manufacturer materials and
equipment quoted in his Tender.
D.3 The Contractor shall, within 60 days after receipt of the order to commence, submit to the
Engineer in triplicate certified copies of the unpriced agreements with the manufacturers of the
materials and equipment to be used in the works. Such agreements shall embody all the
appropriate specification clauses including testing and inspection and shall state delivery
periods.
D.4 Materials and equipment furnished by the Contractor shall be brand new and of the type
and quality described in the specification. The Contractor shall procure all materials and
equipment, whether specified or substituted, from eligible sources. Where, because of
Employers priorities or other causes, materials or equipment required by the specification
become unavailable, substituted materials or equipment may be used.
D.5 The Engineers decision as to whether substitution shall be permitted and as to what
substitute materials.
E.
Inspection of Materials and Equipment
E.1 Materials and equipment furnished by the Contractor which will become a part of the
permanent works shall be subject to inspection at any one or more of the following locations as
determined by the Engineer: at the place of production or manufacture, at the shipping point, or
at the site.
E.2 The allow sufficient time to provide for inspection, the Contractor shall submit to the
Engineer, at the time of issuance, copies in triplicate of purchase orders, including drawings
and other pertinent information, covering materials and equipment on which inspection will be
made as advised by the Engineer, or shall submit other evidence in the event such purchase
orders are issued verbally or by letter. The inspection of materials and equipment or the waiving
of the inspection thereof shall in no way relieve the Contractor of the responsibility for furnishing
materials and equipment meeting the requirements of the specification.
Page 119 of 244
F.
Rejected Materials
F.1 Should any materials, equipment or manufactured articles prove to be, in the judgment of
the Engineer or as a result of testing, unsound or of inferior quality or in any way unsuitable
for the works in which it is proposed to employ them, such materials, equipment or
manufactured articles shall not be used in the works but shall be branded, i f in the opinion of
the Engineer this is necessary, and shall forthwith be removed from the site and replaced at
the Contractors expense and in each case as the Engineer shall direct.
G.
Approved Manufacturers Instructions
G.1
The Contractor shall supply the equipment, materials or other items from the
approved manufacturers listed or equal and approved.
G.2
All equipment or materials shall be delivered to the site in the manufacturers original
unopened containers with the manufacturers brand and name clearly marked on.
G.3
All equipment or materials shall be assembled, mixed, fixed, applied installed or

otherwise incorporated in the works in accordance with the printed instructions of the
manufacturer of the equipment or materials and/or the relevant standards as
specified.
H.
Certification and Third Party Inspection
H.1 A l l material provided by Contractor shall be procured from ISO/BS certified

manufacturers. The certificate should cover all the processes associated with the production of
the manufactured item and should be submitted to the Engineer approval with the material
submittals by the Contractor. Upon the request of the Engineer, the Contractor shall propose
an internationally accredited and reputable audit firm to act as a third party inspector who shall
certify that all material manufactured and shipped for the project have been manufactured and
conforms to the specified international standard governing the manufacture of the finished
item / product as specified in the project Tender Documents. The scope of the third party
inspection shall cover at least the quality control tests listed in the forth coming sections of the
Specification. The cost of the third party inspection shall be borne by the Contractor.
Page 120 of 244
SECTION 4.03
4.03.1
PIPES, FITTINGS AND ACCESSORIES
MATERIALS
The following table lists the type of pipe material that should be used for sewage network
for different pipe diameters and soil types:
Usage Recommendations
Type of Pipe
Dry Areas
(Non-aggressive
soil)
VC
Dry Areas
(Aggressive soil)
Wet Areas
(Ground water)
(Aggressive soil)
For diameters 200 to 600
GRP-GRE
For diameters 700 900mm with granular With granular bedding and
Stiffness not less than bedding
textile protection
5000N/m2
Concrete pipes
internally coated with
polyethylene with
thickness 3mm
For diameters
1000 mm
For diameters 1000 mm

with additional external
protection (paint with not
less than two layers of
bituminous)
The following paragraph describes the specifications of each of these pipes:
A.
Ductile iron pipe (used for force main)
A.1 Ductile iron pipe for pressure shall be to BS EN 598 [6] or equivalent SASO
Standards. Unless otherwise indicated in the Bill of Quantities or the Drawings, Class
K9 shall be used for all pipe diameters, and in the case where pressure does not exceed
16 bars for large diameters, class K8 pipes shall be used.
A.2 Ductile iron fittings shall be to BS EN545 [1] or ISO 253 1or equivalent with socket
/ spigot ends. Joint deflection at installation shall not exceed 50% of the maximum
allowed by manufacturer.
A.3 Spigot and socket ended pipes shall be used for straight runs and adjacent to
elbows or fittings. These joints shall be provided with rubber gaskets, and an external
thrust block is required at elbows or fittings. Anchored or self restrained joints shall be
used for sections adjacent to elbows in areas where space is restricted or indicated on
the Drawings or BOQ. Anchored joints are to be push-in, self anchored type able to
take up the axial forces thus allowing concrete thrust blocks to be dispensed with. The
Contractor shall submit calculations verifying the number of restrained joints required
noting that pipe pressure testing will be made when pipes are partially backfilled and
joints are exposed.
Page 121 of 244
A.4 Rubber gasket to BS/EN 545 or ISO 4633.
A.5 Flanged pipes wherever specified shall have screwed-on or cast-on flanges to sustain
working pressure of NP 16 minimum.
A.6 Flanges shall conform to BS 4504 [2].
A.7 Factory protection for pipes:

- Pipes shall be internally lined with cement and aluminum oxide to ISO 7186 or BS
4027 or equivalent in addition to polyurethane sheets lining with 2 mm
thickness according to the detailed specification in Item (A-8) below.
Externally, pipe shall be coated with metallic zinc to BS EN 545 [1] or ISO 8179
or equivalent and followed by a bitumen nontoxic coat to BS 3416 [4] or ISO
8179 or equivalent.
A.8 Additional Site Protection for Metal Pipes (high corrosion areas)
A.8.1 Polyurethane Coating

The coating shall be 100% solid polyurethane consists of two components: one
isocyanides-rich solution and one oplyol-rich solution. The coating shall be completely
continuous and free from all holidays, voids, pinholes or other defects. The test certificate
shall state the property of the coating and shall specify the test method used. The
polyurethane coating system shall comply with the data included in the following Tables:
Technical Data of Polyurethane External Coating

Material
Color
Density
Tensile Strength
Adhesion to Steel
Dielectric Strength
Water Absorption
Impact Resistance
Temperature Resistance
Salt Water Spray
Elongation
Chemical Resistance
Thickness
Polyurethane, 2 Components airless applicator

Black
1 .6g/mm3
25N/ mm3
> 8Mpa (Stee grit blasted SA21/2)
200 Kv/cm
3.5% at 25C
> 15Nm
90C continuous
No effect after 1000hrs
> 10%
Water solution of salts, acids, and bases of pH 1-14
1-1.5mm
Page 122 of 244
A.8.2 Polyethylene Sleeves

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 minimum nominal thickness of the sleeve shall be 0.0 10 inch (250 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 0.915 to 925g/ml. The sleeve shall be free from
pinholes, gels, undispresed raw materials and particles of foreign matter. The film may not
contain more than 5% by weight of material other than polyethylene.
Polyethylene sleeving shall be stored in cool dry store away from direct sunlight or excessive
heat, the length of the roll, the pipe size for which it is intended.
A.8.3 Repair of Coating and Lining

In case of repairs are needed the Contractor shall take immediate action to correct the
situation.
A l l the repairs to the coated or lined pipe and fitting shall be at the Contractor own expense.
The Contractor shall submit the repair procedure to the Employer for approval.
The procedure shall comply with the manufacturer specification.
A.8.4 Anti Corrosion Pipe Wrapping Tape
The tape shall be supplied 150 mm or 225 mm wide in 15 m or 25 m rolls, or approved by

Engineer depending upon the requirements.
Pipe diameters up to 200mm, 150mm width tape shall be used.
Pipe diameters above 200mm, 225mm width tape shall be used.
The adhesive compound shall be of the pressure sensitive type (that is, not requiring a primer
in order to achieve bond to the substrata) and shall have thickness between 0.75 to 0.90 mm.
Flow coefficient of bitumen viscosity at 200C and 175C shall be 5.5 poise and 7.5 poise
respectively.
Page 123 of 244
The tape shall be supplied with a wider high quality silicon release paper covering complete
tape. Both sides of the tape shall have a minimum of 5mm wider silicon release paper to
prevent edge contamination.
During storage at maximum storage temperature of 500 C for six months, the adhesive
material shall not flow out of the release paper and there shall not be any end blocking.
Wrapping tape shall be marked with the following information:
Manufacturers name & logo
Date of manufacture
Width of the tape
Batch number
A.8.5 Wrapping Procedure

To increase the wrapping protection efficiency, pipe diameters up to 300mm must be
wrapped using semi-automatic tape wrapping machine and for pipe diameters above 3
00mm, fully automatic wrapping machine should be used.
A.8.6 Storage
Wrapping tape should be stored in dry, cool, well ventilated condition, out of direct sunlight.
A.8.7 Packing
Roll shall be placed in a cardboard carton in layers in vertical position. A proper separator for
safe storage shall separate each layer. The boxes shall be marked at two places given name
and logo of manufacturer, tender no., type, size and quantity of material in black/blue color
letters with a minimum height of 50mm.
Page 124 of 244
The wrapping tape shall also conform to the following specifications given
below; Data Sheet
S. No.
1
Color
1.1 Backing
3
4
5
6
7
8
9
11
12
13
14
15
16
17
18
19
20
21
Property
1.2 Adhesive Compound

1.3 Release Paper
Backing Thickness Min.
Total Thickness Min.
Elongation
Tensile Strength Tape
Modules
Tear Strength
Impact Resistance (Two Layers)
Viscosity at 200C
Viscosity at 175C
Adhesion to Steel
Adhesion to Tape
Electrical
Dielectric Strength
Insulation Resistance
Cathodic Disbondment
General
Water Vapor permeability
Water Absorption
Bacterial Growth Disbondment
Temperature
For Wrapping
In Service
For Storage
Test Method
-
BS 2782
BS 2782
BS2782
ASTM D1004
DIN 30627
Cone & Plate
Cone & Plate
ASTM D 1000
ASTM D 1000
Unit
-
mm
mm
%
N/mm2
N/mm2
N
Nm
Poise
Poise
N/mm
N/mm
Data
Blue RAL
5000/5001/
5005/5010/2017
Black
White / Cream
0.75
1.5
270
14.8
50
50
15
5.5
7.5
2.75
2.75
BS 2782
ASTM D 257
ASTM G 8
kV
Ohm/cm2
mm2
30
1012
NIL
BS 2782
ASTM D 570
-
g/m2/24h
%
-
0.4
0.1
NIL
- C
- C
- C
0 to + 50
0 to + 50
Up to + 50
A.9 Factory protection for fittings:
Fittings shall be coated internally and externally as per EN 545 Clause 4-5 with minimum
epoxy content 70% and minimum thickness 10 mil. Fittings shall be internally coated with
fusion bonded epoxy.
Page 125 of 244
A.10 Testing on Ductile Iron Pipes

The following tests shall be carried out on samples from every batch of DI pipes delivered to
site. A report of the third party inspector shall cover at least these tests all as approved by the
Engineer. A l l tests shall be carried out according to BS/EN545 or ISO 2531 equivalent:
C.
Visual inspection
Microscopic structure
Tensile strength
Elongation
Brinell hardness
Lining thickness
Composition and thickness of external coating
Ring bending and detachment of lining for pipes > 500 mm diameter
Hydrostatic test
Vitrified Clay Pipes
C.1 Use vitrified clay pipes for sewer networks with pipe diameters from 200 to 600 mm.
C.2 Vitrified clay pipes and fittings shall be to SASO 235/236-1995 or BS EN 295 [18] and
shall be marked accordingly.
C.3 Pipes and fittings shall be glazed and shall comply with BS 295-1 Clause 2 and in
particular sub-clause 2.2, 2.3, 2.5, 2.9, 2.10 & 2.14.
C.4 Pipes and fittings shall be Class 160 for pipes 500mm diameter and Class 120 for pipes
600mm diameter crusting strength per Class in KN/m2 as given in Table 5 of BS 295 part 1.
Pipe may also be classified as standard strength or extra strength.
C.5 Jointing material: sealing elements shall be polyurethane to Clauses 3.12 & 3.13.
C.6 Joints shall be water tight to Clauses 3.2 & 3.3 of EN 295.
C.7 Pipes shall be supplied with approved flexible and telescopic rubber ring joints which
shall be capable of withstanding the specified tests pressures applied both internally and
externally
Page 126 of 244
C.8 Junctions on clay pipe sewers shall be of similar material and suitable for use with flexibly
jointed pipes
C.9 Before any length of pipe is laid, it shall be inspected and stood or slung vertically at the
side of the trench and rung with a wooden mallet. Any damaged or cracked pipe shall be
rejected.
C.10 Tests on vitrified Clay Pipes

The following tests shall be carried out on vitrified clay pipes and products. The third party
inspection report shall cover the following quality control test all as per SASO 235-1995 or DIN
1230 or the applicable standard specifications:
Visual inspection
Minimum bore
Length
Deviation from straightness
Crushing strength
Water tightness
Polyurethane sealing elements

Angular deflection
D. GRP Pipe
D.1
Use GRP pipes for sewer networks with minimum stiffness 5000 N/m2 for diameters
700mm to 1000mm.
D.2
Pipes and fittings shall be to BS 5480, 1990 [11] or AWWA C950-01/ or equivalent.
D.3
Pipe and fittings shall include a corrosion resistant internal liner, a structural wall and a
resin rich exterior surface.
D.4
The liner consists of 90% resin and 10% glass reinforcement and shall have a nominal
thickness of 1.0 mm. The liner inner surface in contact with liquid shall be 0.2 mm
thick and shall be reinforced with "C" glass. The remainder of the liner thickness, shall
consist of 60% resin and 40% glass reinforcement which shall be acid resistant
chopped "E" glass to BS 3496 or glass fiber rovings to BS 3691.
Page 127 of 244
D.5 The pipe structural wall shall consist of glass reinforcement, and fine silica sand, all
impregnated with resin. The fine silica sand shall be added to the structural layer to achieve the
design thickness for the required stiffness specified such that the overall hoop flexural modulus
(E) for pipe is not less than 24 GN/m2. Silica sand and filler content shall not exceed 50%.
Continuous glass filament reinforcement in the structure wall shall be 10% minimum by
weight.
D.6 Pipes shall be provided with a resin rich outer layer reinforced with one layer of "C" glass
veil. The exterior layer shall have a minimum thickness of 0.2 mm. The layer shall consist of
resin rich 90% and reinforced with one layer of C glass 10%.
D.7 The resin used for the corrosion resistant internal liner of the pipe and fittings shall be
high grade polyester resin (vinyl ester) type. For the structural wall and exterior layer of the pipe
a high grade isophthalic polyester resin shall be used. No dark pigments shall be used in the
pipe or fittings. A l l resins shall be tested to ASTM C-58 1.
D.8 All glass reinforcements except for the inner and outer surfaces of the pipe and fittings
shall be of the "E" type. Surface reinforcement shall be of the "C" glass type.
Page 128 of 244
D.9 Pipes shall be designed for a life of not less than 50 years. Contractor shall submit
calculations for initial and long term deflection with Truck loads, Buckling, Vacuum, Pressure
Class, and Strain corrosion in accordance with Appendix "A" of AWWA, C-950-01 or
equivalent. The maximum calculated long term deflection should not exceed 3%. Copies of
the design calculations shall be submitted to the Engineer for approval.
Stiffness: Minimum 5,000 N/m2. Suitability of stiffness shall be verified by

Contractor for the various trench and pipe laying conditions and as
recommended by the manufacturer. Pressure class 6 kg/cm2 minimum or as
shown on Drawings.
Longitudinal Strength: Conform to BS 5480 [11] table 2 or ASTM D3262 table

7.
Hoop strength shall be according to ASTM D3517 Table 8.
Strain corrosion resistance tests shall be carried out as per ASTM D 3681 or
BS 5480 strain corrosion value at 50 years to equal or exceed 0.7%.
Markings shall be to BS 5480 [11] clause 11.
Joints shall be GRP double socket couplings with rubber rings to ISO 4633 or
BS EN 68 1-2 [10]. The allowable angular deflection shall conform to the
requirements of BS 5480 [11] Table 3.
D.10 Testing on GRP Pipes: The following tests shall be carried out on manufactured pipes.
Details of testing program shall be submitted to the Engineer for review and approval prior to
commencement of pipe manufacture. The manufacturer quality control scheme shall be to BS
5750-8 [12] or ISO 9004. Guidance on quality control and sampling shall be BS 5480
Appendix Q [11]. At least the following tests shall be carried out and reported for approval.
Visual inspection
Longitudinal Strength :
Hydraulic Test
:
Stiffness
:
Wall Thickness
:
Diameter
:
Hardness
:
Loss of Ignition
:
Hoop Tensile
:
to ASTM D3262
to ASTM 3517 on every pipe.
to ASTM D 2412 or BS 5480 [11] to BS 5480
[11]
to BS 5480 [11] to ASTM 2583
to ASTM D 2584 to ASTM 3517
Page 129 of 244
E.
Concrete pipes for Gravity Networks
E.1 Use Concrete pipes lined with HDPE for main sewer lines with diameters greater than or
equal 1000 mm.
E.2 Concrete pipe shall be to BS 5911 or ASTM C14M-99 or DIN 4032 Class KW. Cement
used in manufacture shall be ordinary Portland cement to BS EN 197-1 [3]
E.3 Joints shall be gasket type with flexible spigots and sockets. The shape of the joint must
be designed to prevent any movement of the gasket during assembly and as such produce
full water-tightness. Rubber gasket shall be to ISO 4633 or BS EN 68 1-2 [10].
E.4 Factory Protection for Pipes:
Internally, pipes smaller than 900 mm diameter shall be coated with coal tar
epoxy with 70% minimum epoxy content. Coat minimum thickness shall be 1000
micron. Concrete pipes larger than 900 mm diameter shall be internally lined
with suitable HDPE sheeting. The thickness of the lining shall not be less than
3 mm. Pipes shall be PE lined in the factory, and lining of the joints shall be
made on site and then the spark test and other relevant field tests shall be
made. All defective and damaged surfaces shall be repaired in conformance with
the recommendations of the manufacturer. The lining shall be capable to
withstand safely the wastewater temperatures which could reach 45 C and shall
form a watertight surface.
Externally two layers of bitumen to BS 3416 [4] or hot applied coal tar based
material to BS 4164 [5] with 300 micron minimum dry film thickness.
E.5 Testing for Concrete Pipes

The following tests shall be carried out on samples of concrete pipes delivered to site. The test
report of the third party inspector shall cover at least the following tests all as specified by
adopted international standards.
Visual inspection
Water absorption test
Hydrostatic
Crushing test, works proof test load and maximum test load
Tests for flexible joints
Deflection, straight draw, shear
Page 130 of 244
4.03.2
A.
Pipe Bedding
A.1 Pipe bedding material shall be as specified in section 2.04.5 of Division 2 herein before
B.
Pipe Laying and Jointing - Generally
B.1
The pipe shall be brought to grade and approved prior to the lowering of the pipe into
the trench. Pipes shall be laid to slopes shown on drawings.
B.2
Lowering of the pipe into the trench shall be carried out using ropes, wire slings, band
slings, and spreader beams etc. as recommended by manufacturer for each type of
pipe and as approved.
B.3
All material shall be carefully examined for damage and tested in accordance with
manufacturer's instructions before laying to the satisfaction of Engineer.
B.4
The Contractor shall examine material to ensure internal coating or lining and outer
coating or sheathing is undamaged. I f damaged, make good or dispose of as
directed.
B.5
Pipe Cleanliness: The Contractor shall remove dirt and other materials before lowering
and clear construction debris from inside of pipe before making joint.
B.6
Pipe Placement: The Contractor shall lay pipes on even formations true to grade and
line, with sockets (if any) facing up the gradient.
B.7
Pipe on Solid Ground: The Contractor shall cut holes in bottom of trench to allow
proper jointing and for barrel of pipe to bear evenly on the bedding for its full length.
Page 131 of 244
B.8 Pipe on Granular Bedding: The Contractor shall scoop out locally at sockets/couplings to
enable pipe to rest uniformly on barrel and adjust to exact line and level. After testing the
Contractor shall lay and compact further granular material in 150 mm layers or as approved to
levels shown on the Drawings.
B.9 Pipe on Concrete Bed or Surround: The Contractor shall provide rectangular blocks of
concrete Class 210/25, made in approved moulds at least 14 days before use, and hardwood
folding wedges approved by the Engineer and also provide two concrete blocks for each pipe,
set and bone into correct level on formation bottom and lay pipe properly centred and
socketed. The Contractor shall insert two hardwood folding wedges of width equal to width of
concrete block between body of pipe and block and drive together until pipe is brought to
exact level required and leave blocks and wedges undisturbed while pipes are being jointed
and concrete bed and haunch or surround are being placed. The Contractor shall ensure
blocks and wedges are of sufficient size and strength to prevent settlement of pipe and leave
sufficient space to enable joints to be made, tested and inspected.
B.10 Pipe Plugs: When pipe laying is not in progress, the Contractor shall close open ends of
pipes with properly fitted temporary wooden plugs or standard caps as directed.
B.11 Minimum cover over pipes is 1.5 m unless shown on drawings or instructed by the
Engineer.
C.
Jointing
C.1
Manufacturer's instructions shall be followed regarding placement of bedding and

backfilling, cleanliness of joint surfaces, lubricant used, correct location of
components, provision of correct gaps between end of spigot and back of socket for
flexible joints etc.
C.2
Deflection of Joint: The Contractor shall not deflect flexible joints beyond 50 percent
maximum permissible angles given by manufacturer and/or relevant Standard.
C.3
Patent Detachable and Flexible Joints: The Contractor shall strictly comply with
special instructions issued by manufacturers of proprietary joints when laying and
jointing.
C.4
Differing Pipe and Fitting Material: The Contractor shall joint with adaptors as
recommended by pipe manufacturer.
Page 132 of 244
D.
Line and Gradient
D.1 In Open Excavation: The Contractor shall provide and maintain sight rails and boning
rods properly painted to ensure correct alignment of pipe runs. Sight rails shall be positioned
either vertically above the lines of pipes or immediately adjacent thereto. At no time are there
to be less than three sight rails in position on each length of pipeline under construction to any
one gradient.
D.2 Wherever possible and as per the Engineer instructions, the Contractor should use the
suitable recent surveying devices to adjust the line and gradient of pipelines.
D.3 In heading the Contractor shall provide and maintain marks to establish line and level of
pipeline. Marks shall be fixed in each working shaft and two further marks established in
each length of heading.
E.
Floatation
E.1
Prevention: Whenever water is excluded from interior of pipe the Contractor shall
place sufficient backfill above pipe to prevent floatation.
E.2
Removal of Pipe: The Contractor shall correct bedding and relay any pipe that has
floated.
F.
Pipe Built into Structures
F.1
Treatment of External Surface: The Contractor shall thoroughly clean outside surface
of pipes to be built-in immediately before installation and remove protective coating
to metal pipes, where ordered. The Contractor shall roughen clay and concrete pipes
as directed and paint plastic pipes with appropriate solvent cement and sprinkle with
dry coarse sand whilst wet. The Contractor shall cut away sheathing from sections to
be built-in and after installation restore protection up to external face of structure with
approved bituminous material.
F.2
Flexible Joints: The Contractor shall install two flexible joints or flexible patented
joints adjacent to structures and place the first joint not more than one pipe diameter
from face of structure and second not more than the following distances away from
first:
-
Pipelines not exceeding 450 mm: 2 pipe diameters
Page 133 of 244
Pipelines Over 450 mm and Not Exceeding 1000 mm: 1.2 m
Pipelines Over 1000 mm: 1.8 m.
In general, the length of the short pieces may be selected as recommended by the pipe
manufacture.
4.03.3
A.
PIPE WORK TESTING
Field Testing: Generally
A.1 Provision of Test Equipment: A l l items for test have to be provided on site before the test
i.e pressure gauges, instruments, water etc...
A.2 The Contractor shall carry out tests in the presence of the Engineer.
A.3 Fittings and Joints: The Contractor shall permanently anchor fittings before testing and
leave all joints exposed for checking.
A.4 Test Sections: The Contractor shall limit test sections to not more than 500 m.
A.5 Test Sections: The Contractor shall test pressure lines between valve chambers whenever
possible.
A.6 Test Sections: The Contractor shall test gravity sewers in sections between manholes.
A.7 Test Sections: No testing shall be carried out against or through the pressure reducing
valves. The setting of the pressure reducing valves shall not be changed for testing purposes.
A.8 Closed Valve: The Contractor shall not test against a closed valve unless there is no
acceptable alternative.
A.9 The Contractor shall apply pressure by manually operated test pump or, in the case
of large diameter mains, by power driven test pump, if approved
Page 134 of 244
A.10 The Contractor shall examine exposed joints and repair visible leaks.
A.11 Failure: Should a test fail, the Contractor shall locate the leak and replace or make good
defective pipe or replace and make good faulty joint. The Contractor shall retest main.
A.12 Records: The Contractor shall keep test records in an approved form and hand original
copy to the Engineer immediately after completion of test.
B.
Hydrostatic Testing of Pressure Headers (Force Main)
B.1
Pressure Lines: The Contractor shall carry out hydrostatic test while pipeline is
partially backfilled.
B.2
The pipeline shall be filled slowly with water from the lowest point. After filling with
water, absorbent pipes shall be allowed to stand for at least 24 hours before testing
to allow for complete absorption.
B.3
Entrapped air shall be bled and pressurising shall then proceed until the specified
test pressure is reached in the lowest part of the pipeline section under test. Further
quantities of entrapped air shall be bled while the pressure is being raised.
B.4
Unless otherwise specified, the test pressure shall be equal to 1.5 times the
maximum working pressure of the pipeline as shown on the Drawings or as
determined by the Engineer on Site, but shall in no case exceed 75% of the factory
hydrostatic test pressure.
B.5
The test pressure shall be maintained for one hour by pumping using a separate
test pump. Pumping shall then be stopped for 2 hours, at the end of which time the
line shall be re-pressurized to the original test pressure and the volume of water
pumped into the line recorded.
B.6
The pipeline shall be deemed to have failed the test i f visible leaks are detected
(regardless of leakage being within the allowable specified limit) or i f the volume
of water pumped to restore original test pressure after the period when pumping
was stopped exceeds or 0.1 litre/day per km of pipe per mm of pipe diameter for
each 3 kg/ cm2 of applied pressure for other pipe material.
Page 135 of 244
C.
Hydrostatic Testing of Non-Pressure Pipelines
Non pressure lines shall be air tested for the whole pipeline after partial backfilling above the
pipeline except the connections then hydrostatic tested for the whole pipeline after complete
backfilling and before surface reinstatement and pavement.
Testing procedures should be as per BS 5886 and as per the following steps:
C.1 Procedure shall be as described for pressure pipelines.
C.2 Test Pressure: 1.25 m head of water above pipe soffit at highest point and not greater than
6 m head of water at lowest point of section under test. I f maximum head is exceeded, the
Contractor shall test section in stages.
C.3 Test period shall last 30 minutes.

