QCS 2014 Quality Control and Assurance Specifications

QCS 2014
Contents
Page 1
CONTENTS
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SECTION 2
Part 1
Part 2
Part 3
Part 4
Part 5
Part 6
Part 7
Part 8
Part 9
Part 10
Part 11
Part 12
Part 13
Part 14
Part 15
GENERAL
Introduction
Use and Maintenance of the Site
Site Access and Entry onto the Site
Protection
Interference
Project Meetings
Submittals
Building Demolition
Materials
Occupational Health and Safety
Engineers Site Facilities
Contractors Site Facilities
Setting Out of the Works
Temporary Works and Equipment
Temporary Controls
Traffic Diversions
Project Co-ordination
Other Contractors
Regulatory Requirements
Clearance of the Site
Final Inspection and Handover Procedures
New Technologies and Innovations
Design and Supervision Consultant Quality Requirement
Construction Dewatering
SECTION 1
Part 1
Part 2
Part 3
Part 4
Part 5
Part 6
Part 7
Part 8
Part 9
Part 10
Part 11
Part 12
Part 13
Part 14
Part 15
Part 16
Part 17
Part 18
Part 19
Part 20
Part 21
Part 22
Part 23
Part 24
QUALITY ASSURANCE AND QUALITY CONTROL

General
Submittals
Contractors Quality Personnel
Document and Data Control
Quality Records
Quality Audits
Inspection And Test
Materials
Nonconformance Monitoring
Laboratories
Site Meetings And Reports
Failure By The Contractor To Meet Acceptable Quality Performance
Suspension of Work
APPENDIX A Sampling and Testing Frequencies
APPENDIX B Templates
(Contractors Project Quality Plan Template, Contractors Inspection And Test
Plan Template, and Quality Non-conformance Template)
Contents
Page 2
GROUND INVESTIGATION
General
Boreholes
Pits and Trenches
Soil Sampling
in-Situ Testing, Instrumentation and Monitoring
Laboratory Testing
SECTION 4
Part 1
Part 2
Part 3
Part 4
Part 5
Foundations and Retaining Structures

General Requirements for Piling Work
Concrete Works for Piling
Shadow Foundations
Deep Foundations
Retaining Structures
SECTION 5
Part 1
Part 2
Part 3
Part 4
Part 5
Part 6
Part 7
Part 8
Part 9
Part 10
Part 11
Part 12
Part 13
Part 14
Part 15
Part 16
Part 17
Part 18
Part 19
Part 20
CONCRETE
General
Aggregates
Cementitious Materials
Water
Admixtures
Property Requirements
Concrete Plants
Transportation and Placing Of Concrete
Formwork
Curing
Reinforcement
Joints
Inspection and Testing Of Hardened Concrete
Protective Treatments for Concrete
Hot Weather Concreting
Miscellaneous
Structural Precast Concrete
Prestressed Concrete
Testing of Water Retaining Structures
Personnel Qualifications and Certification
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SECTION 3
Part 1
Part 2
Part 3
Part 4
Part 5
Part 6
SECTION 6
Part 1
Part 2
Part 3
Part 4
Part 5
Part 6
Part 7
Part 8
Part 9
QCS 2014
ROADWORKS
General
Site Clearance
Earthworks
Unbound Pavement Materials
Asphalt Works
Concrete Road Pavements
Asphalt Plants
Recycled and Stabilised Road Materials
Recycled Aggregate for Roadworks
Contents
Page 3
Vehicle Crash Barriers

Kerbs, Footways and Paved Areas
Fencing
Traffic Signs, Markings and Studs
Works in Relation To Services
Road Lighting
Traffic Signals
Road Drainage
Geosynthetics
Miscellaneous
SECTION 7
Part 1
Part 2
Part 3
Part 4
Part 5
Part 6
GREEN CONSTRUCTIONS
Introduction
Global Sustainability Assessment System - GSAS
Energy
Water [W]
Indoor Environment
Cultural and Economic Value
SECTION 8
Part 1
Part 2
Part 3
Part 4
Part 5
Part 6
Part 7
Part 8
Part 9
Part 10
Part 11
Part 12
DRAINAGE WORKS
General
Earthworks
Pipes and Fittings Materials
Pipeline Installation
Valves, Penstocks and Appurtenances
Miscellaneous Metal Works
Miscellaneous GRP Works
Protective Coatings and Painting
Trenchless Pipeline Construction
Pipelines Cleaning and Inspection Survey
Sewer Rehabilitation
Vacuum Sewerage System
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Part 10
Part 11
Part 12
Part 13
Part 14
Part 15
Part 16
Part 17
Part 18
Part 19
SECTION 9
Part 1
Part 2
Part 3
Part 4
Part 5
Part 6
Part 7
Part 8
Part 9
Part 10
Part 11
Part 12
Part 13
Part 14
QCS 2014
MECHANICAL AND ELECTRICAL EQUIPMENT

General
Submersible Pumps
Centrifugal Pumps (Dry Well)
Centrifugal Pumps (Split Casing)
Archimedian Screw Pumps
Surge Control System
Lifting Equipment
Electric and Pneumatic Actuators
Odour Control Equipment-Carbon Type
Odour Control Equipment-Scrubber Type
Screening Equipment
Grit Removal Equipment
Aeration Equipment
Air Blowers and Compressors
QCS 2014
Contents
Page 4
Settlement Tank Equipment

Tertiary Treatment Granular Filters
Sludge Thickening and Dewatering Equipment
Mixers and Stirrers
Chlorination Plant Equipment
Washwater Systems
Miscellaneous Equipment
Ventilation Systems
SECTION 10
Part 1
Part 2
Part 3
Part 4
Part 5
INSTRUMENTATION, CONTROL AND AUTOMATION

General
Telemetry/SCADA
Primary Elements
Panel Mounted and Miscellaneous Instruments
Control Panels and Control Room Hardware
SECTION 11
Part 1
Part 2
HEALTH & SAFETY

Regulatory Document
Safety and Accident Prevention Management / Administration System
(SAMAS)
SECTION 12
Part 1
Part 2
Part 3
Part 4
Part 5
EARTHWORKS RELATED TO BUILDINGS

General
Excavations
Filling
Utility Trenches
Installation of Protective Membranes
SECTION 13
Part 1
Part 2
Part 3
Part 4
Part 5
MASONRY
General
Mortar and Grout
Accessories
Unit Masonry
Masonry Laying
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Part 16
Part 17
Part 18
Part 19
Part 20
Part 21
Part 22
SECTION 14
Part 1
Part 2
Part 3
Part 4
Part 5
ROOFING
General
Membrane Roofing
Metal and Plastic Roofing
Roof and Deck Insulation
Roofing Tiles
SECTION 15
Part 1
Part 2
Part 3
SECTION 15 INSULATION OF BUILDINGS

General
Building Insulation
Cold Stores
Contents
Page 5
STRUCTURAL STEELWORKS
General
Materials
Drawings
Fabrication
Welding
Bolting
Accuracy of Fabrication
Erection
Accuracy of Erected Steelwork
Protective Treatment
SECTION 17
Part 1
Part 2
Part 3
Part 4
Part 5
Part 6
METALWORK
General
Materials Classification
Metal Doors and Windows
Architectural Metal Work
Light Metal Support and Cladding Support
Workmanship
SECTION 18
Part 1
Part 2
Part 3
Part 4
Part 5
Part 6
Part 7
CARPENTRY, JOINERY AND IRONMONGERY

General
Wood Treatment
Structural Timber (Rough Carpentry)
Architectural Timber (Finished Carpentry, Millwork)
Joinery
Fasteners and Adhesives
Ironmongery (Hardware)
SECTION 19
Part 1
Part 2
Part 3
Part 4
Part 5
Part 6
Part 7
PLUMBING WORK
General
Water Distribution
Plumbing Pipework in Trenches
Cold Water Storage
Hot Water Storage
Commissioning of Systems
Plumbing for Gases
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SECTION 16
Part 1
Part 2
Part 3
Part 4
Part 5
Part 6
Part 7
Part 8
Part 9
Part 10
SECTION 20
Part 1
Part 2
Part 3
Part 4
Part 5
Part 6
Part 7
QCS 2014
DRAINAGE WORKS FOR BUILDINGS

General
Internal Drainage Works
External Drainage Works
Drainage Pipes in Trenches
Structures Related To Drainage Work
Surface Water Drainage
Commissioning Of Systems
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ELECTRICAL WORKS
General Provisions for Electrical Installation
MV Factory Built Assemblies (FBAs)
Protective Devices
Motor Starters
Low Voltage Variable Speed Controllers
Cables and Small Wiring
Conduits and Conduit Boxes
Trunking
Cable Trays
Wiring Accessories and General Power
Light Fittings
Emergency Lighting
Telephone Installations
Structured Cabling Systems
Electric Motors
Power Factor Correction Capacitors
Standby Diesel Generator Set
Uninterruptible Power Supply Systems
Sound and Call Systems
Elevators/Escalators
Lightning Protection
Earthing and Bonding
Inspection and Testing
Documentation Format
Electrical Identification
Electromagnetic Compatibility
Battery and Battery Charger
Small Enclosures
Underfloor Ducts
Duct Bank and Manholes
Power Distribution Transformers
11 kv Switchgear
Actuators
HV Variable Frequency Drive
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SECTION 21
Part 1
Part 2
Part 3
Part 4
Part 5
Part 6
Part 7
Part 8
Part 9
Part 10
Part 11
Part 12
Part 13
Part 14
Part 15
Part 16
Part 17
Part 18
Part 19
Part 20
Part 21
Part 22
Part 23
Part 24
Part 25
Part 26
Part 27
Part 28
Part 29
Part 30
Part 31
Part 32
Part 33
Part 34
Contents
QCS 2014
SECTION 22
Part 1
Part 2
Part 3
Part 4
Part 5
Part 6
Part 7
Part 8
Part 9
AIR CONDITIONING, REFRIGERATION AND VENTILATION

General
Central Refrigeration and Air Conditioning Equipment
Unitary Equipment
Air Handling Equipment
Chilled Water Pipework
Ductwork and Air-Side Equipment
Thermal Insulation
Exhaust Fans
Accessories
SECTION 23
Part 1
Part 2
FIRE FIGHTING AND FIRE ALARM SYSTEMS

General
Fire Alarm and Detection Systems
QCS 2014
Contents
Page 7
Analogue Addressable Fire Alarm Systems

Fire Fighting System
Testing and Commissioning
SECTION 24
Part 1
Part 2
Part 3
Part 4
Part 5
Part 6
Part 7
Part 8
Part 9
Part 10
Part 11
Part 12
Part 13
Part 14
FINISHES TO BUILDINGS
General
Lath and Plaster
Dry Lining (Wall Board)
Special Wall Surfaces
Tiles
Terrazzo
Stone Flooring
Unit Masonry Flooring
Floor Screeds and Treatments
Joints, Caulking and Sealants
Recessed Duct Covers
Carpeting
Other Floor Coverings
Ceilings
SECTION 25
Part 1
Part 2
Part 3
Part 4
GLASS AND GLAZING

General
Glass
Workmanship
Glazed Curtain Walling System
SECTION 26
Part 1
Part 2
Part 3
Part 4
PAINTING AND DECORATING

General
Surface Preparation for Painting
Primers, Paints and Coatings
Wall Coverings of Decorative Papers/Fabrics
SECTION 27
Part 1
Part 2
Part 3
Part 4
Part 5
Part 6
Part 7
Part 8
Part 9
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Part 3
Part 4
Part 5
SECTION 28
Part 1
Part 2
Part 3
EXTERNAL WORKS
General
Block Paved Areas
Fences and Gates
Fountains and Aquatic Features
Site Furniture
Flag Poles
Protective or Shade Cover Systems
Play Field and Park Equipment
Miscellaneous Other External Works
LANDSCAPING
Landscape Planting
Landscape Irrigation System
Play Equipment General Specification
QCS 2014
Contents
RAILWAYS
Design Related Issues Aspects
Site Clearance
Geotechnical Specifications
Tunnel
Cut and cover Structure
Earthworks and Roadworks
Concrete Structures
Steel Structures
Drainage
Railway Track
Monitoring and Instrumentation
Survey and Setting Out
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SECTION 29
Part 1
Part 2
Part 3
Part 4
Part 5
Part 6
Part 7
Part 8
Part 9
Part 10
Part 11
Part 12
Page 8
QCS 2014
Introduction
Page 1
INTRODUCTION
The purpose of the technical regulation QS 27/2014 [Qatar Construction Specifications 2014 (QCS2014)] is to provide technical guidance in connection with the execution of constructions in the State of
Qatar. Such guidance includes the establishment of the minimum acceptable material quality and
workmanship for those kinds of work which commonly occur in engineered projects in the State of
Qatar.
Qatar Construction Specifications 2014 (QCS 2014) supersedes Qatar National Construction
Standards 2010 (QCS 2010) in all respects.
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While working earnestly to benefit from new engineering developments, Laboratories and
Standardisation Affairs in the Ministry of Environment requests that all those undertaking works
projects in the State of Qatar to implement the specifications contained herein.
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We welcome any observations, suggestions or additions for future issues.
QCS 2014
Document History
Page 1
DOCUMENT HISTORY
The purpose of the Document History is to record changes to Qatar Construction Specifications. In the
event of a revision to the technical regulation, Laboratories and Standardisation Affairs in the Ministry
of Environment will issue the amended pages and re-issue the Document History.
The Document History pages should contain a description of the change, the issue reference and the
date of issue as noted below. The updated Document History should replace the superseded history
and the revised pages of the technical regulation should be placed in the appropriate position in the
technical regulation.
The technical regulation QS 27/2007 [Qatar National Construction Standards 2007 (QCS 2007)]
replaces Qatar Construction Specification 2002 (QCS 2002) and it supersedes in all respects.
The technical regulation QS 27/2010 [Qatar Construction Specifications 2010 (QCS 2010)]
replaces the technical regulation QS 27/2007 [Qatar National Construction Standards 2007
(QCS 2007)] and it supersedes in all respects.
Further, the technical regulation QS 27/2014 [Qatar Construction Specifications 2014 (QCS
2014)] replaces the technical regulation QS 27/2010 [Qatar Construction Specifications 2010
(QCS 2010)] and it supersedes in all respects.
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Description
Date
Original Issue
April 2000
Qatar Construction Specification 2002
Revision I
November 2002
Qatar National Construction Standards 2007
Revision II
July 2007
Qatar Construction Specifications 2010
Revision III
March 2011
Revision IV
October 2014
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Qatar Construction Specification
Issue
QCS 2014
Acknowledgements
Page 1
ACKNOWLEDGEMENTS
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The Qatar Construction Specifications (QCS 2014) has been drawn upon the technical knowledge and
experience of a number of Governmental Ministries, Departments and Authorities in the State of
Qatar. The QCS technical committee and associated subcommittees whose members are
acknowledged below spearheaded the current revision of QCS 2014.
Eng. Khalid Al-Emadi

Chairman of QCS
Manager of Q&S Dept. Ashghal
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Dr. Mohammed Saif Al-Kuwari

Assistant Undersecretary
Ministry of Environment
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Abdul Hameed M. Al-Yahri

Sec. of the committee
Yousef Mahmoud Ahmed Nooh

Asst. Sec. of the committee
H/ of the Documents Editing
Quality Supervisor -Ashghal
Meshal Saoud Al Mesallam

Ministry Of Energy & Trade
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Nasser Al- Naimi

Deputy Chairman of QCS
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Technical Committee for Preparing and Development of QCS
Dr. Noureddin Daas
Moaaz Hashim
Dr. Khaled Hassan
Osman Elhussien
Chairperson of Concrete Committee

Chairperson of Road Committee

Member of: Rail committee
Quality Expert - Ashghal
Member of Concrete Committee

TRL
Chairperson of Rail Committee

Member of Road committee
Quality Researcher - Ashghal
Sharif Mohamed
Chairperson of Drainage Committee
Member of Rail Sub-committee
Design Engineer- Ashghal
Gareth Thomas
Chairperson of: Quality Committee
Quality Assurance & Quality
Control Expert - Ashghal
Ehab G Saleh
Chairperson of: Safety Committee
Safety Specialist - Ashghal
QCS 2014
Acknowledgements
Page 2
Sub Committees Members
Adel M. Quraan
Reviewers
CH2M HILL
Adrian Black
Safety Committee
MWH
Ahmed Mohd. Sayd

Concrete Committee
Allan McEwan
Quality Committee
KBR
Ahmed Sami
Roads Committee
Ashghal
Amr Elmotasem
Concrete Committee
AEB
Arthur Hannah
Roads Committee
(TRL) London
David Matyus
Concrete Committee
QPMC
David Lewis
Roads Committee
AMEY
Dick Steer
Drainage Committee
Ashghal
Dr.Hany Mohamed
Reviewers
Ashghal
Effrosyni Plexousaki
Quality Committee
ANAS
Elie Khairallah
Concrete Committee
ACTS
Essam El Sarag
Green Building
GORD
Fatih Trk
Concrete&RailCommittee
Mace / EC Harris
Fraser McCaskill
Quality Committee
Mace / EC Harris
Gary Cook
Roads Committee
ANAS
Ghaleb Al Zubi
Reviewers
ACES
Gireesh Babu
Concrete Committee
QDC
Hazem Abdel Rahman

Roads Committee
Ashghal
Huw Woodyatt
Roads Committee
Exova
Issam A. Sarhan
Website Developer
MOE
Jaafar. Al-Aloosi
Concrete Committee
Ashghal
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Abdulrahim Sukik
Concrete Committee
ACES
Jaafer Mohammed
Roads Committee
MOE
Jose Vellattukudy
Drainage Committee
Ashghal
Karunarathna T A
Drainage Committee
Ashghal
Karen OSullivan
Roads Committee
FUGRO
Kim Catrambone
Roads Committee
Parsons Brinckerhoff
Konstantinos k
Roads Committee
Ashghal
Martin Cahalan
Quality Committee
AMEY
Mathhar Mustafa
Concrete Committee
Hilti Qatar
Markus Kretschmer
Concrete&RailCommittee
Qatar Rail
Melina Davies
Roads Committee
Mohammed Adil
Document Controller
Ashghal
Mohammed Al-Yahri
Drainage Committee
Ashghal
QCS 2014
Acknowledgements
Page 3
Mohanasundaram
Concrete Committee
QDC
Michael De Roos
Safety Committee
Ashghal
Michelle Magbojos
Roads Committee
Ashghal
Neil Courtman
Quality Committee
Mace
Neil Kirkpatrick
Green Building
Nicholas Ray
Quality Committee
CH2MHill
Packiaraj
Drainage Committee
Ashgha
Petru Ghicu
Drainage Committee
Ashghal
Peter E. Sebaaly
Roads Committee
ANAS
Peter Latham
Concrete Committee
ReadyMix
Peter Sutton
Safety Committee
AMEY
Rabih Boukaidbey
Concrete Committee
ACTS
Rania Hashim Abadi

Roads Committee
Ashghal
Rawshan Haniffa
Document Controller
Ashghal
Rabih Fakih
Concrete Committee
GREY MATTERS
Rolando Matias
Quality Committee
Roy Cupples
Roads Committee
Ashghal
Salah Mousa
Safety Committee
Ministry of Labor
Richard James Ellis

Roads Committee
Gulf Laboratories
Robert Overett
Roads Committee
Saleem Purayil Purayil

Document Controller
Ashghal
Shyam Sundar
Concrete Committee
QDC
Sheik Pahary
Safety Committee
QPM
Subrato Mukherjee
Concrete Committee
QDC
Srinivasan Samiappan
Concrete Committee
QDC l
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Mohamed El sherbiny
Green Building
Ashghal
Tom Baines
Safety Committee
EC Harris
Yasser Berzan
Safety Committee
Ashghal
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Acknowledgements
Page 4
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QCS 2014
Dr Mohamed Saif Al-Kuwari
Undersecretary Assistant of MoE
Preparing and Development of Qatar Building Code Committee

Technical Committee for Preparing and Development of QCS
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ORGANIZATIONAL CHART
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Eng. Khalid Al-Emadi

Chairman of QCS
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Nasser Al-Naimi
Deputy Chairman of QCS
Abdul Hameed M. Al-Yahri, Yousef Mahmoud Ahmed Nooh, Gareth H. Thomas, Noureddin Daas, Moaaz Hashim, Osman Elhussien, Sharif Mohamed, Ehab Saleh
et
Sub Committees
QUALITY
Gareth H. Thomas
Effrosyni Plexousaki
Neil Courtman
Allan McEwan
Martin Cahalan
Nicholas Ray
Rolando Matias
Fraser McCaskill
CONCRETE
Noureddin Daas
Khaled Hassan
Jaafar Isam S. Al-Aloosi
Rabih Fakih
David Matyus
Peter Latham
Gireesh Babu.K.M
Srinivasan Samiappan
Shyam Sundar Rajaram
Mohanasundaram Rangasamy
Ahmed Mohamed El Sayd
Amr Elmotasem Elkady
Abdulrahim Mohammed
Mathhar Ghazi Mustafa
Sabet Hajem Ibrahi
Elie Khairallah
Subrato Mukherjee
Rabih Bahij Boukaidbey
Fatih Trk
ROADS
GREEN BUILDING
DRAINAGE
SAFETY
RAIL
Moaaz Hashim
Osman Elhussien
Jaafer Mohammed Al Saidi
Gary Cook
Huw Woodyatt
Richard James Ellis
Arthur Hannah
Khaled Hassan
Michelle Magbojos
Khalid Al- Emadi

Noureddin Daas
Mohamed El sherbiny
Essam El Sarag
Neil Kirkpatrick
Sharif Mohamed
Dick Steer
Mohammed Homoud Al-Yahri
Petru Ghicu
Jose Vellattukudy
Packiaraj Thangaswamy
Karunarathna T A. Kithsiri
Ehab Saleh
Yasser Berzan
Peter Sutton
Tom Baines
Salah Mousa
Michael De Roos
Adrian Black
Sheik Pahary
Osman Elhussien
Moaaz Hashim
Sharif Mohamed
Markus Kretschmer
Fatih Turk
Contributors to
Road Section
Peter E. Sebaaly
Karen OSullivan
Konstantinos Kanellaidis
Recycling
Robert Overett
Moaaz Hashim
Osman Elhussien
Gary Cook
Ahmed Sami Sayed Abbas
Road Lighting Work Group
Website Developer
Kim Catrambone
Melina Davies
Hazem Abdel Rahman
David Lewis
Roy Cupples
Rania Hashim Al-Abadi
Issam A. Sarhan
Reviewers
Document Controllers
Dr.Hany Mohamed
Ghaleb Al Zubi
Adel M. Quraan
Yousef Mahmoud Nooh

Saleem Puthiya Purayil
Mohammed Adil
Rawshan Haniffa
QCS 2014
Feedback
Page 1
FEEDBACK
It is intended that the technical regulation, Qatar Construction Specifications (QCS), will be amended
periodically. Any suggestions for amendments to Qatar Construction Specifications should be sent to
Laboratories and Standardisation Affairs in the Ministry of Environment.
By post:
The Coordinator
Laboratories & Standardisation Affairs
PO Box 23277
Doha, Qatar
By e-mail:
qcs@moe.gov.qa
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Section number and title

Part number and title
Clause and paragraph number
Page
Your name and contact details
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Please ensure that the following information are included in all correspondences:
Please use the following feedback form where possible and applicable.
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QCS 2014 Feedback
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Section name and title
Clause and paragraph number
Comments / Suggestions / Technical Justifications
Date
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Name and contact details
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Part name and title
QCS 2014
Section 01: General

Part
01: Introduction
Page1
INTRODUCTION ........................................................................................... 2
1.1
GENERAL ...................................................................................................... 2
1.1.1
1.1.2
1.1.3
1.1.4
Scope of this Section

Scope of the Qatar Construction Specification
References
Precedence of Specification and Documents
1.2
COMPLIANCE ............................................................................................... 3
1.2.1
1.2.2
Compliance with the Qatar Construction Specification

Compliance with the General Conditions of Contract
1.3
STANDARDS ................................................................................................. 3
1.3.1
1.3.2
1.3.3
References to Standards
3
Government Published Specifications, Regulations, Notices and Circulars 3
Survey Marks
5
1.4
TERMS AND DEFINITIONS .......................................................................... 5
1.4.1
1.4.2
1.4.3
1.4.4
1.4.5
1.4.6
1.4.7
1.4.8
1.4.9
1.4.10
1.4.11
1.4.12
1.4.13
1.4.14
1.4.15
1.4.16
1.4.17
1.4.18
1.4.19
1.4.20
1.4.21
1.4.22
General
Approved
Contract
Contract Documents
Contractor
Drawings
Engineer
Engineers Representative
Government
Government Departments and Utility Services
Guarantee
Independent Agency
Owner
Permanent Works
Plant
Project Documentation
Singular and Plural
Site
Specifications
Specified
Temporary Works
Works
1.5
ABBREVIATIONS AND SYMBOLS ............................................................... 7
1.5.1
1.5.2
General
Site Conditions
1.6
LANGUAGE ................................................................................................. 10
1.6.1
Contract Language
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QCS 2014
Section 01: General

Part
01: Introduction
Page2
INTRODUCTION
1.1
GENERAL
1.1.1
Scope of this Section
This Section specifies the general clauses applicable to Works being carried out in
accordance with this Specification.
1.1.2
Scope of the Qatar Construction Specification
The clauses in this Specification are applicable to each and every part of the Works. Their
function is to bring together all those statements which are normally common to most types
of work.
The Qatar Construction Specification applies to the entire Works, whether on the Site or in
yards, workshops and factories employed elsewhere in connection with the Works.
1.1.3
References
The following standards are referred to in this Part:
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BS 6100......................Building and civil engineering: Vocabulary
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BS ISO 80000 ............Quantities and Units
BS EN 1991-1-4 .........Eurocode 1. Actions on structures. General actions. Wind actions
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BS EN 1992-1-1 .........Eurocode 2. Design of concrete structures. General rules and rules for
buildings
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ASCE/SEI 7-05...........Minimum Design Loads for Buildings and other Structures

Guide to the Design of Concrete Structures in the Arabian Peninsula, 2008
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Seismic hazard and seismic design requirements for the Arabian Peninsula region. The 14th
World Conference on Earthquake Engineering October 2008
Civil Aviation Authority wind records. Ministry of Communication & Transport, Department of
Civil Aviation & Meterology.
1.1.4
Precedence of Specification and Documents
The precedence of documents shall be:

(a)
Particular Conditions of Contract.
(b)
General Conditions of Contract.
(c)
Project Specific Specification.
(d)
Project Specific and General Drawings.
(e)
Qatar Construction Specification.
QCS 2014
Section 01: General

Part
01: Introduction
Page3
COMPLIANCE
1.2.1
Compliance with the Qatar Construction Specification
Unless otherwise stated in the Project Documentation, the Contractor shall comply with every
requirement of the Qatar Construction Specification that is relevant to the type of work
forming any part of the Contract and shall adopt whichever permissible option or alternative
that is best suited to the needs of the construction work being undertaken.
Any information in the Contract documents as to the whereabouts of existing services and
mains is approximate and for the guidance of the Contractor who shall not be relieved of his
obligations under of the General Conditions of Contract .
1.2.2
Compliance with the General Conditions of Contract
The Qatar Construction Specification is intended for use with the General Conditions of
Contract.
The Contractor shall comply with the provisions of the General Conditions of Contract in the
course of construction of the Works.
1.3
STANDARDS
1.3.1
References to Standards
Any standard referred to in this Specification shall be deemed to be the version and/or
standard(s), that was current forty-two days prior to the date of return of Tenders.
Any standard referred to in this Specification shall be taken as a reference to an equivalent

Specification.
The Contractor shall have copies of all referenced standards applicable to the work being
undertaken. Translations of standards not written in English shall be provided where
necessary.
1.3.2
Government Published Specifications, Regulations, Notices and Circulars
The works shall be executed in accordance with the following Government specifications,
regulations, notices and circulars:
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1.2
(a)
The General Conditions of Contract.
(b)
The Qatar Construction Specification (QCS) issued by the Qatar Standards,

Laboratories and Standardisation Affairs, Ministry of Environment, 2014 and all
revisions and addenda issued by the same ministry prior to the date of the
announcement inviting tenderer.
(c)
The Code of Practice and Specification for Road Openings in the Highway prepared by
the Ministry of Industry & Public Works, January 1992.
(d)
The Guide for Civil Users of Explosives in Qatar prepared by the former Ministry of
Public Works.
(e)
The Qatar Survey Manual prepared by the Survey Section of the former Ministry of
Industry & Public Works.
QCS 2014
Section 01: General

Part
01: Introduction
Page4
The Qatar Traffic Manual prepared by the former Ministry of Public Works and the
Qatar Highway Design Manual prepared by MMAA, 1997.
(g)
The Traffic Control at Road Works Manual issued by the former Ministry of Industry &
Public Works.
(h)
Rules, Regulations and Code of Practice for Design and Installation of Air
Conditioning, Heating, Ventilation & Refrigeration (ACHVR) Systems for Government
Buildings, 2nd Edition, 1989, prepared by Qatar General Electricity and Water
Corporation (QGEWC).
(i)
Regulations for the Installation of Electrical Wiring by the former Qatar National
Telephone Services.
(j)
The Regulations for the Installation of Electrical Wiring, Electrical Equipment and Air
Conditioning Equipment, Feb 2006 Edition prepared by the Qatar General Electricity
and Water Corporation (QGEWC).
(k)
Rules and Regulations for Plumbing Works prepared by the Qatar General Electricity
and Water Corporation (QGEWC).
(l)
Any current and relevant regulations, notices or circulars issued by the Public Works
Authority, Ministry of Municipal Affairs & Agriculture (including the previous Ministry of
Public Works and the previous Ministry of Industry and Public Works), Qatar General
Electricity and Water Corporation (QGEWC) (including the previous Ministry of
Electricity and Water), Qatar Telecom (Q-TEL), the Qatar Standards, the Supreme
Council for the Environment and Natural Reserves or the appropriate local Municipality
prior to the date of the announcement inviting tenderer.
(m)
State of Qatar Law No. 30 of 2002 and all subsequent amendments concerning The
Environment and Natural Resources Protection Articles 6, 17, 19 & 35.
(n)
State of Qatar Law No. (6) of 1987 and all subsequent amendments concerning
Materials and Equipment from Qatar or other CCASG countries.
(o)
The Method of Measurement for Road and Bridgeworks published by the Ministry of
Industry and Public Works, Civil Engineering Department , 1987.
(p)
Standard Method of Measurement of Building Works published by the Ministry of

Public Works, Engineering Services Department, 1973.
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Safety Rules issued by the Electricity Networks Department of the former Ministry of
Electricity and Water.
(q)
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(f)
(r)
The Jointing Manual prepared by the Electricity Networks Department of the former
Ministry of Electricity and Water.
(s)
The Labour Law, No. (14) of The Year 2004 Published by Labour Department of
Ministry of Civil Service Affairs & Housing, 2005.
(t)
Developers Drainage Guide prepared by the Public Works Authority, 2007.
(u)
Qatar Traffic Law No. 19 of the Year 2007.
(v)
CDD (Civil Defence Department) Fire Safety Handbook.
(w)
Civil Defence Law No. 9 of the Year 2012.
(x)
Worker Rights Booklet 2009 (National Human Rights Committee).
The Contractor shall be deemed to have his own copy of the Government specifications,
regulations, notices and circulars given at (a) to (t) above.
QCS 2014
Section 01: General

Part
01: Introduction
Page5
Where any standard publication, specification, regulation, notice, etc or any correspondence
refers to a Government Ministry, department, division, section, etc it will be deemed to be the
same as any successor Ministry, department, division, section, etc which has or may
subsequently be officially promulgated by the Government of the State of Qatar.
1.3.3
Survey Marks
The Contractor shall consult the Engineer prior to any earth or other works to determine if the
work is likely to disturb survey marks. If the Engineer requires a survey mark to be moved
the Contractor will be responsible for recreating the survey mark to an approved design and
specification, and for resurveying the point using survey companies approved by the
Engineer authority.
The Contractor shall be responsible for the protection of the survey marks within the
boundaries of the site for the duration of the contract period, and shall be liable for all costs of
any remedial work required by the Engineer.
On the practical completion of the Works the Engineer will issue a certificate stating that all
survey marks, whether disturbed or otherwise by the Contractor, have been reinstated or
protected to the satisfaction of the Engineer.
In the event of failure to comply with the requirements of this Clause the Engineer, without
prejudice to any other method of recovery, may deduct the costs of any remedial work after
the practical completion date carried out by the Engineer, from any monies in its hands or
which may become due to the Contractor.
1.4
TERMS AND DEFINITIONS
1.4.1
General
The following terms and conditions shall apply when used within, or in association with, the
Qatar Construction Specification. Terms, which are restricted in their application to certain
types of material or workmanship, are dealt with in the appropriate Section.
The definitions given in the General Conditions of Contract shall apply to this specification.
1.4.2
Approved
means terms such as approved, approved by, to the approval, as directed and the like
refer always to approval or directions given by the Engineer in writing.
1.4.3
Contract
means the binding agreement entered into between the parties and the Contractor for the
construction of the Works.
1.4.4
Contract Documents
means documents which together form the Contract
1.4.5
Contractor
means the party responsible for the construction of the Works.
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QCS 2014
Section 01: General

Part
01: Introduction
Page6
Drawings
The drawings included in the Project Documentation.
1.4.7
Engineer
means the party appointed by the Owner to administer the Contract
1.4.8
Engineers Representative
means the party appointed from time to time by the Engineer to perform duties on behalf of
the Engineer whose authority and delegated powers shall be notified in writing to the
Contractor by the Engineer.
1.4.9
Government
means the Government of the State of Qatar, including its ministries and offices
1.4.10
Government Departments and Utility Services
means any governmental, semi-governmental, administrative, fiscal or judicial ministry,

department, commission, authority, tribunal, agency, municipality or body, and shall include
the provider of electricity, gas, water, wastewater and other public services, and any party
with a regulatory function under the laws of the State of Qatar.
1.4.11
Guarantee
A Guarantee is a written assurance that a material, product, component, item of equipment,

finishing or any other part of the Works meets certain defined standards or quality criteria
and/or lasts for a certain length of time.
A warranty is the same as a Guarantee as defined in Clause 1.4.17.1.
1.4.12
Independent Agency
means a party where specified in the Contract Documents or as instructed by the Engineer
as an Approved agency who is responsible for specific tasks assigned to that party by the
Contract Documents
1.4.13
Owner
means the party for whom the Project is being undertaken and to whom the handover of the
final product will be made.
1.4.14
Permanent Works
means the permanent works, forming part of the Works, to be designed and / or executed
and completed by the Contractor under the Contract.
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1.4.6
QCS 2014
Section 01: General

Part
01: Introduction
Page7
Plant
means, irrespective of ownership, all plant, facilities, temporary structures and

accommodation, equipment, tools, appliances, apparatus, machinery, vehicles and other
things required for the design, execution and completion of the Works and the remedying of
defects, whether imported or locally supplied, but excluding Temporary Works and any other
things intended to form or forming part of the Permanent Works
1.4.16
Project Documentation
All documents associated with and applicable to the Project Contract.
1.4.17
Singular and Plural
Words importing the singular only also include the plural vice versa where the context
requires.
1.4.18
Site
Means the places provided by the Owner where the permanent works are to be executed and
to which Plant and Materials are to be delivered, any other places that may be specified in the
Contract Documents or by an instruction of the Engineer as forming part of the Site
1.4.19
Specifications
All specifications contained in the Contract including any modifications or additions thereto as
may from time to time be issued or approved in writing by the Engineer.
1.4.20
Specified
Specified in the Project Documentation.
1.4.21
Temporary Works
means temporary works of every kind (other than Plant) required on the Site for the execution
and completion of the Permanent Works and the remedying of Defects.
1.4.22
Works
means all works, supplies and services of any kind, including Permanent Works and
Temporary Works, required for the project and to satisfy the requirements of the Contract
Documents.
1.5
ABBREVIATIONS AND SYMBOLS
1.5.1
General
Units shall generally be in accordance with the Systm International dUnits and the relevant
provisions of BS ISO 80000
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1.4.15
QCS 2014
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microns
ampere
Celsius
centi
day
diameter
gram (me)
hour
hectare
joule
kilo
litre
mega
metre
milli
Newton
number
number
Pascal
radius
second
tonne
volt
Watt
se
A
C
c
d
dia
g
h
ha
J
k
l
M
m
m
N
No.
nr
Pa
r
sec
t
V
W
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American Association of State Highway and Transportation Officials

American Concrete Institute
American National Standards Institute
American Society of Mechanical Engineers
American Society for Testing & Materials
American Welding Society
American Water Works Association
British Standard
British Standard Institution
Cement and Concrete Association
Commission of approval of Electrical Equipment
Chartered Institution of Building Services Engineers
Concrete Industry Research and Information Association
Concrete Reinforcing Steel Institute
Concrete Society
Deutsches Institute fur Normung (German Institute for Standardization)
Electronic Industries Association
European Standards (Euro-Norm)
Federal Highway Authority
Factory Mutual Engineering Division
Gulf Standards
Institution of Civil Engineers
International Electrotechnical Commission
Institution of Electrical Engineers
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AASHTO
ACI
ANSI
ASME
ASTM
AWS
AWWA
BS
BSI
C & CA
CEE
CIBSE
CIRIA
CRSI
CS
DIN
EIA
EN
FHWA
FM
GS
ICE
IEC
IEE
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Reference to a technical society, institution, association or governmental authority is made in

the Specifications in accordance with the following abbreviations:
Page8
The following abbreviations are used in this Specification:
Section 01: General

Part
01: Introduction
Section 01: General

Part
01: Introduction
IEEE
ISO
LPC
LPCB
MMAA
NEMA
NFPA
PCI
PWA
QCS
QGEWC
QS
Page9
Institute of Electrical and Electronic Engineering

International Organization for Standardization
Loss Prevention Council
Loss Prevention Certification Board
Ministry of Municipal Affairs and Agriculture
National Electrical Manufacturers Association
National Fire Protection Agency
Prestressed Concrete Institute
Public Works Authority (Ashghal)
Qatar Construction Specification
Qatar General Electricity & Water Corporation
Qatar Standards (Laboratories and Standardisation Affairs, Ministry of
Environment)
Qatar Telecom Provider
Swedish Standards Institute
United Kingdom Department of Transport
Urban Planning and Development Authority
Verband Deutscher Elektrotechniker (Association for Electrical, Electronic
and Information Technologies)
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Ooredoo
SIS
UK DOT
UPDA
VDE
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QCS 2014
Site Conditions
The Site conditions shall be assumed to be as follows for tendering purposes:
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1.5.2
Maximum ambient temperature .......................... 50C
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Minimum ambient temperature ........................... 5C
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Design ambient temperature ............................... 50C

Maximum metal temperature under the sun ....... 85C
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Maximum ambient humidity ................................ 100%

Minimum ambient humidity ................................. 20%
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Design ambient humidity ..................................... 100%

50-year return period Wind Speed:
(a) Nominal wind speed for 3 sec gust 38 m/s (A per ASCE 7-05 / IBC 2012)
(b) Mean hourly wind speed. 25 m/s (as per BS 6399-2)
(c) Mean 10 minutes wind speed 27 m/s (as per BS EN 1991-1-4)
Yearly rainfall ....................................................... 80 - 150 mm

2
The wind is very directional and that the W-NNW sector predominates for velocities greater
than 8m/s (30km/h). However, the wind in coastal areas tends to exhibit a diurnal pattern,
with onshore winds during daylight hours changing to offshore at night.
The temperature is relatively mild from October to May and hot from June to September.
The relative ambient humidity is generally low from October to May and generally high from
June to September.
Under certain climatic conditions, considerable condensation may take place.
A considerable amount of salt is contained in the atmosphere which together with the
relatively high ambient humidity, can produce sever corrosion problems.
QCS 2014
Section 01: General

Part
01: Introduction
Page10
Distribution and occurrence of rainfall events are very erratic. Rainfall events are generally of
a high intensity with a short duration and usually occur between December and March.
The prevailing wind directions are from the north and west.
The seismic design for all building structure shall be based upon local seismic accelerations
recommended as per ASCE 7-10, IBC 2012 or BS EN 1998-1:2004. Local seismic spectral
accelerations based upon uniform hazard response spectra for 475 year and 2475 year
return period as below.
Peak Ground Acceleration
(PGA)
2475 year
475 year
2475 year
475 year
0.045
0.10
0.090
0.147
0.045
2475 year
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475 year
0.065
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Wind tunnel test is recommended for buildings under below criteria

Total building height exceeding 120m from ground.
(b)
Structure with irregular geometry or shape.
(c)
Unusual terrain or surrounding structure in the area.
(d)
Any other factor as per design requirements or designer recommendation.
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(a)
The ratio of the wind speed for any return period to the 50 year return period wind speed as
per Peterka & Shahid Equation is
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1 second Spectral
Acceleration (g) S1
as
10
0.2 second Spectral

Acceleration (g) - Ss
Building structure design working life shall be minimum as specified below
10
Examples
Temporary structures (a)
10 to 25
Replaceable structural parts, eg. Gantry girders, bearings
15 to 30
Storage and similar structures
50 to 75
Building structures and other common structures
120
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Indicative design
working life (years)
Design working
life category
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12
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VT / V50 = [0.36+0.1 ln (12T)]
(a)
Civil engineering structures like bridges, tunnel etc.
Structures or parts of structures that can be dismantled with intention of being reused, arent temporary
structures.
1.6
LANGUAGE
1.6.1
Contract Language
All communications, meetings and documentation shall be in English.

END OF PART
QCS 2014
Section 01: General

Part
10: Occupational Health and Safety
Page 1
10
OCCUPATIONAL HEALTH AND SAFETY .................................................... 3
10.1
GENERAL ...................................................................................................... 3
3
3
4
5
6
6
7
7
7
8
8
10
10
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10.1.1 Scope
10.1.2 Responsibility
10.1.3 Organisation for Occupational Health and Safety
10.1.4 Reporting Accidents
10.1.5 General Sanitation
10.1.6 Safety Notice Board
10.1.7 Compensation for Damage
10.1.8 Occupational Health and Safety Performance
10.1.9 Occupational Health and Safety Leadership and Accountability
10.1.10 Safe-working Arrangements
10.1.11 Labour Rights, Benefits & Obligations
10.1.12 Language barriers and communications issues
10.1.13 Communications, Consultations and Participation
10.1.14 Management Review
CONTRACTOR OCCUPATIONAL HEALTH AND SAFETY PLAN ............. 11
10.2.1
10.2.2
10.2.3
10.2.4
10.2.5
10.2.6
General
Occupational Health and Safety Policy
Risk Assessment and Job Hazard Analysis
Intervention
Requirement for Training
Method Statements
10.3
EMERGENCY RESPONSE PLAN (ERP) .................................................... 19
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10.3.1 General
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10.2
11
16
16
16
17
19
19
EARTHQUAKE EMERGENCY MANAGEMENT PLAN ............................... 20
10.4.1
10.4.2
10.4.3
10.4.4
10.4.5
10.4.6
10.4.7
Background
Requirements
Phase One: Gap Analysis (as is)
Phase Two: Implementation (to be)
Phase Three: Future Requirements
What Should We Do During An Earth Quake?
What Should We Do After An Earth Quake?
10.5
SPECIAL SAFETY REQUIREMENTS AND PRECAUTIONS ..................... 24
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10.4
10.5.1 Permits
10.5.2 Guarantee
10.5.3 Mechanical Plant, Machinery and Equipment
10.5.4 Existing Utilities
10.5.5 Excavations
10.5.6 Warning Signs
10.5.7 Confined Spaces
10.5.8 Lifting Operation
10.5.9 Lifting Gear
10.5.10 Scaffolding
20
21
21
22
22
23
23
24
24
24
25
26
28
28
30
30
31
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Section 01: General

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Page 2
10.5.11 Hot work and Welding

10.5.12 Compressed Gas Cylinders
10.5.13 Working at Height
10.5.14 Electrical
10.6
32
33
34
36
FIRST AID ................................................................................................... 37
10.6.1 First Aid and Clinic

10.7
37
FIRE PRECAUTION AND PREVENTION ................................................... 37
10.7.1 General
10.7.2 Emergency Equipment
10.7.3 Hazardous Substances
SAFETY OF THE PUBLIC ........................................................................... 41
10.8
37
39
40
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10.8.1 Working in Public Areas
41
WELFARE, SAFETY AND PROTECTION OF WORKMEN ........................ 42
10.9.1
10.9.2
10.9.3
10.9.4
10.9.5
10.9.6
10.9.7
General
Personal Protective Equipment (PPE) / Attire
Safety Equipment
Support Facilities for Contractors Staff and Labour
Summer Working Conditions and fatigue
Additional Environmental Protection and Pollution Control
Plant and Equipment Test Certificates
10.10
LABOUR ACCOMODATION ....................................................................... 46
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10.9
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10.10.1 General
10.10.2 Quality of Labour Accommodation
10.10.3 Provision for Fire Safety
10.10.4 Provision for Health Care
10.10.5 Access to Transport
10.10.6 Access to Religious, Social and Domestic Facilities
10.10.7 Access to Communications
10.10.8 Number, Quality and Location of Sanitation Facilities
10.10.9 Food Preparation Areas
10.10.10 Pest and Vermin Control
10.10.11 Security at Labour Accommodation
10.10.12 Social Issues
10.10.13 Competence of Labour Accommodation Management
10.10.14 Environmental Conditions at Labour Accommodation
10.10.15 Health and Safety for Labour Accommodation Residents
42
42
42
43
45
45
46
46
46
47
47
48
48
49
49
49
50
50
50
51
51
52
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Section 01: General

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Page 3
10
OCCUPATIONAL HEALTH AND SAFETY
10.1
GENERAL
10.1.1
Scope
This Part specifies the Health, Safety and Welfare requirements for construction and its
associated practices.
Related Sections and Parts are as follows.
Section 11
Health and Safety
Protection
Building Demolition
Materials
Setting-out of the Works
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Part 8
Part 9
Part 11
Part 13
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This Section
Responsibility
It is the Contractors responsibility to implement an Occupational Health and Safety

Management System meeting as a minimum the requirements of BS OHSAS 18001. It shall
be the duty of the Contractor to provide the following:
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10.1.2
Safe plant and equipment;
(b)
Safe means of handling, transporting and storage of articles and substances;
(c)
Adequate training, instruction, information and supervision;
(d)
A safe place of work with safe access to and egress from the place of work;
(e)
A safe and healthy environment; and
(f)
Adequate welfare facilities.
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(a)
It is the Contractors responsibility to conduct his operations in such a manner as to prevent

injury to persons or damage to property. The Contractor shall take precautions for protection
against risks and shall inspect Occupational Health and Safety conditions where the Works
are being executed.
The Contractor shall conform to all Acts, Orders and Regulations made by any official
authority with respect to Occupational Health and Safety.
The Contractor shall note that Occupational Health and Safety (OHS) shall be treated with
high importance at all stages of the Contract. Contractor shall understand that the Contract
Price includes the Execution Programme for provision and implementation of an
Occupational Health and Safety Policy and Plan to ensure the highest standards are
enforced throughout Construction, Pre-commissioning and Commissioning.
QCS 2014
Page 4
The Contractors attention is drawn to the requirements of latest revision of:

Qatar Construction Specification QCS,
(b)
Qatar Law No.14 of the Year 2004 The Labour Law, and the ministerial decisions
issued in implementation of the provisions of the Labour Law issued by Law No. 14 of
2004,
(c)
Qatar Traffic Law No. 19 of the Year 2007,
(d)
Environmental Protection Law No. 30 of the Year 2002 and Decision No. (4) for the
year 2005 by issuing the executive regulations of Environmental Protection Law,
(e)
Civil Defence Law No. 9 of the Year 2012,
(f)
CDD (Department of Civil Defence) Fire Safety Handbook; and
(g)
Worker Rights Booklet 2009 (National Human Rights Committee).
(a)
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Section 01: General

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The Contractor is required to fully comply with the stated requirements relating to
Occupational Health and Safety. In the event that legislation is updated the latest version
shall be followed.
The Contractor shall ensure that Contractor Personnel and Subcontractors employees
comply with all requirements of latest revision of QATAR legislation mention above (but not
limited to). Compliance with the standards shall be considered as a minimum requirement
and Contractor shall establish additional arrangements as circumstances may require. Any
failure by Contractor to obtain copies of that mentioned laws applicable to the Contract shall
in no way relieve the Contractor from any responsibilities or obligation under the Contract.
The Contractors Representative shall be responsible for all Occupational Health and Safety
matters during the performance of the Work up to and including the Completion Date. The
Contractors Representative shall ensure that an effective Occupational Health and Safety
management organization is maintained at all times to undertake the duties to comply with
this requirement.
10.1.3
Organisation for Occupational Health and Safety
The Contractor shall submit an Occupational Health and Safety Organisation Plan detailing
planning and management considerations for construction at an organisational level for the
Engineers approval within Thirty (30) days of the award of the Contract.
The Occupational Health and Safety Organisation Plan shall provide the names,
qualifications, experience and skills of all the Safety Team and key support staff.
The Contractor shall submit the names of the following to the Engineer for approval:-
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(a)
The details of its proposed competent and experienced Occupational Health and
Safety Manager. The minimum education for the proposed Occupational Health and
Safety Manager are but not limited to Bachelor degree in Engineering / Science or
equivalent with 10 years experiences in the same field as Safety Manager and the
ability to communicate with all nationalities, plus Professional OHS Qualification by
Examination (NEBOSH, IOSH Managing Safely, OSHA 30 hours, ... etc), Management
Qualification prefer certified as BS OHSAS 18001 lead auditor, implementation and
continues improvement Relevant Training Attendance. The Engineer shall review the
details and if necessary interview the proposed individual to assess his/her suitability
for the position prior to giving approval for appointment. The Contractor is not
QCS 2014
Section 01: General

Part
Page 5
permitted to execute any form of Work on the Worksite until such time as an approved
Occupational Health and Safety Manager has been deployed on a full time basis to the
Worksite. The Contractor shall not remove the appointed Occupational Health and
Safety Manager without prior approval from the Engineer.
(b)
Deputy Occupational Health and Safety Manager who is capable of performing all of
the duties of the Occupational Health and Safety Manager in the event of his absence.
The requirements and procedure outlined in Clause (a) above applies equally to the
appointment of the Deputy Occupational Health and Safety Manager.
The Contractor shall appoint Occupational Health and Safety Officers and support staff in
sufficient numbers to ensure the effective function of the Occupational Health and Safety
discipline within the Contractors organisation. The minimum education for the Occupational
Health and Safety Officer are HND / HNC with 4 years experiences in the same field as
Safety officer, certified from NEBOSH, IOSH or OSHA 30 hours, Professional in control and
monitoring the site activity. The Contractor shall appoint and deploy full time on the Worksite
one Occupational Health and Safety Officer for each and every 50 persons employed at the
Worksite. For a less than 50 persons employed at the Worksite, a minimum of one (1) Safety
Officer shall be present on site during all working hours each day throughout the Contract
period. This is in addition to the Occupational Health and Safety Manager and his Deputy.
The Safety Officers shall have no other duties, either on-site or off-site, other than
Occupational Health and Safety duties, and shall be exclusive to one site.
The Contractor shall ensure that each and every Subcontractor employed on the Worksite
appoints suitably competent and experienced qualified Occupational Health and Safety staff
to ensure the effective function of the Occupational Health and Safety discipline within the
Subcontractors organisation. The requirements and procedure outlined above for contractor
Occupational Health and Safety staff to be applies equally to the appointment of the
Subcontractor Occupational Health and Safety Staff. The Subcontractor shall appoint and
deploy full time on the Worksite one Occupational Health and Safety Officer for each and
every 50 persons that they employ at the Worksite. Any Subcontractor that employs more
than 100 persons will appoint an Occupational Health and Safety Manager. This is in addition
to the Occupation Occupational Health and Safety Officers.
10.1.4
Reporting Accidents
The Contractor shall promptly report to the Engineer any accident whatsoever arising out of,
or in connection with, the Works whether on or adjacent to the Site which caused death,
personal injury or property damage, giving full details and enclosing statements of witnesses.
Promptly shall mean immediately by telephone where it impacts on the operation of the
project and electronically in all cases never more than 24 hours.
The Contractor shall implement arrangements for effectively managing any emergency
incident that may occur as a result of Work and/or on the Worksite.
The Contractor shall make all necessary arrangements for emergency preparedness
including, but not limited to, medical equipment and facilities, trained personnel,
communication systems, transportation, search and rescue equipment.
The Contractor shall produce and submit to the Engineer monthly performance reports and
incident reports. Reports shall be in the format approved by the Engineer.
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The Contractor shall refer to, and in particular, QCS 2013 (Section 11, Part 2) for all incident
classifications and definitions.
Incident Investigation final reports to be submitted for all lost time major / reportable Incidents
within 10 days of the incident. All incidents that result in lost time from work, near miss,
dangerous occurrence or damage to property (asset) shall be reported. The normal steps to
be taken after an incident shall be;
Submit incident notifications immediately;
(b)
Conduct the investigation;
(c)
Prepare the report with conclusions and recommendations;
(d)
Prepare appropriate plan of corrective action;
(e)
Include in monthly Health and Safety statistics report;
(f)
Submit to Engineer for review and re-submittal if required.
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(a)
General Sanitation
The Contractor shall maintain the Site and all working areas in a sanitary condition and in all
matters of health and sanitation shall comply with the requirements of the Supreme Council
of Health and the Public Works Authority.
The Contractor is responsible for all measures necessary to prevent the breeding of
mosquitoes on the Site for the duration of the Contract.
The Contractor shall ensure that pests are not permitted to the Site facility by initiating a
routine pest control program. Non-toxic pest control methods shall be used.
The disposal surplus water and the accompanying growth of trees and the proliferation of
insects and rodents. Does the site cause an environmentally danger to the surrounding area?
10.1.6
Safety Notice Board
The Contractor shall set up and maintain (cleaned and legible) throughout the course of the
Contract safety notice boards in prominent places on the Site. These notice boards shall be
located in positions approved by the Engineer such that they are clearly visible to the
Contractors employees. They shall be fully illustrated and provide details of key safety
procedures to be followed.
The notice boards shall be in Arabic, English and;
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10.1.5
(a)
In all other languages which are the mother tongue of five or more of the Contractors
employees, or
(b)
The preferred languages (can be understood) by the workers on the Worksite.
The Contractors employees shall be made fully aware of the notice boards prior to
commencing duties on Site.
The Contractor shall maintain up to date copies of all industry codes and standards that apply
to the Work.
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Compensation for Damage
Claims for compensation arising from damage or injury caused by the Contractors failure to
provide adequate Occupational Health and Safety measures shall be the sole responsibility
of the Contractor.
The Contractor shall notify the Engineer of any claim made against him which is in any way
connected to the Contract.
The Contractor is required to copy to the Engineer any formal Occupational Health and
Safety related communication between the Contractor and enforcing authorities or
government organizations.
10.1.8
Occupational Health and Safety Performance
The Contractor shall ensure acceptable Occupational Health and Safety performance of all
Subcontractors, visitors, vendors, public and other parties that may enter the Worksite or the
amounts identified in the Bills of Quantities.
Should acceptable Occupational Health and Safety performance not be maintained by the
Contractor then the Engineer may, in addition to any other amounts withheld under the
Contract, withhold up to 10% of the amount of any interim invoice issued by the Contractor.
The Contractor shall develop and implement programmes which shall act as incentives for
their teams at all levels, to make a positive contribution to good health and safety
performance.
10.1.9
Occupational Health and Safety Leadership and Accountability
The Contractor shall be committed to Health and Safety leadership and this is to be achieved
through working in partnership with the main project stakeholders including the Engineer and
the Client.
The Contractor shall demonstrate commitment to the safety, health and welfare of all
stakeholders and workers on projects and shall demonstrate leadership in achieving the
following objectives:
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10.1.7
(a)
A safe, healthy workplace
(b)
Be consulted on their working conditions, to be heard, and to influence their working

conditions
(c)
Return home from work unharmed at the end of each working day; to which everyone
has a right to.
The Contractor shall provide opportunities through forums and meetings involving important
project stakeholders, including the Client, The Engineer, sub-contractors and other relevant
contractors to raise health and safety issues, assist in the development of leadership
programmes, share good practice and be recognised for good performance.
The Contractors senior management shall visibly demonstrate support, commitment,

Leadership and Accountability on all health and safety issues by the following actions:
(a)
The Engineers Zero Harm Initiative;
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Training employees to work safely;
(c)
Recognizing and rewarding employees;
(d)
Identify risks to health and safety and develop mitigation/control plans and
communicate these to workers;
(e)
Reinforce safe work practices;
(f)
Place health and safety as the first item on the agenda at meetings.
(g)
Allocate adequate resources for health and safety management and implementation
(h)
Develop health and safety targets and objectives and measure and review
performance;
(i)
Foster positive health and safety culture and behaviour through their own actions;
(j)
Treat health and safety as a core value equal in importance with productivity, quality
and ethical standards;
(k)
Participate in health and safety meetings and safety walkabouts;
(l)
Develop efficient contingency plans and allocate adequate emergency resources;
(m)
Provide trained and competent workforce;
(n)
Promote personal health and well-being; and
(o)
Seek to exceed current legislation in relation to welfare and labour facilities.
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10.1.10 Safe-working Arrangements
The Contractor shall have arrangements to empower their staff to make sensible decisions
about their own safety and the safety of others affected by what they do, and not put
themselves or others at risk of harm.
Contractor to have safe-working arrangement that ensures:
Employees can stop work immediately where they believe they or others are at risk of
harm
(b)
That health and safety concerns can be raised and associated actions taken
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No disciplinary action is taken against those who use the worksafe arrangement to
raise a genuine health and safety concern
(d)
That the process is cascaded to their subcontractors
All such arrangements shall be briefed to all staff, including any agency or sub contract staff
before they start work.
Where safety concerns are raised or a stop work process has been invoked employers shall
document them and the action taken to resolve them; and shall advise others working on the
project were the issue is likely to impact on them or be similar to those faced by other
organisation
10.1.11 Labour Rights, Benefits & Obligations

1
The Contractor shall document implementation of Labour Law, in particular with respect to
the following:
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Recruitment The Contractor shall maintain an up-to-date list of all agents/agencies

used and should provide copies of licences for same to the Engineer. The Contractor
shall, through their best endeavours, satisfy themselves, and the Engineer, that
recruitment agents/agencies used do not charge recruits any fees inconsistent with
those allowed for under the Labour Law (Qatar Law no.14 of the year 2004).
(b)
Contracts The Contractor shall retain, for inspection by the Engineer, copies of
written employment contracts for all employees working on the project. Such
employment contracts shall be in accordance with the requirements of the Labour Law
and no contract clause may contravene the Labour Law.
(c)
Wages A Wage Register shall be retained in accordance with the requirements of

the Labour Law. The Contractor shall update the Wage Register to ensure that
employee wages, including relevant overtime payments, are paid in a timely fashion
and in a manner consistent with the requirements of the Labour Law. These records
shall be available for inspection by the Engineer and shall clearly identify overtime
payments and rates.
(d)
Severance Pay The Contractor shall retain records to demonstrate that payment of
severance payments have been made, where appropriate, in accordance with Article
132 of the Labour Law.
(e)
Records & Files These shall be retained in accordance with the Labour Law, and
shall be made available to the Engineer for inspection.
(f)
Work Rules & Disciplinary Rules These shall be in accordance with the Labour Law,
shall be conspicuously displayed, and shall be provided to the Engineer.
(g)
Working Hours & Leave - The Contractor shall retain records to demonstrate that all
employees working hours and leave allowances are consistent with the requirements
of the Labour Law.
(h)
Collective Labour Disputes - Any/all collective labour disputes shall be dealt with in
accordance with the requirements of the Labour Law. Complete records of all such
disputes shall be retained by the Contractor for review by the Engineer. As a
minimum, the Contractor shall inform the Engineer immediately, on receipt of
complaint/claim from the employees.
Subcontracts As such, obligations, relating to Recruitment, Contracts, Wages,
Records & Files, Work Rules & Disciplinary Rules, Working Hours & Leave and
Collective Labour Disputes shall be passed on to the subcontractor in the event that
works are subcontracted by the Contractor. Similarly, subcontractor records shall be
made available to the Engineer.
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(a)
The Contractor shall provide copies of Contracts, Work Rules, Disciplinary Rules, Pay Slips,
etc. to employees in a range of appropriate languages, as widely understood by the
workforce.
The Contractor shall submit a monthly declaration to the Engineer outlining compliance with
Labour Law in relation to payment of wages and working hours for the preceding period.
The Contractor shall facilitate contact between project employees and relevant independent
bodies such consulates, NGOs, or other relevant organisations offering social support. A list
of such local contacts shall be provided to new employees during their induction process.
An up-to-date list of contact details for these organisations shall also be displayed in public
areas such as the canteen, recreational areas, etc.
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10.1.12 Language barriers and communications issues

1
The Contractors shall ensure that their workforce fully understand site health and safety
requirements, including emergency arrangements and site rules in place. The language
needs of personnel shall be addressed during induction and through training. Emphasis
should be placed on ensuring proper supervision of all staff, but in particular those who may
have difficulties in understanding verbal or written communications. Where practicable,
signage shall make maximum use of pictograms.
Those who have responsibility for managing Contractor personnel on construction site shall
be able to communicate in both written and oral English to a standard appropriate to the
tasks being performed. Note that there may be personnel who are not competent in the
English language, and this is permitted provided that the Contractor can demonstrate that:
(b)
Such team members shall receive the required health and safety training / briefing
(including any emergency procedures) before commencing work in a form that they
understand
(c)
Appropriate arrangements are made to ensure that instructions are effectively

communicated to and understood by all team members
(d)
Particular attention has been given to the communication requirements of safety

critical workers. ensuring a translator is available who is capable of instructing the nonEnglish speaking personnel in safety and other operational matters, and
(e)
Maintaining a reasonable ratio of non-English speaking personnel to each translator at

all times.
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Such team members are able to give oral instructions and warnings to others
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Special provisions for safety critical instructions conveyed by the translator shall be recorded
as being received and clearly understood by each non-English speaking person. Such
records shall include those for safety induction, emergency procedures, safety method
statements and safety awareness talks.
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10.1.13 Communications, Consultations and Participation

The Contractor shall be required to disseminate and transfer information regarding Health
and Safety issues. Typical information to be communicated should include but not be limited
to; any new policies or procedures and general awareness.
The Contractor shall ensure communications arrangements are in place to inform of key
health and safety issues. These will include lessons learnt from incidents, sharing of good
practice, health and safety campaigns and initiatives. Contractors shall have processes in
place to ensure an appropriate cascade to all site personnel.
The following methods of communication but not limited to shall be observed;
(a)
Meetings; Health and safety meetings shall be conducted on a weekly basis separate
from other meeting that have safety on the agenda
(b)
Safety Alerts; Safety alerts shall be produced by the Contractor after a Major
Accident/Incident or when appropriate.
(c)
Notice Boards; Information that shall be included as a minimum on an office notice

board is any relevant emergency procedures, policy statement, safety alerts or updates
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(d)
Campaigns; Health and safety campaigns must be initiated by the Contractor to

implement throughout the year. At least 4 campaigns must be run annually on a prorata basis. One of the campaigns must detail heat stress before the summer months.
(e)
Posters/Signs; Must be focused on themes relevant to site specific work

activities/hazards
(f)
Safety Awards; The Contractor shall initiate a scheme whereby he recognises and
rewards for positive health and safety related performance by individuals. This shall be
on a monthly basis and communicated throughout the project workforce.
10.1.14 Management Review

The Contractor has to supply evidence that their senior management have carried out a
management review, at least annually, of their OHSE systems to ensure continuous
improvement.
The review shall include, but not limited to, where appropriate, an evaluation of and / or
changes to:
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Health and safety policy;
(b)
Objectives and targets;
(c)
Action plans;
(d)
Follow-up action from previous meetings;
(e)
Health and safety system suitability;
(f)
Audit results;
(g)
Preventive and corrective actions;
(h)
Regulatory changes;
(i)
Continual improvement measures;
(j)
Performance measures;
(k)
Major procedure and risk review changes; and
(l)
Health and safety plans.
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(a)
CONTRACTOR OCCUPATIONAL HEALTH AND SAFETY PLAN
10.2.1
General
The Contractor shall prepare a Contract specific Occupational Health and Safety Plan (the
Safety Plan) and submit a Safety Plan to the Engineer for review and approval within thirty
(30) days of the award of the Contract. The Contractor is not permitted to Work on the
Worksite until such time as the Plan has been approved by Engineer. It will be a condition
precedent to starting the works that the Contractor will have an approved Health and Safety
Plan, Traffic Management Plan, and an Emergency Response Plan.
The Safety Plan shall include the Contractors proposals for the maintenance of safety on the
Site. These proposals shall address the safety measures applicable with respect to all tasks
to be undertaken in the construction of the Works.
The Safety Plan shall include the Contractors proposals for accident prevention. Accident
prevention shall include but not be limited to training, monitoring and review of safety related
procedures, enforcement of safety related matters and promoting safety awareness.
10.2
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The Safety Plan shall include a safety organisation chart showing the names and
responsibility of all safety personnel deployed both on and off the Worksite to maintain
acceptable Occupational Health and Safety performance of the Contract and the Work at all
times, even outside the normal working hours, in particular night-time and holiday working.
(refer to 10.1.3)
The Contractor is required to work in areas where dangerous concentrations of gases may
be present in manholes, trench excavations and the like. It is the Contractors responsibility to
provide all necessary detection equipment and to ensure that, if toxic or explosive gases are
found, adequate measures are taken to protect his staff, workmen and members of the
public.
The Safety Plan shall be specific to one Contract.
The Contractor shall regularly review the suitability of the Safety Plan. The Contractor shall
undertake a full formal review of the Safety Plan annually on the date of award of the
Contract or when necessary but no less than 6 monthly intervals and submit the findings of
the review to the Engineer within 14 days of that date along with an amended plan should any
amendment be required.
The Safety Plan shall contain the Contractors Occupational Health and Safety Policy. (refer
to 10.2.2)
The Plan for construction works shall support and supported by the Contractors systems for
risk management in particular risk assessment and method statement (refer to the
Regulatory Document Section 11 Part 1 in particular section 1.1.7: Risk Assessments and
Method Statement and Guidance document Section 11 Part 2 Section 2.4: Guidance on Risk
Assessment and Method Statement). The plan shall include a schedule of risk assessments
for all work activities in relation to the project. The plan shall include a list or schedule of
identified work activities for which method statement will be developed before their
execution..
10
The Safety Plan shall include the contract risk assessment and detail the arrangements for
ensuring that it is updated to reflect any changes throughout the duration of the Work.
11
The Safety Plan shall detail the arrangements for undertaking job hazard analysis and
ensuring that such analysis is included in each and every method statement.
12
The Safety Plan shall detail the management arrangements and standards to be used for
each of the following:
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(a)
Scaffolding
(b)
Suspended Working Platforms
(c)
Fall Prevention and Fall Arrest
(d)
Prevention of Falling Objects
(e)
Excavations
(f)
Electricity
(g)
Structural Steel Erection
(h)
Demolition and Dismantling
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False work and Formwork
(j)
Reinforcement and Concreting
(k)
Cladding and Roof work
(l)
Confined Spaces
(m)
Lifting Appliances and Lifting Gear
(n)
Mobile Plant and Vehicles
(o)
Mobile Elevating Working Platforms
(p)
Construction Lifts
(q)
Machinery and Equipment
(r)
Power Tools
(s)
Hazardous Substances
(t)
Hot Work and Welding
(u)
Fire Prevention and Protection
(v)
Access and Egress
(w)
Housekeeping
(x)
Warning Signs and Barricades
(y)
Material Handling, Transportation and Storage
(z)
Lock Out and Tag Out
(aa)
Temporary Works
(bb)
Temporary Facilities
(cc)
Underground and Overhead Utilities
(dd)
Working Over or Adjacent to Water
(ee)
Working Environment
(ff)
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Personal Protective Equipment