C.4 Allowable Leakage: 0.125 litres/linear metre/metre diameter/30 minutes.
D.
Hydraulic Individual Joint Test for Pipes Exceeding 1000 mm.
D.1
Procedure: The Contractor shall carry out procedures to BS 5886 [23], Type 2 testing
after partial backfilling, or equivalent. The Contractor shall pressurize joint to 2 bars and wait for
10 minutes at the end of which repressure to 2 bars and again wait for 5 minutes. No pressure
drop should be observed at the end of the latter period.
D.2
Test Pressure: 2 bars
D.3
Test Period: 5 minutes.
D.4
Allowable Leakage or Pressure Drop: None
E.
Air Testing of Pipelines
E.1
The Contractor shall carry out tests to BS EN 752-2 [22] and plug length under test.
E.2
The Contractor shall apply pressure by approved method (ie. hand pump) until a
pressure equivalent to 100 mm head of water is indicated on a U-tube connected to the system.
Page 136 of 244
E.3
The Contractor shall allow 5 minutes for stabilisation of air temperature and adjust
pressure to 100 mm
E.4 Pressure Drop: Pressure shall not be allowed to fall by more than 25 mm in a period of 5
minutes.
E.5 Failure to pass the air test is not conclusive and i f no leakage can be traced by external
application of soapy water to all sealing areas then an hydrostatic test shall be carried out
before final rejection.
F.
Visual Inspection Test
F.1
Timing: The Contractor shall carry out test after total backfilling of length under test.
F.2
Limit of length to be tested at one time is three full- length pipes unless otherwise
approved.
F.3
Apparatus: The Contractor shall use rubber tyred bogies that do not damage lining of
pipe and an adequate supply of electric lamps.
F.4
The Contractor shall check joints by means of feelers to ensure rubber rings are
correctly located.
F.5
The Contractor shall check pipe barrel for visible cracks.
G.
Deflection Tests for GRP Pipes
G.1 The Contractor shall conduct deflection tests for GRP pipes as required by the Engineer
at 3 stages. Deflection shall be measured at the spigot end at mid point and at socket end.
Stage 1: At completion of primary backfill (deflection at this stage should be

below 0.5%).
Stage 2: At final backfill (Maximum allowable deflection 2.5%).
Stage 3: Six months after final backfill (maximum allowable deflection 4.0%).
Page 137 of 244
G.2 Pipes not passing the deflection tests at stage 2 or stage 3 shall be removed and
replaced.
H.
Testing of Water Retaining Structures
H.1 A ll water retaining structures such as reservoirs, tanks, basins ponds, regardless of
the construction material, lining or final surface treatment shall be tested or
Water-tightness.
H.2 Tightness testing shall be carried out according to ACI 350.1-01/350.1R-01.
H.3 Allowable losses of water, after correction for evaporation, precipitation etc. shall be
as set in the table below:
Type of structure
Tanks/Reservoirs/Channels/Conduits for sewer,
Concrete pipes, Open or covered (Stormwater
Channels not included)
Test and Criteria*

HST-VIO & HST-NML
Settling tanks/Basins
HST-VIO & HST-NML
* For designations refer to ACI 350.1 - 01/350.1 R-01.
H.4 Notwithstanding satisfactory completion of the water absorption test, any leakage
visible on the outside faces of the structure shall be stopped. Any caulking or making good
of cracks in the wall section shall, where practicable, be carried out from the inside face,
and to the satisfaction of the Engineer.
H.5 Upon completion of the test, the Contractor shall empty the structure, dispose of the
contents and shall clean the structure and any equipment therein of all deposits left by the
water.
I.
Field Protection and Coating
I.1 Iron Pipes: Polyethylene sleeving shall be to ANSI/AWWA C 105, Section 4.1 or ISO
8180 or in accordance with the manufacturer's instructions. Sleeving shall be heavy duty
blue color polyethylene with a minimum thickness of 225 microns.
Page 138 of 244
I.2 Patented Detachable and Flexible Joints and Flanged Connections: The Contractor shall
protect metal joints with mastic compound and protective tape in accordance with the
manufacturer's instructions. Minimum overlap shall be 55% and the Contractor shall press out
firmly all folds and irregularities.
J.
Cleaning and Inspection of Sewers
J.1 Cleaning: The Contractor shall clean pipeline of silt and debris after backfilling pipe
trenches and completing manholes, hatch boxes etc. but before surfaces are permanently
reinstated and make ready for inspection by the Engineer.
J.2 Inspection: Pipelines of 700 mm diameter and over are, where practicable, shall be
inspected from the inside and when necessary a suitable trolley is to be provided for this
purpose.
J.3 Inspection: Pipelines less than 700 mm diameter and larger pipelines which cannot be
inspected from the inside, are to be inspected by passing a cylinder of diameter 25 mm less
than the internal diameter of the pipe and length not less than the internal diameter of the pipe
through each pipeline.
K.
Waterproofing of Structures
K.1 Waterproofing of water retaining structures shall not be commenced until tested for
water-tightness and found satisfactory.
K.2 The waterproofing compound shall penetrate and react with the concrete to form
crystals that seal all capillaries, tracts and shrinkage cracks in the concrete structure. The
compound shall consist of a mixture of chemicals, quartz, sand and cement supplied in
powder form ready to mix with water. Application shall be carried out in accordance with the
manufacturer's recommendations and as approved by the Engineer.
Page 139 of 244
SECTION 4.04
4.04.1
A.
VALVES, HOUSE CONNECTIONS AND SUNDRY WORKS
GENERAL
Scope
A.1 These works shall consist of furnishing all materials, constructing, installing and
completing in all respects of works described in this Specification and indicated on the
Drawings.
4.04.2
A.
VALVES
Gate Valves
A.1 Type: Size 50 mm to a diameter less than 300mm and shall be of ductile cast iron (GGG
40) to DIN3202 or equivalent and operation system shall be of non corrosive cast iron and
shall be non rising and gate of copper or cast iron covered with rubber.
A.2 Socket (DIN 8061, DIN 8062, ISO 3606, ISO 4422) or equivalent with flanges to (DIN
3202, F4 or equivalent).
A.3 Material of flanged valve and socket:
Valve body from ductile cast iron to (GGG40) (EN-JS 1030)
Gate of the type covered with rubber.
Valve stem of stainless steel and shall be of non rising type, and valve shall be
operated manually or with a stem.
A.4 Testing: valves shall be tested to DIN 3230 Part 4 EN 12266 or equivalent.
A.5 Operation: Either manually or operation key with a rising stem relative to depth of
installation. It may need an internal disk and shall be as Engineers direction and
manufacturers regulations.
Page 140 of 244
A.6 Protection: Casting surfaces internally and externally with epoxy at a thickness not less
than 250 microns as per specifications.
B.
Butterfly Valves
B.1 Type: To BS EN 593, double flange for NP 10/16 bar or equivalent.
B.2 Component Parts:
Butterfly valve with the fixed plate not connection with the stem.
Valve body and plate of ductile cast iron (GGG 40)
Valve length as per German Specifications: (DN 3202 F4) series 14 & EN558-1
or equivalent.
Valve stem of anti corrosive cast iron
Flanges to DIN 2501 or equivalent.
Opening & closing of valve shall be done by gearbox mounted on valve.
B.3
Protection: Casting surfaces internally and externally with epoxy at a thickness not less
than 250 microns as per specifications.
C.
Check Valves for Sewer Lines
C.1 Check valves shall be to BS EN 12334 [28], swing, straight, for horizontal use and
suitable for working pressure of 16 bars.
C.2 Material of Component Parts: Ductile iron from basic materials listed in BS EN 12334 [28]
Table 5, under 'copper alloy faced' column.
C.3 Special Requirements: Seating or facing rings are to be renewable. An arrow showing
direction of flow is to be visible from outside and cast integral with the valve housing.
Page 141 of 244
C.4 End Connections: Either flanged to BS 4504 [2], or screw ended to BS 21 [26] to suit
joints specified for adjoining pipes.
C.5 Factory Protection: Casting surfaces are to be given an initial coat of protective paint
immediately after shot blasting and a second coat on assembly. Protective coating is to be hot
applied coal tar or bitumen to BS 4164 [5] or BS 3416 [4] respectively. Minimum thickness of
coating shall be 250 microns.
D.
Flap Valves
D.1 Type: To be flange mounted, designed for use on end closures to prevent entrance of
backwater. Seating plane is to have 10 deg. inclination.
D.2 Materials: Cast iron body and cover, bronze seat faces, bronze hinge pins and spring
pins, cast iron follow ring and plated steel ring draw bolts. Materials subject to dezincification
or de-aluminuzation are not to be used.
D.3 End Connections: I f flange mounted, flanges are to be to DIN 2501 or equivalent.
D.4 Protection by epoxy with a thickness not less than 250 microns as per specifications.
E.
Air Valves for Pressurized Sewage Mains
E.1 Generally: Valves are to have cast iron body, cover and baffle to BS EN 1561 [29], Grade
14, stainless steel float and float guide, Buna-N seat or needle and Dirlin internal linkages. Air
valves are to have long float stem and body to keep valve operating mechanism free from
contact with sewage by maintaining an air gap between mechanism and waste media. Float is
to hang freely in centre of valve body with 12 mm clearance all around to prevent large solids
getting above the float. Valves are to be fitted with blow off valves, quick disconnect couplings
and minimum 2.0 m of hose to permit backflushing without dismantling valve. Valves are to
be factory tested to 1.5 times working pressure and factory coated with bituminous coating to
BS 4164 [5] or BS 3416 [4] respectively. Thickness of coat shall be 10 mils.
Page 142 of 244
E.2 Single Air Valves: Type I (or air vacuum valve) for releasing or admitting air during filling
or emptying of pipes. Type I I (or air release valve) for automatically releasing, under
pressure, accumulated air at summits of mains. Air valves 50 mm and smaller are to have
screwed inlet to B.S.P. thread with gunmetal male screwed stop valve. Air valves larger than
50 mm are to be flanged to BS 4504 [2] or DIN 2501 or equivalent and have nitrite rubber
lined butterfly valve with nylon coated disc on stainless steel shaft operated by lever handle
with indicator and locking thumb screw. Valves are to be suitable for working pressures up to
NP16.
E.3 Double Air Valves (or Combination Air Valves): These are required for relieving air under
pressure and in bulk, are to be an assembly of an air vacuum and an air release valve. Valves
shall be suitable for working pressures up to NP16.
4.04.3
HOUSE CONNECTIONS FOR SEWER NETWORKS
A.
Work includes providing and installation of pipes from the manhole or the sewer inlet
to the collector outlet and the property border as shown on drawings. This includes all
the components and requirements.
B.
Material of sewer house connection pipes shall be vitrified clay as per section 4.3.1 of
this document or uPVC as per section C and of diameters 100 to 200 mm according to
drawings and Bill of Quantities. Piping from inspection chamber to property shall be
same as that used by owner.
C.
UPVC Pipe for Gravity Flow
C.1 Pipes shall conform to Saudi Standards SASO 14 or DIN 8061 / 8062 with 10 bars
working pressure or Class (4) as indicated on the Drawings or the B i l l of Quantities.
Concrete encasement shall be added to pipes with covers less than 1 .0m or more than 5.0m.
C.2 Fittings and joints shall comply with ISO 4422 or BS EN 1452 [9] Part 3 or DIN 8063 or
equivalent and manufactured from same material of pipe.
C.3 Joints shall be to DIN 8063 part 1, socket spigot with rubber sealing rings shall be to BS
EN 681-2 [10].
Page 143 of 244
C.4 The following test shall be carried out on samples from every batch of PVC pipes
delivered to site. The report of the third party inspector shall cover at least the following tests
as requested by DIN 8061/8062:
Visual inspection
Pipe diameter / roundness
Wall thickness
Hydrostatic test
Stress resistance tests
Impact test
Elevated temperature cycling test
Resistance to sulfuric acid
C.5 Pipes and fittings shall be protected from the direct rays of the sun at all times by means
of reflective cover sheets.
D.
Connection locations shall be as per drawings and as per Engineers and as per
Engineers directions during execution and number and diameters that shall be
constructed as per drawings and B i l l of Quantities.
E.
House connection construction: the Contractor shall clean site and trenches and refill
and lay pipes and put bedding for pipes and paving to specifications as in the main
network.
F.
Records: the Contractor shall keep accurate records for house connections locations
showing diameter length and location. Records shall be in specified formats and shall
be ready for revision. These records shall be submitted to the Client when work finish.
The Contractor shall show this information on graphs in coordination with the Engineer
also securing three copies to be submitted to the Client and as shown in 4-4-7 of this
specifications.
4.04.4
A.
JOINTING MATERIALS AND ADAPTORS
Generally
A.1 Gaskets: Elastomeric full face 3 mm thick joint rings to ISO 4633 or BS EN 681-2 [10]
with dimensions to BS 3063 [38].
Page 144 of 244
A.2 Rings: Elastomeric to ISO 4633 or BS EN 681-2 [10] with dimensions to manufacturer's
recommendations to suit type of joint required.
A.3 Bolts and Nuts: ISO metric black hexagon to BS 4190 [39], minimum tensile strength 433
MN/m2, maximum elongation 17%. After fixing, bolt projection shall to be maximum 6 mm,
minimum 3 mm.
A.4 Washers: Black steel shall be to BS 4320 [40] or ISO/R 887.
A.5 Dielectric joints shall have insulating gasket between flanges and Teflon sleeves and
washers between bolts and nuts and flanges. Joints are to be suitable for operating pressure
of system.
A.6 Saddle connections should meet the following requirements:
B.
Saddle diameter should be less than sewer line diameter.
Drilling should be done correctly to avoid any crack / damage to existing line
and to use proper drilling machine/core.
Concrete surround the branches to protect from impacts
Branch piece should not project into the main sewer.
Flexible Couplings
B.1
Type: Gasket sleeved type, to allow angular deflection and axial movement of two
joined pipe ends and to maintain permanent, leak-tight joint.
B.2
Components comprise one centre sleeve, two end followers or flanges, two
rubber-compounded wedge-section gaskets and sufficient draw bolts and nuts to properly
compress gaskets. Tightening of bolts to draw end followers together is to compress gaskets
in recess between centre sleeve and followers onto pipe ends to effect positive seal.
B.3
Size: Couplings are to have diameter specifically supplied for and to properly fit type
of joined pipe ends. Centre sleeve is to be of adequate thickness and whole coupling suitable
for minimum working pressures shown on the Drawings.
Page 145 of 244
B.4 Centre Sleeve and Followers shall be true circular sections, free from irregularities, flat
spots or surface defects and formed from steel mill sections with space between sleeve and
follower designed to provide confinement of gasket.
B.5 Bolts shall be special steel having minimum yield strength of 2800 kg/cm2 (40,000 psi)
and ultimate strength of 4200 kg/cm2 (60,000 psi). Bolts shall be track-head design to prevent
turning when nut is drawn up and threads are to be rolled with a nominal diameter larger than
diameter of shank. Manufacturer shall supply information regarding recommended torque to
which bolts are to be tightened.
B.6 Gaskets shall be synthetic rubber-base compound with other products to produce
material which will not deteriorate from age, heat or exposure to air and which is resilient and
able to resist cold flow of material so that joint will remain sealed and tight indefinitely when
subjected to shock, vibration, pulsation, temperature and adjustment of connected pipes.
B.7 Factory Protection: Coupling shall be factory painted internally with 10 mils coating of
epoxy and externally with red primer to AWWA 203 Type B chlorinated rubber solution
compatible with bitumen, coal tar and general paints.
B.8 Installation: Couplings are to be assembled on site in accordance with manufacturer's

instructions to ensure permanently tight joints under all conditions of expansion, contraction,
shifting and settlement.
C.
Dismantling Couplings
C.1
Type: These shall ensure extensible connection between sections of pipework, to be

mounted next to valves to enable easy dismantling from pipework or to permit joining
pipework when butterfly valve is removed for maintenance.
C.2
Components: Dismantling piece shall be flanged type composed of two parts, one
sliding into the other, and a free flange to compress a trapezoidal section seal to
ensure water tightness. Coupling shall have locking devices to provide elements of
complete rigidity.
C.3
Construction: A l l steel with flanges class PN 10, PN 16 or PN 25 depending upon

coupling location on pipework.
Page 146 of 244
C.4 Size: Couplings shall have diameter specifically supplied for and to properly fit type of
joined ends of pipes and valves. Coupling shall permit tightening of end flanges without risk of
misalignment. Seal shall be locked after end joints are tightened.
D.
Flanged Adaptor: Ferrous
D.1 Material: Cast iron to BS EN 545 [1].
D.2 Length of adaptor shall be 200 mm for diameters up to 150 mm, 250 mm for diameters
between 200 and 300 mm and as approved for diameters larger than 300 mm.
D.3 Factory Protection: Coated with bitumen or coal tar to BS 3416 [4] or 4164 [5]
respectively.
4.04.5
VALVE ACCESSORIES
Hand-wheels shall be to BS 5163 [25], of cast iron to BS EN 1561 [29]. Hand-wheels are to be
marked 'CLOSE' with an arrow to indicate clockwise direction of closure. Diameters and other
constructional details shall be to manufacturer's standards. Hand-wheels are to be supplied at
a rate of 1 in 5 valves.
4.04.6
A.
Generally
A.1
Prior to Installation, the Contractor shall inspect for cleanliness of bores, seating
surfaces etc. and for handling damage, cracks, missing parts and tightness of
pressure-containing bolting.
A.2
The Contractor shall ensure gates and hydrants are in closed position before
installation.
A.3
Operate hydrants through one complete opening and closing cycle in the position in
which they are to be installed to ensure proper functioning.
Page 147 of 244
B.
Installation of Valves
B.1 Prior to installation, valves shall be inspected for cleanliness of bore, seating
surfaces etc. and for handling damage, cracks, missing parts and tightness of bolting.
Valves shall be in close position before installation.
B.2 Valves shall be operated through one complete opening and closing cycle in the
position in which they are to be installed to ensure proper functioning.
B.3 Valves shall be set and jointed to the pipe in the manner specified for laying and
jointing pipe and in accordance with the manufacturer's recommendations. Each valve
shall be provided with a concrete pad as shown on the Drawings so that the pipe does not
support the weight of the valve. Valves shall not be used to spring misaligned pipe into
alignment during installation.
B.4 Valves without concrete pads shall be placed on firm footing to prevent settling and
excessive strain on connection to pipe.
B.5
All stressed bolts (bonnet, seal plate and end connections) shall be inspected for
adequate tightness after installation and prior to field testing.
B.6 Valves shall be protected against action of external agents by a coat of approved
bituminous compound, applied cold by hand brushing after pressure tests on pipelines
have been completed. Buried bolts etc., shall be protected against corrosion, with
approved paint or polyethylene wrapping.
C.
Sewer Building Connections
C.1 Location: The Contractor shall agree location and invert level of connections with the
Engineer before starting construction.
C.2 The Contractor shall programme connections to follow closely construction of sewer.
C.3 Execution: Connection to sewer shall be at manhole, where possible, and add flexible
joint when connecting at manholes without any additional payment connection can be done by
Y junction.
Page 148 of 244
C.4 Minimum Grade: The Contractor shall lay connections at minimum grade of 20 per 1000
unless otherwise approved.
C.5 The Contractor shall install, bed and test connections in same manner as main sewers.
C.6 For empty lots on those under construction, house connections should be also added for
future connection.
4.04.7
RECORDS
The Contractor shall maintain accurate records details for the whole project components and
show details for the following works, these records should be submitted in both hardcopy and
digital forms, three copies for each form. Digital data and drawings should be prepared in
compliance with geographic information system (GIS) and digital mapping in the directorate (if
any).
A. As-built house connection plan:

This record showing the sketch of the particular section indicating the downstream MH &
Upstream MH. Downstream MH usually shown on the lower portion of the record sheet, thus,
a reader is facing Upstream of the section. Listed below is the information required for this
record;
When house connection/s are constructed in a section
Mainline number
Mainline section number
Length of mainline pipe
Mainline pipe and type of pipe
Invert level of Upstream MH
Invert level of Downstream MH
Connection number & position (numbering will be designated in chronological order
while positioning for left or right derived when facing upstream of the section)
Type of connection (deep connection; shallow connection; backdrop connection to

MH; shallow connection to MH)
House connection pipe diameter
Distance from Downstream MH
Distance from centerline of sewer to end lateral (end lateral could be a inspection
chamber I.C., a clean-out C.O or a end plug EP for future connections)
Invert of street sewer
Invert of end lateral
Number of I.C. or C.O.
A column of remarks must be provided for future up-dating of house connection/s
Page 149 of 244
B. As-built House Connection Profile

This record shows the profile information of each house connection/s constructed in a section
installed Y junctions on the mainline for future house connection requires no profile record.
A sketch is to be shown for the particular house connection with complete informations as listed
below;
Mainline number
Mainline section number
Mainline Pipe and type of pipe
House connection number & position
Distance from Downstream manhole
Type of connection
House connection pipe and type of pipe
House connection slope
Lengths:
From centerline of mainline to property wall/limit

From centerline of end lateral to property wall/limit
Length where pipe slope is derived
Elevations:
Ground elevation at end lateral

Ground elevation at mainline
Invert elevation of mainline
Outlet Invert elevations
C. Mainline Records
There are three (3) important records to be maintained from constructed mainlines, these are
the general lay-out and bench mark, site plan and the line profiles. Description of these records
are as follows;
C.1 For general lay-out & bench mark

This drawing must be prepared in A-0 size drafting film covering the whole area of work
executed by the contractor with an appropriate scale that will accommodate on drawing sheet.
Required informations are as follows:
Line numbers
Manhole numbers
Page 150 of 244
Name of street
Name of important landmark in the area (i.e mosque, school, garden, hospital, clinic,
shopping mall, government offices, etc)
Location of bench marks with there designated numbers and elevations
A separate table is to be allocated describing the complete bench marks used in the
project.
C.2 For Site Plans

This drawing must be prepared in A-0 size drafting film with a scale of 1:1,000 showing in
segments for the entire area of work executed by the Contractor. Required informations are as
follows;
Line numbers
Manhole numbers
Coordinates for each and every manholes
Lateral distance location for each and every manhole
(i.e. distance from center of manhole to property wall or sidewalk curb stone or street
light post or fire hydrant traffic light post or any favorable base of measurement)
Properties of sections (pipe diameter & type of pipe, length & slope)
Elevations:
Ground level of manholes

Invert level of manholes
Invert levels of incoming pipes in the manhole but only i f there is drop in invert
from manhole
Name of street
Name of important landmark in the area (i.e. mosque, school, garden, hospital, clinic,
shopping mall, government offices, etc)
C.3 For Line Profiles

This drawing must be prepared in A-0 size drafting film with a scale of 1:1,000 horizontal and
1:100 vertical for the entire mainlines constructed in the whole area of work by the Contractor.
Required information is as follows:
-
Line number
Surface condition
Ground level
Invert level
Depth-to-invert
Distance
Chainage
Page 151 of 244
Pipe data (pipe diameter & type of pipe, slope and bedding)
Rock levels
Underground utilities crossing either below or over the mainline pipes
Type of utility
Description
Top elevation
Incoming line in the manhole
Line number
Pipe invert level
Pipe diameter & type of pipe
Page 152 of 244
SECTION 4.05
4.05.1
A.
BEDDING, SURROUND, HAUNCHING, ENCASEMENT AND