Site Traffic Control (including setting and taking down of all temporary traffic devices)
(gg)
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The Safety Plan shall detail the arrangements that the Contractor shall use to ensure
acceptable Occupational Health and Safety performance of all Subcontractors that may enter
the Worksite. It shall detail the arrangements for evaluating Subcontractors prior to them
being contracted to undertake Work. It shall detail the methods that the Contractor shall use
to monitor their work and the penalties that shall be imposed should acceptable standards
not be maintained.
14
The Safety Plan shall detail the manner in which the Contractor shall review, approve and
incorporate all Subcontractor Occupational Health and Safety plans, risk assessments and
method statements and incorporate them into their Occupational Health and Safety
management system.
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The Safety Plan shall detail the arrangements that the Contractor shall use to ensure
acceptable Occupational Health and Safety performance of all persons on the Worksite. In
particular it shall detail the arrangements for penalties and disciplinary action that shall be
taken should Contractor Personnel, Subcontractor employees or any other person on the
Worksite not comply with Occupational Health and Safety requirements.
16
The Safety Plan shall detail the arrangements that the Contractor shall use to control and
ensure acceptable Occupational Health and Safety performance of visitors and delivery
personnel that may enter the Worksite.
17
The Safety Plan shall detail the Contractors arrangements for effectively managing any
emergency incident that may occur as a result of Work or on the Worksite. The detail shall
include the facilities required for emergency preparedness.
18
The Safety Plan shall detail the arrangements for notification and investigation of any incident
that may occur as a result of Work or on the Worksite.
19
The Safety Plan shall detail the arrangements for the Contractors monthly performance
reporting and incident reporting.
20
The Contractor shall ensure that their project monthly health and safety statistics report is
completed and submitted by the agreed date to the Engineer and Quality & Safety
Department. The Engineer will provide the necessary format for this report. The information
collected will be submitted to the Engineer and Quality & Safety Department.
21
The Safety Plan shall detail the arrangements for assessing the general Health of employees
and any job specific Health checks that may be required.
22
The Safety Plan shall detail the arrangements for self-inspection and auditing that shall be
used to monitor the Work.
23
The Safety Plan shall detail the arrangements for tracking and effectively closing any
Occupational Health and Safety related nonconformity or deficiency that may be identified as
a result of monitoring. Written records of inspection, auditing and tracking shall be
maintained and made available to any representative of Client on request.
24
The Safety Plan shall detail the arrangements for ensuring that all Contractor Personnel and
Subcontractor employees are trained and competent to undertake their work in accordance
with the required standards. In particular the Safety plan shall detail the training and
competence requirements for the following employees;
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(a)
Supervisors
(b)
Electricians
(c)
Mobile plant and vehicle operators
(d)
Crane and lifting appliance operators
(e)
Riggers
(f)
Excavation Supervisors
(g)
Machinery operators
(h)
Scaffolders
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(i)
Scaffolding Supervisors
(j)
Confined space workers
(k)
Confined space supervisors
(l)
All persons working at height
Page 15
The Safety Plan shall detail the training arrangements specify the type and nature of training
to be given including but not limited to induction, pre-work briefings, tool box talks, general
awareness training, skills training and formal training conducted by training professionals or
agencies. Written records of the attendees, training given and assessment of competency
shall be maintained by the Contractor and made available for inspection by any
representative of Client upon request.
26
The Safety Plan shall detail the Contractors arrangements for promoting the awareness of
Occupational Health and Safety issues through notices, posters, newsletters, booklets,
Occupational Health and Safety alerts and any other means. All such information shall be
provided in the languages preferred by the training recipients of the training.
27
The Safety Plan shall detail the arrangements that the Contractor shall make to reinforce
good performance. Such arrangements shall include incentive schemes to reward Contractor
Personnel, Subcontractor employees or areas of Work that demonstrate exemplary
Occupational Health and Safety performance.
28
The Safety Plan shall include details of all meetings that are held to specifically deal with
Occupational Health and Safety issues. In particular the Contractor shall hold a monthly
meeting chaired by the Contractors Representative, which Client shall be invited to attend,
with the following items on the agenda;
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Suitability of the Contractors Occupational Health and Safety organization for the ongoing and planned Work;
(b)
Effectiveness of the Contractors

system;
(c)
Significant areas of planned activity and associated risk;
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Method statement review and job hazard analysis planning;

Tracking and closure of any identified deficiencies or nonconformities;
(e)
Occupational Health and Safety management
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(f)
Incident review;
(g)
Occupational Health and Safety promotion planning;
(h)
Training needs assessment;
(i)
Auditing and inspection planning;
The Occupational Health and Safety Plan shall describe the Contractors Safety Management
System that will be used throughout and shall conform with all requirements defined within
the Contract and related documentation The contents shall include but not be limited to the
following:
(a)
Front Cover
(b)
Table of Contents
(c)
Project Scope, Requirements and Occupational Health and Safety Objectives
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Occupational Health and Safety Policy and BS OHSAS 18001 Certificate (if applicable)
(e)
Control of Occupational Health and Safety Plan
(f)
Reference Documentation
(g)
Safety Organisation and Responsibilities
(h)
Subcontractor Occupational Health and Safety
(i)
Risk Assessments and Method Statement
(j)
Non-conformance, Corrective and Preventative Action
(k)
Incident Reporting
(l)
Audits
(m)
Training
(n)
Key Performance Indicators and Continual Improvement
(o)
Management Review
(p)
Safety Meetings
(q)
Monthly Safety Report
(r)
Appendices
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(d)
Occupational Health and Safety Policy
The Contractor shall comply with the Client vision, mission and strategic objectives.
The Contractor shall develop and implement its own written Occupational Health and Safety
Policy which shall be Project specific and demonstrate the Contractors understanding of and
commitment to maintaining standards of Occupational Health and Safety (OHS) that are
consistent with and an integral part of the Contractors business strategy.
The Contractor must set objectives and targets that shall be applicable to SMART - Specific,
Measurable, Achievable, and Realistic and to a Time scale.
10.2.3
Risk Assessment and Job Hazard Analysis
Refer to Section 11 Part 1 (Regulatory Document) in particular section 1.1.7 and Section 11
Part 2 (SAMAS) in particular section 2.4
10.2.4
Intervention
A system of positive intervention shall be used throughout the Project and the Contractor
shall adopt the system by authorizing and requiring all Contractor Personnel and
Subcontractor employees to intervene in any unsafe act or condition and take immediate
corrective action to prevent any incident occurring.
Work may be monitored by any representative of Client who may intervene in any unsafe act
or condition and require the Contractor to take immediate corrective action to prevent any
incident occurring.
The Contractor is required to acknowledge that the system of positive intervention in use on
the Project is one that shall enhance the following;
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10.2.2
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(a)
levels of understanding and awareness of Occupational Health and Safety issues

throughout the Project;
(b)
levels of personal responsibility and accountability for Occupational Health and Safety
issues;
(c)
levels of proactively towards Occupational Health and Safety issues;
(d)
levels of compliance with contractual requirements and Project Occupational Health

and Safety standards;
(e)
incident and injury prevention
The Contractor may be the focus of Occupational Health and Safety audits conducted by any
representative of Client. The Contractor is required to cooperate with such audits and to
acknowledge all audit findings. The Contractor shall take all corrective and preventive actions
that may be required to address any nonconformity identified during such auditing.
The Contractor may be the focus of Occupational Health and Safety inspections conducted
by any representative of Client. The Contractor is required to cooperate with and
acknowledge such inspections and take all corrective and preventive actions that may arise
as the result of such inspections.
The Contractor shall undertake routine Occupational Health and Safety inspections and
audits for the on-going Work. Written records of inspections and audits shall be maintained
and made available to any representative of Client upon request.
The Contractor may be issued with stop work instructions from the Engineer for any
observed cases of serious or imminent danger associated with the Work. On receipt of a
stop work instruction the Contractor shall refrain from work until such time as remedial action
has been taken to alleviate the serious or imminent danger and to prevent it reoccurring.
The Contractor shall stop work if any unknown or unplanned conditions occur that give rise to
serious or imminent danger. In such circumstances the Contractor shall assess the risks
associated with any remedial work required and revise the method statements and job
hazard analysis. The revised method statement shall be reviewed and approved by the
Contractors Occupational Health and Safety Manager. Revised method statements shall be
approved by the Engineer before recommencing Work.
10.2.5
Requirement for Training
The Contractor shall conduct training including contract specific induction, pre-work briefings,
tool box talks, general awareness training, skills training and formal training conducted by
training professionals or agencies. The contract specific induction will be at least 2 hours
duration, approved by the Engineer and provided for all persons that enter the Worksite.
Such induction training will be reviewed, revised and repeated for all persons that enter the
Worksite at periods not exceeding 6 months throughout the duration of the Work. All training
shall be provided in the languages preferred by the recipients of the training.
The Contractor is required to provide employees of Client with Occupational Health and
Safety training relating to Work undertaken by the Contractor. Training is an integral part of
job performance.
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The Contractor shall provide all Contractor Personnel and Subcontractors employees with
individually unique Contract specific photo identity cards. Such cards shall be made available
to any representative of Client on request. The Contractor shall not permit any Contractor
Personnel or Subcontractors employees to access the Worksite unless they have been
issued with their individually unique photo identity card. Such cards will not be issued prior to
the Contractor Personnel or Subcontractors employee attending the Contractors induction
training course.
The Contractor shall appoint a competent supervisor for each and every area of the following
Work activities
Temporary & permanent electrical installation
(b)
Crane and lifting appliance operations
(c)
Scaffolding erection, alteration and dismantling
(d)
Confined space entry
(e)
Excavation
(f)
Working at height
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(a)
The Contractor shall produce a health and Safety Training Matrix based on training needs
analysis of all personnel working on the project. The matrix must detail positions against the
training courses required from the analysis. All training courses provided to employees shall
be free of charge, i.e. the cost will be borne by the Contractor.
The training topics will be based on a number of factors, such as but not limited to;
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Trends in monthly statistics;
(b)
Objectives that have been set;
(c)
Recurring issues on site; and
(d)
Accident/incidents on site.
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Courses designed to meet the needs of specific operatives involved in specialized trades
including their roles and responsibilities must be provided through training. The following
training could be consider as specialist, but not limited to:
Safe entry into confined spaces;
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(b)
Crane operation;
(c)
Slingers/banks men;
(d)
Scaffolding/ false work/temporary works;
(e)
Abrasive wheels;
(f)
Woodworking machinery;
(g)
Excavation support equipment;
(h)
First aid;
(i)
Fire Marshall;
(j)
Accident Investigation;
Note any external training must be delivered by a competent organisation (i.e. 3th
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QCS 2014
The Contractor shall provide training and instruction to their employees in relation to the
performance of their work. This training shall be provided during working hours and
immediately after an employee commences employment. It shall include:
(a)
Occupational hygiene.
(b)
Essential elements of local laws and regulations.
(c)
Policies and procedures concerning aspects of human rights those are relevant to
operations.
The Contractor shall actively encourage the following for their workforce:
Creating employment opportunities.
(b)
Facilitating training opportunities for employees with a view to improving skill levels.
(c)
Ensuring non-discrimination in hiring and promotion practices.
(d)
Promoting life-long learning and on-the-job training.
(e)
All training shall be provided in appropriate languages, based on the demographics of

the labour accommodation facility.
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The Contractor shall retain records of all training provided to labour accommodation
residents. Such records shall include, as a minimum, the name, age and nationality of those
attending the training course/session and the type of training provided. These records shall
be available for inspection by the Engineer.
11
The Contractors shall conduct Emergency Drills to thoroughly test its emergency
preparedness and response within 6 months of the date of award of the Contract and
thereafter at periods not exceeding 6 months throughout the duration of the Work.
12
The Contractor shall hold a Contract Specific Occupational Health and Safety Meeting
chaired by the Contractors representative on a monthly basis throughout the duration of the
WORK. Additionally the Contractor shall include Occupational Health and Safety as an item
on the agenda for each and every meeting held and ensure that the subject is actively
discussed.
13
The Contractor shall provide contract specific Safe Practice Booklets for each and every
person employed on the Worksite and provide training on the content of the booklet.
10.2.6
Method Statements
Refer to Section 11 Part 1 (Regulatory Document) in particular section 1.1.7 and Section 11
Part 2 (SAMAS) in particular section 2.4
10.3
EMERGENCY RESPONSE PLAN (ERP)
10.3.1
General
The Contractor shall prepare an emergency response plans for the project and the following
but not limited to shall be addressed;
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(a)
Responsibilities;
(b)
Risk assessment and hazard identification and controls for potential emergencies;
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Hazard identifications and controls;
(d)
Coordination with outside emergency response organizations;
(e)
Arrival of outside emergency response groups;
(f)
Emergency response equipment;
(g)
Emergency drills;
(h)
Tests of emergency preparedness and response program;
(i)
Crisis management plan - major events emergency response plan;
(j)
Evacuation procedure;
(k)
Medical facilities;
(l)
Site fire prevention and response reporting;
(m)
Environmental spills and releases;
(n)
Security including (bomb threat);
(o)
Malicious threats; and
(p)
Severe weather conditions.
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(c)
It shall be mandatory that all personnel are aware and understand what actions to take and
when to take them in the event of an emergency situation. The Contractor shall provide such
information, instruction and training as may be required to assist the personnel to respond
appropriately, in the event of an emergency.
The Contractor shall develop ERPs for review by the Engineer in order to verify the suitability
and capability of arrangements. The Contractor shall ensure a schedule is produced to
conduct drills and exercises on a regular basis at the sites under its control.
Records of drills and exercises conducted shall to be kept together with details of follow up
actions and performance assessments for audit purpose.
The first emergency drill shall be conducted within first the 30 calendar days following
commencement of operations; afterwards emergency drills shall be conducted on a 6
monthly basis as a minimum.
All ERPs shall be reviewed and whenever necessary revised and updated every 6 months,
periodic auditing must be carried out to ensure compliance.
10.4
EARTHQUAKE EMERGENCY MANAGEMENT PLAN
10.4.1
Background
During the month of April 2013 earthquakes occurred in Iran with varying degrees of tremors
felt in the State of Qatar and the wider Middle East Region.
April 16th 2013 was by far the larger earthquake measuring 7.8 on the Richter scale with the
tremors physically being felt in numerous locations and buildings across the region. Whilst
events of this type are rare, the impacts could be serious both from a human and business
scale.
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Following these events it is clear that should have an earthquake evacuation procedure. This
emergency management plan has been developed; however it requires integration into the
existing emergency and evacuation plans.
It is to be advised that the earthquake procedure whilst very important is one element of a
much larger requirement for Emergency Management Planning to ensure that all scenarios
and eventualities are addressed inclusive of crisis management and business continuity.
10.4.2
Requirements
Outlined below is a suggested approach that could be taken to take into account those other
elements of emergency planning starting with a review of the current arrangements for
buildings, towers and associated structures inclusive of car parks.
The suggested overall approach would be a three phase priority approach. The first phase
identifying the as is situation to the desired outcome of to be and the future requirements,
but this is not limited and may require additional elements as recommended by other experts.
10.4.3
Phase One: Gap Analysis (as is)
Engage the relevant technical experts for the various aspects of the review, inclusive of but
not limited to Fire Design Engineer, Health and Safety Consultant, training providers etc.
Review all existing emergency process, procedures, plans and protocols within the
organisation and engage with other stakeholders such as Civil Defence to understand any
wider requirements, etc.
Review of all buildings physical emergency evacuation systems to ensure they meet relevant
codes and legislative requirements.
Review all evacuation assembly points and engage other building owners nearby the
organisation building.
Develop work assignments for the organisation personnel and Safety Wardens during
earthquakes.
Review the organisation buildings maintenance department records.
Identify relevant codes, legislative requirements and specific procedures needed for forward
planning.
Identify salient issues for consideration namely high rise building, crowded indoor public
places, indoor safety, outdoor safety, automobiles etc.
Identify non-structural hazards such as file cabinets, rack storage units, book shelves, HVAC
...etc.
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Involve other stakeholders such as the organisation Health and Safety Section, Civil Defence,
Ministry of Environment, other building owners in the immediate district etc to ensure their
views, requirements, interests and responsibilities are established.
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Review existing business resiliency and continuity plans, process and procedure.
12
Review existing crisis management plans, process and procedure.
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Indicate future planning and requirements inclusive of the proposed new and existing car
park.
14
Include training and awareness plan for the wider organisation based upon the identified
training needs.
15
Undertake training and awareness for any developed process and procedures.
16
Produce gap analysis report detailing all required changes, upgrades to process, procedures,
plans, training requirements, emergency systems etc.
17
Present outcomes of gap analysis.
18
Develop an initial implementation plan, methodology and programme for Phase 2 and 3
based upon the outcomes of the Gap Analysis.
19
Review plans to backup computer records and equipment of vital records.
10.4.4
Phase Two: Implementation (to be)
Implement agreed gap analysis outputs/approach inclusive of all manuals, procedures,

technical information required.
Develop administrative processes and procedures to support the plan.
Communicate the plan to all those affected at different level of the business.
Include for planning of any associated drills and lessons learnt.
Implement lessons learnt into plan, processes and procedures.
Establish periodic review of emergency systems.
10.4.5
Phase Three: Future Requirements
Advise if engagement of further consultants/engineers to undertake seismic survey of

existing buildings.
Development of business continuity plans.
Development of post-earthquake assessment procedures.
Development of crisis management plans.
Undertake training and awareness for any developed process and procedures.
Include for planning of any associated drills and lessons learnt.
Development of all related support materials.
Development of coordination procedures with Civil Defence and other authorities during
earthquakes.
Periodic review of emergency planning systems.
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What Should We Do During An Earth Quake?
Stay calm!
If you're indoors, stay inside and if you're outside, stay outside.
If you're indoors, stand against a wall near the centre of the building, stand in a doorway, or
crawl under heavy furniture (a desk or table i.e. cover your head and neck).
Drop down onto your hands and knees.
Stay away from windows and outside doors.
If you're outdoors, stay in the open away from power lines or anything that might fall. Stay
away from buildings.
Don't use matches, candles, or any flame.
Broken gas lines and fire don't mix.
If you're in a car, stop the car and stay inside the car until the earthquake stops.
10
Don't use elevators or put yourself at risk.
11
For impaired mobility, if you cannot drop to the ground, try to sit or remain seated so you are
not knocked down. If you are in a wheelchair lock your wheels. Protect your head and neck
with a large book, a pillow, or your arms.
10.4.7
What Should We Do After An Earth Quake?
Check yourself and others for injuries. Provide first aid for anyone who needs it.
Check the building, water, and electric lines for damage. If any are damaged, isolate if
possible and report to relevant authorities.
Turn on the radio. Don't use mobile phones unless it's an emergency.
Stay out of damaged buildings.
Stay inside buildings unless directed to do otherwise.
Evaluate and critique once a crisis situation is stabilised.
Expect further aftershocks.
Stay away from beaches. Tsunamis sometimes hit after the ground has stopped shaking.
If you're at work follow the emergency arrangements and instructions for the particular
building after the earthquake.
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SPECIAL SAFETY REQUIREMENTS AND PRECAUTIONS
10.5.1
Permits
A permit-to-work system (Hot work, Excavation, Scaffolding & Electric work) shall be
observed (correctly issued, Signed & Client requirement enforced) when undertaking any
work on an existing utility, service, item of equipment or structure.
A permit-to-enter system shall be observed (correctly issued, Signed & Client requirement
enforced) when undertaking any work in a confined space.
10.5.2
Guarantee
Where the Contract requires work to be carried out within or adjacent to any pipeline or at a
sewage treatment plant, the Contractor shall comply with any requirement of the Public
Works Authority.
10.5.3
Mechanical Plant, Machinery and Equipment
Sufficient suitable standby plant shall be immediately available in cases where the safety of
the Works or of personnel depends upon mechanical plant.
Test and thorough examination by a competent person of all equipment that is capable of
storing energy, such as air receivers and pressure vessels, is required at periods not
exceeding 12 months. Reports of such test and examination will be held on the Worksite and
made available to the employer on request.
The Contractor will make arrangements for all mobile plant and vehicles that enter the
Worksite to be checked by 3rd party certification to ensure the following are provided and in
good working order:
Braking systems
(b)
Steering systems
(c)
Gauges and warning lights

Operating controls
(d)
(a)
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10.5
(e)
Windscreens and wipers
(f)
Reversing alarms
(g)
Rear view mirrors
(h)
Roll over protection devices
(i)
Wheels, tyres, track
(j)
Pneumatic and hydraulic hoses
(k)
Seat belts and anchors
(l)
Fuel lines and tanks
(m)
Electrical control systems
(n)
Suspension and stabilization systems
(o)
Bodywork, covers and panels
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Mobile plant and vehicles that are defective will be removed from use in work areas and
taken to a repair facility on the Worksite or removed from the Worksite.
Repair work will only be carried out by trained and authorised mobile plant and vehicle repair
technicians.
Whenever maintenance work is ongoing the machinery or equipment will be isolated and deenergized.
All mobile plant and vehicle operators will hold relevant Qatari driving licenses for the
category of plant or vehicle that they operate. In addition operators of mobile plant will be in
possession of a 3rd party training certificate to verify that they have the skills necessary for
safe use of the plant.
Operators will use mobile plant and vehicles only in accordance with their operating manuals.
The Contractor will conduct a job hazard analysis for each item of machinery and equipment
that will be used.
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The following site rules will be observed by all mobile plant and vehicle operators:
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Mobile plant and delivery vehicles will not be reversed without a banks man in
attendance.
(b)
No passengers will be carried on mobile plant or vehicles other that in seats that are
specifically designed for carrying passengers.
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(a)
The Contractor shall prevent oil / fuel leak causing environmentally pollution.
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The Contractor will eliminate or reduce the associated hazards for construction lift such as,
construction lift failure, falling persons and falling objects by meeting or bettering these
specifications. And:
All construction lifts will have flat base plates without holes or openings, enclosed sides
and roof that are designed to prevent from falling objects.
All construction lifts will have overload protection devices that prevent movement of the
platform if it is overloaded.
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10.5.4
Existing Utilities
Prior to excavating in any area, the location of existing utilities shall be confirmed from asbuilt drawings, contact with utility authorities and trial holes.
Excavation in the vicinity of any utility shall be carried out to the requirements of the utility
owner.
Protection for utilities is the least effective means of controlling any associated risk. Where
Contractors use this method the following will be provided:
(a)
Marker posts or blocks that clearly indicate the nature, depth and path of all
underground utilities.
(b)
Where traffic routes pass over underground utilities temporary protection will be
provided. Warning signs stating the maximum vehicle weight that may safely cross the
utility will be positioned on the access route at each side of the utility.
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(c)
Temporary barriers or fences that run parallel to the route of any overhead utilities.
Warning signs detailing the nature of any overhead utilities on the barriers or fences.
(d)
Where traffic routes pass below overhead utilities warning signs stating the maximum
vehicle height and height restrictors will be positioned on the access route at each side
of the overhead utility.
Where any construction activity adjacent to a utility is undertaken the minimum clearance
distances will be clearly established and communicated to each and every person involved
with the construction activity.
Traffic routes and material stockpile areas will be clearly identified and established prior to
excavation work commencing. All excavation areas, traffic routes and stockpile areas are to
be surveyed for overhead services. Any services identified are to be removed or clearly
marked with height restrictors and warning information.
10.5.5
Excavations
During the planning stage all materials and equipment required for the safe excavation work
must be clearly identified. Such equipment and materials may include the following:
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(b)
Solid Barriers
(c)
Vehicle stop blocks
(d)
Access ladders or scaffolding
(e)
Ventilation
(f)
Lighting
(g)
Signage
(h)
Pumps
(i)
Generators
(j)
Air Monitoring Devices
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Movement Monitoring Equipment
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(l)
Rescue Equipment
For all excavation work a competent excavation supervisor will be appointed. The level of
training and experience required to determine competence will vary depending on the
complexity of the excavation. He will have previous experience of the type of excavation work
to be undertaken and formal Occupational Health and Safety training relating to the safety of
excavation work.
Temporary safety barriers should be used to protect workers and the travelling public from
excavations that are more than 300mm deep in accordance with the Qatar Work Zone Traffic
Management Guide.
Once the design requirements are known a job hazard analysis of the excavation work will be
completed by the excavation supervisor with the assistance of Occupational Health and
Safety staff and engineers as required. The Job Hazard Analysis will clearly identify the job
specific risks and control measures for the excavation work.
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Prior to commencement of any excavation work all persons involved will be given a pre-work
briefing based on the Job Hazard Analysis relating to the risks and required control measures
for the excavation work. The appointed excavation supervisor will be responsible for
presenting and recording the briefing.
Prior to commencement of work all materials, plant and equipment will be checked to ensure
that they are in good condition. In particular the condition of all mechanical excavators will be
checked to ensure that:
All windows in the drivers cab are clean, unbroken and unobstructed.
(b)
Rear view mirrors are securely attached, unbroken and clean.
(c)
All track plates and connectors are in good condition and secured with proprietary
locking pins.
(d)
All dipper arm joints and attachments are secured with proprietary pins and locking
pins.
(e)
All task and indicator lighting is in working order.
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(a)
Trucks will only be operated by persons with valid Qatari driving licenses. Plant such as
excavators, loading shovels etc shall only be operated by trained and competent operators
that hold valid 3rd Party certification for the type of plant being operated. This certification is
required in addition to Qatari driving license requirements.
When the reversing of trucks is necessary for the collection or delivery of materials a banks
man will be in attendance. All banks men will be provided with high visibility clothing and be
trained in the safety aspects of reversing vehicles. Where vehicles are reversing up to an
excavation or travelling alongside an excavation vehicle stop blocks or vehicle barriers will be
provided to prevent them falling into the excavation.
Continuous adequate solid barriers will be placed around all excavations over 1.2m deep at a
distance at least of 1.2m. Where night time pedestrian or vehicle access is adjacent to
excavation then all solid barriers will be fitted with warning lights.
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Pedestrian access to and from all excavations will be by means of ladder or adequately
constructed staircases. The possibility of a person falling from a height of more than 2m from
the access will be prevented. The horizontal distance between access points will not exceed
15m.
11
All ladders used on the Project will be manufactured in accordance with an internationally
recognised standard. Any ladder that is found to be defective will be removed from use
immediately.
12
All straight ladders will be positioned at an angle to minimize the risk of slipping or falling
backwards. The distance between the base of the vertical plane and the base of the ladder
will be 1 unit out for each 4 units in height of the vertical plane.
13
Ladders that are used to gain access from one level to another will extend at least 1m above
the upper level surface. Where a general access ladder run extends a distance of more than
6m a landing point with a firm level platform and fall prevention measures will be provided at
each and every 6m.
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Excavations shall be kept clean and tidy at all times. Accumulated waste and unused
materials will be removed from excavations on a daily basis. All excavations will be
thoroughly cleaned prior to any backfilling operations commencing.
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To prevent the risk associated with falling objects excavated materials, other materials and
equipment shall not be stored at the edge of any excavation. A clear distance of 2m shall be
maintained around all excavations.
10.5.6
Warning Signs
The Contractor shall set up and maintain (cleaned and legible) throughout the course of the
Contract enough traffic diversion signs in accordance with the Qatar Work Zone Traffic
Management Guide and additional warning signs & guides.
Additional areas that require warnings signs and barriers are:

Excavations over 1.2m deep
(b)
Any edge, opening or platform from where a person may fall more than 2m
(c)
Electrical transformers and substations
(d)
Confined space entry points
(e)
Areas below and around working at height and heavy lifting operations
(f)
Areas of open water more than 1m deep
(g)
Areas where flammable goods are stored
(h)
Areas where radiation sources are used or stored
(i)
Areas within Worksites that are classed as non-construction areas
(j)
Areas within non construction areas where construction activity is on-going
(k)
Areas below overhead utilities
(l)
Areas above underground services
(m)
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Areas where test and commissioning activities are on-going
Warning signs will clearly state the nature of the hazard and instruct people of the correct
actions to take. Warning signs will be manufactures in accordance with internationally
recognised standards. All signs will be in English, Arabic and the languages preferred (can
be understand) by the workers on the Worksite.
All safety barriers and barricades are to comply with the Qatar Work Zone Traffic
Management Guide..
10.5.7
Confined Spaces
Entry into a confined space will only be permitted where a competent person is appointed to
directly supervise the work. The competent person will hold a certificate of training or license
that is issued by a 3rd party. The competent person will be appointed in writing by the
Contractor and the appointment will be copied to the employer.
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Any person that enters into a confined space will have received formal training in the safe
methods of entry and working in a confined space. Such training will include the
arrangements for emergency communication and response. In addition every person that
enters into a confined space will be given a briefing by the appointed competent person
relating to the specific hazards of the work and the control measures that have been detailed
in the job hazard analysis.
Any person that acts as an attendant for confined space work will have received formal
training in the safe methods of rescue from a confined space and the arrangements for
emergency communications with external emergency services.
The contractor will only permit trained workers, under the direct supervision of an authorised
competent person, with confined space attendants present, to enter a confined space.
Internal combustion engines will not be taken into a confined space or operated in a position
where their exhaust gasses may be drawn into the confined space.
Persons entering into a confined space will wear a full body rescue harness that is attached
to a rescue line anchored outside the confined space
The contractor will implement a safe working procedure for confined space entry that
includes the following:
Preparation of a confined space entry permit
(b)
Provision of all equipment necessary for entering into and working in the confined
space including access, lighting, mechanical ventilation, gas detectors,
communication, personal protective equipment and emergency rescue equipment. All
such equipment will be manufactured in accordance with internationally recognised
standards
(c)
Provision of warning signs and barriers around the confined space entry point
(d)
Setting up emergency communication and rescue equipment
(e)
Issue of a permit to enter the confined space
(f)
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Checking of the atmosphere inside the confined space and installation of ventilation
equipment
(g)
Installation of lighting
(h)
Entry into and work in the confined space.
(i)
Monitoring of conditions in the confined space.
(j)
Continuous checking and recording of all persons entering into and exiting from the
confined space by the confined space attendant
(k)
Completion of work and removal of all equipment from the confined space
(l)
Accounting for all persons and equipment that entered the confined space
(m)
Securing the entry point to the confined space
(n)
Closing the confined space entry permit
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Lifting Operation
The Contractor will appoint a competent lifting operations supervisor for the Worksite. The
lifting operation supervisor will ensure that the requirements of this specification are met at all
times.
Rigging of loads and signalling of cranes will be undertaken only by trained and competent
persons. All riggers will be required to wear a blue construction safety helmet and a red high
visibility vest for the purpose of easy identification on the Worksite.
Cranes will only be operated by trained and competent operators who are in possession of an
operators license issued by a 3rd party. In addition appropriate Qatari driving licenses are
required for all mobile equipments.
A thorough examination of each lifting appliance will be made by a 3rd party inspector at
periods not exceeding 12 months and after substantial re-erection, alteration or repair. Load
capacity to be displayed.
All lifting appliances on the Worksite will have a copy of the manufacturers operating manual
and load rating charts available for use and kept with the operator cabinet or machine.
Before a mobile crane is positioned for a lift, attention will be paid to the condition of the
ground upon which the crane will stand, as this will be subjected to high point-loadings from
outriggers or tyres. Dependent upon the nature of the ground and/or the size of the crane to
be used, a special hard standing may have to be prepared.
The maximum safe working wind speeds for all construction activity and in particular lifting
operations and Working at height activity is 25 Knots. The construction will monitor the
weather conditions and suspend work when wind speeds in excess of the maximum safe
working speeds are anticipated.
Outriggers will be properly set and locked if a locking device is provided. When controlled
remotely from the cab, the operator will make a physical check to ensure that each pad has
an adequate bearing before a load is lifted. Sound timber packing or metal plates will be used
under each outrigger pad to distribute the load. It is essential that outriggers are supported at
the jacking points and not under the outrigger beams. Also, lifting location to be barrier off.
A method statement and job hazard analysis will be provided to the Engineer for all structural
steel erection activity. No structural steelwork erection will commence prior to approval of the
method statement and job hazard analysis by the Engineer. All structural steel erectors will
be fully conversant with the construction method, sequence and hazard control measures
prior to any work activity commencing.
10.5.9
Lifting Gear
Lifting gear means any chain sling, rope sling, or similar gear, and any ring, link, hook, plate
clamp, shackle, swivel or eye bolt, used on the Worksite.
All lifting gear will be subjected to a thorough examination by a competent person from 3rd
party at intervals not exceeding 6 months. Identity number and SWL to be check.
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10.5.8
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A wire rope used in raising, lowering or suspension of a load, will not be used if it is kinked,
significantly rusted, the core is visible or the rope has visible broken wires, exceeding 5% of
the total or in any length equal to 10 times the diameter of the rope.
Riggers will check the condition of lifting gear prior to each and every lift.
Any lifting gear that is found to be defective will be removed from service and sprayed with
red paint to indicate that it is not to be used. All defective equipment will be removed from the
Worksite.
A system will be established on the Worksite for storage of all lifting equipment not regularly
in use. Such equipment will not be left in the work areas.
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10.5.10 Scaffolding
For all scaffolding construction activity and dismantling activity a competent scaffolding
supervisor will be appointed. The level of training and experience required to determine
competence will vary depending on the complexity of the scaffolding structure to be erected
or dismantling. Industry standards and codes detail competency requirements.
All employees involved in scaffolding construction activities and dismantling activity will be
trained in the safe methods of working and in particular the manner in which fall prevention or
arrest is to be achieved. Contractors will maintain detailed information of the training provided
and the methods that they have used for assessment of competency and suitability for all
employees undertaking scaffolding construction activities.
All scaffolding erection areas and dismantling areas will be provided with barriers and
warning signs to exclude all personnel that are not specifically involved with the scaffolding
construction and dismantling activity. Where such areas are adjacent to roadways barriers
with a capability to prevent vehicles entering the area will be erected or dismantling. Where
such areas are adjacent to members of the public or 3rd parties then screening and falling
object protection will be provided. The appointed scaffolding supervisor is to be made
responsible for ensuring that exclusion zones are in place and maintained at all times whilst
scaffolding construction and dismantling activity is on-going.
All materials being used for scaffolding construction will be checked prior to them being used
to ensure they are in good condition. Any materials found to be defective will be clearly
marked as defective and discarded or removed from the construction area to ensure that
they are not used.
Scaffolding that has been constructed in accordance with the design will be inspected for use
by displaying green scaff tag at all access points of the scaffolding detailing the following
information:
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(a)
the unique identification and location of the scaffolding inspected
(b)
the name of the person making the inspection
(c)
the date that the inspection was completed
(d)
the intended use and capacity of the scaffolding
(e)
the required re-inspection frequency for the scaffolding
The person making the scaffold inspection will maintain written details of the inspection that
they have conducted to enable them to verify their scaff tag system.
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All scaffolding that does not display green scaff tag for use will be fitted with red scaff tag
states that the scaffolding is not fit for use and the access points will be removed or made
unusable.
Users of scaffolding will at all times conduct their work in a manner that eliminates the
possibility of falling objects.
Users of scaffolding are to be prohibited from altering or dismantling any part of scaffolding.
10
Users of scaffolding are required to maintain unobstructed access and egress at all times. All
debris and materials no longer required will be removed from scaffolding on a daily basis. All
materials and equipment used on scaffolding will be stored in a manner that does not
obstruct the free movement of the people using the scaffolding.
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The frequency of re-inspection of scaffolding every 7(seven) days will be displayed on the
green scaff tag. Users of scaffolding are required to check that the period of re-inspection
has not been exceeded before using the scaffolding. In any case where the re-inspection
date has been exceeded the user will request the appointed scaffolding supervisor to make
the re-inspection and to re-sign the green scaff tag for use. The user will not access the
scaffolding until such time as the re-inspection has been made.
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Before any dismantling activity is undertaken on scaffolding it will be removed from use. All
green scaff tag will be removed and replaced with red scaff tag which is not fit for use and all
scaffolding access points will be removed or made unusable.
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The contractor will only use electric welding equipment in accordance with the following
requirements:
Welding cables and equipment will be properly maintained and inspected before use.
Defective equipment will be removed from use and arrangement for repair will be
made.
(b)
Electric welding cables are to be kept as short as possible and routed away from
pedestrian walkway areas.
(c)
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(d)
All connections between welding equipment and welding cables will be securely bolted.
(e)
Pipelines containing flammable liquids or gases, or electrical cables will not be used as
a ground.
(f)
When electrode holders are to be left unattended, the electrodes will be removed and
the holder placed where it is protected from unintentional contact.
(g)
A fire resistant container will be provided for spent electrode stubs.
(h)
Welding machines will be turned off when being moved or when the equipment is not
in use.
Electric welding operations will only be undertaken with earth return electrodes
connected to the work piece.
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10.5.11 Hot work and Welding
Tanks, vessels and drums that have contained flammable or toxic liquids will be filled with
water or thoroughly cleaned before hot work or welding is undertaken on them.
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Where coatings are present on materials to be heated the coating will be removed to prevent
the coating being heated.
Suitable portable fire extinguishing equipment will be located within 6 meters of any hot work
location.
10.5.12 Compressed Gas Cylinders

The Contractor will only use compressed fuel gasses in accordance with the following
requirements;
Cylinders will not be transported with regulators, gauges and hoses attached.
(b)
Cylinders will be transported in an upright position and will not be hauled in equipment
beds or truck beds on their side.
(c)
Cylinders lifted from one elevation to another will be lifted only in racks or containers
designed for that purpose. Cylinders will not be hoisted by the valve cap or by means
of magnets or slings.
(d)
Cylinders will not be used as, or placed where they may become part of, an electrical
circuit.
(e)
Cylinders will be protected from extreme heat and from being struck by moving
equipment and falling objects.
(f)
Cylinders will not be taken into a confined space.
(g)
Cylinders will not be used as rollers; will be transport on appropriate trolley.
(h)
Damaged or defective cylinders will not be used or be permitted to remain on the

Worksite.
(i)
Type of gas clearly marked on cylinders and segregation of incompatible gases is

required.
(j)
Oxygen cylinders will be kept free of oil and grease.
(k)
Cylinders will be secured in place during use and storage. Securing shall be around
the body of the cylinder, securing around the cylinder neck or cap will be prohibited.
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(a)
Cylinder valves will be closed at all times when cylinders are not in use.
(m)
A key wrench is required to be in place on the valve of acetylene cylinders at all times
during use.
(n)
Fuel gas and oxygen hoses will be of different colours and will not be interchanged.
(o)
All hose, valve and regulator assemblies will incorporate a flashback arrestor.
(p)
Hoses are to be kept as short as possible and routed away from walkway areas.
(q)
Under no circumstances are damaged hoses or torches to be used.
(r)
Torches will be ignited by friction lighters or other approved devices only.
(s)
Fuel gases will only be used for the purposes of cutting or heating. They will never be
used for pressure testing or ventilation.
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10.5.13 Working at Height

Contractors are required to reduce the risk of persons falling from height by providing a
means of fall prevention or arrest for every person on the Worksite that is exposed to a risk
of falling a distance of 2m or more.
Supervisors of persons using fall arrest systems will be trained in the correct installation, use
and maintenance of fall arrest systems. Training will be provided by a 3rd party. All persons
required to use fall arrest systems will receive formal training in safe working at height prior to
using such systems.
The use of safety belts as part of a fall arrest system is prohibited.
Safe access to the point at which a person will attach themselves to a fall arrest system will
be provided. In cases where a person using a safety harness has to detach the lanyard from
the anchor point and reattach it to a different anchor point, whilst being in a position where
the risk of falling exists, double lanyards will be used with one of the lanyards remaining
attached to the anchor point at all times.
Where any form of fall arrest system is used the contractor will put in place arrangements to
rescue any person that is caught by the fall arrest system. The rescue system and equipment
will be capable of rescuing any person that may be unconscious whilst suspended and or
suffering from suspension trauma. The system will be capable of rescuing the suspended
person within 3 minutes of the fall being arrested.
All edges of working platforms and work areas that objects may fall from will be provided with
securely fixed continuous toe boards that are at least 200mm high.
All holes and openings in floor areas will be fitted with temporary covers to prevent objects
falling to lower levels of the structure.
Where work is on-going on the exterior faces of structures the working platforms that are
used to gain access will be fitted with lightweight mesh or netting to prevent objects falling
from them.
Materials and equipment will not be stored or located within 2m of edges of working areas or
platforms.
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All materials and waste that may be blown by the wind from raised structures will be secured
and stored in a manner that prevents them from being blown from the structure.
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Where designated pedestrian walkways, entrances or exits are located beneath edges or
openings where work is on-going steel framed and sheeted canopies will be erected to
protect pedestrians from falling objects.
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The contractor will produce a method statement and job hazard analysis for all roof and
canopy work activity. For work on new structures safety information will be obtained from the
designers and incorporated into the method statement and job hazard analysis. For work on
existing structures where design information is not available then a survey of the existing
structure will be made to identify hazards such as:
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(a)
Fragile coverings
(b)
Holes and openings
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(c)
Exposed edges
(d)
Lack of safe access
(e)
Damage or disrepair of the existing structure
(f)
Adjacent structures, facilities or services
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A method statement and job hazard analysis will be provided to the Engineer for all roof and
canopy work activity. No work will commence prior to approval of the method statement and
job hazard analysis by the Engineer. All roof and canopy installation workers will be fully
conversant with the construction method, sequence and hazard control measures prior to any
work activity commencing.
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The contractor will meet the following roof and canopy work specific Occupational Health
and Safety requirements:
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The storage of materials on roof surfaces will be minimized at all times
(b)
Storage of materials on roof surfaces is not permitted within 2m of any edge or eave
(c)
All openings and non-walkable areas will be protected by barriers and signage to
prevent pedestrian access
(d)
All waste will be removed from the work areas on a daily basis and prior to any areas
being left unattended
(e)
All areas of roof or canopy covering will be fully fixed at the time of positioning. The
practice of laying large areas of unfixed coverings is prohibited
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(a)
The structure that the suspended working platform is attached to or mounted on will be
surveyed and assessed to ensure that it is capable of supporting the loads that the
equipment will impose on it.
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The installation, maintenance, use and dismantling of suspended working platforms will be
under the control of a competent person that is appointed by the Contractor. The competent
person will be fully familiar with each and every type of suspended working platform in use on
the Worksite. Persons who work from suspended working platforms will have received formal
training to ensure the safety of themselves and of other persons that may be affected by the
operation with particular emphasis on the correct use of the equipment, working at height and
falling object prevention.
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The following requirements will be met for all use of suspended working platforms;
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(a)
Users will not alter or interfere with any part of the suspended working platform, control
or safety devices.
(b)
The work area below the suspended working platform will be clearly marked a
pedestrian exclusion zone will be created.
(c)
The user will check all controls and safety devices on a daily basis to ensure that they
are functioning correctly.
(d)
Use will cease whenever wind speed in excess of the maximum permissible is
anticipated.
(e)
The suspended working platform will be maintained in a horizontal position whilst it is

in use.
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(f)
The practice of transferring people or materials from the suspended working platform
is prohibited other than at the designated access points.
(g)
Every person working from a suspended working platform shall wear a full body safety
harness that is attached to an independent lifeline.
(h)
The platform will be kept free of loose materials or articles liable to endanger or
interfere with the workers hand hold or foot hold
(i)
The power supply will be disabled whenever the suspended working platform is left
unattended.
10.5.14 Electrical
This specification applies to all temporary electrical systems on the Worksite and all electrical
equipment used for construction, commissioning and testing purposes. The requirements
given are minimum requirements and Contractors are required to equal or better them.
A competent electrician or electrical engineer will be appointed or employed on every

contract. The competency requirements will be determined by the nature of the temporary
electrical system that will be installed on the Worksite
The Contractor will reduce risk by using cordless tools or electrical equipment that is
operated at reduced voltages. Only intrinsically safe electrical equipment will be permitted for
use at any location where flammable atmospheres may exist or confined space.
All electrical equipment used on the Worksite will be manufactured in accordance with an
internationally recognised standard.
Portable Power Tools will be of a double insulated type.
Jointing of all electrical cables and wires shall be by means of proprietary terminations or
connectors. The practice of twisting and taping electrical components together to create a
connection is prohibited.
Temporary power supplies for the Worksite may be provided from generators or via a
Worksite specific transformer connected to the national power network. All generators and
transformers on the Worksite shall be located in areas that are fenced and secured to
prevent any unauthorized entry. Each such location will be provided with portable fire
extinguishers. All electrical systems shall be bonded to the earth.
All electrical circuits that are created will be protected by earth leakage circuit breakers
(ELCB). All metal components of an electrical system shall be earthed. Distribution of
electrical power shall be provided through distribution panels and switches that are enclosed
or housed in securely closed and locked boxes or cabinets.
Warning signs that clearly indicate electrical hazards shall be fixed to all electrical switch
boxes and distribution panels. Similar signs shall be displayed at all transformers, generators
and overhead power line locations.
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All signs and notices shall be in English and Arabic and the language preferred (can be
understand) by the workers employed on the Worksite.
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All electricity supply cables shall be buried or properly supported and protected and shall be
armoured. Flexible cable shall only be allowed for hand lamps and hand held tools and shall
not exceed 6 metres in length. Industrial type plugs and sockets shall be used. All electrical
installations shall be in charge of a competent person who shall accept full responsibility for
its use and any alterations or additions thereto. The name, designation and telephone
number of such person shall be prominently displayed close to the main switch or circuit
breaker of the installation, and also in the Contractors site office.
10.6
FIRST AID
10.6.1
First Aid and Clinic
The Contractor shall provide and maintain first aid Boxes / Clinic (according to number of
workers as per Qatar Law No.14 of the Year 2004 The Labour Law) complete with all first
aid kits and equipment (as a minimum but not limited to Clean room with potable water
supply, Stretcher, Ambulance, Standby Vehicle, ... etc) necessary for the initial care of any of
the Contractors or Engineers personnel who may be injured.
The box shall be kept in a conspicuous place in the establishment and shall be available to
the workers.
The use of the box shall be entrusted to a worker trained in providing first-aid medical
services.
As a minimum, there should be a first aid box with Medical record book in all areas where
work is in progress.
The Contractor shall ensure that the first aid Kits and equipment at each first aid box / clinic
is complete and within expiration date in all respects at all times.
At each first aid box / clinic the names and contact Telephone numbers of the Contractors
staff who are trained to render first aid shall be displayed.
The Contractor shall provide and maintain Periodic medical examinations for workers and
follow up (maximum every year from employment date).
10.7
FIRE PRECAUTION AND PREVENTION
10.7.1
General
The Contractor shall take all necessary precautions against fire as required by the insurance
company insuring the Works, the Department of Civil Defence and the Engineer.
Quantities of flammable materials on site shall be kept to an absolute minimum and shall be
properly handled and stored. Any handling and storage recommendations made by Material
Safety Data Sheet (MSDS) and the manufacturers of flammable materials shall be strictly
adhered to.
All flammable materials storage areas will be located at least 20m away from other
structures, areas where combustible materials are stored and areas where sources of ignition
are found. Storage areas will be freely ventilated to eliminate any possible build up of
flammable vapour or gas. Flammable material storage facilities will not be constructed of
combustible materials.
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Except as otherwise provided herein, the Contractor shall not permit fires to be built or open
type heating devices to be used in any part of the Site.
The Contractor shall provide, regularly checked and maintain approved by Department of
Civil Defence fire fighting equipment in the site offices, the stores and about the Works where
applicable. The type, amount and location of fire fighting equipment shall be to the
requirements of the Department of Civil Defence. The Contractor shall confirm to the
Engineer in writing that the requirements of the Department of Civil Defence have been met.
The Contractor shall make arrangements with the Department of Civil Defence to inspect the
Works and promptly carry out their recommendations at his own expense if requested to do
so by the Engineer.
Combustible fuel oils shall be stored in designated storage areas. Fuel oil shall only be
contained in tanks or containers that are in good condition. Tanks and containers will be
located in bounded areas capable of containing any spillage or leak. Bounded areas will be
kept free of water and debris. All pump equipment and fuel oil lines or hoses will be
maintained regularly to ensure that there no leaking parts. Fuel oil lines and hoses will be
terminated with filler nozzles or valves that stop the flow of fuel oil when the device is not
held. Any electrical equipment such as lighting and pumps that is located in fuel oil storage
areas shall have an operating voltage of 110V or less.
Hot work and welding operations at height require particular controls to prevent people or
materials below being exposed to the risks of the work activity, the following controls will be
put in place;
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All work activity will be coordinated with other activities in areas below
(b)
Areas below will be cleared of all combustible and flammable materials.
(c)
Fire blanket / Fire retardant material will be used to cover any combustible materials
that cannot be cleared.
(d)
Fire blanket / Fire retardant material must be removed after hot work and welding
activities are completed.
(e)
A fire watchman will remain at the site of hot work activity for 30 minutes after work is
finished.
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(a)
The Contractor will provide training in the correct selection and use of portable fire
extinguishers for every person employed at the Worksite.
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Portable fire extinguishers will be provided at the following locations:
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(a)
Every electrical generator, transformer and main distribution panel
(b)
Every piece of mobile plant and equipment
(c)
Every area of flammable materials storage and use
(d)
Every area of hot work activity
(e)
Every temporary structure
(f)
Every work area where combustible materials are present.
Smoking will be prohibited in any areas where flammable or combustible materials are
stored. It will also be prohibited in any temporary structure other than in clearly designated
and defined smoking areas. Smoking areas will be cleaned on a daily basis, a means of
extinguishing cigarettes will be provided.
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Fire escape routes, exits and assembly areas will be provided for all enclosed temporary
structures and permanent structures under construction. All such areas will be kept free from
obstructions at all times. Wherever possible in permanent structures under construction the
fire escape routes, exits and assembly areas used will be those designed for use in the
occupied structure.
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Information and warning signs will be provided at the following locations or areas:
Flammable materials stores
(b)
Combustible materials stores
(c)
Temporary fire systems
(d)
Portable fire extinguishers
(e)
Fire escape routes, exits and assembly areas.
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The Contractor shall make all arrangements to keep access for Fire Brigade cleared and
Emergency Alarms audible in all areas.
10.7.2
Emergency Equipment
Temporary fire protection equipment for the Worksite will be provided by the Contractor for
the duration of the contract. Such equipment may include but is not be limited to:
Portable fire extinguishers
(b)
Fire sand buckets
(c)
Fire water storage and distribution systems
(d)
Fire suppression systems
(e)
Fire / Smoke / Gas detection systems
(f)
Fire warning / Alarm / Emergency Evacuation systems
(g)
Procedures
(h)
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Emergency contact telephone numbers / Communications

Breathing apparatus and / or respirators (if applicable)
(i)
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(j)
Torches
(k)
Loud Hailer
(l)
Emergency lighting
(m)
Adequate and safe Emergency Exit / Doors are provided
(n)
Assembly / Muster point
Escape routes, access ways to alarm points, extinguishers, hydrants and other fire fighting
equipment and first aid kits kept clear of obstruction at all times
All structures that are normally occupied by five to twenty five people will be provided with the
following:
(a)
Portable fire extinguisher equipment.
(b)
First aid kit.
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(c)
Trained first aider.
(d)
Emergency contact information notices.
(e)
Telephone or radio communication equipment.
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All temporary facility structures that are normally occupied by twenty five to one hundred
people will be provided with the above plus the following:
(a)
Smoke detectors
(b)
One first aid kit for each 25 people.
(c)
Designated emergency evacuation routes.
(d)
An emergency preparedness and evacuation plan.
(e)
An emergency alarm system.
(f)
An emergency evacuation drill at periods not exceeding 6 months.
(g)
An area set aside for the heating and consumption of food.
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All temporary facilities structures that are normally occupied by more than 100 people will be
provided with the above plus the following:
A fire water system
(b)
An appointed nurse
(c)
Emergency lighting system
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All temporary fire protection equipment will be manufactured, inspected, tested and
maintained in accordance with the Department of Civil Defence or internationally recognised
standards.
10.7.3
Hazardous Substances
The Contractor will control the use, handling, transportation and storage of hazardous
substances to reduce the associated health risks. These requirements below are the
minimum that the Contractor will meet to comply with their contractual Occupational Health
and Safety obligations.
Radioactive materials are hazardous substances and any use of such materials on Site will
require a method statement and job hazard analysis to be submitted to the Engineer for
approval prior to any radioactive material being delivered to the Worksite.
Where any spillage of liquid occurs the contractor will take action to immediately clean the
spillage and remove any contaminated materials from the Worksite.
To effectively control the hazards associated with the use, storage, handling and
transportation of hazardous substances the Contractor will:
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(a)
Maintain a register of all hazardous substances on the Worksite
(b)
Obtain Material Safety Data Sheets for all hazardous substances
(c)
Make an assessment of the health risks associated with the intended use of each
hazardous substance
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(d)
Provide the control measures required to reduce the risks identifies to acceptable
levels. Acceptability will be based on internationally recognised best practices and
standards
(e)
Train people that use, handle or transport hazardous substances in the associated
risks and control measures
(f)
Provide routine health checks for employees that are exposed to hazardous
substances
(g)
Provide appropriate spill containment and disposal Spill kit
(h)
Toxic/ hazardous substance correctly tagged/ labelled/ signage and secured
(i)
Adequate storage provided and Class B fire extinguisher near by
SAFETY OF THE PUBLIC
10.8.1
Working in Public Areas
The Contractor must ensure that control measures are in place to protect the public,
workforce and assets by providing appropriate lighting, fencing, barricades, and lockable
units. Adequate levels of security including the use of trained security guards will be required.
The Contractor must also ensure appropriate warning signage is displayed and where
appropriate safe pedestrian walkways are identified and maintained.
Safety and security procedures shall be implemented in accordance with the Qatar Work
Zone Traffic Management Guide and as required by the Department of Civil Defence and the
police. These shall be included, as a minimum, warning signs and lights, adequate
barricades, railings, road hump for reduced & control speed and other safeguards as
required by the nature and location of the work being undertaken.
Access to all properties shall be maintained by adequately sign posted diversions, temporary
bridges or other facilities.
A night watchman shall be assigned to ensure that all barricades, lights and other protective
apparatus are maintained during the hours of darkness.
Designated pedestrian routes will be clearly signed and with firm even surfaces that are free
from distractions. Where such routes traverse level changes they will be slopped at gradients
not exceeding 10% or cut with steps of even height and a tread width of at least 400mm.
Slopes and steps will have anti-slip surfaces. Where the edges of pedestrian routes are
raised more than 1.2m above the surrounding level solid barriers will be provided at each
raised edge to prevent people from falling.
All such equipment shall be routed away from pedestrian access areas. Where such
equipment crosses pedestrian areas it will be located under the pedestrian area or over it at a
height of at least 2.5m above the surface. Where such equipment is routed over a pedestrian
area it will be clearly marked with warning signs.
No electrical cables, hoses or pipes shall be routed along any staircase, ladder access or
across any doorway. This applies to both temporary and permanent works.
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10.8
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Contractor shall provide Client with photocopies of passports, police clearances and any
similar personal security documentation necessary to obtain Client temporary identification
cards and passes for Contractor Personnel to enter Client STP / PTP / premises. Contractor
shall ensure that Contractor Personnel display such identification at all times when they are
on Client STP / PTP / premises.
The Contractor will provide a method statement and job hazard analysis for all demolition and
dismantling activities. Everyone involved in the work needs to know what measures are to be
taken to control the risks and a pre work briefing based on the method statement and job
hazard analysis will be given and recorded by the supervisor. Workers will be closely
supervised to ensure that the control measures required are put into practice. An exclusion
zone will be created around the demolition or dismantling area to prevent persons not directly
involved with the work activity around the work area gaining access. The Contractor will not
allow materials to fall into any area where people are working or passing through. Protection
screens, fences or canopies may be needed to control falling objects.
10.9
WELFARE, SAFETY AND PROTECTION OF WORKMEN
10.9.1
General
The Contractor must make arrangements for suitable welfare facilities to be present from the
start of the work. There are specific requirements for provision of welfare facilities in the
(Section 11, Part 1 Regulatory Document, 1.1.8, Appendix 1)
10.9.2
Personal Protective Equipment (PPE) / Attire
All the Contractors personnel shall be provided with safety helmets, eye protection and foot
protection. Safety helmets, eye protection and foot protection shall be worn at all times by all
Contractors personnel on the Site except.
All the Contractors personnel shall be provided with gloves, hearing protection, safety
reflecting vests, dust mask and other protective clothing suitable for the nature of work they
are performing and their working environment (Shorts and sleeveless shirts are prohibited).
All the Contractors personnel shall wear high visibility clothing as the outer layer of clothing
at all times when working on a road or within a road works zone in accordance with the Qatar
Work Zone Traffic Management Guide.
The need for other types of PPE will be identified by the contractor as part of their job hazard
analysis or risk assessment process.
The Contractor will display signage detailing the requirements for mandatory PPE throughout
to Worksite. Signage shall be in a format that is easily recognisable to all persons on site
regardless of their preferred language.
10.9.3
Safety Equipment
Construction equipment must only be used in the manner and limitations for which it is
designed, inspected regularly with colour code sticker and Qatar license for driver / operators
must be available.
Adequate hard barricading, temporary bridges, temporary footpaths, lighting, warning tape
and sign posting shall be provided at all excavations.
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Adequate bracing and shoring shall be provided at all excavations. 2m spoils clearance from
the excavated pit and sloping shall be maintained (if applicable).
Correctly made ladders must be provided for access into excavations and onto scaffolding
and buildings. Contractors self-made ladders shall not be used.
Scaffolding shall be erected in accordance with the international recognize standard, best
practises and manufacturers recommendations and shall be fitted with toe boards, guardrails
(top & mid rail), proper access, fully boarded platforms, tagging system and hand railing
(refer to 10.3.10).
The following basic safety equipment is required for any works in confined spaces and shall
be supplied by the Contractor:
gas detectors/monitors complete with carrying case, rechargeable batteries and
battery charger, calibration kit, all to the approval of the Engineer; consumable items
and sensors to be replaced in accordance with the manufacturers recommendations
during the course of the Contract (2 No.)
(b)
full body rescue safety harness with lifelines and shackles (6 No.)
(c)
lifting frame complete with fall arrest device (1 No.)
(d)
constant flow escape breathing apparatus complete with storage cases (2 No.)
(e)
automatic positive pressure self-contained breathing apparatus complete with

storage case (1 No.)
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(a)
The Contractor shall maintain all safety equipment in good working order with up to date
calibration and test certificates where appropriate.
The Contractor shall ensure that any personnel working above 2 m using fall protection
devices with valid 3rd party certificate and to provide them proper training in the selection and
use of fall protection devices.
The Contractor shall provide and maintain in good working order one compressed air escape
respirator set (Drger Saver Auto PP or similar) in the Contractors site office.
10
One oxygen resuscitation unit shall be provided in the Contractors site office.
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Truck or Trailer Mounted Attenuators (TMAs), or lorry mounted crash cushions must be used
in accordance with the Qatar Work Zone Traffic Management Guide.
10.9.4
Support Facilities for Contractors Staff and Labour
The Contractor shall provide, regularly clean and maintain for the duration of the Contract
potable water, washing facilities and sufficient Toilets (with steel exhaust fan) & sanitary
facilities for use by workmen in accommodation areas, at messing facilities and in areas
where work is in progress.
The Contractor shall provide and maintain for the duration of the Contract messing facilities
and a separate designated area for the consumption of food for his staff and labourers.
Cooking and dining facilities that are provided will be operated and maintained in a clean and
hygienic condition. Food preparation and storage areas will be separated from eating areas.
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(a)
No person with any communicable disease will be permitted to work in any kitchen or
dining room
(b)
Kitchen workers who have cuts or skin conditions on their hands will not be permitted
to work in any kitchen or dining area
(c)
Kitchen workers that handle or serve food will wear latex gloves, hairnets and clean
clothing.
When allowed for in the Project Documentation, the Contractor may provide accommodation
facilities for his staff and labourers at the Site. Such facilities shall be maintained in a proper
manner and to the satisfaction of the appropriate government departments and the Engineer.
The Contractor shall provide transportation between staff accommodation and areas of work
for his staff and labourers.
The Contractor shall provide sufficient bins for waste and scrap regularly collected,
segregated and removed from site.
Arrangements for the temporary storage of waste on site shall be made in clearly designated
and defined areas that have fences and signs to clearly indicate the nature of the waste
where combustible wastes are stored portable fire extinguishers will be provided.
Waste collection points will be provided throughout the work areas and will be clearly marked
with signage to indicate the nature of the waste that is to be collected. Waste will be
separated and collected in the following categories:
Metals
(b)
Oils
(c)
Concrete & Stone
(d)
Tyre & rubber
(e)
Glass
(f)
General
(g)
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Sewage
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Chemical
Where temporary facilities are created for the storage of materials and equipment such areas
shall be clearly defined and fenced. Notices will be displayed to indicate the nature of the
storage area.
(a)
Any hazardous substances that are stored shall only be kept in accordance with the
suppliers recommendations and the requirements of the Hazardous Substances
Specifications.
(b)
Flammable materials and fuel oil storage areas must be separated from other
temporary structures or works under construction by a distance of 30m.
(c)
Where materials are stored in stacks they will not be stacked to a height of more than
1.5 m where the materials are to be manually handled. Materials for mechanical
handling that are on pallets or contained in bins will not be stacked more that 3 units
high with the base bin or pallet being on firm level ground.
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Circular materials such as pipes and tubes will be stored in a manner that prevents
item from rolling. They will be placed in a container or frame, or have timber wedges of
an adequate size inserted between the materials and the ground to prevent rolling.
The Contractors will make arrangements to maintain an adequate working environment and
take into account the requirements of this specification to fulfil their contractual obligations
relating to Occupational Health and Safety. Adequate arrangements will be based on
internationally recognised standards.
Ergonomics and proper layout of work area.
(b)
Darkness or poor visibility increases the risk of persons on the Worksite slipping,
tripping or falling. It also increased the risk of operator error for plant, vehicle,
machinery and equipment operations. To reduce such risks the Contractor will provide
the following:
(a)
Temporary lighting for all Worksite access areas and roads that will be used
during the hours of darkness.
(ii)
Task lighting for all work activity at night or in areas with poor visibility.
(iii)
Emergency lighting for pedestrian access routes in areas of poor visibility and
those used during night time working.
(iv)
Ensure the absence of glare.
(v)
Proper lighting in corridors.
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Summer Working Conditions and fatigue
During the period from June 15th until August 31st, work under direct sun rays is prohibited
from 11:30 am to 3:00 pm unless special arrangement is taken by the Contractor to control
and ease effect of the direct sun on the workers. This arrangement should be approved by
the Engineers Representative and should be agreed upon before implementation.
High outdoor temperatures expose persons on the Worksite to the risk of dehydration. The
Contractor will provide shaded rest areas, rest periods and drinking water supplies for all
persons on the Worksite.
Sunlight exposes persons on the Worksite to the risk of skin disorders. Employers will
provide work wear that covers the skin for employees working in direct sunlight. Sunlight may
also cause glare for operators of mobile plant, vehicles, machinery and equipment which
increases the risk of operator errors. The Contractor will provide shaded operating positions
to reduce such risks.
Contractor shall develop suitable management arrangements to control working hours and/
or shift patterns in order to address and manage the risk of fatigue.
10.9.6
Additional Environmental Protection and Pollution Control
The Contractor shall comply with all conditions of Environmental Clearance issued for the
Contract by the Ministry of Environment (MoE), and also where relevant, the predecessor to
the MoE, the Supreme Council for the Environment and Natural Reserves.
The Contractor shall comply with all rules and regulations regarding environmental protection
and pollution control issued by the MoE, and also where relevant, the predecessor to the
MoE, the Supreme Council for the Environment and Natural Reserves.
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10.9.5
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Plant and Equipment Test Certificates
Cranes, whether used to construct the Works or provided as part of the permanent Works,
must have a current test certificate.
Each sling, shackle or other item of loose lifting tackle, whether used to construct the Works
of provided as part of the permanent Works, must have either a current manufacturers test
certificate or a current test certificate.
Test certificates must be issued by a competent testing authority approved by the Engineer.
The Contractor must have a copy of each test certificate on site available for inspection by
the Engineer.
The following British Standards and Code of Practice shall be complied with:
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Mobile and Tower Cranes: BS 1757, BS 2799 and CP 3010
(b)
Overhead Cranes: BS 466 and BS 5744
(c)
Slings: BS 1290
(d)
Chain Blocks: BS 3243
(e)
Shackles: Alloy : BS 3551, High Tensile Steel : BS 3032
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LABOUR ACCOMODATION
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10.10.1 General
These specifications for workers' accommodation can be accepted for implementation as

long as in the interest of the worker provided they do not disturb the labour accommodation
requirements of the decision of the Minister of Labour No. (17) for the year 2005 or any other
matters developed in this context.
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10.10
10.9.7
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10.10.2 Quality of Labour Accommodation

The Contractor shall provide space per person that meets or exceeds what is required by
local legislation or 4.5 m2 per person within each room/accommodation unit.
The residential density shall not exceed (the lower of): that specified by appropriate local
regulation or 4 persons per room/accommodation unit.
The Contractor shall provide personal storage space for residents belongings including
secure storage for valuables.
The Contractor shall provide allowances for open spaces and pedestrian movement (e.g.
hard surface walkways with minimum 0.75 m width) and shaded communal areas.
Where permissible under local planning guidelines, the Contractor shall provide air
conditioned communal areas such as television/games rooms.
The Contractor shall designate pick up and drop off points (for buses) in such a way as to
minimize walking distances for residents and to minimize noise and air quality impacts on
residential buildings.
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The Contractor shall configure buildings/units in such a way as to create a sense of place
and community.
The Contractor shall provide tea and coffee making facilities in kitchen and mess areas.
The Contractor shall provide physical barriers (e.g. fencing or landscaping) to visually screen
the camp from adjacent worksites, etc.
10
The Contractor shall provide written evidence that all local planning guidelines have been
adhered to when designing large scale, project related, labour accommodation facilities.
Local planning guidelines indicate the numbers and type of community facilities which should
be provided for a given population. Consideration shall be given at planning stage to the
availability and capacity of communal facilities and spaces in the surrounding area. Where
such facilities are not readily accessible, provision of public transport to access such facilities
shall be considered.
11
The Contractor shall be aware of any changes in law relating to the provision of temporary
labour accommodation.
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10.10.3 Provision for Fire Safety
The Contractor shall provide for adequate fire-fighting equipment in the labour
accommodation (notwithstanding other local laws and regulations requiring same).
All relevant signage, notices, documentation and training relating to fire safety at labour
accommodation shall be provided in appropriate languages, based on the demographics of
the facility.
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10.10.4 Provision for Health Care
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The Contractor shall retain detailed records of all medical treatment carried out on-site.
Records shall be retained for all instances of residents being transported for off-site medical
attention. Such records shall include, as a minimum, the name, age and nationality of the
treated party, and the nature of the complaint. These records shall be used to identify
medical trends and implement proactive treatment to reduce absenteeism.
The Contractor shall provide all labour accommodation residents with access to a level of
healthcare beyond basic first aid. Such facilities shall be readily accessible by residents,
staffed by professional medical staff and have appropriate provisions and equipment. The
exact specification of the facility shall be determined on a case-by-case basis, depending on
the location and population of the labour accommodation.
The Contractor shall provide a facility to transport those requiring medical attention from the
labour accommodation to and from appropriate off-site medical facilities, free-of-charge and
in a timely manner.
The Contractor shall provide medical insurance for all workers in accordance with Qatar
Labour Law.
The Contractor shall include a Public Health Training module as part of induction training for
all new labour accommodation residents. As a minimum, this shall address:
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(a)
Personal hygiene and the appropriate use of the sanitary facilities provided (flush
toilets, showers, hand washing, waste disposal facilities etc.).
(b)
Awareness of communicable diseases (including Sexually Transmitted Diseases), their

transmission and prevention.
(c)
Practical information regarding residents rights and means of access to on-site and
off-site medical facilities.
(d)
Food safety.
(e)
Littering, safe disposal of waste and related community hygiene standards.
The Contractor shall promote public health awareness throughout all facets of the
accommodation. This shall include:
(a)
Signage in kitchens, bathrooms etc. promoting hygienic practices.
(b)
Educational videos and presentations.
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The Contractor shall provide access to transport, free-of-charge to/from:

Worksites, including backup services from worksite to labour accommodation for those
who failed to access scheduled services.
(b)
Availability nearby for community facilities, shops and recreation areas during leisure
time.
(c)
Religious facilities at suitable times.
(d)
Off-site medical facilities, including emergency access at all times.
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10.10.5 Access to Transport
Transport services shall be scheduled in such a way as to minimise waiting times and
maximise accessibility.
The Contractor shall use safe modes of transport only. The practice of transporting workers
in open-back trucks is forbidden.
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10.10.6 Access to Religious, Social and Domestic Facilities

1
The size and number of religious, social and domestic facilities shall be relative to and
appropriate to the population of the labour accommodation.
The Contractor shall facilitate access to religious facilities for those required to work on
Fridays.
The Contractor shall provide an on-site hall to facilitate religious practices. Alternatively,
transport may be provided to facilitate off-site worship.
The Contractor shall provide adequate shaded areas to facilitate social interaction. Similarly,
an appropriately sized, air-conditioned communal area(s) shall be provided (e.g. television
and games room). The size and number of these facilities shall be relative to and
appropriate to the population of the labour accommodation.
The Contractor shall provide preferably on-site, open spaces (for sports and recreation).
Where space constraints are such that this is impossible, readily accessible off-site spaces
shall be provided.
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The Contractor shall provide access nearby to basic domestic amenities.

include, as a minimum:
These shall
(a)
Access to banking/money transfer services, including transportation to banking/money

transfer facilities.
(b)
Laundry facilities.
(c)
Retail outlet(s) selling, as a minimum, essential items (e.g. food items, clothing,
toiletries, phone cards, stamps etc.).
(d)
Communications.
These services shall preferably be available on or within walking distance of the labour
accommodation.
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10.10.7 Access to Communications

The Contractor shall provide a telephone, available at all times, for calling the emergency
services. This facility shall be centrally located, conspicuous and all residents shall be aware
of this facility.
The Contractor shall provide access nearby to the following:
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Retail outlet selling mobile phone credit.
(b)
Postal service, both inward and outbound.
(c)
Facility for residents to receive emergency messages (e.g. in case of family

emergency abroad).
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10.10.8 Number, Quality and Location of Sanitation Facilities

The Contractor shall adhere to an appropriate standard for the provision of toilets and
showers etc. These facilities shall be maintained in good working order and shall be cleaned
regularly.
The Contractor shall develop and implement a Waste Management Plan for the labour
accommodation. This plan shall address the collection, segregation, storage, transport (offsite) and disposal (recycling) of wastes.
The Contractor shall provide adequate sanitary means for the disposal of waste water
(including sewerage) from labour accommodation. The Contractor shall provide adequate
management of surface water runoff to prevent the accumulation of standing/stagnant water
(and the associated health risks).
The Contractor shall provide laundry areas, separate from washrooms and food preparation
areas. Such laundry areas shall be adequately drained.
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10.10.9 Food Preparation Areas

1
The Contractor shall adhere to relevant local regulations relating to food preparation facilities.
In the absence of such local regulations, an appropriate regional standard shall be applied
The Contractor shall provide adequate food preparation facilities to allow cultural sensitivities
to be respected such as separate preparation areas for meat and vegetables, and
appropriate labelling and handling of food products.
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Where meals are provided to residents, the food offered shall be culturally appropriate based
on the demographics of residents.
10.10.10 Pest and Vermin Control

1
The Contractor shall engage a pest control company to service the labour accommodation
site.
Self closing doors fitted with fine mesh shall be installed at the entrances to food premises,
washrooms, living areas and any other enclosed spaces.
10.10.11 Security at Labour Accommodation

The Contractor shall provide adequate security personnel, based on the size, layout and
population of labour accommodation.
The Contractor shall provide Protocols (Codes of Conduct) for the security personnel
operating at labour accommodation. These Protocols shall clearly define the nature and
permitted magnitude of response to security incidents. They shall also set out the
circumstances under which security incidents should be handed over to Police control.
Protocols will be developed in consultation with the Engineer
The Contractor shall ensure that all security personnel are adequately trained in the Protocols
for security personnel.
The Contractor shall retain records of all security incidents arising at labour accommodation.
Such records shall include, as a minimum, the name, age and nationality of all those involved
(including security personnel), and the nature of the incident. These records shall be made
available to the Engineer.
The Contractor shall provide labour accommodation residents with secure facilities for the
storage of personal items and valuables.
The Contractor shall manage the movement of goods and personnel onto the
accommodation facility.
The Contractor shall maintain adequate lighting on and around the labour accommodation at
all times, therefore making it safer for residents to move around at all times.
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10.10.12 Social Issues

1
Any social issues arising at labour accommodation shall be addressed at regular project
Quality, Health, Safety and Environment (QHSE) meetings.
The Contractor shall include an Intercultural Understanding module as part of induction

training for all new labour accommodation residents. This shall include:
(a)
Basic introduction to cultural norms and practices of other accommodation residents.
(b)
An explanation of native or local customs, festivals or religious rites.
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The Contractor shall enforce a ban on the sale, possession and consumption of solvents,
alcohol and inhalants, for the purposes of intoxication, on labour accommodation sites. The
Contractor shall use its best endeavours to prevent these substances from entering labour
accommodation facilities.
The Contractor shall provide residents with contact details for relevant bodies such as
consulates, NGOs, or other relevant organisations offering social support. A list of such local
contacts shall be provided to new employees during their induction process. An up-to-date
list of contact details for these organisations shall also be displayed in public areas such as
the canteen, recreational areas, etc.
Any incidents of suicide or attempted suicide shall be investigated as a social issue to try to
determine the root causes with a view to reducing the likelihood of a recurrence. This may
include the engagement of qualified medical personnel to assist in this process (such as
psychiatrists or psychologists).
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10.10.13 Competence of Labour Accommodation Management
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The Contractor shall provide Protocols (Codes of Conduct) for the labour accommodation
management personnel. These Protocols shall clearly define the nature of issues and
incidents which are considered within the remit of labour accommodation management.
They shall also include guidelines outlining appropriate parties to whom incidents should be
referred and at what stage. Protocols will be developed in consultation with the Engineer
The Contractor shall retain records of all issues and incidents, at labour accommodation,
which are reported to or dealt with by labour accommodation management. Such records
shall include, as a minimum, the name, age and nationality of all those involved (including
members of the accommodation management team), and the nature of the issue or incident.
These records shall be made available to the labour accommodation management company.
The Contractor shall ensure that no member of labour accommodation management accepts
any form of payment by way of bribery or extortion or for any reason. Similarly the Contractor
shall commit to permanently removing any member of labour accommodation management,
from the accommodation, if they are found to have accepted or demanded such payments.
In this event, the Contractor shall report any such offences to the appropriate local authorities
to determine if a criminal offence has been committed.
The Contractor shall maintain labour accommodation facilities to a high standard and not
allow them to fall into disrepair.
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10.10.14 Environmental Conditions at Labour Accommodation

1
The Contractor shall provide the Engineer with copies of the relevant environmental permits
relating to the construction and operations of their labour accommodation facilities. The
nature of the permitting requirements will be dependent on the jurisdiction of the facility.
Where labour accommodation is to be sited on or close to work sites/industrial sites, the

accommodation facilities shall be located up-wind (based on prevailing wind) of the site and
the distance between the camp and air discharge points around the site shall be maximised.
Noise levels shall not exceed the requirements for night time hours residential areas, as
outlined in local laws and regulations.
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The accommodation area shall be separate from the work site and shall not be used for any
operation activities (e.g. storage, workshops, etc.).
Where on site facilities such as a Sewage Treatment Plant (STP) are located on or close to
the accommodation, planning requirements in relation to buffer zones, etc. shall be respected
and integrated into site layout. Similarly, adequate buffer zones shall be included to ensure
that sleeping accommodation is not immediately adjacent to main roads.
Appropriate waste management, storage and disposal facilities shall be provided on site.
There shall be no burning of wastes on site. Similarly, there shall be no fires onsite.
Use of labour accommodation facilities shall be restricted to those normally resident in the
accommodation. Where necessary, separate facilities, e.g. toilets, etc., shall be provided for
adjacent work sites, etc.
Roads and parking areas shall be paved, or where this is impractical, dust suppression
techniques shall be used to keep dust levels down within labour accommodation.
The Contractor shall appoint/engage a team of personnel dedicated to cleaning communal

areas around the camp on a regular (daily) basis.
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10.10.15 Health and Safety for Labour Accommodation Residents

The Contractor shall extend Workmens Compensation and Employers Liability Insurance to
cover their staff while resident in labour accommodation.
The Contractor shall extend the accident reporting requirements, to include accidents
occurring at off-site labour accommodation directly associated with the Project.
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END OF PART
QCS 2014
Section 01: General

Part
11: Engineers Site Facilities
ENGINEERS SITE FACILITIES .............................................................................. 2
11.1
11.1.1
GENERAL ............................................................................................................... 2
Scope
2
11.2
11.2.1
11.2.2
11.2.3
11.2.4
ENGINEERS SITE OFFICES ................................................................................. 2

General
2
Type 1 Offices
2
Type 2 Offices
3
Car Parking Facilities
6
11.3
11.3.1
11.3.2
11.3.3
11.3.4
11.3.5
UTILITY CONNECTIONS ........................................................................................ 6

General
6
Electricity
6
Water
6
Telephone
7
Internet
7
11.4
11.4.1
11.4.2
11.4.3
11.4.4
11.4.5
11.4.6
11.4.7
PROVISION OF EQUIPMENT AND SUPPLIES ...................................................... 7

General
7
Computers and Scanners/Printers
7
Photocopier
8
Measuring and Recording Equipment
9
Stationary Supplies
9
Safety Equipment and Clothing
10
Telephones and Facsimile Machines
10
11.5
11.5.1
11.5.2
ATTENDANCE ...................................................................................................... 11
Assistance to the Engineer
11
Contract Administration
11
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QCS 2014
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Part
11
ENGINEERS SITE FACILITIES
11.1
GENERAL
11.1.1
Scope
This Part specifies the requirements for the Engineers temporary site facilities and includes
site offices, utility connections, provision of equipment and supplies and attendance.
Related Sections and Parts are as follows

Part 10
Part 13

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This Section
ENGINEERS SITE OFFICES
11.2.1
General
The Contractor shall provide site offices the type and number as stated in the Project
Documentation. The position of the site offices shall be to the approval of the Engineer.
Upon removal of the site offices, the area occupied or otherwise affected by them shall be
reinstated to its original condition.
11.2.2
Type 1 Offices
Unless described elsewhere in the Project Documentation the Contractor shall provide,
maintain and remove on completion of the Works the Engineers site offices described in this
Clause.
The Contractor shall proceed with the provision of a site office for the exclusive use of the
Engineer immediately following the award of the Contract and shall provide temporary
alternative accommodation to the Engineers approval until such time as the office is made
available.
The office shall have a minimum area of 20 m and shall comply with the following:
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11.2
(a)
The structure shall be weatherproof.
(b)
The windows and doors shall be dust-proof and the windows shall be fitted with fly
screens.
(c)
The office shall be air-conditioned to maintain a maximum steady dry bulb temperature
of 25C at a relative humidity of 50% under the expected climatic conditions expected
at the Site.
(d)
Adequate effective lighting and power outlets shall be installed in accordance with the
latest requirements of the Qatar General Electricity & Water Corporation.
(e)
The walls and ceilings shall be painted with emulsion paint.
The office shall be provided with the following furniture to the approval of the Engineer:
(a)
1 No. kneehole pattern desk with a total of six lockable drawers, approximately 1500 x
800 x 760 mm in size.
QCS 2014
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(b)
1 No. swivel chair with armrests.
(c)
2 No. stacking or folding chairs.
(d)
1 No. hanging file or plan chest suitable for AO size prints.
(e)
1 No. wastepaper basket.
(f)
1 No. two drawer filing cabinet.
(g)
1 No. wall mounted pin board, 1000 x 2000 mm in size.
Sanitary and washing facilities shall be provided for the exclusive use of the Engineer and
shall include a WC and a wash-hand basin an adequate supply of hot and cold water shall be
provided at all times.
The Contractor shall insure the site offices against fire, burglary and other risks.
The Contractor shall keep on site at all times an adequate supply of clean, fresh, chilled
drinking water for the consumption of the Engineer.
The Contractor shall maintain the offices in a clean and sanitary condition.
11.2.3
Type 2 Offices
The Engineers site offices described in this Clause shall be provided in lieu of Type 1 Offices
only where it is a stated requirement of the Project Documentation.
The offices shall be portable units, mounted on skids or similar and where directed in the
Project Documentation shall become the property of the Government on completion of the
Contract. On completion of the Contract, the offices which are to become the property of the
Government shall be repaired and redecorated to the satisfaction of the Engineer; they shall
then delivered to a location designated by the Engineer within 50 km of the Site.
The buildings shall conform to the general configuration shown below. The number of each
type of unit shall be as stated in the Project Documentation.
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QCS 2014
The Contractor shall proceed with the provision of the portable offices, which shall be for the
exclusive use of the Engineer immediately following the award of the Contract and shall
provide temporary alternative accommodation to the Engineers approval until such time as
the offices are made available.
The Contractor shall submit to the Engineer for approval a comprehensive specification and
drawings showing the accommodation proposed complete with furnishings, equipment and
fittings before placing any orders.
The units shall be mounted on adequate concrete foundations and shall be provided with
concrete access steps where necessary.
The units may be constructed of composite timber framed panels with wood or metal
cladding, any combination of these, or alternative forms or construction which comply with
the following levels of performance:
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Walls
Thermal conductance Fire resistance

-
0.60 w/m C
hour
Roof
Thermal conductance Roof resistance

-
0.60 m C
hour
Roof coverings shall be selected for durability, freedom from excessive maintenance, and the
ability to withstand extreme exposure to sun, heat and humidity.
The units shall be finished internally and externally with low maintenance materials.
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10
The offices shall be air-conditioned with wall mounted units to maintain each room at a
maximum steady dry bulb temperature of 25C at a relative humidity of 50% under the
expected climatic conditions expected at the Site. Extract fans capable of 10 air changes per
hour shall be provided in the kitchen and toilets.
11
The installation and testing of wiring and electrical equipment in the units shall be in
accordance with the latest requirements of the Qatar General Electricity & Water
Corporation.
12
Each office shall be provided with the following furniture to the approval of the Engineer:
1 No. swivel chair with armrests.
(c)
No. stacking or folding chairs.
(d)
1 No. hanging file or plan chest suitable for AO size prints.
(e)
1 No. wastepaper basket.
(f)
1 No. two drawer filing cabinet.
(g)
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Each toilet shall be provided with the following sanitary fittings to the approval of the Engineer
and an adequate supply of hot and cold water at all times:
1 No. low level WC suite.
(b)
1 No. Wash-hand basin.
(c)
1 No. shower tray, mixer fittings, rose and shower curtain.
(d)
1 No. toilet roll holder, towel rail, soap dish and mirror.
(e)
a suitable number of cups, saucers and drinking glasses.
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(a)
The samples and meeting room shall be provided with the following furniture to the approval
of the Engineer:
(a)
(b)
No. folding or stacking chairs.
(c)
1 No. wall mounted blackboard, 1000 x 2000 mm in size.
(d)
(e)
1 No. shelf unit for approved samples with 5 tiers of shelves 400 mm wide x 2400 mm
long overall.
2 No. tables, each approximately 1200 x 2000 mm in size.
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1 No. kneehole pattern desk with a total of six lockable drawers and
approximately 1500 x 800 x 760 mm in size.
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(a)
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All furniture and equipment shall remain the property of the Contractor and shall be removed
following completion of the Works unless otherwise noted in the Project Documentation.
16
The Kitchen shall be provided with the following equipment to the approval of the Engineer
(a)
1 No. stainless steel single bowl single drainer sink with hot and cold water and
cupboards underneath
(b)
1 No. floor mounted two door cupboards to match sink.
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(c)
Cabinets and shelves to match sink, as required.
(d)
2 ring cooker and microwave.
(e)
1 No. Refrigerator/Freezer with a capacity no less than 500 litres.
(f)
1 No. three pint kettle and sufficient crockery and cutlery.
(g)
A suitable number of mugs, cups, saucers and drinking glasses.
(h)
Table coasters for use on desk tops.
(i)
Hand towels and drying up cloths, laundered regularly.
(j)
Dishwashing facilities, clothes, sponges and washing up liquid, all replaceable.
(k)
Cleaning brushes, mop, bucket and floor clothes.
The Contractor shall insure the site offices against fire, burglary and other risks.
18
The Contractor shall keep on site at all times an adequate supply of clean, fresh, chilled
drinking water for the consumption of the Engineer.
19
The Contractor shall maintain the Offices in a clean and sanitary condition.
20
Each type of unit shall be provided with fire extinguishers and water cooler.
11.2.4
Car Parking Facilities
Parking areas shall be paved or have a finished surface as approved by the Engineer and
shall be covered with a suitable canopy to provide shading.
The number of shaded car parking spaces required shall be 2 No. for Type 1 Offices and 6
No. for Type 2 Offices unless otherwise stated in the Project Documentation.
11.3
UTILITY CONNECTIONS
11.3.1
General
The Contractor shall make all arrangements and pay all charges in connection with the
installation, maintenance, operation and removal of the service utilities described in this
Clause.
11.3.2
Electricity
The Contractor shall arrange for the provision of an uninterrupted electrical power supply to
the Engineers offices during all working hours and any at other time as requested by the
Engineer for the duration of the Contract.
11.3.3
Water
The Contractor shall arranged for the provision of an uninterrupted water supply to the
Engineers offices during all working hours and at any other time as requested by the
Engineer for the duration of the Contract.
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The Contractor shall provide inline filters on all water supplies into Employer and Engineers
site Facilities. The Contractor shall maintain these at regular intervals as per manufacturer
instruction throughout the duration of the Work order.
11.3.4
Telephone
The Contractor shall arrange for the provision of two (2) land lines for the sole use of the
Engineer for Type 1 Offices and three (3) land lines for the sole use of the Engineer for Type
2 Offices.
The Contractor may recover the net cost of international calls made by the Engineer.
11.3.5
Internet
.The Contractor shall arrange for the provision of a dedicated and uninterrupted internet
access to the Engineers offices during all working hours and at any other time as requested
by the Engineer for the duration of the Contract. The internet connection should be provided
with a bandwidth running at a minimum of 1 mbps upload capacity.
11.4
PROVISION OF EQUIPMENT AND SUPPLIES
11.4.1
General
The following items of equipment, supplies and associated level of service shall all be
provided unless detailed elsewhere in the Contract Documentation.
11.4.2
Computers and Scanners/Printers
The Contractor shall provide new network/internet capable computers and scanners/printers
for the sole use of the Engineer. The number of computers and scanners/printers required
and their performance specification shall be as detailed in the Project Documentation. The
Contractor shall also supply and install any computer software as detailed in the Project
Documentation.
The Contractor shall maintain the computers and scanners/printer for the duration of the
Contract and provide all consumables necessary for its operation.
The Contractor shall be responsible for installing legal copies of operating system and
software, trouble shooting, supplying of required consumables and maintenance of the
system.
Operating system and software requirements shall be as specified by the Engineer, with the
following as a minimum:
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(a)
Latest version of Microsoft Windows Operating System
(b)
Latest version of Microsoft Office
All software must be of latest version and Arabic enabled, to the approval of the Engineer.
The Contractor shall ensure that all computers and scanners/printers provided for the
Engineers use are networked within the Engineers facilities to the satisfaction of the
Engineer.
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The Contactor shall provide new desktop computers and laptops as shown in the Schedule
of Rates minimum 20-inch Flat Panel VGA/analogue colour monitors for use by the Engineer.
The Desktop and laptop computers shall comply with the following:
Intel Core 2 Duo Processor (1.86GHz,1066MHz,2MB cache)
(b)
1000GB(7200rpm)Serial ATA Hard Drive
(c)
56k Modem
(d)
32X DVD+/-RW Drive
(e)
Wireless network adaptor (Wi-Fi)
(f)
Wireless Keyboard & Mouse
(g)
Card Reader
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(a)
The Desktop and laptop computers shall comply with the following: New licensed copies of
MS Windows, MS Office Professional, MS Project and AUTOCAD, Primavera P6 and
Primavera Contract Manager (PCM) SOFTWARE SHALL BE PROVIDED.
10
Colour printer shall be of the laser type suitable for A3 size paper and having scanning and
copying facilities built in. It shall be quiet in operation (Hewlett Packard Desk Jet (latest
model) or similar).
11
The Computer equipment shall be returned to the Contractor at the end of Maintenance
Period. The Contractor shall be responsible for supply of all necessary cartridges and paper
and for maintenance of the equipment by the manufactures agent throughout the period of
the Work order.
12
The Contractor shall provide all necessary voltage stabilization equipment to ensure troublefree operation of the computer equipment.
13
All computers and printers shall be networked.
11.4.3
Photocopier
The Contractor shall provide a new photocopier for the sole use of the Engineer. The
performance specification for the photocopier shall be as detailed in the Project
Documentation.
The Contractor shall maintain the photocopier for the duration of the Contract and provide all
consumables necessary for its operation.
Contractors shall provide a new floor standing, stationary platen, and plain paper colour
photocopier for use and approved by the Engineer.
The photocopier shall be provided with an automatic document feeder capable of copying
both sides.
The Range of copy sizes of the photocopier shall be from A3 size (297420mm) to A4 size
(210297mm), portrait and landscape. Three paper storage trays shall be provided.
The photocopier shall be capable of reducing/enlarging originals by 50% to 200% in 1%

increments.
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The photocopier shall have an A4 size rotating paper cassette and automatic paper
size/zoom ratio selection.
Throughput shall be not lesson than 40 A4 copies per minute.
The photocopier shall be able to scan and email documents.
10
The photocopier shall be returned to the contractor at the end of period of Maintenance. The
contractor shall be responsible for supplying the necessary paper and maintenance of the
equipment by the manufactures agent throughout the work order.
11.4.4
Measuring and Recording Equipment
The Contractor shall provide measuring and recording equipment for the sole use of the
Engineer. The following items, which shall be to the approval of the Engineer, shall be
provided for the duration of the Contract:
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1 No. Electronic Distance Measurement (EDM) station.
(b)
1 No. 1 Total Station theodolite (or equivalent) including all necessary tripods, prisms
etc.
(c)
1 No. Automatic engineers level including tripod.
(d)
1 No. Metric levelling staff.
(e)
1 No. Calibrated steel survey band 50m long.
(f)
2 No. 30m nylon tapes.
(g)
2 No. 25 m metal tapes.
(h)
4 No. 5m pocket tapes.
(i)
6 No. Ranging rods.
(j)
1 No. Masons Spirit level.
(k)
1 No. Bitmac thermometer.
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1 No. digital camera.

Level and field books as required.
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(a)
Other equipment such as pegs, tools, etc, which are necessary for the checking of the Works
shall be provided as requested by the Engineer.
The Contractor shall maintain and replace as necessary the equipment for the duration of the
Contract. Surveying instruments shall be new or in as good as new condition, of an approved
make with a current certificate of adjustment.
11.4.5
Stationary Supplies
The Contractor shall supply stationary for the Engineer for the duration of the Contract.
Stationary items shall include, but not necessarily be limited to, the following:
(a)
Files and file dividers (A4 and A3 size).
(b)
Paper (A4 and A3 size).
(c)
Writing pens, marker pens, highlighter pens (various colours).
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Part
(d)
Pencils (various colours).
(e)
Pencil sharpeners.
(f)
Erasers.
(g)
Staplers and staples.
(h)
Hole punches.
(i)
Paper chips and bull dog clips.
11.4.6
The Contractor shall supply safety equipment and clothing for the Engineer and his staff.
Safety equipment and clothing shall include, but not necessarily be limited to, the following:
Safety helmets, boots, gloves, High visibility vests, safety glasses (Clear and tinted)
(b)
Safety belts and harnesses.
(c)
Boiler suits.
(d)
Any other PPE identified by the Contractors job hazard analysis or risk assessment
process
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(a)
The Contractor shall also supply gas detection equipment and breathing apparatus in
accordance with the relevant provisions of Part 10 of this Section, Occupational Health and
Safety.
11.4.7
Telephones and Facsimile Machines
For Type 1 Offices, the Contractor shall supply and install a telephone and facsimile
machine. The telephone and facsimile machine should conform to the relevant provisions of
any Telecom Provider standard or requirement.
For Type 2 Offices, the Contractor shall supply and install a telephone in each office and the
meeting room. Each telephone shall be connected to a private address box exchange
(PABX) system. The Contractor shall also supply and install a facsimile machine. The
telephones, PABX system and facsimile shall conform to the relevant provisions of any
Telecom Provider standard or requirement.
The Contractor shall provide a new A4 size plain paper desktop facsimile machine complying
with the following:
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(a)
2 Line 24 character LCD Display
(b)
ITU compatible
(c)
Resolution horizontal scanning 8 pixel/mm
(d)
Vertical scanning Standard 3.85 lines/mm
(e)
Fine 7.7 lines/mm
(f)
150 sheet paper tray (80g/m2
The facsimile machine shall be returned to the contractor at the end of maintenance period.
The Contractor shall be responsible for supply of all necessary toner or ink cartridges and
plain white paper and for maintenance of the equipment by the manufactures s agent
throughout the Work order.
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The Contractor shall provide six digital cameras and one digital video camera for the
exclusive use of the Engineer or his designated representative and supply software,
batteries, cables and USB flash drives or external hard drives as required. The Digital
camera shall have a minimum specification of 35-105 zoom, with a minimum of 16.0
megapixels for prints up to 2030, 8GB internal memory and video/audio facility. The
cameras shall be returned to the contractor at the end of the contract period
11.5
ATTENDANCE
11.5.1
Assistance to the Engineer
The Contractor shall provide every assistance to the Engineer in carrying out his duties.
The Contractor shall provide for the use of the Engineers Representative and his staff, any
chainman/assistants to carry out any duties whatsoever, as required by the Engineers
Representative.
11.5.2
Contract Administration
The Contractor shall provide secretaries, cleaners and tea persons for the exclusive use of
the Engineer for the duration of the Contract.
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END OF PART
QCS 2014
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Part
12: Contractors Site Facilities
Page 1
12
CONTRACTORS SITE FACILITIES GENERAL ........................................... 2
12.1
GENERAL ...................................................................................................... 2
12.1.1 Scope
12.1.2 References
2
2
12.2
CONTRACTORS SITE FACILITIES ............................................................. 2
12.2.1
12.2.2
12.2.3
12.2.4
12.2.5
Buildings
Site Fabrication Areas
Materials Storage Area
Power, Water, Lighting and Heating
Miscellaneous
12.3
PROJECT SIGN BOARD............................................................................... 3
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2
2
3
3
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12.3.1 Project Sign Board
ADVERTISING .............................................................................................. 4
4
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12.4.1 Photographs
12.4.2 Name Boards and Other Advertising
PROVISION OF HAMAD MEDICAL CORPORATION AMBULANCE SPOKE

STATION ....................................................................................................... 4
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12.5
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12.5.1 General
12.5.2 Requirements
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12
CONTRACTORS SITE FACILITIES GENERAL
12.1
GENERAL
12.1.1
Scope
This Part specifies the requirements for the Contractors temporary site facilities.
12.1.2
References
Related Sections and Parts are as follows:

Part 9 Materials.
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CONTRACTORS SITE FACILITIES
12.2.1
Buildings
The Contractor shall provide all offices, sheds, stores and other buildings necessary for him
to undertake all duties, obligations and activities associated with the construction of the
Works.
All buildings shall be supplied and maintained in good condition and shall be of neat
appearance.
The position of all the Contractors temporary site buildings shall be to the approval of the
Engineer.
The Contractor shall maintain an office at the Site for the duration of the Contract. This office
shall be open at all times during Site working hours.
Upon completion of the Contract, all temporary site buildings shall be removed and the area
occupied or otherwise affected by them reinstated to its original condition.
The Government of Qatar will grant a right of access only within the road reservation. Should
the Contractor need to use adjacent areas of land for camps, plant site etc, he shall arrange
for the right to use the said land himself.
This clause in no way invalidates the obligations of the General Conditions of Contract.
12.2.2
Site Fabrication Areas
The Contractor shall provide an area suitable for assembly and fabrication purposes.
Fabrication areas shall simulate factory conditions if required in the Project Documentation.
12.2.3
Materials Storage Area
The Contractor shall provide sufficient and appropriate materials storage areas. The storage
areas shall be suitable for the materials to be stored in them and shall offer necessary
protection where required.
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12.2
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The Contractor shall ensure that the storage areas comply with the relevant provisions of
Part 9 of this Section, Materials.
12.2.4
Power, Water, Lighting and Heating
The Contractor shall provide, maintain and subsequently remove temporary services for
power supply, water supply, lighting and heating.
All electrical installations shall be in the charge of a competent person who shall accept full
responsibility for its use and any alterations or additions thereto. The name, designation and
telephone number of such person shall be prominently displayed close to the main switch or
circuit breaker of the installation, and also in the Contractors site office.
Site work power tool supplies (except for operation of pumps) shall be of 110 volts (55 volts
to earth). All electricity supply cables shall be buried or properly supported and protected and
shall be armoured. Flexible cable shall only be allowed for hand lamps and hand held tools
and shall not exceed 6 metres in length. Industrial type plugs and sockets shall be used.
All site electrical installations shall comply with the requirements of the current regulations of
QGEWC.
12.2.5
Miscellaneous
The Contractor shall provide, maintain and subsequently remove temporary roads, paths,
parking areas and refuse disposal areas. The area occupied by temporary roads, paths,
parking areas and refuse disposal areas or otherwise affected by them shall be restored to
their original condition on completion of the Contract.
12.3
PROJECT SIGN BOARD
12.3.1
Project Sign Board
Standard Signboard: The Contractor shall provide and erect a temporary signboard at the
location of his approved site compound. In addition he shall provide signboards at the start
and end of each ongoing work location for all works whether major or minor.
Project Identification Signboard: Information signboards shall be clearly displayed on

approaches to works in the highway at each ongoing work location for all works whether
major or minor. These shall be provided by the Contractor and shall be positioned so as not
to cause hindrance to the movement of vehicular or pedestrian traffic. The signs shall be
mounted on sturdy metal frames, be mobile and reusable, and shall be illuminated at night.
The Project sign boards shall comply with the standard details, as updated by the project
drawings and specifications, and shall be to the approval of the Engineer. In addition, the
Contractor shall obtain all necessary approvals from the relevant authorities prior to erection.
The Contractor shall be responsible for the structural stability of the signboards but shall
submit details of his proposals for support to the Engineer for approval.
The Contractor shall maintain, move and adapt the signboards as required during the
progress of the Works and shall remove them upon completion.
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ADVERTISING
12.4.1
Photographs
The Contractor shall not use photographs or any details of his work in connection with the
Contract in any form of publicity or advertisement in any part of the world without having first
obtained the Engineers approval to its content and context.
12.4.2
Name Boards and Other Advertising
Details of any further sign boards other than as designed in Clause 12.3.1 or advertisements
that the Contractor may wish to erect on site shall be to the approval of the Engineer.
12.5
PROVISION OF HAMAD MEDICAL CORPORATION AMBULANCE SPOKE

STATION
12.5.1
General
Ambulance Spoke Station is a temporary structure. This can be relocated quickly to any
location in a rapidly changing infrastructure, which is a vital component of the design. It is
designed to provide covered parking for up to two ambulances and accommodation for a
small crew room for up to four paramedics. The crew need shelter from the summer heat in a
safe environment in a prime response location to be ready for emergency calls. The stations
are versatile and designed to be completely self-contained. It doesn't require to be connected
to Electricity, Water or Sewerage or require any physical links to service providers. All of its
power is provided by solar panels. The cabin can be dismantled and moved to another site
within 48 hours, enabling Hamad Medical Corporation to relocate these small stations. The
station does not require any form of building foundations, just level ground. Depending on the
location, some stations may require minor works for access to and from the road.
The contractor will in no way be relieved of his responsibility under Qatari law to provide
medical care, facilities, insurance, etc. to workers on site, and that Hamad Medical
Corporations facility is mainly for the purpose of the general public (so that Hamad Medical
Corporation can respond more quickly to emergency incidents in a rapidly changing
infrastructure)
12.5.2
Requirements
If instructed by the Engineer, the Contractor shall make provision within or adjacent his site
facilities for an Ambulance Spoke Station.
The Contractor is only required to provide an area for the for the facilities. The Ambulance
Spoke Station and vehicles will be provided and installed by Hamad Medical Corporation or
an entity on their behalf.
The area shall be a minimum of 10 metres by 17 metres.
The area must be levelled as the surrounding area of the Contractor facilities.
The areas shall be provided with clear access to the road network.
Access to the Ambulance Spoke Station is required 24hours/day 7 days/week.
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Ambulance vehicle access is required to at least one long side.
Access for maintenance (water resupply, cleaning, removal of waste etc.) is required to one
short side.
The allocated area shall be approved in writing by the Engineer after consultation with
Hamad Medical Corporation.
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END OF PART
QCS 2014
13
Section 01: General

Part
13: Setting Out of the Works
Page 1
SETTING OUT OF THE WORKS .................................................................. 2
13.1
GENERAL ...................................................................................................... 2
13.1.1 Scope
2
13.2
SITE INFORMATION AND INSPECTION ..................................................... 2
13.2.1 Site Information
2
13.2.2 Site Inspection
2
13.3
LEVELS AND REFERENCE GRID ................................................................ 2
13.3.1 Temporary Bench Marks
2
13.3.2 Site Grid
3
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13.4
SURVEYING .................................................................................................. 3
13.4.1 Site Survey
3
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13.5
SETTING OUT ............................................................................................... 3
13.5.1 Setting Out of the Works
3
13.5.2 Setting Out of Works Sited on Private Land
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Page 2
13
SETTING OUT OF THE WORKS
13.1
GENERAL
13.1.1
Scope
This Part specifies the requirements for setting out of the Works and includes locating
existing services, surveying the Site and establishment of temporary bench marks.
The Engineer reserves the right to order levels to be taken at any time considered necessary
for the full and proper supervision and measurement of the Works.
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Engineers Site facilities.
Part 11
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This Section
SITE INFORMATION AND INSPECTION
13.2.1
Site Information
Before commencing the setting out of the Works the Contractor shall ascertain the location of
all existing underground services within the Site boundary. The Contractor shall prepare a
plan detailing the location of the services.
Any conflict between existing services and any part of the proposed Works shall be brought
to the attention to the Engineer without delay.
Any re-work resulting from the Contractors failure to locate and identify services shall be
undertaken at the Contractors cost.
13.2.2
Site Inspection
Before commencing the setting out of the Works, the Contractor and the Engineer shall
make an inspection of the Site.
Where appropriate, the Engineer shall require the Contractor to arrange for surveys to be
undertaken, in conjunction with the owners or occupiers, of the condition of roads, properties,
lands and crops which may be affected by the Works. Before any work affecting such roads,
properties, lands or crops is commenced, the Contractor shall confirm in writing to the
Engineer that the relevant survey is a true and accurate record of their condition.
13.3
LEVELS AND REFERENCE GRID
13.3.1
Temporary Bench Marks
. The Contractor shall establish accurate temporary bench marks on permanent blocks from
which the levels to which the Works are to be constructed may be transferred. The location
of temporary bench marks shall be agreed with the Engineer. The level of temporary bench
marks shall be related to the Qatar National Height Datum.
The Contractor shall prepare a plan detailing the location of the bench marks and temporary
bench marks and keep it up to date for the duration of the Contract.
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The Contractor shall protect and maintain the temporary bench marks until the Works are
complete. Upon completion of the Works the Contractor shall clear away the temporary
bench marks to the satisfaction of the Engineer.
The Contractor is responsible for checking the accuracy of temporary bench mark. Any rework resulting from incorrect or inaccurate temporary bench marks shall be undertaken at the
Contractors cost.
13.3.2
Site Grid
When it is a requirement of the Project Documentation, or unless otherwise notified by the

Engineer, the Contractor shall establish a Site Grid. The orientation of the Site Grid shall be
determined by the layout of the proposed works and as agreed with by the Engineer. Grid
spacing shall be 20m in each direction unless otherwise notified by the Engineer. Grid
notation shall be numerical in one direction (y-axis) and alphabetic in the other (x-axis).
The grid shall be tied to the Qatar National Grid. An existing control station related to the
Qatar National grid will be indicated by the Engineer for this purpose.
13.4
SURVEYING
13.4.1
Site Survey
The Contractor shall provide the Site survey and the correctness of that survey shall be
entirely the Contractors responsibility.
The Site survey shall comply with the requirements of the Qatar Survey Manual as a
minimum.
The Contractor shall, within 3 weeks of the date of commencement of the Works, carry out a
check of the co-ordinates and levels of all permanent monuments, bench marks and survey
markers used in the determination of the site survey model and proposed to be used for the
setting out of the Works.
13.5
SETTING OUT
13.5.1
The Contractor shall carry out at his own cost the setting out of the Works.
The Contractor shall be responsible for:
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(a)
True and proper settings out of the Works in relation to reference data given
in the Project Documentation.
(b)
Accurately setting out the positions, levels and dimensions of all parts of the Works.
Any delay or loss resulting from errors in the setting out of the Works shall be the
responsibility of the Contractor. Setting out shall be reviewed by the Engineer before
commencing the Works, but such approval shall in no way relieve the Contractor of his
responsibility for the correct execution of the Work.
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Page 4
The Contractor shall provide measuring and recording equipment for the Engineer in
accordance with the relevant provisions of Part 11 of this Section, Engineers Site Facilities.
The Contractor shall maintain all measuring and recording equipment in good working order
at all times.
The Contractor shall provide all assistance which the Engineer may require for checking the
setting out and taking measurements of the Works, including labour, equipment and
transportation.
13.5.2
Setting Out of Works Sited on Private Land
The Contractor shall notify the Engineer in writing fourteen (14) days in advance of his
intention to set out any of part of the Works that lies in private land.
The Contractor shall ensure that all requirements and instructions of private land owners are
strictly adhered to.
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END OF PART
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Section 01: General

Part
14: Temporary Works and Equipment
Page 1
TEMPORARY WORKS AND EQUIPMENT ............................................................. 2
14.1
14.1.1
GENERAL ............................................................................................................... 2
Scope
2
14.2
14.2.1
TEMPORARY WORKS ........................................................................................... 2

General
2
14.3
14.3.1
TEMPORARY EQUIPMENT .................................................................................... 2

General
2
14.4
14.4.1
TEST CERTIFICATES FOR CRANES AND LIFTING TACKLE ............................... 3

General
3
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14
TEMPORARY WORKS AND EQUIPMENT
14.1
GENERAL
14.1.1
Scope
This Part specifies the requirements for Temporary Works required in connection with
construction of the Works and temporary plant and equipment required in connection with
aiding the construction of the Works. It does not include overpumping activities in respect of
sewers and drains.
Related Parts and Sections are as follows:

Quality Assurance and Quality Control
Section 11
Health and Safety
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Section 2
Occupational Health and Safety concerning temporary works and equipment is covered in
Section 11 Health and Safety
Quality Controlling temporary works and equipments is covered in

Assurance and Quality Control
14.2
TEMPORARY WORKS
14.2.1
General
Everything used for and in connection with the Temporary Works shall be fit for the purpose,
in serviceable condition and in compliance with any relevant standard.
The Contractor shall design his Temporary Works to be of adequate strength, stability and
suitability.
The Contractor shall submit details of any Temporary Works proposed to the Engineer for
review before commencing the work. Such details shall include, but not be limited to design
calculations and drawings. The submission to the Engineer of any such details shall not
relieve the Contractor of his responsibility for sufficiency of the Temporary Works or of his
other duties and responsibilities under the Contract.
The Contractor is responsible for ensuring that Temporary Works are not in any way
detrimental to existing structures in any way. Particular care shall be taken with scaffolding to
avoid staining or mechanical damage to finishing.
The Contractor shall make safe and reinstate all areas affected by Temporary Works.
14.3
TEMPORARY EQUIPMENT
14.3.1
General
The Contractor shall provide and maintain in good condition on the Site all plant, tools and
vehicles necessary for the proper and safe execution of the Works.
Temporary equipment shall be fit for the purpose for which it is to be used.
Section 2 Quality
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Temporary equipment shall only be operated by personnel who are trained and qualified.
14.4
TEST CERTIFICATES FOR CRANES AND LIFTING TACKLE
14.4.1
General
Cranes, whether used to construct the Works or provided as part of the permanent Works,
must have a current test certificate.
Each sling, shackle or other item of loose lifting tackle, whether used to construct the Works
or provided as part of the permanent Works, must have either a current test certificate.
Test certificates must be issued by a competent testing authority approved by the Engineer.
The Contractor must have a copy of each test certificate on site available for inspection by
the Engineer.
The following Standards and Code of Practice shall be complied with and where such
documents are replaced or superseded the Contractor shall comply with the latest version:
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Mobile and Tower Cranes: BS 1757, BS 2799 and CP 3010.
(b)
Overhead Cranes: BS 466 and BS 5744.
(c)
Slings: BS 1290, BS EN 1492, ISO 4309 / 3481 Pt 2, ASME B30.9.
(d)
Chain Blocks: BS 3243.
(e)
Shackles: Alloy: BS 3551/ BS 6994.
(f)
Chain: BS 4942 part 1 & 6.
(g)
Hooks: BS 2903, ASME B30.10.
(h)
Ring and link: BS 2902.
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A monthly inspection of lifting appliances shall be carried out by a competent person

employed by the Contractor. Full records of all such inspections and tests shall be kept by the
Contractor in an approved form and shall be made available to the Engineer immediately
upon demand. Copies of monthly inspection reports shall be submitted to the Engineer.
END OF PART
QCS 2014
Section 01: General

Part
15: Temporary Controls
Page 1
TEMPORARY CONTROLS ..................................................................................... 2
15.1
15.1.1
GENERAL ............................................................................................................... 2
Scope
2
15.2
15.2.1
15.2.2
15.2.3
15.2.4
15.2.5
15.2.6
15.2.7
TEMPORARY CONTROLS ..................................................................................... 2

Construction Cleaning
2
Dust Control
2
Noise
2
Nuisance and Trespass
2
Pollution Control
3
Surface Water and Groundwater Control
3
Environmental protection
4
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15
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Section 01: General

Part
Page 2
15
TEMPORARY CONTROLS
15.1
GENERAL
15.1.1
Scope
This Part specifies the Contractors responsibilities with respect to temporary controls needed
to protect the Works and the environment.

This Section
Part 5
Interference
TEMPORARY CONTROLS
15.2.1
Construction Cleaning
The Contractor shall be responsible for the proper upkeep and maintenance of the Site and
Works and shall remove from the Site all rubbish and other waste as it accumulates.
Materials and equipment shall be positioned, stored and stacked in an orderly manner.
Properly constructed rubbish chutes shall be used for clearing the debris from upper floors.
Debris shall be accumulated in suitable pre-determined areas and removed from the Site as
often as is practical.
On completion of the Works, any protective tape and other temporary coverings shall be
removed and the internal and external surface of the structure shall be thoroughly cleaned to
completely remove all dust, dirt, stains, handmarks, paint spots, plaster, mortar droppings
and other blemishes.
15.2.2
Dust Control
The Contractor shall conduct his operations and activities in such a manner that no operation
shall be included which will emit into the atmosphere any flying dust or dirt which might
constitute a nuisance.
15.2.3
Noise
The Contractor shall restrict the use of plant, machinery, equipment and work practises likely
to produce unacceptable noise levels to normal working hours.
15.2.4
Nuisance and Trespass
All reasonable means shall be used to avoid inconveniencing owners and occupiers of
adjacent properties. All plant, machinery or equipment shall be placed and used on the Site
so as to avoid any nuisance or trespass on adjoining property.
Should it be necessary for any plant, machinery or equipment to project or operate over
adjoining property, the Contractor shall obtain the permission of the adjoining owner or
occupier. Details of approvals shall be submitted to the Engineer in writing.
No workmen employed on the Works shall be allowed to trespass upon adjoining properties.
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15.2
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If in the execution of the Works it is necessary for the Contractor to enter adjacent properties,
he shall firstly obtain the permission of the owners of the property. The Contractor shall
ensure that any instructions made by the owners of the properties are strictly adhered to.
The Contractor shall be held responsible for and shall indemnify the Employer against all
claims, which may arise out of his failure to comply with provisions of items 1. 2. 3 and 4 of
Clause 1.15.2.4
15.2.5
Pollution Control
The Contractor shall ensure that none of his operations or work practises result in the
polluting of the air, underground strata or any existing watercourse, canal, lake, reservoir
borehole and aquifer.
The Contractor shall rectify any problem resulting from pollution caused by the Contractor to
the satisfaction of the Engineer.
The Contractor will be held responsible for and shall indemnify owner against all claims in
connection with noise, vibration, dust, smoke, diesel spillage and any other nuisance arising
from the execution of the Works.
15.2.6
Surface Water and Groundwater Control
The Contractor shall keep the Work well drained until the Engineer certifies that the whole of
the Works is substantially complete and shall ensure that so far as is practicable all work is
carried out in the dry. Excavated areas shall be kept well drained and free from standing
water.
The Contractor shall construct, operate and maintain all temporary dams, water courses and
other works of all kinds including pumping and well-point dewatering that may be necessary
to exclude water from the Works while construction is in progress. Such temporary works
shall not be removed without the approval of the Engineer.
Notwithstanding any approval by the Engineer of the Contractors arrangements for the
exclusion of water, the Contractor shall be responsible for the sufficiency thereof and for
keeping the Works safe at all times, particularly during periods of rainfall that may result in
flooding. Any damage to the Works arising through the Contractors failure to provide
sufficient protection against water, including flooding, shall be made good at his own
expense.
It is the Contractors responsibility to dispose of all extracted groundwater and collected

surface water. The Contractor shall submit details of his proposed disposal methods to the
Engineer for approval. Discharge of groundwater and/or surface water to existing drainage
facilities shall only be permitted if written approval is given by Public Works Authority and/or
concerned other authorities; copies of such approvals shall be submitted to the Engineer.
The Contractor is to take all necessary precautions to avoid floatation of any structure.
The Contractor shall ensure that his groundwater control activities do not adversely affect any
existing structure or service.
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15.2.7
Environmental protection
The Contractor shall comply with all conditions of the environmental clearance issued for the
project by the Supreme Council for the Environment and Natural Reserves.
The Contractor shall comply with all rules and regulations regarding environmental protection
and pollution control issued by the Supreme Council for the Environment and Natural
Reserves.
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END OF PART
QCS 2014
Section 01: General

Part
16: Traffic Diversions
Page 1
16
TRAFFIC DIVERSIONS................................................................................. 2
16.1
GENERAL ...................................................................................................... 2
16.1.1
16.1.2
16.1.3
16.1.4
16.1.5
Scope
Conformance
Safety
System Description
Traffic Police Requirements
16.2
TEMPORARY TRAFFIC DIVERSIONS ......................................................... 3
2
2
2
2
2
3
3
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16.2.1 General Requirements

16.2.2 Maintenance of Traffic flow
QCS 2014
Section 01: General

Part
Page 2
TRAFFIC DIVERSIONS
16.1
GENERAL
16.1.1
Scope
This Part specifies requirements associated with traffic diversions. Traffic diversions include
for work in, or affecting the use of, roads, footpaths and right of ways and may comprise the
construction and maintenance of paved and unpaved detour carriageways including all
earthworks and the provision of adequate drainage, lighting, sign posting, street furniture and
traffic control devices.

Part 4
Protection
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This Section
16
Conformance
Signs, control and control devices associated with traffic diversions shall conform to the
relevant provisions of Traffic Control at Roadworks produced by the Ministry of Public
Works (latest edition/version) and shall be to the approval of the Traffic Police and the Public
Works Authority.
16.1.3
Safety
The Contractor is responsible for all safety issues associated with the installation, operation,
maintenance and removal of traffic diversions.
The Contractor shall provide lighting in accordance with the relevant provisions of Part 4 of
this Section, Protection.
16.1.4
System Description
Where the diversion of any existing road, footpath or public right or way is temporarily
necessitated by the Works, the Contractor shall provide and maintain an alternative which
shall be operational before interference with the existing facility.
Temporary traffic control devices as well as any other traffic management requirement shall
be erected and maintained by the Contractor for the duration of any activity in, or affecting the
use of, roads, footpaths and right of ways.
16.1.5
Traffic Police Requirements
Before any work in, or affecting the use of, any road, footpath, and right of way is
commenced, the Contractors proposed method of working shall be agreed with, and
confirmed in writing to, the Engineer and the Traffic Police.
Throughout the execution of the Works and the maintenance period, the Contractor shall cooperate with the Traffic Police concerning works in, or access to, roads, footpaths and right of
ways. The Contractor shall inform the Engineer of any requirements of, or arrangements
made with, the Traffic Police.
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16.1.2
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Section 01: General

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Page 3
TEMPORARY TRAFFIC DIVERSIONS
16.2.1
General Requirements
The Contractor shall prepare detailed plans showing any proposed traffic diversions. The
plans shall fully detail the diversion in all respects and shall include construction details if
necessary. The plans shall show the position of ramps, traffic signs, cones, barriers,
demarcation posts and tape, flashing lights and any other traffic control devices. The plans
shall be submitted to the Engineer for review and shall be approved by the Traffic Police.
Traffic diversion apparatus shall not be erected until the Traffic Police have reviewed and
approved the traffic diversion plans.
Persons acting as flagmen shall be physically and mentally qualified, trained in their duties
and courteous. Each flagman on duty shall be identified with appropriate and distinctive
apparel approved by the Engineer and equipped with bilingual STOP/GO signs. Reflective
apparel is required for flagging duties during darkness.
Where paved carriageways, unpaved carriageways or ramps are required, they shall be
provided and maintained to a standard suitable in all respects for the class or classes of
traffic or pedestrians requiring the use of them.
On completion, all traffic diversion works and apparatus shall be removed and land affected
by them reinstated to its original condition.
16.2.2
Maintenance of Traffic flow
The Contractor shall allow for the construction of temporary diversions to permit all existing
traffic movements for the duration of the Contract period.
All diversions shall be constructed in accordance with the latest edition/version of Qatar
Traffic Manual Traffic Control at Roadworks booklet and the Qatar Highway Design Manual,
and shall be approved prior to the implementation by both the Engineer and Traffic Police. It
is the Contractors responsibility to ensure that any traffic diversion required is properly
signed, demarcated, illuminated, controlled and maintained at all times.
Upon the Engineers request, the Contractor shall install and commission temporary traffic
signals capable of handling the diverted traffic.
Sequential arrow boards operating on a 24-hour basis (engine or solar powered) must be
used at all diversion points.
Within the limits of the project where pedestrian traffic is present, all excavated areas,
regardless of depth, must be cordoned off by means of wired mesh panels of height no less
than 1.8m connected together to form a continuous barrier wall.
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16.2
END OF PART
QCS 2014
17
Section 01: General

Part
17: Project Co-ordination
Page 1
PROJECT CO-ORDINATION ........................................................................ 2
17.1
GENERAL ...................................................................................................... 2
17.1.1 Scope
2
17.1.2 Responsibility
2
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CO-ORDINATION .......................................................................................... 2
Contractors Activities
2
Sub-Contractors
3
Other Contractors
3
Other Ministries
3
Liaison with the Public Utility Authorities and other Contractors
3
17.2
17.2.1
17.2.2
17.2.3
17.2.4
17.2.5
QCS 2014
Section 01: General

Part
Page 2
17
PROJECT CO-ORDINATION
17.1
GENERAL
17.1.1
Scope
This Part specifies the co-ordination activities for which the Contractor is responsible.

Part 18
Other Contractors
Part 19
Regulatory Requirements
This Section
Responsibility
The Contractor shall be responsible for the proper co-ordination of all his activities associated
with the construction of the Works including that required between the Engineer, utility
owners, government departments, sub-contractors and other contractors.
No major operations shall be commenced or work outside the usual working hours be carried
out without the consent in writing of the Engineer or without full and complete notice also in
writing being given to him sufficiently in advance of the time of operation so as to enable him
to make such arrangements as he may deem necessary for its inspection.
17.2
CO-ORDINATION
17.2.1
Contractors Activities
The Contractor shall undertake the following co-ordination activities:
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Co-ordinate construction activities under the various Sections of these Specifications

to assure efficient and orderly installation of each part of the Works.
Co-ordinate construction operations included under the various Sections of this
Specification that is dependent upon each other for proper installation, connection, and
operation.
(b)
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17.1.2
(c)
Where installation of one part of the Work is dependent on installation of other

components, either before or after its own installation, the Contractor shall prepare
schedules and construction activities in the sequence required to obtain the best
results.
(d)
Where availability of space is limited, co-ordinate installation of different components

to assure maximum accessibility for required maintenance, service and repair.
(e)
Make adequate provisions to accommodate items scheduled for later installation.
(f)
Where necessary, prepare memoranda for distribution of each party involved outlining
special procedures required for co-ordination; include such items as required notices,
reports and attendance at meetings.
(g)
Prepare similar memoranda for the Engineer, separate contractors and subcontractors where co-ordination of their work is required.
QCS 2014
Section 01: General

Part
Page 3
(h)
Take special care and precautions for specific co-ordination requirements for the
installation of plant and items of equipment.
(i)
Co-ordinate the scheduling and timing of required administrative procedures with other
construction activities to avoid conflicts and ensure orderly progress of the work.
Sub-Contractors
The Contractor is responsible for co-ordinating the work of his sub-contractors in all respects.
17.2.3
Other Contractors
The Contractor shall co-ordinate his work as necessary with other contractors in accordance
with the relevant provisions of Part 18, Other Contractors, of this Section.
17.2.4
Other Ministries
The Contractor shall co-ordinate his work as necessary with other Ministries in accordance
with the relevant provisions of Part 19, Regulatory Requirements, of this Section.
17.2.5
Liaison with the Public Utility Authorities and other Contractors
The Contractor shall liaise with all public utility authorities for water, electricity, telephones,
etc and shall:
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17.2.2
Provide public utility authorities with storage areas where applicable.
(b)
Assist in unloading of stores and equipment.
(c)
Ensure that all services or diversions of services are installed under the carriageway
and footways before they are surfaced.
(d)
Work out an overall programme for any works to be carried out by public utility
authorities and ensure that this programme is maintained.
(e)
Keep public utility authorities informed of the Contractors own progress.
(f)
Arrange for supply of services for all the affected permanent and temporary
accommodation, buildings, shops, trading areas etc even if it is not clearly mentioned
in the Project Documentation for the duration for the Contract:
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Give the appropriate public utility authority adequate notice in writing that he intends to
install dry ducts so that a representative of the utility concerned may attend the
installation and record the location of the ducts together with the Contractor.
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(a)
The Contractor shall make due allowance for carrying out the works, whilst public utility
authorities are working on the Site, during the Contract period. This due allowance shall
include programming of the works to suit the programmes of the public utility authorities.
The Contractor shall at all times be responsible for the compliance with these requirements
of his sub-contractors.
Before final surfacing of any carriageways or footways takes place, the Contractor is
responsible for ascertaining from all public utility authorities that their underground works
have been completed. In the event that the Contractor failing to carry out this obligation to the
satisfaction of the Engineer and completed surfacing is subsequently disturbed, the Engineer
may instruct the Contractor to carry out work at his own expense.
END OF PART
QCS 2014
Section 01: General

Part
18: Other Contractors
Page 1
18
OTHER CONTRACTORS.............................................................................. 2
18.1
GENERAL ...................................................................................................... 2
18.1.1 Scope
18.2
ACCESS FOR OTHER CONTRACTORS ..................................................... 2
18.2.1 Unhindered Access

18.3
CO-OPERATION AND CO-ORDINATION WITH OTHER CONTRACTORS 2
18.3.1 Co-operation at Site Level

18.4
FACILITIES FOR OTHER CONTRACTORS ................................................. 2

2
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18.4.1 Site Facilities for Other Contractors
QCS 2014
Section 01: General

Part
18: Other Contractors
Page 2
OTHER CONTRACTORS
18.1
GENERAL
18.1.1
Scope
This Part specifies the requirements for access to the Site for other contractors, for
co-operation and co-ordination with other contractors and for the provision of facilities with
other contractors.
18.2
ACCESS FOR OTHER CONTRACTORS
18.2.1
Unhindered Access
The Contractor shall allow other contractors unhindered access to any part of the Works
when in the opinion of the Engineer those parts are sufficiently completed.
18.3
CO-OPERATION AND CO-ORDINATION WITH OTHER CONTRACTORS
18.3.1
Co-operation at Site Level
The Contractor shall carry out his work in a manner that causes the minimum amount of
interference to other contractors working on the Site.
The Contractor shall co-ordinate his operations with the activities of other contractors where
necessary in order to avoid conflicts and ensure orderly progress of the Works.
Those works associated with existing or future service installation shall only be carried out by
a contractor or sub-contractor approved by the public utility authority concerned. The
Engineer shall require proof of such approval in writing prior to the commencement of works.
18.4
FACILITIES FOR OTHER CONTRACTORS
18.4.1
Site Facilities for Other Contractors
If specified in the Contract, the Contractor shall provide site facilities for other contractors.
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END OF PART
QCS 2014
Section 01: General

Part
19: Regulatory Requirements
Page 1
REGULATORY REQUIREMENTS -------------------------------------------------------------------------- 2

GENERAL---------------------------------------------------------------------------------------------------------- 2
19.1.1
SCOPE --------------------------------------------------------------------------------------------------------------- 2
19.1.2
REFERENCES ------------------------------------------------------------------------------------------------------- 2
19.2
NOTICES ------------------------------------------------------------------------------------------------------------- 3
19.2.1
GENERAL ------------------------------------------------------------------------------------------------------------ 3
19.2.2
NOTICE OF INTENT ------------------------------------------------------------------------------------------------- 3
19.3
MISCELLANEOUS --------------------------------------------------------------------------------------------------- 3
19.3.1
W ORK REQUIRED TO BE CARRIED OUT BY THE DEPARTMENT ----------------------------------------------- 3
19.3.2
REGULATIONS OF ROAD OPENINGS----------------------------------------------------------------------------- 3
19.4
PROVISION FOR PERSONS WITH DISABILITIES ----------------------------------------------------- 4
19.4.1
SCOPE --------------------------------------------------------------------------------------------------------------- 4
19.5
THERMAL COMFORT ----------------------------------------------------------------------------------------------- 5
19.6
THERMAL INSULATION --------------------------------------------------------------------------------------------- 5
19.7
ACOUSTICAL CONTROL ------------------------------------------------------------------------------------------- 5
19.8
W ASTE MANAGEMENT -------------------------------------------------------------------------------------------- 5
19.8.1
CONSTRUCTION AND DEMOLITION W ASTE --------------------------------------------------------------------- 5
19.8.2
BULK W ASTE COLLECTION --------------------------------------------------------------------------------------- 6
19.8.3
W ASTE STORAGE -------------------------------------------------------------------------------------------------- 6
19.8.4
W ASTE COLLECTION ---------------------------------------------------------------------------------------------- 6
19.8.5
RECYCLABLE W ASTE MANAGEMENT FACILITIES: ------------------------------------------------------------- 6
19.9
BUILDING FACADE/ EXTERNAL CLADDING MATERIAL -------------------------------------------------------- 7
19.9.1
CERTIFICATION AND APPROVAL ---------------------------------------------------------------------------------- 7
19.9.2
MATERIAL PROPERTIES ------------------------------------------------------------------------------------------- 7
19.10
EXTERNAL FACADE CLEANING AND MAINTENANCE FOR HIGH RISE BUILDINGS -------------------------- 8
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19.1
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19.10.1 GENERAL ------------------------------------------------------------------------------------------------------------ 8

19.10.2 MAINTENANCE MANUAL ------------------------------------------------------------------------------------------- 8
19.10.3 ACCESS OF CLEANING AND MAINTENANCE -------------------------------------------------------------------- 8

19.10.4 CLEANING ----------------------------------------------------------------------------------------------------------- 9
19.10.5 INSPECTION --------------------------------------------------------------------------------------------------------- 9
19.11
PROVISION OF ABLUTION FACILITIES IN PUBLIC BUILDINGS ------------------------------------------------- 9
QCS 2014
Section 01: General

Part
Page 2
REGULATORY REQUIREMENTS
19.1
GENERAL
19.1.1
Scope
This part specifies the requirements for co-ordination, co-operation and liaison with the
following utility and infrastructure owners:
This part also specifies the requirements for co-ordination, co-operation and liaison with the
following authorities and departments:
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ASHGHAL- Infrastructure Affairs

ASHGHAL- Building Affairs
ASHGHAL- Assets Affairs
Qatar General Electricity & Water Corporation- KAHRAMAA
Qatar Telecom - Provider
Qatar Petroleum, QP
Q Rail
19
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Civil Aviation Authority

Ministry of Awqaf and Islamic Affairs
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Authorities having Municipal jurisdiction (Ministry of Energy & Industry, New Industrial area,
RLIC, MIC etc.)
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Ministry of Interior (Civil Defense Department, Traffic Police, Department of Immigration,

Security Systems Department, etc)
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Ministry of Municipal Affairs and Urban Planning (MMUP)

Private Engineering Office
The above shall collectively be known as Department in this Part.
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Traffic Diversions
Project Co-ordination
Section 7
Section 11
Section 15
Section 25
Green Construction
Health and Safety
Insulation of Buildings
Glass and Glazing
This Section
Part 16
Part 17
Where any requirement(s) conflict with any other requirement(s) of Authorities or

Departments in the State of Qatar, the most stringent requirement(s) shall prevail.
19.1.2
References
Al Wakra City Zoning Plan and Regulations Report, 2008, Ministry of Municipality & Urban
Planning, State of Qatar
Civil Defense Regulations, Fire Prevention Department, General Administration of Civil
Defense, Ministry of Interior, State of Qatar
QCS 2014
Section 01: General

Part
Page 3
Code on Barrier-Free Accessibility in Buildings, 2002 (ver 1.0), Building and Construction
Authority, Singapore
Conditions and Descriptions of the Expedient Workers Residences, Resolution of the
Minister of Civil Service and Housing Affairs No. (17) of 2005, State of Qatar
NFPA 101 Life Safety Code, 2012 Edition, National Fire Protection Association, U.S.A.
Planning and Building Regulations for Flats & Flat Complexes, 1994, Planning Department,
Ministry of Municipal Affairs & Agriculture, State of Qatar
Planning and Building Regulations for Villas & Villa Complexes, 1995, Planning Department,
Ministry of Municipal Affairs & Agriculture, State of Qatar
Qatar Highway Design Manual, 1997 (Rev 0), Civil Engineering Department, Ministry of
Municipal Affairs & Agriculture, State of Qatar
Qatar Survey Manual, UPDA, The Centre for GIS State of Qatar.
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Qatar Traffic Manual Vol. 1

Qatar Traffic Manual Vol. 2
Universal Design Guidelines, 2006, Building and Construction Authority, Singapore
NOTICES
19.2.1
General
All notices required to be given by the Contractor to the Department shall be in writing and
delivered by hand. The Contractor shall furnish the Engineer with a copy of all notices
issued by the Contractor.
19.2.2
Notice of Intent
The Contractor shall give at least seven days notice to the Department of the date upon
which it is intended to operate plant or equipment or carry out any work for which permission
has been given in writing by the Department: such operations or work shall only be carried
out in the presence a representative of the Department unless written confirmation shall
have been obtained that this unnecessary.
19.3
MISCELLANEOUS
19.3.1
Work required to be carried out by the Department
If the Department requires work to be carried out on its installations during the execution of
the Works, the Contractor shall provide all facilities to the Departments contractor or
workmen. The Contractor shall co-ordinate the work of the Department and his own
activities, and when necessary shall amend his programme to suit the requirements of the
Department and shall keep the Engineer informed of all arrangements made.
19.3.2
Regulations of Road Openings
For Works including road openings, the Contractor shall comply with all relevant provisions
of the following Parts of this Section or direction of the Engineer.
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19.2
Part 16
Part 21
Traffic Diversions.
Final Inspection and Handover
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Section 01: General

Part
Page 4
19.4
PROVISION FOR PERSONS WITH DISABILITIES
19.4.1
Scope
The aim of this provision is to set out the fundamental design and construction requirements
and guidelines for making those buildings specified in Table 1 accessible to persons with
disabilities.
Table 1: Accessibility for Persons with Disabilities
No
Accessible areas
Residential buildings:
(a) 3-storeys and below
All communal areas and facilities at ground floor.
(b) 4-storeys and above
All communal areas and facilities.
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Types of buildings
Office buildings
All areas intended for access by employees or

public.
Shophouses
The ground floor for non-residential use shall be

accessible to employees or public.
Shopping complexes and multipurpose

complexes

public.
Hotels and boarding houses

public.
Religious buildings and Mosques
All areas intended for access by worshippers or

public.
Places of public resort
Cinemas, theatres, concert halls, stadia

or other places of public resort where
permanent seating arrangement is
provided

public.
Schools, colleges, universities or

institutions of learning

public.
10
Hostels, halls of residence or dormitories All areas intended for access by staff, students or
public.
11
Sports complexes and public swimming

pools
All areas intended for public access.
12
Restaurants and eating establishments

public.
13
Markets and hawker or food centres
All areas intended for public access.
14
Hospitals, clinics, dispensaries, nursing

homes, homes for the aged and welfare
homes
All areas intended for access by staff, patients,

inmates or public.
15
Factories, workshops and industrial

buildings 4-storeys and above

public.
16
Transport stations, interchanges,

passenger terminals and administration
buildings in depots

public.
17
Vehicle parks (surface parking or vehicle

parking buildings)
Prescribed areas.
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public.
QCS 2014
Section 01: General

Part
Page 5
The Owner is recommended to follow and adopt suitable and relevant international barrier
free access guidelines which will allow persons with disabilities to enter, move around and
leave an establishment without hindrances.
Universal Design is a continuous process of innovation targeted at improving usability for

everyone. It is also known that Universal Design is the design of products and environment
to be usable by all people, to the greatest extent possible, without the need for adaptation or
specialised design. It is highly recommended that the Owner adopt Universal Design until the
authority (MMUP) approve reference.
19.5
THERMAL COMFORT
The heating, ventilation and air conditioning (HVAC) system must be capable of providing
the following range of conditions for 95% of the year
Lower Limit
DB: 22.5 C
Relative humidity
RH: 30% (min)
Upper Limit
DB: 25.5 C
RH: 60% (max)
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Dry bulb temperature
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For occupant comfort, normal occupied spaces should have a terminal air velocity between
(0.2-0.3) m/s.
19.6
THERMAL INSULATION
As specified in section 15
19.7
ACOUSTICAL CONTROL
As specified in section 15
19.8
WASTE MANAGEMENT
19.8.1
Construction and Demolition Waste
For all new buildings unless or until specified otherwise, at least fifty percent (50%) by
volume or weight of waste material generated during the construction and/ or demolition of
buildings must be diverted from disposal in landfills. Diverted materials must be recycled or
reused.
This should be done through one or more of the following three paths:
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(a)
Concrete and Asphalt waste must be diverted to Construction Waste Treatment Plant.
(b)
Excavated soil, land-clearing debris and hazardous waste must be diverted to places
designated by the concerned Department of MMUP.
(c)
Other recyclable materials such as woods plastics and metals can be used at site or
diverted to a Recycling Facility.
The following materials are exempt from the calculation of the percentage of waste diverted
from disposal at landfill facilities:
(a)
Excavated soil and land-clearing debris; and
(b)
Hazardous waste
QCS 2014
Section 01: General

Part
Page 6
Bulk Waste Collection
For all new residential apartment buildings, an area must be provided for residents to place
items of bulky waste such as furniture, electrical appliances and sanitary ware. The area
2
provided must cover a space of approximately ten square meters (10 m ). The area does not
have to be designated solely for the purpose of bulky waste collection (eg: set aside to the
car park).
The bulky waste storage area must be reachable, must not restrict access to the building
and comply with safety and fire requirement.
19.8.3
Waste Storage
For all new villas and apartments (single family units), domestic kitchen must be provided
with a minimum storage facility of two ten (10) liter waste receptacles clearly labeled for
recyclable and non-recyclable. The storage facility should be in a proper place within the
kitchen.
19.8.4
Waste Collection
All new buildings which require chute for general waste, in accordance with Qatar MMUP
Regulations, one of the following must be provided:
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19.8.2
A second chute must be provided to handle recyclable material and discharge into a
separate receptacle within the waste management area; or
(b)
The garbage room on each floor must have a minimum floor area of two square
2
meters (2 m ) where recyclable waste can be stored until collected daily by the
building operator. Waste must be transported through designated medium (chute,
service elevator etc.) into the waste management area.
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(a)
All new buildings which does not require chute for general waste, in accordance with Ministry
of Municipal Affairs and Urban Planning Regulation, the garbage room on each floor must
2
have a minimum floor area of three square meters (3 m ) where non-recyclable and
recyclable waste can be stored until collected daily by the building operator. Waste must be
transported in a service left discharge into a designated receptacle within the waste
management.
19.8.5
Recyclable Waste Management Facilities:
For all new buildings other than villas, a sorting and storage facility for recyclable materials
must be provided.
This facility must be easily accessible and comply with the requirements of the location,
access and specifications of general waste areas in accordance with Qatar Municipality
Building Regulations.
The sorting and storage facility may be part of the general waste management facility or a
separate facility.
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(a)
Recycled waste facility incorporated into the general waste collection:

2
The size of the room must be increased by 10% and not less than 5 m , to allow
additional room to sort and store the recyclable waste.
QCS 2014
(b)
Section 01: General

Part
Page 7
Recycled waste facility separated from the general waste collection:

The recycled waste facility must be sized as a percentage from the total Built Up Area
(BUA) of the building in accordance with Table 2.
Where the Total Built Up Area (BUA) of the building falls between the figures outlined in the
Table, linear interpolation must be used to determine an appropriate percentage area for the
recyclable storage space.
Table 2: Sizing Requirements for Storage of Recyclables
Built Up Area (BUA)
Minimum Space for Storage of Recyclables
Less than 500 m2
7.5m
1.5% of BUA
5,000 m
0.8% of BUA
1,000 m
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500 m
0.35% of BUA
10,000 m or greater
0.25% of BUA
BUILDING FACADE/ EXTERNAL CLADDING MATERIAL
19.9.1
Certification and approval
External Cladding material must be tested by an approved 3

manufacturer shall have certified ISO 9000 compliant QMS.
External Cladding materials that are combustible must be submitted to the Qatar Civil
Defense for review and approval. Submissions shall include copies of relevant test reports
and details on the proposed fixings used to secure the material to the building. On approval,
a Qatar Civil Defense certificate for the External Cladding material will be issued to the
submitting party.
19.9.2
Material properties
External Cladding Material (ECM) fixed to buildings shall be non-combustible and shall be
composed of environmentally friendly materials and substances.
ECM not complying with 19.8.2.1 above must have the following fire propagation and flame
spread properties.
rd
party test laboratory. The
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19.9
(a)
(b)
When tested in accordance with BS 476 Part 6:

(i)
Fire Propagation index, no greater than 4.0
(ii)
any sub index must not be greater than 2.0, and
When tested in accordance with BS 476 Part 7:

(i)
flame spread after 10 minutes must be less than 25 mm
Alternative test methods and Standards such as AS, BSI and ISO may be used to verify
compliance in test reports provided the method of testing is demonstrated to be equivalent
and verifies an equal or better fire performance result to those nominated in 19.8.2.2 above.
Details of the ECM's approval and listings, its method of fixing and the extent of usage shall
be included in the proposed Building Plans fire safety submission for compliance verification.
QCS 2014
19.10
Section 01: General

Part
Page 8
EXTERNAL FACADE CLEANING AND MAINTENANCE FOR HIGH RISE

BUILDINGS
19.10.1 General
1.
Any building measuring 28 meters or above in height is classified as a high rise building as
per Qatar Civil Defense Department. This section is intended to provide a framework for the
cleaning and maintenance of the faade for high rise buildings. The faade will require both
cleaning and maintenance to achieve its anticipated life and desired purpose. Failure to
undertake this work can considerably reduce the life of materials, components and finishes.
The provision of correct documentation and instruction at the completion of construction will
permit the building owner to gain the best achievable performance from the faade.
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A maintenance manual should be produced for the completed works. The number and
specific requirements for the manual should be specified at tender stage. The manual should
be developed in parallel with the design and should include, but not be limited to, the
following information:
The name, address and telephone number of each firm and/ or sub-contractor
involved in the supply of materials, components, assemblies and finishes.
(b)
A clear and concise description of the construction used to form the various areas of
faade on the particular project.
(c)
Copies of material, component and finishes certification and test reports as required
by the Specifier.
(d)
A method statement showing the means of access to all parts of the wall and safe
loadings.
(e)
A method statement covering the procedures for replacement of damaged or

otherwise defective materials or components, and materials and components that
have a design life less than the design of the faade and will therefore require
replacement during the life of the faade.
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(a)
Recommendations for routine maintenance, cleaning, suitable cleaning agents and

any lubrication/adjustments to working parts.
(f)
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19.10.2 Maintenance Manual
(g)
A full set of construction drawings updated to include any changes made up to the
time of completion.
(h)
The terms and conditions of any guarantees.
19.10.3 Access of Cleaning and Maintenance

1
The Building Owner/ Specifier should provide a means of access which enables all parts of
the faade to be safely reached for the purpose of cleaning, inspection and maintenance.
The intended method of access should be established at the design stage and the relevant
loads catered for. Particular care should be made to define all possible imposed loads
including impact loads and uplift forces on projections by snagging.
The access system should comply with the appropriate British Standards (BS 6037, BS
5974). Specifiers should also make themselves aware of any statutory obligations related to
Occupational Health and Safety at Work.
QCS 2014
Section 01: General

Part
Page 9
The access system should not be capable of imparting forces upon the cladding system
exceeding those agreed at the design stage. It is important that the various parties agree the
design parameters early in the design process.
The access equipment should be maintained, examined periodically by a competent person

and certified in accordance with statutory regulations.
19.10.4 Cleaning
The supplier of the faade should provide instruction for the proper cleaning and routine
maintenance of the faade.
Cleaning of the faade should be undertaken by trained personnel working to an agreed

procedure, based upon the faade contractors recommendations, at a frequency not less
than the recommended intervals.
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19.10.5 Inspection
The faade should be inspected at regular intervals to an agreed method. The faade
contractor, in consultation with the project team, should suggest methods and procedures to
be utilized. The purpose of this inspection includes, but is not necessarily limited to, the
following:
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To review the effectiveness of cleaning methods employed.
(b)
To monitor the performance of the materials and components of the faade system
against their anticipated life.
(c)
Inspecting for damage or failure of any part of the system.
(d)
Checking on the effectiveness of maintenance or remedial work.
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(a)
It is recommended that a detailed inspection plan is drawn up at the time of construction in

consultation between the design and construction teams. The inspection plan should include
procedures and recording methods to enable a systematic monitoring of the condition of the
Curtain wall and assist in the prediction of the need for preventative maintenance or
replacement of component parts.
Inspections should be carried out by suitably experienced persons to the specific procedures
detailed in the inspection plan. The results of these inspections should be compared with
previous inspections where appropriate. The building owner should ensure these results are
available for reference.
19.11
PROVISION OF ABLUTION FACILITIES IN PUBLIC BUILDINGS
The public buildings, for the purpose of provision of Ablution facilities are considered to be
Offices, Shopping Centres, Malls and Hypermarkets.
The occupant load (population) for each building type shall be calculated as per guidelines of
Qatar Civil Defense Department.
Separate Ablution facilities are to be provided for Men and Women close to the Prayer Area.
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QCS 2014
Page 10
The number of Ablution stalls shall be calculated as per Table 3 below.