THRUST BLOCKS
GENERAL
Scope
A.1 Pipe bedding, surround and ways of securing pipe installations are specified in this
Section.
4.05.2
MATERIALS
A.
Pipe bedding and/or surround, and filling materials under and around pipes shall
comply with the appropriate requirements of Section 2.04.
B.
A l l concrete work shall comply with the appropriate requirements of Division 5.
C.
Concrete bedding shall be Class 110/25.
D.
Concrete for encasements, thrust blocks, arches and haunches shall be Class 25
0/20.
E.
Compressible board shall be 20 mm thick fibrous material or similar approved

material.
4.05.3
A.
WORKMANSHIP
Placing Concrete
A.1 After placing pipe the Contractor shall pour concrete in trench and thoroughly work under
pipe to provide solid and uniform bedding.
Page 153 of 244
A.2 After pipe joint is completed the Contractor shall place the balance of concrete or
haunching and work into place on both sides simultaneously.
A.3 The Contractor shall form vertical construction joints in concrete beds, surrounds etc. at
the face of pipe joints with compressible board and finish to profile of the concrete and pipe.
The Contractor shall f ill any gap between spigot and socket with approved resilient material.
B.
Placing Material Other than Concrete
B.1 The Contractor shall place surround or bedding material in bottom of prepared trench and
carefully hand tamp to minimum thicknesses.
B.2 After pipe has been laid the Contractor shall place additional material or haunching in
successive layers not exceeding 150 mm thick on both sides simultaneously and completely
f ill spaces between pipe and side of trench and carefully hand tamp without disturbing the
pipe.
C.
Thrust Blocks
C.1 Thrust blocks shall be provided at bends and other fittings on pressure pipelines.
Additional excavation shall be made as required after pipeline has been jointed. No pressure
is to be applied to the thrust block until concrete has matured for at least 3 days.
Page 154 of 244
SECTION 4.06 MANHOLES AND CHAMBERS
4.06.1
A.
GENERAL
Scope
A.1 This section specifies works related to:
4.06.2
Sewage manholes and Inspection Chambers.
Valve chambers for sewer force mains.
MATERIALS
A.
Excavation and backfilling generally shall comply with the appropriate requirements of
Divisions 2 & 3 of the Specification.
B.
Concrete work generally shall comply with the appropriate requirements of Division 5
of the Specification.
C.
Reinforcement shall conform to the requirements as specified in Section 5.03 "Steel

E.
Precast units to BS 5911 [13] Part 200 or ASTM C478. Except for thickness which
shall be as indicated on the Drawings. Concrete shall be Class 250/20. Cement shall
be ordinary Portland cement to BS EN 197 [3].
F.
Plain and reinforced concrete for cast In-Situ units shall be Class 2 10/25 and 250/25
respectively. Cement shall be ordinary Portland cement to BS EN 197 [3].
G.
Coatings shall be as specified in A5 and A6 of section 3.06.3. Alternative internal

coating is given in Section 3.06.4.
Page 155 of 244
H.
Covers and frames shall be gray cast-iron non-rocking, locking, as per Ministry of
Transport specification and shall comply with BS EN 124 or ISO 1083 or DIN 1229 or
equivalent. Wording on cover shall indicate nature of network (Sewerage
) as
required by Employer. Grades shall be as follows:
In Roadways: Heavy duty test load 40 tons
In Sidewalks, Carriage Drive and Cycle Tracks: Medium duty test load 25 tons
In Footpaths: Light duty, test load 7 tons
I.
Manhole covers shall be of circular pattern with 600 mm diameter unless otherwise
indicated on Drawings. Frames shall be provided with opening for fixing bolts which
ensure solid frame embedment into manhole concrete neck. Covers and frames shall
be coated with two layers coal tar epoxy (70% epoxy, 30% coal tar) to BS 3416 [4].
Minimum thickness 250 microns.
J.
Step irons shall be mild steel to BS 4211 [51], galvanized to BS EN ISO 1461 [52] with
200 grams of zinc per square meter and covered with two layers of polyethylene (PE) or
polypropylene.
K.
Safety chains shall be 12 mm diameter wrought iron short link chain, galvanized to BS
EN ISO 1461 [52] with 200 grams of zinc per square meter.
L.
Guardrailing shall be tubular, mild steel, medium grade to BS 1387 [15] with welded
joints, galvanized to BS EN ISO 1461 [52] with 200 grams of zinc per square meter.
M.
Fixing bolts shall be steel, type suitable for particular purpose and use and to
approval. When used to fix galvanized material, washers are to be galvanized and
fixing bolts and nuts cut to pre-plating limits and electroplated with zinc to BS EN
12329 [53].
N.
Steel castings shall be mild to medium strength castings and shall conform to
AASHTO M103 (ASTM A27). Unless otherwise shown on the Drawings or instructed
by the Engineer, castings shall be grade 65-3 5 fully annealed. Steel castings shall
conform to the dimensions shown on the Drawings. Test bars shall be prepared and
tested as specified in AASHTO M103.
Page 156 of 244
O.
Wrought iron plates and shapes shall conform to the dimensions shown on the
Drawings. Rolled wrought iron bars and shapes shall conform to the requirements of
ASTM A207. Wrought iron plates shall conform to ASTM A42.
P.
The Contractor shall submit to the Engineer all specified test coupons and
Manufacturers' Certificates of Guarantee for all structural steel, cast iron, cast steel
and wrought iron parts stating that the materials supplied meet the appropriate
AASHTO or ASTM specification. The submission of such test certificates shall not
relieve the Contractor of his obligations to carry out independent tests at an approved
laboratory, as directed by the Engineer, at his own expense.
4.06.3
A. Manholes and Inspection Chambers
A.1
Construction: In-situ concrete or precast concrete as indicated on Drawings or as

proposed by Contractor as per the site requirements but the distance between two
consecutive manholes should not exceed 100 m, the minimum distance will be
according to site situation and as directed by the Engineer. In-situ units shall comply
with the provisions of Division 5 for concrete works of this specifications.
A.2
Precast units shall be cast in steel watertight forms at least 3 weeks before sections
are used. Lowest unit shall be bedded on in situ concrete base and bed and haunch in
cement mortar. Joints of units shall be liberally coated with approved bituminous
material of trowelling grade prior to fixing. Joints shall be filled solid and neatly striked
off surplus compound. Work shall remain undisturbed for 7 days thereafter.
Alternatively joints may be sealed with approved preformed jointing strip in
accordance with manufacturer's instructions. The precast concrete cover slab shall be
bedded in cement mortar on the top unit.
A.3
Channels in bottom of manhole shall be smooth, semi-circular and sized equal to

diameter of adjacent sewers. For straight through manholes, channels of half pipe
sections shall be installed. Changes in direction of flow shall be made with smooth
curves as large as manholes permit. Changes in size and grade of channels shall be
gradual and even.
A.4
Benching shall be formed with sulphate resisting concrete Class 250/20 to rise
vertically from top of channels to a height not less than soffit of outlet pipe, then it shall
be sloped upwards 1 in 10 to walls. Floating shall then be carried out within 3 hours
with a coat of sulphate resisting cement-sand mortar 1:2. Smooth finishing shall then
be accomplished with a steel trowel.
Page 157 of 244
A.5 Manholes and chambers shall be coated externally with three layers of asphaltic
composition that shall be applied by brush in accordance with manufacturer's instructions.
Minimum thickness shall be 600 microns.
A.6 Internal faces of chambers shall be coated with four coats of coal tar epoxy paint, 70%
epoxy and 30% coal tar. The coating shall be applied by brush in accordance with
manufacturer's instructions. Minimum thickness shall be 1000 microns.
A.7 Internal faces of manholes shall be coated with GRP or HDPE and base surfaces of
manholes shall be covered with epoxy mortar.
A.8 Step irons shall be cast into precast units or grouted into preformed mortices. Step irons
shall not be used as lifting eyes. Devices for lifting and handling are to be provided on exterior
faces.
A.9 Adjustment of level shall be accomplished with concrete rings after completion of
surrounding levels. Final levels shall be even and accurate.
A.10 Fames for covers and gratings shall be solidly bedded in mortar and fixed firmly using
fixing bolts. Position centrally over opening and level and square with surrounding finishes.
Set cover in position to prevent twisting.
A.11 The Contractor shall test manholes as follows:
B.
Plug manhole inlets and outlets.
Fill manhole with water and allow to stand for at least 24 hours or such longer
period to allow for complete absorption.
Re-top with water.
Allowable leakage over 24 hours shall not to exceed 1% of total volume of

manhole, otherwise necessary repair and re-testing shall be carried to achieve
the required results.
Drop Manholes
B.1 For drops greater than 600 mm between the invert of pipe entering the manhole and crown
of pipe exiting the manhole, drop manholes shall be used. Pipes and connections of the drop
structure shall be wrapped with concrete Class A as shown in drawings.
Page 158 of 244
C.
Valve Chambers (on Force Mains)
C.1 Construction shall be in situ concrete, precast concrete or blockwork as indicated on the
Drawings.
C.2 When masonry is used in lieu of concrete for square or rectangular structures, the inside
dimensions of the structure shall be of the dimensions shown on the Drawings unless ordered
otherwise by the Engineer. The mortar for masonry shall be as specified in Section 5.01
"Concrete and Concrete Mixes and Testing ". The brick or concrete block shall be laid with full
mortared joints and with sufficient header courses to tie the masonry together properly as
C.3 External coating shall consist of two coats of asphaltic composition applied by brush in
accordance with manufacturer's instructions. Minimum thickness shall be 400 microns.
C.4 The covers frame shall be set as per clause B.2 above.
D.
Inlets and Gullies
D.1 Construction shall be in situ concrete, precast concrete or blockwork as indicated on the
Drawings
D.2 When masonry is used in lieu of concrete for square or rectangular structures. This will be
as per clause B.2 above.
D.3 Castings shall be set in full mortar beds or otherwise secured as shown on the Drawings
and approved by the Engineer. Mortar for setting castings shall be mixed as specified in Section
5.01 "Concrete and Concrete Mixes and Testing". Castings shall be set accurately to correct
elevation so that no subsequent adjustment is necessary
E.
Cleaning
E.1 All chambers, catch basins, catch pits, manholes, inlets and outlets shall be thoroughly
cleaned of any accumulations of silt, debris or foreign matter of any kind, and shall be free from
such accumulations at the time of final inspection.
Page 159 of 244
F.
Coating
F.1
Structural steel cover plates shall be coated with two coats of coal tar epoxy 250
microns dry film thickness.
G.
GRP Lining for Internal Surfaces of Manholes and Chambers:
G.1
GRP lined manholes and chambers shall be used in case of high aggressive soil and
for high sulphate acids, and shall be constructed in accordance with the Drawings and
shall incorporate a GRP lining at least 7 mm thick to all internal faces.
G.2
Benchings and channels shall be preformed, inverted and filled with concrete.
Alternatively, the GRP lining may be applied in situ after constructing the benching.
G.3
GRP lining to walls shall consist of a preformed tube of a white (or near white) colour,
incorporating lugs moulded onto the outside face at 500 mm centres to allow bonding
to the concrete surround. The lining shall have adequate strength to withstand
handing, and shall not buckle or distort during pouring of the concrete surround.
Internal bracing may be used during pouring to maintain circularity and verticality.
G.4
Precast cover slabs shall incorporate a preformed flat sheet of white (or near white)
GRP on the soffit, bonded to a circular GRP tube to form the access opening. Both
linings shall incorporate lugs molded onto the surface to allow bonding to the concrete.
G.5
The overall size of the lining to the soffit of the slab shall be 150 mm greater than the
internal diameter of the manhole onto which the slab is to be placed.
G.6
In all cases, the outer surface of the GRP, exposed to sewage/sewer atmosphere,
shall consist of a chemically resistant layer comprising vinyl ester resin suitably
reinforced with a C glass or synthetic tissue veil. This layer shall be no less than 2
mm thick, and shall have a resin content by weight of approximately 90% at the exposed
surface, reducing to 65%-75% at the inner surface. The remainder of the liner shall
consist of vinyl ester or isophthalic resins and E or ECR glass chopped strand mat.
G.7
Joints in the lining tubes shall not normally be permitted.
Page 160 of 244
G.8 Joints between preformed GRP benchings and lining tubes shall be made using an
external sleeve 200 mm long bonded onto both units, and then bandaged using suitable
resin and chopped strand mat. Such bandaging shall extend 75 mm either side of the edge of
the sleeve. On the inside face of the manhole, the joint between the benching and liner tube
shall be filled with vinyl ester paste to produce a smooth finish.
G.9 I f GRP linings to benching are to be formed in situ, the surface of the wall lining tube
shall be lightly abraded over a height of 150 mm from benching level. A fillet of 50 mm radius
shall than be formed of vinyl ester paste at the junction of benching and wall. The GRP lining
to the channels and benchings shall then be built up by applying isophthalic or vinyl ester
resin to the whole of the benching, fillet and abraded wall lining. A layer of E or ECR mat
shall then be rolled into the resin using a suitable steel roller to exclude all air and provide
complete immersion of the glass fibre in the resin.
G.10 After a period to allow pre-gel to get to a tacky state, a second coat of resin shall be
applied followed by a further layer of glass fibre mat. This process shall be repeated until the
total thickness of lining is approximately 4 mm. Vinyl ester resin and C glass or synthetic
tissue veil shall then be used to complete the lining.
G.11 Top surface of benching shall incorporate silica sand to form a non-slip surface.
G.12 The precast cover slab shall be seated on the walls using sand/cement mortar. The joint
shall be raked out 15 mm deep on the inside face and pointed with an approved pitch
extended polyurethane sealant.
G.13 GRP ladders of an approved pattern as specified may be purpose made to suit the
depth of each manhole and chamber. Fixings for ladders shall be approved stainless steel stud
anchors. Fixings holes shall be grouted with epoxy mortar and sealed as above. Rungs or
treads shall be ribbed to provide a non-slip surface.
G.14 The Contractor shall provide the Engineer with a 7 year unconditional guarantee
against failure of all GRP linings whether caused by defective materials or workmanship. The
guarantee shall be valid from the date of completion of the installation and must be handed
to the Engineer before the issue of the Certificate of Completion.
G.15 GRP sealing plates shall be provided to all sewage manhole chambers, sump and
holding tanks access covers. The sealing plates shall be capable of adequately withstanding
10% sulphuric acid at 50 deg.C (122 deg. F) for a period of 100 days and shall be a
minimum of [] mm thick and shall be designed to withstand a loading of 7.5 kN/m.
Page 161 of 244
The sealing plates shall be in the form of a plug with a flange to accommodate restraining bolts
and to prevent the plate passing into the manhole. The plates shall incorporate a synthetic
rubber (neoprene or similar approve) sealing ring integrally fixed to the GRP plate to produce
a gas and sand tight joint between it and a specially profiled frame edge without the use of
restraining bolts. Two GRP lifting handles shall be provided securely laminated to the plate.
The underside of the plate shall have a resin rich finish and there shall be no exposed fibres.
Cut and/or drilled faces shall be sealed with resin. The resins and glass used in the fabrication
of the plates shall be generally as specified for GRP pipes.
H . HDPE Lining for Manholes

The internal surfaces of manholes shall be properly protected against the corrosive and
aggressive effects of the wastewater on the long term. A l l concrete surfaces shall be
internally lined with suitable HDPE sheeting structured in the form of T lock, spiked, sure grip
or equivalent as approved and in accordance with the manufacturer recommendations. Liners
should be welded in a circular form and introduced during the production of pipes. Liner
thickness shall be 3 mm.
H.1
Physical characteristics of HDPE liners

-
Density
Temperature resistance
Friction equivalent to manning
Water Absorption
Elongation at Yield
Elongation at Break
Tensile Strength at Yield
Puncture Resistance
Melt Flow rate/ index
Heat reversion 100C/hr
0.94 g/cm3
up to 80C
0.013
DIN 53495 0.25%
DIN 53455/6/4 - 17%
DIN 53455/6/4 - min 400%
DIN 53455/6/4 - min 15 N/mm2
DIN 16726 - 2000 mm
190/5 ISO 1133
ASTM D1204 1%
H.2 Chemical Properties

Unaffected by continuous exposure to dilute solutions of acids, alkaline chemicals, corrosive
salts, alcohols as they occur in sewage, petroleum products normally occurring in sewage,
vegetable and animal oils and fungus and bacteria.
The Contractor shall submit full details of the materials and their workmanship as per the
manufacturer recommendations and the Engineers approval. Special care shall be taken to
protect the surfaces between the manholes and the steps, inlet and outlet sewer pipes.
Page 162 of 244
H.3 Installation
The seaming of concrete HDPE protective liners is carried out by extrusion welding. The
installation should only be performed by qualified and authorized installers. The following
should also be ensured:
Stud shear force is over 1800 N/stud in longitudinal and horizontal directions
High pull-out resistance of up to 42 t/m2, and 1000 N/stud
High mechanical bond-long lasting sealing.
The lining shall be permanently and physically attached to the concrete with an anchoring
system manufactured from the same material as the lining and shall be suitable for casting into
concrete. The anchoring system shall withstand a pull out test of at least 18kN/m applied
perpendicular to the concrete surface for a period of one minute without rupture of the anchors
or withdrawal from the concrete.
Lining shall have a smooth glossy finish, be impermeable to gases and liquids and non
conducive to bacteria or fungus growth.
Lining shall be capable of being repaired at any time during the life of the structure in
accordance with the lining manufacturers instructions.
The lining shall be capable of withstanding a back hydrostatic pressure of 2 bars applied to the
under surface of the lining without losing anchorage and without rupture and leakage.
All lining shall be factory tested for pin holes using an electrical spark tester set at 20,000 volts
minimum. Sheets having holes shall be satisfactorily repaired in the factory prior to delivery.
Page 163 of 244
PART 5: Concrete Works
PART 5: CONCRETE WORKS
SECTION 5.01
5.01.1
A.
CONCRETE AND CONCRETE MIXES AND TESTING
GENERAL
Scope
A.1 These Works shall consist of the Specifications for concrete materials including sampling,
testing and storage of such materials, concrete strength requirements, concrete testing
procedures and requirements, and job mixes.
5.01.2
A.
MATERIALS
Cement
A.1 Cement shall be Portland Cement, originating from manufacturers approved by the
Engineer and shall comply with ASTMC 150:97a and BS 12 or AASHTO M85 Type I in the case
of Ordinary Portland Cement and with BS 4027 or AASHTO M85 Type I I or Type V as directed
by the Engineer in the case of Sulphate Resisting Portland Cement.
A.2 Only one type or brand of cement shall be used in any one structural member. Mixing of
types or brands will not be permitted.
A.3 A l l cement shall be subject to approval and shipments of cement shall be accompanied by
a manufacturer's Certificate of Guarantee and/or laboratory test certificate. Approval of any
cement sample shall not relieve the Contractor of the responsibility to fabricate concrete of the
specified strength.
A.4 When tests at the factory or field tests subsequent to the original approval tests show that
the cement does not comply with the specifications, the entire consignment from which the
sample was taken shall be rejected and the Contractor shall immediately remove the rejected
material from the Site and replace it with cement which meets the required specifications.
Page 164 of 244
A.5 Whenever low alkali cement is specified the total alkali content estimated as sodium
oxide equivalent, shall not exceed 0.60% by weight. Approval of any cement sample shall not
relieve the Contractor of the responsibility to fabricate concrete of the specified quality and
strength.
A.6 I f no local test certificate is available, the Contractor shall obtain from each proposed
manufacturer a typical sample of cement which shall be fully and independently tested in
accordance with the appropriate standard and the results submitted for approval. Primary and
secondary sources of the required cements shall be given. All costs associated with the testing
shall be allowed for by the Contractor. All costs associated with the testing shall be allowed for
by the Contractor.
A.7 Details shall also be submitted of the manufacturer's name and address of producing
works, manufacturer's description of cement type and brand name and standards to which
compliance is guaranteed.
A.8 Average values and corresponding maximum and minimum values in respect of the
following composition and properties shall be submitted, covering a continuous production

period of at least 6 months ending not earlier than 3 months before submission of the data. The
Contractor shall state i f any material or production process changes have been made since the
end of the above period; i f any are proposed, brief details shall be given.
Composition
Insoluble residue Silica

(SiO2) Alumina (Al2O3)
Total Iron (Fe2O3) Calcium
(CaO) Magnesium (MgO)
Potassium (K2O) Sodium

(Na2)
Properties
Lime saturation factor (LSF)

Alumina-iron ratio (A/F)
Tri-calcium aluminate (Ca3Al) Free
lime in clinker (as CaO) Total acid
solution alkalis Heat of hydration
at 7 days
at 28 days
Fineness (sq.m/kg)
Sulfate (SO3)
Setting times
Initial (min)
Sulfur (S) Chloride
(Cl)
Loss on ignition
Soundness (mm)
Compressive strength
3 days
7 days
28 days
3 months
Page 165 of 244
A.9 The requirement of item A.8 may be dispensed with at the discretion of the Engineer, who
shall give such dispensation in writing.
A.10 The manufacturer's bulk average test certificate for each consignment of cement shall be
submitted, showing the results for chemical composition and physical properties determined in
accordance with the relevant standard. Samples shall be taken for each consignment of cement
and tested as directed by the Engineer in an approved independent laboratory, at the cost of the
Contractor.
A.11 Where bulk cement deliveries are proposed, the Contractor shall provide all information
required by the Engineer concerning off-site storage and loading arrangements and shall provide
reasonable facilities for the Engineer to inspect these arrangements for approval purposes.
Consignments shall be used in the order in which they are delivered.
A.12 Storage capacity shall be sufficient to meet the schedule of work so that continuous work
is achieved. Cement shall be stored in moisture-proof storage sheds. Neither stale, caked, nor
reclaimed or re-sacked cement shall be used. The Contractor shall not store cement in areas
subject to flooding.
A.13 Cement remaining in bulk storage at the mill, prior to shipment, for more than 6 months or
cement stored in bags in local storage by the Contractor or a vendor for more than 3 months
after shipment from the mill, must not be used for concrete works.
B.
Aggregates
B.1 Potential aggregate sources shall be examined and particular attention shall be paid to the
following aspects of the deposits and the actual or proposed extraction and production
arrangements:
Name, location, local national grid reference, type of deposit, potential variability,
methods of extraction.
Methods and degree of control exercised over extraction.
Processing methods, types of plant, number of processing stages, standards of

maintenance and process control, producer's laboratory facilities and technical
staffing.
Stockpiling arrangements, loading and supply arrangements.
Page 166 of 244
Potential variations in end-products due to variations inherent in the deposit and

in the existing methods of extraction, processing and stockpiling.
Possible modifications to existing extraction, processing, storage and handling

arrangements, and to supervision arrangements to reduce end-product
variations.
Possible requirements for supplementary processing on site.
Photographs shall be provided of each of the proposed new sources and related
production arrangements. The source photographs should preferably include low
level (helicopter) aerial photographs and close-ups of working faces.
B.2 Aggregate deposits shall be sampled and tested in an appropriate and systematic manner
to assess their potential variability and to assist in determining appropriate methods of extraction
and processing.
B.3 The deposit investigation and sampling programs shall be relevant to each type of deposit
and shall be devised and supervised by an experienced approved engineering geologist, after
he has made a field reconnaissance of the potential deposit areas, or the existing workings.
B.4 Each size of aggregate shall be sampled at the discharge points on the production plant
(i.e. conveyors or hoppers, not stockpiles) at three well spaced intervals during the course of
each of three consecutive production days; these samples shall be designated "production
samples".
B.5 In addition, selected samples shall be taken from producer's stockpiles to represent any
readily visible variations in physical characteristics, or appearance, or materials ready for
loading, these samples shall be designated "stockpile samples".
B.6 A l l samples shall be taken by arrangement with and in the presence of the Engineer, or
his representative, and shall be tested as required below.
B.7 Representative portions of the above samples shall be taken for reference purposes and
shall be split and retained on site by the Contractor and by the Engineer.
Page 167 of 244
C.
Testing Aggregates
C.1 Each production sample shall be tested for the following:
Proportion of natural (uncrushed) material (% by weight) gradings, passing

75mm sieve (U.S. Sieve No.200 to AASHTO M92 or ASTM M81) when tested
in accordance to AASHTO T 11 .
Total acid soluble chloride content and total acid soluble sulfate content (% by
weight).
Flakiness and elongation indices.
C.2 Representative portions of equal weight shall be taken from each of the production
samples of each size of aggregate and then combined to provide composite production
samples for each size of aggregate. The composite samples shall be tested as for the
individual unless otherwise directed by the Engineer. The tests shall be as follows:
Potential Reactivity tests for alkali-silicate and alkali-carbonate reactions:

petrographic examination in accordance with ASTM C295, rapid chemical
method in accordance with ASTM C289 and rock expansion test in accordance
with ASTM C586.
I f one or more of the tests referred to above are positive then the mortar prism
test in accordance with ASTM C227 shall be carried out.
Partial chemical analysis, including insoluble residue (ASTM D3042-84),

chloride content, sulfate content and calculated approximate composition.
ASTM Soundness Test C88, using sodium sulfate solution or ASTM