Table 3: Provision of Ablution Facility
Facility Type
Occupant Population
No. of Ablution Stalls
Up to 50
02
For 51 and above
01
For each additional 50
Up to 200
02
For 201 and above
01
Up to 200
02
Office Building
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Shopping Centre
Hypermarket
Shopping Mall
01
01
201- 2000 people
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For 2001 and above
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END OF PART
Section 01: General

Part
QCS 2014
Section 01: General

Part
02: Use and Maintenance of the Site
Page 1
USE AND MAINTENANCE OF THE SITE ............................................................... 2
2.1
2.1.1
GENERAL ............................................................................................................... 2
Scope
2
2.2
2.2.1
USE OF THE SITE .................................................................................................. 2

General
2
2.3
2.3.1
MAINTENANCE OF THE SITE................................................................................ 2

General
2
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QCS 2014
Section 01: General

Part
02: Use and Maintenance of the Site
Page 2
USE AND MAINTENANCE OF THE SITE
2.1
GENERAL
2.1.1
Scope
This Part specifies the uses and maintenance requirements of the Site.
Related Sections and parts are as follows:

This Section
Part 10
Part 11
Part 12

Contractors Site Facilities
USE OF THE SITE
2.2.1
General
The Site shall not be used for any purpose other than that of carrying out the Works.
Temporary camps, housing and cooking facilities shall not be permitted on the Site unless
otherwise stated in the Project Documentation. When temporary camps, housing and
cooking facilities are permitted they shall comply with Section 1 Part 10.
2.3
MAINTENANCE OF THE SITE
2.3.1
General
In accordance with the Conditions of Contract the Site, the equipment used upon it and the
Works shall be kept clean at all times.
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2.2
END OF PART
QCS 2014
Section 01: General

Part
20: Clearance of the Site
Page 1
CLEARANCE OF SITE ............................................................................................ 2
20.1
20.1.1
GENERAL ............................................................................................................... 2
Scope
2
20.2
20.2.1
20.2.2
20.2.3
20.2.4
FINAL CLEARING ................................................................................................... 2

General
2
Internal and External Surfaces
2
The Site
2
Miscellaneous
3
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20
QCS 2014
Section 01: General

Part
Page 2
CLEARANCE OF SITE
20.1
GENERAL
20.1.1
Scope
This Part specifies the requirements for the final clearance of the Site.
20.2
FINAL CLEARING
20.2.1
General
Final clearing shall be done before the final inspection.
All waste materials shall be removed from the Site and disposed of properly.
20.2.2
Internal and External Surfaces
The Contractor shall clean all interior and external surfaces exposed to view. The Contractor
shall undertake the following to the satisfaction of the Engineer:
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20
Remove temporary labels, stains and foreign substances.
(b)
Polish transparent and glossy surfaces.
(c)
Clean roofs, gutters, downspouts, and drainage systems.
(d)
Remove debris and surface dust from limited access spaces.
(e)
Broom clean concrete floors and unoccupied spaces.
(f)
Clean light fixtures and lamps so they operate at maximum efficiency.
(g)
Other cleaning tasks as specified by the Engineer.
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(a)
The Site
The Contractor shall clean the Site and shall undertake the following to the satisfaction of the
Engineer:
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20.2.3
(a)
Sweep paved areas and rake all other surfaces.
(b)
Remove litter and foreign substances.
(c)
Remove stains, chemical spills and other foreign deposits.
(d)
Any other cleaning tasks as specified by the Engineer.
The Contractor shall abide by the latest regulations of the Ministry of Municipal Affairs and
Agriculture and relevant municipalities in clearance of construction works refuse.
QCS 2014
Section 01: General

Part
Page 3
Clearance and transportation of construction works refuse:

(a)
The Contractor shall undertake to carry out the following within a maximum period of
30 days after completion of the agreed building or project and preparing it for use or
stoppage of work for an indefinite period.
(i)
Removal of the entire Contractors equipment, machinery and other belongings

from the work site.
(ii)
Clearance of all earth, debris and refuse whatsoever and transporting them to
the location designated by the concerned municipality, delivering the building or
project absolutely clean and free of any such materials and delivery of the
surrounding area levelled to the natural level of the street pavement.
In the case of Contractors delay or refusal to carry out such a job, he shall have to pay
a penal compensation as defined in the contract for delay for each day or part of day.
This compensation shall be final and the judiciary shall not be entitled to mitigate it and
it does not require establishing the occurrence of any damage to the owner.
(c)
In addition, the Owner shall be entitled to clear the refuse himself and transport it to the
location designated by the concerned municipality. The Owner shall deduct the cost of
refuse clearance, transport and any other related costs including the office expenses
and overhead cost from the payment or the money due to the Contractor. He may also
stop the final payment due to the Contractor until such refuse has been cleared and a
certificate confirming this has been obtained from the concerned Municipality.
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(b)
Miscellaneous
The Contractor shall clean or replace all mechanical filters for equipment included in the
Works and for equipment directly affected by the construction of the Works.
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20.2.4
END OF PART
QCS 2014
Section 01: General

Part
21: Final Inspection and Handover Procedures
Page 1
21
FINAL INSPECTION AND HANDOVER PROCEDURES .............................. 2
21.1
GENERAL PROCEDURES FOR INSPECTION AND HANDOVER .............. 2
21.1.1
21.1.2
21.1.3
21.1.4
Scope
Pre-requisite for Final Inspection
Approvals from Public Authorities
Hand Over
21.2
ITEMS TO BE PROVIDED BY THE CONTRACTOR .................................... 4
2
2
3
3
21.2.1 Provision of Tools, Spare Parts and Maintenance Materials

21.2.2 Guarantee Warrantees and Bonds
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21.3.1 Operation Data

21.3.2 Operation and Maintenance Manuals
21.3.3 Operational, Field and Performance Testing
MECHANICAL AND ELECTRICAL WORKS ................................................. 4
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21.3
4
4
4
4
5
PROJECT RECORD DOCUMENTS.............................................................. 5
21.4.1
21.4.2
21.4.3
21.4.4
General
Record Drawings
Record Specifications
Maintenance Period Final Inspection
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5
6
6
6
QCS 2014
Section 01: General

Part
Page 2
21
FINAL INSPECTION AND HANDOVER PROCEDURES
21.1
GENERAL PROCEDURES FOR INSPECTION AND HANDOVER
21.1.1
Scope
This Part specifies the requirements and procedures associated with the inspection and
handover of the Works.
Related sections and Parts are as follows:

Part 7
Part 9
Part 20
Submittals
Materials
Clearance of Site
Section 2
Section 9

Mechanical and Electrical Equipment
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This Section
Pre-requisite for Final Inspection
The Contractor shall complete the following to the satisfaction of the Engineer before
requesting the pre-handover Inspection:
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21.1.2
Submit final manufacturer certification, guarantees, warranties and similar documents.
(b)
Submit occupancy permits, operating certificates, final inspection and test certificates
and similar releases enabling full and unrestricted use of the Works.
(c)
Submit record drawings, operation and maintenance manuals, final project

photographs, damage or settlement surveys, property surveys and similar physical
items.
(d)
Complete submittal of record documents.
(e)
Make final changeover of locks and deliver the keys to the Engineer.
(f)
Complete start-up, testing of system, and training of the Owners operations and
maintenance personnel; submit equipment operating data as well as all test reports
and test data required by the Contract.
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(a)
(g)
Dismantle and remove temporary facilities and services from the Site; this includes
utilities, construction tools, buildings and facilities, mock-ups, and similar elements
(h)
Complete final cleaning.
(i)
Repair and restore exposed finishes which have been marred or otherwise damaged.
(j)
Handover all spare parts, tools and maintenance equipment.
(k)
In Network Projects, partial handling over would be acceptable, if it completely met all
the above mentioned requirements.
(l)
Closure of all identified Non-conformance and deficiencies to the satisfaction of the

Engineer
QCS 2014
Section 01: General

Part
Page 3
When the Contractor has completed and cleaned the Works to the satisfaction of the
Engineer the Contractor shall request a final inspection. The request shall be forwarded to
the Owner by the Engineers Representative and a suitable date for the inspection shall be
arranged. The Contractor, Engineers Representative, maintenance department (if any) and
the supervising consultant (if any) shall be present. A list of outstanding items (if any) shall
be agreed and issued to the Contractor.
Upon completion of the listed outstanding items a further inspection shall be requested by the
Contractor, the request shall be forwarded to the Owner by the Engineers Representative
and a suitable date for the inspection shall be arranged. The Contractor, Engineers
Representative, maintenance department (if any) and the supervising consultant (if any) shall
be present.
A list of any items still outstanding shall be issued to the Contractor. If any of these are
deemed to be significant the Contractor shall complete these items and then request another
inspection as described in clause 21.1.2-2.
In respect of pumping station or Works involving mechanical or electrical equipment if items

outstanding are deemed not to be significant or if no outstanding items remain then a 7 day
commissioning and running test shall be initiated. On completion of all tests and agreement
by the Engineers Representative that the plant is considered operable then it shall be
handed over. A 14 day training period for the maintenance department staff on the operation
of the pumping station shall commence.
For works that have no mechanical or electrical equipment if the outstanding items are
deemed not to be significant or if no outstanding items remain the Works inspected shall be
handed over.
21.1.3
Approvals from Public Authorities
The Contractor shall obtain all clearance certificates and approvals required as a prerequisite
to connecting the Works to the permanent water and/or power supply.
The Contractor shall co-ordinate with the Engineer to obtain the necessary documents from
the Qatar General Electricity & Water Corporation regarding connection to the permanent
water and/or power supply.
21.1.4
Hand Over
When the Contractor considers that the Works are complete he shall submit the following:
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(a)
A certificate stating that the Works are complete and that all the requirements of the
Project Documentation have been met.
(b)
A certificate stating that the Works have been inspected.
(c)
A certificate from the appropriate Municipality regarding cleanliness of the Site.
(d)
Approval from the PWA regarding satisfactory trench reinstatement in the Highway (if
applicable).
QCS 2014
Section 01: General

Part
Page 4
ITEMS TO BE PROVIDED BY THE CONTRACTOR
21.2.1
Provision of Tools, Spare Parts and Maintenance Materials
The Contractor shall provide all tools, spare parts and maintenance materials specified in the
Project Documentation.
The Contractor shall provide an itemised list of all the items to be furnished under this
Clause. Each item to be furnished shall be given a unique reference number. The list shall
include the reference number, a description of the item and the appropriate Specification
Section and Paragraph.
All the items furnished under this Clause shall be packaged for long term storage. Any items
requiring special storage conditions shall be brought to the attention of the Engineer.
All items furnished under this Clause shall be provided with a mark or tag for identification
purposes. The mark or tag shall include the reference number detailed in Clause 21.2.1-2.
Unless otherwise instructed, all items furnished under this Clause shall be delivered to the
Government Stores in accordance with the relevant provision of Part 9 of this Section,
Materials.
21.2.2
Guarantee Warrantees and Bonds
The Contractor shall provide notarised copies of all guarantees, warranties and bonds as
required by the Project Documentation. The guarantees, warranties and bonds should be
assembled in a binder with a durable plastic cover, complete with a table of contents.
The start of the warranty or guarantee period shall be either:
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21.2
The date when any item is placed into full time operation for the Governments benefit
and with the Engineers approval.
(b)
The date of issue of the completion certificate.
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(a)
MECHANICAL AND ELECTRICAL WORKS
21.3.1
Operation Data
The Contractor shall provide all operating data for all mechanical and electrical equipment
supplied under the Contract.
The operating data shall be presented on A4 size paper in ring binder with a durable plastic
cover.
21.3.2
Operation and Maintenance Manuals
The Contractor shall provide approved Operation and Maintenance Manuals in accordance
with the relevant provisions of Section 9, Mechanical and Electrical Equipment and Part 7 of
this Section, Submittals.
21.3
QCS 2014
Section 01: General

Part
Page 5
Operational, Field and Performance Testing
After all construction and starting is complete and before taking-over of any part of the
Works, the Contractor shall perform operational, field and performance tests as called for in
the Project Documentation.
The Contractor shall demonstrate operation of the facilities of the Engineer showing proper
sequence of operation as well as satisfactory performance of the system and individual
components. Any improper operation of the system or any improper, neglected or faulty
construction shall be repaired or corrected to the satisfaction of the Engineer. The Contractor
shall make such changes, adjustments or replacement of equipment as may be required to
make same comply with the Specifications, or replace any defective parts or material.
Failure of the system to perform at the specified level at the time of testing will be the
responsibility of the Contractor. In the event of failure of equipment to meet the specified
performance, the Owner reserves the right to reject such equipment or system, withhold
retention money or make claims on the Performance Bond.
The Contractor shall submit a consolidated schedule of operation, field and performance
tests no later than three (3) months before the schedule start of the first test and weekly a
schedule of tests to be carried out the following week. The Contractor shall inform the
Engineer not later than 24 hours in advance of changes in the scheduling of a test.
For all specified performance tests, the Contractor shall prepare and submit the following:
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21.3.3
A draft test procedure no later than two (2) months in advance of the schedule test
date.
(b)
A final test procedure no later two (2) weeks in advance of the scheduled test date.
(c)
A test report within two (2) weeks of the successful completion of the test.
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PROJECT RECORD DOCUMENTS
21.4.1
General
Project Record Documents shall be kept separate from construction/working documents.
Project Record Documents shall be stored in facilities that provide a suitable environment to
prevent damage or deterioration and to prevent loss.
Project Record Documents shall include, but not be limited to the following:
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21.4
(a)
Drawings.
(b)
Specifications.
(c)
Addenda.
(d)
Variation orders.
(e)
Correspondence.
(f)
Transmittals
(g)
Inspection and Test Records
QCS 2014
Section 01: General

Part
Page 6
Record Drawings
Record drawings shall be clearly and correctly red-marked by the Contractor to show all
changes made during the construction process. The record drawings shall show the Works
as executed in accordance with the relevant provisions of Part 7 of this Section - Submittals.
21.4.3
Record Specifications
Record specifications shall be clearly and correctly annotated to show all changes made
during the construction process.
21.4.4
Maintenance Period Final Inspection
During the last month of the period of maintenance the Engineer will notify the maintenance
department that the maintenance period is about to expire. An inspection of the Works by
the Engineers Representative, maintenance department, and the Contractor shall be
undertaken to verify that all outstanding items have been completed.
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END OF PART
QCS 2014
Section 01: General

Part
22: New Technologies and Innovations
Page 1
22
NEW TECHNOLOGIES AND INNOVATIONS............................................... 2
22.1
GENERAL PROCEDURES FOR APPROVAL............................................... 2
22.1.1
22.1.2
22.1.3
22.1.4
22.1.5
Scope
Pre-requisite for Approval
Technologies And Innovations Of Interest
Documentation
Final Inspection And Approval
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2
2
3
3
QCS 2014
Section 01: General

Part
Page 2
NEW TECHNOLOGIES AND INNOVATIONS
22.1
GENERAL PROCEDURES FOR APPROVAL
22.1.1
Scope
Qatar is committed to researching and using new technology and innovations within
construction industry. Because of this commitment it is open to proposals from outside
agencies in the use of new technologies and innovations.
This Part specifies the requirements associated with the proposal and approval of new
technologies and innovations for use in construction in Qatar.
22.1.2
Pre-requisite for Approval
New technologies / innovations are allowed for use in any project on experimental or
research basis after getting an approval from National Committee For Construction and
Building materials Specifications (NCCBS) of the Ministry of Environment and any other
concerned parties.
The period allowed for such an experiment or research shall be limited to a trial period of a
maximum of two years after which it will be evaluated prior to approval or otherwise by the
concerned parties.
The supplier will be required to submit a guarantee certificate for an agreed period of time.
The supplier shall submit a written warranty to bear all fiscal and legal responsibilities as a
result of using the experiment if not meeting the suppliers claims/specifications. He shall
remove any material or debris left from the experiment.
22.1.3
Technologies And Innovations Of Interest
The following are of particular interest to Qatar :

(a)
Polymer Modified Bitumen (PMB)

Superpave
(b)
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(c)
Performance Grade Binders suitable for the climatic conditions of Qatar (i.e. PG 76-10)
(d)
Cold Laid Asphalt
(e)
Rubber Recycling
(f)
Stone Mastic Asphalt (SMA)
(g)
Glass Reinforced Plastic (GRP) pipes
(h)
Polyethylene (PE) Plain and Corrugated pipes
(i)
Fibre Reinforced Concrete
(j)
Recycling of materials from demolished buildings and roads
Notwithstanding the above Qatar wishes suppliers to propose technology and innovations
that it believes can benefit Qatar and the environment.
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Page 3
22.1.4
Documentation
The technology provider shall be requested to submit with his proposals the following
documents:
Drawings
(b)
Specifications
(c)
Technology Reference and Manual
(d)
Specifications and Source
(e)
Reference from previous clients
(f)
Transmittals
(g)
Inspection and Test Records
(h)
Health and Safety requirements
(i)
Environmental requirements
(j)
Material Safety Data Sheet (MSDS) regarding but not limited to transportation,
handling & storage, and First Aid requirements
(k)
Financial arrangements
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(a)
Final Inspection And Approval
Final approval of the technology will be dependant on NCCBS visits, inspection and tests.
Upon satisfaction of the committee, written approval shall be given and the specifications
incorporated into the QCS.
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22.1.5
END OF PART
QCS 2014
Section 01: General

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Part
23: Design & Supervision Consultant Quality Requirements
DESIGN & SUPERVISION CONSULTANT QUALITY REQUIREMENTS................................ 2
23.1
23.1.1
23.1.2
23.1.3
GENERAL ............................................................................................................... 2
Scope
2
References
2
Definitions
2
23.2
23.2.1
23.2.2
23.2.3
23.2.4
23.2.5
23.2.6
DESIGN CONSULTANT QUALITY REQUIREMENTS ............................................ 3

Quality Responsibility and Duties
3
Quality System Documentation
3
Quality Plan
4
Construction Inspection and Test Requirements Specification
5
Design Consultant Verification of Sub Consultants
5
Quality Records
5
23.3
23.3.1
23.3.2
23.3.3
23.3.4
23.3.5
23.3.6
23.3.7
23.3.8
23.3.9
23.3.10
23.3.11
23.3.12
23.3.13
23.3.14
23.3.15
SUPERVISION CONSULTANT QUALITY REQUIREMENTS.................................. 5

Quality Responsibilities and Duties
5
7
Quality Plan
8
Inspection and Test Plans (ITPS)
9
Technical Procedures, Work Instructions and Method Statements
9
Monitoring by Supervision Consultants
10
Review of Contractor Quality Documentation
10
Inspection Responsibilities
11
Inspections and Test Surveillance Points
11
Visits
12
Supervision Consultant Verification
12
Interfacing
12
Punch Lists
12
Protection of the Works
12
Quality Records
12
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DESIGN & SUPERVISION CONSULTANT QUALITY REQUIREMENTS
23.1
GENERAL
23.1.1
Scope
This Part specifies the Quality Assurance activities to be performed by Design and
Supervision Consultants during all phases of the Contract and should be read in conjunction
with all other parts of the Contract.
The purpose of this part is to define Design and Supervision Consultants responsibility for
demonstrating that the work under the contract is executed to the quality standards required
by the contract and to outline verification activities.
23.1.2
References
The following standards are referred to in this part:
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Quality Management systems. Fundamentals and vocabulary
BS EN ISO 9001:2008
Quality Management systems. Requirements
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BS EN ISO 9000:2005
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BS ISO 10006:2003 ...Quality Management systems, Guidelines for Quality Management in

Projects
BS EN ISO 19011:2011
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BS ISO 10005:2005 ...Quality Management systems. Guidelines for Quality Plans

Guidelines for auditing management systems
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QCS Qatar Construction Specification

Definitions
Defect or Non-conformance: any part of the Works not executed, provided or completed in
accordance with the Contract. For the avoidance of doubt and without limiting the generality
of the expression the term shall be taken to include any item of Plant, material, goods or work
incorporated or used in the Works which does not or may not conform to the relevant quality
standards or pass the tests prescribed in or to be inferred from the Contract
Owner: The Ministry, Municipality, Department, Affairs, Agency, Authority, or individual for
whom the Project is being undertaken and to whom the handover of the final product will be
made.
QA & QC: Quality Assurance & Quality Control and this may be written as QA/QC.
QA: Quality Assurance. Part of quality management focused on providing confidence that
quality requirements will be fulfilled. QA involves a continuous evaluation of the adequacy
and effectiveness of the overall Quality Management System in order to evaluate the
deviation from established quality objectives.
QC: Quality Control. Part of quality management focused on fulfilling quality requirements.
The QC involves specific control points during design, fabrication or construction stages to
check the fulfilling of design criteria, acceptance criteria (tolerance, etc.), performance criteria
or functional criteria.
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23.1.3
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QMS: Quality Management System. A set of interrelated or interacting processes, activities

or tasks to direct Project resources to achieve established quality policy and objectives.
Quality Management: Coordinated activities to direct and control an organization with

regards to quality.
23.2
DESIGN CONSULTANT QUALITY REQUIREMENTS
23.2.1
Quality Responsibility and Duties
The Design Consultant shall be responsible for setting up implementing and monitoring his
own Contract Specific Quality Management System meeting the requirements of this part.
The Design Consultant shall be responsible for quality auditing, monitoring and oversight of
any sub-consultants under their control.
The Design Consultant shall perform and or witness any examinations and tests necessary to
demonstrate conformance of the works to the requirements of the Contract and shall accept
only works by the Contractor that so conform:
The Design Consultant shall establish and maintain a system of records which shall provide
objectives evidence that the supervision Consultant is meeting the requirements of this
specification and that the Contractors control and inspections are effective in meeting the
minimum standards required under their contract. Records shall be made available to the
Engineer in accordance with the requirements stated herein or elsewhere in the contract.
The Design Consultant will be subject to monitoring through audit and surveillance by the
Engineer. In both cases the Design Consultant shall promptly rectify any negative findings
with their Quality System rectify non-conformities and corrective actions found during audit
and surveillance activities directed at them.
No part of the Quality system shall be used to preclude or otherwise negate the requirement
of any part of the contract, or the obligation of the Design Consultant pursuant to the
Contract.
The Design Consultant shall appoint a suitably qualified, Quality Manager to verify that the
requirements of this specification are met. The proposed Quality Manager shall be subject to
approval by the Engineer.
23.2.2
The Design Consultant Quality system shall Include as a minimum the following
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(a)
Quality Plan as detailed in 23.2.3 below
(b)
Procedures and work instruction: The Design Consultant Quality system must include
all relevant technical procedures and other pertinent documentation to ensure that the
design works are completed in accordance with the contract, with specific reference to
the minimum requirements of standards reference in 23.1.2 above and including the
mandatory procedures required by ISO 9001:2008.
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Part
(c)
Quality Records: In addition to (and including) quality records identified in the contract
or other applicable codes, standards or procedures, the Design Consultant shall
identify project quality records in compliance with the minimum requirements
standards referenced in 23.1.2 above.
(d)
Reference and other related documents.
Quality system documents shall be submitted to the owner for review, comment and approval
within 30 days after contract award. In the event that comments are made on the contract
Quality system documentation submitted for review and comment, the design consultant
shall make adjustments, correction, amendment or alteration required. Such comment will be
made on the premise that the adjustment, correction, amendment or alteration is within the
scope of the contract and will not affect the contract conditions, specifications, guarantees,
price or the like in anyway.
Adjustments, corrections, amendments or alterations made by the Design Consultant to the

contract quality system shall, after revision be resubmitted by the Design Consultant to the
owner for review and approval.
23.2.3
Quality Plan
Design Consultants are required to submit Quality Plan (addressing their design activities)
which are specific (not generic) to the Contract, meeting as a minimum the requirements of
the standards referenced in 23.1.2 above. This plan shall reference, or include other
documentation which is relevant to the Contract. However as a stand-alone document, the
Quality Plan shall clearly indicate how the Quality process shall be applied to meet the
requirements of the contract. Particular emphasis is to be placed on the following.
Relevant extracts from the Corporate Quality Manual reference to specifications,
standards etc;
(b)
List of all procedures applicable to the project;
(c)
QA/QC Organisation;
(d)
Document Control;
(e)
(f)
(g)
List of all procedures applicable to the Consultants Project Quality System;
(h)
Audits (including internal and external Audits Plans);
(i)
Management Review;
(j)
Quality objectives, Key Performance Indicators (KPIs)
(k)
Allocation of resources;
(l)
Responsibilities and authority for all phases of work;
(m)
Control of Non-conformance, corrective and preventive actions.
(n)
Contract Changes;
(o)
Lessons learned and continual improvement;
(p)
Purchasing Process e.g. Sub Consultants.
(q)
Quality Records
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Inspection and Test;
Specific work practices;
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The Design Consultants Quality plan will make reference to and take into account applicable
codes, standards, specifications, quality characteristics and regulatory requirements as
necessary. It will identify the criteria by which the design and developments inputs and
outputs should be accepted, and how, at what stage(s) and by whom, the outputs should be
reviewed, verified and validated.
The Design Consultants Quality Plan will also state the following.
How request for changes and development will be controlled to meet Contractual
requirements;
(b)
Who is authorised to initiate a change request;
(c)
How changes will be reviewed in terms of their impact;
(d)
Who is authorised to approve or rejects changes;
(e)
How the implementation of changes will be verified;
(f)
When design and development reviews take place;
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(a)
Construction Inspection and Test Requirements Specification
The Design Consultant shall provide a specification addressing the complete inspection and
testing regime related to their design output, taking into account the requirements of the
QCS. This shall be guiding document by which Supervision Consultants and Contractors will
be held accountable for all on and off site tests and inspections to be performed. The
Inspection and Test Requirements Specifications must be sufficiently detailed to leave no
questions regarding the number of samples required or types of tests to be made over and
above the requirements of the QCS and which standards must be complied with.
23.2.5
Design Consultant Verification of Sub Consultants
The Design Consultant is required to perform audits and verification activities at any sub
consultants premises to gain assurance that the subcontracted product conforms to specified
requirements.
23.2.6
Quality Records
In addition to (and including) quality records identified in the contract or other applicable
codes, standards or procedures, the Design Consultant shall determine project Quality
records in compliance with requirements of ISO 9001:2008 and other relevant standards
stated in contract documents and 23.1.2 above.
The list of quality records generated during the life of the contract, and made available upon
request for review by the Owner, shall be indexed by the Design Consultant in his Quality
Plan.
The Design Consultant shall maintain Registers for all incoming and outgoing documents.
23.3
SUPERVISION CONSULTANT QUALITY REQUIREMENTS
23.3.1
Quality Responsibilities and Duties
The Supervision Consultant shall be responsible for setting up implementing and monitoring
his own Contract Specific Quality Management System meeting the requirements of this part
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23.2.4
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The Supervision Consultant shall be responsible for quality auditing, monitoring and oversight
of themselves any consultants, contractors, sub-contractors (Including laboratories) under
their control.
The Supervision Consultant shall perform and/or witness any examinations and tests
necessary to demonstrate conformance of the works to the requirements of the Contract and
shall accept only works by the Contractor that comply with the specified requirements.
The Supervision Consultant shall witness sampling and related testing performed on as well
as testing performed in external Third Party Laboratories.
The Supervision Consultant shall establish and maintain a system of records which shall
provide objectives evidence that the supervision Consultant is meeting the requirements of
this specification and that the Contractors control and inspections are effective in meeting the
minimum standards required under their contract. Records shall be made available to the
Engineer in accordance with the requirements stated herein or elsewhere in the contract.
The Supervision Consultant will be subject to monitoring through audit and surveillance by
the Engineer. In both cases the Supervision Consultant shall promptly rectify any negative
findings with their quality system rectify non-conformities and corrective actions found during
audit and surveillance activities directed at them.
The Supervision Consultants shall follow up on all findings (NCRs, CARs Observations)
issued on the project to, or by the contractor or other entities under the contract.
No part of the quality system shall be used to preclude or otherwise negate the requirement
of any part of the contract, or the obligation of the Supervision Consultant pursuant to the
Contract.
The Supervision Consultant is responsible for ensuring the contactors Work meets all
technical and quality requirements of the contract and shall keep continuous records of
action taken and shall advise the Engineer in writing of significant alteration to construction or
manufacturing techniques to ensure that specified requirements are met.
10
The Supervision Consultant shall conduct audit and surveillance activities to provide
evidence of the use and effectiveness of the Contractors quality system throughout the
execution of the contract.
11
The Supervision Consultant will ensure that the Contractor has included the quality
assurance requirements of the contract into subcontracts entered into by the Contractor.
12
The Supervision Consultant shall provide an effective audit and surveillance process for
works performed by a Contractors Subcontractors..
13
The Supervision Consultant shall verify that the Contractors Project Quality Plan, Inspection
and Test Plans and other such quality documentation includes or references the Quality
Plans, and Inspection and Test Plans of subcontractors and vice versa. All of these
documents must be reviewed and approved by the Supervision Consultant.
14
The Supervision Consultant shall hold contract specific QA/QC meetings chaired by the
Consultant on a monthly basis throughout the duration of the Work. Topics to be addressed
at the site quality meeting shall include, but shall not be limited too:
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Reviewing of the previous months Quality
(b)
Current Performance of the activities
(c)
Providing 4 week look ahead of planned activities
(d)
Non Conformance of activities
(e)
Key performance indicators
(f)
Audit schedule
(g)
Status of inspection of test plans and method statements
(h)
Quality Training
(i)
Contractors Project quality plan and quality control plans review and on-going
effectiveness
(a)
The Supervision Consultant shall be responsible for providing a Monthly Quality Report
template, meeting the Owner requirements, to the Contractor and reviewing the completed
reports submitted by the Contractor.
16
The Supervision Consultant shall be responsible for completing any QA/QC Questionnaires
or Reports required by the Owner.
17
The Supervision Consultant shall appoint a suitably qualified, full time, Quality Manager to
verify that the requirements of this specification are met. The proposed Quality Manager shall
be subject to approval by the Owner.
23.3.2
The Supervision Consultant Quality System shall include as a minimum the following
elements.
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Quality Plan as detailed in 23.2.3 below
(b)
Procedures and work instruction: The Supervision Consultant Quality system must
include all relevant technical procedures and other pertinent documentation to ensure
that the design works are completed in accordance with the contract, with specific
reference to the minimum requirements of standards reference in 23.1.2 above
including the mandatory procedure required by ISO 9001:2008
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(a)
(c)
Quality Records: In addition to (and including) quality records identified in the contract
or other applicable codes, standards or procedures, the Supervision Consultant shall
identify project quality records in compliance with the minimum requirements
standards referenced in 23.1.2 above
(d)
Reference and other related documents
These Quality system documents shall be submitted to the Owner for review, comment and
approval within 30 days after contract award. In the event that comments are made on the
contract quality system documentation submitted for review and comment, the Supervision
Consultant shall make adjustments, correction, amendment or alteration required. Such
comment will be made on the premise that the adjustment, correction, amendment or
alteration is within the scope of the contract and will not affect the contract conditions,
specifications, guarantees, price or the like in anyway.
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Part
Adjustments, corrections, amendments or alterations made by the Supervision Consultant to

the contract quality system shall, after revision be resubmitted by the Supervision Consultant
to the Owner for review and approval.
23.3.3
Quality Plan
Supervision Consultants are required to submit Quality Plans (addressing their supervision
activities) which are specific (not generic) to the Contract, meeting as a minimum the
requirements of the standards referenced in 23.1.2 above. This plan shall reference, or
include other documentation which is relevant to the Contract. However as a stand-alone
document, the Quality Plan shall clearly indicate how the Quality process shall be applied to
meet the requirements of the contract. Particular emphasis is to be placed on the following
requirements of ISO 9001:2008.
Relevant extracts from the Corporate Quality Manual reference to specifications,
standards etc;
(b)
List of all procedures applicable to the project;
(c)
QA/QC Organisation;
(d)
Document Control;
(e)
Inspection and Test;
(f)
Specific work practices;
(g)
List of all procedures applicable to the Consultants Project Quality System;
(h)
Audits (including internal and external Audits Plans);
(i)
Management Review;
(j)
Quality objectives, Key Performance Indicators (KPIs)
(k)
Allocation of resources;
(l)
Responsibilities and authority for all phases of work;
(m)
Control of Non-conformance, corrective and preventive actions.
(n)
(o)
(p)
Purchasing Process e.g. Sub Consultants.
(q)
Quality Records;
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(a)
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Contract Changes;
Lessons learned and continual improvement;
The Supervision Consultants Quality Plan will make reference to applicable codes,
standards, specifications, quality characteristics and regulatory requirements as appropriate.
It will identify the criteria by which inputs and outputs should be accepted, and how, at what
stage(s), and by whom, the outputs should reviewed, verified and validated.
The Supervision Consultants Quality Plan will also address the following:
(a)
How request for changes and development will be controlled to meet Contractual
requirements;
(b)
Who is authorised to initiate a change request;
(c)
How changes will be reviewed in terms of their impact;
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(d)
Who is authorised to approve or reject changes;
(e)
How the implementation of changes will be verified;
(f)
When reviews take place;
(g)
Redline and As-Built process;
Where design is required by the Contractors contract, the Supervision Consultant

responsibilities for the Contractors design work shall be as defined under the contract,
however not withstanding this the Supervision Consultant shall responsible for auditing this
function of the Contractors quality system.
23.3.4
Inspection and Test Plans (ITPS)
As per the requirements of QCS, the Supervision Consultants shall require the Contractor to
submit Inspection and Test Plans to the Supervision Consultant a minimum 30 days prior to
the programmed work start date covered by each Inspection and Test Plan.
The Minimum requirements for the Contractors Inspection and Test Plan are defined in QCS,
and the supervision Consultant is responsible for ensuring the Contractors Inspection and
Test Plan as a minimum meet these requirements or the recommendations of the Design
Consultants.
The Supervision Consultants shall ensure that the Contactors Inspect and Test Plan
adequately cover any Inspections and test points (Hold/Witness/Surveillance/Record Review)
required for the Supervision Consultant to ensure that the works are completed in
accordance with the contract.
Where the Design Consultant for the Contract has detailed specific specifications or
inspection and test requirements, the supervision Consultants shall ensure these have been
addressed within the Contractors Inspect and Test Plan. Where a discrepancy exits between
Inspections and Test requirements of the Design Consultant and the requirements of QCS,
the more stringent requirements shall be adopted.
The Supervision Consultant is responsible for reviewing and approving all Inspection and
Test Plans and other such documentation submitted by the Contractor and returning to the
Contractor within two weeks of their receipt unless otherwise agreed.
The Supervision Consultant shall ensure that inspection of processes, materials, good,
services and subcontracted works are described in the Inspection and Test plan submitted by
the Contractor.
23.3.5
Technical Procedures, Work Instructions and Method Statements
The Supervision Consultants shall verify through audit and surveillance that the Contractors
quality system includes all relevant Technical Procedures, Work Instructions Method
Statements and Inspection and Test Plans to ensure that the Works are completed in
accordance with the contract. These shall be submitted by the contractor in accordance with
the submission schedule agreed with the Supervision Consultant including those which form
part of the Contractors Quality System.
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The Supervision Consultants own Quality system likewise shall include relevant Technical
Procedures, Work Instructions Method Statements and Inspection and Test Plans to ensure
that the works are completed in accordance with the contract with specific reference to the
development and implementation of Quality Procedures specified in ISO 9001:2008. These
shall be submitted to the Owner by the Supervision Consultant in accordance with the
submission schedule agreed with the Owner including those which form part of the
Supervision Consultants corporate quality system.
23.3.6
Monitoring by Supervision Consultants
Surveillance by the Supervision Consultants will include a variety of typical activities:

review of contractor documentations
(b)
audits of Contractor
(c)
attendance at Hold/Witness/Surveillance Points
(d)
Record Review
(e)
Visits to Contractors off site works etc
(f)
Factory Acceptance Tests
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(a)
With the exception of visits, these activities will be announced to the Contractors in advance.
The Supervision Consultants shall give reasonable notice to the Contractor who is required to
make or arrange to be made available all facilities, documentations records and personnel,
including those of any subcontractors, which are required for any surveillance activity to be
taken.
The Supervision Consultants shall advise the Contractor in writing of any deficiency or
deviation in the contract quality system which comes to the Supervision Consultants
attention as a result of surveillance activities. The Contractor shall be required to rectify the
system within as short a period as may be reasonably expected considering the deficiency or
deviation. The Supervision Consultant may direct the Contractor in writing to stop the
operation and immediately carry out any corrective action, and the Contractor must comply
with such direction at his cost. All deficiencies uncovered shall be documented with a NonConformance Report or Corrective Action Request as appropriate (Refer to QCS, Section 2
for a NCR template).
23.3.7
Review of Contractor Quality Documentation
All audits of the Contractor shall be conducted in accordance with a schedule establish by the
Supervision Consultant. These audits are to be performed in accordance with formal
procedures by trained and qualified auditors.
The types of audit to be conducted are as follow:
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(a)
Systems Audit: One System audit will undertaken at or before the start of work on the
contract deliverables (the specified Works). The audit will be conducted against the
requirements of ISO9001:2008
(b)
Compliance Audits: A number of compliance audits will be conducted at defined

milestones in the contract deliverable period. The scope of a compliance audit shall be
set by the supervision Consultant to suit the timing of activities, and the findings of the
system audit. For example, the scope of a compliance audit could cover any of the
following:
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(i)
the complete requirements of the standards and the contract,
(ii)
specific elements of the standard
(iii)
specific clauses of the contract
(iv)
the whole or a part of a single end-to-end process.
Product audit: This is a Quality audit of particular deliverable products to check their
compliance with specified requirements. Such audits should include performance
testing where appropriate.
The Audit Notification shall also be copies to the Owner for information and they may attend
these audits as an observes. The Audit Reports shall be submitted to the Owner within 7
days.
23.3.8
Inspection Responsibilities
For all work the Supervision Consultant shall:
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Review and check that the contractors Method statement and Inspection & Test Plans
are in accordance with the contract Surveillance Points.
(b)
Inspect all works to verify Contractors compliance with the Method Statements,
Inspections and Test Plans, Construction Drawings and Specifications.
(c)
Verify that notices of nonconformity have been properly actioned.
(d)
Oversee the sampling and testing of materials to ensure conformity to the

specifications and the contract.
(e)
Review all test results and verify that they are in conformity with the Specifications and
the Contract.
(f)
Maintain comprehensive records to verify the above.
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(a)
Inspections and Test Surveillance Points
The Supervision Consultant shall nominate his own surveillance points to observe the
Contractors and Subcontractors activities and maintain evidence of such surveillance.
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23.3.9
(a)
Hold Points Specific critical task in procurement, manufacturing, inspection and

testing for which the Supervision Consultant is pre-notified, in advance of the task and
for which no further work is carried out until the supervision Consultant has verified and
confirmed conformity by signing off the relevant Records Forms
(b)
Witness Points- Specific critical task in procurement, manufacturing, inspection and

testing for which the Supervision Consultant is pre-notified in advance of the task and
for which the Supervision Consultant may elect to attend or waive. When attended, the
Supervision Consultant shall confirm conformity by signing off the relevant Record
Forms. When then Supervision Consultant waives his right to inspect, it should be
recorded as such on the appropriate Record Forms.
(c)
Surveillance points- Any procurement, manufacturing, inspection and testing task, so

identified on the Inspection and Test Plan, performed on a random basis, without
notification by the supervision Consultant.
(d)
Record Review- When specified this point requires the Supervision Consultant to
Collect and review for approval the contractor Inspection & Rest Records.
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23.3.10 Visits
1
The Supervision Consultants is empowered to visit any of the Contractors or Subcontractors

work sites for any purpose at reasonable times. The Contractors will assist with such visits
and make available those records and personnel necessary to satisfy the supervision
Consultants requirements. Such visits may include surveillance points identified by the
Contractor and Subcontractors. These visits may include works situated outside of Qatar.
23.3.11 Supervision Consultant Verification

1
The Supervision Consultant has the right to perform verification activities at the Contractors
and the Subcontractors premises (including the construction site) to gain assurance that the
subcontracted product conforms to specified requirements.
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The Supervision Consultant is responsible for ensuring that the interfaces between the
contract works and different packages of work and different Contracting entities are managed
appropriately and that technical integrity and configuration control is maintained.
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23.3.12 Interfacing
The Supervision Consultants shall be responsible to ensure that the Contractor prepares
punch lists at appropriate inspection and acceptance stages to record the outstanding work.
Defects identified during the punch list walk downs will also require NCRs to be raised, other
than for minor defects. The Owner or its nominee may at any time add pending items or
defects or Nonconformances to Punch Lists.
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23.3.13 Punch Lists
The Supervision Consultant has the responsibility to ensure that the Contractor is taking
necessary precautions for the protection of works before the Initial/Final
Acceptance/Handover to owner or its nominee.
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23.3.14 Protection of the Works
23.3.15 Quality Records
In addition to (and including) quality records identified in the contract or other applicable
codes, standards or procedures, the Supervision Consultant shall determine project Quality
records in compliance with requirements of ISO 9001:2008 and other relevant standards
stated in contract documents and 23.1.2 above.
The list of quality records generated during the life of the contract, and made available upon
request for review by the Owner, shall be indexed by the Supervision Consultant in his
Quality Plan.
The Supervision Consultant shall maintain Registers for all incoming and outgoing
documents.
END OF PART
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CONSTRUCTION DEWATERING
GENERAL
Scope
REQUIREMENTS
Current Procedure Requirements
Relevant Qatari Laws and Regulations
EIA Requirements
Air Quality Standards
Noise Standards
Discharge to Surface and Groundwater Network Standards
Environmental Impact Assessment (EIA)
Geotechnical and Geo-Environmental Study Requirements
Existing Groundwater Monitoring Documents
Risk Assessment of Construction Dewatering
Dewatering Monitoring Plan
Training Requirements
DEWATERING TECHNIQUES
Construction Dewatering Methods Guide Lines
Sump Pits
Well System
Deep Wells
Ditches/ French Drains
Cut-Off Excavation Barriers
Dewatering Effluent Treatment
Settlement Tank
Settlement Tank Types
Tank Size
OTHER TREATMENT
Silt and Fine Grained Soils
Contamination of Groundwater
DISPOSAL OPTIONS
DISCHARGE TO SEA
Discharge to Sea via Surface and Groundwater Network
Direct Discharge to Sea
Discharge to Lagoons:
Discharge by injection to deep groundwater aquifer (Deep well injection)
Groundwater Recycle & Reuse Onsite
Integrated Management of Construction Dewatering
Construction Environmental Management Plan (CEMP)
Monitoring Plan
Training Plan
Odour Control
Health & Safety Considerations
Site Investigation
Design Considerations
Housekeeping Considerations
24
24.1
24.1.1
24.2
24.2.1
24.2.2
24.2.3
24.2.4
24.2.5
24.2.6
24.2.7
24.2.8
24.2.9
24.2.10
24.2.11
24.2.12
24.3
24.3.1
24.3.2
24.3.3
24.3.4
24.3.5
24.3.6
24.3.7
24.3.8
24.3.9
24.3.10
24.4
24.4.1
24.4.2
24.5
24.6
24.6.1
24.6.2
24.6.3
24.6.4
24.6.5
24.6.6
24.6.7
24.6.8
24.6.9
24.6.10
24.6.11
24.6.12
24.6.13
24.6.14
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24: Construction Dewatering
Appendices
2
2
2
2
2
2
3
3
3
3
3
3
4
4
5
6
7
7
8
8
8
9
9
9
9
9
10
10
10
12
12
13
13
15
16
17
18
19
19
19
20
20
20
21
21
21
22
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CONSTRUCTION DEWATERING
24.1
GENERAL
24.1.1
Scope
This Part specifies the general procedures and requirements for construction dewatering.
It should be noted that legislative requirements, standards and requirements detailed in this
Part are minimum standards, and methods should be employed with the intent to continually
improve on these standards.

Earthworks
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Section 8
Section 9
24
REQUIREMENTS
24.2.1
Current Procedure Requirements
There are four types of construction dewatering disposal options that require licensing in
Qatar, as follows:
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24.2
Discharge to the Sea via surface and groundwater network; the licensing authority
should be ASHGHAL and MOE.
(b)
Direct discharge to the Sea; if the discharge is pumped directly to the sea, then the
Ministry of Environment (MOE) should be the licensing authority.
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Discharge to Lagoon totally covered with geotextile from all sides. This method
of disposal requires a license from MOE.
(ii)
Discharge to Lagoon not covered. This method of disposal requires a license

from MOE.
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(i)
Discharge through Deep Well Injection. This method of disposal requires a license
from MOE.
(c)
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24.2.2
Relevant Qatari Laws and Regulations
The list of parameters required by MoE for dewatering permit is included in Appendix A
together with Annex 4 of Law 30 of 2002 which specifies the limits for the discharged water
into the marine environment (refer to Appendix A). The annex controls the parameters of
pollutants in the water disposed to the marine environment whether via the Surface and
Groundwater Network, or direct discharge to the sea.
If the construction dewatering effluent is discharged to foul network, the discharging party is
liable to having committed a criminal offence.
In the case of illegal discharge to Surface and Groundwater Network, the discharging party
will be subjected to legal actions taken by the licensing authorities.
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EIA Requirements
Environmental approvals from the MoE as per Article 7 of the Law No. 30 of 2002.
24.2.4
Air Quality Standards
The air quality standards are controlled by the Law No. 30 of 2002 under Annex (3/First).The
standards applicable to dewatering activities may include the following:
Maximum limits (of air pollutants) allowed for emissions from the movable sources; and
Ambient air quality standards.
24.2.5
Noise Standards
The noise levels are also controlled by the Qatari Legislation under Law No. 30 of 2002
Annex (2/Fifth).
24.2.6
Discharge to Surface and Groundwater Network Standards
Executive Bylaws of Environment Protection Law Issued under Ordinance Law No. (30) Of
2002. Annex No. (4) Criteria and Specifications of the Hazardous Materials when disposed
of in the Water Environments (MoE regulations).
24.2.7
Environmental Impact Assessment (EIA)
For projects requiring an EIA at the design stage, the EIA should be carefully reviewed by
the Design Consultant / Contractor. The EIA should be forwarded to MoE for their approval
and for issuing the relevant Environmental Permit.
Where available, the EIA will contain details of geotechnical surveys including groundwater,
adopted from the previously mentioned report.
Although the EIA may not directly contribute to the construction dewatering design, it will
document possible contamination in the area and environmental constraints, and should
therefore be considered when preparing construction dewatering application papers. Existing
contamination, or potential for contamination, should be carefully considered and must be
taken into account when dewatered groundwater is tested for compliance.
To ensure that dewatering systems are designed to maximise environmental protection and
to assist in expediting license approval processes, the above investigations shall be taken
into consideration as early in the project as possible and included when applying for the
discharge permit.
24.2.8
Geotechnical and Geo-Environmental Study Requirements
After the awarding of the Contract to the Contractor and prior to obtaining the discharge
permit, if required by the Contract or requested by the Engineer, the Contractor shall carry
out a geotechnical and geo-environmental investigations in order to confirm the geotechnical
and environmental conditions on site and groundwater levels.
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24.2.3
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The geotechnical and geo-environmental study must as a minimum identify soil types,
permeability, groundwater hydrology, and the required drawdown for the construction
activities. This study is required if the area is suspected for contamination or if the EIA at the
design stage has indicated the existence of contamination.
The output of the geotechnical and geo-environmental study should include as a minimum
the following items:
(a)
Time required for construction dewatering.
(b)
Flow rate of the dewatering discharge.
(c)
Required drawdown.
(d)
Method of construction dewatering based on all of the above findings.
To assist in the approval process all of the above information must be provided in the
application for discharge.
It is important to note that the requirements of the Geotechnical and Geo-environmental

study are completely subject to project settings, type of contamination, and MoEs specific
requirements of each project.
24.2.9
Existing Groundwater Monitoring Documents
It is the Contractors responsibility to ensure he has been providing the latest existing
groundwater level information from Ashghal and the MoE. This information should be used
by the Contractor to assist in determining the current site conditions.
All groundwater information gathered during studies by the Contractor, are to be submitted to
Ashghal for reference and inclusion in the country database. The collection of this
information is paramount to the continuous improvement of government information
databases.
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24.2.10 Risk Assessment of Construction Dewatering

It is important to note that risks are site specific and depend on the intent of the Contractor.
The Contractor is responsible for developing, implementing and managing a Risk
Management System and conducting a Risk Assessment in terms of dewatering activities
and otherwise onsite.
This Risk Management System and Risk Assessment shall be the submitted to the Engineer
for the approval within the 30 days of the contract award.
Risk assessment in this instance can be defined as the identification and characterisation of
the nature of existing and potential adverse effects to humans and the environment resulting
from dewatering activities employed on site.
Risk is a function of the probability of an event occurring and the degree of damage that
would result should it happen.
Details and information gathered during the concept design and associated site studies
(geotechnical, groundwater & environmental) are needed to assess the risks associated with
the proposed activities. The assessment allows significant risks to be identified so that they
can be targeted for action.
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The initial risk assessment needs to also be regularly reviewed and will become an integral
part of the Construction Environmental Management Plan. This includes a review of existing
risks and the identification of new risks detected through the surveillance or the monitoring
program.
To conduct the Risk Assessment the Contractor should undertake the following key steps:
(a)
Information gathering:
A risk assessment requires information about site conditions.
(b)
Risk identification:
Risk analysis:
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(c)
Hazard identification involves the identification of risks/hazards that could lead to an

adverse effect on the receiving environment and/or health & safety.
Risk analysis considers the likelihood of the risk being realised.

Consequence analysis:
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Consequence analysis determines the effect on the environment and health & safety
should a risk be realised.
The overall risk is a function of the likelihood of the activity or event causing environmental
harm or impacting on health & safety and the consequence should that risk be realised.
The risks are then ranked according to their magnitude and mitigation strategies developed.
10
The objective of this process is to identify and rank all potential risks that may arise from the
dewatering of the construction site and then reduce risks to acceptable levels by
implementing a suitable method of dewatering and/or action plan.
11
Risks generally associated with dewatering activities onsite include but not limited to the
following:
(a)
Soil and slope stability and soil erosion due to dewatering activities.
Soil contamination. Whether contamination exists in the project area prior to
commencement of construction or is caused by dewatering activities.
(b)
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(c)
Change of groundwater properties due to dewatering practices.
(d)
Excessive abstraction (dewatering) of groundwater which affects nearby groundwater

related activities.
(e)
Health and safety related issues.
(f)
Risks associated with impacts of dewatering activities on surrounding environment

and sensitive receptors.
(g)
Risks associated with failure of dewatering system and/or disposal methods.
24.2.11 Dewatering Monitoring Plan

1
When dewatering activities are included within the project site, the Contractor shall prepare a
Dewatering Monitoring Plan as detailed below.
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The Dewatering Monitoring Plan shall be submitted to the Engineer for approval within 30
days of contract award.
The monitoring plan will assist the licensing authority, as well as the Contractor, in keeping
track of dewatering activities onsite, and identify corrective actions to be carried out.
The monitoring plan can also assist in identifying liability issues concerned with reported
dewatering problems and accidents.
Outline and components of monitoring plan are as follow:

Identification of opportunities to reuse the dewatering effluent onsite in order to reduce
the amount of disposed effluent.
(b)
Dewatering techniques being employed on site
(c)
Disposal methods employed on-site and relevant monitoring plan to ensure

compliance with discharge limits.
(d)
Copy of discharge limits.
(e)
Roles and responsibilities of the Environmental Advisor on site.
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(a)
Roles and responsibilities have to be clearly defined when designing a dewatering system.
These roles and responsibilities are to be submitted as an essential element to satisfy the
Construction Environmental Management Plan requirements when applying for the
dewatering effluent discharge permit.
Refer to Appendix B for an example of inspection sheet for the dewatering process.
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24.2.12 Training Requirements
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The Contractor shall prepare a Construction Dewatering Training Plan submitted along with
the necessary documentation for a discharge permit.
The construction dewatering training plan shall be submitted to the Engineer for approval
within 30 days of contract award.
The training plan will assist the licensing authority in evaluating the level of knowledge
passed on to the Contractors staff, and is therefore an indirect indication on how well the
dewatering process is being executed. The components of the submitted training plan are
detailed below.
The integration of construction dewatering training into the Training Plan of the Contractor is
essential to introduce all staff to construction dewatering related information.
It is recommended that information on dewatering equipment and related emergencies are

included in the training provided to staff entering or working on the site.
The training for all staff does not have to be comprehensive; however, it should include basic
items such as:
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(a)
Brief explanation of the construction dewatering purpose
(b)
Introduction to the dewatering equipment. Inclusion of photos in the training

presentation.
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Health and safety related concerns, education on related emergencies, and contact
information of person in charge of dewatering to be provided in the presentation.
24.3
DEWATERING TECHNIQUES
24.3.1
Construction Dewatering Methods Guide Lines
The design of effective construction dewatering methods should be based on a number of

information sources:
Geotechnical and groundwater site investigations undertaken at the commencement
of any project;
(b)
Information provided by any geotechnical study undertaken during the concept design
stage[if applicable];
(c)
Groundwater information sourced from relevant authorities; and,
(d)
A site risk assessments.
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(a)
The Contractors choice of dewatering method will depend primarily on the soil type and
permeability and the amount of groundwater to be removed. Whilst the Contractor will be
trying to find the most cost effective method of dewatering (based on the geotechnical report)
he shall implement the most effective dewatering method which minimises environmental
damage, protects the health & safety of on-site personnel and meets all legislative discharge
limits.
It is important to note that if contamination exists in the area all precautions need to be
implemented. Contamination will be dealt with in coordination with MoE by safe disposal in
designated areas as per the Environmental Law number 30 for 2002.
The figure below demonstrates the range of common dewatering techniques, whilst
accounting for soil permeability and drawdown.
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Range of Application of Pumped Well Groundwater Control Techniques

** Source: Preene, M. Roberts, T. Powrie, W. Dyer, M R (2000)- Groundwater Control Design &
Practice (CIRIA C515), London, CIRIA.
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As seen in the above figure, the choice of dewatering method depends on the required
drawdown and permeability. The drawdown is determined during the design stage of
structures and the groundwater investigation stage at the start of the project and the
permeability is tested during the geotechnical investigation stage.
After the drawdown is determined, the Contractor shall choose the method of dewatering
based on the permeability of soil. The method can vary during the stages of the project
depending on the required drawdown. The shaded areas near the methods boundaries
indicate that the choices can overlap, and then the Contractor can decide between the two
(or more) options.
Filtering and filling materials of aggregate is required by most dewatering methods.

Therefore when required, aggregates to be used shall be free draining, washed and free of
debris (organic or non-organic). Preference is for a single sized aggregate (less than 10%
fines).
Whilst the range of dewatering practices varies across sites depending on their size,
construction depth and site conditions, the most commonly used methods of dewatering in
Qatar are indicated below. Each methods use depends on the requirements and stage of
project.
24.3.2
Sump Pits
The Sump Pit method is the simplest form of dewatering system on a construction site.
Sump pits are generally utilised as a quick, least cost, solution and can be seen to be used
at the start of projects as the excavation stage commences. Provided with an aggregate
lining, as per O&M requirements, sump pits can be an effective means of filtering
groundwater, unless the groundwater has come into contact with silt and/or limestone, which
usually results in reported high turbidity.
If soil has silty characteristics; it is recommended that proper installation of geotextile and
aggregates in sump pits be implemented in order to improve the quality of dewatering
effluent and significantly decrease turbidity.
24.3.3
Well System
The most common practice of dewatering used in Qatar is the implementation of a Well
System. Wells are systematically drilled around the construction area and submersible
pumps placed into these wells. This practice appears to work effectively for many projects,
especially those building projects that require excavations for deep basements.
24.3.4
Deep Wells
Deep wells are rarely used in Qatar. Deep wells are usually equipped with filter packs &
submersible pumps, and are operated using a control cabin.
Although not found to be present in Qatar at present, deep wells have unlimited drawdown,
they require a minimum spacing of 10 meters, and have far greater efficiency.
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Ditches/ French Drains
Ditches and French drains (commonly known as trenches in construction projects in Qatar)
are also used on Qatars construction sites. The ditches are formed in a pre-planned
manner, allowing groundwater flow to surface in the deeper level trenches. Perforated pipes
are then placed in the trenches, and groundwater extracted through these pipelines to be
filtered. These trenches were particularly common in infrastructure network projects.
Graded aggregates and geotextile layer to be used when laying out the pipelines.
24.3.6
Cut-Off Excavation Barriers
Cut Off barriers are designed to limit and/or control groundwater entering the construction
site from a neighbouring property. An assessment of groundwater infiltration is required to
determine to what extent barriers are required and how they are constructed.
Commonly used excavation barriers in Qatar include structural concrete walls and secant
piles. Both techniques are applicable to most types of soil and provide slope stability for
deep excavated areas.
24.3.7
Dewatering Effluent Treatment
24.3.8
Settlement Tank
The settlement tank is the most common and most effective methods of treatment in Qatar.
The settlement tank is primarily used to maximise the distance that the effluent has to travel
prior to reaching the discharge point, and therefore increasing the settlement efficiency.
All projects in Qatar which apply for a discharge permit are obligated to provide a settlement
tank.
When choosing the settlement tank, the choice should be based on the following factors:
The type of soil to be dewatered.
(c)
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24.3.5
(d)
Retention time required for solids to settle. This will also be based on the soil type.
Flow rate quantity and frequency.

Possible peak factors flows.
(b)
24.3.9
Settlement Tank Types
The common types of weir tanks used are Regular tank and V-notch tanks (30, 60, and
90). The V-notch tanks serve to accelerate the passing of the effluent through the tank.
For safety purposes, it is recommended that tanks be suitably covered with a top cover or
specific lid, to ensure unauthorised access is not permitted.
It is important to note that sometimes these tanks are used onsite as a discharge tanks.
Therefore, it is important that tanks are used as settlement tanks and be marked clearly as
such.
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24.3.10 Tank Size

1
In order to make a decision on the tank size, the volume of tank are to be estimated as per
the below equations.
The volumes calculated depend primarily on the retention time of water in the tank, and the
flow rate of discharge.
Equation
3
V=Qt
The tank's depth
d = V/A
d: depth (m)
3
V: volume(m )
2
A: surface area(m )
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Tank volume
V: Volume (m )
3
Q: Expected flow rate (m /hour)
t: retention period (hour)
It is important to note that these equations are to be used as a guide only, but do provide a
basis for calculating the minimum tank size required based on the flow rate provided by the
Contractor.
For fine grained type of soils, it is preferred to have secondary methods of treatment as
detailed below.
24.4
OTHER TREATMENT
24.4.1
Silt and Fine Grained Soils
For the removal of silt and fine grained suspended particles, the following inexpensive
methods can be effectively applied:
Dewatering Tank:
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a dewatering tank can remove sediment (sand, silt, and visible oil). The dewatering
tank is equipped with a fabric filter. The flow passes through the filter before being
discharged at the bottom end of the tank. The tank can be used in addition to the weir
tank or any other treatment method. It is portable, inexpensive and many types of filter
clothes can be used.
Yet, the dewatering tanks should be subjected to periodic cleaning based on the visual
inspection or reduced flow, through lifting the sand and silt from the tank.
(b)
Gravity Bag Filter:

(Also known as dewatering bag) is made of geotextile fabric that can filter out silt and
fine grained soil particles. This filter is easy to install, inexpensive, and becomes more
effective as sediment builds up inside the bag. The type of bag should be selected
based on the flow rates of discharge and permeability of soil.
This method is to be used as a secondary treatment for groundwater. It requires
continuous monitoring to avoid hose failure, particularly if sediment builds up in a
manner that interferes with the acquisition of a reasonable flow rate discharge.
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The Gravity Bag Filter does not require cleaning, as it is a disposable filter. The filter is
to be disposed of in accordance with the waste management guidelines of the project.
The filter is to be replaced when it starts passing solids, or blocks the passing of water
at a rate that is adequate.
(c)
Slurry Water
The drilling [slurry] muds containing substantial quantities of organic liquids and
water-soluble salts are treated to render them environmentally acceptable for
disposal (C M Wilwerding 1989)
Slurry water occurrence is common during dewatering processes in Qatar. While there
is filtration equipment and water treatment technology available to treat slurry water,
these are best used in countries with a different climate to that of Qatars.
The best option for treating slurry by filtration is using a Centrifugal Filter. However, as
previously mentioned, this is not a preferable to be used in Qatar as slurry can be dried
easily in a more environmentally friendly manner.
It is also important to note that even when treatment equipment is used, the resulting silt will
have to be disposed at a licensed landfill, along with having to dispose of the equipment at
its end of service life.
If the silt contains hazardous material, then a license should be issued from MoE as per the
procedures detailed in Annex (7.2) of the Qatari Law of Environment (Copy of the
procedures together with the form of application is provided in Appendix (C)). And if the silt
has no hazardous materials then the license shall be issued from the concerned
Municipality.
To eliminate the issues with incompatible equipment and hot climates, it is recommended
that treatment methods be designed to manage the slurry either onsite by drying the first
instance before transfer to landfill, or by transfer to the landfill directly.
The conventional drying process comprises laying out of slurry mud on an air permeable
drying bed lined with suitable material.
The drying process must commit to the following environmental considerations:
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(a)
Amount of slurry generated must not exceed the capacity of the spreading system.
(b)
Drying process must not impose nuisance or emit odor.
(c)
Drying process must not impose health and safety risks.
The choice of drying process, whether by using a centrifuge machine or a drying lagoon is
subject to project settings and expected amount of slurry to be generated.
The slurry handling process is to be submitted with the dewatering permit application if
generation of slurry is expected to occur.
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24.4.2
Contamination of Groundwater
In the event of discovering the contamination of the receiving environment such as

groundwater by dewatering effluent, the contractor is obligated to report the discovery to the
licensing authority (ASHGHAL, MoE) and the effluent is to be dealt with as per the
construction Environmental Management Plan (CEMP). Samples of groundwater should be
taken and tested. Reasonable suspicion can be established by one of the following
methods:
Possible history of contamination in the area; such as prior land use (eg. petrol
station), or the area is known to have septic tank issues.
(b)
EIA: if there is an EIA prepared for the project, it should be reviewed and approved by
MoE in order to eliminate the possibility of contamination. If the EIA indicates the
presence of contamination, the Contractor is obligated to report the findings to MoE for
their feedback, and test for the type of contamination detected in the EIA.
(c)
The Contractor shall use the following Water Quality Assessment to establish the
possibility of contamination in the area.
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(a)
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Water Quality Assessment
The following questions provide n initial assessment of the quality of the water to be
discharged from the dewatering operation.
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Common
Sense Test
1. Review the project records. Is there any reason to suspect that the
water may be polluted by something other than sediment?
No
Yes
2. Is the water located in an area of known contamination?
No
Yes
Does the water have an abnormal visual feature, such as: (circle)
Oily Sheen, Floating Foam, Murky Appearance, Unusual
Colour
Other
Smell Test
Does the water have an odor? No

Yes
Possible odors include gasoline, petroleum, ammonia, sewage,
etc.
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Sight Test
If you answered YES to any of the above questions, explain:

If you answered YES to any of the questions in the assessment or suspect that the
water contains pollutants other than sediments, contact the Engineer for assistance
with additional testing and management options.
Water Quality Assessments

** Adapted from Source: The office of Environmental Engineering, California Department of
Transportation (Caltrans), Field Guide to Construction Site Dewatering, USA, 2001.
In the event of discovering groundwater contamination, the Contractor is obligated to report the
discovery to the Engineer and Licensing Authority (MOE / ASHGHAL) and the effluent is to be dealt
with as per the Construction Environmental Management Plan (CEMP), or as directed by the
Engineer.
24.5
DISPOSAL OPTIONS
Qatar construction sites use four (4) common means of disposal, namely:
(a)
Discharge to sea via the Surface and Groundwater Network;
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(b)
Direct Discharge to the sea;
(c)
(A) Discharge to lagoon totally covered by geotextile from all sides;

(B) Discharge to lagoon not covered, and;
(d)
Discharge by injection to deep groundwater aquifer (Deep well injection).
The following section discusses the options available in Qatar in terms of dewatering effluent
disposal, and describes the best option depending on the circumstances of the project.
24.6
DISCHARGE TO SEA
24.6.1
Discharge to Sea via Surface and Groundwater Network
Disposal of dewatering effluent to the Surface and Groundwater Network is the most
common practice in Qatar. The Surface and Groundwater Network eventually leads to
outfalls that discharge to Sea.
The disposal to the network directly via pipelines, or via tankers, depends on the availability
of Surface and Groundwater Network in the project area.
The Surface and Groundwater Network is an acceptable option for disposal given that
Contractor is also reusing the effluent on site whenever possible.
If a Contractor chooses to discharge to the Surface and Groundwater Network, obtaining a

license from ASHGHAL is required to allow the discharge of groundwater to the Surface and
Groundwater Network. A license from the Ministry of Environment is also required through
the submission of an Environmental Permit Application.
Measurements of flow rates must be undertaken in order to monitor the discharge flow and
ensure that it is within the limits provided to the licensing authority (refer Appendix A for
discharge limits).
The Contractor must provide the licensing authority with the maximum expected flow rate (i.e
the peak flow) and the expected average flow rate, in order to avoid back flooding when
flows exceed the capacity of the manhole assigned to the Contractor. Therefore, the
contractor should install a flow meter at the construction site in order to measure the
quantities of groundwater flow.
The Contractor should also notify the licensing authority if peak flows are expected to be
reached frequently during the winter season, particularly when heavy rain is forecast, so as
to avoid penalties if the manhole back floods.
If a Contractor is operating from an area which is not served by a Surface and Groundwater
Network, and determines that the most cost effective solution is to use tankers to transport
dewatering effluent to the nearest assigned manhole, the Contractor is then obligated to
provide a brief statement demonstrating the traffic impacts caused by their tankers.
If the resultant traffic impact proves to be significant, the Contractor is either to consider
other options of disposal, or retain dewatering effluent onsite and then transport the effluent
when traffic is less congested, therefore minimising traffic impacts.
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In the event that tankers are used to transport dewatering effluent, in order to monitor
discharge to Surface and Groundwater Network the Contractor must record all particulars
associated with its removal, such as:
(a)
Installing a flow meter at the construction site in order to measure the quantities of
groundwater flow.
(b)
Record of tankers coming to and leaving the site (eg. registration plate no., capacity,
records of water quality)
(c)
Volumes of effluent transported.
The recording of tanker movements is in addition to the installation of a meter on the

weir/sediment tank.
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When applying for the discharge permit the following documents are required:
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Official letter from the company addressed to: The Manager of Drainage Networks
O&M Dept- Asset Affairs- ASHGHAL. (Includes start and end date of dewatering
works & method of statement for dewatering).
(b)
Application form for pumping groundwater to be filled and stamped.
(c)
Copy of building permit.
(d)
Copy of the site map.
(e)
Copy of ID card of the applicants engineer.
(f)
Copy of the registration company.
(g)
Copy of Road Opening (RO) Permit.
(h)
Copy of Traffic Department Approval, as part of the RO Permit
(i)
Testing of samples, and conformation of compliant results prior to obtaining the twomonth permit. The Contractor must note that the sample testing is to be carried out
after obtaining the five-day temporary permit, and is to be submitted after the previous
requirements are submitted and a temporary permit is granted.
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(a)
Once the application is submitted, the project is given a reference number which includes a
serial number, type of discharge (e.g groundwater) and the date of application. Drawing and
comments are then returned to the applicant for information and/or action and the applicant
will be advised the applicable disposal option and a manhole to be assigned for the
discharge.
14
The applicant is issued a temporary permit for five days. The purpose of the temporary
permit is to allow the applicant to obtain approvals from the concerned authorities, and install
the equipment in order to take water samples.
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During the temporary dewatering permit; only discharge is allowed for collecting samples
and to proceed with other department requirements. All samples are taken by laboratory
representative from the list of laboratories approved by ASHGHAL and MOE; its prohibited
for samples to be taken by the Contractor. The collected samples should be tested for Total
Suspended Solids (TSS, turbidity and the short list of parameters included in Appendix A.
Test results should be uploaded online to QSD by the laboratory. Yet, it should be
highlighted here that any testing activities are not only limited to the parameters provided on
the short list developed by QSD; it should also cover the list of parameters required by MOE
for dewatering permit. Approval is then granted if the test results meet the requirements of
discharge. The Quality Limits are attached in Appendix A.
16
If the installation requires a road crossing, a RO permit is required. If not, a RO is not

required. The applicant must obtain a license from the concerned authorities for installation
of all tanks and hoses.
17
Following the issuance of the permit, regular inspections by the O&M staff are carried out.
The Contractor is then required to undertake weekly laboratory tests for TSS and turbidity of
effluent samples, and bi-monthly tests prior to renewing the permit. Permit renewal request
should be submitted in 7 days advance before expiry day of the previous permit. The bimonthly tests are for TSS, turbidity and the short list of parameters included in Appendix A
together with the parameters listed under Annex (4) of the law of Environment number
30/2002.
18
A copy of the Permitting Application and pro-forms are attached in Appendix C.
19
Refer to Appendix D for a flowchart of the permitting procedure for the discharge to sea via
Surface and Groundwater network.
24.6.2
Direct Discharge to Sea
MOE is the licensing authority for discharging dewatering effluent direct to the Sea.
If a Contractor found that the applicable option for dewatering is the direct discharge to sea,
a secondary method of treatment must be installed to allow the dewatering effluent to settle
before reaching the discharge outfall point. The discharge to the outfall point is achieved
through the use of pipelines or transportation via tankers. Based on the number of tankers,
the transportation may be subjected to a traffic impact assessment study based on the
requirements of MOE.
The Contractor may therefore be subject to a number of pertinent laws and regulations:
When issuing direct sea discharge permits, MOE have the following concerns that need to
be addressed as per Annex 4 of the Qatari Law of Environment and the list of parameters
required by MOE for dewatering permit (included in Appendix A), which includes the test of
the following parameters:
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(a)
Bacterial counts
(b)
Turbidity and TSS levels
(c)
Presence of Petroleum compounds.
(d)
Presence of heavy metals.
(e)
Others, as per MoE requirements.
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Refer to Appendix D for a flowchart of the permitting procedure for the direct discharge to
sea. A copy of the environmental permit application form is included in Appendix E.
For more information, contact MoE on:

Telephone +974 4420 7777
24.6.3
Fax
+ 974 4420 7000
Email
Responsibility@moe.gov.qa
Discharge to Lagoons:
A. Discharge to Lagoon totally covered with geotextile from all sides

Lagoons are licensed by MOE.
It is recommended that a lagoon totally covered with geotextile from all sides, formed in a
depressive area, is used in locations where it is logistically impossible or cost and socially
prohibitive to deliver effluent to the Surface and Groundwater Network using other means.
If Contractor chooses to discharge the dewatering effluent to a lagoon, license is given by

MOE. The dewatering to lagoons is mainly based on the requirements by MOE which is
given for case by case. The use of this option is depending on the water quality. Yet, the
general requirements of MOE can be summarised in the following information:
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Dewatering effluent quantity.
(b)
Detailed Engineering drawings for the lagoon showing the geotextile lining of the
lagoon.
(c)
Duration of dewatering discharge
(d)
Dewatering effluent quality. Dewatering effluent quality is tested initially against the list
of parameters required by MoE for dewatering permit (included in Appendix A). And
then tested weekly. Monthly testing is also required for selected parameters.
(e)
Coordinates of lagoon, inclusive of dewatering discharge points.
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Location map
Others, as per MOE requirements.
(g)
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(a)
Refer to Appendix D for a flowchart of the permitting procedure for the discharge through
the use of lagoons. A copy of the environmental permit application form is included in
Appendix E.
For more information, contact MOE on:

Telephone +974 4420 7777
Fax
+ 974 4420 7000
Email
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B. Discharge to Lagoon not covered

6
The discharge to a logon which is not covered is depending on the discharged water quality.
Similar to the above option, the licensing authority for this option is the Ministry of
Environment. The list of parameters required by MOE for dewatering permit is included in
Appendix A. The general requirements of MOE are similar to the above option.
Refer to Appendix C for a flowchart of the permitting procedure for the discharge through
the use of lagoons. A copy of the environmental permit application form is included in
Appendix E.
For more information, contact MOE on:

Telephone +974 4420 7777
+ 974 4420 7000
Email
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Fax
Discharge by injection to deep groundwater aquifer (Deep well injection)
Disposal by injection to groundwater aquifer is a common method in Qatar to dispose of

treated effluent of sewage treatment plants. Yet, the use of deep well injection for the
discharge of dewatering effluent to groundwater aquifer is also done in few big projects.
However and prior to the discharge to the deep well, a careful assessment of geological
conditions must be conducted in order to determine the suitable depth and location of porous
aquifer reservoirs and identifying the safe rate of injection to the deep aquifer. Generally, the
depth of the deep well should not be less than 400 600 m deep, which is the expected
depth of Umm Er Radhumma (UER) aquifer.
In all cases, MOE require the contractor to conduct an Environmental Assessment for the
impact from the project as soon as drilling of the deep well and the analysis of the samples is
achieved. This shall be done by a qualified consultant with previous experience in similar
projects.
The general requirements of MOE for the use of the deep well injection can be summarised
in the following information:
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24.6.4
(a)
Duration of dewatering discharge.
(b)
Dewatering effluent quality. Dewatering effluent quality is tested initially against the
parameters specified in the standards for the water use for irrigation purpose of the
Qatari Law of Environment. And then periodically testing each week based on MoE
requirements.
(c)
The parameters required for the physical, chemical, biological, microbiological

analysis includes but not limited to: EC, Temperature, DO, pH, Turbidity, FRC, TPH,
O&G, Sulphide, Metals, BOD, COD, TOC, surfactants, VOC, BETX, TDS, TSS, PAHs,
TAlk, Nitrate, Nitrite, Ammonia, TKN, Phosphorus, Chloride, Sodium, Sulphite, Total
Phenol, Carbonate, E-Coli, Faecal Coliform, Bacteria and SAR.
(d)
A0 design map for the whole project including the location of the injection well and
network of shallow trenches connecting the wells.
(e)
Comparison study between the use of the shallow networking and the perforated
pipelines.
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(f)
Drilling of monitoring wells to suitable depth to monitor the impact on the shallow
aquifer.
(g)
Providing the injection wells with emergency valves to stop injection in case of
contamination.
Refer to Appendix D for a flowchart of the permitting procedure for the discharge through
the use of deep well injection. A copy of the environmental permit application form is
included in Appendix E.
As mentioned above, the injection of dewatering effluent to groundwater aquifer is licensed

by MOE and is completely subject to their approval, therefore for further information, please
contact MOE on:
Fax
+ 974 4420 7000
Email
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Groundwater Recycle & Reuse Onsite
It is recommended, where environmentally safe and cost effective, that dewatering effluent is
reused or recycled onsite.
The reuse options onsite will depend on a number of factors, including the type of project.
The contractor should propose the treatment in case the water is polluted by organic and
inorganic chemicals or subjected to biological contamination. The treatment should focus but
not limited to low DO, presence of Bacteria, elevated levels of TSS or turbidity and presence
of oil.
The CEMP should be used to identify all opportunities of reuse onsite. Yet, the options for
the reuse of the groundwater should be discussed with MOE and shall be subjected to the
approval by MOE.
Options could include but not be limited to:

Control of dust onsite. (Subject to the level of safety and quality of dewatering
effluent).
(a)
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24.6.5
(b)
Reuse of dewatering effluent.
(c)
Concrete curing.
(d)
Excavation activities requiring water.
(e)
Washing of machinery and site equipment.
(f)
Watering of onsite landscaping, when the turbidity is very low to avoid compromising
the integrity of the soil.
(g)
If the dewatering effluent quality is within limits of soil compaction parameters

requirements (refer to QCS), it can be used for soil compaction purposes.
Contractor to conduct a feasibility study to evaluate whether its feasible to erect an RO

system for dewatering effluent treatment, in order to use the dewatering effluent instead of
fresh potable water.
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The feasibility study is to compare both options in terms of financial viability.
24.6.6
Integrated Management of Construction Dewatering
Construction dewatering practices are better managed if they are integrated with existing
construction management systems, such as a CEMP, monitoring plan and training
programmes. The dewatering practice will then form part of the regular construction
inspection/monitoring program.
24.6.7
Construction Environmental Management Plan (CEMP)
The CEMP is prepared to minimise the impacts of the project and its activities on the
receiving environment. The CEMP is prepared prior to mobilising to site.
The Contractor should uses the geotechnical investigations and previous EIA (if applicable)
as guidelines when preparing the CEMP.
When dewatering activities are included within the project site, the preparation of the CEMP
should include the following:
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Identification of opportunities to reuse the dewatering effluent onsite in order to reduce

the amount of disposed effluent.
(b)
Dewatering techniques being employed on site
(c)
Disposal methods employed on-site and relevant monitoring plan to ensure

compliance with discharge limits.
(d)
Copy of discharge limits.
(e)
Roles and responsibilities of the Environmental Advisor on site.
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(a)
Roles and responsibilities have to be clearly defined when designing a dewatering system.
These roles and responsibilities are to be submitted as an essential element to satisfy the
CEMP requirements when applying for the dewatering effluent discharge permit.
Refer to Appendix B for an example of inspection sheet for the dewatering process.
24.6.8
Monitoring Plan
The environmental monitoring plan is used to monitor the anticipated impacts of the project o
the surrounding and receiving environments. It is imperative that, should dewatering
activities exist on site, there is integration all testing and monitoring requirements.
Integration of monitoring plans may be between systems within individual sites or between
several sites, depending on management systems or owners
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(a)
Environmental monitoring plan: The environmental monitoring plan is to outline the

steps required for monitoring of construction dewatering practices. The integration of
dewatering practices into the monitoring plan will pave the way to introduce a
dewatering monitoring plan.
(b)
The findings of the dewatering monitoring reports are to be summarised and included
in the environmental monitoring reports.
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The dewatering practices monitoring plan: Introduction of a dewatering practices

monitoring plan, sampling points, variables, frequencies and reporting. This plan
should be cyclic which stands to be audited as part of the master environmental
monitoring plan. Corrective actions from audits are to be implemented to ensure
improved performance.
Training Plan
The integration of construction dewatering training into the training plan of the Contractor is
essential to introduce all staff to construction dewatering related information.
It is recommended that information on dewatering equipment and related emergencies are

included in the training provided to staff entering or working on the site.
The training for all staff does not have to be comprehensive; however, it should include basic
items such as:
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Brief explanation of the construction dewatering purpose
(b)
Introduction to the dewatering equipment. Inclusion of photos in the training

presentation.
(c)
Health and safety related concerns, education on related emergencies, and contact
information of person in charge of dewatering to be provided in the presentation.
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Training for dewatering staff, however, should be the responsibility of the Project Consultant
and as per each Project needs and requirements. The training should be comprehensive and
should include all components dewatering staff need to be familiar with.
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24.6.10 Odour Control
The odour levels have been given a threshold value as indicated in the Qatar Construction
Specifications (QCS). Therefore, it is highly recommended to measure the level of odour
parameters, a devise should be installed within the construction site to measure odour
parameters (eg: H2S).
The QCS has identified two types of odour control equipment; control equipment carbon type
and control equipment scrubber type. Refer to Section 9 Part 9 and Part 10 for details.
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24.6.11 Health & Safety Considerations

1
Health and safety issues are the most important part of any construction project. It is
recommended that health and safety measures in relation to dewatering practices are
enforced strictly, in order to prevent and/or minimise on-site accidents.
In addition to the conventional health and safety measures implemented in construction

sites, the following considerations are to be incorporated to contribute to the health and
safety practices relating to construction dewatering:
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24.6.12 Site Investigation

1
During the initial site investigations, the Contractor has to identify potential health and safety
risks in the project area. Examples of risks are: potential contamination posing health and
safety concern to labour workers and site staff, slope stability issues due to dewatering
practices... etc.
Identified risks have to be considered and mitigated against during design and execution of
dewatering.
This exercise can be undertaken during the Risk Assessment process as described earlier in
this Guideline.
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24.6.13 Design Considerations

The design of dewatering stage is the most convenient stage to plan properly in order to
prevent foreseeable health and safety issues arising during operational dewatering.
All designs must take into account the health & safety considerations associated with
dewatering, which include but are not limited to:
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Preparation of layout plan for dewatering equipment.
(b)
Ensure access to dewatering equipment, without compromising the safety of staff.
(c)
Ensure that all dewatering equipment especially equipment placed offsite- is marked
clearly with name of project and Contractor, and contact person details.
(d)
Provide protective covers for assigned manholes which do not hinder the discharged
flow.
(e)
The mandatory use of PPE. All staff entering a projects safe zone have to be wearing
appropriate safety gear. This also applies to staff managing dewatering equipment
offsite.
(f)
The Contractor is to exercise duty of care when designing, installing and operating the
dewatering equipment and process.
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(a)
24.6.14 Housekeeping Considerations

It is recommended that during the regular inspection of projects, the licensing authority is to
observe the status of housekeeping of dewatering equipment. Inadequate housekeeping can
expose staff and visitors to injury.
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APPENDICES
Short List of Parameters as provided by ASHGHALMoE list of Parameters for Dewatering Permit Environmental Laws and Regulations- Annex 4, Law 30 of 2002
23
Appendix B:
Dewatering Process Inspection Sheet
32
Appendix C:
Discharge Permit Forms
36
Appendix D:
Application for Permit- Procedure Flowchart for each Dewatering Option
40
Appendix E:
Environmental Permit Application- MoE
45
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Appendix B
DEWATERING PROCESS INSPECTION SHEET
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Appendix C
DISCHARGE PERMIT FORMS
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Appendix A
SHORT LIST OF PARAMETERS AS PROVIDED BY ASHGHAL
MOE LIST OF PARAMETERS REQUIRED FOR DEWATERING PERMITS
ENVIRONMENTAL LAWS AND REGULATIONS ANNEX 4, LAW 30 OF 2002
36
36
40
Appendix E
ENVIRONMENTAL PERMIT APPLICATION MOE
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APPLICATION FOR PERMIT PROCEDURE FLOWCHART FOR
EACH DEWATERING OPTION
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MoE list of Parameters required for Dewatering Permits
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Environmental Laws and Regulations Annex 4, Law 30 of 2002
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Appendix D
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Application for Permit Procedure Flowchart for each Dewatering Option
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Part
15: Appendix B - Templates
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CONTRACTORS INSPECTION AND TEST PLAN TEMPLATE
15.2

Part
Page 16
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QUALITY NON-CONFORMANCE TEMPLATE
15.3

Part
END OF PART
Page 17
QCS 2014

Part
02: Submittals
Page 1
SUBMITTALS .......................................................................................................... 2
2.1
2.1.1
2.1.2
2.1.3
2.1.4
2.1.5
2.1.6
2.1.7
GENERAL ............................................................................................................... 2
Project Quality Plan
2
Quality Organisation Plan
3
Inspection and Test Plans
4
Quality Checklists
5
Key Performance Indicators
5
Method Statements
6
Commissioning Plan
6
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Part
02: Submittals
Page 2
SUBMITTALS
2.1
GENERAL
2.1.1
The Contractor shall prepare the necessary Contract specific Project Quality Plan as
specified in this Section, the Contract Documents and as a minimum meeting the
requirements ISO 9001 and ISO 10005 and submit them to the Engineer for review and
approval within 30 days of the award of Contract. The Contractor is not permitted to Work on
the worksite until such time as the plan has been approved by the Engineer.
The Contractor shall regularly review the suitability of the Project Quality Plan. The Contractor
shall undertake a full formal review of the quality plans annually with reference to the date of
award of the Contract and submit the findings of the review to the Engineer within 14 days of
that date along with an amended plan should any amendments be required.
The Project Quality Plan shall describe the Contractors Quality Management System that will
be used throughout the Contract and the contents shall include but not be limited to the
following:
Front Cover
(b)
Table of Contents
(c)
Project Scope, Requirements and Quality Objectives
(d)
Quality Policy and ISO 9001 Certificate (if applicable)
(e)
Control of Project Quality Plan
(f)
(g)
Project Management, Planning and Resources
(h)
Management, Organisation and Responsibilities
(i)
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Contract Review
Project Deliverables
(j)
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(a)
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(k)
Communication with the Engineer
(l)
Management of Documents, Data and Records
(m)
Design (Including Temporary Works)
(n)
Procurement of Services, Equipment and Materials
(o)
Method Statements
(p)
Inspection and Test
(q)
Product Identification and Traceability
(r)
Owner Supplied Product
(s)
Handling, Storage, Packaging and Delivery
(t)
(u)
Control of Inspection, Measuring and Test Equipment
QCS 2014

Part
02: Submittals
Audits
(w)
Training
(x)
(y)
Management Review
(z)
Quality Meetings
(aa)
Monthly Quality Report
(bb)
Commissioning
(cc)
Interface Management
(dd)
Project Completion and Handover
(ee)
Appendices
rw
And include as a minimum:
a detailed description of procedures, instructions, and reports to be used to ensure

compliance with the Project Documentation
(b)
a detailed description of procedures for reviewing shop drawings, samples, certificates

and other submittals necessary for compliance with the Project Documentation
(c)
a detailed description of procedures used to identify, report and resolve problems
(d)
a description of the services provided by outside organisations such as testing

laboratories, architects, and consulting engineers
(e)
a detailed description of inspections and tests required
(f)
copies of forms and reports to be used to document quality assurance operations
(g)
the names of personnel responsible for each part of the Works
(h)
a submittal status log listing required submittals and action required by the Contractor
and Engineer
(i)
a detailed description of document and submittal control procedures
(j)
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an inspection and test schedule keyed to the construction programme

procedures to identify and control the use of items and materials
(k)
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(v)
Page 3
No construction shall begin and no requests for payment from the Contractor shall be
processed until the Contractors Project Quality Plan is approved.
A Contractors Project Quality Plan Template with guidance notes is included in Part 15
Appendix B of this Section. The format of the Contractors Project Quality Plan must follow
this template including all clauses contained within.
2.1.2
The Contractor shall submit a Quality Organisation Plan to the Engineer for approval no later
than thirty (30) days from the start of the Contract.
The Quality Organisation Plan shall provide the names, qualifications, experience and skills
of all the QA/QC Team including Corporate QA/QC Manager, Quality Management
Representative and key support staff.
QCS 2014

Part
02: Submittals
Page 4
The Quality Organisation Plan shall show the organisation of Contractors quality team and
shall include, but not be limited to, the following:
(a)
an organisation chart identifying all personnel responsible for quality
(b)
Identify the quality team showing that the team is independent of the job supervisory
staff with clear lines of authority to top tier management.
(c)
Indicate and describe the area of responsibility and authority of each individual in the
quality assurance team.
The Quality Organisation Plan should also define quality responsibilities of any of the
Contractors team with responsibilities under the Contractors Project Quality Plan.
The Contractors Quality staff shall have relevant educational and professional qualifications,
and training as defined in 3.1.7 (1). The Contractor is not permitted to execute any form of
the works at the worksite until such time as approved quality personnel have been deployed
on a fulltime basis to the worksite. The Contractor shall not remove or replace the appointed
quality personnel without prior approval from the Engineer.
The Quality Organisation Plan may form part of the Project Quality Plan or be prepared as a
standalone document and cross-referenced within the Project Quality Plan.
2.1.3
As part of the Project Quality Plan the Contractor shall submit an Inspection and Test Plan
Schedule to the Engineer for approval no later than thirty (30) days from the start of the
Contract.
The Inspection and Test Plan schedule shall define the Inspection and Test Plans to be
prepared for the Works and the target dates for their submission to the Engineer for his
approval.
The Inspection and Test Plans shall consider the requirements of each Section of the
Specification and shall identify, as a minimum, the following:
(b)
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(c)
the required inspection and testing frequency
(d)
the acceptance/rejection criteria
(e)
whom from the Contractors team is responsible and qualified to perform the inspection
or test
(f)
Quality Records to be generated
(g)
Hold, Witness, surveillance and Record Review points of the Contractors team, the
Engineer and any other agencies having jurisdictional authority over the work relating
to each inspection and test to be performed.
Details each activity, inspection and test to be performed

Reference to specifications, standards etc.
(a)
Each inspection and test shall have a unique reference number.
Inspection and Test Plans are required to address the Contractors on and off site Work and
preparation, submission and approval of related documentation.
QCS 2014

Part
02: Submittals
Page 5
Inspection and Test Plans are required for all operations including major temporary works
and commissioning.
No work covered by the Inspection and Test Plan shall begin until the plan has been
approved by the Engineer.
A Contractors Inspection and Test Plan Template with guidance notes is included in
Appendix B of this Section and must be used by the Contractor
2.1.4
Quality Checklists
The Contractor shall develop specific quality checklists for all activities to be checked as per
the Inspection and Test Plans and submit to the Engineer for the approval with the Inspection
Test Plans submission prior to the start of the activity.
The Contractor shall inspect the work and sign off the relevant checklist and Inspection
Request prior to the final inspection with the Engineer.
The checklist shall be attached with the Inspection Request and other relevant attachments
and submitted to the Engineer.
2.1.5
The Contractor shall develop and report Key Performance Indicators (KPIs). KPIs are a set
of quantifiable measures that are used to gauge performance of the Contractors
Performance.
The KPIs shall be defined in the Contractors Project Quality Plan and be subject to
Engineers approval.
The Contractor is responsible for developing his own KPIs for all elements of his contract
(Contractual, Commercial, Safety etc.) but as a minimum shall address the following KPIs.
Time between opening and closure of Nonconformance Reports (NCR) and Corrective
Action Requests (CAR).
(b)
Time between identification of a Nonconformance or Corrective Action and actual

raising on the system.
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(c)
NCR and CAR statistics per areas, sections, discipline, subcontractor etc.
(d)
Percentage of reoccurring NCRs and CARs Trends on NCRs and CARs.
(e)
Approval status of critical documentation for the progress of the works (Method
Statements, ITPs etc.).
(f)
Statistical data from inspections as per the Inspection & Test Plans (Pass vs failed,
pass first time, etc.).
(g)
Completion packages (As-Built folders) progress.
Reporting of the KPIs shall include a graphical bar chart representation on a month by month
basis from the start of the Contract.
QCS 2014

Part
02: Submittals
Page 6
Method Statements
Contractor shall ensure that Method Statements address quality issues. Refer to Section 11
Part 1 (Regulatory Document) in particular section 1.1.7 and Section 11 Part 2 (SAMAS) in
particular section 2.4
2.1.7
Commissioning Plan
The Contractor shall submit a Commissioning Plan to the Engineer for approval no later than
sixty (60) days unless agreed otherwise with the engineer before the start of the
commissioning of the Works or any part thereof.
The Commissioning Plan shall consider the requirements of each Section of the Specification
in turn and shall identify the following:
2.1.6
all required commissioning work required by that Section of the Specification
(b)
any prerequisites to commissioning
(c)
a list of the commissioning procedure
(d)
a detailed description of the duties and responsibilities on the personnel involved in the
commissioning process
(e)
a detailed list of the tests/checks/activities that will be performed, linked to the relevant
construction activities and referenced to any links/documents to the ITPs performed
during the construction
(f)
specific reference to the witness/hold and review points of the engineer
(g)
a detailed list of the standards /specifications/regulatory requirements that need to be

performed
(h)
a detailed description of the interactions/communication

organization/public service or other legal/regulatory institutions
(i)
a detailed description of the test/activities of the maintenance needed during the life
time of the project, with reference to any special requirements/qualifications of the
personnel involved in the maintenance activities
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a detailed description of any spare parts/equipment/fixtures and other type of the of

consumables that might be needed, with an estimation of quantities, for the life time of
the project
(j)
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(a)
(k)
a detailed description of the as built project file that will be created after the
commission phase
(l)
a procedure for up-date and revision of the commissioning plan
No work covered by the Commissioning Plan shall begin until the plan has been approved.
END OF PART
QCS 2014

Part
03: Contractors Quality Personnel
Page 1
CONTRACTORS QUALITY PERSONNEL ............................................................. 2
3.1
3.1.1
3.1.2
3.1.3
3.1.4
3.1.5
3.1.6
3.1.7
3.1.8
INTRODUCTION ..................................................................................................... 2
General
2
Quality Assurance Manager
2
Quality Control Manager
2
Quality Engineer
2
Quality Inspector
3
Personnel Qualifications
3
Quality Staff Requirement
3
Quality Training for Contractors Employees and Labour
5
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Page 2
CONTRACTORS QUALITY PERSONNEL
3.1
INTRODUCTION
3.1.1
General
Contractor shall, throughout the execution and completion of the Works and the remedying
defects therein have on his staff at the Site office(s) a dedicated Quality Team dealing only
with matters regarding the quality and protection against damage before, during and after
execution of Works as specified in this section. This team shall be qualified and experienced
in their work and shall have the authority to issue instructions and shall take protective
measures to prevent execution of Works that do not comply with the Specifications.
The Contractor shall notify the Engineer in writing prior to re-assigning or replacement of any
of the quality team designated in the Quality Organisation Plan.
The Contractor shall have adequate quality personnel on the site during all production
operations, including adequate coverage during night shift operations and off site work.
The Contractor's quality team shall have the authority to stop any portion of the work which
does not comply with the requirements of the Project Documentation.
Minimum qualifications and experience of the Contractors Quality Personnel shall be as

defined in the Contract.
3.1.2
Where required by this section, the Contractor shall designate and assign a full time Quality
Assurance Manager who shall be responsible for overseeing the implementation and
operation of the Project Quality Plan at all levels. The Quality Assurance Manager shall report
directly to Top Tier Management and be independent of the Contractors organisation
responsible for construction.
3.1.3
Control Manager who reports directly to the Quality Assurance Manager and shall be
responsible for supervision of the construction quality control management activities and
ensuring compliance with the Contractors Inspection and Test Plans and associated
specification and contract documentation.
3.1.4
Quality Engineer
Where required by this section, the Contractor shall designate and assign a Quality Engineer
who reports directly to the Quality Assurance Manager or Quality Control Manager and shall
be responsible for assisting
them with their day to day responsibilities and may be
assigned to cover several locations or areas of work relating to the Contract. Where a Quality
Assurance Manager or Quality Control Manager are not required by this section the Quality
Engineer shall be assigned all the responsibilities defined in clause 3.1.2, 3.13, and 3.1.7.
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Page 3
Quality Inspector
The Contractor shall designate and assign a Quality Inspector for each shift for each location
where work is being performed. Each Quality Inspector shall be qualified by training and
experience in all the construction or fabrication activities being conducted at the location of
work and is directly responsible for ensuring compliance with the Contractors Inspection and
Test Plans and associated specification and contract documentation.
3.1.6
The Contractor shall identify activities requiring qualified production, inspection, and test
personnel and establish their minimum competence level.
The Contractor shall maintain records of personnel qualifications as quality records.
3.1.7
Unless otherwise specified by the Engineer the Contractor shall employ fulltime qualified
quality personnel for the Work as per below tables.
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3.1.5
No of workers on Worksite
Requirement
as
No
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1 Quality Inspector (Part time, 15 hours of duty per

week)
Less than 10
2.
More than 11 but less than 50
3.
4.
1 Quality Assurance Manager and

1 Quality Engineer per 500 workers and
1 Quality Inspector per 100 workers
More than 1501

1 Quality Control Manager and
1 Quality Inspector
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1 Quality Engineer and

QCS 2014

Part
Page 4
Quality Management and Control staff Qualifications & Experience Matrix

Minimum Qualifications
Required
Position
Minimum Years of
Experience
Minimum Key
Competencies
Degree in relevant
12 years, 5 of which at
Engineering discipline and Management Level and 3
related training in Quality
years Regional experience
Management Techniques.
Internationally recognised
Lead Auditor Certificate
Qualified Professional who

can manage a Quality
Management System and
coordinate specialised
activities. Excellent written
& verbal communication
skills in English
Quality Control
Manager
Degree in relevant
Excellent written & verbal
Engineering discipline and Management Level and 3 communication skills in
years Regional experience English
Quality Engineer
Degree in relevant
Engineering discipline.
Quality Inspector
Certificate or Diploma in
the appropriate
engineering discipline
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Quality
Assurance
Manager
Good written & verbal

communication skills in
English
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10 years experience in
related Quality Control
Activities and 3 years
Regional experience
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related Quality Control and communication skills in
Materials Testing activities English
along with 2 years
Regional Experience
The Contractor shall appoint deputy quality personnel who are capable of performing all the
duties of the quality personnel in the event of their absence.
The Contractor shall appoint support staff in sufficient numbers to ensure the effective
function of the quality related work within the Contractors organisation.
The Contractor shall ensure that every Sub-contractor employed on the Worksite appoints
suitably qualified quality staff to ensure the effective function of the quality related issues
within the Sub-contractors organisation. The Sub-contractor shall appoint and deploy fulltime
on the Worksite one Quality Inspector for every 100 workers that they employ at the
Worksite. Any Sub-contractor that employs more than 100 workers will appoint a Quality
Engineer. This shall be in addition to the Contractors Quality Team.
QCS 2014

Part
Page 5
The Contractor shall conduct quality training including Contract specific induction, pre-work
briefings, skills training, tool box talks and formal training conducted by training professionals
or agencies for all the Contractors employees. The Contract specific induction will be at least
1 hour duration, approved by the Engineer and provided for all persons involved in the
Works. Such induction training will be reviewed, revised and repeated at intervals not
exceeding 12 months throughout the duration of the Work. All training shall be provided in the
languages preferred by the recipients of the training. Training shall focus on improving
competency and skill for those performing activities that impact quality.
The Contractor must conduct regular tool box talks to his Labour workforce Such training
should include as a minimum Health and Safety issues and Construction Method best
practice.
The Owner may organise quality related training, meetings, seminars, workshops or similar
events at any time throughout the Contract Period. The Contractor is required to participate
in such events when requested at his own expense.
The Contractor shall maintain records of all training conducted including details of the training
given and a list of attendees, including attendees signature and ID numbers.
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3.1.8
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END OF PART
QCS 2014

Part
04: Document & Data Control
Page 1
DOCUMENT & DATA CONTROL ............................................................................ 2
4.1
4.1.1
4.1.2
4.1.3
INTRODUCTION ..................................................................................................... 2
General
2
Document and Data Approval and Issue
2
Document and Data Changes
2
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Part
Page 2
DOCUMENT & DATA CONTROL
4.1
INTRODUCTION
4.1.1
General
The Contractor shall establish and maintain documented procedures to control all documents
and data that relate to the requirements of the Specification. Documents and data can be in
the form of any type of media, such as hard copy or electronic media.
to the Contract.
4.1.2
The documents and data shall be reviewed and approved for adequacy by authorised
personnel prior to issue. A master list or equivalent document control procedure identifying
the current revision status of documents shall be established and be readily available to
preclude the use of invalid and/or obsolete documents. This control shall ensure that:
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The pertinent issues of appropriate documents are available at all locations where
operations essential to the effective functioning of the quality system are performed
(b)
Invalid and/or obsolete documents are promptly removed from all points of issue or
use, or otherwise assured against unintended use
(c)
Any obsolete documents retained for legal and/or knowledge preservation purposes
are suitably identified
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(a)
Where practicable, the nature of the change shall be identified in the document or
appropriate attachments.
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4.1.3
END OF PART
QCS 2014

Part
05: Quality Records
Page 1
QUALITY RECORDS..................................................................................... 2
5.1
5.1.1
INTRODUCTION ........................................................................................... 2
General
2
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Part
05: Quality Records
Page 2
QUALITY RECORDS
5.1
INTRODUCTION
5.1.1
General
The Contractor shall establish and maintain documented procedures for identification,
collection, indexing, access, filing, storage, maintenance and disposition of quality records.
The Contractor shall supplement these quality records as necessary to monitor quality
throughout the Contract period.
Quality records shall be maintained to demonstrate conformance of materials and equipment

to specified technical requirements and the effective operation of the quality system.
All quality records shall be legible and shall be stored and retained in such a way that they
are readily retrievable in facilities that provide a suitable environment to prevent damage or
deterioration and to prevent loss.
As a minimum, the quality record for any particular item shall include:
name of item
(b)
item number
(c)
item description
(d)
suppliers name
(e)
serial number or other identification (where applicable)
(f)
Specification reference (where applicable)
(g)
verification of receipt of all required supporting documentation
(h)
quantity of items
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location and installation of item

inspection/test procedure reference
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(k)
non-conformance number (if applicable)
(l)
Observations / comments.
(m)
Signatures of responsible person
END OF PART
QCS 2014

Part
06: Quality Audits
Page 1
QUALITY AUDITS ................................................................................................... 2
6.1
6.1.1
6.1.2
GENERAL ............................................................................................................... 2
Contractors Quality Audit
2
Engineers Quality Audit
2
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Part
06: Quality Audits
Page 2
QUALITY AUDITS
6.1
GENERAL
6.1.1
The Contractor shall establish and maintain documented procedures in line with ISO 190011
for planning and implementing internal quality audits to verify whether quality activities and
related results comply with planned arrangements and to determine the effectiveness of the
quality system.
Internal quality audits shall be scheduled on the basis of the status and importance of the
activity to be audited and shall be carried out by personnel independent of those having direct
responsibility for the activity being audited. Unless otherwise agreed with the Engineer in
writing, the Contractor shall carry out a full system quality audit every three months.
The results of the audits shall be recorded and brought to the attention of the personnel
having responsibility in the area audited. The management personnel responsible for the
area shall take timely corrective action on deficiencies found during the audit.
Follow-up audit activities shall verify and record the implementation and effectiveness the
corrective action taken.
The results of the Contractors quality audits shall be made available for review by the
Engineer. The Contractor shall implement any recommendations made by the Engineer
based on the results of the internal audit.
The Contractor shall allow the Engineer to observe the Contractors internal audit upon
request.
Quality audits must be undertaken by suitably qualified personnel with an internationally

recognized audit qualification to recognized standards.
6.1.2
The Engineer may undertake a quality audit of any of the Contractors activities at any time
during the course of the Contract. The Contractor shall make all personnel and facilities
available to the Engineer as necessary to undertake quality audits.
The Engineer shall make the results of his quality audit available to the Contractor for review.
The Contractor shall implement any recommendations made by the Engineer based on the
results of the Engineers quality audit.
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END OF PART
QCS 2014

Part
07: Inspection and Test
Page 1
INSPECTION AND TEST ........................................................................................ 2
7.1
7.1.1
7.1.2
7.1.3
7.1.4
7.1.5
7.1.6
7.1.7
INTRODUCTION ..................................................................................................... 2
General
2
Inspections and Tests
2
Inspection and Test Status
3
Inspections by the Engineer during construction
3
Inspections by the Engineer during Defects Liability Period
4
Workmanship
4
Measuring and Test Equipment
4
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Part
Page 2
INSPECTION AND TEST

INTRODUCTION
7.1.1
General
The Contractor shall provide equipment, instruments, qualified personnel, and facilities
necessary to inspect the work and perform the tests required by the Project Documentation.
The Contractor shall repeat tests and inspections after correcting non-conforming work until
all work complies with the requirements. All re-testing and re-inspections shall be performed
at no additional cost to the Client.
The Engineer may elect to perform additional inspections and tests at the place of the
manufacture or the shipping point to verify compliance with applicable Specifications.
Inspections and tests performed by the Engineer shall not relieve the Contractor of his
responsibility to meet the Specifications. Inspections and tests by the Engineer shall not be
considered a guarantee that materials delivered at a later time will be acceptable. All costs
associated with the foregoing shall be borne by the Contractor.
Inspections and tests conducted by persons or agencies other than the Contractor, shall not
in any way relieve the Contractor of his responsibility and obligation to meet all Specifications
and referenced standards.
7.1.2
All inspections and tests shall be conducted in accordance with written test procedures as
detailed in the Project Quality Plan and Inspection and Test Plans that have been reviewed
and approved by the Engineer.
Mandatory Products and Materials Sampling and Testing Frequencies are included in Part
14, Appendix A of this section. The Contractor shall follow the Sampling and Testing
Frequencies stipulated in Appendix A unless otherwise stated in the Contract. The table in
Appendix A shall be read and understood in tandem with the footnotes in Appendix A.
Inspection and test procedures submitted for approval shall include, but not be limited to, the
following:
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7.1
(a)
(b)
references to Clauses of this Specification and other standards along with applicable
inspection/test levels specified therein
(c)
prerequisites for the given inspection/test
(d)
required tools, equipment
(e)
necessary environmental conditions
(f)
acceptance criteria
(g)
data to be recorded
(h)
reporting forms
(i)
Identification of items inspected and tested.
(j)
Contractors and Engineers Hold, Witness, Surveillance and Record Review Points
QCS 2014

Part
Page 3
Approved procedures and instructions shall be readily available and used by inspection and
test personnel at the time of inspection or test. All revisions to these procedures and
instructions shall be approved prior to being used to inspect or test the work. No deviations
from the approved procedures and instructions shall be allowed without written authorisation
from the Engineer.
Inspection and testing work shall be performed by personnel designated by the Contractor.
Such personnel shall not be the same as those performing the work.
The Contractor shall furnish the Engineer with a signed inspection report for each item of
work inspected and tested. The report shall indicate whether the item of work, material
and/or equipment complies with all the inspection/test criteria. The Contractor shall submit
inspection/test results to the Engineer prior to incorporating the item(s) into the work.
Inspection/test failures shall be reported to the Engineer immediately.
Inspection and test reports shall, as a minimum, identify the following:

(b)
name of inspector/tester
(c)
observations/comments
(d)
specified requirements
(e)
acceptability
(f)
deviations/non-conformance
(g)
corrective action
(h)
evaluation of results
(i)
authorised signature
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The Contractor shall clearly document and identify the inspections and test status of
all materials and equipment throughout construction. Identification may be by means of
stamps, tags, or other control devices attached to, or accompanying, the material or
equipment.
7.1.3
The inspection and test status of materials, equipment and construction work shall be
identified by suitable means, which indicates the conformance or non-conformance of
materials, equipment and construction work with regard to inspection and tests performed.
The identification of inspection and test status shall be maintained, as defined in the Quality
Assurance Plan and/or documented procedures, throughout the course of construction to
ensure that only materials, equipment and construction work that have passed the required
inspections and tests are used or installed.
7.1.4
The Contractors Inspection and Test Plans will define Hold, Witness, Surveillance and
Record Review points for the Engineer during construction. The contractor shall prepare,
document and implement a Request for Inspection system that defines how the Engineer will
be given sufficient notice to inspect the works in accordance with the Inspection and Test
Plans.
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Part
Page 4
The Engineer will give the Contractor due notice of his intention to carry out any inspections
during the defects liability period.
The Contractor shall arrange for a responsible representative to be present at the times and
dates named by the Engineer.
The Contractors representative shall render all necessary assistance and take note of all
matters to which his attention is directed by the Engineer
7.1.6
Workmanship
The Contractor shall comply with industry standards except when more restrictive tolerances
or specified requirements indicate more rigid standards or more precise workmanship.
Only persons qualified to produce workmanship of the required quality shall perform works
The Contractor shall comply with manufactures published installation instructions / guides in
full, including each step in sequence. Should instructions conflict with project documentation,
the Contractor shall request clarification from the Engineer before proceeding.
7.1.7
The Contractor shall establish and maintain documented procedures which conform to
accepted and approved national or international standards to control, calibrate and maintain
inspection, measuring and test equipment used by the Contractor to demonstrate the
conformance of materials, equipment and/or construction work with the requirements of the
Inspection, measuring and test equipment shall be used in a manner which ensures that the
measurement uncertainty is known and is consistent with the required measurement
capability
The Contractor shall establish a unique identification number for each item of measuring and
test equipment. This unique identification number shall be permanently affixed to each item
of measuring and test equipment
The Contractor shall ensure that each item of inspection, measuring and test equipment is
calibrated at intervals recommended by the manufacturer. Valid calibration certificates for
measuring and testing equipment shall be present and available for inspection during
inspections and tests.
The Contractor shall establish a log of all measuring and test equipment and record:
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7.1.5
(a)
equipment description
(b)
identification number
(c)
date of the last calibration
(d)
date that the next calibration is due.
QCS 2014
Page 5
The Contractor shall assess and record the validity of the previous measuring results when
the equipment is subsequently found not to confirm to requirements. The Contractor shall
take appropriate action on the equipment and any product affected.
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END OF PART

Part
QCS 2014

Part
08: Materials
Page 1
MATERIALS .................................................................................................. 2
8.1
8.1.1
8.1.2
8.1.3
GENERAL ...................................................................................................... 2
Plant, Materials, Goods and Workmanship
2
Handling and Storage of Materials
2
Identification and Control of Items and Materials
2
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Part
08: Materials
Page 2
MATERIALS
8.1
GENERAL
8.1.1
All Plant, materials, goods and workmanship shall be of the respective kinds described in the
Contract with necessary approvals from the concerned authorities and in accordance with the
Engineer's instructions and shall be subjected from time to time to such tests as the Engineer
may direct at the place of manufacture or fabrication or on the Site or at all or any such
places. The Contractor shall provide such assistance, instruments, machines, labour and
material as are normally required for examining, measuring and testing any work and the
quality, weight or quantity of any materials used and shall supply samples of materials before
incorporation in the Works for testing as may be selected and required by the Engineer.
8.1.2
The Contractor shall establish procedures for handling and storage of materials and
equipment.
The Contractors storage and handling procedures shall be designed to prevent damage,
deterioration, distortion of shape or dimension, loss, degradation, loss of identification, or
substitution.
The handling procedures shall address the use, inspection and maintenance of special
devices such as crates, boxes, containers, dividers, slings, material handling and
transportation equipment and other facilities.
The Contractor shall identify equipment and/or material requiring special handling or storage.
8.1.3
The Contractor shall establish control procedures to ensure that equipment and materials are
properly used and installed.
The Contractor shall identify all items and materials so that they are traceable throughout all
inspections, test activities, and records. For stored items, the identification method shall be
consistent with the expected duration and type of storage.
The Contractor shall record equipment and material identifications and ensure that they are
traceable to the location where they are incorporated into the Works.
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END OF PART
QCS 2014

Part
09: Nonconformance Monitoring
Page 1
NONCONFORMANCE MONITORING .................................................................... 2
9.1
9.1.1
9.1.2
9.1.3
9.1.4
9.1.5
9.1.6
INTRODUCTION ..................................................................................................... 2
General
2
Review and Disposition of Nonconforming Items
2
Corrective Action
3
Identification of Nonconforming Items
3
Acceptance and Approval of Nonconforming items
4
Nonconformance Records
4
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Page 2
NONCONFORMANCE MONITORING
9.1
INTRODUCTION
9.1.1
General
The Contractor shall ensure that product which does not conform to Specification
requirements is identified and controlled to prevent its unintended use or delivery. A
documented procedure shall be established to define the controls and relate responsibilities
and authorities for dealing with nonconforming product:
by taking action to estimate the detected nonconformity
(b)
by authorizing its use, release or acceptance under concession by the Engineer
(c)
by taking action to preclude its original intended use or application
(d)
by taking action appropriate to the effects, or potential effects, of the nonconformity

when nonconformity product is detected after delivery or use has started .
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(a)
When Conforming product is corrected it shall be subject to re-verification to demonstrate

conformity to requirements.
Records of the nature of nonconformities and any subsequent actions taken, including
concessions obtained by the engineer, shall be maintained.
The monitoring system shall apply to material and equipment as well as installation and
construction which fail to conform to the Contract.
A Contractors Quality Nonconformance Template is included in Part 15 Appendix B of this

Section and must be used for recording Nonconformance.
9.1.2
The responsibility for review and authority for the disposition of nonconforming items shall be
defined in the Quality Plan.
Nonconforming items shall be reviewed in accordance with documented procedures. A

nonconforming item may be:
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(a)
reworked to meet the specified requirements
(b)
accepted with or without repair if agreed in writing by the Engineer
(c)
re-graded for alternative applications
(d)
rejected or scrapped.
The proposed use or repair of an item which does not conform to the requirements of the
Project Documentation shall be reported to the Engineer.
The description of the
nonconformity and of repairs shall be recorded to denote the actual condition.
Repaired and/or reworked products shall be inspected in accordance with the Quality
Assurance Plan and/or documented procedures
QCS 2014

Part
Page 3
9.1.3
Corrective Action
The Contractor shall take action to eliminate the causes of nonconformities in order to
prevent recurrence. Corrective actions shall be appropriate to the effects of the
nonconformity encountered.
A documented procedure shall be established to define requirements for:
Reviewing nonconformities (including Engineer complaints)
(b)
Determining the causes of nonconformities
(c)
Evaluating the need for action to ensure that conformities do not occur
(d)
Determining and implementing actions needed
(e)
Records of the results of action taken and
(f)
Reviewing the effectiveness of the corrective action taken
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(a)
Any corrective or preventive action taken to eliminate the causes of actual or potential
nonconformities shall be to a degree appropriate to the magnitude of problems and
commensurate with the risks encountered.
The Contractor shall implement and record any changes to the documented procedures for
implementing corrective and preventive action.
The Contractor shall take prompt action to identify the causes of each nonconformance and
the corrective action necessary prevent recurrence. The results of failure and discrepancy
report summaries, Contractor evaluations, and any other pertinent applicable data shall be
used for determining corrective action. Information developed during construction, tests, and
inspections that support the implementation of required improvements and corrections shall
be used to support the adequacy of corrective action taken.
The procedures for preventive action shall include:
determination of the steps needed to deal with any problems requiring preventive
action
(b)
the use of appropriate sources of information such as processes and work operations
which affect product quality, concessions, audit results, quality records and service
reports to detect, analyse and eliminate potential causes of nonconformities
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(c)
initiation of preventive action and application of controls to ensure that it is effective
(d)
ensuring that relevant information on actions taken is submitted for management

review
9.1.4
The Contractor shall clearly identify each nonconforming item with a status tag or other
distinguishing mark. The Contractor shall establish procedures for installing, monitoring, and
removing these status tags and identify personnel authorised to remove status tags.
QCS 2014

Part
Page 4
9.1.5
Acceptance of the Contractors proposed disposition of Nonconforming items should be his

obtained in writing from the Engineer prior to the undertaking of any remedial works by the
his Contractor.
Close out of Nonconforming items must be agreed in writing by the Engineer.
9.1.6
The Contractor shall provide the Engineer with the following information for each
nonconformance:
(b)
description of nonconformance
(c)
evaluation of nonconformance to establish the cause
(d)
recommended corrective action
(e)
date nonconformance was identified
(f)
date corrective action was completed
(g)
description of final corrective action.
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identification of nonconformance
unique sequential reference number
(b)
date issued
(c)
originator
(d)
description of item deemed to be in nonconformance
(e)
(f)
(g)
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The Contractor shall establish and maintain a nonconformance log. The log shall contain the
following information as a minimum:
Contractors recommended and final disposition

Engineers acceptance of Contractors recommended and final disposition
(a)
(h)
date closed
(i)
remarks, as applicable
END OF PART
QCS 2014
Section 03: Ground Investigation

Part
01: General
Page 1
GENERAL ............................................................................................................... 2
1.1
1.1.1
1.1.2
1.1.3
INTRODUCTION ..................................................................................................... 2
Scope
2
References
2
Definitions
2
1.2
1.2.1
1.2.2
1.2.3
1.2.4
1.2.5
1.2.6
1.2.7
SUBMITTALS .......................................................................................................... 3
Programme of Works
3
Preliminary Logs
3
Exploratory Hole Logs
4
Preliminary Laboratory Test Results
5
Digital Data
5
Form of Report
5
Approval of Report
6
1.3
QUALITY ASSURANCE .......................................................................................... 6
1.4
1.4.1
1.4.2
1.4.3
1.4.4
1.4.5
1.4.6
1.4.7
1.4.8
1.4.9
1.4.10
1.4.11
1.4.12
1.4.13
1.4.14
1.4.15
1.4.16
GENERAL PROJECT/SITE CONDITIONS .............................................................. 7

General
7
Working Areas
7
Turf and Topsoil
7
Paved Areas
7
Paving Slabs and Blocks
7
Claims for Damage
8
Geotechnical and Environmental Personnel
8
Location of Exploratory Holes
8
Ground Elevation of Exploratory Holes
8
Exploratory Work
8
Methods of Investigation
8
Safety and Management
9
Anomalous Conditions
9
Surface Water Control
9
Photographs
9
Facilities for the Engineer
10
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Part
01: General
Page 2
GENERAL
1.1
INTRODUCTION
1.1.1
Scope
General requirements and information for the execution of ground investigations.
Related Sections are as follows:
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Section 1 ......... General

Section 2 ......... Quality Assurance and Quality Control
Section 4 ......... Foundations and Retaining Structures
Section 6 ......... Roadworks
Section 8 ......... Drainage Works
Section 12 ....... Earthworks Related to Buildings
References
The following standards and other documents are referred to in this Part:
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1.1.2
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BS 5930......................Code of practice for site investigations

BS EN 1997................Ground Investigation and testing
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ASTM D 420 ...............Site Characterization for Engineering, Design, and Construction

Purposes
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ASTM D 2488 .............Description and Identification of Soils (Visual-Manual Procedure)
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Deere D. U. et al., Design of surface and near-surface construction in rock. Proc. 8th US
symposium on rock mechanics. AIME, New York, 1967
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Code of Practice and Specifications for Road Openings in the Highway issued by the
Government.
Definitions
Topsoil: the surface layer of earth that contains organic material and can also support
vegetation.
Soil: earthen material not classified herein as topsoil or hard stratum.
Hard stratum and obstruction: The words 'hard stratum' and 'obstruction' shall mean
natural or artificial material, including rock, which cannot be penetrated except by the use of
chiselling techniques, rotary drilling, blasting or powered breaking tools. The term 'hard
stratum' shall apply during boring, where it is shown that condition (1) or condition (2) below
are fulfilled, provided that the boring rig involved is in good working order and is fully manned:
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1.1.3
(a)
Condition (1) 100 mm diameter undisturbed sample tubes cannot be driven more
than 300 mm
(b)
Condition (2) a standard penetration resistance test shows a resistance in excess

of 35 blows/75 mm.
QCS 2014

Part
01: General
Page 3
Fill: deposits or embankments which have been formed by persons, as distinct from
geological agencies.
Exploratory Hole/Trench/Excavation: any boring, pit trench, ditch or shaft formed for the
purpose of ground investigation.
Boring: hole in earth, excavated by either percussion or auger equipment.
Drilling: any hole in rock, excavated by rotary equipment.
Borehole: exploratory hole excavated by boring or drilling techniques.
1.2
SUBMITTALS
1.2.1
Programme of Works
The Geotechnical Investigation Contractor shall prepare a programme of works for the
investigation which will give a detailed schedule showing proposed time schedule for all
aspect of the work, details of all plant and equipment to be used in addition to a list of
personnel who will work on the project.
1.2.2
Preliminary Logs
The Geotechnical Investigation Contractor shall prepare a preliminary log of each exploratory
hole. For trial pits and trenches, a trial pit or trench map showing each face of the pit or
trench shall be provided, as appropriate. Preliminary logs shall be submitted to the Engineer
in duplicate within seven working days of completion of the explorations to which they refer
to, and shall contain the information required for the exploratory hole logs.
Geotechnical Investigation Contractor activities shall fully comply with Ministry of Environment
(MOE) requirements and/or those of other Government Departments, Ministries and
Statutory Organizations.
The Geotechnical Investigation Contractor shall obtain all necessary work permits and
security permits prior to commencement of Geotechnical investigation of the site.
The investigation shall provide detailed information on the nature of the sub-strata, superficial
deposits and ground water table at the site together with general recommendations for
designing foundations and earthworks, new road pavements, culverts, retaining walls, etc.
The geotechnical investigation Exploratory Boreholes shall be spaced as mentioned in

Section 2.
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Part
01: General
Page 4
The geotechnical investigation Exploratory Boreholes depths shall be as mentioned in Table

1.1.
Table 1.1: Minimum Depth of Boreholes
No of floors
Depth of Boreholes (m)
3 or Less
10
12
13
0.7
3S
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>8
2m below the inverted level;

1.5width of excavation.
2D (D=Diameter or equivalent diameter of the tunnel/underground structure.
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For trenches, pipeline and Tunnels, the depth of Boreholes shall be the larger value of:
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Notes:
The depth of boreholes is measured from foundation level.
S is the number of floors.
For structures small in plan area, exploration should be made at a minimum of three points,
unless other reliable information is available in the immediate vicinity. Where a structure
consists of a number of adjacent units, one exploration point per unit may suffice.
For piles the depth of Boreholes is at least below the depth of pile tip by 5m or 5D (D is the
diameter of the pile at the toe) whichever is greater.
For roads, the depth of Boreholes shall be greater than 2m below the proposed formation
Level.
The exploratory hole logs shall be prepared and presented to a suitable vertical scale. The
logs shall include all the information that follows, such information having been updated as
necessary in the light of laboratory testing and further examination of samples and cores.
Information for exploratory hole logs:
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1.2.3
Drilling
Pit and
Trench
Static
and
Dynamic
Probing
National grid co-ordinates
Ground level related to the datum
Elevation of each stratum referred to the datum
()
Rotary
Borehole
All the designated information
QCS 2014

Part
01: General
Page 5
Drilling
Pit and
Trench
Static
and
Dynamic
Probing
()
Details of groundwater observations
()
Symbolic legend of strata in accordance with BS

5930
()
Rotary
Borehole
Description of each stratum in accordance with BS
5930 and initials of person who carried out the
logging (and responsible Supervisor if under
training)
Core recovery as percentage of each core run
Rock Quality Designation, RQD (Deere et al. 1967)
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Note: means information required; () means information required if applicable.
Laboratory test results shall be submitted to the Engineer in batches at the completion of
each week's testing. Legible photocopies of work sheets are acceptable.
1.2.5
Digital Data
Data from the investigation shall be provided in digital form to the approval of the Engineer.
1.2.6
Form of Report
The report shall comprise of a factual or interpretative or both types of reports as required by
the Employer or Engineer. Reports shall begin with a cover page showing the name of the
Contract and the names of the Employer, Engineer and Geotechnical Investigation
Contractor. Report pages shall be numbered consecutively.
The factual report shall contain, as a minimum, the following information:

A statement from the Engineer on the purpose and rationale of the investigation.
(a)
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1.2.4
(b)
A description of the work carried out, including reference to specification and

standards adopted and any deviations from them.
(c)
Exploratory hole logs.
(d)
In-situ test records.
(e)
Laboratory test results.
(f)
Plan with locations of exploratory holes.
(g)
Site location plan.
(h)
Geological cross-sections (if appropriate).
The plans shall be to a stated scale and shall include a north arrow. Additional information
shall be provided as designated.
QCS 2014

Part
01: General
Page 6
The interpretative report shall contain the following information:

(a)
A written appraisal of the ground and water conditions.
(b)
Analysis and recommendations as designated.
When so designated, the Geotechnical Investigation Contractor shall supply the calculations
and analyses on which recommendations are based.
Approval of Report
A draft copy of the factual report and the interpretative report shall be submitted to the
Engineer for approval before submission of the final report.
1.3
QUALITY ASSURANCE
Only Geotechnical Investigation Contractors holding a current approval certificate from the
Central Materials Laboratory shall be permitted to carry out ground investigations.
The work shall be carried out in accordance with the relevant British Standards or equivalent.
Where specifically designated, all work shall be carried out in accordance with a quality
management system established in accordance with Section 2 Quality Assurance and Quality
Control of the QCS. Records to indicate compliance with quality management shall be made
available to the Engineer on request.
The Geotechnical Investigation Contractor shall provide full time professional attendance on
site. The professional attendant shall be approved by the Engineer, and shall be responsible
for the technical direction of all fieldwork.
The Geotechnical Investigation Contractors geotechnical and environmental personnel

employed on the Contract shall be competent to undertake the work required. Categories of
personnel who may be required by the Contract are as follows:
(b)
Graduate Engineer/Geologist/Environmental Scientist.

Graduate Engineer/Geologist/Environmental Scientist with at least three years of
(c)
Technician.
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1.2.7
relevant experience since graduation.
(d)
Professional Engineer/Geologist/Environmental Scientist with at least five years of

relevant experience.
(e)
Professional Engineer/Geologist/Environmental Specialist with at least ten years of

All drillers employed on the Contract shall be experienced and competent in percussion or
auger boring or rotary drilling, to the complete satisfaction of the Engineer. One competent
drilling supervisor per site shall be permanently on the Site during borehole operations.
QCS 2014

Part
01: General
Page 7
GENERAL PROJECT/SITE CONDITIONS
1.4.1
General
Geotechnical Investigation Contractor shall only use access routes to and between
exploration sites that are approved by the Engineer.
Where the presence of underground services is likely, exploratory holes shall be started by
means of a hand excavated inspection pit.
In addition to any designated notice, at least one working day's notice of the intended time of
entry shall be given to the land owner and occupier of the exploration site.
All work shall be carried out with the least possible damage to the Site and its environs.
All barriers breached or otherwise disturbed during the execution of site operations shall be
immediately repaired or replaced to the same standard.
Working hours shall be restricted to those designated.
Daily allocation sheets detailing the work carried out shall be submitted in duplicate at the
end of each days work.
1.4.2
Working Areas
Operations shall be confined to the minimum area of ground required for the Works. Unless
otherwise designated, on completion of each exploration all equipment, surplus material and
rubbish of every kind shall be cleared away and removed from the Site. Damage to land or
property in the vicinity of the exploratory hole and on access routes shall be made good. The
whole of the Site and any ancillary works shall be left in a clean and tidy condition.
1.4.3
Turf and Topsoil
Turf and topsoil shall be stripped from the site of each exploration and stockpiled for future
replacement. Vegetation and topsoil adjacent to the exploration which may be damaged by
the operations shall either be removed and stockpiled as above, or otherwise protected from
damage. After completion of the exploration all topsoil shall be replaced and the Site
restored to its original condition.
1.4.4
Paved Areas
Pavement from paved areas (other than paving slabs and blocks) shall be broken out to the
minimum extent necessary for each exploration. After completion of the exploration and
backfill of the excavation, the disturbed subgrade shall be compacted and the paving
replaced.
Restoration of highway pavement shall be in accordance with the current Code of Practice
and Specification for Road Openings in the Highway issued by the Government.
1.4.5
Paving slabs and blocks shall be removed from the Site, as required for each exploration,
and stored for reuse.
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1.4
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Part
01: General
Page 8
Contiguous paving slabs and blocks which are liable to be damaged by the operations shall
either be removed and stored as above or otherwise protected from damage.
After completion of the exploration and backfill of the excavation, the disturbed subgrade
shall be compacted and the paving slabs and blocks relayed.
1.4.6
Claims for Damage
Any damage, or claim for compensation for damage by owners or occupiers of the Site, shall
be reported to the Engineer.
1.4.7
In addition to the provision of the designated personnel by the Geotechnical Investigation

Contractor, the Engineer may specifically require the services of geotechnical and
environmental personnel for advice, assistance or preparation of interpretative reports. The
form of interpretative reports shall be agreed with the Engineer. Details of the qualifications
and experience of the personnel shall be supplied to the Engineer.
1.4.8
The location of each exploratory hole shall be measured from an approved grid co-ordinate
system, and shall be accurate to within 1 m, and the position recorded on a plan as
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designated.
The elevation of the ground at each exploratory hole shall be established, on the basis of the
Qatar National Datum unless otherwise designated or approved by the Engineer, to the
nearest 0.05 m.
1.4.10
Exploratory Work
The location and depth of each exploratory hole shall be as designated. The Engineer may,
after consultation with the Geotechnical Investigation Contractor, vary the location and depth
of any exploratory hole and the sequence or quantity of in-situ testing depending on the
actual ground conditions encountered. When the position of an exploratory hole has been
varied, the Geotechnical Investigation Contractor shall take all necessary measurements and
shall inform the Engineer of the revised co-ordinates and ground elevation or other
measurements required to locate the exploratory hole.
1.4.11
The Engineer will have the option to require any of the following methods of investigation.
These options will comprise, but not necessarily be limited to, the following:
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1.4.9
(a)
Desk study.
(b)
Geological mapping.
(c)
Topographic survey.
(d)
Aerial photographs.
or any other methods described in this Section.
QCS 2014

Part
01: General
Page 9
The Geotechnical Investigation Contractor shall submit detailed Job Hazard Analysis (JHA)
to all site activities including but not limited to potential hazard, who/what might be harmed,
control/ recovery measure, responsible personetc.
The presence and nature of known areas of hazardous or contaminated ground are
designated, based on available records. If evidence of further hazardous or contaminated
ground is encountered, the Geotechnical Investigation Contractor shall immediately so inform
the Engineer. If required by the Engineer, the Geotechnical Investigation Contractors work
plan shall be revised appropriately to take into account the nature and level of contamination
encountered. Where contaminated land is present or suspected the Geotechnical
Investigation Contractor shall take the appropriate health and safety precautions as directed
by the Engineer and where appropriate by the Civil Defence Department of the Government.
Care shall be taken to avoid contaminating the egress from the Site.
A method statement indicating the safety procedures to be followed during the investigation
of hazardous or contaminated ground shall be provided by the Geotechnical Investigation
Contractor before beginning the investigation in the hazardous or contaminated ground.
Traffic safety and management measures shall be provided, in accordance with the
provisions of traffic control of Section 1, General. Where the circumstances of any particular
case are not designated, proposals for dealing with such situations shall be submitted to the
Engineer for approval.
1.4.13
Where anomalous or unexpected features are revealed, the Geotechnical Investigation

Contractor shall immediately inform the Engineer.
1.4.14
Surface water or other water shall be prevented from entering the exploratory hole, except as
permitted by the Engineer.
1.4.15
Photographs
Colour photographs shall be taken and supplied by the Geotechnical Investigation Contractor
as designated. Each photograph shall clearly show all necessary details, and shall have its
scale identified.
A single gloss colour print (size 150 mm by 100 mm) copy of each photograph shall be
submitted to the Engineer for his approval, within seven working days of the photography. In
the event that the photographs are of a quality unacceptable to the Engineer, they shall be
retaken.
On acceptance of the quality of the photograph, two complete sets of prints of all the
photographs shall be presented, annotated and submitted in bound volumes, together with
the original photograph digital format with the factual report.
Particular requirements for photographs of cores and pits and trenches are given in Parts 3
and 4
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1.4.12
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01: General
Page 10
1.4.16
When required by the particular contract documentation, facilities to the designated standard
shall be provided for the use of the Engineer, as described in Section 1.
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END OF PART
QCS 2014

Part
02: Boreholes
Page 1
BOREHOLES .......................................................................................................... 2
2.1
2.1.1
2.1.2
GENERAL ............................................................................................................... 2
Scope
2
References
2
2.2
2.2.1
2.2.2
2.2.3
BOREHOLES GENERALLY .................................................................................... 2

Method and Diameter
2
Addition of Water to the Borehole
3
Backfilling
3
2.3
2.3.1
PERCUSSION BORING .......................................................................................... 3

Hard Stratum or Obstruction in Percussion Boring
3
2.4
2.4.1
2.4.2
2.4.3
AUGER BORING ..................................................................................................... 3

Hand Auger
3
Continuous Flight Auger Boring
3
Hollow Stem Flight Auger
3
2.5
2.5.1
2.5.2
2.5.3
2.5.4
2.5.5
2.5.6
ROTARY DRILLING ................................................................................................ 3

General
3
Drilling Fluid
4
Rotary Drilling with Core Recovery
4
Rotary Drilling without Core Recovery
6
Backfilling
6
Photographs
6
2.6
BOREHOLES OVERWATER .................................................................................. 6
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Part
02: Boreholes
Page 2
BOREHOLES
2.1
GENERAL
2.1.1
Scope
Advancement of boreholes by percussion boring, auger boring, and rotary drilling.