Soundness Test C88, using magnesium sulfate solution.
Aggregate Impact Value by the Los Angeles test in accordance with AASHTO
T96-83 ASTM C131-81, ASTM C535-81.
10% Fine Value to BS 812.
Aggregate Abrasion Value to BS 812.
Specific Gravities and Water Absorption to BS 812 or approved ASTM

equivalent.
Page 168 of 244
C.3 Stockpile samples shall be examined and tested in as many of the above mentioned
respects as are considered relevant by the Engineer.
C.4 The properties of the aggregates shall be such that the Drying Shrinkage of concrete
prepared and tested in an approved laboratory in accordance with the United Kingdom Building
Research Station Digest No. 35 (Second Series) shall not exceed 0.045 percent. The Initial
Drying Shrinkage of all the proposed concrete mixes prepared and tested in an approved
laboratory in accordance with BS 1881 shall not exceed 0.06 percent.
C.5 Aggregate for use in concrete or mortar that will be subject to wetting, extended exposure
to humid atmosphere, or contact with moist ground, shall not contain material that is
deleteriously reactive with the alkalis in the cement, or any which may be additionally present in
the aggregates and mixing water or water in contact with the concrete or mortar, in amounts
sufficient to cause excessive localized or general expansion of concrete or mortar. The following
shall be observed:
D.
Under no circumstances shall the Contractor use Dacite, Andesite, Rhyolites,

Opal Cherts and Tuffs.
Coarse and fine aggregates shall be tested for reactivity potential in accordance
with the methods listed above and shall satisfy the various criteria given for
innocuous aggregates in the relevant standard.
In case the aggregate source has no previous records and no performance

history, potential reactivity should be evaluated using the specified tests.
However, i f the aggregate has been used in previous works in adjacent location
and performed well without showing signs of Alkali reaction, the results of these
tests should not be used as the only factor deciding the usage of the aggregate.
The Engineer shall then decide on this matter.
The period of the tests is minimum 14 weeks to 26 weeks unless the accelerated
test is used instead of the mortar bar test (ASTM C227).
Fine Aggregates
D.1 Fine concrete aggregates shall conform to AASHTO M6 and shall consist of natural sand
or crushed rock having hard and durable particles or, i f approved by the Engineer, other inert
materials having similar characteristics, 100% passing 9.5 mm sieve and 2% to 10% passing
0.15 mm sieve. It shall not contain harmful materials such as iron pyrites, coal, mica, shale or
similar laminated materials such as flat and elongated particles or any materials which may
attack the reinforcement in such a form or in sufficient quantity as to adversely affect the
strength, durability and texture of the concrete.
Page 169 of 244
D.2 The Contractor shall, when directed by the Engineer, wash the fine aggregates to
remove deleterious substances or for consistency of concrete colour. Such washing shall be
carried out using fresh water. The water shall be replaced regularly as deemed necessary to
maintain its chloride and/or sulfate content low.
D.3 The total acid soluble sulfate content (BS 812: Part 118) of fine aggregate, expressed as
sulphur trioxide (SO3), shall not exceed 0.40% by dry weight (AASHTO T260-82, BS812: Part
117). The total acid soluble chloride content, expressed as sodium chloride (NaCl), shall not
exceed 0.10% by dry weight of fine aggregate. The following additional requirements shall
apply to the concrete mix:
Total sulfate content (as SO3) of any mix, excluding that present in the cement
but including any present in the other materials, shall not exceed 2.5% by
weight of cement in the mix.
Total chloride content (as NaCl) of any mix, including any chloride present in
the other materials and in the mix water, shall not exceed 0.35% by weight of
cement in the mix.
D.4 Fine aggregate shall meet the following additional requirements:
Fineness modulus, AASHTO M6: +0.20% of approved value which shall be not
greater than 3.1 or less than 2.3. Sieve analysis to AASHTO T27.
Sodium or Magnesium Sulfate Soundness AASHTO T104: max 12%, 18% loss
respectively.
Content of Clay Lumps and Friable Particles, AASHTO T112-82: 3% max.
Sand Equivalent AASHTO T176: min 75%.
Coal and Lignite, AASHTO T113-82: 0.5% Max.
Organic Impurities AASHTO T21-81: darker than standard colour.
D.5 The amount of hollow shells likely to form voids and present in material retained on a
2.36 mm sieve determined by direct visual separation, shall not exceed 3% by weight of the
entire sample.
D.6 When sampled and tested in accordance with the appropriate sections of BS 812 (using
BS 812 test sieves) the grading of fine aggregates shall be within the limits of the grading
zones given in Table 4 of BS 882. The fine aggregate shall be described as a fine aggregate of
the grading zone into which it falls.
Page 170 of 244
D.7 I f the fineness modulus varies by more than 0.2 from the value assumed in the concrete
mix design, the use of such fine aggregate shall be discontinued until suitable adjustments
can be made in the mix proportions to compensate for the difference in gradation.
E.
Coarse Aggregates
E . 1 Coarse concrete aggregates shall conform to AASHTO M80 and shall consist of gravel,
crushed gravel, or crushed stone free from coating of clay or other deleterious substances. It
shall not contain harmful or any other materials which may attack the reinforcement in such a
form or in sufficient quantity as to adversely affect the strength and durability of the concrete. I f
necessary, coarse aggregate shall be washed to remove deleterious substances, or for
consistency of concrete colour.
E.2 The total acid soluble sulfate content (BS812: Part 118) of coarse aggregate expressed
as sulphur trioxide (SO3), shall not exceed 0.40% by weight (AASHTO T260-82, BS812: Part
117). The total acid soluble chloride contents of coarse aggregates, expressed as sodium
chloride (NaCl), shall not exceed 0.05% by weight. These limits are subject to the following
overriding requirements:
The total sulfate content (as SO3) of any mix, excluding that present in the
cement but including any present in the other materials, shall not exceed 2.5%
by weight of cement in the mix.
The total chloride content (as NaCl) of any mix, including any chloride present
in the other materials and the mix water, shall not exceed 0.35% by weight of
cement in the mix.
E.3 Coarse aggregate shall also meet the following additional requirements:
Sodium or Magnesium Sulfate Soundness AASHTO T104: 5 cycles: Max 12%,

18% loss respectively.
Abrasion, in Accordance with AASHTO T96 Max 40% loss.
Content of Clay Lumps and Friable Particles AASHTO T112-81: Max 1% by

weight.
Soft Fragments and Shale AASHTO M80: max 5% by weight.
Flakiness Index, BS812: 30% max. Elongation index, BS 812:30% max.
Coal and Lignite, AASHTO T113-82: 0.5% max.
Page 171 of 244
E.4 The grading of coarse aggregate shall comply with AASHTO M43.
E.5 The coarse concrete aggregate, when tested according to AASHTO T27, shall meet the
following gradation requirements and shall be graded within the limits stated in Table 5.1.1.
Table 5.1.1: Limits of Gradation for Coarse Aggregates
Percent Passing by Weight for
AASHTO
Sieve
Size
3'
2 1/2"
2"
1 1/2"
1"
3/4"
1/2"
3/8"
No. 4
No. 8
No. 200
mm
75
63
50
37.50
25.0
19.0
12.5
9.5
4.75
2.36
0.075
Grading
I
100
90-95
30-65
10-30
0-5
0-1
Grading
II
100
95-100
35-70
10-30
0-5
0-1
Grading
III
100
95-100
35-70
10-30
0-5
0-1
Grading
IV
100
95-100
25-60
0-10
0-5
0-1
Grading
V
100
95-100
20-55
0-10
0-5
0-1
Grading
VI
100
90-100
40-70
0-15
0-5
0-1
E.6
The type of grading for coarse concrete aggregates shall depend on the maximum
size of aggregate, which shall not be larger than one-fifth (1/5) of the narrowest
dimension between sides of forms, nor larger than two-thirds (2/3) of the minimum
clear spacing between reinforcing bars, whichever is least.
E.7
Before batching, all types of coarse aggregate shall be separated into fractions having
uniform grading as determined by the Engineer.
E.8
However, the number of fractions and their gradings shall be fixed on the basis of the
maximum size of the aggregates in the cement concrete as proposed below
-
For fractions up to 1-1/4":

(31.5 mm)
between 3/8" and 3/4"

(9.5 - 19.0 mm).
For fractions up 1-1/2" to 3":

(37.5-75 mm)
between 3/4" and 1-1/4"

(19.0 - 31.5 mm)
Page 172 of 244
F. Combined Aggregates
Combined aggregate is composed of a mixture of coarse aggregates and fine aggregates. They
shall be used only in proportions with the prior approval of the Engineer.
F.2 In no case shall materials passing the No. 200 (0.075 mm) sieve exceed 3% by
weight of the combined aggregate.
F.3 The combined concrete aggregate gradation used in the work shall be as specified,
except that when approved or directed by the Engineer. Grading 7 of Table 5.1.2 shall be
used for curbs, handrails, parapets, posts and other similar sections or members with
reinforcement spacing too close to permit proper placement and consolidation of the
concrete.
F.4 Changes from one gradation to another shall not be made during the progress of
work, unless approved by the Engineer.
F.5 For the proportion of each fraction of coarse aggregate and for the proportion of fine
and coarse aggregate, the combined gradings in Table 5.1.2 shall be utilized as a
guideline for the mix proportion design as to guarantee the maximum densities of the
concrete. Before batching, however, the Engineer or his representative shall check only the
compliance of the grading of the fine and coarse aggregate with the requirements of the
Specifications, since the grading of each fraction ultimately remains the sole responsibility
of the Contractor.
Table 5.1.2: Limits of Gradation for Combined Aggregates
AASHTO
Sieve
Size
3"
2 1/2"
2"
1 1/2"
1"
3/4"
1/2"
3/8"
No. 4
No. 8
No. 16
No. 30
No. 50
No.100
No.200
mm
75
63
50
37.50
25.0
19.0
12.5
9.5
4.75
2.36
1.18
0.600
0.300
0.150
0.075
Combined Aggregate Percent Passing by Weight for

Grading
1
100
88-95
78-90
66-81
51-70
43-62
32-53
27-48
19-38
9-27
4-19
3-15
2-11
1-7
0-3
Grading
2
100
88-95
74-86
56-75
47-67
36-58
30-53
22-42
10-29
5-21
4-17
2-13
1-8
0-3
Grading
3
100
80-92
63-80
52-72
41-60
36-54
23-43
12-30
6-22
4-19
2-14
1-8
0-3
Grading
4
100
93-98
70-88
60-79
47-66
40-60
28-49
16-36
7-25
5-21
2-15
1-9
0-3
Grading
5
100
87-96
73-86
57-74
48-68
34-55
24-40
9-28
7-23
4-17
2-10
0-3
Grading
6
100
80-96
61-80
52-72
38-56
25-41
11-29
8-24
5-19
2-11
0-3
Grading
7
100
73-86
61-79
43-64
26-46
13-33
10-28
5-21
2-12
0-3
Page 173 of 244
G.
On Site Storage of Aggregates
G.1 Adequate stocks of tested and approved aggregates shall be maintained on site and the
capacity of the storage bins for each type and grading of aggregate shall be sufficient to hold the
respective quantities required for the maximum amount of concrete which the Contractor is
obliged or intends to pour in any continuous operation in one day. Stockpiles shall be built in
layers of 1.50 m maximum height and segregation of the aggregates prevented. Different
grades of aggregates shall be totally separated by concrete block walls.
G.2 Dense concrete or bituminous slabs shall be laid with sufficient falls to cover all aggregate
stockpile areas or bins and shall extend to cover all surrounding areas where aggregates are
likely to be discharged or handled. These areas shall be swept and kept clean at all times to
ensure that the aggregates are not contaminated by the adjacent ground through trafficking or
otherwise, and shall be constructed with adequate drainage for surplus water.
G.3 Windbreaks shall be provided where aggregates might suffer excessive contamination by
windblown materials. During periods of heavy rain the bins or compounds shall be covered by
tarpaulins or other approved means.
H.
Rejection of Aggregates
H.1 The general or localized build up of fines in aggregate stockpiles shall not be allowed and
any material which, in the opinion of the Engineer, is so affected will be rejected after testing.
H.2 Aggregates which have suffered segregation or contamination during processing, handling
at source, transportation to the site, stockpiling and handling on site, or which otherwise do not
conform with requirements of the Specifications, either locally or generally, will be rejected and
shall be removed promptly from the site.
H.3 Aggregates which are found to be contaminated during transportation or during stockpiling
or during handling shall be promptly removed from the site by the Contractor notwithstanding
any prior approval of the source which may have been given by the Engineer.
Page 174 of 244
I.
Washing and Processing Aggregate
I.1 The Contractor may be required to carry out on site supplementary processing or effective
washing of coarse and fine aggregates where the aggregate producer's methods, in the opinion
of the Engineer, may not result in end products which consistently comply with all requirements
of the Specifications, or where aggregates suffer unacceptable changes during loading at
source or during subsequent transportation to the site, or otherwise.
J.
Water
J.1
A l l sources of water to be used with cement whether for mixing or curing of concrete, or
compaction of backfill around the concrete structures, shall be approved by the Engineer.
I f at any time during construction, water from an approved source becomes
unsatisfactory, the Contractor shall provide satisfactory water from other mains sources.
J.2
Water shall be free from injurious quantities of oil, alkali, vegetable matter and salt as
determined by the Engineer. The water shall be reasonably clear and shall contain not
more than one quarter (0.25) percent solids by weight. Water shall comply with the
requirements of AASHTO T26 and BS 3148. I f the specific conductance is less than
1500 microohms per centimeter the total solids content requirement may be waived.
J.3
Non-potable water may be used when potable water is not available provided the
impurities do not exceed the values given in Table 5.1.3.
J.4
Mortar prepared with water submitted by the Contractor for approval shall show no
marked change in time of set, no indication of unsoundness and a reduction of not more
than ten (10) percent in mortar strength when compared with mortar made with water of
known satisfactory quality.
J.5
The water used in the mix design shall be the same as the water approved for site use.
J.6
Water used for prestressed concrete structures or for concrete containing or in contact
with aluminium fittings or fixtures shall not contain chloride ions.
Page 175 of 244
Table 5.1.3 : Maximum Permitted Impurities in Non-Potable Water

Impurity
Chloride as (Cl-)
a) Prestressed concrete
or concrete in bridge
decks
Method
Max. Concentration
(ppm)
500
ASTM D512
Sulfates as SO4
1000
300
ASTM D516
Alkalis as
(Na2O+K2O)
Total solid
600
5000
b) Other reinforced
concrete in moist
environment or containing
aluminum embodiments or
dissimilar metals or with
stay in place galvanized
metals form
AASHTO T-26
K.
Admixtures
K.1
The quantity and method of using admixtures shall be in accordance with the
manufacturer's recommendations and in all cases shall be subject to the approval of
the Engineer.
K.2
In all cases the Contractor shall provide the following information for the Engineer's
approval:
K.3
The quantity to be used, in kilograms per kilogram of cement and in kilograms

per cubic meter of concrete.
The detrimental effects caused by adding a greater or lesser quantity in

kilograms per cubic meter of concrete.
The chemical name(s) of the main active ingredient(s).
Whether or not the admixture leads to the entraining of air.
The Contractor shall demonstrate the action of an admixture by means of trial mixes.
Page 176 of 244
K.4 The use of calcium chloride in any form is prohibited.
K.5 Reference may be made to ACI Committee 212 report "Guide for Use of Admixtures in
Concrete".
L.
Admixture to Produce High Workability
L.1 Concrete for use in certain construction shall contain an approved superplasticising
agent, when so directed by the Engineer. The superplasticiser shall be stored and used
strictly in accordance with the manufacturer's instructions and must be fully compatible with
all proposed concrete mix constituents. The optimum dosage of the additive shall be
determined by site and laboratory trials to the Engineer's approval. The Contractor shall
submit to the Engineer full details of his proposed mix design which must ensure that the
minimum strength requirements as specified for the particular use of the concrete are
achieved. Only when the Engineer has approved the proposed mix design may such a mix be
used in full compliance with the Specifications.
L.2 The Contractor's mixing and transporting plant shall be so designed that accurate
metering of the superplasticising agent is possible and so that the additive may be introduced
immediately before placing.
M. Admixture to Increase Density
M.1 Silica Fume: silica fume (SF) may be used as a cement replacement and shall be in
accordance with ASTM C 1240-05. There shall be a maximum of 5 percent replacement of the
OPC. The silica fume shall be obtained from an approved supplier.
The approved supplier shall provide documentation to establish the following:
that the silica fume complies with ASTM C 1240-05.

The silica fume results from the production of silicon or ferro-silicon alloys
containing at least 85 percent silicon.
That source of supply shall remain the same for the construction period of the
project.
That the supply shall be adequate to meet the anticipated peak requirement.
Chemical analyses to give the percentages of the following materials:
-
Si 02 (Min. 85)
Ca 0 (Max. 1.0)
S 03 (Max. 3.0)
C (Percentage 4)
Mg O (Percentage 5)
CL (Max. 0.1)
Page 177 of 244
Loss on ignition as low as possible.

Percentage of particles retained on 45 micron sieve (maximum 10).
Specific surface area and method of test, together with corresponding particle
size (minimum 1 5m2/g)
Delivery of silica fume to the concrete batching plant shall be in dry powder form, with a
bulk density between 200 and 650 kg/cu.m.
Manufacturers test certification shall be supplied for each delivery of silica fume and shall
confirm that the silica fume complies with the above requirements and shall be submitted
by contractor not later than the day of delivery of the silica fume.
Engineer shall have the right to call for tests, the cost of which are to be borne by the
contractor, on each delivery of silica fume, i f necessary to establish or confirm that the
silica fume meets the above requirements.
5.01.3
A.
DEFINITIONS
Crushing Strength
A.1 The crushing strength of a test cylinder prepared in accordance with AASHTO T23 and
AASHTO T126. Alternative standard cubes may be tested in accordance to BS specifications.
B.
Average Strength
B.1 The mean of the crushing strengths of specimens taken from a sample of concrete.
C.
Characteristic Strength
C.1 The value of the crushing strength below which 5% of the population of all possible
strength measurements of the specified concrete are expected to fall.
D.
Fresh Concrete
D.1 Concrete during the initial period of two hours from the addition of water to the cement.
Page 178 of 244
E.
Batch
E.1 The quantity of concrete mixed in one cycle of operations of a batch mixer or the quantity of
concrete conveyed ready-mixed in a vehicle, or the quantity discharged during one minute from
a continuous mixer.
F.
Sample
F.1 A quantity of concrete taken from a batch whose properties are to be determined.
G.
Regular Sampling
G.1 The sampling of concrete nominally of the same mix received regularly from the same
source.
H.
Specimen
H.1 Cylinder or cube taken from a sample for testing.
5.01.4
CONCRETE STRENGTH REQUIREMENTS
A.
Design Mixes
A.1
Mixes for the classes of concrete shown in Table 5.1.4 shall be designed by the
Contractor, when specified for use in any part of the Works. The quantity of water used
shall not exceed that required to produce a concrete with sufficient workability to be
placed and vibrated in the particular locations required. Unless otherwise approved by
the Engineer, the mix designs shall be on the basis of continuously graded aggregates
and all mix designs shall be submitted to the Engineer for approval.
A.2
The Cement content in any mix shall not exceed 450 kg/cu.m.
Page 179 of 244
A.3 The 7-day compressive strengths shall not be less than 75% of the specified 28 day
strengths. I f the 7 days results are below 75% of the required 28 days strength, the
Contractor may postpone works related to the suspected concrete until the 28 days results
are available and successful, or i f the Contractor decides to continue work, he may do so
under his own responsibility and risk.
A.4 The ultimate cylinder compressive strength of concrete shall be determined on test
specimens obtained and prepared in accordance with AASHTO T23 and AASHTO T126
except that six inch by twelve inch cylinders shall be used for all compression tests.
Alternatively, the Engineer may require ultimate compressive strength of concrete to be
determined on test specimen obtained by taking and airing cubes in accordance with BS
1881. The Contractor shall furnish single-use cylinder moulds conforming to AASHTO
M205, or when approved by the Engineer, re-usable vertical moulds made from heavy
gauge metal.
Table 5.1.4: Concrete Class and Design Mixes

Class of
Concrete
Cylinder Works
Strength @ 28 Days
kg/cm2
Equivalent Works
Cube Strength @ 28
Days kg/cm2
Maximum Size of
Aggregate
mm
Minimum Cement
Content kg/m3
110/25
140/25
170/60
210/50
210/25
210/20
250/20
250/30
310/20
360/20
110
140
170
210
210
210
250
250
310
360
140
180
210
260
260
260
310
310
385
450
25
25
60
50
25
20
20
30
20
20
220
250
275
300
325
325
350
350
375
425
B.
Nominal Concrete Mix
B.1
Concrete for use as backfilling for structural excavation shall be either no-fines
concrete or cyclopean concrete as directed by the Engineer. The cement :
aggregate ratio of such nominal mixes shall be not greater than 1:15 and the
minimum cylinder strength at 28 days not less than 50kg/cm2.
B.2
No-fines concrete shall comply with the grading in Table 5.1.5 and shall be mixed
and laid in general conformity with this Section 5.01.
Page 180 of 244
B.3 Plums used in cyclopean concrete shall consist of non-reactive broken stone spalls or
boulders ranging in size from 200mm to 300mm. They shall be free from sharp or angular
edges and shall not form more than 30% of the total volume of concrete. They shall be evenly
graded and shall be soaked in water prior to incorporation in the mix. Plums shall be evenly
distributed in the concrete mix with a minimum cover of 100mm.
Table 5.1.5: Grading For No-Fines Concrete
GRADING OF AGGREGATE
Sieve Size
90 mm
40 mm
20 mm
10 mm
C.
% by Dry Weight
Passing
100
85-100
0-20
0-5
Compliance with Strength Requirements
C.1 Cylinders (or cubes) from concrete as mixed for the Work will be tested in accordance with
AASHTO T22 (BS 1881 for cubes) after seven (7) days and twenty eight (28) days. Test
specimens shall be made and cured in accordance with AASHTO T23. These specimens will
be the basis for acceptance of the concrete in the structure.
C.2 Prior to the commencement of any concreting work and subsequently, whenever a change
is intended, preliminary tests shall be carried out. From each of three samples of materials, a
trial mix shall be made. For each class of concrete, the trial mixes shall represent at least two
different water cement ratios. From each trial mix, six cylinders (or cubes) shall be made, three
for testing at 7 days, and three for testing at 28 days. The average strength of the cylinders (or
cubes) tested for each sample shall be taken as the preliminary cylinder (or cube) strength of
the mix.
C.3
The Engineer will require the preliminary test to be repeated i f the difference in strength
between the greatest and the least strength is more than 20 per cent of the average.
C.4 The water /cement ratio and slump adopted in the preliminary tests for each class of
concrete shall be used in the works concrete. It shall be such that, i f selected for use at the
Site, the concrete can be worked readily into the corners and angles of the forms and around
the reinforcement without permitting the materials to segregate, or free water to collect on the
surface.
C.5 Preliminary tests shall have these minimum ultimate strengths given in Table 5.1.6.
Page 181 of 244
C.6 During the first four days of the commencement of concreting with any particular mix, two
sets of six works cylinders (or cubes) in each set shall be made each day. Three cylinders (or
cubes) from each set shall be tested at 7 days, and 3 at 28 days. The above works tests shall
be carried out for each class of concrete. Subsequently, the frequency of making sets of test
cylinders (or cubes) and the number in each shall be as directed by the Engineer.
Table 5.1.6: Preliminary Tests for Strength
Class of Concrete
110/25
140/25
170/60
210/50
210/25
210/20
250/20
250/30
3 10/20
360/20
Cylinder Strength
(kg/cm2)
170
210
240
290
290
290
325
325
395
440
Equivalent Cube Strength

(kg/cm2)
210
260
300
360
360
360
400
400
490
550
C.7 The cylinders (or cubes) shall be cured in the same manner and environment as the
members they represent. The cylinder (or cube) strength shall be accepted as complying with
the specified requirement for work cylinder (or cube) strength i f none of the compressive
strengths of the cylinders (or cubes) falls below the minimum strengths given in Table 5.1.4 or
i f the average strength is not less than the specified minimum works cylinder (or cube)
strength and the difference between the greatest and least cylinder (or cube) strength is not
more than 20 per cent of the average.
C.8 Alternatively, the criterion of acceptable test results shall be that not more than 5 per cent
of works cylinders fall below the specified strength. For this to be fulfilled, the mean strengths
of works cylinders (or cubes) less 1.64 times the standard deviation should not be less than the
required strength. This calculation shall be made for both 7 and 28 day cylinder (or cube) tests
as soon as 24 cylinders (or cubes) have been tested at each age. Thereafter, it shall be
repeated as further test results become available at a frequency determined by the Engineer.
The number of cylinders (or cubes) considered in each calculation shall be the total number of
cylinders (or cubes) of the mix in question tested from the commencement of the Works.
C.9 Cores shall be taken in accordance with ACI 318-95, article 5.6.4, and tested in
accordance with AASHTO T24. Load testing shall be carried out in accordance with ACI 3
18-89, chapter 20. The Contractor shall hire an authorized independent laboratory to carry out
such tests at no extra cost to the Client.
Page 182 of 244
C.10 The Engineer may make additional test cylinders to ascertain the effectiveness of the
methods by which the structure is being cured, and also to determine when the structure may be
placed in service. These cylinders shall be cured in the field in the same manner as the concrete
placed in the structure, and the Contractor shall protect the cylinders from all damage.
C.11 The Contractor shall take every precaution to prevent injury to the test cylinders during
handling, transporting and sorting. He will be held solely responsible for any test failure caused
by improper handing and transportation, or any other cause which may be detrimental to the
test cylinder.
C.12 In order that the test cylinders may be transported from field to laboratory undamaged,
the Contractor shall provide a minimum of two (2) approved boxes. [One (1) for the Contractor's
use and one (1) for the Engineer's use.] Boxes shall be of such size to receive a minimum of six
(6) test cylinders and leave space for sawdust packing around all surfaces of the cylinders.
Boxes shall be approved by the Engineer. The Contractor shall, when directed by the Engineer,
provide as many additional boxes as may be required by the remoteness and/or magnitude of
the concrete work.
C.13When test cylinders fail to meet minimum strength requirements, the Engineer may require
core samples to be taken to determine the acceptability of such structures. The Contractor shall,
at his own expense, furnish all equipment required for such core samples.
5.01.5
COMPOSITION OF CONCRETE
A.
Mix Proportions
A.1
The Contractor shall consult with the Engineer as to mix proportions at least forty-five
(45) days prior to beginning concrete work. The actual mix proportions of cement,
aggregates, and water shall be determined by the Contractor under the supervision of
the Engineer.
A.2
The Contractor shall, in the presence of the Engineer, prepare trial-mixes for each class
of concrete required for the project, made with the approved materials to be used in the
Work. The proportions of the trial-mixes shall be such as to produce a dense mixture
containing the cement content specified and meeting the plasticity requirements and the
preliminary test strength requirements specified for the designated class of concrete.
Page 183 of 244
A.3 I f the materials supplied by the Contractor are of such a nature or are so graded that
proportions based on minimum cement content cannot be used without exceeding the
maximum allowable water content, the use of admixtures to maintain the water content within
the specified limit shall be permitted. At all times the concrete mix shall satisfy the durability
requirements by satisfying the minimum and maximum limits specified of cement and water
contents respectively. No additional payment shall be paid due to adding extra amount of cement
to the mix.
A.4 The Engineer will review the Contractor's trial - mixes and break the test cylinders at seven
(7) and twenty-eight (28) days. The Engineer will then determine which of the trial-mixes shall
be used. I f none of the trial-mixes for a class of concrete meets the specifications, the Engineer
will direct the Contractor to prepare additional trial-mixes. No class of concrete shall be
prepared or placed until its job-mix proportions have been approved by the Engineer.
A.5 The approval of the job-mix proportions by the Engineer, or his assistance to the
Contractor in establishing those proportions, in no way relieves the Contractor of the
responsibility of producing concrete which meets the requirements specified in these
specifications.
A.6 A l l costs connected with the preparation of trial-mixes and the design of the job-mixes
shall be borne by the Contractor, except that the Engineer shall not charge the Contractor for
laboratory supervision and the breaking of the test cylinders.
B.
Design Limits
B.1 The following will be designated by the Engineer within the limits of the specifications:
The minimum cement content in sacks per cubic meter of concrete.
The maximum allowable water content in litres per sack of cement, or equivalent
units, including surface moisture, but excluding water absorbed by the
aggregates.
The ratio of coarse and fine aggregates.
Slump or slumps designated at the point of delivery.
Page 184 of 244
C.
Ch a n g es t o M ix De si g n
C. 1 Changes in mix proportions requested by the Contractor to previously approved mix

designs shall only be made after new approval by the Engineer.
C. 2 When, in the opinion of the Engineer, cement is being lost due to windy conditions, the
Contractor shall add additional amounts of cement as directed by the Engineer. No additional
payment will be made for the added cement.
C. 3 As the work progresses, the Engineer reserves the right to require the Contractor to
change the proportions from time to time i f conditions warrant such changes to produce
satisfactory results. Any such change may be made within the limits of the specifications at no
additional compensation to the Contractor.
C. 4 When in the opinion of the Engineer, an adjustment for protection against concrete
deterioration due to salty environment is necessary, he may require the cement content be
increased ten (10) per cent over and above that cement content used in the approved trial-mix
design for non-salty environment. Water content shall be adjusted accordingly to obtain a
dense workable mix. All Structure footings and column lengths to the first construction joint
above the ground surface for the entire project are subject to this increased cement content. No
additional payment will be made for the increase in cement content.
C. 5
Failure of the mix to meet specifications determined by the Engineer under items A and B
in this sub-section will be grounds for the Engineer to reject the concrete.
C. 6 Mortar for laying stone for grouted stone riprap, grouted stone wash checks or grouted
stone ditch lining shall be composed of one (1) part of portland cement and three (3) parts of
fine aggregate by volume with water added to make a workable mix of such consistency as to
perform properly the functions required for the work being done. Amount of water added shall
be approved by the Engineer. The following criteria shall be observed:
Aggregates for masonry mortar shall conform to AASHTO M45.
Portland cement shall conform to AASHTO M85, Type I , I I or III.
Page 185 of 244
5.01.6
A.
REQUIREMENTS FOR COMBINING MATERIALS
Measurement for Proportioning Materials
A.1 The cement shall be measured in bulk or as packed by the manufacturer, a sack of cement
shall weigh 50 kilograms. Measurement shall be accurate to within 3.0 per cent throughout the
range of use.
A.2 The mixing water shall be measured by weight or by volume. In either case the
measurement shall be accurate to within 2.0 percent throughout the range of use.
A.3 The aggregates shall be measured by weight. The measurement shall be accurate to
within (+ or - 2.0% fine , coarse aggregates) throughout the range of use.
A.4 Additives shall be measured by volume i f in liquid form and by weights i f solid. The
measurement shall be accurate to within 3.0 per cent throughout the range of use.
B.
Assembly and Handling of Materials
B.1 Aggregates shall be assembled in such quantities that sufficient material approved by the
Engineer is available to complete any continuous pour necessary for structures. The batching site
shall be of adequate size to permit the stockpiling of sufficient unsegregated materials having
proper and uniform moisture content to ensure continuous and uniform operation. Aggregates
shall enter the mixer in a manner approved by the Engineer and so as to ensure that no matter
foreign to the concrete or matter capable of changing the desired proportions is included. In the
event that 2 or more sizes or types of coarse or fine aggregates are used on the same project,
only 1 size or type of each aggregate may be used on one continuous pour.
B.2 A l l aggregates shall be stockpiled before use in order to prevent segregation of material,
to ensure a uniform moisture content, to provide uniform conditions for proportioning plant
control and to aid in obtaining concrete that is uniform as to materials and moisture content.
The use of equipment or methods of handling aggregates which results in the degradation of
the aggregates is strictly prohibited. Bulldozers with metal tracks shall not be used on coarse
aggregate stockpiles. A l l equipment used for handling aggregates shall be approved by the
Engineer. Stockpiling of aggregates shall be in the manner approved by the Engineer, and in
addition, every precaution shall be taken to prevent segregation. Segregation shall be
prevented by making no layer higher than 1.5 meters and i f 2 or more layers are required, each
successive layer shall not be allowed to "cone" down over the next lower layer. Aggregates
shall not be stockpiled against the supports of proportioning hoppers and weighing devices.
Page 186 of 244
B.3 Segregated aggregates shall not be used until they have been thoroughly remixed and the
resultant pile is of uniform and acceptable gradation at any point from which a representative
sample is taken. The Contractor shall remix aggregate piles when ordered by the Engineer.
B.4 I f aggregates are to be transported from a central proportioning plant to the mixer in
batch-boxes or dump trucks, such equipment shall be of sufficient capacity to carry the full
volume of materials for each batch of concrete. Partitions separating batches shall be approved
by the Engineer and shall be adequate and effective to prevent spilling from one compartment
to another while in transit or being dumped.
B.5 Cement may be stored in bulk (unpacked) or in bags in securely locked dry places. The
following shall apply:
C.
A l l cement bags shall be marked with the date of manufacture. Additionally, all
bags shall be marked with the date of storage so that they can be taken out for
use in the same order as they were brought in to storage.
Cement bags shall be placed on wooden shelves at least 100 mm above ground
and 150 mm clear of walls.
Unpacked cement shall not be used six months after manufacture and bagged
cement three months after manufacture.
No cement shall be used which has been affected by humidity, regardless of the
date of manufacture.
Cement shall be transported to the mixer in the original sacks. Each batch
shall contain the full amount of cement for the batch. Batches where cement
is placed in contact with the aggregates may be rejected unless mixed within
1.5 hours.
Mixing
C.1 Concrete shall be mixed in quantities required for immediate use. Concrete which has
developed initial set shall not be used. Retempering concrete by adding water or by other
means will not be permitted. Concrete that is not within the specified slump limits at the time of
placement shall not be used and shall be disposed of as directed by the Engineer.
C.1.1 I f washed sand is used while still wet the mixing time starts with the addition of cement
to the aggregate, even i f the water required for the mixing has not been added.
Page 187 of 244
C.2 The concrete may be mixed at the site of the Works, in a central-mix plant, or in truck
mixers. The mixer shall be of an approved type and capacity. Ready-mixed concrete shall be
mixed and delivered in accordance with the requirements of Sub-Section 5.01.7 "Ready-Mixed
Concrete and Central-Mixed Concrete".
C.3 The coarse aggregate shall first be loaded into the mixer followed by the fine aggregate.
Some mix water shall be added to the mix before the cement is loaded into the mixer. Water
shall be continually added throughout the mixing. Additives, i f required and approved by the
Engineer, shall be added according to the manufacturers' instructions. Retarders shall be
added within one minute or 25% of the total mixing time whichever is the smaller.
C.4 The manufacturers' instructions shall be followed in respect of overloading the mixer and
the selections of the rate of revolutions of the mixer.
C.5 To avoid segregation in the fresh concrete, the free drop height on emptying the mixer shall
be not greater than 1.5 meters.
C.6 After mixing, the concrete shall be homogeneous and comply with the provisions of these
specifications. The Engineer may, i f the mix fails to produce concrete of the required strength
vary the mix time.
D.
Central Mixing
D.1
Means provided for storing cement shall be as approved by the Engineer. The
Contractor shall clean all conveyors, bins and hoppers of unapproved cement before
starting to manufacture concrete for the Works.
D.2
Coarse and fine aggregate to be used in concrete shall be kept in stockpiles and bins
apart from aggregate used in other work. Aggregate shall come from a source approved
by the Engineer. The Contractor shall clean all conveyors, bins and hoppers of
unapproved aggregate before starting to manufacture concrete for the Works.
D.3
The Contractor shall be responsible for producing concrete that is homogeneous and
complies with the provisions of these specifications.
D.4
Mixed concrete from the central-mixing plant shall be transported in truck mixers, truck
agitators, non-agitating trucks having special bodies or other approved containers.
Page 188 of 244
D.5 The time elapsing from the time water is added to the mix until the concrete is deposited
in place shall be not greater than:
For concrete produced on site and transported by means other than transit
mixers or agitated trucks.

Thirty minutes when air temperature is 25C or higher.

Forty minutes when air temperature is 18C or below.
Interpolated time between 18C and 25C.
For concrete transported by transit mixer or agitators, the time taken for 300
revolutions of the transit mixer or agitator or 20 minutes, whichever is the
lesser.
The maximum haul time may be reduced at the Engineer's discretion i f the
slump changes or there are signs of the concrete beginning to dry.
D.6 The Contractor when supplying concrete from a central plant shall have sufficient plant
capacity and transporting equipment to ensure continuous delivery at the rate required. The
rate of delivery of concrete during concreting operations shall be such as to provide for the
proper handling, placing and finishing of the concrete. The method of delivery and handling
the concrete shall be such as will facilitate placing with a minimum of rehandling and without
damage to the structure or the concrete. Methods of delivery and handling for each site shall
be approved, by the Engineer. The Engineer may delay or suspend the mixing and placing of
concrete at any site, for which he considers the Contractor's delivery equipment inadequate,
until such time as the Contractor provides additional approved delivery equipment.
5.01.7
READY-MIXED CONCRETE AND CENTRAL MIXED CONCRETE
A.
General
A.1
"Ready-Mixed Concrete" and "Central-Mixed Concrete" shall consist of a mixture of

cement, water and aggregate, without air entraining or water-reducing admixture. When
air-entraining or water-reducing or any other type of admixture is required it shall be at
the Engineer's discretion. The terms ready-mixed or central-mixed concrete shall
include transit-mixed concrete and will be referred to hereinafter as ready-mixed
concrete.
A.2
Ready-mixed concrete may be used in the construction of all Works, when approved
by the Engineer.
Page 189 of 244
A.3 Approval of any ready mixed concrete plant will be granted only when an inspection of the
plant indicates that the equipment, the method of storing and handling the materials, the
production procedures, the transportation and rate of delivery of concrete from the plant to
the point of use, all meet the requirements set forth herein.
A.4 Ready-mixed concrete shall be mixed and delivered to the point of use by means of one
of the following combinations of operations:
Mixed completely in a stationary central mixing plant and the mixed concrete
transported to the point of use in a truck mixer or tank agitator operating at
agitator speed, or when approved by the Engineer, in non-agitating equipment
(known as "central-mixed concrete").
Mixed completely in a truck mixer at the batching plant or while in transit

(known as transit-mixed concrete).
Mixed completely in a truck mixer at the point of use following the addition of
mixing water (known as truck-mixed concrete).
A.5 Permission to use ready-mixed concrete from any previously approved plant may be
rescinded at any time upon failure to comply with the requirements of the Specification.
B.
Materials
B.1 A l l materials used in the manufacture of ready-mixed concrete shall conform to the
requirements of Sub-Section 5.01.2 "Materials".
C.
Equipment
C.1 Equipment shall be efficient, well maintained, and shall be of the type and number as
outlined in the Contractor's Program of Work. Transit mixers and agitator trucks shall comply
with the standards specified in ASTM C94. Non-agitating equipment used for transporting
concrete shall be water tight and be equipped with gates that will permit controlled discharge
of concrete and, when required by the Engineer, be fitted with covers for protection against the
weather.
Page 190 of 244
D.
Supply
D.1 Where transit mixers are used, the constituent materials shall be mixed dry in the mixer and
water added directly before pour and mixed at the speed and number of turns in accordance with
the manufacturers' recommendations.
D.2 Where concrete is mixed at a central plant on or off site, the concrete may be supplied to
the pouring area by agitator trucks or transit mixers which rotate at the speed specified by the
manufacturers. Non-agitating trucks may be used if the central plant is on site.
D.3 Time of haul shall not exceed the maximum stated in sub-item D.5 of subsection 5.01.6 of
the Specification.
E.
Uniformity Tests
E.1 Four samples of fresh concrete shall be taken, two after 15% of discharge from the truck
mixer or agitator truck and two after 85% discharge and within 20 minutes. Slump and
compaction factor tests shall be carried out including any other tests specified or required by
the Engineer.
F.
Samples
Samples for strength test shall be taken as specified in Clause C of subsection 5.01.4
F.1
of the Specification.
F.2
At least six specimens shall be prepared per sample. Three of these shall be tested at 7
days and three at 28 days.
G.
Control of Delivery
G.1 Driver of delivery trucks shall be provided with trip tickets, which shall be signed by a
responsible member of the central plant staff, for submission to the Engineer. The ticket shall
contain the following information.
-Name and address of the Central Plant.
-Serial number of the ticket and date.
-Truck number.
Page 191 of 244
Class and/or strength of concrete.

Cement content of the mix.
Loading time.
Slump
Any other type of relevant information.
G.2 The Engineer may send his representative to the central plant who may:
Check the batching and mixing.

Verify loading time.
Take a copy of the trip ticket.
G.3 The Contractor and/or concrete supplier shall afford the Engineer and/or his
representative, without charge, all facilities necessary to take samples, conduct tests and
inspect the central plant to determine whether the concrete is being furnished in accordance with
the Specification.
G.4 Concrete delivered in outdoor temperatures lower than 5 degrees C, or if the temperature
is expected to drop below 5 degrees C during the curing period, shall arrive at the Works having
a temperature of not less than 10 degrees C nor greater than 32 degrees C.
G.5 In supplying ready-mixed concrete, the plant shall have sufficient batching and transporting
capacity to ensure continuous delivery at the rate required. The rate of delivery of concrete
during concreting operations shall provide for the proper handling, placing and finishing of
concrete. I f the rate of delivery does not provide a continuous concrete operation, the Engineer
may suspend all or parts of further concrete work until such time as the Contractor provides
sufficient additional delivery equipment which, in the opinion of the Engineer, will provide for a
continuous concrete operation.
Page 192 of 244
SECTION 5.02
5.02.1
A.
CONCRETE HANDLING, PLACING AND CURING
GENERAL
Scope
A.1 These operations shall consist of the placing, compacting and curing of concrete for
mass concrete, reinforced concrete and prestressed concrete structures.
5.02.2
MATERIALS
A. General
A.1 A l l concreting materials shall comply with section 5.01 "Concrete and Concrete Mixes
and Testing" of the Specification.
5.02.3
A.
PLACING
General
A.1 Before preparing and placing any concrete, the Contractor shall submit a work plan to the
Engineer for approval. Besides specifying the characteristics of the concrete to be employed,
this plan shall indicate the time at which placing is to start, the way in which it is to be
performed, and the time at which it is to finish. The Engineer's approval shall be sought in
writing by the Contractor at least 24 hours in advance.
A.2 The method and sequence of pour, the equipment to be used, the method of compaction
and curing procedure shall be approved by the Engineer, prior to concrete pour.
A.3 In order to allow proper vibration of the concrete, it shall be placed in horizontal layers
which, at no time shall be thicker than fifty centimeters (after vibration).
Page 193 of 244
A.4 I f the concrete is placed in successive phases, there shall be no separations, or

discontinuity, or difference of appearance between two successive placings. Before each
successive placing is made, the surface of the concrete already in place shall be carefully
roughened, cleaned, washed free of loose particles and dampened.
A.5 Concrete shall be placed in such a way that it shall be left undisturbed once it is placed
(for example, slabs shall be executed by starting to place the concrete at the side opposite the
one from which the concrete is poured, so that there shall be no risk of it being disturbed by
workers or equipment, or of tools falling in).
A.6 When concrete is placed for upright reinforced concrete structures, the placing must be
completed (for small structures) or interrupted (for large structures) before the concrete which
has already been placed has started to harden and might, therefore, be disturbed, i f the
operation of placing were continued. In such cases placing shall be started again only after
twenty four hours have passed. This procedure is intended to avoid the risk of the concrete
which has already been placed coming away from the reinforcing bars, because it is moved or
disturbed during setting and the initial phase of hardening.
A.7 When the concrete is placed, its temperature shall be nearly the same as that of the
reinforcing bars, in order to avoid poor adhesion due to the different coefficients of thermal
expansion of the two materials. The reinforcing bars shall, therefore, be protected from the sun
(or the cold in winter) or cooled by water jets prior to the placing of the concrete, or the pouring
shall start during the cooler hours of the day and be suspended when the temperature rises
above thirty three degrees C.
A.8 The free-drop height of concrete shall be not greater than 1 .5m and the method of placing
shall be such as to suit the conditions and prevent segregation.
A.9 Placing of concrete shall be continuous between predetermined points such as

construction joints, contraction joints and expansion joints.
A.10 Concrete shall be placed so as to avoid segregation of the materials and the
displacement of the reinforcement. Concrete shall not be deposited in large quantities at any
point in the forms and then run or worked along the forms, thus causing segregation of the
materials.
A.11 The concrete shall be deposited in the forms in horizontal layers and the work shall be
carried on rapidly and continuously between predetermined planes agreed upon by the
Contractor and the Engineer.
Page 194 of 244
A.12 The slopes of chutes, where used, shall be not greater than 1 vertical to 2 horizontal or
smaller than 1 vertical to 3 horizontal. The slope of the chute shall be constant along its length.
The capacity of the chute shall be adequate to deliver the required volume of concrete at the
required rate.
A.13 Aluminum pipes shall not be used for delivering concrete. The internal diameter of
delivery pipes, i f used, shall be not less than 8 times the maximum aggregate size. At the point
of delivery, pipes shall be vertical.
A.14 Where bucket and hopper are used for delivery of concrete, the discharge opening shall
be not less than 5 times the maximum aggregate size. The sides of hoppers shall be sloped at
not less than 60 degrees to the horizontal.
A.15 When buggies are used to transport fresh concrete, they shall be run on level tracks
which are securely fixed. The buggies shall be run smoothly without sudden jerks and the
distance shall be not greater than 60 meters.
A.16 All chutes, buckets and hoppers, buggies and pipes shall be kept clean and free from
coatings of hardened concrete by thorough flushing with water after each run. The water used
for flushing shall be discharged clear of the concrete already in place.
A.17 The external surface of all concrete shall be thoroughly worked during the placing by
means of tools of an approved type. The working shall be such as to force all coarse aggregate
from the surface and to bring mortar against the forms to produce a smooth finish, substantially
free from water and air pockets, or honeycomb.
A.18 Concrete shall be deposited in water only with the permission of the Engineer and under
his supervision. The minimum cement content of the class of concrete being deposited in water
shall be increased 10 per cent without further compensation and the slump shall be
approximately 15 centimeters.
A.19 When depositing in water is allowed, the concrete shall be carefully placed in the space in
which it is to remain in a compact mass, by means of a tremie, bottom-dumping bucket or other
approved means that does not permit the concrete to fall through the water without adequate
protection. The concrete shall not be disturbed after being deposited. No concrete shall be
placed in running water, and forms which are not reasonably watertight shall not be used for
holding concrete deposited under water.
Page 195 of 244
A.20 When casing is used in drilled shafts, the casing shall be smooth and properly oiled in
accordance with the manufacturers' manual and shall extend sufficiently above the grade of the
finish shaft to provide excess concrete to be placed for the anticipated slump due to the casing
removal. When the casing is to be pulled, the concrete placed in the casing shall have such a
slump and be of such workability that vibrating of the concrete will not be required.
A.21 No concrete work shall be stopped or temporarily discontinued within 45 centimeters of

the top of any finished surface unless such work is finished with a coping having a thickness
less than 45 centimeters in which case the joint shall be made at the under edge of the coping.
A.22 Concrete in simple slab spans shall be placed in one continuous operation for each span,
unless otherwise directed on the Drawings or directed by the Engineer.
A.23 Concrete in in-situ beam and slab construction shall be placed in one continuous
operation, or when so shown on the Drawings or approved by the Engineer, may be placed in
two separate operations, each of which shall be continuous; first, to the top of the girder stems,
and second, to completion. Where a construction joint is permitted between the girder stem and
the roadway slab, shop drawings including complete details of key or other methods of bonding
will be prepared by the Contractor and submitted to the Engineer for approval. When such a
joint is permitted, deck concrete shall not be placed until the concrete in the girder stem has
hardened sufficiently so as not to be damaged by the concreting operations of the deck pour.
A.24 Concrete in arch rings shall be placed in such a manner as to load the centering
uniformly. Arch rings shall be divided into section such that each section can be cast for the full
cross-section in one continuous operation. The arrangement of the section and the sequence of
placing shall be as approved by the Engineer, and shall be such as to avoid the creation of initial
stress in the reinforcement. The section shall be bonded together by suitable keys or dowels.
When permitted by the Engineer, arch rings may be cast in a single continuous operation.
A.25 The method used for transporting concrete batches, materials, or equipment over
previously placed floor slabs or floor units or over units of structures of continuous design types
shall be subject to approval by the Engineer. Trucks, heavy equipment and heavy
concentrations of materials will be prohibited on floor slabs until the concrete has attained its
design strength.
Page 196 of 244
A.26 Slump Limits

Concrete Type
Compacted by vibration
Compacted by rod
Slump Limit * (mm)