This Section
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Section 4, ........ Foundations and Retaining Structures

Section 6, ........ Roadworks
Section 8, ........ Drainage Works
Section 12, ...... Earthworks Related to Buildings
Part 1 ............... General
References
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2.1.2
BS 5930 ......................Code of practice for site investigations.
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BS EN 1997 ................Ground Investigation and testing
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Purposes
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Engineering Group of the Geological Society Working Party Report The logging of rock cores
for engineering purposes (1970).
BOREHOLES GENERALLY
2.2.1
Method and Diameter
The method of advancement and the diameter of a borehole shall be such that the boring
can be completed and logged to the designated depth, and samples of the designated
diameter can be obtained, in-situ testing carried out and instrumentation installed.
The following methods may be employed for advancement of a borehole unless otherwise
designated:
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2.2
(a)
Percussion boring.
(b)
Auger boring (If hollow stem augering is proposed, the Contractor shall satisfy the
Employer that the SPT values obtained are not effected by disturbance of the soil by
the auger head, or the presence of material within the hollow stem.).
(c)
Rotary drilling.
QCS 2014

Part
02: Boreholes
Page 3
Jetting with water shall not be used to assist the advance of the borehole, except where
approved by the Engineer. Where the borehole penetrates below the water table and
disturbance of the soils is likely, a positive hydraulic head shall be maintained in the borehole.
2.2.3
Backfilling
The Contractor shall backfill boreholes in such a manner as to minimise subsequent

depression at the ground surface due to settlement of the backfill. In some circumstances,
grout or special infilling may be required by the Engineer. Where artesian or other water
conditions make normal backfilling impracticable, the Contractor shall consult and agree with
the Engineer a procedure for sealing the borehole.
2.3
PERCUSSION BORING
2.3.1
In a borehole where percussion boring is employed and a hard stratum or obstruction is

encountered, the Contractor shall employ chiselling techniques for a period of up to 1 h.
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2.2.2
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Should this not penetrate through the hard stratum or obstruction the Contractor shall inform
the Engineer, who may instruct the use of one or more of the following:
continuation of chiselling techniques
(b)
rotary or other approved drilling until the stratum is penetrated
(c)
abandonment of the borehole.
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(a)
AUGER BORING
2.4.1
Hand Auger
Hand auger boring may be appropriate in suitable self-supporting strata.
2.4.2
Where continuous flight auger boring is used, it shall be carried out under the full-time
supervision of a person meeting the requirements of Part 1 Clause 1.5 Paragraph 5 Item (c)
who shall produce, as boring proceeds, a record of the material and groundwater
encountered.
2.4.3
Where hollow stem flight auger boring is used, the equipment used shall be such as to bore
and recover samples as designated. Sampling shall be carried out through the hollow stem.
2.5
ROTARY DRILLING
2.5.1
General
Rotary drilling may be required for the recovery of cores, or for the advancement of a hole in
rock, with or without core recovery.
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Part
02: Boreholes
Page 4
Drilling Fluid
The drilling fluid shall normally be clean water, air or air mist. However, with the approval of
the Engineer, drilling muds, additives or foam may be used.
2.5.3
Unless otherwise designated rotary core drilling shall be carried out by a double or triple tube
coring system incorporating a removable inner liner or split tube. The triple tube system may
be affected by use of a double tube barrel with an approved semi-rigid liner.
Rotary core drilling shall produce cores of not less than the designated diameter throughout
the core length. Care shall be exercised in the drilling so as to optimise core recovery.
The first drill run in each hole shall not exceed 1 m in length. Subsequent drill runs shall not
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2.5.2
normally exceed 3 m in length and the core barrel shall be removed from the drill hole as
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Removal of cores and labelling of liners shall be carried out as follows:

All operations entailed in recovering the cores from the ground after completion of
drilling shall be carried out in a manner such as to minimise disturbance to the cores.
(b)
Core barrels or inner tube in case of wireline shall be held horizontally while the
innermost liner containing the core is removed without vibration and in a manner to
prevent disturbance to the core. The core should be rigidly supported at all times while
it is being extruded and during subsequent handling, and the liner containing the core
must not be allowed to flex
(c)
Immediately after removing the liner the top and bottom shall be marked in indelible
ink. The ends of liners shall be capped and sealed using adhesive tape. Liners shall
as
(a)
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often as is required to obtain the best possible core recovery or alternatively the core
samples shall be retrieved by means of wireline. The Engineer may designate in-situ testing
between drill runs.
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be cut to the length of the enclosed core. Alternatively, should a metallic split tube be
used, the samples shall be placed in half cut PVC pipes sealed with the second half
after core samples description with marking of the core run on the PVC tube and the
core box.
(d)
Where the length of core recovered from any single core run is such that it cannot be
accommodated in one channel of the core box, the liner shall be cut to coincide, if
possible, with existing fractures. The liner either side of the cut shall be marked 'cut'
and the ends capped as above.
(e)
Each section of liner shall be marked with the contract title, exploratory hole reference
number, date and the depths of the top and bottom of the drill run.
(f)
Core obtained without a liner and that from within the core catcher but not inside the
liner shall be wrapped in two layers of plastic cling film and labelled to indicate the
depth and exploratory hole reference number.
Core boxes, packing, labelling, storing shall be carried out as follows:

(a)
Core boxes shall be soundly constructed and fitted with stout carrying handles,
fastenings and hinged lids. The total weight of the cores and box shall together not
exceed 60 kg.
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Part
02: Boreholes
Page 5
Cores shall be rigidly and securely packed at the site of drilling and during all
subsequent handling and storage the cores shall remain packed unless required for
examination or testing. Cores shall be placed in the box, in their liners where used,
with the shallowest core to the top left hand corner, the top being considered adjacent
to the hinged section. Cores from the core catcher shall also be placed in the core
boxes at the correct relative depth.
(c)
Depth shall be indicated on the core box by durable markers at the beginning and end
of each drill run. Rigid core spacers shall be used to indicate missing lengths. The
contract title, exploratory hole reference number and the depth of coring contained in
each bore shall be clearly indicated in indelible ink inside, on top and on the right-hand
end of the box and on the inside of the box lid.
(d)
Core boxes containing core shall be kept horizontal and moved and handled with care
at all times. Cores shall be protected from direct sunlight. At the end of each day's
work, core boxes shall be stored secure from interference and protected from the
weather.
Cores shall be prepared for examination as follows:

(a)
Cores shall be prepared for examination by the removal of sealing materials and
splitting of liners in such a way as not to damage the cores. Plastic liners shall be cut
lengthways such that at least half the core circumference is exposed. If half PVC is
used, care should be taken while removing and replacing the split half.
(b)
Before examination of the core, the Contractor shall photograph the cores. The time
between beginning preparation and the examination of the prepared and photographed
cores shall be minimised to prevent loss of moisture from the core samples.
(c)
Cores shall be examined and described on site by a person meeting the requirements
of Part 1 Clause 1.5 Paragraph 5 Item (c) in accordance with BS 5930 or ASTM D
2488 and the recommendations of the Engineering Group of the Geological Society
Working Party Report The logging of rock cores for engineering purpose (1970).
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(b)
When the examination of the cores has been completed, the Contractor may be required to
retain separately designated core sub-samples for possible laboratory testing. The Contractor
shall cut the liner and cap and seal the core sub-samples in such a way as to prevent loss of
moisture and sample disturbance. They shall be clearly labelled so that the location, depth
and origin of the sub-samples can be readily identified. Cores in their liners remaining after
the designated sub-samples have been removed shall be end-capped and resealed and
replaced in the original core box location. Rigid spacers shall be placed in the spaces in the
cores boxes previously occupied by the core sub-samples to prevent movement of adjacent
cores and these shall be labelled identically to the core sub-samples that they replace. The
core sub-samples shall be retained in separate core boxes clearly marked to indicate the
origin of the cores contained within.
The Contractor shall protect all cores and transport them including loading and unloading to
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(a)
The Contractor's premises.
(b)
For a number of selected cores, to the designated address.
After submittal of the approved final report, the Contractor shall retain cores, other than those
delivered to the designated address, for a period of time required by the Engineer. The
Engineer's written permission shall be obtained before disposal of the cores, but the required
retention period will normally not exceed three months.
QCS 2014

Part
02: Boreholes
Page 6
2.5.4
Rotary blind bit or rotary percussive drilling may be used to advance a hole. The hole
diameter shall be as designated.
When used for the purpose of locating mineral seams, mineworkings, adits, shafts, other
cavities or anomalous conditions, drilling shall be under the full-time supervision of a person
meeting the requirements of Part 1 Clause 1.5 Paragraph 5 Item (c). As drilling proceeds a
systematic record shall be made of the drilling methods, rate of penetration, loss of flushing
medium, the material penetrated and any cavities or broken ground encountered.
Backfilling
Except where otherwise designated, the Contractor shall backfill rotary drill holes with clean,
well graded aggregate. The aggregate size and gradation shall be approved by the Engineer.
Under special circumstances grout may be required to backfill the holes. The grout shall
consist of equal portions by weight of ordinary Portland cement and bentonite mixed by
machine or hand to a uniform colour and consistency before placing, with a moisture content
not greater than 250 %. The grout shall be introduced at the bottom of the hole by means of
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2.5.5
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a tremie pipe, which shall be raised but kept below the grout surface as the filling proceeds.
Where artesian water conditions or voids make normal grouting impracticable, the Contractor
shall consult and agree with the Engineer a procedure for sealing the drill hole.
2.5.6
Photographs
In addition to the requirements of Part 1, the Contractor shall photograph cores where
required in a fresh condition before logging and ensure that the following criteria are fulfilled:
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A graduated scale in centimetres is provided.
(b)
Labels and markers are clearly legible in the photograph.
(c)
A clearly legible reference board identifying the project title, exploratory hole number,
date, and depth of drill runs shall be included in each photograph.
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Core boxes are evenly and consistently lit.
(d)
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(a)
(e)
The length of the core box in each photograph fills the frame.
(f)
The focal plane of the camera and the plane of the core box are parallel.
(g)
The camera is placed in the same position with respect to the core box in every
photograph.
(h)
The resolution of the camera is not less than 8Mpixels.
(i)
The photograph taken should be in focus along all the core samples length.
2.6
BOREHOLES OVERWATER
When boreholes are required overwater the method of drilling and sampling shall comply in
general with the other requirements given in this Section, with the exception of backfilling.
Overwater boreholes shall be undertaken by the use of overwater staging, work over platform
(WOP) jack-up vessels, anchored floating vessels or any other methods agreed with the
Engineer.
QCS 2014

Part
02: Boreholes
Page 7
Control of the elevation related to the borehole/seabed surface or varying stratums shall be
related to the top of the casing installed. Anchored floating vessels will keep a constant
record of tidal movement between the vessel and the fixed casing elevation and make any
allowances necessary.
Boring or drilling operations will cease when the wave height exceeds the designated
maximum value relating to standing time due to inclement weather, if this item is applicable
to the Contract under the contract specific documentation.
An accurate method of measuring wave height from trough to crest will be installed on the
drilling vessel or platform and calibrated and approved by the Engineer before beginning
drilling operations.
All overwater operations will comply with all local government regulations related to such
work and will also comply fully with any Safety of Lives at Sea (SOLAS) regulations in force at
the time.
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END OF PART
QCS 2014

Part
03: Pits and Trenches
Page 1
PITS AND TRENCHES ........................................................................................... 2
3.1
3.1.1
3.1.2
3.1.3
GENERAL ............................................................................................................... 2
Scope
2
References
2
Quality Assurance
2
3.2
3.2.1
3.2.2
3.2.3
3.2.4
3.2.5
3.2.6
PITS AND TRENCHES GENERALLY ..................................................................... 2

Pit and Trench Dimensions
2
Contaminated Ground
2
Groundwater
3
Protection to Pits and Trenches Left Open
3
Backfilling and Restoration
3
Photographs
3
3.3
3.3.1
3.3.2
3.3.3
INSPECTION PITS .................................................................................................. 3

Excavation Method
3
Services
3
Sidewall Stability
4
3.4
3.4.1
3.4.2
3.4.3
3.4.4
TRIAL PITS AND TRENCHES ................................................................................ 4

Excavation Method
4
Services
4
Sidewall Stability
4
Trial Pits Examination
4
3.5
3.5.1
3.5.2
3.5.3
OBSERVATION PITS AND TRENCHES ................................................................. 4

Excavation Method
4
Services
5
Sidewall Stability
5
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QCS 2014

Part
Page 2
PITS AND TRENCHES
3.1
GENERAL
3.1.1
Scope
Inspection pits, trial pits and trenches, observation pits and trenches.

This Section
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Section 1, ....... General

Section 4, ....... Foundations and Retaining Structures
Section 6, ....... Roadworks
Section 8, ....... Drainage Works
Section 12, ..... Earthworks Related to Buildings.
Part 1, .............. General
References
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3.1.2
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BS 5930 ...................... Code of practice for site investigations
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Purposes
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Government.
Quality Assurance
Trial pits and trenches and observation pits and trenches shall be examined and described
by a geotechnical person meeting the requirements of Part 1 Clause 1.5 Paragraph 5 Item
(c) and photographed, if required.
3.2
PITS AND TRENCHES GENERALLY
3.2.1
Unless otherwise designated
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3.1.3
2.
(a)
Trial pits and observation pits shall have a minimum base area of 1.5 m
(b)
Trial trenches and observation trenches shall not be less than 1 m wide.
3.2.2
Contaminated Ground
Ground that is suspected of being contaminated shall be described by an environmental or

geotechnical person, as appropriate, meeting the requirements of Part 1 Clause 1.5
Paragraph 5 Item (c).
QCS 2014

Part
Page 3
Groundwater
The Contractor shall divert surface water runoff from entering pits and trenches.
Groundwater shall be controlled by the use of wellpoints or sump pumps to permit continuous
work if required.
3.2.4
Where pits and trenches are required to be left open and unattended, the Contractor shall
provide fencing together with all necessary lighting and signing.
Precautions shall be taken to protect the pits and trenches from the adverse effects of
weather during this period.
3.2.5
Pits and trenches shall be backfilled as soon as practicable and reinstated to their original
condition.
The backfill shall be placed in lifts of 150 mm thickness and compacted in such a manner as
to minimise any subsequent settlement of the ground surface.
The use of sand backfill compacted by flooding may be permitted, but this method requires
the approval of the Engineer.
In paved areas, the pavement shall be restored.
3.2.6
Photographs
In addition to the requirements of Part 1, photographs shall clearly show details of the ground
conditions in the pit and trench with any support in place and shall contain a graduated scale.
Material derived from the excavation shall be photographed, when directed by the Engineer.
Artificial lighting shall be used where necessary.
Unless directed otherwise by the Engineer, three photographs will normally be required at
every pit and trench.
3.3
INSPECTION PITS
3.3.1
Excavation Method
Inspection pits for the location of underground services shall be excavated by hand to a
depth of 1.2 m unless otherwise designated.
Hand-operated power tools may be used to assist excavation where necessary.
3.3.2
Services
The locations, depths and dimensions of all services encountered shall be measured and
recorded in the daily report with other designated information.
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3.2.3
QCS 2014

Part
Page 4
Sidewall Stability
Due care shall be exercised to ensure the stability of the sides of the excavation at all times.
3.4
TRIAL PITS AND TRENCHES
3.4.1
Excavation Method
Trial pits and trenches shall be excavated by hand to a maximum depth of 1.2 m or by
machine to the required depth to enable visual examination and sampling from outside the pit
or trench as required.
Where dewatering is required, the pumping equipment used shall be adequate to lower the
water table to the required level.
3.4.2
Services
3.4.3
Sidewall Stability
Excavations deeper than 1.2 m shall be braced if necessary.
3.4.4
All recovered materials from the Trial Pits shall be examined in accordance with BS 5930 or
ASTM D 2488 and the recommendations of the Engineering Group of the Geological Society
Working Party.
Disturbed samples shall be obtained from the trial pits for laboratory testing and geological
description purposes. The samples shall be taken to be representative of the actual site
conditions (i.e. from each layer) and placed in airtight bags, labeled and taken to laboratories
for examination and testing.
Color photographs shall be taken for each excavated trial pit with a metric scale laid into the
pit after cleaning it, indicating the pits details such as trial pit number, date and depth.
3.5
OBSERVATION PITS AND TRENCHES
3.5.1
Excavation Method
Observation pits and trenches shall be excavated by hand or machine and shall be
adequately supported to enable personnel to enter safely and to permit in-situ examination,
soil sampling and testing as required. In areas where dewatering is required, the equipment
and methods proposed must be approved by the Engineer before beginning the work.
All recovered materials from the pit/trench shall be examined in accordance with BS 5930 or
ASTM D 2488.
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3.3.3
QCS 2014

Part
Page 5
Disturbed samples shall be obtained for laboratory testing and geological description
purposes (if required). The samples shall be taken to be representative of the actual site
Color photographs shall be taken for each excavated pit with a metric scale laid into the pit
after cleaning it, indicating the pits details such as trial pit number, date and depth.
3.5.2
Services
3.5.3
Sidewall Stability
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END OF PART
QCS 2014

Part
04: Soil Sampling
Page 1
SOIL SAMPLING ..................................................................................................... 2
4.1
4.1.1
4.1.2
GENERAL ............................................................................................................... 2
Scope
2
References
2
4.2
4.2.1
4.2.2
4.2.3
4.2.4
4.2.5
SAMPLING GENERALLY ........................................................................................ 2

Sampling and Testing Frequency
2
Recording depths of samples
3
Description of samples
3
Labelling, Protection and Transportation of Samples
3
Retention and Disposal of Samples
3
4.3
4.3.1
4.3.2
4.3.3
4.3.4
SOIL SAMPLES....................................................................................................... 3
Small Disturbed Samples
3
Bulk Disturbed Samples
3
Open Tube and Piston Samples
4
Standard Penetration Test Samples
4
4.4
GROUNDWATER SAMPLES .................................................................................. 4
4.5
SAMPLES OF SUSPECTED CONTAMINATED GROUND, GROUNDWATER AND

LEACHATE FOR CHEMICAL ANALYSIS ................................................................ 4
4.6
GAS SAMPLING...................................................................................................... 5
4.7
SPECIAL SAMPLING .............................................................................................. 5
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QCS 2014

Part
04: Soil Sampling
Page 2
SOIL SAMPLING
4.1
GENERAL
4.1.1
Scope
Taking of samples of soil, groundwater, gas and contaminants. Sample handling,

transportation, storage, retention and disposal.

This Section
References
The following documents are referred to in this Part:
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Part 1, .............. General

Part 2, .............. Boreholes
Part 3, .............. Pits and Trenches.
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Purposes
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BS 5930 ......................Code of practice for site investigations
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BSI DD 175 ..............Code of practice for the identification of potentially contaminated land
and its investigation (draft for development).
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BS EN 1997--- ............ Ground Investigation and testing
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ICE et al, Soil Investigation Steering Group (SISG) Publication, Soil investigation in
construction, Part 4, Guidelines for the safe investigation by drilling of landfills and
contaminated land, Thomas Telford, (1993).
SAMPLING GENERALLY
4.2.1
The frequency of sampling and in-situ testing is dependent on the ground conditions. In the
absence of designated requirements the intervals observed shall be as follows:
4.2
(a)
(b)
in boreholes
(i)
first open tube sample (generally in clay soils) or standard penetration test
(SPT) (generally in granular soils) at 0.5 m depth, the next at 1.0 m depth,
thereafter at 1 m intervals to 5 m depth then at 1.5 m intervals.
(ii)
small disturbed samples shall be taken from the topsoil, at each change in soil
(iii)
type or consistency and midway between successive open tube samples or

SPTs.
(iv)
Bulk disturbed samples shall be taken of each soil type.
in pits and trenches
QCS 2014

Part
04: Soil Sampling
Page 3
(i)
Small disturbed samples shall be taken of the topsoil, at each change in soil
type or consistency and between successive bulk disturbed samples.
(ii)
Bulk disturbed samples shall be taken at 1 m depth intervals, with at least one
large bulk disturbed sample of each soil type.
The depths below ground level at which samples are taken shall be recorded. For open tube
and piston samples the depth to the top and bottom of the sample, and the length of sample
obtained shall be given. For bulk samples the limits of the sampled zone shall be recorded.
4.2.3
All samples shall be examined and described by a geotechnical person meeting the
requirements of Part 1, Clause 1.3.1, Paragraph 5 Item (c) in accordance with BS 5930.
Samples of suspected contaminated ground and leachate shall be described by an
environmental or geotechnical person meeting the requirements of Part 1, Clause 1.5,
Paragraph 5 Item (c) in accordance with DD 175. Descriptions shall include colour and smell
with reference to specific inclusions.
4.2.4
Samples shall be clearly labelled in accordance with BS 5930. Samples of fill, groundwater,
leachate or contaminated ground suspected to be toxic or hazardous shall be tagged with a
red label.
Samples shall be protected from direct heat and sunlight.
Samples shall be transported to the Contractor's premises. Where required by the Engineer,
selected samples shall be delivered to the designated address.
4.2.5
Samples shall be kept for the designated period after submission of the approved final report.
This period shall not exceed three months, unless specifically designated otherwise. The
Contractor shall ultimately dispose of all samples other than those delivered to the
designated address.
4.3
SOIL SAMPLES
4.3.1
Small disturbed samples shall weigh not less than 0.5 kg. They shall be placed immediately
in airtight containers, which they should sensibly fill.
4.3.2
Bulk disturbed samples shall be representative of the zone from which they have been taken.
Normal bulk disturbed samples shall weigh not less than 10 kg.
Large bulk disturbed samples shall weigh not less than 30 kg.
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4.2.2
QCS 2014

Part
04: Soil Sampling
Page 4
Open tube and piston samples shall be taken using the sampling equipment and procedures
as described in BS 5930. The diameter shall be 100 mm unless otherwise designated.
Before an open tube or piston sample is taken, the bottom of the hole shall be carefully
cleared of disturb materials and where a casing is being used the sample shall be taken
below the bottom of the casing. Following a break in the work exceeding one hour, the
borehole shall be advanced by 250 mm before open tube or piston sampling is resumed.
Where an attempt to take an open tube or piston sample is unsuccessful the hole shall be
cleaned out for the full depth to which the sampling tube has penetrated and the recovered
soil saved as a bulk disturbed sample. A fresh attempt shall then be made from the level of
the base of the unsuccessful attempt. Should this second attempt also prove unsuccessful
the Contractor shall agree with the Engineer as to alternative means of sampling.
The samples shall be sealed immediately to preserve their natural moisture content and in
such a manner as to prevent the sealant from entering any voids in the sample.
Soil from the cutting shoe of an open tube shall be retained as an additional small disturbed
sample.
4.3.4
When a standard penetration test (SPT) is made, the sample from the split barrel sampler
shall be retained as a small disturbed sample.
4.4
GROUNDWATER SAMPLES
Groundwater samples shall be taken from each exploratory hole where groundwater is
encountered. Where more than one groundwater level is found, each one shall be sampled
separately. Where water has been previously added, the hole shall be bailed out before
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4.3.3
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sampling so that only groundwater is present. The sample volume shall be not less than 0.25
l.
SAMPLES OF SUSPECTED CONTAMINATED GROUND,

GROUNDWATER AND LEACHATE FOR CHEMICAL ANALYSIS
Samples of suspected contaminated ground, groundwater and leachate shall be taken in

accordance with DD 175 and the SISG publication under the supervision of an environmental
or geotechnical person meeting the requirements of Part 1, Clause 1.5, Paragraph 5 Item (c).
The size and type of sample and container, method of sampling and time limitations for
carrying out specific analyses shall be commensurate with the range of analyses to be
carried out or as designated.
4.5
QCS 2014

Part
04: Soil Sampling
Page 5
GAS SAMPLING
Samples of gas for chromatographic analysis shall be obtained from exploratory holes or
standpipes in accordance with DD 175 and the SISG publication. The sampling method shall
relate to the volume of gas available and the type of laboratory analysis. The sampler
receptacle shall be airtight and may include lockable syringes, Teflon-lined bags or gas
bombs.
4.7
SPECIAL SAMPLING
The Engineer may require special sampling. This work will normally require supervision on
site by a geotechnical person and shall be carried out in accordance with BS 5930 or as
designated.
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END OF PART
QCS 2014

Part
05: In-Situ Testing, Instrumentation and Monitoring
Page 1
IN-SITU TESTING, INSTRUMENTATION AND MONITORING............................... 2
5.1
5.1.1
5.1.2
GENERAL ............................................................................................................... 2
Scope
2
References
2
5.2
5.2.1
5.2.2
TESTING, INSTRUMENTATION AND MONITORING GENERALLY ...................... 2

Testing
2
Instrumentation and Monitoring
3
5.3
5.3.1
5.3.2
5.3.3
5.3.4
5.3.5
5.3.6
TESTS ..................................................................................................................... 3
Tests in accordance with BS 1377 or BS EN 1997
3
Tests in accordance with BS 5930
4
Geophysical Methods of Investigation
4
Special In-Situ Testing
4
Hand Penetrometer and Hand Vane for Shear Strength
5
Self-boring Pressuremeter
5
5.4
5.4.1
5.4.2
5.4.3
INSTRUMENTATION AND MONITORING .............................................................. 6

Groundwater
6
Installation of Standpipes and Piezometers
6
Installation of Gas Monitoring Standpipes
6
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IN-SITU TESTING, INSTRUMENTATION AND MONITORING
5.1
GENERAL
5.1.1
Scope
Testing of soils in place, and provision of instrumentation and monitoring of groundwater and
subsurface gases.

This Section
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Part 1 ............... General

Part 2 ............... Boreholes
Part 3 ............... Pits and Trenches.
References
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5.1.2
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Purposes
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BS 1377......................Methods of tests for soils for civil engineering purposes

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BS 7022......................Geophysical logging of boreholes for hydrogeological purposes
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The Geological Society Engineering Group Working Party Report on Engineering

Geophysics, Quarterly Journal of Engineering Geology, 21, pp. 207-271, 1988.
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Clarke B.G. and Smith A., A model specification for radial displacement measuring
pressuremeters, Ground Engineering, Volume 25, No. 2, March, 1992.
TESTING, INSTRUMENTATION AND MONITORING GENERALLY
5.2.1
Testing
The following information shall be submitted for each test record to be included in the daily
report, preliminary log and factual report:
5.2
(a)
Date of test.
(b)
Project name, exploratory hole number and location.
(c)
Depth and location of test or depths covered by test.
(d)
Information on water levels in exploratory hole during testing.
(e)
Original ground level at test site.
(f)
Soil type and description as identified from the sample.
All results shall be reported in SI units.
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Page 3
Where load, displacement or other measuring equipment is used which necessitates regular
calibration, then this shall be carried out in accordance with the relevant standard (the
preferred method) or the manufacturer's instructions, by a calibration service approved by the
Central Materials Laboratory. Evidence of calibrations and copies of calibration charts shall
be supplied to the Engineer prior to commencing work and when otherwise requested.
5.2.2
The top of each standpipe, gas monitoring standpipe and piezometer tube shall be protected
by a cover. The type of protective cover shall be approved by the Engineer.
When instructed by the Engineer, the Contractor shall install a protective fence around the
top of a standpipe or piezometer. The fence shall be constructed of corrosion treated angle
iron, galvanised wire, and corrosion resistant wire mesh fencing suitable for use in the
climate of Qatar or a fence as a agreed upon with the Engineer.
Daily readings of depths to water in groundwater monitoring standpipes and piezometers

shall be made by the Contractor, with an instrument approved by the Engineer.
Where the presence of gas is suspected or when directed by the Engineer, gas
measurements, using an approved in-situ meter, shall be made by the Contractor during
construction of exploratory holes and in gas monitoring standpipes. The depth to water and
barometric pressure shall be measured immediately after each gas measurement.
Unless otherwise designated, piezometers, and standpipes protection shall not be removed
from the site.
Other instrumentation and monitoring shall be carried out as designated.
5.3
TESTS
5.3.1
The following in-situ tests shall be carried out and reported in accordance with BS 1377 or
BS EN 1997:
in-situ density by
(a)
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(i)
Small pouring cylinder method.
(ii)
Large pouring cylinder method.
(iii)
Water replacement method.
(iv)
Core cutter method.
(v)
Nuclear method.
(b)
Static cone penetration test (CPT), capacity to suit scheduled depths unless otherwise
designated
(c)
Dynamic probing (DPH or DPSH).
(d)
Standard penetration test (SPT).
(e)
Plate loading test.
(f)
Shallow pad maintained load test.
QCS 2014

Part
(g)
California bearing ratio (CBR).
(h)
Vane shear strength.
(i)
Apparent resistivity of soil.
(j)
Redox potential.
(k)
Pressurementer or Self-boring Pressuremeter (PMT)
(l)
Pocket Penetrometer.
Page 4
5.3.2
The following in-situ tests shall be carried out where applicable and reported in accordance
with BS 5930:
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Constant head permeability test.

Variable head permeability test.
Packer permeability test.
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(a)
(b)
(c)
Geophysical testing shall be carried out as designated. The Contractor shall submit to the
Engineer a full description of equipment and procedure for each geophysical method
required.
The equipment and procedure, and information to be submitted for the following geophysical
methods of investigation, shall be as described in BS 5930, BS 7022 and the Geological
Society Engineering Group Working Party Report on Engineering Geophysics:
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electrical resistivity method
(b)
seismic refraction and reflection method
(c)
magnetic method
(d)
gravity method
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(a)
(i)
Ground conductivity.
(ii)
Transient electromagnetic.
(iii)
Ground probing radar (optional).
(f)
Borehole geophysical logging.
(g)
Cross-hole seismic method.
(h)
Multi Channel Analysis of Surface Waves (MASW)
(i)
Refraction Microtremor (ReMi)
5.3.4
Special in-situ testing shall be carried out as designated.
The Contractor shall allow for the excavation of boreholes, trenches or trial pits necessary for
the execution of inspection tests.
QCS 2014

Part
Page 5
Inspection tests shall be decided as directed by the Engineer. These tests shall include but
not limited to those in Table 3.2.
Table 3.2: Quality Assurance Tests for Completed Work
Recommended Test per Layer
Deep Fill
(boreholes)
In-situ CBR
Field density
Plate load Test
Layer Thickness
Field density
DCP Test
Layer Thickness
SPT
DCP Test
Pressure meter
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(trench or test pit)
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Large Scale Loading

Hand penetrometer and hand vane tests shall be carried out where required to give a
preliminary estimate of undrained shear strength of the soil tested.
Hand (or pocket) penetrometer equipment shall be of an approved proprietary make with
2
stainless steel tip of end area 31 mm with an engraved penetration line 6 mm from the tip.
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5.3.5
Hand vane equipment shall be of an approved proprietary make with stainless steel vanes
having a length of 19 mm or 33 mm and a length-to-diameter ratio of 2:1. The scale shall be
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The scale shall be suitably graduated. The procedure for the test shall be in accordance with
the manufacturer's instructions. Both unconfined compressive strength and estimated shear
strength shall be reported for the soil tested.
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suitably graduated. The procedure for test shall be in accordance with BS 5930 and the
manufacturer's instructions. Peak shear strength and residual shear strength shall be
recorded.
4
The reported shear strengths for the hand penetrometer and handvane shall be the average
of 3 tests in close proximity. Tests giving inconsistent results shall be reported and
comments on the relevance of the tests noted.
5.3.6
The equipment shall be of the Cambridge type (soft ground) self-boring pressuremeter (SBP)
unless otherwise designated. The instruments, calibration, operator, installation, testing
procedure, on-site data processing and analysis, information to be submitted, report data
processing and analysis and information to be submitted in the report shall be as described
by Clarke and Smith (1992) and as designated..
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Page 6
5.4
INSTRUMENTATION AND MONITORING
5.4.1
Groundwater
When groundwater is encountered in exploratory holes, the depth from ground level of the
point of entry shall be recorded together with depth of any casing. Exploratory hole
operations shall be stopped and the depth from ground level to water level recorded with an
approved instrument at 5 minutes intervals for a period of 20 minutes. If at the end of the
period of 20 minutes the water level is still rising, this shall be recorded together with the
depth to water below ground level, unless otherwise instructed by the Engineer, and the
exploratory hole shall then be continued. If casing is used and this forms a seal against the
entry of groundwater, the Contractor shall record the depth of casing at which no further entry
or only insignificant infiltration of water occurred.
Water levels shall be recorded as required by the Contract and at the beginning and end of
each shift. On each occasion when groundwater levels are recorded, the depth of the
exploratory hole, the depth of any casing and the time shall also be recorded.
Where artesian conditions are encountered, the Contractor shall immediately inform the
Engineer and agree a method for dealing with the conditions.
5.4.2
Standpipes for monitoring groundwater levels and changes in groundwater levels shall be
installed in exploratory holes, as instructed by the Engineer. They shall be to the designated
form and detail, and appropriate dimensions and depths shall be recorded at the time of
installation.
Standpipe piezometers for monitoring groundwater levels in exploratory holes shall be

installed as instructed by the Engineer. They shall be to the designated form and detail, and
appropriate dimensions. The installation details of the standpipe piezometers shall be
recorded.
The Contractor shall install piezometers of the hydraulic, electrical or pneumatic type
described in BS 5930 or as designated by the Engineer.
5.4.3
Standpipes for monitoring gas concentration in exploratory holes shall be installed as

instructed by the Engineer. Warning signs or other safety measures required by the Civil
Defence Department of the Government shall be complied with. Standpipes shall be of the
designated form and detail. All dimensions and depths shall he recorded at the time of
installation.
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END OF PART
QCS 2014

Part
06: Laboratory Testing
Page 1
LABORATORY TESTING ........................................................................................ 2
6.1
6.1.1
6.1.2
GENERAL ............................................................................................................... 2
Scope
2
References
2
6.2
SCHEDULE OF TESTS ........................................................................................... 2
6.3
6.3.1
6.3.2
6.3.3
6.3.4
TESTING PROCEDURES ....................................................................................... 3

General
3
Geotechnical Testing on Contaminated Samples
3
Soil Testing
3
Rock Testing
3
6.4
6.4.2
6.4.3
CHEMICAL TESTING FOR CONTAMINATED GROUND ....................................... 4

Laboratory Testing On Site
6
Special Laboratory Testing
6
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Page 2
LABORATORY TESTING
6.1
GENERAL
6.1.1
Scope
Geotechnical tests and testing procedures carried out in the laboratory or, when designated,
on site.

This Section
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Part 1, .............. General

Part 3, .............. Soil Sampling
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References
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6.1.2
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Purposes
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ASTM SP 402.............Special Technical Publications No. 402
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BS 1377 ......................Methods of tests for soils for civil engineering purposes

BS 1881 ......................Analysis of hardened concrete
BS 812 ........................Testing aggregates
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BS EN 1997--------- .....Ground Investigation and testing
Brown E.T. (Editor). Rock characterisation testing and monitoring. International Society for
Rock Mechanics Suggested Methods. 1981. Pergamon Press.
C2 through C25 and C27 through C31, Methods for examination of waters and associated
materials, HMSO
IRSM Commission on Testing Methods. Suggested method for determining Point Load
Strength (revised version). Int. J. Rock Mech. Min. Sci. and Geomech. Abst., 22,
51-60 (1985).
6.2
SCHEDULE OF TESTS
The Contractor shall prepare a schedule of tests for approval by the Engineer. It may be
necessary to designate additional testing after the results of the original tests are available.
Unless otherwise agreed, testing schedules are to be provided within six working days of the
receipt by the Engineer of the relevant preliminary logs. The Contractor shall inform the
Engineer within six working days from the receipt of the approved testing schedule if a
sample referred to in the schedule is not available for testing.
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Page 3
TESTING PROCEDURES
6.3.1
General
Where applicable, all preparation, testing and reporting shall be in accordance with the
relevant Qatar National Standard or British Standards or ASTM Standards. Where tests are
not covered by these Standards, they shall be performed in accordance with the procedures
in the references or as designated.
Calibration of load-displacement or other measuring equipment shall be carried out in

accordance with the relevant standard (the preferred method) or the manufacturers
instructions by a calibration service approved by the Central Materials Laboratory. Evidence
of current calibrations shall be supplied to the Engineer.
6.3.2
Where geotechnical testing is required on samples of suspected contaminated material,

indicative chemical testing shall be carried out and a safe method of working approved by the
Engineer before any such work is started. It should be noted that this may include but is not
limited to the safe storage, transportation and handling of all suspect material.
6.3.3
Soil Testing
Soil testing shall be carried out and reported in accordance with BS 1377 or ASTM Standards
unless otherwise designated.
6.3.4
Rock Testing
Rock testing shall be carried out and reported in accordance with the following references
and as designated:
Classification.
Natural water content - Brown (1981).
(ii)
Porosity/density - Brown (1981).
(iii)
Void index - Brown (1981).
(i)
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(b)
(c)
(d)
(iv)
Carbonate content - BS 1881.
(v)
Petrographic description -Brown (1981).
Durability.
(i)
Slake durability index - Brown (1981).
(ii)
Soundness by solution of magnesium sulphate - BS 812.
Hardness.
(i)
Shore sclerometer -Brown (1981).
(ii)
Schmidt rebound hardness - Brown (1981).
Aggregates.
(i)
Aggregate crushing value - BS 812.
(ii)
Ten percent fines - BS 812.
(iii)
Aggregate impact value - BS 812.
(iv)
Aggregate abrasion value - BS 812.
(v)
Polished stone value - BS 812.
(vi)
Aggregate frost heave - BS 812.
Strength.
(i)
Uniaxial compressive strength - Brown (1981).
(ii)
Deformability in uniaxial compression -Brown (1981).
(iii)
Tensile strength-Brown (1981).
Direct tensile strength.

Indirect tensile strength by the Brazilian method.
Undrained triaxial compression without measurement of porewater pressureBrown (1981).
(v)
Direct shear strength - Brown (1981).
(vi)
Swelling pressure - Brown (1981).
(vii)
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Swelling pressure index under conditions of zero volume change.

Swelling strain index for a radially confined specimen with axial surcharge.
Swelling strain developed in an unconfined rock specimen.
Point load test - IRSM Commission on Testing Methods (1985).
Geophysical.
Seismic velocity-Brown (1981).
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(i)
(iv)
(f)
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QCS 2014
CHEMICAL TESTING FOR CONTAMINATED GROUND
Chemical testing for contaminated ground shall be carried out and reported in accordance
with the following references and as designated:
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Primary contaminants in soil.

Arsenic total - C4.
(ii)
Cadmium total - C2.
(iii)
Chromium total - C2.
(iv)
hexavalent chromium (undertaken if total chromium content >25 mg/kg dry
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Mass) -C2.
(v)
Lead total - C2.
(vi)
Mercury total - C3.
(vii)
Selenium total - C4.
(viii)
Boron, water-soluble - C5.
(ix)
Copper total - C2.
(x)
Nickel total - C2.
(xi)
Zinc total - C2.
(xii)
Cyanide total (alkali extraction methods) - C6.
(xiii)
Cyanide complex - C6.
(xiv) Cyanide free - C6.

(xv)
Thiocyanate - C6.
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(xvi) (Tests xiii, xiv and xv undertaken if total cyanide >25 mg/kg dry mass. Methods
shall follow alkali extraction.)
(xvii) Phenols total - C7.
(xviii) Sulphide - C8.
(xix) Sulphate - total, acid, soluble - C9.
(xx)
Sulphate - water soluble, 2 : 1 extract - C9.
(xxi) Sulphur free - C10.

(xxii) PH value - C9.
(xxiii) Toluene extractable matter - Cl1.
(xxiv) Coal tar/polyaromatic hydrocarbons (undertaken if toluene extractable matter>

2000 g/kg dry mass of soil) - C12.
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Antimony total - C13.
(ii)
Barium total - C13.
(iii)
Beryllium total - C15.
(iv)
Vanadium total - C13.
(v)
Cyclohexane extractable matter - C14.
(vi)
Freon extractable matter - C15.
(vii)
Mineral oils - C31.
(viii)
Chloride - C9.
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(i)
Contaminants in water.
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(c)
Secondary contaminants in soil.
(i)
Arsenic - C4.
(ii)
Cadmium - C2 and C23.

Chromium - C2 and C24.
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(iii)
(b)
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(xxv) Asbestos. Asbestos content determination shall be carried out by visual

examination and polarised light microscopy.
Hexavalent chromium - C2.
(v)
Lead - C2 and C25.
(vi)
Mercury - C3.
(vii)
Selenium - C4.
(viii)
Boron - C5 and C6.
(ix)
Copper - C2 and C27.
(x)
Nickel - C2 and C28.
(xi)
Zinc - C2 and C29.
(xii)
Cyanide total - C6.
(xiii)
(xiv)
Cyanide free - C6.
(xv)
Thiocyanate - C6.
(xvi)
Phenols total - C7.
(xvii)
Sulphide - C8.
(iv)

Part
Page 6
Sulphate - C9.
(xix)
Sulphur free - C10.
(xx)
PH value - C9.
(xxi)
Polyaromatic hydrocarbons - C 12.
(xxii)
Antimony-C13.
(xxiii)
Barium-C13.
(xxiv)
Beryllium-C15.
(xxv)
Vanadium - C 13.
(xxvi)
Chloride - C9.
(xxvii)
Ammoniacal nitrogen - C16.
(xxviii)
Nitrate nitrogen - Cl7.
(xxix)
Chemical oxygen demand - C18.
(xxx)
Biochemical oxygen demand - C19.
(xxxi)
Total organic carbon - C20.
(xxxii)
Volatile fatty acids - C21.
(xxxiii)
Iron - C22.
(xxxiv)
Manganese - C22.
(xxxv)
Calcium - C31.
(xxxvi)
Sodium - C31.
(xxxvii)
Magnesium - C31.
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Constituents of gas samples.

Carbon dioxide - C30.
(ii)
Hydrogen - C30.
(iii)
Hydrogen sulphide - C30.
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(xxxviii) Potassium - C21.
Methane - C30.
(v)
Nitrogen - C30.
(vi)
Oxygen - C30.
(vii)
Ethane- C30.
(viii)
Propane- C30.
(ix)
Carbon monoxide - C30.
(iv)
6.4.2
When designated, tests listed under laboratory testing shall be carried out on site.
6.4.3
When designated, special laboratory testing shall be carried out.

END OF PART
QCS 2014
Section 04: Foundations and Retaining Structures

Part
01: General Requirements for Piling Work
Page 1
GENERAL REQUIREMENTS FOR PILING WORK ................................................. 2
1.1
1.1.1
1.1.2
1.1.3
1.1.4
1.1.5
GENERAL ............................................................................................................... 2
Scope
2
References
2
General Contract Requirements
2
Submittals
3
Records
3
1.2
1.2.1
1.2.2
GROUND CONDITIONS ......................................................................................... 3

Ground Investigation Reports
3
Unexpected Ground Conditions
4
1.3
1.3.1
1.3.2
1.3.3
MATERIALS AND WORKMANSHIP........................................................................ 4

General
4
Sources of Supply
4
Rejected materials
5
1.4
1.4.1
1.4.2
1.4.3
1.4.4
1.4.5
1.4.6
INSTALLATION TOLERANCES .............................................................................. 5

Setting Out
5
Position
6
Verticality
6
Rake
6
Tolerance Variations
6
Forcible Corrections to Pile
6
1.5
1.5.1
1.5.2
1.5.3
1.5.4
NUISANCE AND DAMAGE ..................................................................................... 6

Noise and Disturbance
6
Damage to Adjacent Structures
7
Damage to Piles
7
Temporary Support
7
1.6
1.6.1
1.6.2
1.6.3
SAFETY .................................................................................................................. 7
General
7
Life-Saving Appliances
7
Driving
7
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Page 2
GENERAL REQUIREMENTS FOR PILING WORK
1.1
GENERAL
1.1.1
Scope
This Part is concerned with all works associated with installation of piles by any of the
recognised techniques.
1.1.2
References
The following standards and codes of practice are referred to in this Part:
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BS 5228......................Noise control on construction and open sites
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Part I, Code of practice for basic information and procedures for noise
control
Part IV, Code of practice for noise and vibration control applicable to
piling operations
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BS 8008......................Safety precautions and procedures for the construction and descent of

machine-bored shafts for piling and other purposes
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BS EN 1997................Eurocode 7, Geotechnical Design.
The following matters, where appropriate, are described in the contract specific
documentation for the Works:
general items related to Works
Nature of the Works.
(ii)
Classes of loads on piles.
(iii)
Contract drawings.
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1.1.3
(b)
(iv)
Other works proceeding at the same time.
(v)
Working area.
(vi)
Order of the Works.
(vii)
Datum.
(viii)
Offices for the Engineer's Representative.
(ix)
Particular facilities and attendance items where not included in this section.
(x)
Details of soil investigation reports.
specific items related to particular type of pile

(i)
Soil sampling, laboratory testing and in-situ soil testing.
(ii)
Designed concrete or grout mixes, grades of concrete or grout, type of cement

and aggregate, grout or concrete admixtures, concreting of piles.

Part
Page 3
Grades and types of reinforcement and prestressing tendons.
(iv)
Pile dimensions, length and marking of piles.
(v)
Type and quality of pile shoe/splice.
(vi)
Type and quality of permanent casing.
(vii)
Specified working loads.
(viii)
Sections of proprietary types of pile, grades of steel, minimum length to be

supplied, thickness of circumferential weld reinforcement.
(ix)
Surface preparation, types and thickness of coatings.
(x)
Test piles, driving resistance or dynamic evaluation and penetration.
(xi)
Detailed requirements for driving records.
(xii)
Acceptance criteria for piles under test.
(xiii)
Disposal of cut-off lengths.
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QCS 2014
(xiv) Preboring.
Submittals
The Contractor shall supply for approval all relevant details of the method of piling and the
plant he proposes to use. Any alternative method to that specified shall be subject to
approval.
The Contractor shall submit to the Engineer on the first day of each week, or at such longer
periods as the Engineer may from time to time direct, a progress report showing the current
rate of progress and progress during the previous period on all important items of each
section of the Works.
The Contractor shall inform the Engineer each day of the intended programme of piling for
the following day and shall give adequate notice of his intention to work outside normal hours
and at weekends.
1.1.5
Records
The Contractor shall keep records, as indicated by an asterisk in Table 1.1, of the installation
of each pile and shall submit two signed copies of these records to the Engineer not later
than noon of the next working day after the pile is installed. The signed records will form a
record of the work. Any unexpected driving or boring conditions shall be noted briefly in the
records.
1.2
GROUND CONDITIONS
1.2.1
Factual information and reports on site investigations for the Works and on the previous
known uses of the Site will be provided by the Engineer where they exist as part of the
specific contract documentation. However, even if a full report is given, including
interpretations, opinions or conclusions, no responsibility is accepted by the Engineer for any
opinions or conclusions which may be given in the reports.
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1.1.4
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Before the start of work the Contractor shall be given a copy of any subsequent information
which may have been obtained relating to the ground conditions and previous uses of the
Site.
1.2.2
The Contractor shall report immediately to the Engineer any circumstance which indicates
that in the Contractor's opinion the ground conditions differ from those reported in or which
could have been inferred from the site investigation reports or test pile results.
1.3
MATERIALS AND WORKMANSHIP
1.3.1
General
All materials and workmanship shall be in accordance with the appropriate British Standards,
codes of practice and other approved standards current at the date of tender except where
the requirements of these standards or codes of practice are in conflict with this Section in
which case the requirements of this Section shall take precedence.
1.3.2
Sources of Supply
The sources of supply of materials shall not be changed without prior approval.
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Table 1.1
Driven segmental
concrete piles
Driven cast-in-place
concrete piles
Bored cast-in-place
concrete piles
Continuous flight
auger concrete or
grout piles
Nominal cross-sectional dimensions or diameter
Nominal diameter of underream/base
Length of preformed pile
Standing groundwater level from direct observation or given site

investigation data.
Date and time of driving, redriving or boring
Date of concreting
Ground level/sea bed level at pile position at commencement of

installation of pile (commencing surface)
Working elevation of pile driver
Depth from ground level at pile position to pile tip
Tip elevation
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Data
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Driven steel, precast

concrete and steel
sheet piles
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Records to be Kept (Indicated by an Asterisk)
Contract
Pile type
Pile reference number (location)
Bored cast-in-place
concrete piles
Continuous flight
auger concrete or
grout piles
Pile head elevation, as constructed
Pile cut-off elevation
Length of temporary casing
Length of permanent casing
Type, weight, drop and mechanical condition of hammer and

equivalent information for other equipment
Number and type of packings used and type and condition of

dolly used during driving of the pile
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Set of pile or pile tube in millimetres per 10 blows or number of

blows per 25 mm of penetration
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Data
concrete piles
Page 5
Driven segmental
concrete piles

Part
concrete and steel
sheet piles
QCS 2014
If required, temporary compression of ground and pile from time

of a marked increase in driving resistance until pile reached its
final level
Soil samples taken and in-situ tests carried out during pile
installation
Length and details of reinforcements
Concrete mix
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If required, the sets taken at intervals during the last 3 m of

driving
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If required, driving resistance taken at regular intervals over the

last 3 m of driving
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Volume of concrete supplied to pile

obstructions
delays
All information regarding

interruptions to the work
and
other
1.3.3
Rejected materials
Rejected materials are to be removed promptly from the Site.
1.4
INSTALLATION TOLERANCES
1.4.1
Setting Out
Setting out of the main grid lines shall be by the Contractor. The installation of marker pins at
pile positions, as required by the Contract, shall be located by the Contractor from the main
grid lines of the proposed structure. Before installation of the pile, the pile position relative to
the main grid lines shall be verified.
QCS 2014

Part
Page 6
Position
For a pile cut off at or above ground level the maximum permitted deviation of the pile centre
from the centre-point shown on the drawings shall be 75 mm in any direction. An additional
tolerance for a pile head cut off below ground level will be permitted in accordance with
Clauses 1.4.3 and 1.4.4.
1.4.3
Verticality
At the commencement of installation, the pile, or pile-forming equipment in the case of a

driven pile, or the relevant equipment governing alignment in the case of the bored pile, shall
be made vertical to a tolerance of within 1 in 100. The maximum permitted deviation of the
finished pile from the vertical is 1 in 75.
1.4.4
Rake
As in clause 1.4.3, the pile, or driving or other equipment governing the direction and angle of
rake shall be set to give the correct alignment of the pile to within a tolerance of 1 in 50. The
piling rig shall be set and maintained to attain the required rake. The maximum permitted
deviation of the finished pile from the specified rake is 1 in 25 for piles raking up to 1:6 and 1
in 15 for piles raking more than 1:6.
1.4.5
In exceptional circumstances where these tolerances are difficult to achieve, the tolerances
of Clauses 1.4.2, 1.4.3 and 1.4.4 may be relaxed by the Engineer, subject to consideration of
the implications of such action.
1.4.6
Forcible corrections to concrete piles to overcome errors of position or alignment shall not be
made. Forcible corrections may be made to other piles only if approved and where the pile
shaft is not fully embedded in the soil.
1.5
NUISANCE AND DAMAGE
1.5.1
The Contractor shall carry out the work in such a manner and at such times as to minimise
noise, vibration and other disturbance in order to comply with current environmental
legislation.
The Contractor shall endeavour to ascertain the nature and levels of noise produced by the
mechanical equipment and plant that will be used. He shall than take steps to reduce either
the level or the annoying characteristics, or both, of the noise. Reference should be made to
BS 5228 Part 1 for prediction of noise level due to different types of mechanical equipment
and plant, and to BS 5228 Part 4 for noise and vibration control techniques applicable to
piling operations.
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1.4.2
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Page 7
If in the opinion of the Contractor, damage will be, or is likely to be, caused to mains, services
or adjacent structures, he shall submit to the Engineer his proposals for making
preconstruction surveys, monitoring movements or vibrations, and minimising or avoiding
such damage.
1.5.3
Damage to Piles
The Contractor shall ensure that during the course of the work, displacement or damage
which would impair either performance or durability does not occur to completed piles.
The Contractor shall submit to the Engineer his proposed sequence and timing for driving or
boring piles, having the intent of avoiding damage to adjacent piles.
1.5.4
Temporary Support
The Contractor shall ensure that where required, any permanently free-standing piles are
temporarily braced or stayed immediately after driving to prevent loosening of the piles in the
ground and to ensure that the pile will not be damaged by oscillation, vibration or ground
movement.
1.6
SAFETY
1.6.1
General
A competent person, properly qualified and experienced, should be appointed to supervise

the piling operations. This person should be capable of recognising and assessing any
potential dangers as they arise; e.g., unexpected ground conditions that may require a
change in construction technique, or unusual smells which may indicate the presence of
noxious or dangerous gases.
Safety precautions throughout the piling operations shall comply with BS 8008 and BS EN
1997. Refer Section 1 for general safety standards to be adopted at a construction site.
1.6.2
The Contractor shall provide and maintain on the Site sufficient, proper and efficient lifesaving appliances to the approval of the Engineer. The appliances must be conspicuous and
available for use at all times.
Site operatives shall be instructed in the use of safety equipment and periodic drills shall be
held to ensure that all necessary procedures can be correctly observed.
1.6.3
Driving
Before any pile driving is started, the Contractor shall supply the Engineer with two copies of
the code of signals to be employed, and shall have a copy of the code prominently displayed
adjacent to the driving control station on the craft, structure or site from which the piles will be
driven.
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1.5.2
END OF PART
QCS 2014

Part
02: Concrete Works for Piling
Page 1
CONCRETE WORKS FOR PILING ......................................................................... 2
2.1
2.1.1
2.1.2
GENERAL ............................................................................................................... 2
Scope
2
References
2
2.2
2.2.1
2.2.2
2.2.3
2.2.4
2.2.5
MATERIALS ............................................................................................................ 2
Cementitious
2
Aggregate
2
Water
2
Admixtures
2
Steel Reinforcement and Prestressing Steel
2
2.3
2.3.1
2.3.2
2.3.3
2.3.4
2.3.5
CONCRETE MIXES FOR PILING WORK ............................................................... 3

General
3
Grade Designation
3
Designed Mix
3
Durability
3
Exposure Classes
3
2.4
2.4.1
2.4.2
2.4.3
2.4.4
2.4.5
2.4.6
2.4.7
PLACING CONCRETE ............................................................................................ 3

General
3
Inspection
4
Cleanliness of Pile Bases
4
Workability of Concrete
4
Compaction
4
Placing Concrete in Dry Borings
5
Placing Concrete under Water or Drilling Fluid
5
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QCS 2014

Part
CONCRETE WORKS FOR PILING
2.1
GENERAL
2.1.1
Scope
This part applies to cast in-situ as well as precast concrete work.
Section 5
Concrete.
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Shallow Foundations
Deep Foundations
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This Section
Part 1,
Part 3
Part 4
Part 5
Page 2
References
The following Standards are referred to in this Part:
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2.1.2
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All Standards mentioned in Section 5
MATERIALS
2.2.1
Cementitious
All cementitious materials shall comply with the requirements of Section 5, Part 3.
All cementitious materials shall be stored in separate containers according to type in

waterproof stores or silos.
2.2.2
Aggregate
Aggregates shall comply with the requirements of Section 5, Part 2.
2.2.3
Water
If water for the Works is not available from a public supply, approval shall be obtained
regarding the source of water. For quality of water refer to Section 5, Part 4.
2.2.4
Admixtures
Admixtures shall comply with the requirements of Section 5, Part 5
2.2.5
Steel reinforcement shall be stored in clean and dry conditions. It shall be clean, and free
from loose rust and loose mill scale when installed in the Works. For requirements of steel
reinforcement refer to Section 5, Part 11.
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2.2
QCS 2014

Part
Page 3
The number of joints in longitudinal steel bars shall be kept to a minimum. Joints in
reinforcement shall be such that the full strength of each bar is effective across the joint and
shall be made so that there is no detrimental displacement of the reinforcement during the
construction of the pile.
For requirements of prestressing steel refer to Section 5, Part 18.
2.3
CONCRETE MIXES FOR PILING WORK
2.3.1
General
For general requirements of concrete mixes, trial mixes, batching, mixing and transportation
of fresh concrete and testing of hardened concrete refer to Section 5.
2.3.2
Grade Designation
Grades of concrete shall be as given in Section 5, Part 6.
2.3.3
Designed Mix
The Contractor shall be responsible for selecting the mix proportions to achieve the required
strength and workability..
Complete information on the mix and sources of aggregate for each grade of concrete and
the water/cementitious ratio and the proposed degree of workability shall be approved before
work commences.
Where low-alkali, sulphate-resisting cement to BS EN 197 is specified, the alkali content

(equivalent sodium oxide) of the cement shall not exceed 0.6 % by weight.
The Contractor shall submit the slump value for approval before work commences.
2.3.4
Durability
For piles exposed to aggressive ground or groundwater, approved measures shall be taken
to ensure durability. Reference shall be made to Section 5, Part 6.
2.3.5
Exposure Classes
The minimum cementitious content and type and the concrete grades shall be specified
based on the exposure classes as given in Table 6.8, Section 5, Part 6.
2.4
PLACING CONCRETE
2.4.1
General
The workability and method of placing and vibrating the concrete shall be such that a
continuous monolithic concrete shaft of the full cross-section is formed.
The concrete shall be placed without such interruption as would produce a cold joint in the
pile. The method of placing shall be approved.
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Part
Page 4
The Contractor shall take all precautions in the design of the mix and placing of the concrete
to avoid arching of the concrete in a temporary casing. No soil, liquid or other foreign matter
which would adversely affect the performance of the pile shall be permitted to contaminate
the concrete.
2.4.2
Inspection
Each pile bore which does not contain standing water or drilling fluid shall be inspected
directly or indirectly before to concrete is placed in it. This inspection shall be carried out from
the ground surface in the case of piles of less than 750 mm diameter. Torches or other
approved means of lighting, measuring tapes, and a means of measuring verticality shall be
provided. For piles of 750 mm diameter or larger, equipment shall be provided by the
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Contractor to enable his representatives and the Engineer to descend into the bore for the
purpose of inspection. Any method of descent and the equipment used shall comply with the
requirements of BS 8008.
On completion of boring and where inspection of a dry pile bore indicates the necessity,
loose, disturbed or softened soil shall be removed from the bore. Where pile bores contain
water or drilling fluid, a cleaning process shall be employed before concrete is placed, or the
concrete shall be placed by tremie method. Large debris or accumulated sediment, or both
of them, shall be removed using appropriate approved methods, which shall be designed to
clean while at the same time minimising ground disturbance below the pile bases. Water or
drilling fluid shall be maintained at such levels throughout and following the cleaning
operation that stability of the bore is preserved.
2.4.4
Slump measured at the time of discharge into the pile bore shall be in accordance with the
standards shown in Table 2.1.
2.4.5
Compaction
Internal vibrators may be used to compact concrete, with the approval of the Engineer
obtained in advance for each specific use.
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2.4.3
Piling mix
workability
Table 2.1
Standards for Concrete Slump
Slump
Minimum
Range
mm
mm
Typical conditions of use
75
75-150
Placed into water-free unlined or permanently lined bore

of 600 mm diameter or over, or where concrete is placed
below temporary casing, and where reinforcement is
widely spaced leaving ample room for free movement of
concrete between bars.
100
100-200
Where reinforcement is not spaced widely, where

concrete is placed within temporary casings, where pile
bore is water-free, and the diameter less than 600 mm
150
150 or more
Where concrete is to be placed by tremie under water or

drilling mud, or by pumping
QCS 2014

Part
Page 5
Approved measures shall be taken to ensure that the structural strength of the concrete
placed in all piles is not impaired through grout loss, segregation or bleeding.
Concrete shall be placed by elephant trunk, and the free fall shall not exceed 1.2 m.
2.4.7
Before placing concrete, measures shall be taken in accordance with Clause 2.4.3 to ensure
that there is no accumulation of silt or other material at the base of the boring, and the
Contractor shall ensure that heavily contaminated bentonite suspension, which could impair
the free flow of concrete from the tremie pipe, has not accumulated in the bottom of the hole.
Concrete to be placed under water or drilling fluid shall be placed by tremie and shall not be
discharged freely into the water or drilling fluid. Pumping of concrete may be approved where
appropriate.
A sample of the bentonite suspension shall be taken from the base of the boring using an
approved sampling device. If the specific gravity of the suspension exceeds 1.20 the placing
of concrete shall not proceed. In this event the Contractor shall modify or replace the
bentonite as approved to meet the specification.
The concrete shall be a rich, coherent mix and highly workable, and cement content shall be
in accordance with Clause 2.3.5.
The concrete shall be placed in such a manner that segregation does not occur.
The hopper and pipe of the tremie shall be clean and watertight throughout. The pipe shall
extend to the base of the bore and a sliding plug or barrier shall be placed in the pipe to
prevent direct contact between the first charge of concrete in the tremie and the water or
drilling fluid. The pipe shall at all times penetrate the concrete which has previously been
placed and shall be withdrawn at a rate such that there shall be a minimum concrete cover of
2 m over the end of the tremie pipe, until completion of concreting. A sufficient quantity of
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2.4.6
concrete shall be maintained within the pipe to ensure that the pressure from it exceeds that
from the water or drilling fluid. The internal diameter of the tremie pipe shall be not less than
150 mm, and the maximum sized aggregate shall be 20 mm. It shall be so designed that
external projections are minimised, allowing the tremie to pass within reinforcing cages
without causing damage. The internal face of the pipe of the tremie shall be free from
projections.
END OF PART
QCS 2014

Part
03: Shallow Foundations
Page 1
SHALLOW FOUNDATIONS .................................................................................... 2
3.1
3.1.1
3.1.2
3.1.3
3.1.4
GENERAL ............................................................................................................... 2
Scope
2
Definition
2
References
2
Limit States Considerations
2
3.2
3.2.1
3.2.2
3.2.3
3.2.4
3.2.5
3.2.6
DESIGN CONSIDERATIONS .................................................................................. 3

General
3
Allowable Bearing Pressure
3
Selection of Types of Shallow Foundation
3
Pad foundations
4
Strip foundations
4
Raft foundations
5
3.3
3.3.1
3.3.2
3.3.3
BASIS OF GEOTECHNICAL DESIGN .................................................................... 5

Design Requirements
5
Design Situations
7
Durability
8
3.4
3.4.1
3.4.2
3.4.3
3.4.4
3.4.5
3.4.6
3.4.7
3.4.8
3.4.9
3.4.10
3.4.11
GEOTECHNICAL DESIGN BY CALCULATION ...................................................... 9

General
9
Actions
10
Ground Properties
12
Geometrical Data
13
Characteristic and Representative Values of Actions
13
Characteristic Values of Geotechnical Parameters
13
Characteristic Values of Geometrical Data
14
Geotechnical Design Report
14
Actions and Design Situations
15
Design and Construction Considerations
15
Foundations on Rock; Additional Design Considerations
16
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QCS 2014

Part
Page 2
SHALLOW FOUNDATIONS
3.1
GENERAL
3.1.1
Scope
The provisions of this Section apply to shallow foundations including isolated, pads, strips and
rafts.
3.1.2
Definition
Shallow foundations are taken to be those where the depth below finished ground level is
less than 3 m and include isolated, pad, strip and raft foundations. The choice of 3 m is
arbitrary; shallow foundations where the depth/breadth ratio is high may need to be designed
as deep foundations.
3.1.3
References
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BS 8004,.....................Code of practice for foundations.
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BS EN 1990................Eurocode 0: Basis of Structural Design

BS EN 1991................Eurocode 1: Actions on structures
BS EN 1992................Eurocode 2: Design of concrete structures -
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BS EN 1993................Eurocode 3: Design of steel structures
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BS EN 1994................Eurocode 4: Design of composite steel and concrete structures

BS EN 1995................Eurocode 5: Design of timber structures
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BS EN 1996................Eurocode 6: Design of masonry structures
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BS EN 1997-1 ............Eurocode 7, Geotechnical design Part 1: General Rules

BS EN 1997-2 ............Eurocode 7, Geotechnical design Part 2: Ground investigation and
testing
BS EN 1998................Eurocode 8: Design of structures for earthquake resistance
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BS 5930......................Code of Practice for Site Investigation

The following limit states shall be considered and an appropriate list shall be compiled:
3.1.4
(a)
Loss of overall stability;
(b)
Bearing resistance failure, punching failure, squeezing;
(c)
Failure by sliding;
(d)
Combined failure in the ground and in the structure;
(e)
Structural failure due to foundation movement;
(f)
Excessive settlements;
(g)
Excessive heave due to swelling, frost and other causes;
(h)
Unacceptable vibrations.
QCS 2014

Part
Page 3
3.2
DESIGN CONSIDERATIONS
3.2.1
General
The depth to which foundations should be carried depends on two principal factors:
(a)
Reaching an adequate bearing stratum;
(b)
Penetration below the zone in which trouble may be expected from seasonal weather
changes.
Other factors such as ground movements, changes in groundwater conditions, long-term

stability and heat transmitted from structures to the supporting ground may be important.
Shallow foundations are particularly vulnerable to certain soil conditions, e.g. loose waterbearing sands and soils that change structure when loaded. Specialist advice should be
sought where such conditions are indicated by ground investigation.
3.2.2
The center of area of a foundation or group of foundations should be arranged vertically

under the centre of gravity of the imposed loading. If this is not possible, the effects on the
structure of rotation and settlement of the foundation need to be considered.
Where foundation support is provided by a number of separate bases these should, as far as
practicable, be proportioned so that differential settlement is minimal.
3.2.3
The selection of the appropriate type of shallow foundation will normally depend on the
magnitude and disposition of the structural loads, the bearing capacity and settlement
characteristics of the ground and the need to found in stable soil.
A pad foundation is used for the purpose of distributing concentrated loads. Unless special
conditions control the design, relatively heavy column loads make it advantageous to use pad
foundations.
Strip foundations may be more appropriate where column loads are comparatively small and
closely spaced or where walls are heavy or heavily loaded.
Adjacent pad foundations can be combined or joined together with ground beams to support
eccentric loads, to resist overturning or to oppose horizontal forces. Walls between columns
may be carried on ground beams spanning between the pad foundations.
Where the allowable bearing pressure would result in large isolated foundations occupying
the majority of the available area, it may be logical to join them to form a raft and spread the
loads over the entire area. The combination of isolated foundations to form a raft sometimes
results in a complex design and a large increase in the reinforcement requirement.
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QCS 2014