70 - 80
100
*
If chemical additives are used to enhance the concrete super plasticization, then
above limits will not be valid.
B.
Pumping
B.1 The use of pumps will only be allowed after they have been carefully checked and
approved by the Engineer. Only low pressure piston type pumps, which will work with a
water/cement ratio of not more than sixty five hundredths (0.65), will be allowed. Using
superplastizisers to facilitate pumping for low water/cement ratios is allowed subject to
Engineer's review and approval.
B.2 In no case will "bell" or any other type of high pressure pump be allowed, since they
require too high a water/cement ratio and because the concrete segregates as a result of the high
pressure at which it is expelled, even i f filled with a suitable nozzle.
B.3 The mix design shall be checked for its suitability for pumping and the concrete shall be
tested regularly during pumping for its uniformity and that its properties have not been altered
by pumping. I f changes to slump, water-cement ratio, consistency or any other characteristics
occur, corrective measures shall immediately be taken to ensure that concrete delivered by
the pump complies with the requirements of the Specification. Samples shall be taken at
discharge from the mixer/agitator truck, from the pump and at discharge from the pump.
B.4 The internal diameter of delivery pipe of the pump shall be not less than 3 times the
maximum aggregate size. The pipes shall not rest on any part of the formwork; they shall be
supported independently and securely and be readily accessible so that sections can easily
be detached to remove any blockage.
B.5 Before approving the use of a pump, the Engineer shall verify that the Contractor has
sufficiently reinforced the concrete placing team and the equipment for placing and vibrating
the concrete.
B.6 Pumping will not be permitted from the inside of the foundation forms while concrete is
being placed. If necessary to prevent flooding, a seal of concrete shall be placed through a
closed chute or tremie and allowed to set.
Page 197 of 244
5.02.4
A.
COMPACTING
General
A.1 The vibration of the concrete can be considered completed when a thin layer of cement
grout appears on the surface and when no more air bubbles, indicating the presence of voids
within the concrete, appear on the surface. At the same time, there must not be too much
vibration or this will produce segregation.
A.2 Vibration may be of three types:
Internal
External
Mixed.
A.3 Vibration of the concrete and operation shall be undertaken in such a way that the proper
and complete vibrations, but avoiding over vibration, is achieved. The guidelines as given in
Standard Practice for Consolidation of Concrete (ACI 309) of Part 2 Concrete Practices and
Inspection, Pavements, of ACI Manual of Concrete Practice (latest edition) issued by American
Concrete Institute (ACI) shall be followed, i f not otherwise directed by the Engineer.
A.4 Internal vibration shall be executed in all sections which are sufficiently large to permit
the insertion and manipulation of immersion vibrators, previously approved by the Engineer,
in accordance with the following recommended practices:
The concrete shall be placed in horizontal layers not thicker than fifty
centimeters.
The vibrator shall be inserted vertically into the concrete to its full length such
as to reach the bottom of the freshly placed layer.
The distance between two successive insertions shall not exceed five times the
diameter of the vibrator itself.
The vibrator shall not rest on or against either the formwork or the main
reinforcing bars.
Page 198 of 244
A.5 External form vibrators shall be used for external vibration when it is impossible to use
internal vibrators (heavily reinforced thin walls, pipes or other precast, small cross-section
element, etc). The water/cement ratio shall be low (0.4 to 0.45) in order to avoid the
segregation of the concrete and, at the same time, to provide rapid hardening and, in
consequence, the early removal of the formwork and the finished element.
A.6 Mixed vibration shall be used in the construction of reinforced or prestressed concrete
beams. External wall vibrators shall also be used. These shall be mounted on the outside of
the formwork after this has been suitably reinforced with ribs of U-bars. The mounting places
of the wall vibrators shall be welded to these reinforcements. They must be symmetrically
positioned on each side of the beam and produce a rotary movement within the concrete
during vibration from the bottom towards the top and from the part placed first towards the
part placed last.
A.7 Only the vibrators in the zone of the formwork with newly placed concrete will be used.
As the casting of the beam advances, the vibrators shall be dismounted and remounted as
necessary.
A.8 It is absolutely essential, that elastic supports be provided both under the bottom of the
beam and in correspondence with the braces or tie rods of the formwork walls.
A.9 The network of reinforcing bars and tensioning cables should not move as a result of the
vibration. To prevent this from happening, either special ties (passing through the formwork
walls), or spacers shall be used. It is better, i f these last are made of concrete and are of a
size and shape that will ensure that the reinforcing and tensioning cables do not move.
A.10 Before starting this kind of work the Contractor shall submit to the Engineer for his
approval a work plan giving the following details:
The position of the external wall vibrators.
Their power, frequency and amplitude.
The number of such wall vibrators that will be utilized at the same time.
The number and type (frequency and size) of the internal vibrators to be used
for the consolidation of the concrete.
The position of the spacers, or the number of ties, to be used to ensure that the
reinforcing bar network and the tensioning cables (if any) do not move during
vibration.
Page 199 of 244
The way in which the concrete is to be placed and the length of time this
operation is expected to take.
A.11 When required, vibrating shall be supplemented by hand spading with suitable tools to
assure proper and adequate compaction.
B.
Poker Vibrators
B.1 The type and size of poker vibrators shall suit the pour size, density of reinforcement and
member dimensions. Unless otherwise authorized by the Engineer, the vibrator shall be
selected from Table 5.2.1 below:
Table 5.2.1: Selection of Poker Diameter for Size of Pour

Size of Pour
(m3/h)
24
5 10
10 20
20 30
30 - 40
Poker Diameter
(mm)
20 45
50 65
60 75
80 115
140 - 170
Speed
(Vibrations/min)
9000
9000
7000
7000
6000
B.2 Poker vibrators shall be inserted into the concrete vertically at regular intervals which shall
be no greater than 0.5m. They shall be inserted quickly and withdrawn slowly. The withdrawal
rate shall be not more than 75mm/sec. A cycle of insertion and withdrawal shall be between 10
and 30 seconds.
B.3 Poker vibrators shall be kept clear of formwork and concrete previously cast.
B.4 Vibrators shall be so manipulated as to work the concrete thoroughly around the
reinforcement and embedded fixtures and into corners and angles of the forms. Vibrators shall
not be used as a means to cause concrete to flow or run into position in lieu of placing.
B.5 Compaction shall be sufficient to achieve maximum density without segregation in the
fresh concrete.
B.6 Standby pokers of the same type shall be provided at all times. The standby shall be not
less than half the number of pokers used for compacting the pour.
Page 200 of 244
B.7 Vibrating shall only be carried out by professional technicians having experience in this
type of work.
C.
Other Vibrators
C.1 Form vibrators, vibrating tables and surface vibrators where required shall first be
approved by the Engineer and they shall conform to the requirements of ACI-309.
C.2 Where form vibrators are used, the form shall be adequately designed so that the
vibration will not cause joints to leak and dimensions and geometry to alter.
C.3 Unless otherwise permitted by the Engineer, the use of form vibrators shall be limited to
members whose thickness does not exceed 150 mm.
5.02.5
CURING
A.
Materials
A.1
Hessian or burlap shall be clean and free from harmful materials. Their unit weight
shall be not less than 230g/sq.m.
A.2
The following impermeable membranes may, with the Engineer's approval, be used:
Clear polyethylene film with no holes, tears, scratches and contamination of

any type.
Hessian coated with white polyethylene of density not less than 300g/sq.m.
The coating may be on one side only but shall be not less than 0.1mm thick and
shall not peel during and after use.
A.3
Curing compounds shall conform to AASHTO M148 (ASTM-C309).
A.4
Sand shall be natural sand, free of silt and clay and contaminants which can be
harmful to the concrete.
A.5 Water shall satisfy the requirements of Section 5.01 of the Specification.
Page 201 of 244
B.
Method of Curing
B.1 The method of curing to be used shall be approved by the Engineer. It shall not cause any
undesirable blemishes such as surface discoloration and surface roughness. Curing
compounds shall not be used on construction joints and surfaces that are to receive
waterproofing, paint or membranes.
B.2 Curing by ponding may be used for horizontal surfaces such as bases, pile caps and
slabs. Large horizontal surface areas shall be separated into ponds not exceeding 5 sq.m. The
ponds shall first be filled between 12 to 24 hours after pour, unless otherwise authorised by the
Engineer, and shall be replenished from time to time so as to maintain the ponding for the
specified curing period. The concrete temperature and the temperature of the curing water
shall be not greater than 10C.
B.3 Unless otherwise approved by Engineer, curing by spraying shall commence between 12
and 24 hours after the concrete pour. The concrete shall be maintained damp at all times during
the curing period by periodic light sprays.
B.4 Members to be cured by wet hessian or wet burlap shall be completely wrapped with the
material which shall be kept moist at all times during the curing period by regular spraying.
Unless otherwise approved by the Engineer, the overlap under normal conditions shall be not
less than one-quarter the width of the hessian or burlap and not less than one-half the width in
windy and/or rainy conditions. Before members are wrapped for curing, they shall first be
evenly moistened. Unless approved by the Engineer, burlaps shall be supplied only in rolls and
burlap bags shall not be used. Secondhand hessian and burlap, i f approved for use, shall be
clean without holes and contamination of any kind that can affect the concrete.
B.5 Waterproof sheets used for curing shall, unless directed by the Engineer, be spread
immediately after the pour. The sheet shall, unless approved by the Engineer, be clear of the
concrete surface but be arranged in such a manner as to prevent the movement by air over the
concrete surface. Waterproof sheets shall not be used when the air temperature is 25C or
higher.
Page 202 of 244
B.6 Curing compounds shall be applied in two applications at a coverage rate of not less than 1
ltr/ 7.4 sq.m. per application or as recommended by manufacturer and the following criteria
shall apply:
The first coat shall be applied immediately after the removal of the forms and the
acceptance of the concrete finish and after the disappearance of free water on
unformed surfaces. I f the concrete is dry or becomes dry, it shall be thoroughly
wet with water and curing compound applied just as the surface film of water
disappears. The second application shall be applied after the first application has
set. During curing operations, any unsprayed surfaces shall be kept wet with
water. The curing membrane will not be allowed on areas against which further
concrete is to be placed.
Hand operated spray equipment shall be capable of supplying a constant and

uniform pressure to provide uniform and adequate distribution of the curing
membrane at the rates required. The curing compound shall be thoroughly
mixed at all times during usage.
The curing membrane shall be protected against damage for the entire specified
curing period. Any coating damaged or otherwise disturbed shall be given an
additional coating. Should the curing membrane be continuously subjected to
injury, the Engineer may require wet burlap, polyethylene sheeting, or other
approved material to be applied at once.
No traffic of any kind will be permitted on the curing membrane until the curing
period is completed, unless the Engineer permits the placement of concrete in
adjacent sections, in which case the damaged areas shall be immediately
repaired as directed.
B.7 Steam curing shall be in accordance with ACI 516 and ACI 517.
C.
Curing Time
C.1
The minimum curing time shall be the number of days given in Table 5.2.2 unless the
average surface temperature of the concrete during the required number of days falls
below 10C, in which case the period of curing shall be extended until the maturity of the
concrete reaches the value given in the Table.
C.2
The minimum curing time given in Table 5.2.2 above shall be compared with the time
required for cylinders (cubes), cured under identical conditions to those which the
concrete is subjected, to attain 70% of the characteristic strength. The greater shall be
taken as the minimum curing time.
Page 203 of 244
D.
Limitation of Temperature Differentials
D.1 The Contractor shall limit the development of temperature differentials in concrete after
placing by any means appropriate to the circumstances including the following:
Limiting concrete temperatures at placing lower than that set out in clause 5.02.6
Use of low-heat cement, subject to the agreement of the Engineer.
Insulation of exposed concrete surfaces by insulating blankets. Such blankets

shall have a thermal conductance C value less than 1.0 W/m2oC.
Leaving formwork in place during the curing period. Steel forms shall be suitably
insulated on the outside.
Preventing rapid dissipation of heat from surfaces by shielding from wind.
Shielding concrete surfaces from clear night skies, together with the use of
heaters where appropriate.
D.2 The Contractor shall ensure that the temperature differentials in a pour do not exceed 20
oC
by appropriate design of mix and use of insulation.
D.3 The Contractor shall take all necessary steps to limit temperature rise such that the
temperature of the concrete shall not, at any stage, exceed 70 oC.
D.4 Thermocouples shall be used in large concrete pours where the possibility of significant
thermal gain is, in the opinion of the Engineer considered to be likely. The disposition of the
thermocouples shall be agreed with the Engineer.
5.02.6
A.
HOT WEATHER CONCRETING
Definitions
A.1 For the purpose of this sub-section of the Specification, Hot Weather is as defined in ACI
305R Chapter 1.
Page 204 of 244
B.
General
B.1 The production and delivery of concrete, the placing and curing and the testing and
inspection of concrete shall, in addition to the requirements of the Specification, accord with the
recommendations of ACI 305R.
Table 5.2.2: Normal Curing Periods
Minimum periods of protection for different types of cement
Conditions Under Number of Days (where the
Equivalent Maturity (degree hours)
Which Concrete is Average Surface Temperature
Calculated as the age of the
maturing
of the Concrete Exceeds 10C
Concrete in Hours Multiplied by
During the Whole Period)
the Number of Degrees Celsius by
which the Average Surface
Temperature of the Concrete
Exceeds Minus 10C
1. Hot weather or
drying winds
2. Conditions not
covered by (1)
NOTE.
Other *
or
RHPC
4
Other *
SRPC
SRPC
OPC
3500
2000
OPC
or
RHPC
1500
2000
1500
1000
Other* includes all permitted cements except OPC, RHPC and SRPC.
KEY. OPC = Ordinary Portland cement.

RHPC = Rapid-hardening Portland cement. SRPC = Sulfate resisting Portland cement.
B.2
No concreting shall commence when the air temperature is 33C and rising. The
Contractor shall schedule his operations to place and finish concreting during the hours
that the air temperature will be below 32C. This should preferably be in the latter part
of the day after the maximum temperature has been reached, and subject to the
approval of the Engineer.
B.3
I f air temperature rises above 33C in shadow during concrete mixing or pouring,
some or all of the following precautions should be applied and according to the
Engineer recommendations:
Covering the storing areas of the gravel. The big size gravel may be cooled using
water spays.
I f cement is stored in silos, it should be painted by reflective material. I f stored in

bags, it should be stored in aired and covered areas.
Page 205 of 244
Cooling the water before adding it to the concrete mix.
Painting the mixers using reflective paint.
Spray water to the forms before pouring the concrete, in case of precast concrete, it
should be poured in shaded areas.
C.
Control of Temperature
C.1 Stockpile of aggregates shall be protected from direct sunlight by suitable covering. I f
directed by the Engineer, they shall be regularly sprayed with clean water.
C.2 Water shall be stored in tanks away from sunlight and insulated by suitable means so as
not to be affected by high air temperature. Water tanks liable to be exposed to sunlight shall be
covered with suitable reflective paint such as white gloss paint.
C.3 I f directed by the Engineer or as a condition for concreting in adverse weather conditions,
sufficient ice shall be added to the mix water to ensure that the temperature of the fresh
concrete shall not exceed 32C.
C.4 The temperature of the concrete at the time of placing shall not be permitted to exceed 33
degrees C. Concrete materials shall be stored in a cool shaded position away from the direct
rays of the sun. Aggregates shall be cooled i f necessary prior to mixing and water shall be
cooled by means of a proprietary water chilling plant.
C.5 Additives as recommended in ACI 305R shall be used to improve workability and/or delay
initial setting.
C.6 Retarding admixtures to facilitate placing and finishing of the concrete shall conform to
AASHTO M194, Type D and used only i f approved by the Engineer.
D.
Mixing and Placing
D.1 The time available for handling and placing of concrete during periods of high temperature
may be considerably reduced and the Contractor must take appropriate precautions. Concrete
should be protected during transportation by use of damp hessian or similar means. No
additional water may be added at the time of mixing without the approval of the Engineer, as
this may lead to additional shrinkage of the concrete. On no account shall water be added
during transportation or placing of the concrete.
Page 206 of 244
D.2 Aggregates and cement shall be thoroughly pre-mixed before adding water.
D.3 Transit mixers, i f used, shall be coated with a reflective paint and while waiting to be
discharged, shall be kept out of direct sunlight.
E.
Concrete Protection
E.1
Before the concrete can be de-shuttered, the formwork and shutters shall be cooled by
spraying with water.
E.2
The concrete and the falsework shall be protected against sunlight, i f directed by the
Engineer.
E.3
I f curing is by hessian, it shall be coated with a white polyethylene backing.
E.4
Members exposed to strong winds shall be provided with windbreakers. The

windbreakers shall, i f directed by the Engineer, be kept moist by regular spraying.
5.02.7
A.
COLD WEATHER CONCRETING
Definitions
A.1 For the purpose of this sub-section of the Specification, Cold Weather is as defined in ACI
306.1, Section 1, Part 1.2.
B.
General
B.1
ACI 306.1-90 "Standard Specification for Cold Weather Concreting" applies.
B.2
The production and delivery of concrete, the placing and curing and the protection
requirement shall be in accordance with the recommendations of ACI 306R-88 "Cold
Weather Concreting".
B.3
No concreting shall commence when the air temperature is 6C and falling, unless
authorised by the Engineer.
Page 207 of 244
C.
Mixing and Placing
C.1 Aggregates and water, forms, reinforcement etc. shall be free of snow, frost or ice.
C.2 Aggregates and water may be pre-heated in which case the aggregates and water shall, i f
directed by the Engineer, be mixed prior to introducing cement in the mix. The aggregates shall
not be pre-heated to a temperature in excess of 100C and the water in excess of 60C with the
additional requirement that the temperature of the water and aggregate mix, before the
introduction of cement, shall not exceed 38C.
C.3 Water may be pre-heated by boiling and added to aggregates not pre-heated provided the
temperature of the water and aggregate mix, before the introduction of cement, does not
exceed 38C.
C.4 The temperature of concrete at the time of discharge shall be between 10 and 27 C and
for three days after the pour not less than 5C.
D.
Protection
D.1
When directed by the Engineer, members shall be protected against cold winds by
suitable windbreaks.
D.2
Adequate insulation by way of insulation boards, planks, sheets etc. shall be provided to
maintain the required minimum concrete temperature during the curing period.
D.3
Protection measures shall be maintained for a period at which the concrete attains a
strength of at least 65% of the characteristic strength.
5.02.8
NIGHT CONCRETING
A.
Night concreting shall not be carried out unless prior approval of the Engineer, in writing,
is obtained.
B.
Details of the artificial lighting system shall be submitted in advance of the proposed
concreting for the Engineer's approval. In all cases, at least one stand-by generator shall
be available at all times of the concreting operation.
Page 208 of 244
SECTION 5.03
5.03.1
A.
STEEL REINFORCEMENT AND FIXING
GENERAL
Scope
A.1 These works shall consist of the supply and fixing of the unstressed steel bars, wires,
mesh and mats for the reinforcement of concrete in accordance with the Drawings and
Specification.
5.03.2
A.
MATERIALS
Reinforcing Bars
A.1 High tensile steel reinforcement bars shall conform to AASHTO M31 (ASTM A615)
Grade 60 (with carbon content not exceeding 0.3%) or to BS 4449 with carbon percentage
that dose not exceed 0.3%.
A.2 M i l d steel reinforcing bars shall conform to AASHTO M31 (ASTM A615) Grade 40 or
BS 4461.
A.3
High tensile, low-alloy steel deformed bar shall conform to ASTM A706.
B.
Welded Fabric Reinforcement
B.1
Welded steel wire fabric shall conform to AASHTO M55 or BS 4482.
B.2
Cold drawn steel wire shall conform to the requirements of AASHTO M32 or in the
case of hard drawn steel wire to BS 4482.
C.
Fabricated Mat Reinforcement
C.1 Fabricated mat reinforcement shall conform to AASHTO M54 (ASTM A184).
Page 209 of 244
D.
Certification and Identification
D.1 Three copies of a mill test report shall be supplied to the Engineer for each lot of billet
steel reinforcement supplied for use on the project. The mill test report shall be sworn to by a
person having legal authority to bind the manufacturer and shall show the following information:
The process or processes used in the manufacture of the steel from which the
bars were rolled.
Identification of each heat of open-hearth, basic oxygen, or electric furnace

and/or each lot of acid bessemer steel from which the bars were rolled.
D.2 The bars in each lot shall be legibly tagged by the manufacturer and/or fabricator before
being offered for inspection. The tag shall show the manufacturer's test number and lot number
or other designation that will identify the material with the certificate issued for that lot of steel.
D.3
The fabricator shall furnish 3 copies of a certificate which shows the heat number or
numbers from which each size of bar in the shipment was fabricated.
E.
Inspection and Sampling
E.1 The sampling and testing of reinforcement bars may be made at the source of supply
when the quantity to be shipped or other conditions warrant such procedure. Bars not
inspected and sampled before shipment will be inspected and sampled after arrival at the site.
5.03.3
A.
CONSTRUCTION
General
A.1 Reinforcing steel shall be protected at all times from damage. All reinforcement shall be
free from detrimental dirt, loose m ill scale, scaly rust, paint, grease, oil or other foreign
substance. There shall be no evidence of pitting or visual flaw in the test specimen or on the
sheared ends of the bars.
A.2
Rust shall be removed by wire brushing or, i f directed by the _ Engineer, by sand
blasting. Light rust without visible sign of peeling need not be removed.
Page 210 of 244
B.
Storage
B.1 Reinforcement shall be stored clear of the ground on platforms, skids or other supports
and be protected against contamination by dirt, grease, oil etc. at all times. I f directed by the
Engineer, the Contractor shall provide cover to the reinforcement.
B.2
Reinforcement of different grades and different diameters shall be stored separately
and marked to facilitate inspection and checking.
C.
Cutting and Bending
C.1
Cutting and bending of reinforcement shall be based on an approved bar bending

schedule.
C.2
Reinforcement shall be cut in specialist cutting machines or cold cut by hand only.
Cutting with oxyacetylene torch is strictly forbidden.
C.3
Bars shall be bent to the following bend diameters:

Bar Diameter, d.
Up to 25 mm
25 to 35 mm
35 to 60 mm
Mild Steel
4d
6d
1 0d
High Yield
6d
8d
1 0d
C.4
All reinforcement shall be bent at the temperature range of 5 degrees C and 100
degrees C. Bending by heating, i f approved by the Engineer, shall be carried out in
such a manner as not to impair the physical and mechanical characteristics of the bar.
C.5
The straight bar length for a hook of 180 shall be not less than 4 times the bar
diameter or 65 mm whichever is the larger.
C.6
The straight bar length of a hook of 90 shall be not less than 12 times the bar
diameter.
C.7
The straight bar length after hook in stirrups shall be 6 times the bar diameter or
60mm whichever is the larger.
Page 211 of 244
C.8 Cold worked bars and hot rolled high yield bars shall not be re-bent or straightened once
having been bent. Where it is necessary to bend mild steel bars projecting from the concrete,
the bend diameter shall comply with the requirements of item C.3 above.
C.9 I f bending of the bar in accordance with this Specification causes the bar to crack, the bar
shall be rejected, irrespective of any prior approval that may have been given, and removed
from the Site.
C.10 Bars shall be cut and bent to the following tolerances:

Bar length (mm)
Upto 1000
1000 - 2000
above 2000
Tolerance (mm)
5
+5, -10
+5, -25
C.11 No adjustment to bar length after bending will be permitted.
D.
Fixing
D.1
Reinforcement shall be placed and maintained in the position shown on the Drawings.
Unless agreed otherwise by the Engineer, all bar intersections shall be securely tied
together with the ends of the wire turned into the main body of the concrete. 1.2 mm
diameter stainless steel wire shall be used for in situ members having exposed soffits.
1.6 mm diameter soft annealed iron wire shall be used elsewhere.
D.2
The correct cover to reinforcement on all exposed faces of concrete shall be

maintained by using approved proprietary spacers. Where instructed by the Engineer
the adequacy of such spacers shall be demonstrated by site trials.
D.3
Concrete cover blocks, where permitted by the Engineer, shall be of approved

dimensions and designed so that they will not overturn when the concrete is placed.
They shall be made with 10 mm maximum size aggregate and the mix proportion shall
be such as to produce the same strength as the adjacent concrete. Tying wire shall be
cast in the blocks for subsequent tying to the reinforcement.
D.4
Wherever it is necessary for the Contractor to splice reinforcement at positions other

than those shown on the Drawings, the approval of the Engineer shall be sought and
obtained before the reinforcement is placed. Splices shall be staggered where possible
and shall be designed to develop the strength of the bar without exceeding the
allowable unit bond stress.
Page 212 of 244
D.5 Proprietary mechanical splicing devices shall be used only with prior approval of the
Engineer in writing. They shall be able to withstand without any slippage a force of not less than
1.25 times the characteristic yield stress of the smaller bar spliced multiplied by the
cross-sectional area of the smaller bar.
D.6 Mesh reinforcement shall comply with the sizes of sheets and diameter and spacing of
bars as shown on the Drawings. The sheets of mesh shall be lapped as shown on the
Drawings. The method of placing the mesh and securing it in position shall be approved by the
Engineer.
D.7 Welding of reinforcement bars, i f allowed by the Engineer, shall be carried out in
accordance with the latest publications of the American Welding Society publication
"Structural Welding Code for Reinforcing Steel", and shall be able to withstand a force of not
less than 1.25 times the characteristic yield stress of the smaller of the welded bars multiplied
by the cross-sectional area of the smaller bar.
D.8
Cold worked steel bars shall not be welded.
D.9 Where galvanizing or epoxy coating is required to be applied to the reinforcement,

specific instructions will be given by the Engineer taking into account the particular design
conditions which apply.
D.10 Dowel Bars: Coat half of each bar with approved proprietary debonding compound or fit
with approved plastics sleeve. Fix bars securely at required level, perfectly level, at right
angles to and centred on the joint. Fit compressible caps to debonded ends of bars.
Page 213 of 244
SECTION 5.04 FORMS, FORMWORK AND FALSE WORK
5.04.1
GENERAL
A.
Scope
A.1
These works shall consist of the design, supply and use of forms, formwork and
falsework for the construction of concrete water tanks.
5.04.2
A.
DEFINITIONS
Forms and Formwork
A.1 The item of the temporary works used to give the required shape and support to poured
concrete. It consists primarily of sheeting material, such as wood, plywood, metal sheet or
plastic sheet, in direct contact with the concrete and joists or stringers that directly support the
sheeting.
B.
Falsework
B.1
Any temporary structure used to support a permanent structure while it is not

self-supporting.
C.
Scaffold
C.1
A temporarily provided structure that provides access, or on or from which persons

work, or that is used to support material, plant or equipment.
D.
Tower
D.1
A composite structure, usually tall, used principally to carry vertical loading.
Page 214 of 244
5.04.3
MATERIALS
A.
Wood
A.1
Soft wood free of faults such as splitting, warping, bending, knots etc.
A.2 When imported softwood or hardwood is used for falsework, the minimum timber grade,
determined in accordance with BS 4978 shall be SC3.
A.3
Hardwood used as load-bearing wedges and packing shall be limited to those listed in
Table 5.4.1.
Table 5.4.1: Permitted Hardwoods for Load-Bearing Wedges and Packing