Part
Page 4
In connection with the provision of foundations to an extension of an existing building,

allowance should be made for differential movement of the foundations between the new and
existing structure; such movement affects the structure above foundations. Where a degree
of cracking and subsequent remedial work is not acceptable, provision for a joint between the
extension and existing building should be considered. Where the foundations of an extension
about the foundations of the existing building, the stability of the existing foundations should
be ensured.
3.2.4
Pad foundations
For buildings such as low rise dwellings and lightly framed structures, pad foundations may
be of unreinforced concrete provided that the angle of spread of load from the pier or base
plate to the outer edge of the ground bearing does not exceed one (vertical) in one
(horizontal) and that the stresses in the concrete due to bending and shear do not exceed
tolerable limits. For buildings other than low rise and lightly framed structures, it is customary
to use reinforced concrete foundations.
The thickness of the foundation should under no circumstances be less than 150 mm and will
generally be greater than this to maintain cover to reinforcement where provided.
Where concrete foundations are used they should be designed in accordance with the design
method appropriate to the loading assumptions.
3.2.5
Strip foundations
Similar considerations to those for pad foundations apply to strip foundations. On sloping
sites strip foundations should be on a horizontal bearing, stepped where necessary to
maintain adequate depth.
In continuous wall foundations it is recommended that reinforcement be provided wherever

an abrupt change in magnitude of load or variation in ground support occurs. Continuous wall
foundations will normally be constructed in mass concrete provided that the angle of spread
of load from the edge of the wall base to the outer edge of the ground bearing does not
exceed one (vertical) in one (horizontal). Foundations on sloping ground, and where
regarding is likely to take place, may require to be designed as retaining walls to
accommodate steps between adjacent ground floor slabs or finished ground levels. At all
changes of level unreinforced foundations should be lapped at the steps for a distance at
least equal to the thickness of the foundation or a minimum of 300mm. Where the height of
the step exceeds the thickness of the foundation, special precautions should be taken. The
thickness of reinforced strip foundations should be not less than 150mm, and care should be
taken with the excavation levels to ensure that this minimum thickness is maintained. For the
longitudinal spread of loads, sufficient reinforcement should be provided to withstand the
tensions induced. It will sometimes be desirable to make strip foundations of inverted tee
beam sections, in order to provide adequate stiffness in the longitudinal direction. At corners
and junctions the longitudinal reinforcement of each wall foundation should be lapped.
Where the use of ordinary strip foundations would overstress the bearing strata, wide strip
foundations designed to transmit the foundation loads across the full width of the strip may be
used. The depth below the finished ground level should be the same as for ordinary strip
foundations.
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Part
Page 5
Where the nature of the ground is such that narrow trenches can be neatly cut down to the
bearing stratum, an economical foundation may be achieved by filling the trenches with
concrete. When deciding the trench width, account should be taken of normal building
tolerances in relation to setting out dimensions. Where the thickness of such a foundation is
500mm or more, any step should be not greater than the concrete thickness and the lap at
such a step should be at least 1 m or twice the step height, whichever is the greater?
Where fill or other loose materials occur above the bearing stratum adequate support is
required to any excavation. Consideration may be given to the use of lean mix mass concrete
replacement under ordinary strip footings placed at shallow depth. This mass concrete can
be poured against either permanent or recoverable shuttering. This form of foundation
provides a method of dealing with local areas where deeper foundations are required.
3.2.6
Raft foundations
General. Suitably designed raft foundations may be used in the following circumstances.
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For lightly loaded structures on soft natural ground where it is necessary to spread the
load, or where there is variable support due to natural variations, made ground or
weaker zones. In this case the function of the raft is to act as a bridge across the
weaker zones. Rafts may form part of compensated foundations.
(b)
Where differential settlements are likely to be significant. The raft will require special
design, involving an assessment of the disposition and distribution of loads, contact
pressures and stiffness of the soil and raft.
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(a)
BASIS OF GEOTECHNICAL DESIGN
3.3.1
Design Requirements
For each geotechnical design situation it shall be verified that no relevant limit state is
exceeded.
When defining the design situations and the limit states, the following factors should be
considered:
Site conditions with respect to overall stability and ground movements;
(a)
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3.3
(b)
Nature and size of the structure and its elements, including any special requirements
such as the design life;
(c)
Conditions with regard to its surroundings (e.g.: neighboring structures, traffic, utilities,
vegetation, hazardous chemicals);
(d)
Ground conditions;
(e)
Ground-water conditions;
(f)
Regional seismicity;
(g)
Influence of the environment (hydrology, surface water, subsidence, seasonal changes

of temperature and moisture).
Limit states can occur either in the ground or in the structure or by combined failure in the
structure and the ground.
QCS 2014

Part
Page 6
Limit states should be verified by any appropriate method such as calculation method as
described in 3.4;
In practice, experience will often show which type of limit state will govern the design and the
avoidance of other limit states may be verified by a control check.
Buildings should normally be protected against the penetration of ground-water or the

transmission of vapor or gases to their interiors.
If practicable, the design results should be checked against comparable experience.
In order to establish minimum requirements for the extent and content of geotechnical
investigations, calculations and construction control checks, the complexity of each
geotechnical design shall be identified together with the associated risks. In particular, a
distinction shall be made between:
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L ight and simple structures and small earthworks for which it is possible to ensure that
the minimum requirements will be satisfied by experience and qualitative geotechnical
investigations, with negligible risk;
(b)
Other geotechnical structures.
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(a)
For structures and earthworks of low geotechnical complexity and risk, such as defined
above, simplified design procedures may be applied.
10
To establish geotechnical design requirements, three Geotechnical Categories, 1, 2 and 3,

may be introduced.
11
A preliminary classification of a structure according to Geotechnical Category should

normally be performed prior to the geotechnical investigations. The category should be
checked and changed, if necessary, at each stage of the design and construction process.
12
The procedures of higher categories may be used to justify more economic designs, or if the
designer considers them to be appropriate.
13
The various design aspects of a project can require treatment in different Geotechnical
Categories. It is not required to treat the whole of the project according to the highest of these
categories.
14
Geotechnical Category 1 should only include small and relatively simple structures:
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(a)
For which it is possible to ensure that the fundamental requirements will be satisfied on
the basis of experience and qualitative geotechnical investigations;
(b)
With negligible risk.
15
Geotechnical Category 1 procedures should be used only where there is negligible risk in
terms of overall stability or ground movements and in ground conditions, which are known
from comparable local experience to be sufficiently straightforward. In these cases the
procedures may consist of routine methods for foundation design and construction.
16
Geotechnical Category 1 procedures should be used only if there is no excavation below the
water table or if comparable local experience indicates that a proposed excavation below the
water table will be straightforward.
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17
Geotechnical Category 2 should include conventional types of structure and foundation with
no exceptional risk or difficult soil or loading conditions
18
Designs for structures in Geotechnical Category 2 should normally include quantitative

geotechnical data and analysis to ensure that the fundamental requirements are satisfied.
19
Routine procedures for field and laboratory testing and for design and execution may be used
for Geotechnical Category 2 designs.
the following are examples of conventional structures or parts of structures complying
with Geotechnical Category 2:
Shallow foundations;
(ii)
Pile foundations;
(iii)
Walls and other structures retaining or supporting soil or water;
(iv)
Excavations;
(v)
Bridge piers and abutments;
(vi)
Embankments and earthworks;
(vii)
Ground anchors and other tie-back systems;
(viii)
Tunnels in hard, non-fractured rock and not subjected to special water tightness
or other requirements.
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(a)
Geotechnical Category 3 should include structures or parts of structures, which fall outside
the limits of Geotechnical Categories 1 and 2.
21
Geotechnical Category 3 should normally include alternative provisions and rules to those in
this standard.
Geotechnical Category 3 includes the following examples:
Very large or unusual structures;
(ii)
Structures involving abnormal risks, or unusual or exceptionally difficult ground

or loading conditions;
(iii)
Structures in highly seismic areas;
(iv)
Structures in areas of probable site instability or persistent ground movements

that require separate investigation or special measures.
(i)
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3.3.2
Design Situations
Both short-term and long-term design situations shall be considered.
In geotechnical design, the detailed specifications of design situations should include, as

appropriate:
(a)
The actions, their combinations and load cases;
(b)
The general suitability of the ground on which the structure is located with respect to
overall stability and ground movements;
(c)
The disposition and classification of the various zones of soil, rock and elements of
construction, which are involved in any calculation model;
QCS 2014

Part
(d)
Dipping bedding planes;
(e)
Mine workings, caves or other underground structures;
(f)
In the case of structures resting on or near rock:

(i)
inter bedded hard and soft strata;
(ii)
faults, joints and fissures;
(iii)
possible instability of rock blocks;
(iv)
solution cavities, such as swallow holes or fissures filled with soft material, and
continuing solution processes;
The environment within which the design is set, including the following:
(i)
effects of scour, erosion and excavation, leading to changes in the geometry of

the ground surface;
(ii)
effects of chemical corrosion;
(iii)
effects of weathering;
(iv)
effects of long duration droughts;
(v)
variations in ground-water levels, including, e.g. the effects of dewatering,

possible flooding, failure of drainage systems, water exploitation;
(vi)
the presence of gases emerging from the ground;
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(g)
Page 8
Earthquakes;
(i)
Ground movements caused by subsidence due to mining or other activities;
(j)
The sensitivity of the structure to deformations;
(k)
The effect of the new structure on existing structures, services and the local
environment.
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(h)
Durability
At the geotechnical design stage, the significance of environmental conditions shall be

assessed in relation to durability and to enable provisions to be made for the protection or
adequate resistance of the materials.
In designing for durability of materials used in the ground, the following should be considered:
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3.3.3
(a)
For concrete:
(i)
(b)
Aggressive agents in the ground-water or in the ground or fill material, such as

acids or sulfate salts;
For steel:
(i)
Chemical attack where foundation elements are buried in ground that is

sufficiently permeable to allow the percolation of ground-water and oxygen;
(ii)
Corrosion on the faces of sheet pile walls exposed to free water, particularly in
the mean water level zone;
(iii)
The pitting type of corrosive attack on steel embedded in fissured or porous

concrete, particularly for rolled steel where the mill scale, acting as a cathode,
promotes electrolytic action with the scale-free surface acting as an anode;
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(c)

Part
For timber:
(i)
(d)
Page 9
Fungi and aerobic bacteria in the presence of oxygen;
For synthetic fabrics:

(i)
The ageing effects of UV exposure or ozone degradation or the combined

effects of temperature and stress, and secondary effects due to chemical
degradation.
Reference should be made to durability provisions in construction materials standards.
3.4
GEOTECHNICAL DESIGN BY CALCULATION
3.4.1
General
Design by calculation shall be in accordance with the fundamental requirements of EN 1990

and with the particular rules of this specification. Design by calculation involves:
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Actions, which may be either imposed loads or imposed displacements, e.g. from
ground movements;
(b)
Properties of soils, rocks and other materials;
(c)
Geometrical data;
(d)
Limiting values of deformations, crack widths, vibrations etc;
(e)
Calculation models.
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(a)
It should be considered that knowledge of the ground conditions depends on the extent and
quality of the geotechnical investigations. Such knowledge and the control of workmanship
are usually more significant to fulfilling the fundamental requirements than is precision in the
calculation models and partial factors.
The calculation model shall describe the assumed behavior of the ground for the limit state
under consideration.
If no reliable calculation model is available for a specific limit state, analysis of another limit
state shall be carried out using factors to ensure that exceeding the specific limit state
considered is sufficiently improbable. Alternatively, design by prescriptive measures,
experimental models and load tests, or the observational method, shall be performed.
The calculation model may consist of any of the following:
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(a)
An analytical model;
(b)
A semi-empirical model;
(c)
A numerical model.
Any calculation model shall be either accurate or err on the side of safety.
A calculation model may include simplifications.
If needed, a modification of the results from the model may be used to ensure that the design
calculation is either accurate or errs on the side of safety.
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Page 10
If the modification of the results makes use of a model factor, it should take account of the
following:
(a)
The range of uncertainty in the results of the method of analysis;
(b)
Any systematic errors known to be associated with the method of analysis.
10
If an empirical relationship is used in the analysis, it shall be clearly established that it is

relevant for the prevailing ground conditions.
11
Limit states involving the formation of a mechanism in the ground should be readily checked
using a calculation model. For limit states defined by deformation considerations, the
deformations should be evaluated by calculation or otherwise assessed.
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NOTE: many calculation models are based on the assumption of a sufficiently ductile
performance of the ground/structure system. A lack of ductility, however, will lead to an
ultimate limit state characterized by sudden collapse.
Numerical methods can be appropriate if compatibility of strains or the interaction between
the structure and the soil at a limit state are considered.
13
Compatibility of strains at a limit state should be considered. Detailed analysis, allowing for
the relative stiffness of structure and ground, may be needed in cases where a combined
failure of structural members and the ground could occur. Examples include raft foundations,
laterally loaded piles and flexible retaining walls. Particular attention should be paid to strain
compatibility for materials that are brittle or that have strain-softening properties.
14
In some problems, such as excavations supported by anchored or strutted flexible walls, the
magnitude and distribution of earth pressures, internal structural forces and bending
moments depend to a great extent on the stiffness of the structure, the stiffness and strength
of the ground and the state of stress in the ground.
15
In these problems of ground-structure interaction, analyses should use stress-strain

relationships for ground and structural materials and stress states in the ground that are
sufficiently representative, for the limit state considered, to give a safe result.
3.4.2
Actions
The definition of actions shall be taken as:
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(a)
Set of forces (loads) applied to the structure (direct action);
(b)
Set of imposed deformations or accelerations caused for example, by temperature

changes, moisture variation, uneven settlement or earthquakes (indirect action).
The values of actions shall be taken from EN 1991 or equivalent international standard,
where relevant.
2
The values of geotechnical actions to be used shall be selected, since they are known before
a calculation is performed; they may change during that calculation.
NOTE: Values of geotechnical actions may change during the course of calculation. In such
cases they will be introduced as a first estimate to start the calculation with a preliminary,
known value.
Any interaction between the structure and the ground shall be taken into account when
determining the actions to be adopted in the design.
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Page 11
In geotechnical design, the following should be considered for inclusion as actions:

the weight of soil, rock and water;
(b)
stresses in the ground;
(c)
earth pressures and ground-water pressure;
(d)
free water pressures, including wave pressures;
(e)
ground-water pressures;
(f)
seepage forces;
(g)
dead and imposed loads from structures;
(h)
surcharges;
(i)
mooring forces;
(j)
removal of load or excavation of ground;
(k)
traffic loads;
(l)
movements caused by mining or other caving or tunneling activities;
(m)
swelling and shrinkage caused by vegetation, climate or moisture changes;
(n)
movements due to creeping or sliding or settling ground masses;
(o)
movements due to degradation, dispersion, decomposition, self-compaction and

solution;
(p)
movements and accelerations caused by earthquakes, explosions, vibrations and

dynamic loads;
(q)
temperature effects, including frost action;
(r)
imposed pre-stress in ground anchors or struts;
(s)
down drag.
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Consideration shall be given to the possibility of variable actions occurring both jointly and
separately.
The duration of actions shall be considered with reference to time effects in the material
properties of the soil, especially the drainage properties and compressibility of fine-grained
soils.
Actions, which are applied repeatedly, and actions with variable intensity shall be identified
for special consideration with regard to, e.g. continuing movements, liquefaction of soils,
change of ground stiffness and strength.
Actions that produce a dynamic response in the structure and the ground shall be identified
for special consideration.
Actions in which ground- and free-water forces predominate shall be identified for special
consideration with regard to deformations, fissuring, variable permeability and erosion.
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NOTE Unfavorable (or destabilizing) and favorable (or stabilizing) permanent actions may in
some situations be considered as coming from a single source. If they are considered so, a
single partial factor may be applied to the sum of these actions or to the sum of their effects.
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Page 12
Ground Properties
Properties of soil and rock masses, as quantified for design calculations by geotechnical
parameters, shall be obtained from test results, either directly or through correlation, theory
or empiricism, and from other relevant data.
Values obtained from test results and other data shall be interpreted appropriately for the limit
state considered.
Account shall be taken of the possible differences between the ground properties and
geotechnical parameters obtained from test results and those governing the behavior of the
geotechnical structure.
The above differences can be due to the following factors:

many geotechnical parameters are not true constants but depend on stress level and
mode of deformation;
(b)
soil and rock structure (e.g. fissures, laminations, or large particles) that may play a
different role in the test and in the geotechnical structure;
(c)
time effects;
(d)
the softening effect of percolating water on soil or rock strength;
(e)
the softening effect of dynamic actions;
(f)
the brittleness or ductility of the soil and rock tested;
(g)
the method of installation of the geotechnical structure;
(h)
the influence of workmanship on artificially placed or improved ground;
(i)
the effect of construction activities on the properties of the ground.
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(a)
When establishing values of geotechnical parameters, the following should be considered:
the value of each geotechnical parameter compared with relevant published data and
local and general experience;
(b)
published and well recognized information relevant to the use of each type of test in
the appropriate ground conditions;
(a)
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(c)
the variation of the geotechnical parameters that are relevant to the design;
(d)
the results of any large scale field trials and measurements from neighboring
constructions;
(e)
any correlations between the results from more than one type of test;
(f)
any significant deterioration in ground material properties that may occur during the
lifetime of the structure.
Calibration factors shall be applied where necessary to convert laboratory or field test results
according to EN 1997-2 into values that represent the behavior of the soil and rock in the
ground, for the actual limit state, or to take account of correlations used to obtain derived
values from the test results.
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Page 13
Geometrical Data
The level and slope of the ground surface, water levels, levels of interfaces between strata,
excavation levels and the dimensions of the geotechnical structure shall be treated as
geometrical data.
3.4.5
Characteristic and representative values of actions shall be derived in accordance with EN

1990:2002 and the various parts of EN 1991.
3.4.6
The selection of characteristic values for geotechnical parameters shall be based on results
and derived values from laboratory and field tests, complemented by well-established
experience.
The characteristic value of a geotechnical parameter shall be selected as a cautious estimate

of the value affecting the occurrence of the limit state.
The selection of characteristic values for geotechnical parameters shall take account of the
following:
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3.4.4
geological and other background information, such as data from previous projects;
(b)
the variability of the measured property values and other relevant information, e.g.
from existing knowledge;
(c)
the extent of the field and laboratory investigation;
(d)
the type and number of samples;
(e)
the extent of the zone of ground governing the behavior of the geotechnical structure
at the limit state being considered;
(f)
the ability of the geotechnical structure to transfer loads from weak to strong zones in
the ground.
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(a)
Characteristic values can be lower values, which are less than the most probable values, or
upper values, which are greater.
For each calculation, the most unfavorable combination of lower and upper values of
independent parameters shall be used.
The zone of ground governing the behavior of a geotechnical structure at a limit state is
usually much larger than a test sample or the zone of ground affected in an in situ test.
Consequently the value of the governing parameter is often the mean of a range of values
covering a large surface or volume of the ground. The characteristic value should be a
cautious estimate of this mean value.
If the behavior of the geotechnical structure at the limit state considered is governed by the
lowest or highest value of the ground property, the characteristic value should be a cautious
estimate of the lowest or highest value occurring in the zone governing the behavior.
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Page 14
When selecting the zone of ground governing the behavior of a geotechnical structure at a
limit state, it should be considered that this limit state may depend on the behavior of the
supported structure. For instance, when considering a bearing resistance ultimate limit state
for a building resting on several footings, the governing parameter should be the mean
strength over each individual zone of ground under a footing, if the building is unable to resist
a local failure. If, however, the building is stiff and strong enough, the governing parameter
should be the mean of these mean values over the entire zone or part of the zone of ground
under the building.
If statistical methods are employed in the selection of characteristic values for ground
properties, such methods should differentiate between local and regional sampling and
should allow the use of a prior knowledge of comparable ground properties.
10
If statistical methods are used, the characteristic value should be derived such that the
calculated probability of a worse value governing the occurrence of the limit state under
consideration is not greater than 5%.
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NOTE : In this respect, a cautious estimate of the mean value is a selection of the mean
value of the limited set of geotechnical parameter values, with a confidence level of 95%;
where local failure is concerned, a cautious estimate of the low value is a 5% fractal.
When using standard tables of characteristic values related to soil investigation parameters,
the characteristic value shall be selected as a very cautious value.
3.4.7
Characteristic values of the levels of ground and ground-water or free water shall be
measured, nominal or estimated upper or lower levels.
Characteristic values of levels of ground and dimensions of geotechnical structures or

elements should usually be nominal values.
3.4.8
The assumptions, data, methods of calculation and results of the verification of safety and
serviceability shall be recorded in the Geotechnical Design Report.
The level of detail of the Geotechnical Design Reports will vary greatly, depending on the
type of design. For simple designs, a single sheet may be sufficient.
The Geotechnical Design Report should normally include the following items, with crossreference to the Ground Investigation Report :
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(a)
a description of the site and surroundings;
(b)
a description of the ground conditions;
(c)
a description of the proposed construction, including actions;
(d)
design values of soil and rock properties, including justification, as appropriate;
(e)
statements on the codes and standards applied;
(f)
statements on the suitability of the site with respect to the proposed construction and
the level of acceptable risks;
(g)
geotechnical design calculations and drawings;
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Page 15
(h)
foundation design recommendations;
(i)
a note of items to be checked during construction or requiring maintenance or

monitoring.
The Geotechnical Design Report shall include a plan of supervision and monitoring, as
appropriate. Items, which require checking during construction or, which require maintenance
after construction shall be clearly identified. When the required checks have been carried out
during construction, they shall be recorded in an addendum to the Report.
In relation to supervision and monitoring the Geotechnical Design Report should state:
the purpose of each set of observations or measurements;
(b)
the parts of the structure, which are to be monitored and the locations at which
observations are to be made;
(c)
the frequency with which readings is to be taken;
(d)
the ways in which the results are to be evaluated;
(e)
the range of values within which the results are to be expected;
(f)
the period of time for which monitoring is to continue after construction is complete;
(g)
the parties responsible for making measurements and observations, for interpreting
the results obtained and for maintaining the instruments.
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(a)
An extract from the Geotechnical Design Report, containing the supervision, monitoring and
maintenance requirements for the completed structure, shall be provided to the owner/client.
3.4.9
Design situations shall be selected in accordance with 3.3.2.
The actions listed in 3.4.2(4) should be considered when selecting the limit states for
calculation.
If structural stiffness is significant, an analysis of the interaction between the structure and
the ground should be performed in order to determine the distribution of actions.
3.4.10
When choosing the depth of a shallow foundation the following shall be considered:
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(a)
reaching an adequate bearing stratum;
(b)
the depth above which shrinkage and swelling of clay soils, due to seasonal weather
changes, or to trees and shrubs, may cause appreciable movements;
(c)
the level of the water table in the ground and the problems, which may occur if
excavation for the foundation is required below this level;
(d)
possible ground movements and reductions in the strength of the bearing stratum by
seepage or climatic effects or by construction procedures;
(e)
the effects of excavations on nearby foundations and structures;
(f)
anticipated excavations for services close to the foundation;
(g)
high or low temperatures transmitted from the building;
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(h)
the possibility of scour;
(i)
the effects of variation of water content due to long periods of drought, and subsequent
periods of rain, on the properties of volume-unstable soils in arid climatic areas;
(j)
the presence of soluble materials, e.g. limestone, clay stone, gypsum, salt rocks;
In addition to fulfilling the performance requirements, the design foundation width shall take
account of practical considerations such as economic excavation, setting out tolerances,
working space requirements and the dimensions of the wall or column supported by the
foundation.
One of the following design methods shall be used for shallow foundations:
a direct method, in which separate analyses are carried out for each limit state. When
checking against an ultimate limit state, the calculation shall model as closely as
possible the failure mechanism, which is envisaged. When checking against a
serviceability limit state, a settlement calculation shall be used;
(b)
an indirect method using comparable experience and the results of field or laboratory
measurements or observations, and chosen in relation to serviceability limit state loads
so as to satisfy the requirements of all relevant limit states;
(c)
a prescriptive method in which a presumed bearing resistance is used.
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(a)
The design of shallow foundations on rock shall take account of the following features:
the deformability and strength of the rock mass and the permissible settlement of the
supported structure;
(b)
the presence of any weak layers, for example solution features or fault zones, beneath
the foundation;
(c)
the presence of bedding joints and other discontinuities and their characteristics (for
example filling, continuity, width, spacing);
(d)
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3.4.11
disturbance of the natural state of the rock caused by construction activities, such as,
for example, underground works or slope excavation, being near to the foundation.
(e)
the state of weathering, decomposition and fracturing of the rock;
Shallow foundations on rock may normally be designed using the method of presumed
bearing pressures. For strong intact igneous rocks, gneissic rocks, limestone and
sandstones, the presumed bearing pressure are limited by the compressive strength of the
concrete foundation.
The settlement of a foundation may be assessed on the basis of comparable experience

related to rock mass classification.
END OF PART
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Part
04: Deep Foundations
Page 1
DEEP FOUNDATIONS ............................................................................................ 4
4.1
4.1.1
4.1.2
4.1.3
4.1.4
4.1.5
4.1.6
4.1.7
4.1.8
4.1.9
PRECAST REINFORCED AND PRESTRESSED CONCRETE PILES .................... 4

General
4
4
Precast Reinforced and Prestressed Concrete Piles
4
Materials and components
5
Prestressing
7
Driving Piles
8
Risen Piles
10
Repair and lengthening of piles
10
Cutting off pile heads
10
4.2
4.2.1
4.2.2
4.2.3
4.2.4
4.2.5
4.2.6
4.2.7
4.2.8
4.2.9
4.2.10
4.2.11
PRECAST REINFORCED CONCRETE SEGMENTAL PILES............................... 10

Scope
10
References
11
Submittals
11
Quality Assurance
11
Tolerances in Pile Dimensions
11
Handling, Transportation, Storage and Acceptance of Piles
12
12
Driving piles
13
Risen Piles
14
15
15
4.3
4.3.1
4.3.2
4.3.3
4.3.4
4.3.5
4.3.6
BORED CAST IN PLACE PILES ........................................................................... 15

Scope
15
References
16
Quality Assurance
16
Materials
16
Boring
17
Extraction of casing
19
4.4
4.4.1
4.4.2
4.4.3
4.4.4
4.4.5
BORED PILES CONSTRUCTED USING CONTINUOUS FLIGHT AUGERS AND

CONCRETE OR GROUT INJECTION TROUGH HOLLOW AUGER STEMS ....... 21
Scope
21
Materials
21
Boring
22
Placing of concrete or grout
23
23
4.5
4.5.1
4.5.2
4.5.3
4.5.4
4.5.5
4.5.6
DRIVEN CAST IN PLACES PILES ........................................................................ 23

Scope
23
Submittals
24
Quality Assurance
24
Materials
24
Driving piles
25
Risen Piles
26
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26
4.6
4.6.1
4.6.2
4.6.3
4.6.4
4.6.5
4.6.6
4.6.7
4.6.8
4.6.9
4.6.10
4.6.11
STEEL PILES ........................................................................................................ 28

Scope
28
References
28
Submittals
28
Quality Assurance
28
Delivery, Storage and Handling
29
Materials
29
Acceptance Standards For Welds
30
Acceptability and inspection of coatings
31
Driving of piles
31
Risen Piles
33
Preparation of pile heads
33
4.7
MICROPILES (TO BE ADDED LATER) ................................................................. 33
4.8
4.8.1
4.8.2
4.8.3
4.8.4
4.8.5
REDUCTION OF FRICTION ON PILES ................................................................ 33

Scope
33
Submittals
33
Friction Reducing Methods
33
Inspection
34
Driving resistance
35
4.9
4.9.1
4.9.2
4.9.3
4.9.4
4.9.5
4.9.6
4.9.7
4.9.8
PILE LOAD TESTING ........................................................................................... 35

Static Load Testing of Piles
35
Presentation of results
45
Low strain Integrity test
47
Grosshole Sonic Logging Test
48
Calliper Logging Test
48
Axial Tensile Load Test
48
Lateral Load Test
48
Alternative Methods for Testing Piles
48
4.10
4.10.1
4.10.2
4.10.3
DESIGN METHODS AND DESIGN CONSIDERATIONS ...................................... 51

Design method
51
Verification of Resistance for Structural and Ground Limit States in Persistent and
Transient Situations
51
51
4.11
4.11.1
4.11.2
4.11.3
4.11.4
4.11.5
4.11.6
4.11.7
4.11.8
4.11.9
4.11.10
AXIALLY LOADED PILES ..................................................................................... 52

Limit state design
52
Compressive Ground Resistance
53
Ultimate compressive resistance from static load tests
54
Ultimate compressive resistance from ground test results
55
Ultimate compressive resistance from dynamic impact tests
56
Ultimate compressive resistance by applying pile driving formulae
56
Ultimate compressive resistance from wave equation analysis
56
Ground tensile resistance
57
Ultimate tensile resistance from pile load tests
57
Ultimate tensile resistance from ground test results
57
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4.11.11 Vertical displacements of pile foundations

4.11.12 Pile foundations in compression
4.11.13 Pile foundations in tension
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TRANSVERSELY LOADED PILES ....................................................................... 58

Design method
58
Transverse load resistance from pile load tests
59
Transverse load resistance from ground test results and pile strength parameters 59
Transverse displacement
60
4.12
4.12.1
4.12.2
4.12.3
4.12.4
58
58
58
QCS 2014

Part
Page 4
DEEP FOUNDATIONS
4.1
PRECAST REINFORCED AND PRESTRESSED CONCRETE PILES
4.1.1
General
The provisions of this Part apply to end-bearing piles, friction piles, tension piles and
transversely loaded piles installed by driving, by jacking, and by screwing or boring with or
without grouting.
4.1.2
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(b)
bearing resistance failure of the pile foundation;
(c)
Uplift or insufficient tensile resistance of the pile foundation;
(d)
Failure in the ground due to transverse loading of the pile foundation;
(e)
Structural failure of the pile in compression, tension, bending, buckling or shear;
(f)
combined failure in the ground and in the pile foundation;
(g)
combined failure in the ground and in the structure;
(h)
Excessive settlement;
(i)
Excessive heave;
(j)
Excessive lateral movement;
(k)
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(a)
Scope
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This Part applies to precast concrete driven piles usually supplied for use in a single
length without facility for joining lengths together.
(a)
4.1.3
(b)
2
References
(a)
BS 7613,.....................Hot rolled quenched and tempered weldable structural steel plates

BS 3100,.....................Steel castings for general engineering purposes
BS 2789,.....................Spheroidal graphite or nodular graphite cast iron
BS 8110,.....................Structural use of concrete.
3
Submittals
(a)
The Contractor shall order the piles to suit the construction programme and seek the
Engineer's approval before placing the order. When preliminary piles are specified,
the approval of the piles for the main work will not necessarily be given until the results
of the driving and loading tests on preliminary piles have been received and evaluated.
QCS 2014
Page 5
Quality Assurance
(a)

Part
After a pile has been cast, the date of casting, reference number, length and, where
appropriate, the prestressing force shall be clearly inscribed on the top surface of the
pile and also clearly and indelibly marked on the head of the pile. Lifting positions shall
be marked at the proper locations on each pile.

(a)
The cross-sectional dimensions of the pile shall be not less than those specified and
shall not exceed them by more than 6 mm. Each face of a pile shall not deviate by
more than 6 mm from any straight line 3 m long joining two points on that face, nor
shall the centre of area of the pile at any cross section along its length deviate by more
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than 1/500 of the pile length from a line joining the centres of area at the ends of the
pile. Where a pile is less than 3 m long, the permitted deviation from straightness shall
Handling, Transportation and Storage of Piles
The method and sequence of lifting, handling, and storage of piles transporting and
storing piles shall be such as to avoid shock loading and to ensure that the piles are
not damaged. Only the designated lifting and support points shall be used. During
transport and storage, piles shall be appropriately supported under the marked lifting
points or fully supported along their length.
(b)
All piles within a stack shall be in groups of the same length. Packing of uniform
thickness shall be provided between piles at the lifting points.
(c)
Concrete shall at no time be subjected to loading, including its own weight, which will
induce a compressive stress in it exceeding 0.33 of its strength at the time of loading
or of the specified strength, whichever is the lesser. For this purpose the assessment
of the strength of the concrete and of the stresses produced by the loads shall be
subject to the agreement of the Engineer.
(d)
Pile may be rejected when the width of any transverse crack exceeds 0.3 mm. The
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(a)
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be reduced below 6 mm on a pro rata basis in accordance with actual length.
measurement shall be made with the pile in its working attitude.
Fabricated Steel Components
4.1.4
(a)
Pile Toes
(a)
In the manufacture of precast concrete piles, fabricated steel components shall comply
with BS 7613 grades 43A or 50B, cast steel components with BS 3100 grade A, and
ductile iron components with BS 2789.
Pile toes shall be constructed so as to ensure that damage is not caused to the pile
during installation. Where positional fixity is required on an inclined rock surface or in
other circumstances, an approved shoe may be required.
Pile Head Reinforcement

(a)
The head of each pile shall be so reinforced or banded as to prevent bursting of the
pile under driving conditions.
QCS 2014

Part
Page 6
Main Reinforcement
(a)
The main longitudinal reinforcing bars in piles not exceeding 12 m in length shall be in
one continuous length unless otherwise specified. In piles more than 12 m long, lap
splicing will be permitted in main longitudinal bars at 12 m nominal intervals, with no
more than 25 % of the bars lapped at one location, and laps staggered by a minimum
of 1.2 m. Laps in reinforcement shall be such that the full strength of the bar is
effective across the joint.
Lap or splice joints shall be provided with sufficient link bars to resist eccentric forces.
(c)
Sufficient reinforcement shall be provided for lifting and handling purposes.
Unless otherwise agreed by the Engineer, concrete shall be compacted with the
assistance of vibrators. Internal vibrators shall be capable of producing not less than
150 Hz and external vibrators not less than 50 Hz. Internal vibrators shall operate not
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(a)
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Concrete
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closer than 75 mm to shuttering.
Vibrators shall be operated in such a manner that neither segregation of the concrete
mix constituents nor displacement of reinforcement occurs.
(c)
Immediately after compaction, concrete shall he adequately protected from the harmful
effects of the weather, including wind, rain, rapid temperature changes and frost. It
shall be protected from drying out by an approved method of curing.
(d)
Piles shall not be removed from formwork until a sufficient pile concrete strength has
been achieved to allow the pile to be handled without damage.
(e)
The period of curing at an ambient temperature of 10 C shall not be less than that
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(b)
shown in Table 4.1. If the temperature is greater or less than 10 C, the periods given
When steam or accelerated curing is used the curing procedure shall be approved.
Four hours must elapse from the completion of placing concrete before the
temperature is raised. The rise in temperature within any period of 30 min shall not
exceed 10 C and the maximum temperature attained shall not exceed 70 C. The rate
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(f)
shall be adjusted accordingly and shall be approved.
(b)
of subsequent cooling shall not exceed the rate of heating.

Table 4.1
Period of Curing at 10 C
Type of cement
Wet curing time after

completion of placing concrete, d
Ordinary Portland
Sulphate-resisting Portland
Portland blast-furnace
Super-sulphated
Rapid-hardening Portland
QCS 2014

Part
Page 7
Formwork
(a)
shaped point or shoe, then the end of the pile shall be symmetrical about the
longitudinal axis of the pile. Holes for handling or pitching, where provided in the pile,
shall be lined with steel tubes; alternatively, approved inserts may be cast in.
(b)
Formwork shall be robust, clean and so constructed as to prevent loss of grout or

aggregate from the wet concrete and ensure the production of uniform pile sections,
free from defects. The piles are to be removed from the formwork carefully so as to
prevent damage.
4.1.5
Prestressing
General
Tensioning shall be carried out only when the Engineer is present, unless otherwise
approved. In cases where piles are manufactured off site, the Contractor shall ensure
that the Engineer is given adequate notice and every facility for inspecting the
manufacturing process.
(b)
Prestressing operations shall be carried out only under the direction of an experienced
and competent supervisor. All personnel operating the stressing equipment shall have
been trained in its use.
(c)
The calculated extensions and total forces, including allowance for losses, shall be
agreed with the Engineer before stressing is commenced.
(d)
Stressing of tendons and transfer of prestress shall be carried out at a gradual and
steady rate. The force in the tendons shall be obtained from readings on a recently
calibrated load cell or pressure gauge incorporated in the equipment. The extension of
the tendons under the agreed total forces shall be within 5 % of the agreed calculated
extension.
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Concrete Strength
The Contractor shall cast sufficient cubes, cured in the same manner as the piles, to
be able to demonstrate by testing two cubes at a time, with approved intervals between
pairs of cubes, that the specified transfer strength of the concrete has been reached.
(b)
(a)
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(a)
Post-Tensioned Piles
(a)
Unless otherwise permitted, concrete shall not be stressed until two test cubes attain
the specified transfer strength.
Ducts and vents in post-tensioned piles shall be grouted after the transfer of prestress.
Grouting Procedure
(a)
Grout shall be mixed for a minimum of 2 min and until a uniform consistency is
obtained.
(b)
Ducts shall not be grouted when the air temperature in the shade is lower than 3 C.
(c)
Before grouting is started all ducts shall be thoroughly cleaned by means of

compressed air.
(d)
Grout shall be injected near the lowest point in the duct in one continuous operation
and allowed to flow from the outlet until the consistency is equivalent to that of the
grout being injected.
(e)
Vents in ducts shall be provided in accordance with Clause 8.9.2 of BS 8110.
QCS 2014
Page 8
Grout
(a)
Unless otherwise directed or agreed by the Engineer

(i)
the grout shall consist only of ordinary Portland cement, water and approved
admixtures; admixtures containing chlorides or nitrates shall not be used
(ii)
the grout shall have a water/cement ratio as low as possible consistent with the
necessary workability, and the water/cement ratio shall not exceed 0.45 unless
an approved mix containing an expanding agent is used
(iii)
the grout shall not be subject to bleeding in excess of 2 % after 3 h, or in excess

of 4% maximum, when measured at 18 C in a covered glass cylinder
approximately 100 mm in diameter with a height of grout of approximately 100
mm, and the water shall be reabsorbed after 24 h.
Records
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Part
The Contractor shall keep detailed records of times of tensioning, measured

extensions, pressure gauge readings or load cell readings and the amount of pull-in at
each anchorage. Copies of these records shall be supplied to the Engineer within
such reasonable time from completion of each tensioning operation as may be
required, and in any case not later than noon on the following working day.
(b)
The Contractor shall keep records of grouting, including the date, the proportions of
the grout and any admixtures used, the pressure, details of interruption and topping up
required. Copies of these records shall be supplied to the Engineer within such
reasonable time after completion of each grouting operation as may be required, and
in any case not later than noon on the following working day.
Driving Piles
Strength of Piles
(a)
Piles shall not be driven until the concrete has achieved the specified strength.
At all stages during driving and until incorporation into the substructure, the pile shall
be adequately supported and restrained by means of leaders, trestles, temporary
supports or other guide arrangements to maintain position and alignment and to
prevent buckling. These arrangements shall be such that damage to the pile does not
occur.
(a)
Leaders and Trestles
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(a)
Performance of Driving Equipment

(a)
The Contractor shall satisfy the Engineer regarding the suitability, efficiency and
energy of the driving equipment. Where designated, dynamic evaluation and analysis
shall be provided.
(b)
Where a drop hammer is used, the mass of the hammer shall be at least half that of
the pile unless otherwise approved by the Engineer. For other types of hammer the
energy delivered to the pile per blow shall be at least equivalent to that of a drop
hammer of the stated mass. Drop hammers shall not be used from floating craft in
such a manner as to cause instability of the craft or damage to the pile.
Length of Piles
(a)
The length of pile to be driven in any location shall be approved prior to the
commencement of driving.
QCS 2014

Part
Page 9
Driving Procedure and Redrive Checks

(a)
The driving of each pile shall be continuous until the specified depth or resistance
(set), or both, has been reached. In the event of unavoidable interruption to driving,
the pile will be accepted provided it can subsequently be driven to the specified depth
or resistance (set), or both, without damage. A follower shall not be used unless
approved, in which case the Engineer will require the set where applicable to be
revised in order to take into account reduction in the effectiveness of the hammer blow.
(b)
The Contractor shall inform the Engineer without delay if an unexpected change in
driving characteristics is noted. A detailed record of the driving resistance over the full
length of the nearest available pile shall be taken if required.
(c)
At the start of the work in a new area or section, a detailed driving record shall be
made over the full length of the first pile and during the last 3 m of subsequent piles
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until consistency of behaviour is established. Where required, detailed driving records

shall also be made for 5 % of the piles driven, the locations of such piles being
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specified by the Engineer.
The Contractor shall give adequate notice and provide all necessary facilities to enable
the Engineer to check driving resistance. A set or resistance measurement shall be
taken only in the presence of the Engineer unless otherwise approved.
(e)
Redrive checks, if required, shall be carried out to an approved procedure.
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Final Set
(a)
When driving to a set criterion, the final set of each pile shall be recorded either as the
penetration in millimetres per 10 blows or as the number of blows required to produce
a penetration of 25 mm.
(b)
When a final set is being measured, the following requirements shall be met:
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(d)
The exposed part of the pile shall be in good condition without damage or
distortion.
(ii)
The helmet, dolly and any packing shall be in sound condition.
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(iii)
(iv)
The hammer shall be in good condition, delivering adequate energy per blow,
and operating correctly.
(v)
The temporary compression of the pile shall be recorded, if required.
Preboring
(a)
The hammer blow shall be in line with the pile axis and the impact surfaces shall
be flat and at right angles to the pile and hammer axis, and the head of the pile
protected against damage from hammer impact.
If preboring is specified, the diameter and depth of prebore shall be as designated.
Jetting
(a)
Jetting shall be carried out only when the Contractor's detailed proposals have been
approved.
QCS 2014
Page 10
Risen Piles
Piles shall be driven in an approved sequence to minimise the detrimental effects of
heave and lateral displacement of the ground.
(b)
When required, levels and measurements shall be taken to determine the movement
of the ground or of any pile resulting from the driving process.
(c)
When a pile has risen as a result of adjacent piles being driven, the Engineer may call
for redriving or other testing to demonstrate that the performance of the pile is
unimpaired. If required, the Contractor shall make proposals for correcting
detrimentally affected piles and for avoidance or control of heave effects in subsequent
work.
4.1.8
Repair of Damaged Pile Heads
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If it is necessary to repair the head of a pile during driving, the Contractor shall carry
out such repair in an approved way which allows the pile-driving to be completed
without further damage. If the driving of a pile has been accepted but sound concrete
of the pile is below the required cut-off level, the pile shall be made good to the cut-off
level, using an approved method so that it will safely withstand the imposed design
load.
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Lengthening of Reinforced and Prestressed Concrete Piles

Any provision for lengthening piles incorporated at the time of manufacture shall be as
designed or approved.
(b)
If no provision for lengthening piles was incorporated at the time of manufacture, any
method for lengthening shall be such that splices are capable of safely resisting the
stresses during driving and under service load and shall be subject to approval.
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(a)
Driving Repaired or Lengthened Piles

Repaired or lengthened piles shall not be driven until the added concrete has reached
the specified strength of the concrete of the pile.
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4.1.7

Part
Unless otherwise directed by the Engineer, when the driving of a pile has been approved the
concrete of the head of the pile shall be cut off to the designated level. The length of splice
reinforcing bars projecting above this level shall be as designated.
Care shall be taken to avoid shattering or otherwise damaging the rest of the pile. Any
cracked or defective concrete shall be cut away and the pile repaired in an approved manner
to provide a full and sound section at the cut-off level.
4.2
PRECAST REINFORCED CONCRETE SEGMENTAL PILES
4.2.1
Scope
This Part applies to piles made of elements cast at a precasting works away from the site,
where work cannot normally be closely supervised by the Engineer. The elements are joined
together as necessary on site during driving using special proven steel joints incorporated
into the pile elements when cast.
4.1.9
QCS 2014

Part
Page 11

This Section
Part 1, .............. General Requirements for Piling Works
Part 2, .............. Concrete Works for Piling
Section 5,
Concrete.
4.2.2
References

Eurocode 7, EN1997-1, Section 7 Pile foundation
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Submittals
Engineer's approval before placing the order. When preliminary piles are specified the
approval for the piles for the main work will not necessarily be given until the results of the
driving and tests on preliminary piles have been received and evaluated.
4.2.4
Quality Assurance
A certificate of quality from the pile manufacturer shall be provided to the Engineer when
required stating that the designated requirements have been fulfilled during manufacture.
Each pile element shall be marked in such a manner that it can be identified with the records
of manufacture, which shall state the date of casting, the cement type, concrete grade,
element length and any other relevant data. On delivery, the pile elements shall be
accompanied by records of manufacture.
4.2.5
The cross-sectional dimensions of the pile shall be not less than those designated.
The head of a pile element or the end of the pile upon which the hammer acts shall be
square to the pile axis within a tolerance of 1 in 50.
Each pile joint shall be square to the axis of the pile within a tolerance of 1 in 150. The
centroid of the pile joint shall lie within 5 mm of the true axis of the pile element.
Each face of a pile element shall not deviate by more than 6 mm from any straight line 3 m
long joining two points on that face, nor shall the centre of area of the pile at any crosssection along its length deviate by more than 1/500 of the pile length from a line joining the
centres of area at the ends of the element. Where a pile element is less than 3 m long the
permitted deviation from straightness shall be reduced below 6 mm on a pro rata basis in
accordance with actual length.
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4.2.3
QCS 2014

Part
Page 12
The method and sequence of lifting, handling, transporting and storing piles shall be such as
to avoid shock loading and to ensure that the piles are not damaged. Only designed lifting
and support points shall be used. During transport and storage, piles shall be appropriately
supported under the marked lifting points or fully supported along their length.
All pile elements within a stack shall be in groups of the same length. Packing of uniform
Concrete shall at no time be subjected to loading, including its own weight, which will induce
a compressive stress in it exceeding 0.33 of its strength at the time of loading or of the
specified strength, whichever is the less. For this purpose the assessment of the strength of
the concrete and of the stresses produced by the loads shall be subject to the approval of the
Engineer.
A pile element shall be rejected when the width of any transverse crack exceeds 0.3 mm.
The measurement shall be made with the pile in its working attitude.
4.2.7
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In the manufacture of jointed precast concrete segmental piles, fabricated steel

components shall comply with BS 7613 grades 43A or 50A, cast steel components
with BS 3100 grade A, and ductile iron components with BS 2789.
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Pile Splices
(a)
The splice joints shall be close-fitting face to face and the locking method shall be
such as to hold the faces in intimate contact. The design and manufacture of the
splicing system shall be approved by the Engineer prior to the commencement of the
Contract.
(b)
A spliced pile shall be capable of withstanding the same driving stresses or service
axial loads, moments and shear stresses as a single unspliced pile of the same crosssectional dimensions and materials.
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4.2.6
(c)
Pile Toes
(a)
during installation. Where fixity is required or socketing into rock, or in other
circumstances, an approved shoe may be required.

(a)
The welding of a joint to main reinforcement in lieu of a lapped connection with

projecting bars affixed to the joint will not be permitted.
Where the pile head is not furnished with a joint, it shall be so reinforced or banded as
to prevent bursting of the pile under driving conditions.
Main Reinforcement
(a)
The main longitudinal reinforcing bars shall be in one continuous length. Splicing of
bars will not be permitted except at element ends.
QCS 2014
Page 13
(b)
Concrete cover to steel reinforcement shall be in accordance with the requirements of

BS 8110.
(c)
In very aggressive ground or exposure conditions, cover greater than 25 mm may be

required, but alternative protection methods may be approved.
Formwork
(a)
If a pile is constructed with a shaped point or shoe, then the end of the pile shall be
symmetrical about the longitudinal axis of the pile.
(b)
Holes for handling or pitching, where provided in the pile, shall be lined with steel
tubes; alternatively, approved inserts may be cast in.
(c)

aggregate from the wet concrete and ensure the production of uniform pile sections.
The piles are to be removed from the formwork carefully so as to prevent damage.
Driving piles
Strength of Piles
occur.
energy of the driving equipment. Where required in the particular specification,
dynamic evaluation and analysis shall be provided.
the pile at the moment of driving unless otherwise approved by the Engineer. For
other types of hammer, the energy delivered to the pile per blow shall be at least
equivalent to that of a drop hammer of the stated mass. Drop hammers shall not be
used from floating craft in such a manner as to cause instability of the craft or damage
to the pile.
(b)
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Piles shall not be driven until the concrete has achieved the specified characteristic
strength.
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4.2.8
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Part
Length of Piles
(a)
The length of pile supplied to be driven in any location and any additional lengths to be
added during driving shall he approved prior to the commencement of pile-driving.
During the execution of the Works, any changes to the supplied lengths shall be
approved.
QCS 2014
Page 14

(a)
Except when making field splices, the driving of each pile shall he continuous until the
specified depth or resistance (set), or both, has been reached. In the event of
unavoidable interruption to driving, the pile will be accepted provided it can
subsequently be driven to the specified depth or resistance (set), or both, without
damage. A follower shall only be used when approved, in which case the Engineer will
require the set where applicable to be revised in order to take into account reduction in
the effectiveness of the hammer blow.
(b)
(c)
At the start of the work in a new area or section a detailed driving record shall be made
over the full length of the first pile and during the last 3 m of subsequent piles until
consistency of behaviour is established. Where required, detailed driving records shall
also be made for 5 % of the piles driven, the positions of such piles being specified by
the Engineer.
(d)
(e)
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Final Set
penetration in millimetres per ten blows or as the number of blows required to produce
(b)
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(a)
The exposed part of the pile shall be in good condition, without damage or
distortion.
(ii)
(iii)
be flat and at right angles to the pile and hammer axis.
(i)
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Part
(v)
The temporary compression of the pile shall be recorded if required.
Jetting
(a)
4.2.9
Preboring
(a)
(iv)
approved.
Risen Piles
(a)

QCS 2014

Part
Page 15
(b)
(c)
unimpaired. If required, the Contractor shall make proposals for correcting piles
detrimentally affected and for avoidance or control of heave effects in subsequent
work.
4.2.10

out such repair in an approved way which allows the driving of the pile to be completed
load.
Where piles are required to be driven to depths exceeding those expected, leaving
insufficient projection for bonding into the following works, the piles shall be extended
or replaced as required by the Engineer using approved materials and methods.
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Lengthening of Piles
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(a)
Unless otherwise specified, when the driving of a pile has been approved the concrete of the
head of the pile shall be cut off to the designated level. The length of splice reinforcing bars
projecting above this level shall be as designated.
4.3
BORED CAST IN PLACE PILES
4.3.1
Scope
This Part applies to bored piles in which the pile bore is excavated by rotary or percussive
means, or both, using short augers, buckets, grabs or other boring tools to advance the open
bore. Where the open bore is unstable, temporary or permanent casing or bentonite
suspension may be used to support the wall of the bore prior to concreting.
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4.2.11
This Section
Section 3, Ground Investigation
Section 5, Concrete
QCS 2014

Part
4.3.2
References
The following codes of practice are referred to in this Part:
Page 16
BS 5573,.....................Code of practice for safety precautions in the construction of large

diameter boreholes for piling and other purposes
BS 5930,.....................Code of practice for site investigation.
4.3.3
Quality Assurance
Inspection
directly or indirectly prior to concrete being placed in it. This inspection shall be carried
out from the ground surface in the case of piles of less than 750 mm diameter.
Torches or other approved means of lighting, measuring tapes, and a means of
measuring verticality shall be provided. For piles of 750 mm diameter or larger,
equipment shall be provided, by the Contractor to enable his representatives and the
Engineer to descend into the bore for the purpose of inspection. Any method of
descent and the equipment used shall comply with the requirements of BS 5573.
Cleanliness of pile bases
On completion of boring and where inspection of a dry pile bore indicates the
necessity, loose, disturbed or softened soil shall be removed from the bore. Where
pile bores contain water or drilling fluid, a cleaning process shall be employed before
concrete is placed. Large debris and accumulated sediment shall be removed using
appropriate approved methods, which shall be designed to clean while at the same
time minimising ground disturbance below the pile bases. Water or drilling fluid shall
be maintained at such levels throughout and following the cleaning operation that
stability of the bore is preserved.
Samples and Testing
The taking of samples and all subsequent handling, transporting and testing shall be
carried out in accordance with Section 3, Ground Investigation.
(b)
If required in the Contract, soil, rock or groundwater samples shall be taken or soil
tests carried out in-situ while the pile is being bored. The samples shall be taken to an
approved laboratory for testing as specified.
(a)
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(a)
4.3.4
Materials
Permanent Casings
(a)
Permanent casings shall be as specified.
Drilling Fluid Supply

(a)
A certificate shall be obtained by the Contractor from the manufacturer of the bentonite
powder showing the properties of each consignment delivered to the Site. This
certificate shall be made available to the Engineer on request. The properties to be
given by the manufacturer are the apparent viscosity range (in Pascal seconds) and
the gel strength range (in Pascal) for solids in water.
QCS 2014
Page 17
Drilling Fluid Mixing

(a)
Bentonite shall be mixed thoroughly with clean fresh water to make a suspension
which will maintain the stability of the pile bore for the period necessary to place
concrete and complete construction. The temperature of the water used in mixing the
bentonite suspension, and of the suspension when supplied to the borehole, shall be
not lower than 5 C.
(b)
Where saline or chemically contaminated groundwater occurs, special precautions

shall be taken to modify the bentonite suspension or prehydrate the bentonite in fresh
water so as to render it suitable in all respects for the construction of piles.
Drilling Fluid Tests

(a)
The frequency of testing drilling fluid and the method and procedure of sampling shall
be proposed by the Contractor for approval prior to the commencement of the work.
The frequency may subsequently be varied as required, depending on the consistency
of the results obtained, subject to approval.
(b)
Control tests shall be carried out on the bentonite suspension, using suitable
apparatus. The density of freshly mixed bentonite suspension shall be measured daily
as a check on the quality of the suspension being formed. The measuring device shall
be calibrated to read to within 0.005 g/ml. Tests to determine density, viscosity, shear
strength and pH value shall be applied to bentonite supplied to the pile bore. For
average soil conditions the results shall generally be within the ranges in Table 4.2.
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Part
Table 4.2.Tests on Bentonite
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Viscosity
Less than 1.10 g/ml
Mud density balance
30 - 90 s
or
less than 0.020 Pa s
Marsh cone method
1.4-10 Pa
Or
4-40 Pa
Shear meter
et
it
9.5 - 12
Fann viscometer*
Fann viscometer
pH indicator paper strips
or electrical pH meter
Where the Fann viscometer is specified, the fluid sample should be screened by a
number 52 sieve (300 m) prior to testing.
Shear strength
(10 minute gel strength)
pH
Test method
se
Density
Range of results at 20 C
as
Property to be measured
(c)
The tests shall be carried out until a consistent working pattern has been established
account being taken of the mixing process, any blending of freshly mixed bentonite
suspension and previously used bentonite suspension, and any process which may be
used to remove impurities from previously used bentonite suspension. When the
results show consistent behaviour, the tests for shear strength and pH value may be
discontinued, and tests to determine density and viscosity shall be carried out as
agreed with the Engineer. In the event of a change in the established working pattern,
tests for shear strength and pH value shall be reintroduced for a period if required.
4.3.5
Boring
Boring Near Recently Cast Piles

(a)
Piles shall not be bored so close to other recently completed piles as to damage them.
QCS 2014
Page 18
Temporary Casings
(a)
Temporary casing of approved quality or an approved alternative method shall be used

to maintain the stability of a pile bore which might otherwise collapse.
(b)
Temporary casings shall be free from significant distortion. They shall be of uniform
cross-section throughout each continuous length. During concreting they shall be free
from internal projections and encrusted concrete which might adversely affect the
proper formation of piles.
(c)
The use of a vibrator to insert and withdraw temporary casing may be permitted by the
Engineer subject to compliance with Noise and Disturbance and Damage to Adjacent
Structures of this section and to the method not causing disturbance of the ground
which would adversely affect the construction or the capacity of piles.
(d)
Where piles are bored under water or bentonite suspension in an unlined state, the
insertion of a full-length loosely fitting casing to the bottom of the bore prior to placing
concrete will not be permitted.
(e)
Where permanent casing is specified to ensure the integrity of a pile, the Contractor
shall submit for approval his proposals regarding the method of installation.
ta
qa
Stability of Pile
Where boring takes place through unstable water-bearing strata, the process of
excavation and the depth of temporary casing employed shall be such that soil from
outside the area of the pile is not drawn into the pile section and cavities are not
created outside the temporary casing as it is advanced.
(b)
Where the use of drilling fluid is specified or approved for maintaining the stability of a
bore, an adequate temporary casing shall be used in conjunction with the method so
as to ensure stability of the strata near ground level until concrete has been placed.
During construction the level of drilling fluid in the pile excavation shall be maintained
within the cased or stable bore so that it is not less than 1.0 m above the level of
external standing groundwater at all times.
(c)
In the event of a rapid loss of drilling fluid from a pile excavation, the bore shall be
backfilled without delay and the instructions of the Engineer shall be obtained before
boring at that location is resumed.
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Part
Spillage and Disposal of Drilling Fluid

(a)
Pumping from Pile Bores

(a)
All reasonable steps shall be taken to prevent the spillage of bentonite suspension on
the Site in areas outside the immediate vicinity of boring. Discarded bentonite shall be
removed from the Site without undue delay. Any disposal of bentonite shall comply
with the regulations of the local controlling authority.
Pumping from pile bores shall not be permitted unless the bore has been sealed
against further water entry by casing or unless the soil is stable and will allow pumping
to take place without ground disturbance below or around the pile.
Continuity of Construction
(a)
For a pile constructed in a stable cohesive soil without the use of temporary casing or
other form of support, the pile shall be bored and the concrete shall be placed without
such delay as would lead to significant impairment of the soil strength.
QCS 2014

Part
Enlarged Pile Bases

(a)
A mechanically formed enlarged base shall be no smaller than the dimensions

specified and shall be concentric with the pile shaft to within a tolerance of 10 % of the
shaft diameter. The sloping surface of the frustum forming the enlargement shall make
an angle to the axis of the pile of not more than 35 .
4.3.6
(a)
Temporary casings shall be extracted while the concrete within them remains
sufficiently workable to ensure that the concrete is not lifted. During extraction the
motion of the casing shall be maintained in an axial direction relative to the pile.
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Concrete Level
When the casing is being extracted, a sufficient quantity of concrete shall be

maintained within it to ensure that pressure from external water, drilling fluid or soil is
exceeded and that the pile is neither reduced in section nor contaminated.
(b)
The concrete level within a temporary casing shall be topped up where necessary
during the course of casing extraction in such a way that the base of the casing is
always below the concrete surface until the casting of the pile has been completed.
(c)
Adequate precautions shall be taken in all cases where excess heads of water or
drilling fluid could occur as the casing is withdrawn because of the displacement of
water or fluid by the concrete as it flows into its final position against the walls of the
pile bore. Where two or more discontinuous lengths of casing (double casing) are
used in the construction the proposed method of working shall be approved.
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(a)
For piles cast in dry bores using temporary casing and without the use of a permanent
lining, pile heads shall be cast to a level above the specified cut-off so that, after
trimming, a sound concrete connection with the pile can be made. The casting level
shall be within the tolerance above the cut-off level shown in Table 4.3, but shall not be
above the original ground level. No pile shall be cast with its head below standing
water level unless approved measures are taken to prevent inflow of water causing
segregation of the concrete as temporary casing is extracted, and, where approved by
the Engineer, the groundwater level for each pile shall be treated as the cut-off level for
the purpose of calculating tolerance.
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(a)
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Pile Head Casting Level Tolerances
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Page 19
(b)
For piles cast in dry bores within permanent lining tubes or permanent casings, or
where their cut-off levels are in stable ground below the base of any casing used, pile
heads shall be cast to a level above the specified cut-off so that, after trimming, a
sound concrete connection with the pile can be made. The casting level shall be within
the tolerance above the cut-off level shown in Table 4.4, but shall not be above the
original ground level.
QCS 2014

Part
Page 20
(c)
For piles cast under water or drilling fluid, the pile heads shall be cast to a level above
the specified cut-off so that, after trimming to remove all debris and contaminated
concrete, a sound concrete connection with the pile can be made. The casting level
above the commencing surface level. Cut-off levels may be specified below the
standing groundwater level, and where this condition applies the borehole fluid level
shall not be reduced below the standing groundwater level until the concrete has set.
(d)
Where the cut-off level of piles lies at depths greater than 10 m below the original
ground level, then the tolerances given in Tables 4.3, 4.4 and 4.5 will be varied after
discussion with the Contractor and before the commencement of the piling to take
account of the special conditions which apply.
Table 4.3
Casting tolerance above cut-off level, m
rw
Cut-off distance below commencing surface,

H, m
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Casting Tolerance above Cut-off Level for Piles Cast In Dry Bores Using Temporary Casing
and Without the Use of a Permanent Lining
ta
0.3 + H/12 + C/8

where C = length of temporary casing
below the commencing surface*
qa
0.15-10.00
*
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If H is greater than C, then this tolerance is no longer applicable and the tolerances in
Table 4.4 will apply.
Table 4.4
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Casting Tolerance above Cut-off Level for Piles Cast in Dry Bores within Permanent Lining
Tubes or Permanent Casings, or Where Their Cut-Off Levels is in Stable Ground below the
Base of Any Casing Used

H, m
0.3 + H/10
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0.15-10.00
Table 4.5
Casting Tolerance above Cut-off Level for Piles Cast Under Water or Drilling Fluid**
H, m
0.15-10.00
**
4
1.0 + H /12 + C/8

below the commencing surface
In cases where a pile is cast so that the cut-off is within a permanent lining tube, the appropriate
tolerance is given by deletion of the casing term C/8 in the table.
Water levels
(a)
During extraction of temporary casings, where circumstances are such that newly
placed unset concrete is brought into contact with external groundwater, precautions
shall be taken to ensure that the internal concrete pressure at all levels within the pile
exceeds the external groundwater pressure.
QCS 2014
After each pile has been cast, any empty bore remaining shall be protected and shall
be carefully backfilled as soon as possible with approved materials.
Disposal of excavated material

(a)
Page 21
Temporary backfilling above pile casting level

(a)

Part
Disposal of excavated material shall be carried out by the Contractor as necessary to

facilitate the Works and to the satisfaction of the Engineer.

(a)
When cutting off and trimming piles to the specified cut-off level, the Contractor shall
take care to avoid shattering or otherwise damaging the rest of the pile. Any cracked
or defective concrete shall be cut away and the pile repaired in an approved manner to
provide a full and sound section at the cut-off level
BORED PILES CONSTRUCTED USING CONTINUOUS FLIGHT AUGERS

AND CONCRETE OR GROUT INJECTION TROUGH HOLLOW AUGER
STEMS
4.4.1
Scope
This Part applies to bored piles which employ a continuous flight auger for both advancing
the bore and maintaining its stability. The spoil-laden auger is not removed from the ground
until concrete or grout is pumped into the pile bore from the base of the hollow-stemmed
auger to replace the excavated soil.
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4.4
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This Section
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Section 3, Ground Investigation.

Section 5, Concrete
Materials
Concrete Mix Design and Workability
4.4.2
(a)
Where not otherwise stated in this Part, the concrete shall comply with Section 5. The
design and workability of concrete to be used in the formation of a pile shall produce a
mix which is suitable for pumping. It shall have a minimum slump of 150 mm unless
3
otherwise approved and a minimum cement content of 340 kg/m . The mix shall be
designed so that segregation does not occur during the placing process, and bleeding
of the mix shall be minimised.
Grout Mix Design and Workability

(a)
Mix design of grout shall be subject to approval. Cement, water and aggregates for
grout shall be according to Section 5. Course aggregate to be used shall be of 6 mm
nominal size and shall be rounded and evenly graded.
QCS 2014
(b)

Part
The workability of grout mixes, where used, shall be measured by a suitable and
approved means. The procedure for monitoring the suitability of grout throughout the
Works shall be stated in writing to the Engineer before beginning of the Works and
shall be subject to approval.
(c)
Additives to the grout shall require prior approval of the Engineer.
Reinforcement
All reinforcement shall be placed with the minimum delay after the completion of the
concreting or grouting operation. It shall be designed and fabricated in cages to permit
it to be placed in the correct position and to the depth specified through the concrete or
grout of the pile. Suitable approved spacers shall be provided to maintain the specified
concrete or grout cover to steel.
(b)
The transverse reinforcement of any reinforcing cage shall be approved and may
consist of either spirals, hoops or links.
(c)
Longitudinal main steel reinforcement shall be continuous over the specified length.
Where splices are necessary, the number of laps shall be kept to a minimum and bars
shall be welded or joined together in an approved manner.
(d)
Reinforcement shall be supported and centred so that it will provide the required
projection above the cut-off level, and the proper concrete cover.
Boring
General
During uncased boring with continuous flight auger, the feed forward and speed
(revolutions per minute) are to be adjusted according to the soil conditions in a way
that the excavation of soil will be limited to a quantity that the lateral support of the
uncased borehole wall will be ensured.
Removal of Augers from the Ground
Piles shall not be bored so close to other piles which have recently been cast as to
damage them.
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(a)
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(a)
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4.4.3
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(a)
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Page 22
(a)
Depth of Piles
(a)
Augers shall not be extracted from the ground during the boring or construction of a
pile in such a way that an open unsupported bore or inflow of water into the pile section
would result. While withdrawing the continuous flight auger, the auger shall be rotated
in the same direction as during drilling into the soil or shall be withdrawn without
rotation.
Any failure of a pile to reach the designated depth shall be reported to the Engineer
without delay and a full statement of the reasons given.
Suitability of Boring Equipment

(a)
The piles shall be bored using approved and suitable equipment capable of
penetrating the ground without drawing surrounding soils laterally into the pile bore.
QCS 2014

Part
4.4.4
Equipment for Supply of Concrete or Grout to Piles

(a)
Grout or concrete shall be supplied to the pile through suitable tubing and the hollow
auger stem. All pipe fitments and connections shall be so constructed that grout does
not leak during the injection process.
Commencement of Concrete or Grout Supply to Each Pile

(a)
The base of the auger stem shall be fitted with a suitable means of sealing it against
ingress of water and soil until concrete or grout placing begins.
(b)
At the beginning of concrete or grout placement this sealing device shall be removed
by the application of concrete or grout pressure. Care shall be taken to ensure that the
auger is lifted only sufficiently to initiate the flow of concrete or grout, and that water
inflow and soil movement at the base of the auger are minimised. The technique and
equipment used to initiate and maintain the concrete or grout flow shall be such that a
pile of the full specified cross-section is obtained from the maximum depth of boring to
the final pile cut-off level.
The concrete or grout shall be supplied to the pile at a sufficient rate during auger
withdrawal to ensure that a continuous monolithic shaft of the full specified crosssection is formed, free from debris or any segregated concrete or grout.
(b)
The rate of withdrawal of the auger, the injection pressures and the rate of supply of
concrete or grout shall be measured and recorded throughout the phase of auger
withdrawal for each pile.
(c)
The Contractor shall submit proposals for his method of monitoring construction for
approval before beginning the Works.
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Completion of Piles
If the concrete or grout placing in any pile cannot be completed in the normal manner,
then the pile shall be rebored before concrete has hardened and shall be completely
replaced.
(a)
ta
(a)
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Rate of Supply of Concrete or Grout
Casting Level of Pile Head

Concrete or grout shall be cast to the original ground level in all cases, and the
reinforcing cage set, as appropriate.
(a)
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Page 23
4.4.5
When cutting off and trimming piles to the specified cut-off level, the Contractor shall take
care to avoid shattering or otherwise damaging the rest of the pile. Any laitance, or
contaminated, cracked or defective concrete shall be cut away and the pile repaired in an
approved manner to provide a full and sound section up to the cut-off level.
4.5
DRIVEN CAST IN PLACES PILES
4.5.1
Scope
This Part applies to piles for which a permanent casing of steel or concrete is driven,
reinforcement placed within it if required, and the casing filled with concrete. It also applies to
piles in which a temporary casing is driven, reinforcement placed within it and the pile formed
in the ground by filling the temporary casing with concrete before and during its extraction.
QCS 2014

Part
Page 24

This Section
Section 5, Concrete
Submittals
Where the Contractor wishes to form a pile with an enlarged base, details of the proposed
method of forming the base and the materials to be used shall be submitted at the time of
tendering.
4.5.3
Quality Assurance
Before placing concrete in a pile casing, the Contractor shall check in an approved manner
that the casing is undamaged, and free from water or other foreign matter. In the event of
water or foreign matter having entered the pile casing, either the casing shall be withdrawn,
repaired if necessary and re-driven, or other action shall be taken as may be approved to
continue the construction of the pile.
4.5.4
Materials
Permanent Casings
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Permanent casings shall be as specified. Where a permanent casing is to be made

from a series of short sections it shall be designed and placed so as to produce a
continuous water-free shaft. The dimensions and quality of the casing shall be
adequate to withstand the stresses caused by handling and driving without damage or
distortion.
external cross-section throughout each continuous length. During concreting they
shall be free from internal projections and encrusted concrete which might prevent the
(a)
Temporary Casings
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(a)
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4.5.2
Pile Shoes
(a)
Pile shoes shall be manufactured from durable material capable of withstanding the
stresses caused by driving without damage, and shall be designed to give a watertight
joint during construction.
Reinforcement
(a)
This type of pile shall normally be reinforced over its full length unless permanently
cased. The use of shorter reinforcement in piles which are not permanently cased
shall be subject to the approval of the Engineer.
(b)
The number of splices in longitudinal steel bars shall be kept to a minimum. The full
strength of each bar shall be effective across each splice, which shall be made so that
there is no detrimental displacement of the reinforcement during the construction of
the pile.
QCS 2014

Part
4.5.5
Driving piles
Piling Near Recently Cast Piles

(a)
Casings shall not be driven or piles formed so close to other piles which have recently
been cast as to damage them.