Standard name
Ash
Beech
Greenheart
Jarrah
Karri
Keruing
Oak
Botanical species
Fraxinus excelsior
Fagus sylvatica
Ocotea rodiaei
Eucalyptus marginata
Eucalyptus diversicolor
Dipterocarpus spp
Quercus spp
B.
Plywood
B.1
When plastic coated plywood is used, the Phenol resin on melamine shall be not less
than 20% of the total coating weight.
C.
Steel
C.1
Except as otherwise specified or shown on the Drawings, the grades and qualities shall
conform to the following applicable standards of AASHTO and ASTM:
Structural carbon steel shall conform to AASHTO M183M (ASTM A36M).
Structural steel for welding shall conform to AASHTO M183M (ASTM A36M).
High-strength low-alloy structural steel shall conform to AASHTO M222

(ASTM A588).
Page 215 of 244
D.
Aluminum
D.1 Aluminum shall conform to the requirements of ASTM B22 1.
E.
Other Materials
E.1 Other materials, with the approval of the Engineer, may be used for falsework. These
include, but not limited to, fibre-glass reinforced plastic, polystyrene, polyethylene, PVC,
rubber, concrete, brick etc.
5.04.4
A.
DESIGN
General
A.1 Forms and formwork and falsework shall be designed by the Contractor and submitted to
the Engineer with full design calculations, detailed drawings, material specification and test
certificates for approval. Falsework shall be capable of temperature changes without causing
damage to the concrete.
A.2
Falsework design shall be in accordance with BS 5972 "Code of Practice for

Falsework".
A.3 I f the Contractor intends to use ready made proprietary type of falsework, he shall submit
all relevant data, including independent test certificates, which will enable the Engineer to
determine whether or not the Contractor's proposed falsework are acceptable.
A.4 Notwithstanding any approval of falsework design by the Engineer, the Contractor will
not be relieved of his responsibility for the adequacy and correctness of the design,
manufacture and assembly of the falsework.
B.
B.1
Fabrication of Steel
Except as otherwise specified or as shown on the Drawings, all details concerning

fabrication shall conform to "AASHTO Standard Specifications for Highway Bridges".
Page 216 of 244
B.2 Fabrication of all metal for steel structures and the erection of steel structures shall be in
accordance with shop and erection drawings furnished by the Contractor and approved by the
Engineer before any fabrication is commenced.
B.3
Fabrication tolerances shall comply with tolerances stated on the Drawings.
B.4 Compliance with tolerances shall be achieved both during and after fabrication before any
surface preparation. Remedial measures to remove imperfections must be approved by the
Engineer.
B.5 Approval of Contractor's drawings shall in no way release the Contractor from his
responsibilities for work under the Contract. Three copies of each shop and erection drawing
prepared by the Contractor shall be submitted to the Engineer for his approval and further
copies of corrected or amended drawings shall be submitted i f required before final approval is
given. These drawings shall conform to the general drawings, stress sheets, design
specifications and fabrication tolerances. Shop drawings shall include a full and clear set of
marking drawings.
B.6
Weld to be visually inspected by the Engineer. I f testing is deemed to be required, the
Contractor shall bear all costs.
C.
Forms and Formwork
C.1
Formwork shall be sufficiently rigid so as to prevent any grout loss during concreting
and shall not distort due to environmental effects and concreting operations so that
member dimensions, shape, required finish and texture are within the tolerances
specified.
C.2
Forms and formwork shall be designed to be readily assembled, stripped and

transported without distortion to panels and members of the formwork.
C.3
The method of stripping forms without damaging the concrete or special textured
surface finish, i f incorporated, shall be fully considered in the design.
C.4
I f form liners are to be used to achieve the specified surface finish, samples of a size
as directed by the Engineer shall be submitted for approval.
Page 217 of 244
C.5 Form lining shall not bulge, warp or blister, nor shall it stain the concrete. Form lining
shall be used in the largest practicable panels to minimize joints. Small panels of the lining
material shall not be permitted. The joints in the lining shall be tight and smoothly cut.
Adjacent panels of form lining shall be so placed that the grain of the wood will be in the
same direction (all horizontal or all vertical). Thin metal form lining will not be permitted.
Undressed lumber of uniform thickness may be used as backing for form lining. Wooden
plyform, of adequate thickness which is properly supported to meet the above requirements,
may be used in lieu of the lined forms specified herein.
C.6 Metal forms, i f used, shall be of such thickness that the forms will remain true to shape.
All bolt and rivet heads shall be countersunk. Clamps, pins or other connecting devices shall
be designed to hold the forms rigidly together and to allow removal without injury to the
concrete. Metal forms which do not present a smooth surface or do not line up properly shall not
be used. Care shall be exercised to keep metal forms free from rust, grease or other foreign
matter. Under such circumstances the continued use of the metal forms will depend upon
satisfactory performance and their discontinuance may be required at any time by the Engineer.
Steel panels or panels with metal frames and wood or combination shall be so designed as to
leave no lipping or ridges in the finished concrete.
C.7 The width and thickness of the lumber, the size and spacing of studs and wales shall be
determined with due regard to the nature of the Work and shall be sufficient to ensure rigidity
of the forms and to prevent distortion due to the pressure of the concrete.
C.8 Where the bottom of the forms is inaccessible, the lower form boards shall be left loose
or other provisions made so that extraneous material may be removed from the forms
immediately before placing the concrete.
C.9 Unless otherwise directed by the Engineer, the exterior side of forms shall be painted
with an approved, good quality high gloss white oil base enamel paint prior to placing
concrete. Paint shall be applied to metal forms only. When complete coverage is not obtained
with one coat, the Engineer will order additional coats as he deems necessary to obtain
complete coverage. Forms shall be repainted when ordered by the Engineer.
C.10 Unless provided otherwise on the Drawings or directed by the Engineer, all exposed
edges shall be bevelled by using dressed, millcut, triangular molding, having 20 millimeter
sides.
C.11 Forms shall be maintained after erection to eliminate warping and shrinkage.
Page 218 of 244
D.
Falsework
D.1 Falsework and centering shall be designed to provide the necessary rigidity to support all
loads placed upon it without settlement or deformation in excess of the permissible tolerance
for the structure given in the Specifications. Falsework columns shall be supported on
hardwood, concrete pads or metal bases to support all falsework that cannot be founded on rock,
shale or thick deposits of other compact material in their natural beds. Falsework shall not be
supported on any part of the structure, except the footings, without the written permission of the
Engineer. The number and spacing of falsework columns, the adequacy of sills, caps and
stringers and the amount of bracing in the falsework framing shall be subject to approval of the
Engineer.
D.2 A l l timber shall be of sound wood, in good condition and free from defects that might
impair its strength. I f the vertical members are of insufficient length to cap at the desired
elevation for the horizontal members, they shall preferably be capped and frames constructed
to the proper elevation. Ends of the vertical members shall be cut square for full bearing to
preclude the use of wedges. I f vertical splices are necessary, the abutting members shall be of
the same approximate size, the ends shall be cut square for full bearing, and the splices shall be
scabbed in a manner approved by the Engineer.
D.3 The Contractor shall compute falsework settlement and deflection for bridges so that when
the final settlement is complete, the structure will conform to the required camber, section and
grade as shown on the Drawings.
D.4 The Contractor shall provide means for accurately measuring settlement in falsework
during placement of concrete, and shall provide a competent observer to observe and correct the
settlement.
D.5 Screw jacks, i f used, shall be designed for use with a slenderness ratio not exceeding 60.
The slenderness ratio shall be taken as the ratio of the clear distance between effective bracing
in both horizontal directions to the diameter of the screw jack measured at the root of the
thread. The manufacturers' certificate showing the ultimate load capacity of the screw jack shall
be submitted with the design calculations for the falsework. I f directed by the Engineer, the
Contractor shall furnish a test certificate carried out at an approved independent laboratory.
D.6 Props and towers supporting forms or partially completed structures shall be
interconnected in plan orthogonally at levels to be determined in the design. They shall also be
interconnected by diagonal bracings in orthogonal vertical planes.
Page 219 of 244
5.04.5
A.
FINISHES
T yp es o f Finishes
A.1 Class F1: This class of surface finish denotes a special finish required from aesthetic
considerations. In additions to the requirements of Class F2 finish, the following additional

requirements shall apply.
It is of major importance that the special finishes required on F1 surfaces are

uniformly and consistently maintained with no variation in the colour or
consistency of the concrete within the same structure. In order to achieve this,
the Contractor shall make trial panels of the formed finishes specified. These
panels shall be not less than 1.5 m high and 1 m wide and 250 mm thick and
shall be cast in the manner and with materials as proposed for the actual Work.
These panels are for the approval of the liners and are preliminary to the test
samples carried out on site.
The Contractor shall provide at his own expense as many panels as required by
the Engineer until a satisfactory trial panel has been accepted by the Engineer.
The Contractor shall submit to the Engineer and obtain his approval for all details
before commencement of trials. These samples when approved, will form the
standard against which the corresponding finishes on the actual work will be
judged. In all cases of approvals, the decision of the Engineer alone will be final.
Where forms and form-liners to be used for the special finishes specified are
manufactured outside the Country, the forms and form-liners shall not be
permitted on Site until the Engineer has inspected the forms and form-liners and
is satisfied that they are suitable for the Works. Samples and trial panels carried
out at the place of manufacture to demonstrate to the Engineer that the forms
and formliners and the methods of assembling and de-shuttering them are
acceptable shall not be paid for and will not relieve the Contractor of the
requirement for carrying out trial panels on site as described above.
I f the required finish in the opinion of the Engineer, has not been obtained in the
Works, the Contractor shall promptly carry out at his own expense all measures
required by the Engineer to obtain the specified finish. These may include grit
blasting followed by the application of polyester or epoxy paint. Where such
remedial action is ordered by the Engineer, the entire exposed surface shall be
so treated irrespective of whether or not the defective areas are localised or
extensive.
A.2 Class F2: Formwork shall be lined with a material approved by the Engineer to provide a
smooth finish of uniform appearance. This material shall leave no stain on the concrete and
shall be so joined and fixed to its backing so that it imparts no blemishes. It shall be of the same
type and obtained from only one source for any one structure.
Page 220 of 244
The Contractor shall make good any imperfections in the finish as directed by the Engineer.
Internal ties and embedded metal parts will not be permitted unless otherwise approved by the
Engineer.
A.3 Class F3: Irregularities in the finish shall be no greater than those resulting from the use
of wrought thick square edged boards arranged in a uniform pattern. The finish is intended to
be left as struck. Imperfections such as fins and surface discoloration shall, however, be
made good as and when required by the Engineer.
A.4
Class F4: No special requirements.
A.5 Permanently exposed concrete surfaces to classes F1, F2 and F3 finish shall be
protected from rust marks and stains of all kinds. Internal ties and embedded metal parts will
not be permitted.
A.6 The Contractor shall submit to the Engineer all details of formwork, liners, joints, and
materials including fabrication drawings and stating procedures involved in the use of formwork
for approval before commencement of any work on fabrication. No formwork shall be brought
to site without the prior approval of the Engineer. Adequate time shall be allowed by the
Contractor in his programme for these approvals after consultation with the Engineer.
B.
Unformed Finishes
B.1
Class U1: The concrete shall be uniformly levelled and screeded to produce a plain or
ridged surface as described in the Contract. No further work shall be applied to the
surface unless is used as the first stage for Class U2 or Class U3 finish.
B.2
Class U2: After the concrete has hardened sufficiently, the concrete Class U1 surface
shall be floated by hand or machine sufficiently to produce a uniform surface free
from screed marks.
B.3
Class U3: When the moisture film has disappeared and the concrete has hardened
sufficiently to prevent laitance from being worked to the surface, a Class U1 surface
shall be steel-trowelled under firm pressure to produce a dense, smooth uniform
surface free from trowel marks.
Page 221 of 244
5.04.6
TOLERANCES
A.
The tolerances in the forms and formwork shall be such that members formed shall be
within the tolerances for the size and type of the member specified elsewhere in the
Specification.
B.
Falsework shall be fixed such that the completed structure shall be within the required
tolerances in plan, elevation and slope for the size and type of structure specified
elsewhere in the Specification.
C.
Surfaces which are to receive deck waterproofing shall be finished to an accuracy

such that when tested with a three meter long straight edge, the maximum depression
shall not exceed five mm.
5.04.7
CONSTRUCTION REQUIREMENTS
A.
The forms and falsework shall be inspected by the Engineer after assembly on the
work area and immediately before concreting. No pour shall commence until the forms
and falsework have been approved by the Engineer.
B.
The inside surfaces of all forms shall, except for pavement formwork, or unless
otherwise agreed by the Engineer, be coated with a release agent approved by the
Engineer. Release agents shall be applied strictly in accordance with the
manufacturer's instructions and shall not come into contact with the reinforcement or
prestressing tendons and anchorages. Different release agents shall not be used in
formwork which will be visible in the finished work.
C.
Immediately before concrete is placed, all forms shall be thoroughly cleaned out.
D.
Forms that are to be re-used shall be thoroughly cleaned and re-oiled and, i f
necessary, shall be reconditioned by revision or reconstruction. Unsatisfactory lumber
will be condemned by the Engineer, and shall be removed from the Site.
E.
Formwork shall be constructed so that the side forms of members can be removed
without disturbing the soffit forms. I f props are to be left in place when the soffit forms
are removed, these props shall not be disturbed during the striking. Top shuttering is
to be provided to concrete i f the slope angle exceeds 25 degrees.
Page 222 of 244
F.
Runways used to move plant, equipment or materials shall be clear of the

reinforcement and shall be robust enough not to deflect excessively or cause
movement to the forms due to dynamic effects.
G.
During concreting, the forms and their supports shall be constantly monitored for signs
of imminent failure. There shall be skilled operatives in constant attendance during
concreting who are qualified to make immediate adjustments to the forms and
falsework so that concreting can satisfactorily be completed.
H.
The Engineer may suspend concreting operations if , in his opinion, the forms and
falsework are in danger of failure and that the actions taken by the Contractor are
insufficient or inadequate to guarantee the safe and satisfactory completion of concreting.
In such an event, the Engineer may instruct the Contractor to remove, at his expense,
the concrete already poured.
I.
I f at any period of work, during or after placing of concrete, the forms show signs of
sagging or bulging, the Contractor, at his own expense, shall remove the concrete to
the extent directed by the Engineer, bring the forms to the proper position, and place
concrete.
J.
Immediately after the removal of the forms, all fins caused by form joints and other
projections shall be removed and all pockets cleaned and filled with a cement mortar
composed of 1 part by volume of Portland cement and 2 parts sand. Sufficient white
Portland cement shall be mixed with the cement in the mortar, so that when dry the
colour will match the surrounding concrete. Patches shall be moistened prior to
mortaring to obtain a good bond with the concrete. When directed by the Engineer, the
Contractor shall at his own expense, substitute an approved epoxy grout for the
Portland cement mortar or provide an epoxy bonding agent to be used in conjunction
with the Portland cement mortar. I f , in the judgment of the Engineer, pockets are of
such extent or character as to materially affect the strength of the structure or to
endanger the life of the steel reinforcement, he may declare the concrete defective and
require the removal and replacement of that portion of the structure affected. The
resulting surfaces shall be true and uniform. Portions of the structure which cannot be
finished or properly repaired to the satisfaction of the Engineer shall be removed.
5.04.8
REMOVAL OF FORMWORK AND FALSE WORK
A. To facilitate finishing, forms on handrails, ornamental work, and other vertical surfaces that
require a rubbed finish, shall be removed as soon as the concrete has hardened sufficiently that
it will not be injured, as determined by the Engineer. In determining the time for the removal of
forms, consideration shall be given to the location and character of the structure, weather and
other conditions influencing the setting of the concrete.
Page 223 of 244
B.
Formwork shall be removed in a manner not to damage the concrete, and at times to
suit the requirements for its curing and to prevent restraint that may arise from elastic
shortening, shrinkage or creep.
C.
Any remedial treatment to surfaces shall be agreed with the Engineer following
inspection immediately after removing the formwork and shall be carried out without
delay. Any concrete surface which has been treated before being inspected by the
Engineer, shall be liable to rejection.
D.
Where the concrete compressive strength is confirmed by tests on concrete cylinders

(cubes) stored under conditions approved by the Engineer that simulate the field
conditions, formwork supporting concrete in bending may be struck when the strength is
10 N/sq.mm or three times the stress to which it will be subjected, whichever is the
greater.
E.
For ordinary structural concrete made with ordinary Portland cement only, in the
absence of control cylinders (cubes) the period before striking shall be in accordance
with the minimum periods given in Table 5.4.2 unless otherwise directed by the
Engineer.
Type of Formwork
Vertical formwork to columns, walls
and large beams
Soffit formwork to slabs
Props to slabs
Soffit to formwork to beams
Props to beams
Minimum Period Before Striking

Surface Temperature of Concrete
16C
7C
tC
12 hrs
18 hrs
300
hours
t-10
4 days
6 days
100
days
t-10
10 days
5 days
100
days
t-10
9 days
14 days
230
days
t-10
14 days
21 days
360
hours
t-10
Page 224 of 244
SECTION 5.05 PLAIN AND REINFORCED CONCRETE STRUCTURES
5.05.1
A.
GENERALLY
Scope
A.1 This Section of the Specification describes the construction of plain and reinforced concrete
structures.
5.05.2
A.
MATERIALS
Concrete
A.1 Concrete shall be produced and supplied in accordance with Section 5.01 "Concrete and
Concrete Mixes and Testing".
B.
Reinforcement
B.1 Reinforcement shall conform to Section 5.03 "Steel Reinforcement and Fixing".
C.
Formwork and Falseworks
C.1 Formwork and Falsework shall be designed and supplied in accordance with Section 5.04
"Forms, Formwork and Falsework".
D.
Plant and Equipment
D.1 Plant and Equipment shall conform with the requirements set in Volume 1 and shall be
according to the type and number outlined in the Contractor's detailed Program of Work as
Page 225 of 244
5.05.3
A.
CONSTRUCTION
General
A.1 The Contractor shall notify the Engineer his intention to concrete at least 24 hours in
advance.
A.2 The Engineer shall check and certify that:
B.
The form and formwork meet the Specification requirements.

The falsework and support props are in accordance with the approved
Drawings.
The reinforcement conforms to the Drawings and that the correct covers have
been provided.
The forms are free of dirt and other deleterious matter.
Concreting
B.1 Handling, placing and curing shall be in accordance with Section 5.02 "Concrete
Handling, Placing and Curing".
C.
Slump
C.1 Slump shall be within the limits given in Section 5.02 of the Specification.
D.
Construction and Expansion Joints
D.1 Whenever the work of placing concrete is delayed until the concrete shall have taken its
initial set, the point of stopping shall be deemed a construction joint. So far as possible the
location of construction joints shall be as shown on the Drawings, but i f not shown on the
Drawings, they shall be planned in advance and the placing of concrete carried out
continuously from joint to joint. The joints shall be perpendicular to the principal lines of stress
and in general be located at points of minimum shear.
Page 226 of 244
D.2 Where dowels, reinforcing bars or other adequate ties are not required by the Drawings,
keys shall be made by embedding water soaked bevelled timbers in soft concrete. The key
shall be sized as shown on the details, or as directed by the Engineer, which shall be removed
when the concrete has set. In resuming work the surface of the concrete previously placed shall
be thoroughly cleaned of dirt, scum, laitance or other soft material with stiff wire brushes, and i f
deemed necessary by the Engineer, shall be roughened with a steel tool. The surface shall
then be thoroughly washed with clean water and pointed with a thick coat of neat cement
mortar, after which the concreting may proceed.
D.3 Expansion joints shall be constructed at the locations, of the materials and to the
dimensions shown on the Drawings.
E.
Cold Joints
E.1
When the continuous placement of concrete in any structural member is interrupted or

delayed, for any reason, for a period long enough for the previously partially placed
concrete to take its initial set, the Engineer shall declare such a joint a cold joint in which
case the Contractor shall immediately remove the previously partially placed concrete
from the forms. No extra payment will be made for the initial placement or the removal of
concrete which is wasted because of a cold joint. The Engineer may suspend all or any
part of the subsequent concrete work until he deems the Contractor has corrected the
cause for the cold joint occurrence.
E.2
The Engineer may, with due consideration to the location of the cold joint and/or the
importance of the member, allow the Contractor to retain the partially placed concrete
and complete the concreting by a subsequent pour, which for permission, the Engineer
shall instruct the Contractor to carry out at his own expense some or all of the following
measures before completing the pour:
Surface leitance shall be removed from the surface of the partially placed
concrete by wire brushing or light tooling or by sand blasting as directed by the
Engineer without damage to reinforcement and formwork.
Shear keys shall be cut in the partially placed concrete. The shape, size and
orientation of the shear keys shall be as directed by the Engineer. The
reinforcement and formwork shall not be damaged.
The cleaned surface of the partially placed concrete shall be coated with an
approved bonding agent before placing the subsequent pour.
Additives to facilitate bonding shall be added to the concrete used for the
subsequent pour.
Page 227 of 244
F.
Dowel bars of a type and length to be approved by the Engineer shall be

installed in the partially placed concrete using non-shrink cement grout or resin
grout as directed by the Engineer. The size and spacing of the dowel bars shall
be approved by the Engineer. Their installation shall not damage the
reinforcement or formwork.
The partially placed concrete and the subsequent concrete shall be stressed by
prestressing bars of a size and type approved by the Engineer to achieve a level
of compressive stress at the interface approved by the Engineer. The method of
installing the prestressing bars and type of anchors used shall be approved by the
Engineer. Unless otherwise agreed by the Engineer, the drill hole shall be
grouted with a cement grout containing expanding additive to the manufacturer's
recommendations.
Finishing
F.1 To be as shown on Drawings.

G.
Concrete Cover to Reinforcement
G.1
The cover shall be not less than the size of the bar or the maximum aggregate size plus
5 mm or as shown on drawings. In the case of bundled bars, it shall be equal to or
greater than the size of a single bar of equivalent area plus 5 mm.
G.2
Where surface treatment such as grooved finish or bush hammering cuts in to the face
of the concrete, the expected depth of the treatment shall be added to the cover.
G.3
The cover to reinforcement should also be determined by considerations of durability

under the envisaged conditions of exposure. Minimum cover to reinforcement under
particular severe conditions shall be determined by Engineer on site.
H.
Tolerances
H.1 The horizontal and vertical dimensions of in-situ concrete members, but not cross-sections,
shall be within the following tolerances:
Length (mm)
Up to 3000
3001-4500
Vertical lines out of plane
Tolerance (mm)
3
6
5 + 1 for every 3000 out of true line.
Page 228 of 244
H.2 Slab and wall thicknesses and the cross-sectional dimensions of in-situ beams, columns,
piers etc., shall be within the following tolerances:
Member Dimensions (mm)
Up to 500
501 -750
Additional for every subsequent 100 mm
Tolerance (mm)
6
10
1 mm
H.3 The horizontal and vertical dimensions of pre-cast members, but not cross-sections, shall
be within the following tolerances:
Length (mm)
Tolerance (mm)
Up to 3000
3000 and over
2
5
H.4 Slab and wall thicknesses and the cross-sectional dimensions of in-situ beams, columns,
piers etc., shall be within a tolerances of 3 mm.
Member Dimensions (mm)
Up to 500
501- 750
Additional for every subsequent
250 mm
H.5
For in-situ and pre-cast construction the tolerance between the short side and the long
side shall be within the following limits:
Member Size (mm)
Up to 3000
3000 and over
Tolerance (mm)
3
6
H.6
For in-situ and precast construction the straightness or bow, defined as deviation form
the intended line, shall be within the following tolerances:
Member Length (mm)
Up to 3000
3000 and over
Tolerances (mm)
3
6
Page 229 of 244
H.7 The alignment of members shall be within the following tolerances:
Column and Piers: 1:400 of column or pier length.

Others:
1:600 of length.
H.6 The flatness of a surface, measured with a straight edge of 1.5 meter, shall be not greater
than 6 mm at any point.
H.7 Twist, measured as the deviations of any corner from the plane containing the other three
corners, shall be within the following limits.
Member Length (mm)
Up to 6000
Above 6000
Tolerance (mm)
6
12
Page 230 of 244
SECTION 5.06 WATERPROOFING FOR STRUCTURES
5.06.1
A.
GENERAL
Scope
A.1 These works shall consist of furnishing and placing approved waterproofing membrane
and dampproofing course to external concrete surfaces in contact with earth and furnishing and
placing epoxy coating to internal surfaces of concrete walls, slabs, and beds and furnishing
and installing waterstops to waterproof construction and expansion joints, all as shown on
the Drawings or as directed by the Engineer.
5.06.2
A.
MATERIALS
Asphalt
A.1 Waterproofing asphalt shall conform to AASHTO M 115 (ASTM D 449); Type I for use
below ground, and Type I I for use above ground.
A.2 Primer for use with asphalt in waterproofing shall conform to AASHTO M 116 (ASTM D
41).
B.
Bitumen
B.1 Waterproofing bitumen shall conform to AASHTO M 118 (ASTM D 450). Type I I shall be
furnished unless otherwise specified.
B.2 Primer for use with coal-tar bitumen in dampproofing and waterproofing shall conform to
AASHTO M 121 (ASTM D 43).
C.
Waterproofing Fabric
C.1 Waterproofing fabric shall conform to AASHTO M 117 (ASTM D 173).
Page 231 of 244
D.
Self-Adhesive Polyethylene Sheet
D.1 Flexible, preformed waterproof membrane comprising strong, high-density polyethylene

film with self-adhesive rubber/bitumen compound, and having the following minimum
properties:
-
Total thickness
Weight
Tensile strength
Elongation
Tear resistance
Puncture resistance
:
:
:
:
:
:
1.5 mm
1.6 kg/m2
42 n/mm2
210% long.; 160% trans.
340 n/mm long.; 310 n/mm trans.
220 n 65 mm
or other equal and approved.
E.
Tar for Absorptive Treatment
E.1 Tar for absorptive treatment shall be a liquid water-gas tar that conforms to the following
requirements:
F.
Specific gravity, 25/25C .......... 1.030 to 1.100

Specific viscosity at 40C (Engler), not more than .....................3.0
Total distillate, percent by weight, to 300C, not more than ..... 50.0
Bitumen (soluble in carbon disulfide) not less than, percent .... 98.0
Water, not more than, percent ..................................................3.0
Tar Seal Coat
F.1 Tar seal coat shall conform to AASHTO M 52, Grade RTCB-5 (ASTM D 490).
G.
Joint Fillers
G.1 Filler for use in horizontal and vertical joints in waterproofing work shall be a straight
refined oil asphalt conforming to the following requirements:
Flash point
Not less than 232C.
Softening point
48.9C to 54.4C.
Page 232 of 244
Penetration
Loss on heating
Ductility
Total bitumen (soluble in carbon disulfide): not less than 99.5 percent. H .
At 0C, 200 grams, 1 minute, not less than 15.At

25C, 100 grams, 5 seconds, 50 to 60. At 46C, 50
grams, 5 seconds, not more than 300.
At 163C, 50 grams, 5 hours, not more than 0.5
percent.
At 25C, 5 centimeters per minute, not less than
85.
Waterstops
H . 1 Extruded PVC, heavy duty, of the types and sizes shown on the Drawings, and complete
with junction pieces shall be obtained from any of the following manufacturers:
Expandite Ltd.
Greenstreak Plastic Products
Servicised Ltd
H . 2 Copper water stops shall be copper sheets of the thickness shown on the Drawings and
shall conform to the requirements of AASHTO M 138 (ASTM B 152).
H . 3 Plain rubber water stops shall be formed from a stock composed of a high grade
compound made exclusively from new plantation rubber, reinforcing carbon black, zinc oxide,
accelerators, anti-oxidants, and softeners. This compound shall contain not less than 72 percent
by volume of new plantation rubber. The tensile strength shall be not less than 246 kg per
sq.cm, with an elongation at breaking of 550 percent when tested in accordance with ASTM D
412. The unit stresses producing 300 percent and 500 percent elongation shall be not less than
77 kg. and 198 kg. per sq.cm, respectively. The Shore Durometer indication (hardness) shall be
between 55 and 65 when tested in accordance with ASTM D 676. After 7 days in air at 126
degrees (plus or minus 1 degree) C or after 48 hours in oxygen at 126 degrees (plus or minus 1
degree) C both at 21 kg per sq.cm, the tensile strength and elongation shall not be less than 65
percent of the original when tested in accordance with ASTM D 572.
Page 233 of 244
H.4 Synthetic rubber water stops shall be formed from a compound made exclusively from
neoprene, or SBR, reinforcing carbon black, zinc oxide, polymerization agents, and softeners.
This compound shall contain not less than 70 percent by volume of neoprene or SBR. The tensile
strength shall be not less than 175 kg. per square centimeter with an elongation at breaking of
425 percent when tested in accordance with ASTM D 412. The Shore Durometer indication
(hardness) shall be between 50 and 70 when tested in accordance with ASTM D 676. After 7
days in air at 126 degrees (plus or minus 1 degree) C or after 48 hours in oxygen at 126
degrees (plus or minus 1 degree) C, and 21 kg per sq.cm. pressure, the tensile strength shall
be not less than 65 percent of the original when tested in accordance with ASTM D 572.
I.
Proprietary Waterproofing Systems
I.1 Proprietary waterproofing systems shall be bituminous membranes reinforced with layers of
suitable reinforcement, bituminous coated polythene sheet, plasticized polyvinyl chloride sheet,
other approved membranes or applications of resinous reinforced coatings. The type to be used
shall be as indicated on the Drawings and shall be chosen according to its location and
serviceability. The specific system shall be approved after site trials, should the Engineer
decide these to be necessary.
J.
Epoxy Coating System
J.1 An approved epoxy coating system shall be furnished and applied to the internal concrete
surfaces of culverts and open channels as shown on the Drawings or as directed by the
Engineer. The thickness of the epoxy coating shall be at least 400 microns in accordance with
the manufacturer's recommendations.
K.
Chemical Water Proofing Coating
K.1 Chemical waterproof coating shall be surface-applied material that causes capillary
waterproofing system to protect concrete in-depth. Manufacturer's details are as follows:
Page 234 of 244
5.06.3
A.
SURFACE PREPARATION
Waterproofing
A.1 A l l concrete surfaces which shall be waterproofed shall be reasonably smooth and free
from projections or holes which might cause puncture of the membrane. The surface shall be
dry, so as to prevent the formation of steam when the hot asphalt or tar is applied, and,
immediately before the application of the waterproofing, the surface shall be thoroughly cleaned
of dust projecting tying wire and loose material.
A.2 No waterproofing shall be done in wet weather, nor when the temperature is below 4
degrees C, without special authorization from the Engineer. Should the surface of the concrete
become temporarily damp, it shall be covered with a 50 mm layer of hot sand, which shall be
allowed to remain in place from 1 to 2 hours, or long enough to produce a warm and
surface-dried condition, after which the sand shall be swept back, uncovering sufficient surface
for beginning work, and the operation repeated as the work progresses.
B.
Dampproofing
B.1 The surface to which the dampproofing coating shall be applied shall be cleaned of all
loose and foreign material and dirt and shall be dry. When necessary the Engineer may require
the surface to be scrubbed with water and a stiff brush, after which the surface shall be allowed
to dry before application of the primer.
5.06.4
INSPECTION, DELIVERY AND STORAGE
A.
A l l waterproofing materials shall be tested before shipment. Unless otherwise ordered

by the Engineer, they shall be tested at the place of manufacture, and, when so tested,
a copy of the test results shall be sent to the Engineer by the chemist or inspection
bureau which has been designated to make the tests, and each package shall have affixed
to it a label, seal, or other mark of identification, showing that it has been tested and
found acceptable, and identifying the package with the laboratory tests.
B.
Factory inspection is preferred, but in lieu thereof and/or addition thereof, the Engineer
may order that representative samples, properly identified, be sent to him for test prior to
shipment of the materials. After delivery of the materials, representative check samples
shall be taken which shall determine the acceptability of the materials.
C.
A l l materials shall be delivered to the work in original containers, plainly marked with
the manufacturer's brand or label.
Page 235 of 244
D.
5.06.5
A.
Water proofing and damp proofing material shall be stored in a dry, protected place.
Rolls of waterproofing fabric and membranes shall not be stored on end.
CONSTRUCTION
Asphalt and Bitumen Waterproofing Fabric
A.1 Asphalt shall be heated to a temperature between 148.7 degrees C and 176.5 degrees C
and tar for hot application shall be heated to a temperature between 93.3 degrees C and 121
degrees C with frequent stirring to avoid local overheating. The heating kettles shall be
equipped with thermometers.
A.2 In all cases, the waterproofing shall begin at the low point of the surface to be
waterproofed, so that water will run over and not against or along the laps.
A.3 The first strip of fabric shall be of half-width; the second shall be full-width, lapped the
full-width of the first sheet; and the third and each succeeding strip shall be full-width and
lapped so that there will be two layers of fabric at all points with laps not less than 50 mm wide.
All end laps shall be at least 300 mm.
A.4 Beginning at the low point of the surface to be waterproofed, a coating of primer shall be
applied and allowed to dry before the first coat of asphalt is applied. The waterproofing shall
then be applied as follows.
A.5 Beginning at the low point of the surface to be waterproofed, a section about 500 mm
wide and the full length of the surface shall be mopped with the hot asphalt or tar, and there
shall be rolled into it, immediately following the mopping, the first strip of fabric, or half-width,
which shall be carefully pressed into place so as to eliminate all air bubbles and obtain close
conformity with the surface. This strip and an adjacent section of the surface of a width equal to
slightly more than half of the width of the fabric being used shall then be mopped with hot
asphalt or tar, and a full width of the fabric shall be rolled into this, completely covering the
first strip, and pressed into place as before. This second strip and an adjacent section of the
concrete surface shall then be mopped with hot asphalt or tar and the third strip of fabric
"shingled" on so as to lap the first strip not less than 50 mm. This process shall be continued
until the entire surface is covered, each strip of fabric lapping at least 50 mm over the last strip.
The entire surface shall then be given a final mopping of hot asphalt or tar.
Page 236 of 244
A.6 The completed waterproofing shall be a firmly bonded membrane composed of two layers
of fabric and three moppings of asphalt or tar, together with a coating of primer. Under no
circumstances shall one layer of fabric touch another layer at any point or touch the surface, as
there must be at least three complete moppings of asphalt or tar.
A.7 In all cases the mopping on concrete shall cover the surface so that no gray spots appear,
and on cloth it shall be sufficiently heavy to completely conceal the weave. On horizontal
surfaces not less than 49 liters of asphalt or tar shall be used for each 10 sq.m. of finished work,
and on vertical surfaces not less than 61 liters shall be used for each 10 sq.m. The work shall
be so regulated that, at the close of a day's work, all cloth that is laid shall have received the
final mopping of asphalt or tar. Special care shall be taken at all laps to see that they are
thoroughly sealed down.
A.8 At the edges of the membrane and at any points where it is punctured by such
appurtenances as drains or pipes, suitable provisions shall be made to prevent water from
getting between the waterproofing and the waterproofed surface.
A.9 A l l flashing at curbs and against girders, spandrel walls, etc., shall be done with separate
sheets lapping the main membrane not less than 300 mm. Flashing shall be closely sealed
either with a metal counter-flashing or by embedding the upper edges of the flashing in a groove
poured full of joint filler.
A.10 Joints which are essentially open joints but which are not designed to provide for
expansion shall first be caulked with oakum and lead wool and then filled with hot joint filler.
A.11 Expansion joints, both horizontal and vertical, shall be provided with sheet copper or lead
in "U" or "V" form in accordance with approved details. After the membrane has been placed,
the joint shall be filled with hot joint filler. The membrane shall be carried continuously across all
expansion joints.
A.12 At the ends of the structure the membrane shall be carried well down on the abutments
and suitable provision made for all movement.
B.
Proprietary Waterproofing Membranes
B.1 Proprietary waterproofing membranes shall be installed strictly in accordance with the
manufacturer's instructions and shall be laid so that no air is trapped between it and the concrete
surface or between successive layers of sheeting.
Page 237 of 244
B.2 Unless otherwise specified joints between sheets shall be lapped with end laps of at least
150 mm and side laps of at least 100 mm. The joints shall be arranged so that at no points are
there more than three thicknesses of sheeting and, as far as possible so that water will drain away
from the exposed edge.
C.
Damage Patching of Waterproofing Fabrics
C.1 Care shall be taken to prevent injury to the finished fabric membrane by the passage over it
of workmen or wheelbarrows, or by throwing any material on it. Any damage which may occur
shall be repaired by patching. Patches shall extend at least 300 mm beyond the outermost
damaged portion and the second ply shall extend at least 75 mm beyond the first.
C.2 Proprietary waterproofing membranes shall be repaired according to the manufacturer's

specifications and as directed by the Engineer.
D.
Dampproofing
D.1 Concrete, brick, or other surfaces that shall be protected by dampproofing shall be
thoroughly cleaned before the primer is applied. They shall then be brush or spray painted with
two or more coats (as indicated on the Drawings) of tar or asphalt for absorptive treatment.
Below ground not less than two coats shall be applied, using 0.56 L/sq.m. of surface. On the
well-primed surface one application of tar or asphalt seal coat shall be applied by brush, using
0.45 L/sq.m.
D.2 Care shall be taken to confine all paints to the areas to be waterproofed and to prevent
disfigurement of any other parts of the structure by dripping or spreading of the tar or asphalt.
E.
Protection of Waterproofing and Dampproofing
E.1 Over the waterproofing membrane and dampproofing course, there shall be constructed a
protection course which, unless otherwise specified or shown on the Drawings, shall be a 50
mm course of mortar mixed in the proportion of one part Portland cement and two parts sand.
This mortar course shall be reinforced midway between its top and bottom surfaces with wire
netting of 150 mm mesh and No. 12 gauge, or an approved equivalent. The top surface shall be
troweled to a smooth, hard finish and, where required, true to grade.
Page 238 of 244
E.2 The construction of the protection course shall follow the waterproofing so closely that the
latter will not be exposed without protection for more than 24 hours.
E.3 Unless otherwise shown on the Drawings or directed by the Engineer, vertical faces
waterproofed or dampproofed shall be protected by a porous concrete block wall of not less than
225 mm thickness. I f approved by the Engineer, a proprietary synthetic sheeting may be used as
the protective layer in lieu of the porous concrete block wall.
F.
Chemical Waterproofing
Conditions and rate of application shall be in accordance with manufacturer's

F.1
recommendations.
G.
Water Stops
G.1 Copper sheets for water stops shall be of the width and shall be bent to the shapes shown
or ordered. The sheet copper in each joint shall be continuous, separate pieces being
connected by thoroughly workmanlike soldered joints to form a complete watertight unit. The
sheet copper shall be placed in such manner as to ensure its embedment in the concrete on
each side of the joints in the positions shown on the Drawings.
G.2 Rubber water stops shall be installed in accordance with the details shown on the
Drawings. The water stops shall be formed with an integral cross section which shall be uniform
within 3 mm in width and the web thickness or bulb diameter, within plus 1.5 mm and minus
0.75 mm. No splices shall be permitted in straight strips. Strips and special connection pieces
shall be well cured in a manner such that any cross section shall be dense, homogenous, and
free from all porosity. A l l junctions in the special connection pieces shall be full molded. During
the vulcanizing period the joints shall be securely held by suitable clamps. The material at the
splices shall be dense and homogenous throughout the cross section. Field splices shall be either
vulcanized, mechanical, using stainless steel parts, or made with a rubber splicing union of the
same stock as the water stop, at the option of the Contractor. A l l finished splices shall
demonstrate a tensile strength of not less than 50 percent of the unspliced material.
H.
Testing
H.1 Unless otherwise agreed by the Engineer in writing, at least one site trial application of the
waterproofing system shall be carried out to determine the suitability of the surface preparation,
method of application and effectiveness of the protective layer. The size of membrane laid shall
be not less than 2.0 mete
Page 239 of 244
SECTION 5.07
5.07.1
A.
JOINT SEALING AND JOINT FILLER
GENERAL
Scope
A.1 These works shall consist of furnishing and installing joint sealing and preformed
expansion joint filler materials as and where shown on the Drawings, or as directed by the
Engineer.
5.07.2
A.
MATERIALS: JOINT SEALING COMPOUNDS
Hot Type
A.1 This type shall be a mixture of virgin synthetic rubber or reclaimed rubber, or a
combination of the two, with asphalt plasticisers and tactified. Ground cured rubber scrap shall
not be used.
A.2 The joint sealing compound, after heating and application, shall form a resilient and
adhesive compound capable of effectively sealing joints in concrete against the infiltration of
moisture and foreign material through repeated cycles of expansion and contraction. It shall be
capable of being brought, by heating, to a uniform, smooth pouring consistency, free from
lumps, and suitable for completely filling the joints and without damage to the material. It shall
not flow from the joints or be picked-up and tracked by vehicle tyres at summer temperatures.
A.3 The pour point shall be at least 11 degrees C lower than the safe heating temperature.
The safe heating temperature is defined as the highest temperature to which the material can
be heated and still meet all requirements of this specification. No sample of the material will be
tested until the manufacturer furnishes his recommended safe-heating and pouring
temperatures.
A.4 After 6 hours of continuous heating, with constant mixing in the laboratory at the
manufacturer's recommended pour temperature, the joint sealer shall meet all requirements of
this specification.
A.5 The penetration at 25 degrees C, 150 gm, 5 sec, shall not be less than 50 mm nor more
than 90 mm.
Page 240 of 244
A.6 The flow at 60 degrees C and at a 75 degree angle shall not exceed 10 mm in 5 hours.
A.7 Ductility at 25 degrees C shall be not less than 350 mm.
A.8 The material when tested at minus 17.8 degrees C to 100 percent extension 1270 mm
extended to 2540 mm shall, after 5 cycles, show no surface checking, cracking, separation or
other opening in the material or between the material and the block. At least 2 test specimens
in a set of 3 specimens representing a given sample shall meet this requirement.
A.9 Recovery shall be not less than 25 percent.
A.10 Compression recovery of bond specimens shall be not less than 10 mm in 15 minutes.
A.11 No failure in cohesion or adhesion shall occur.
A.12 Samples for testing shall consist of not less than a 4.5 kilogram sample from each batch
of the joint sealer. A batch shall be considered as all finished material that was manufactured
simultaneously or continuously as a unit between the time of compounding and the time of
packaging or placing in shipping containers. Each package or container shall be marked
properly to indicate clearly the batch of which it forms a part. The material shall be sampled in
accordance with the requirements of the "Standard Methods of Sampling Bituminous Materials"
(ASTM D140) for solid materials in cakes.
A.13 Testing shall be in accordance with AASHTO T 187 except that the tolerances on
dimensions of test specimens, Article 6.3 shall be + 0.13 cm and the temperature tolerances,
Article 6.4 shall be + 2.2 degrees C.
B.
Cold Type
B.1 This type shall be homogeneous material of such consistency that it can be applied by
means of high-pressure pump through suitable nozzles to completely f ill the joints. The
compound may be blended with a suitable solvent or solvents by the manufacturer to provide
better workability during installation in the joints. The volatility of these solvents must be such
that they will evaporate within a short time after installation leaving a material that is adhesive
and resilient.
Page 241 of 244
B.2 The flow during a 5 hour period at 60 degrees C shall not exceed 50 mm.
B.3
After evaporation of the solvent, the penetration at 25 degrees C, 150 gm, 5 sec, shall
not exceed 220 mm.
B.4 When the compound is tested at minus 17.8 degrees C, the development at any time
during the test procedure of a crack, separation or other opening which is at any point over 64
mm deep in the material or between the material and the concrete block, shall constitute failure
of the test specimen. The failure of more than 1 test specimen in a group of 3 specimens,
representing a given sample of joint sealing compound shall be cause for rejection of the
sample on the basis of this requirement.
B.5 Cold-type joint compound shall be tested in accordance with ASTM D 1851, except that
the material for test specimens Article 7(c) will be stirred manually rather than mechanically.
B.6 Preformed Polychloroprene Elastomeric Joint Seals shall comply with the requirements
of AASHTO M 220 (ASTM D 2628).
C.
Joint Sealant for movement joints in water retaining structures shall be polysulphide
based compound to BS 4254 or as manufactured by:
Man: Expandite Ltd. Ref:
Thioflex 600
Man: Servicised Ltd. Ref:
Paraseal
D.
Exposed Joint Sealant for movement joints is to be approved polysulphide rubber

based compound unless otherwise specified.
Man: Dunlop Ltd.
Ref: High butyl mastic 421.8
Man: Expandite Ltd. Ref:
Thioflex 600
E.
Backing strip shall be the type recommended by joint sealant manufacturer.
Page 242 of 244
5.07.3
A.
PREFORMED EXPANSION JOINT FILLER
Description
A.1 This type of filler shall be a non-extruding and resilient bituminous type and shall have
relatively little extrusion and a moderate to high amount of recovery after release from
compression.
B.
Requirement
B.1 Nonextruding and resilient type of expansion joint filler shall conform to all the
requirements of the Standard Specification for "Preformed Expansion Joint Fillers for
Concrete Paving and Structural Construction (Nonextruding and Resilient Bituminous
Types)", AASHTO M 213 (ASTM D 1751).
C.
Movement Joint Sheet Material Filler
C.1 For expansion joints in water retaining structures is to be bonded granular cork to ASTM
D 1752 or ASTM D 1751 or as manufactured by:
Man: Expandite Ltd Ref:
Cork filler
Man: Servicised Ltd Ref:
Kork-Pak
5.07.4
CERTIFICATE OF GUARANTEE
A. The Contractor shall furnish the Engineer with a manufacturer's certificate of guarantee for
each type of joint material delivered to the Site. The certificate shall note compliance with the
appropriate specifications and shall state the results of the tests performed on the material,
as required by the specifications. The Contractor shall, when so directed by the Engineer,
have the joint material tested for conformance to the applicable specifications at an approved
testing laboratory. A l l costs connected with certificate of guarantee and any subsequent
quality testing shall be at the Contractor's expense.
Page 243 of 244
5.07.5
A.
CONSTRUCTION
Joints shall be:
B.
Straight, vertical, horizontal or as detailed or approved.

Formed to accommodate projecting reinforcement.
Movement joints are defined as:
Formed expansion joints.

Formed contraction joints.
Induced contraction joints.
C.
Formed Movement Joints: Construct rigid stop ends and formwork at formed
movement joints to permit separate construction of structurally separate parts of the
work.
D.
Construction Joints: Where not coincident with movement joints submit proposals for
positions of construction joints and obtain approval.
E.
Construction Joints: Lightly roughen face to expose coarse aggregate unless

otherwise instructed. Wet and cover with 1:1 cement and sand grout immediately prior
to placing fresh concrete. Stop roughening 25 mm from arrises to surfaces exposed to
view in finished work. Remove small mortar lips from exposed arrises with
carborundum stone. Face is to be clean and damp before fresh concrete is placed
against it.
F.
Concrete Floors: Side and end forms are to be square edged with steel top surface.
G.
Waterbars: Nail to forms prior to concreting and butt joint in accordance with the
manufacturer's instructions.
H.
Sealing of Movement Joints: Preparation and application is to be strictly as

manufacturer's recommendations. Joints are to be thoroughly clean and dry, free from
oil and loose material. Vigorously wire brush or grit blast the joint faces and clean out
with compressed air. Prime faces of joint and allow to dry. Where exposed to view mask
edges of joint with tape before priming and remove immediately after sealing. Apply
sealant ensuring maximum adhesion to sides of joint and a neat, smooth and clean
finish.
Page 244 of 244

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Table of Contents

SECTION 1.01 FORMAT AND REFERENCING .............................................. 1

Technical Specification For Sewer Network

1.06.1 GENERAL ............................................................................................. 26

SECTION 2.01 SCOPE ................................................................................. 36

Technical Specification For Sewer Network

2.05.2 MATERIALS .......................................................................................... 74

PAVEMENT AND ROADS SURFACE FINISHING . 83

SECTION 3.01 SCOPE .................................................................................. 83

PIPE WORKS AND NETWORK ACCESSORIES . 112

SECTION 4.01 SCOPE ................................................................................... 112

Technical Specification For Sewer Network

4.02.3 RIGHT OF WAY (ROW)...................................................................... 114

CONCRETE WORKS ................................................................. 164

5.03.1 GENERAL ........................................................................................... 209

Technical Specification For Sewer Network

5.03.2 MATERIALS ........................................................................................ 209

Technical Specification For Sewer Network

PART 3 : PAVEMENT AND ROADS SURFACE FINISHING

PART 5 : CONCRETE WORKS

PART 1: General Requirement

Technical Specification For Sewer Network

SECTION 1.01 FORMAT AND REFERENCING

PART 1: General Requirement

Technical Specification For Sewer Network

A l l the provisions of these Section/s shall be construed as Specifications for such

PART 1: General Requirement

Technical Specification For Sewer Network

ABBREVIATIONS AND DEFINITIONS OF TERMS

Titles and Terms

B.1 AASHTO - American Association of State Highway and Transportation Officials:

PART 1: General Requirement

Technical Specification For Sewer Network

International Organization for Standardization

PART 1: General Requirement

Technical Specification For Sewer Network

linear meter/s kilometer/s

PART 1: General Requirement

Technical Specification For Sewer Network

ACCEPTED - Accepted in writing by the Engineer (or by the Employer where

ADDENDUM/NOTICE - Amendment of or revision to any of the Contract

APPROVED - Approved in writing by the Engineer, including subsequent

CERTIFICATE OF GUARANTEE - A signed statement by a person having

DIRECTED - Directed in writing by the Engineer, including subsequent written

PRESPLITTING - Establishment of a free surface, or shear plane, in rock cuts,

SHEATHING - Backfilling to the inside faces of structures such as retaining

SOIL STABILIZATION - Procedure whereby cement, bitumen or lime is added

SUBGRADE - The top surface of embankment or excavated area on which the

PART 1: General Requirement

Technical Specification For Sewer Network

SUBGRADE LAYER - The top layer of material, of at least 200 mm compacted

SUBSIDIARY WORKS - Works which are subsidiary to or necessary or essential to, or

WORKING DRAWINGS - Shop drawings, steel bending schedules, stress sheets,

PART 1: General Requirement

Technical Specification For Sewer Network

SCOPE AND CONTROL OF WORKS

CONTRACTOR'S WORK AREAS

PART 1: General Requirement

Technical Specification For Sewer Network

The Contractor, i f so required by the Engineer, whether before or after completion of

PART 1: General Requirement

Technical Specification For Sewer Network