(a)
energy of the driving equipment
(b)
Drop hammers shall not be used from floating craft in such a manner as to cause
instability of the craft.
Length of Piles
Driving Procedure
(a)
Each pile casing shall be driven continuously until the specified or approved depth or
resistance (set), or both, has been reached. In the event of unavoidable interruption to
driving, the pile will be accepted provided on resumption the casing can be driven to
the specified depth or resistance (set), or both, without damage.
(b)
driving characteristics is encountered. A detailed record of the driving resistance over
the full length of the nearest available subsequent pile shall be taken if required.
(c)
over the full length of the first pile to be installed and over the last 3 m of the driving of
subsequent piles until consistency of behaviour is established. Where required,
detailed driving records shall also be made for 5 % of the piles driven, the positions of
such piles being specified by the Engineer.
(d)
The Contractor shall give adequate notice and provide all facilities to enable the
Engineer to check driving resistance. A set shall be taken only in the presence of the
Engineer unless otherwise approved.
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Final Set
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The length of pile to be driven in any location shall be approved.
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(a)
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Page 25
(a)
Where piles are driven to a set, the final set of each pile, pile shell or casing shall be
recorded either as the penetration in millimetres per ten blows or as the number of
blows required to produce a penetration of 25 mm.
(b)
(i)
The exposed part of the pile casing shall be in good condition, without damage
or distortion.
(ii)
The dolly, helmet and packing, if any, shall be in sound condition.
(iii)
(iv)
(v)
Temporary compression of the pile casing shall be recorded if required.
QCS 2014
If preboring is specified the pile casing shall be pitched after preboring to the
designated depth and diameter.
Jetting
(a)
Page 26
Preboring
(a)

Part
approved by the Engineer
Internal Drop Hammer

Where a casing for a pile without an enlarged base is to be driven by an internal drop
hammer, a plug consisting of concrete grade 20 with a water/cement ratio not
exceeding 0.25 shall be placed in the pile. This plug shall have a compacted height of
not less than 2.5 times the diameter of the pile. Fresh concrete shall be added to
ensure that this height of driving plug is maintained in the casing throughout the period
of driving, and in any event a plug of fresh concrete shall be added after 1.5 h of
normal driving or after 45 min of hard driving, or, should the driving of a pile be
interrupted for 30 min or longer, fresh concrete shall be added prior to driving being
resumed.
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(a)
Risen Piles
Piles shall be driven in an approved sequence to minimise any detrimental effects of heave
and lateral displacement of the ground.
When required, levels and measurements shall be taken to determine the movement of the
ground or any pile resulting from the driving process.
When a pile has risen with detrimental effects as a result of adjacent piles being driven the
Contractor shall, if required, submit to the Engineer his proposals for correcting or
compensating for this and for avoidance or control of heave effects in subsequent work.
4.5.7
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4.5.6
(a)
sufficiently workable to ensure that the concrete is not lifted.
Concrete Level
(a)

maintained within it to ensure that pressure from external water or soil is exceeded and
that the pile is neither reduced in section nor contaminated.
(b)
Concrete shall be topped up as necessary while the casing is extracted until the
required head of concrete to complete the pile in a sound and proper manner has been
provided. No concrete is to be placed once the bottom of the casing has been lifted
above the top of the concrete.
Vibrating Extractors
(a)
The use of vibrating casing extractors will be permitted subject to Part 1 (Noise and
Disturbance) and (Damage to Adjacent Structures).
QCS 2014

Part
Page 27
Concrete Casting Tolerances

(a)
For piles constructed without the use of a rigid permanent lining, pile concrete shall be
cast to the original ground level.
(b)
Where piles are constructed inside rigid permanent lining tubes or permanent casings,
pile heads shall be cast to a level above the specified cut-off so that, after trimming, a
sound concrete connection with the pile can be made. In this case, the tolerance of
casting above the cut-off level shall be determined according to Table 4.6.
Table 4.6
Casting Tolerance above Cut-off Level for Piles Constructed Inside Rigid Permanent Lining
Tubes or Permanent Casings
Cut-off distance below original
ground, H, (m)
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Casting tolerance above cut-off level

(m)
2.2 + H/10
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Repair of damaged pile heads and making-up of piles to the correct level
When repairing or extending the head of a pile, the head shall be cut off square in
sound concrete, and all loose particles shall be removed by wire brushing, followed by
washing with water.
(b)
If the driving of a pile has been accepted but sound concrete of the pile is below the
cut-off level, the pile shall be made good to the cut-off level with concrete of a grade
not inferior to that of the concrete of the pile.
as
(a)
Lengthening of cast-in- place piles after driving

When it is required to extend a cast-in-place driven pile above ground, the materials to
be used and procedures to be adopted shall be subject to the approval of the
Engineer.
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(a)
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0.15 to any depth
Lengthening of permanent pile casings during construction

The lengthening of permanent steel pile casings by adding an additional length of the
same steel casing during construction shall be carried out in accordance with the
relevant clauses of this Section or by other approved methods. The use of casing
extension materials and methods other than those specified shall be subject to
approval.
(a)

(a)
After each pile has been cast, any hole remaining shall be protected and shall be
carefully backfilled as soon as possible with approved materials.

(a)
provide a full and sound section to the cut-off level.
QCS 2014

Part
Page 28
4.6
STEEL PILES
4.6.1
Scope
This Part applies to driven steel piles designed to act as bearing piles.

This Section
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Section 5, Concrete
References
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4.6.2
ta
BS 4, ..........................Structural steel sections
BS 3100, ....................Steel casting for general engineering purposes.
qa
BS 5135, ....................Process of arc-welding of carbon and carbon manganese steels

BS 6265, ....................Resistance steam welding of uncoated and coated low carbon steel
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BS 7613, ....................Hot rolled quenched and tempered weldable structural steel plates
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API 5L,........................Interpretation of non-destructive testing.

Submittals
Where coatings are specified, the Contractor shall submit for approval full details of the
coating procedure and surface preparation according to relevant British or Swedish
Standards.
4.6.4
Quality Assurance
The Contractor shall provide the Engineer with Works test certificates, analyses, and mill
sheets, together with a tube manufacturer's certificate showing details of the pile number,
cast number of the steel and a record of all tests and inspections carried out. The Engineer
has the right to inspect any stage of the manufacturing processes and shall be given
adequate notice by the Contractor of such processes and production tests, provided that,
once he has been notified, any delay in his attendance does not cause delay to, or disrupt,
the manufacturing process. The Contractor shall provide the Engineer with samples for
independent testing when requested.
The Contractor shall submit for approval full details of the welding procedures and
electrodes, with drawings and schedules as may be necessary. Tests shall be undertaken as
may be required by the relevant British Standard or as may be required by the Engineer.
Only welders who are qualified in the approved welding procedure in accordance with the
tests laid down in the relevant British Standard, or who have a proven record over the
previous six months, or who have attained a similar standard, shall be employed on the
Works. Proof of welders' proficiency shall be made available to the Engineer on request.
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4.6.3
QCS 2014

Part
4.6.5
The Contractor shall

(a)
Order the piles to suit the construction programme.
(b)
Obtain the Engineer's approval before placing the order.
Page 29
When preliminary piles are specified, the approval for the piles for the main work will not
necessarily be given until the results of the driving and tests on preliminary piles have been
received and evaluated.
Each pile shall be clearly numbered and its length shown near the pile head using white
paint. In addition, before being driven, each pile shall be graduated at appropriate intervals
along its length and at intervals of 250 mm along the top 3 m.
All piles within a stack shall be in groups of the same length and on approved supports. All
operations such as handling, transporting and storing of piles shall be carried out in a manner
such that damage to piles and their coatings is minimised.
4.6.6
Materials
Pile Shoes
ta
qa
Cast steel shoes shall be of steel to BS 3100, grade Al. Flat plate and welded
fabricated steel shoes shall be grade 43A or 50A, conforming to BS 7613 and related
standards.
Strengthening of Piles
The strengthening to the toe of a pile in lieu of a shoe or the strengthening of the head
of a pile shall be made using material of the same grade as the pile unless otherwise
approved.
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Manufacturing Tolerance
All piles shall be of the type and cross-sectional dimensions specified. For standard
rolled sections the dimensional tolerances and weight shall comply with the relevant
standard. The tolerance on length shall be -0 and +75 mm unless otherwise specified.
For proprietary sections the dimensional tolerances shall comply with the
manufacturer's standards. The rolling or manufacturing tolerances for proprietary
sections shall be such that the actual weight of section does not differ from the
theoretical weight by more than +4 % or -2 % unless otherwise agreed. The rolling
or manufacturing tolerances for steel tubular piles shall be such that the actual weight
of section does not differ from the theoretical weight by more than 5 %.
(a)
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Straightness of Piles
(a)
For standard rolled sections the deviation from straightness shall be within the
compliance provisions of BS 4, Part 1. When two or more rolled lengths are joined by
butt-jointing, the deviation from straightness shall not exceed 1/600 of the overall
length of the pile.
(b)
For proprietary sections made up from rolled sections, and for tubular piles, the
deviation from straightness on any longitudinal face shall not exceed 1/600 of the
length of the pile nor 5 mm in any 3 m length.
QCS 2014
Page 30
Fabrication of Piles
(a)
For tubular piles where the load will be carried by the wall of the pile, and if the pile will
be subject to loads that induce reversal of stress during or after construction, the
external diameter at any section as measured by using a steel tape on the
circumference shall not differ from the theoretical diameter by more than 1.
(b)
The ends of all tubular piles as manufactured shall be within a tolerance on ovality of
1 % as measured by a ring gauge for a distance of 100 mm at each end of the pile
length.
(c)
The root edges or root faces of lengths of piles that are to be shop butt-welded shall
not differ by more than 25 % of the thickness of pile walls not exceeding 12 mm thick
or by more than 3 mm for piles where the wall is thicker than 12 mm. When piles of
unequal wall thickness are to be butt-welded, the thickness of the thinner material shall
be the criterion.
Matching of Pile Lengths
Longitudinal seam welds and spiral seam welds of two lengths of tubular piles being
joined shall, whenever possible, be evenly staggered at the butt. However, if in order
to obtain a satisfactory match of the ends of piles or to meet specified straightness, the
seams cannot be staggered evenly, then they shall be staggered by at least 100 mm.
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Welding
Welding of H-piles and piles that will be subjected to stress reversal, during or after
construction, shall be in accordance with BS 5135.
(b)
For a tubular pile where the load will be compressive and non-reversible and will be
carried by the wall of the pile or by composite action with a concrete core, the welding
shall be to BS 5135 or BS 6265.
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(a)
Coating Piles for Protection against Corrosion

Where coatings are specified they shall be provided in accordance with the Particular
Specification. In general, coatings will not be called for where piles are fully in contact
with undisturbed natural soils or below the standing water table. Cathodic protection
may be called for when there is a possibility of stray electrical current from the
supported structure flowing to earth through the piles.
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Part
4.6.7
Acceptance Standards for Shop Welds

(a)
Longitudinal or spiral welds made in the manufacture of tubular piles are subject to the
acceptance standard for interpretation of non-destructive testing specified in latest
edition of API 5L. The maximum projecting height of weld reinforcement shall not
exceed 3 mm for wall thicknesses not exceeding 13 mm and 5 mm for wall
thicknesses greater than 13 mm.
(b)
Longitudinal welds joining the constituent parts of the box or proprietary section shall
be in accordance with the manufacturer's specification.
(c)
The maximum projecting height of weld reinforcement for circumferential welds in

tubular piles shall be the same as specified above for longitudinal welds in tubular
piles.
QCS 2014

Part
Page 31
Acceptance Standards for Site Butt Welds

(a)
Welds shall comply with the requirements of the Weld Quality Acceptance Standards
for Site Butt Welds in Steel Bearing Piles published by British Steel Corporation,
General Steels Group.
The finished coating shall be generally of smooth and uniform texture and free from sharp
protuberances or pin holes. Excessive sags, dimpling or curtaining will not be acceptable.
Any coat damaged by subsequent processes, or which has deteriorated to an extent such
that proper adhesion of the coating is in doubt, shall be removed and the surface shall be
cleaned to the original standard and recoated with the specified number and thicknesses of
coats.
The completed coating shall be checked for thickness by an approved magnetic thickness
gauge. Areas where the thickness is less than that specified shall receive approved
additional coating.
Average measured thickness should be equal to or greater than the specified thickness and
no single reading should be less than 85 % of the specified thickness. The completed
coating shall also be checked for adhesion by the cross-hatching method with lines spaced at
ten times the thickness of the coating. Adhesion tests should not be carried out prior to
seven days after coating.
The tests shall be made on 10 % of the piles. Areas where the adhesion is not approved
shall be sand blasted and recoated. The coating shall be approved before pitching and
driving of the piles.
4.6.9
Driving of piles
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At all stages during driving and until incorporation in the superstructure, the free length
of the pile shall be adequately supported and restrained by means of leaders, trestles,
temporary supports or other guide arrangements to maintain position and alignment
and to prevent buckling. In marine works, lengths which remain unsupported after
driving shall be adequately restrained until incorporated into the permanent Works.
These constraint arrangements shall be such that damage to piles and their coatings is
minimised.
(a)
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4.6.8

(a)
energy of the driving equipment. Where required in the Contract, dynamic evaluation
and analysis shall be provided.
(b)
such a manner as to cause instability of the craft.
QCS 2014
Length of Piles
(a)
The length of pile to be driven and any additional lengths of pile to be added during
driving shall be approved by the Engineer.

the pile will be accepted provided it can be driven to the specified depth or resistance
(set), or both, without damage.
(b)
A follower shall not be used unless approved, in which case the Engineer will require
the set where applicable to be revised in order to take into account reduction in the
effectiveness of the hammer blow.
(c)
The Contractor shall inform the Engineer as soon as an unexpected change in driving
characteristics is noted. A detailed record of the driving resistance over the full length
of the nearest subsequent pile shall be taken, if required by the Engineer.
(d)
At the start of the work in a new area or section a detailed record shall be made over
the full driving length of the first pile, and during the last 3 m of the driving of
subsequent piles, to establish the driving behaviour. Where required, detailed driving
records shall also be made for 5 % of the piles driven, the locations of such piles being
(e)
(f)
Redrive checks, if required, shall be carried out in accordance with an approved

procedure.
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(a)
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When a final set or resistance is being measured, the following requirements shall be
met:
(b)
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Final Set or Resistance
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Part
(i)
distortion.
(ii)
The dolly and packing, if any, shall be in sound condition.
(iii)
(iv)
The hammer shall be in good condition, delivering adequate energy per blow
(v)
The temporary compression of the pile shall be recorded, if required by the

Engineer.
Preboring
(a)
If preboring is specified the pile shall be pitched after preboring to the designated
depth and diameter.
QCS 2014

Part
Page 33
Jetting
(a)
approved.
Risen Piles
When required by the Engineer, levels and measurements shall be taken to determine the
movement of the ground or any pile resulting from the driving of adjacent piles.
When a pile has risen as a result of adjacent piles being driven, the Engineer may call for
redriving or other testing to demonstrate that the performance of the pile under load is
unimpaired. If required, the Contractor shall make proposals for correcting detrimentally
affected piles and for avoidance or control of heave in subsequent work.
4.6.11
If a steel superstructure is to be welded to piles, the pile cut-off shall be square and to within
5 mm of the elevations shown on the Drawings. If pile heads are to be encased in concrete
they shall be cut to that same tolerance and protective coatings shall be removed from the
surfaces of the pile heads down to a level 100 mm above the soffit of the concrete.
4.7
MICROPILES (TO BE ADDED LATER)
4.8
REDUCTION OF FRICTION ON PILES
4.8.1
Scope
This Part includes preapplied bituminous or other proprietary friction-reducing coating, preapplied low-friction sleeving, formed-in-place low-friction surround, and preinstalled lowfriction sleeving.
Related Parts are as follows:
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4.6.10
This Section
4.8.2
Submittals
Where the particular method of reducing friction is not specified, the Contractor shall submit
full details of the method which he proposes.
4.8.3
General
(a)
Where a means of reducing friction on any specified length of pile is required by the
Contract, the Contractor shall provide a suitable interface between pile and soil by one
of the following, or other approved, methods
QCS 2014
Page 34
(i)
Preapplied bituminous or other proprietary friction-reducing coating.
(ii)
Preapplied low-friction sleeving.
(iii)
Formed-in-place low-friction surrounds.
(iv)
Preinstalled low-friction sleeving.
Preapplied Bituminous or other Friction-Reducing Coating Materials

(a)
Where a proprietary product is specified, the process of cleaning pile surfaces, and the
conditions and methods of application shall conform to the manufacturer's current
instructions. All materials shall conform to the manufacturer's specification, which
shall be given to the Engineer before any coating is applied.
(b)
Where a friction-reducing material has been applied to a preformed pile prior to

installation, it shall be protected from damage during handling and transportation. In
the event of inadvertent damage to the coating, it shall be repaired on site, prior to the
pile being driven, to the same specification as the original coating. Where bituminous
materials are involved, precautions shall be taken as necessary in hot weather to
prevent excessive flow or displacement of the coating. The coated piles shall be
adequately protected against direct sunlight and, if stacked, they shall be separated to
prevent their coatings sticking together.
(c)
In the case of applied coatings, the piles shall not be driven when the air temperature
is such that the coating will crack, flake or otherwise be damaged prior to entry into the
ground. Where bituminous materials are involved, driving shall be carried out while
the temperature is at or above 5 C unless otherwise approved or called for in the
manufacturer's instructions.
Formed-In-Place Low-Friction Surround

Where a hole is bored in the ground and filled with low-friction material through which a
pile is subsequently driven or placed, the method and the properties of the low-friction
material both above and below standing groundwater level, together with the
dimensions of the prebored hole in relation to the pile, shall be approved by the
Engineer.
(a)
Piles may be driven with a preapplied low-friction sleeving subject to the approval of
the detailed design and method by the Engineer.
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Preapplied Low-Friction Sleeving
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Part
Preinstalled Low-Friction Sleeving

(a)
Where a system is employed involving placing a low-friction sleeve in the ground prior
to pile installation, the detailed materials and method of installation of the sleeving shall
be approved by the Engineer.
4.8.4
Inspection
The Engineer may call for piles to be partially exposed or extracted at the commencement of
a contract in order to demonstrate that the method of installation does not impair the
effectiveness of the system in the circumstances of use on the particular site. Where damage
is found to have occurred, or is likely to occur in the opinion of the Engineer, additional
measures or variation of the method may be called for. At the discretion of the Engineer,
further inspections shall be carried out to ascertain the effectiveness of the additional
measures.
QCS 2014

Part
Page 35
4.8.5
Driving resistance
Allowance shall be made in driving piles to a required resistance or set for any differences
between the short-term driving resistance and the long-term static resistance of the coating
or surrounding low-friction material which is in use.
4.9
PILE LOAD TESTING
4.9.1
Scope
This Part deals with the testing of a pile by the controlled application of an axial load. It
covers vertical and raking piles tested in compression (i.e. subjected to loads or forces
in a direction such as would cause the piles to penetrate further into the ground) and
vertical or raking piles tested in tension (i.e., subjected to forces in a direction such as
would cause the piles to be extracted from the ground).
References
The following standard is referred to in this Part:
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(a)
Allowable pile capacity: a load which is not less than the specified working load and
which takes into account the pile's ultimate bearing capacity, the materials from which
the pile is made, the required factor of safety, settlement, pile spacing, downdrag, the
overall bearing capacity of the ground beneath the piles and any other relevant factors.
The allowable pile capacity indicates the ability of a pile to meet the specified loading
requirements.
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Definitions
When required, the design and full details of the proposed load application system
shall be submitted to the Engineer prior to the commencement of testing. The load
application system shall be satisfactory for the required test.
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(a)
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Submittals
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BS 1881, ....................Methods of testing concrete.
(b)
Compression pile: a pile which is designed to resist compressive (downward) axial

load.
(c)
Constant rate of penetration (CRP) test: a test in which the pile is made to penetrate
the soil at a constant controlled speed, while the loads applied at the top of the pile in
order to maintain the constant rate of penetration are continuously measured. The
purpose of the test is to derive the ultimate bearing capacity of a pile and not its load
settlement characteristics.
(d)
Constant rate of uplift (CRU) test: the same in principle as the CRP test, but the pile is
subject to tension rather than compression. The purpose of the test is to determine
the 'pull-out' capacity of a pile.
(e)
Design verification load (DVL): a test load, in lieu of a specified working load, applied
to a single pile at the time of testing to determine that site conditions conform to design
assumptions. This load will be peculiar to each preliminary (test) pile and should equal
the maximum specified working load for a pile of the same dimensions and material,
plus allowances for soil-induced forces and any other particular conditions of the test.
QCS 2014
Page 36
Kentledge: ballast used in a loading test.
(g)
Maintained load test: a loading test in which each increment of load is held constant
either for a defined period of time or until the rate of settlement falls to a specified
value.
(h)
Preliminary pile: a test pile installed before the commencement of the main piling
works or a specific part of the Works for the purpose of establishing the suitability of
the chosen type of pile and for confirming its design, dimensions and bearing capacity.
(i)
Proof load: a load applied to a selected working pile to confirm that it is suitable for the
load at the settlement specified. A proof load should not normally exceed the design
verification load plus 50 % of the specified working load.
(j)
Raking pile: a batter pile, installed at an inclination to the vertical.
(k)
Reaction system: the arrangement of kentledge, piles, anchors or rafts that provides a
resistance against which the pile is tested.
(l)
Specified working load (SWL): the designated load on the head of a pile.
(m)
Tension pile: a pile which is designed to resist a tensile (upward) axial force.
(n)
Test pile: any pile, preliminary or part of the works, to which a test is applied.
(o)
Ultimate bearing capacity: the load at which the resistance of the soil becomes fully
mobilised through friction, end bearing or a combination thereof.
(p)
Working pile: one of the piles forming the foundation of a structure.
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(f)
Notice of Construction
(b)
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The Contractor shall give the Engineer at least 48 hours' notice of the
commencement of construction of any preliminary pile which is to be testloaded.
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(i)
Method of Construction
Each preliminary test pile shall be constructed in a manner similar to that to be
used for the construction of the working piles, and by the use of similar
equipment and materials. Any variation will be permitted only with prior approval.
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(i)
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Construction of a preliminary pile to be tested

Part
(c)
Boring or Driving Record

(i)
(d)
For each preliminary pile to be tested, a detailed record of the conditions

experienced during boring and of the progress during driving, shall be made and
submitted to the Engineer daily, not later than noon on the next working day.
Where the Engineer requires soil samples to be taken or in-situ tests to be
made, the Contractor shall include that in the daily report, as well as the test
results.
Concrete Test Cubes

(i)
In the case of concrete piles, four test cubes shall be made from the concrete
3
used in the manufacturer of each preliminary test pile and from each 50 m of
the concrete used in the manufacture of working piles. If a concrete pile is
extended or capped for the purpose of testing, an additional four cubes shall be
made from the corresponding batch of concrete. The cubes shall be made and
tested in accordance with BS 1881.
QCS 2014

Part
(ii)
(e)
If a test is required on a working pile the Contractor shall cut off or otherwise
prepare the pile for testing as required by the Engineer.
Cut-off Level
(i)
The cut-off level for a preliminary test pile shall be approved by the Engineer.
Supervision
The setting-up of pile testing equipment shall be carried out under competent
supervision and the equipment shall be checked to ensure that the set-up is
satisfactory before the commencement of load application.
(b)
All tests shall be carried out only under the direction of an experienced and competent
supervisor experienced with the test equipment and test procedure. All personnel
operating the test equipment shall have been trained in its use.
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(a)
Safety precautions
General
Design, erection and dismantling of the pile test reaction system and the
application of load shall be carried out according to the requirements of the
various applicable statutory regulations concerned with lifting and handling
heavy equipment and shall safeguard operators and others who may from time
to time be in the vicinity of a test from all avoidable hazards.
Kentledge
Where kentledge is used, the Contractor shall construct the foundations for the
kentledge and any cribwork, beams or other supporting structure in such a
manner that there will not be differential settlement, bending or deflexion of an
amount that constitutes a hazard to safety or impairs the efficiency of the
operation. The kentledge shall be adequately bonded, tied or otherwise held
together to prevent it becoming unstable because of deflexion of the supports or
for any other reason.
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(i)
(b)
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(i)
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(a)
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The pile test shall not be started until the strength of the cubes taken from the
pile exceeds twice the average direct stress in any pile section under the
maximum required test load, and the strength of the cubes taken from the cap
exceeds twice the average stress at any point in the cap under the same load.
Variation of procedure will be permitted only if approved by the Engineer.
Preparation of a Working Pile to be Tested

(i)
(f)
Page 37
(ii)
When kentledge constitutes the principal component of a reaction system, its

weight for each test shall be at least 25% greater than the maximum test load
for that test. The weight may be determined by scale or the density and volume
of the constituent materials. In adding kentledge, care shall be taken to properly
position the centre of gravity of the stack.
QCS 2014
(c)

Part
Tension Piles, Reaction Piles and Ground Anchorages
(i)
Where tension piles, reaction piles or ground anchorages constitute the principal
components of a reaction system, they shall be so designed that they will resist
the forces applied to them safely and without excessive deformation which could
cause a safety hazard during the work. Such piles (which, unless approved, will
not be working piles) or anchorages shall be driven in the specified locations,
and all bars, tendons or links shall be aligned to provide a stable reaction in the
direction required. Any welding employed to extend or to fix anchorages to a
reaction frame shall be carried out so that the full strength of the system is
adequate and unimpaired.
Testing Equipment
(i)
In all cases the Contractor shall ensure that when the hydraulic jack and loadmeasuring device are mounted on the pile head the whole system will be stable
up to the maximum load to be applied.
(ii)
If in the course of carrying out a test any unforeseen occurrence should take
place, further loading shall not be applied until a proper engineering assessment
of the condition has been made and steps have been taken to rectify any fault.
Reading of gauges should, however, be continued where possible and if it is
safe to do so.
(iii)
Where an inadequacy in any part of the system might constitute a hazard,

means shall be provided to enable the test to he controlled from a position
remote from of the kentledge stack or test frame.
(iv)
The hydraulic jack, pump, hoses, pipes, couplings and other apparatus to be
operated under hydraulic pressure shall be capable of withstanding a pressure
of 1.5 times the maximum pressure used in the test without leaking. The
maximum test load expressed as a reading on the gauge in use shall be
displayed and all operators shall be made aware of this limit.
Pile Head for Compression Test

For a pile that is tested in compression, the pile head or cap shall be formed to
give a plane surface which is normal to the axis of the pile, sufficiently large to
accommodate the loading and settlement measuring equipment and adequately
reinforced or protected to prevent damage from the concentrated load applied
by the loading equipment.
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(d)
Page 38
(f)
(ii)
Any test pile cap shall be concentric with the test pile; the joint between the cap
and the pile shall have a strength equivalent to that of the pile.
(iii)
Sufficient clear space shall be made under any part of the cap projecting beyond
the section of the pile so that, at the maximum expected settlement, load is not
transmitted to the ground by the cap.
Pile Connection for Tension Test

(i)
For a pile that is tested in tension, means shall be provided for transmitting the
test load axially without inducing moment in the pile. The connection between
the pile and the loading equipment shall be constructed in such a manner as to
provide strength equal to 1.5 times the maximum load which is to be applied to
the pile during the test.
QCS 2014
Page 39
Reaction systems
(i)
The reaction for compression tests shall be provided by kentledge, tension piles
or specially constructed anchorages. Kentledge shall not be used for tests on
raking piles except where the test set-up has been specifically designed to
conform to Item 7(g). and has been approved by the Engineer.
(ii)
Where kentledge is to be used, it shall be supported on cribwork and positioned

so that the centre of gravity of the load is as close as possible to the axis of the
pile. The bearing pressure under supporting cribs shall be such as to ensure
stability of the kentledge stack.
Tension Tests
(i)
The reaction for tension tests shall be provided by compression piles, rafts or
grillages constructed on the ground. In all cases the resultant force of the
reaction system shall be coaxial with the test pile.
(ii)
Where inclined piles or reactions are proposed, full details shall be submitted for
approval prior to the commencement of testing.
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Working piles shall not be used as reaction piles without approval from the
Engineer.
(ii)
Where working piles are used as reaction piles their movement shall be
measured and recorded to with an accuracy of 0.5 mm, and recorded.
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(i)
Spacing
Where kentledge is used for loading vertical piles in compression, the distance
from the edge of the test pile to the nearest part of the crib supporting the
kentledge stack in contact with the ground shall be not less than 1.3 m.
(ii)
The centre-to-centre spacing of vertical reaction piles from a test pile shall
conform to Paragraph 1 above, but shall be not less than three times the
diameter of the test pile or the reaction piles or 2 m, whichever is the greatest,
except in the case of piles of 300 mm diameter (or equivalent) or less, where the
distance may be reduced to 1.5 m. Where a pile to be tested has an enlarged
pile cap, the same criterion shall apply with regard to the pile shaft, with the
additional requirement that no surface of a reaction pile shall be closer to the
pile cap of the test pile than one half of the pile cap plan dimension.
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(i)
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(d)
Working Piles
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(b)
Compression Tests
(a)

Part
(iii)
(e)
Where ground anchorages are used to provide a test reaction for loading in
compression, no section of fixed anchor length transferring load to the ground
shall be closer to the test pile than three times the diameter of the test pile.
Where the pile to be tested has an enlarged pile cap, the same criterion shall
apply with regard to the pile shaft, with the additional requirement that no section
of the fixed anchor transferring load to the ground shall be closer to the pile cap
than a distance equal to one half the pile cap plan dimension.
Adequate Reaction
(i)
The reaction frame support system shall be adequate to transmit the maximum
test load in a safe manner without excessive movement or influence on the test
pile. Calculations shall be provided to the Engineer when required to justify the
design of the reaction system.
QCS 2014
(f)

Part
Care of Piles
(i)
Page 40
The method employed in the installation of the reaction system shall be such as
to prevent damage to any test pile or working pile.
Equipment for applying load

The equipment used for applying load shall consist of a hydraulic ram or jack. The
jack shall be arranged in conjunction with the reaction system to deliver an axial load
to the test pile. Proposals to use more than one ram or jack will be subject to approval
by the Engineer of the detailed arrangement. The complete system shall be capable of
safely transferring the maximum load required for the test. The length of stroke of a
ram shall be sufficient to account for deflexion of the reaction system under load plus a
deflection of the pile head by up to 15 % of the pile shaft diameter unless otherwise
specified or agreed prior to commencement of test loading.
Measurement of load
A load measuring device shall be used and in addition a calibrated pressure gauge
included in the hydraulic system. Readings of both the load measuring device and the
pressure gauge shall be recorded. In interpreting the test data the values given by the
load measuring device shall normally be used; the pressure gauge readings are
required as a check for gross error.
(b)
The load measuring device may consist of a load measuring column, pressure cell or
other appropriate system. A spherical seating of appropriate size shall he used to
avoid eccentric loading. Care shall be taken to avoid any risk of buckling of the load
application and measuring system. Load measuring and application devices shall be
short in axial length in order to secure stability. The Contractor shall ensure that axial
loading is maintained.
(c)
The load measuring device shall be calibrated before and after each series of tests,
whenever adjustments are made to the device or at intervals appropriate to the type of
equipment. The pressure gauge and hydraulic jack shall be calibrated together.
Certificates of calibration shall be supplied to the Engineer.
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(a)
Control of loading
The loading equipment shall enable the load to be increased or decreased smoothly or
to be held constant at any required value.
(a)
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(a)
12
Measuring pile head movement

(a)
Maintained Load Test

(i)
(b)
In a maintained load test, movement of the pile head shall he measured by one
of the methods in Items 11 (d), (e), (f), (g) in the case of vertical piles, or by one
of the methods in 11 (d), (f), (g) in the case of the raking piles, as required.
CRP and CRU Tests

(i)
In a CRP or a CRU test, the method in Item 11 (d) shall be used. Checklevelling of the reference frame or the pile head shall not be required. The dial
gauge shall be graduated in divisions of 0.02 mm or less.

Part
(c)
Page 41
Reference Beams and Dial Gauges

(i)
An independent reference beam or beams shall be set up to enable

measurement of the movement of the pile to be made to the required accuracy.
The supports for a beam shall be founded in such a manner and at such a
distance from the test pile and reaction system that movements of the ground
do not cause movement of the reference beam or beams which will affect the
accuracy of the test. The supports of the beam or beams shall be at least three
test pile diameters or 2 m from the centre of the test pile, whichever distance is
the greater.
(ii)
Check observations of any movements of the reference beam or beams shall be

made and a check shall be made of the movement of the pile head relative to a
remote reference datum at suitable intervals during the progress of the test.
(iii)
The measurement of pile movement shall be made by four dial gauges rigidly
mounted on the reference beam or beams, bearing on prepared flat surfaces
fixed to the pile cap or head and normal to the pile axis. Alternatively, the
gauges may be fixed to the pile and bear on prepared surfaces on the reference
beam or beams. The dial gauges shall be placed equidistant from the pile axis
and from each other. The dial gauges shall enable readings to be made to an
accuracy of at least 0.1 mm and have a stem travel of at least 25 mm.
Machined spacer blocks may be used to extend the range of reading. Equivalent
electrical displacement-measuring devices may be substituted.
Optical Levelling Method
An optical levelling method by reference to a remote datum may be used.
(ii)
Where a level and staff are used, the level and scale of the staff shall be chosen
to enable readings to be made to within an accuracy of 0.5 mm. A scale
attached to the pile or pile cap may be used instead of a levelling staff. At least
two reliable independent datum points shall be established. Each datum point
shall be so situated as to permit a single setting-up position of the level for all
readings.
(iii)
No datum point shall be located where it can be affected by the test loading or
other operations on the Site.
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Reference Wires and Scales
(e)
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QCS 2014
(i)
Two parallel reference wires, one on either side of the pile, shall be held under
constant tension at right angles to the test pile axis between supports formed as
in the method in Item 11 (d). The wires shall be positioned against scales fixed
to the test pile head in an axial direction and the movements of the scales
relative to the wires shall be determined.
(ii)
Check observations of any movements of the supports of the wires shall be

made and a check shall be made on the movement of the pile head at approved
time intervals. Readings shall be taken to within an accuracy of 0.5 mm.
Other Methods
(i)
The Contractor may submit for approval any other method of measuring the
movement of the test pile head.
QCS 2014
Protection of testing equipment

(a)
Protection from Weather

(i)
(b)
Throughout the test period all equipment for measuring load and
shall be protected from exposure to adverse effect of weather.
movement
Prevention of Disturbance
(i)
14
Page 42
Construction activity and persons who are not involved in the testing process
shall be kept at a sufficient distance from the test to avoid disturbance to the
measuring apparatus. Full records shall be kept of any intermittent unavoidable
activity that might affect the test set-up.
Notice of test
commencement of the test. No load shall be applied to the test pile before the
commencement of the specified test procedure.
Test procedure
ta
Proof Load Test Procedure (working compression piles)
The maximum load which shall be applied in a proof test shall normally be the
sum of the design verification load (DVL) plus 50 % of the specified working load
(SWL). The loading and unloading shall be carried out in stages as shown in
Table 4.7. Any particular requirements given in the particular contract
documentation shall be complied with.
(ii)
Following each application of an increment of load, the load shall be maintained

at the specified value for not less than the period shown in Table 4.7 and until
the rate of settlement is less than 0.25 mm/h and decreasing. The rate of
settlement shall be calculated from the slope of the line obtained by plotting
values of settlement versus time and drawing a smooth curve through the
points.
(iii)
Each decrement of unloading shall proceed after the expiry of the period shown
in Table 4.7.
(iv)
For any period when the load is constant, time and settlement shall be recorded
immediately on reaching the load, at not more than 5 min intervals up to 15 min;
at approximately 15 min intervals up to 1 h; at 30 min intervals between 1 h and
4 h; and 1 h intervals between 4 h and 12 h after the application of the increment
of load.
qa
(i)
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(a)
15
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(i)
13

Part
(v)
Where the methods of measuring pile head movement given in Item 11 is used,
the periods of time for which loads must be held constant to achieve the
specified rates of settlement shall be extended as necessary to take into
account the lower levels of accuracy available from these methods and to allow
correct assessment of the settlement rate.
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Page 43
Table 4.7
Minimum time of holding load
25% DVL
50% DVL
75% DVL
100% DVL
75% DVL
50% DVL
25% DVL
0
100% DVL
100% DVL + 25% SWL
100% DVL + 50% SWL
100% DVL + 25% SWL
100% DVL
75% DVL
50% DVL
25% DVL
0
100% DVL
100% DVL + 50% SWL
100% DVL + 75% SWL
100% DVL + 100% SWL
100% DVL + 75% SWL
100% DVL + 50% SW
100% DVL + 25% SW
100% DVL
75% DVL
50% DVL
25% DVL
0
1h
1h
1h
1h
10 min
10 min
10 min
1h
6h
1h
6h
10 min
10 min
10 min
10 min
10 min
1h
6h
6h
1h
6h
10 min
10 min
10 min
10 min
10 min
10 min
10 min
1h
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Load *
(b)
SWL denotes specified working load; DVL denotes design verification load.
Test Procedure for Preliminary Compression Piles
et
it
Applicable
to tests on
Preliminary
Pile only
(i)
The procedure to be adopted for carrying out load tests on preliminary

compression piles shall be either the extended proof load test procedure or the
constant rate of penetration testing procedure given below. A normal proof load
test will constitute the first stage of such a test unless otherwise specified.
(ii)
Extended proof load test procedure. Where test pile is to be loaded up to the
sum of design verification load (DVL) plus 100 % of the specified working load,
the loading procedure may be carried out as a continuation of the proof load
testing procedure given in Item 14 (a).
(iii)
Following the completion of the proof load test, the load shall be restored in two
stages (DVL, DVL +50 % SWL), and shall subsequently be increased by stages
of 25 % of the specified working load. Following each application of an
increment of load, the load shall be maintained at the specified value for the
period shown in Table 4.7 and until the rate of settlement is decreasing and is
less than 0.25 mm/h.

Part
Page 44
(iv)
Where verification of required minimum factor of safety is called for or the pile is
to be tested to failure, the loading procedure shall be continued after reaching
DVL +100 % SWL stage by increasing the load in increments of 25 % of the
specified working load or other specified amount until the maximum specified
load of the test is reached. Following each application of increment of load, the
load shall be maintained at the specified value for not less than 1 h and until the
rate of settlement is decreasing and is less than 0.25 mm/h, or other approved
rate appropriate to the stage of loading and its proximity to a failure condition.
Permissible settlement at the load corresponding to the required minimum factor
of safety called for in the design will not normally be specified.
(v)
The rate of settlement shall be calculated from the slope of the line obtained by
plotting values of settlement versus time and drawing a smooth curve through
the points. Reduction of load at the end of the test shall be gradual as required
by Item 14 (a).and the final rebound of the pile head shall be recorded.
(vi)
Constant rate of penetration (CRP) testing procedure. Where it is required to

determine the ultimate load of a preliminary compression pile, and particularly
where piles are largely embedded in and bearing on clay soils, the CRP testing
procedure will normally be specified.
(vii)
The rate of movement of the pile head shall be maintained constant in so far as
is practicable and shall be approximately 0.01 mm/s.
(viii)
Readings of loads, penetration and time shall be made simultaneously at regular

intervals; the interval chosen shall be such that a curve of load versus
penetration can be plotted without ambiguity.
(ix)
Loading shall be continued until one of the following results is obtained
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as
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QCS 2014
The maximum required test load.
2.
A constant or reducing load has been recorded for an interval of

penetration of 10 mm.
ov
A total movement of the pile base equal to 10 % of the base diameter, or

any other greater value of movement specified, has been reached.
et
it
3.
er
1.
(x)
(c)
16
The load shall then be reduced in five approximately equal stages to zero load,
penetration and load being recorded at each stage.
Testing of Piles Designed to Carry Load in Tension

(i)
The testing of piles designed to carry load in tension shall follow the same
procedure as specified in 4.9.1
(ii)
In testing by the constant rate of uplift method, overall movements of the pile
head will normally be less than those expected in a constant rate of penetration
test. The rate of movement of the pile head shall be maintained at approximately
0.005 mm/s in so far as is practicable.
Completion of a test
(a)
Removal of Test Equipment
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(b)

Part
Page 45
(i)
On completion of a test and subject to the approval of the Engineer, all

measuring equipment and load application devices shall be dismantled and
checked. All other test equipment, including kentledge, beams and supporting
structures shall be removed from the test pile location. Measuring and other
demountable equipment shall be stored in a safe manner so that it is available
for further tests, or removed from the Site as approved by the Engineer.
(ii)
Temporary tension piles and ground anchorages shall be cut off below ground
level, and off-cut materials removed from the Site. The ground shall be restored
to the original contours.
Preliminary Test Pile Cap

Unless otherwise specified, the head of each preliminary test pile shall be cut off
below ground level, off-cut material shall be removed from the Site and the
ground restored to the original contours.
Proof Test Pile Cap
rw
On completion of a test on a proof pile, the test pile cap shall be prepared as
specified and left in a state ready for incorporation into the Permanent Works.
Any resulting off-cut materials shall be removed from the Site.
Results to be submitted
as
4.9.2
ta
(i)
qa
(c)
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(i)
During the progress of a test, all records taken shall be available for inspection by the
Engineer.
(b)
Results shall be submitted as
Preliminary report of the test results to the Engineer, unless otherwise directed,
within 24 hours of the completion of the test, which shall show.
For a test by maintained load: for each stage of loading, the period for
which the load was held, the load and the maximum pile movement at the
end of the stage.
et
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1.
ov
(i)
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(a)
2.
(ii)
For a CRP or CRU test: the maximum load reached and a graph of load
against penetration or load against uplift.
The final report of recorded data as prescribed in Item 15 (b).within ten days of
the completion of the test.
Schedule of Recorded Data

(a)
The Contractor shall provide information about the test pile in accordance with the
following schedule where applicable.
(i)
General.
1.
site location contract identification
2.
proposed structure
3.
main contractor
4.
piling contractor
5.
engineer client/employer
6.
date and time of test
QCS 2014

Part
Pile details.
1.
all types of pile
2.
identification (number and location)
3.
specified working load (SWL)
4.
design verification load (DVL)
5.
original ground level at pile location
6.
head level at which test load was applied
7.
type of pile
8.
vertical or raking, compression or tension
9.
shape and size of cross-section of pile, and position of any change in

cross-section
10.
shoe or base details
11.
head details
12.
length in ground
13.
tip Elevation
14.
dimensions of any permanent casing
15.
concrete piles
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(ii)
Page 46
concrete mix/grade
aggregate type and source
cement type and cement replacement and type where used
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admixtures
et
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ov
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(iii)
16.
slump
cube test results for pile and cap
date of casting of precast pile
reinforcement
steel piles
steel quality
coating
filling or core materials type and quality, if applicable
Installation details.
1.
2.
all piles
dates and times of boring, driving and concreting of test pile
difficulties and delays encountered
date and time of casting concrete pile cap
bored piles
type of equipment used and method of boring
temporary casing - diameter, type and length

Part
Page 47
full log of pile borehole
method of placing concrete
Volume of concrete placed
driven preformed and driven cast-in-place piles
Method of support of hammer and pile driven length of pile or

temporary casing at final set
Hammer type, and size or weight
Dolly and packing, type and condition
Driving log (depth, hammer drop, blows per 250 mm,

interruptions or breaks in driving)
Final set in number of blows to produce penetration of 25 mm
Redrive check, time interval and set in number of blows to

produce penetration of 25 mm or other agreed amount at final
set and at redrive set, for a drop hammer or for a single acting
hammer the length of the drop or stroke, for a diesel hammer
the length of the stroke and the blows per minute, for a double
acting hammer the operating pressure and the number of blows
per minute
condition of pile head or temporary casing after driving
use of a follower
use of preboring
use of jetting
lengthening
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(iv)
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QCS 2014
Test procedure.
mass of kentledge
1.
tension pile, ground anchorage or compression pile details
3.
plan of test arrangement showing position and distances of kentledge

supports, rafts, tension or compression piles or ground anchorages, and
supports to pile movement reference system
4.
jack capacity
5.
method of load measurement
6.
method(s) of penetration or uplift measurement
et
it
2.
(v)
Test results.
1.
in tabular form
2.
in graphical form: load plotted against pile head movement
3.
ambient temperature records during test.
4.9.3
This test shall be carried out in accordance with ASTM D5882 in a frequency as mentioned in
Section 2
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This test shall be carried out in accordance with ASTM D4428, D6760 in a frequency as
mentioned in Section 2
4.9.5
Section 2
4.9.6
Section 2
4.9.7
Lateral Load Test
Section 2
4.9.8
Scope
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4.9.4
This Part outlines the alternative methods for testing piles. A significant advance in
identifying the existence of defects in construction of piles has been the development
and adoption of modern integrity testing systems which may be employed to check the
quality of construction when required by the Engineer.
(b)
Dynamic pile-testing is normally used to evaluate the pile capacity, soil resistance
distribution, and immediate settlement characteristics, hammer transfer energy
(efficiency), and pile stresses during driving. The results obtained relate directly to
dynamic loading conditions.
(c)
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(a)
This Section
Section 2
Quality Assurance
(a)
The testing shall be carried out by an approved firm.
(b)
The interpretation of tests shall be carried out by persons competent in the test
procedure, and the full test results and findings shall normally be given to the Engineer
within 10 d of the completion of each phase of testing. Full details of the ground
conditions, pile dimensions and construction method shall be made available to the
specialist firm when required in order to facilitate interpretation of the tests.
Integrity-testing of piles
(a)
General

Part
Page 49
(i)
Integrity-testing of piles is designed to give information about the physical

dimensions, continuity and consistency of materials used in piles, and not to
give direct information about the performance of piles under the conditions of
loading. The methods available are normally applied to preformed concrete piles
made in a single length, to steel piles and to cast-in-place concrete piles.
(ii)
This type of testing will not be regarded as a replacement for static load testing,
but as a source of supplementary information.
(iii)
There is normally a limit to the length: diameter ratio of pile which can be
successfully and fully investigated in this way, depending on the ground
conditions.
(iv)
In the event that any anomaly is found in the results of such testing, the
Engineer may call for further testing to be carried out in order to investigate the
cause, nature and extent of the anomaly and whether the pile is satisfactory for
its intended use.
Method of Testing
Where integrity-testing is called for but the method is not specified, the method
to be adopted shall be approved by the Engineer and shall be one of the
following
3.
The sonic logging method.
as
The vibration method.
se
Other methods may be adopted subject to the approval of the Engineer and
subject to satisfactory evidence of performance.
In the case of cast-in-place concrete piles, integrity tests shall not be carried out
until 7 d or more have elapsed after pile-casting, unless otherwise approved by
the Engineer.
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Preparation of Pile Heads
(i)
2.
Age of Piles at Time of Testing

(i)
(d)
The sonic method.
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(c)
1.
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(ii)
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(i)
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(b)
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QCS 2014
Where the method of testing requires the positioning of sensing equipment on

the pile head, the head shall be clean, free from water, laitance and loose
concrete and readily accessible for the purpose of testing.
Dynamic pile-testing
(a)
General
(i)
Dynamic pile-testing involves monitoring the response of a pile to a heavy

impact applied at the pile head. The impact is often provided by the pile-driving
hammer and response is normally measured in terms of force and acceleration
or displacement close to the pile head.
(ii)
The results directly obtained refer to dynamic loading conditions. Interpretation

in terms of static loading requires soil- and pile-dependent adjustments, and
corroboration from experience may be required to correlate dynamic testing with
normal static load tests as specified in clause 4.9.1 of this Section.
(iii)
Details of the equipment to be used and of the method of analysis of test results
shall be provided to the Engineer before the commencement of testing.
QCS 2014
(b)

Part
Measuring Instruments
(i)
(c)
All instruments affixed to the pile for the purpose of measuring stress and
movement, and all equipment for receiving and processing data shall be suitable
for the purpose. The equipment required to be attached to the pile shall be
appropriately positioned and fixed to the approval of the Engineer.
Hammer
(i)
(d)
Page 50
The hammer and all other equipment used shall be capable of delivering an
impact force sufficient to mobilise the equivalent specified test load without
damaging the pile.
Preparation of the Pile Head

The preparation of the pile head for the application of the dynamic test load shall
involve, where appropriate, trimming the head, cleaning and building up the pile
using materials which will at the time of testing safely withstand the impact
stresses. The impact surface shall be flat and normal to the axis of the pile.
(e)
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(i)
Time of Testing
Dynamic load tests shall be carried out at appropriate and approved times after
pile installation. The time between the completion of installation and testing for
a preformed pile shall normally be more than 12 h, and in the case of a cast-inplace concrete piles shall be after the concrete has reached 75 % of its specified
28 day strength so that the pile is not damaged under the impact stresses.
Set Measurements
(g)
se
Where required and appropriate, the permanent penetration per blow and
temporary compression of the pile and soil system shall be measured
independently of the instruments being used to record the dynamic test data.
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(i)
Results
Initial the results shall be provided to the Engineer within 24 hours of the
completion of a test. These shall include
(i)
ov
(f)
as
qa
ta
(i)
The maximum force applied to the pile head.
2.
The maximum pile head velocity.
3.
The maximum energy imparted to the pile.
et
it
1.
(ii)
Normally within 10 d of the completion of testing final report shall be given to the
Engineer which includes:
1.
Date of pile installation.
2.
Date of test.
3.
Pile identification number and location.
4.
Length of pile below ground surface.
5.
Total pile length, including projection above commencing surface at time

of test.
6.
Length of pile from instrumentation position to tip.
7.
Hammer type, drop and other relevant details.
8.
Blow selected for analysis.
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Part
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9.
Test load achieved (i.e. total mobilised deduced static load).
10.
Pile head movement at equivalent design verification load.
11.
Pile head movement at equivalent design verification load plus 50 % of

specified working load.
12.
Pile head movement at maximum applied test load.
13.
Permanent residual movement of pile head after each blow.
14.
Temporary compression.
DESIGN METHODS AND DESIGN CONSIDERATIONS
4.10.1
Design method
The design shall be based on one of the following approaches:
.l.
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4.10
The results of static load tests, which have been demonstrated, by means of
calculations or otherwise, to be consistent with other relevant experience;
(b)
Empirical or analytical calculation methods whose validity has been demonstrated by

static load tests in comparable situations;
(c)
The results of dynamic load tests whose validity has been demonstrated by static load
tests in comparable situations;
(d)
The observed performance of a comparable piles foundation, provided that this

approach is supported by the results of site investigation and ground testing.
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as
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(a)
Design values for parameters used in the calculations should be in general accordance with
design parameters from geotechnical investigations report, but the results of load tests may
also be taken into account in selecting parameter values.
Static load tests may be carried out on trial piles, installed for test purposes only, before the
design is finalized, or on working piles, which form part of the foundation.
4.10.2
When considering a limit state of rupture or excessive deformation of a structural element or

section of the ground (Structural and Geotechnical), it shall be verified in accordance with
(Eurocode1997-1) or equivalent.
4.10.3
The behavior of individual piles and pile groups and the stiffness and strength of the structure
connecting the piles shall be considered.
In selecting calculation methods and parameter values and in using load test results, the
duration and variation in time of the loading shall be considered.
Planned future placement or removal of overburden or potential changes in the ground-water

regime shall be considered, both in calculations and in the interpretation of load test results.
The choice of type of pile, including the quality of the pile material and the method of
installation, shall take into account:
et
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QCS 2014
Page 52
the ground and ground-water conditions on the site, including the presence or
possibility of obstructions in the ground;
(b)
the stresses generated in the pile during installation;
(c)
the possibility of preserving and checking the integrity of the pile being installed;
(d)
the effect of the method and sequence of pile installation on piles, which have already
been installed and on adjacent structures or services;
(e)
the tolerances within, which the pile can be installed reliably;
(f)
the deleterious effects of chemicals in the ground;
(g)
the possibility of connecting different ground-water regimes;
(h)
the handling and transportation of piles;
(i)
the effects of pile construction on neighboring buildings.
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(a)
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In considering the aspects listed above, the following items should receive attention:
the spacing of the piles in pile groups;
(b)
displacement or vibration of adjacent structures due to pile installation;
(c)
the type of hammer or vibrator used;
(d)
the dynamic stresses in the pile during driving;
(e)
for those types of bored pile where a fluid is used inside the borehole, the need to
keep the pressure of the fluid at a level to ensure that the borehole will not collapse
and that hydraulic failure of the base will not occur;
(f)
cleaning of the base and sometimes the shaft of the borehole, especially under
bentonite, to remove remolded materials;
(g)
local instability of a shaft during concreting, which may cause a soil inclusion within
the pile;
(h)
ingress of soil or water into the section of a cast-in-situ pile and possible disturbance
of wet concrete by the flow of water through it;
qa
as
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the effect of unsaturated sand layers around a pile extracting water from the
concrete;
(i)
ta
(a)
et
it

Part
(j)
the retarding influence of chemicals in the soil;
(k)
soil compaction due to the driving of displacement piles;
(l)
soil disturbance due to the boring of a pile shaft.
4.11
AXIALLY LOADED PILES
4.11.1
Limit state design
The design shall demonstrate that exceeding the following limit states is sufficiently
improbable:
(a)
ultimate limit states of compressive or tensile resistance failure of a single pile;
(b)
ultimate limit states of compressive or tensile resistance failure of the pile foundation
as a whole;
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Part
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(c)
ultimate limit states of collapse or severe damage to a supported structure caused by

excessive displacement or differential displacements of the pile foundation;
(d)
serviceability limit states in the supported structure caused by displacement of the piles.
Normally the design should consider the margin of safety with respect to compressive or
tensile resistance failure, which is the state in which the pile foundation displaces significantly
downwards or upwards with negligible increase or decrease of resistance.
For piles in compression it is often difficult to define an ultimate limit state from a load
settlement plot showing a continuous curvature. In these cases, settlement of the pile top
equal to 10% of the pile base diameter should be adopted as the "failure" criterion.
For piles that undergo significant settlements, ultimate limit states may occur in supported
structures before the resistance of the piles is fully mobilized. In these cases a cautious
estimate of the possible range of the settlements shall be adopted in design.
4.11.2
To demonstrate that the pile foundation will support the design load with adequate safety
against compressive failure, the following inequality shall be satisfied for all ultimate limit
state load cases and load combinations:
qa
ta
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as
Fc Rc
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Where
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Fc: design axial compression load on a pile or a group of piles
In principle Fc should include the weight of the pile itself and Rc should include the
overburden pressure of the soil at the foundation base. However these two items may be
disregarded if they cancel approximately. They need not cancel if:
(a)
downdrag is significant;
the soil is very light,
(b)
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Rc: design value
(c)
3
the pile extends above the surface of the ground.
For piles in groups, two failure mechanisms shall be taken into account:
(a)
compressive resistance failure of the piles individually;
(b)
compressive resistance failure of the piles and the soil contained between them acting
as a block.
NOTE: The design resistance shall be taken as the lower value caused by these two
mechanisms.
4
The compressive resistance of the pile group acting as a block may be calculated by
treating the block as a single pile of large diameter.
The stiffness and strength of the structure connecting the piles in the group shall be
considered when deriving the design resistance of the foundation.
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Part
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If the piles support a stiff structure, advantage may be taken of the ability of the structure
to redistribute load between the piles. A limit state will occur only if a significant numbe r of
piles fail together; therefore a failure mode involving only one pile need not be considered.
If the piles support a flexible structure, it should be assumed that the compressive
resistance of the weakest pile governs the occurrence of a limit state.
Special attention should be given to possible failure of edge piles caused by inclined or
eccentric loads from the supported structure.
If the layer in which the piles bear overlies a layer of weak soil, the effect of the weak layer
on the compressive resistance of the foundation shall be considered.
10
The strength of a zone of ground above and below the pile base shall be taken into
account when calculating the pile base resistance.
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NOTE: This zone may extend several diameters above and below the pile base. Any weak
ground in this zone has a relatively large influence on the base resistance.
Punching failure should be considered if weak ground is present at a depth of less than 4
times the base diameter below the base of the pile.
12
Where the pile base diameter exceeds the shaft diameter, the possible adverse effect
13
For open-ended driven tube or box-section piles with openings of more than 500 mm in
any direction, and without special devices inside the pile to induce plugging, the base
resistance should be limited to the smaller of:
ov
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as
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11
the shearing resistance between the soil plug and the inside face of the pile;
(b)
the base resistance derived using the cross-sectional area of the base.
et
it
(a)
The manner in which load tests are carried out shall be in accordance with 4.11.2 and shall be
specified in the Geotechnical Design Report.
Trial piles to be tested in advance shall be installed in the same manner as the piles that will
form the foundation and shall be founded in the same stratum.
If the diameter of the trial pile differs from that of the working piles, the possible difference in
performance of piles of different diameters should be considered in assessing the
compressive resistance to be adopted.
In the case of a very large diameter pile, it is often impractical to carry out a load test on a full
size trial pile. Load tests on smaller diameter trial piles may be considered provided that:
4.11.3
(a)
the ratio of the trial pile diameter/working pile diameter is not less than 0,5;
(b)
the smaller diameter trial pile is fabricated and installed in the same way as the piles
used for the foundation;
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(c)

Part
Page 55
the trial pile is instrumented in such a manner that the base and shaft resistance can be
derived separately from the measurements.
NOTE: This approach should be used with caution for open-ended driven piles because of
the influence of the diameter on the mobilisation of the compressive resistance of a soil plug
in the pile.
In the case of a pile foundation subjected to downdrag, the pile resistance at failure, or at a
displacement that equals the criterion for the verification of the ultimate limit state determined
from the load test results, shall be corrected. The correction shall be achieved by subtracting
the measured, or the most unfavorable, positive shaft resistance in the compressible stratum
and in the strata above, where negative skin friction develops, from the loads measured at
the pile head.
During the load test of a pile subject to downdrag, positive shaft friction will develop along the
total length of the pile. The maximum test load applied to the working pile should be in excess
of the sum of the design external load plus twice the downdrag force.
When deriving the ultimate characteristic compressive resistance from values measured in
one or several pile load tests, an allowance shall be made for the variability of the ground and
the variability of the effect of pile installation.
The systematic and random components of the variations in the ground shall be recognized
in the interpretation of pile load tests.
The records of the installation of the test pile(s) shall be checked and any deviation from the
normal execution conditions shall be accounted for.
10
The characteristic compressive resistance of the ground may be derived from the
characteristic values of the base resistance and of the shaft resistance in accordance with
Eurocode1997-1.
4.11.4
Methods for assessing the compressive resistance of a pile foundation from ground test
results shall have been established from pile load tests and from comparable experience.
A model factor may be introduced as described as following to ensure that the predicted
compressive resistance is sufficiently safe :
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(a)
the range of uncertainty in the results of the method of analysis;
(b)
any systematic errors known to be associated with the method of analysis
In assessing the validity of a model based on ground test results, the following items should
be considered:
(a)
soil type, including grading, mineralogy, angularity, density, pre-consolidation,

compressibility and permeability;
(b)
method of installation of the pile, including method of boring or driving;
(c)
length, diameter, material and shape of the shaft and of the base of the pile (e.g.
enlarged base);
(d)
method of ground testing.
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4.11.5
Where a dynamic impact (hammer blow) pile test [measurement of strain and acceleration
versus time during the impact event is used to assess the resistance of individual
compression piles, the validity of the result shall have been demonstrated by previous
evidence of acceptable performance in static load tests on the same pile type of similar
length and cross-section and in similar ground conditions.
When using a dynamic impact load test, the driving resistance of the pile should be
measured directly on the site in question.
NOTE
A load test of this type can also include a process of signal matching to
measured stress wave figures. Signal matching enables an approximate evaluation of shaft
and base resistance of the pile as well as a simulation of its load-settlement behaviour.
The impact energy shall be high enough to allow for an appropriate interpretation of
the pile capacity at a correspondingly high enough strain level.
The design value of the compressive resistance of the pile could be calculated and
verified according to Eurocode1997-1.
4.11.6
Pile driving formulae shall only be used if the stratification of the ground has been
determined.
If pile driving formulae are used to assess the ultimate compressive resistance of individual
piles in a foundation, the validity of the formulae shall have been demonstrated by previous
experimental evidence of acceptable performance in static load tests on the same type of
pile, of similar length and cross-section, and in similar ground conditions.
For end-bearing piles driven into non-cohesive soil, the design value of the compressive
resistance shall be assessed by the same procedure as in 4.11.5.
When a pile driving formula is applied to verify the compression resistance of a pile, the pile
driving test should have been carried out on at least 5 piles distributed at sufficient spacing in
the piling area in order to check a suitable blow count for the final series of blows.
The penetration of the pile point for the final series of blows should be recorded for each pile.
4.11.7
Wave equation analysis shall only be used where stratification of the ground has been determined
by borings and field tests.
Where wave equation analysis is used to assess the resistance of individual compression piles,
the validity of the analysis shall have been demonstrated by previous evidence of acceptable
performance in static load tests on the same pile type, of similar length and cross- section, and in
similar ground conditions.
The design value of the compressive resistance derived from the results of wave equation analysis
of a number of representative piles, shall be assessed by the same procedure as in 4.11.3.
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NOTE Wave equation analysis is based on a mathematical model of soil, pile and driving
equipment without stress wave measurements on site. The method is usually applied to
study hammer performance, dynamic soil parameters and stresses in the pile during driving.
It is also, on the basis of the models, possible to determine the required driving resistance
(blow count) that is usually related to the expected compressive resistance of the pile.
The design of piles in tension shall be consistent with the design rules given in 4.11.2, where
applicable. Design rules that are specific for foundations involving piles in tension are presented
below.
To verify that the foundation will support the design load with adequate safety against a failure in
tension, the following inequality shall be satisfied for all ultimate limit state load cases and load
combinations in accordance with Eurocode1997-1.
For isolated tensile piles or a group of tensile piles, the failure mechanism may be governed by the
pull-out resistance of a cone of ground, especially for piles with an enlarged base or rock socket.
When considering the uplift of the block of ground containing the piles the shear resistance along
the sides of the block may be added to the resisting forces.
Normally the block effect will govern the design tensile resistance if the distance between the piles
is equal to or less than the square root of the product of the pile diameter and the pile penetration
into the main resisting stratum.
The group effect, which may reduce the effective vertical stresses in the soil and hence the shaft
resistances of individual piles in the group, shall be considered when assessing the tensile
resistance of a group of piles.
The severe adverse effect of cyclic loading and reversals of load on the tensile resistance shall be
considered.
Comparable experience based on pile load tests should be applied to appraise this effect.
4.11.9
Pile load tests to determine the ultimate tensile resistance of an isolated pile shall be carried out in
accordance with 4.9.1 and with regard to 4.11.3.
The design tensile resistance could be calculated and verified according to Eurocode1997-1.
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4.11.8
4.11.10 Ultimate tensile resistance from ground test results

1
Methods for assessing the tensile resistance of a pile foundation from ground test results shall
have been established from pile load tests and from comparable experience.
A model factor may be introduced as following to ensure that the predicted tensile resistance is
sufficiently safe.
(a)
(b)
any systematic errors known to be associated with the method of analys is
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The design value of tensile resistance of a pile could be calculated and verified according to
Eurocode1997-1.

1
Vertical displacements under serviceability limit state conditions shall be assessed and checked.
When calculating the vertical displacements of a pile foundation, the uncertainties involved in the
calculation model and in determining the relevant ground properties should be taken into account.
Hence it should not be overlooked that in most cases calculations will provide only an approximate
estimate of the displacements of the pile foundation.
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NOTE For piles bearing in medium-to-dense soils and for tension piles, the safety
requirements for the ultimate limit state design are normally sufficient to prevent a
serviceability limit state in the supported structure.
The occurrence of a serviceability limit state in the supported structure due to pile settlements shall
be checked, taking into account downdrag, where probable.
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NOTE When the pile toe is placed in a medium-dense or firm layer overlying rock or very
hard soil, the partial safety factors for ultimate limit state conditions are normally sufficient to
satisfy serviceability limit state conditions.
Assessment of settlements shall include both the settlement of individual piles and the settlement
due to group action.
The settlement analysis should include an estimate of the differential settlements that may occur.
When no load test results are available for an analysis of the interaction of the piled foundation with
the superstructure, the load-settlement performance of individual piles should be assessed on
empirically established safe assumptions.
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The assessment of upward displacements shall be done and Particular attention should be paid to
the elongation of the pile material.
When very severe criteria are set for the serviceability limit state, a separate check of the upward
displacements shall be carried out.
4.12
TRANSVERSELY LOADED PILES
4.12.1
Design method
The design of piles subjected to transverse loading shall be consistent with the design rules given
in 4.10, where applicable. Design rules specifically for foundations involving piles subjected to
transverse loading are presented below.
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To demonstrate that a pile will support the design transverse load with adequate safety against
failure, the following inequality shall be satisfied for all ultimate limit state load cases and load
combinations:
Ftr Rtr
Where;
Ftr: design value of the transverse load on a pile or a pile foundation
Rtr : design resistance of transversally loaded pile
One of the following failure mechanisms should be considered:
for short piles, rotation or translation as a rigid body;
(b)
for long slender piles, bending failure of the pile, accompanied by local yielding and
displacement of the soil near the top of the pile.
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The group effect shall be considered when assessing the resistance of transversely loaded piles.
It should be considered that a transverse load applied to a group of piles may result in a
combination of compression, tension and transverse forces in the individual piles.
4.12.2
Transverse pile load tests shall be carried out in accordance with 4.9.6.
Contrary to the load test procedure described in 4.9 tests on transversely loaded piles need not
normally be continued to a state of failure. The magnitude and line of action of the test load should
simulate the design loading of the pile.
An allowance shall be made for the variability of the ground, particularly over the top few meters of
the pile, when choosing the number of piles for testing and when deriving the design transverse
resistance from load test results.
Records of the installation of the test pile(s) should be checked, and any deviation from the normal
construction conditions should be accounted for in the interpretation of the pile load test results.
For pile groups, the effects of interaction and head fixity should be accounted for when deriving the
transverse resistance from the results of load tests on individual test piles.
4.12.3
Transverse load resistance from ground test results and pile strength parameters
The transverse resistance of a pile or pile group shall be calculated using a compatible set of
structural effects of actions, ground reactions and displacements.
The analysis of a transversely loaded pile shall include the possibility of structural failure of the pile
in the ground.
The calculation of the transverse resistance of a long slender pile may be carried out using the
theory of a beam loaded at the top and supported by a deformable medium characterized by a
horizontal modulus of subgrade reaction.
The degree of freedom of rotation of the piles at the connection with the structure shall be taken
into account when assessing the foundations transverse resistance.
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4.12.4
The assessment of the transverse displacement of a pile foundation shall take into account:
the stiffness of the ground and its variation with strain level;
(b)
the flexural stiffness of the individual piles;
(c)
the moment fixity of the piles at the connection with the structure;
(d)
the group effect;
(e)
the effect of load reversals or of cyclic loading
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A general analysis of the displacement of a pile foundation should be based on expected degrees
of kinematic freedom of movement.
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END OF PART
(a)
QCS 2014
Section 04: Foundations & Retaining Structures

Part
05: Retaining Structures
Page 2
RETAINING STRUCTURES ---------------------------------------------------------------------------------- 2
5.1
GENERAL---------------------------------------------------------------------------------------------------------- 2
5.2
LIMIT STATES ---------------------------------------------------------------------------------------------------- 2
5.2.2
5.2.3
Ultimate Limit State ---------------------------------------------------------------------------------------------- 2

Serviceability Limit State ---------------------------------------------------------------------------------------- 3
5.3
ACTIONS AND GEOMETRICAL DATA -------------------------------------------------------------------- 3
5.3.1
5.3.2
5.3.3
Actions -------------------------------------------------------------------------------------------------------------- 3
Geometrical data ------------------------------------------------------------------------------------------------- 4
Design Situations ------------------------------------------------------------------------------------------------- 4
5.4
DESIGN AND CONSTRUCTION CONSIDERATIONS ------------------------------------------------- 5
5.5
DETERMINATION OF EARTH PRESSURES ------------------------------------------------------------ 6
5.5.1
5.5.2
5.5.3
5.5.4
5.5.5
General ------------------------------------------------------------------------------------------------------------- 6
At rest values of earth pressure------------------------------------------------------------------------------- 7
Limiting values of earth pressure ----------------------------------------------------------------------------- 7
Intermediate values of earth pressure ----------------------------------------------------------------------- 7
Compaction effects ---------------------------------------------------------------------------------------------- 7
5.6
WATER PRESSURES ------------------------------------------------------------------------------------------ 8
5.7
ULTIMATE LIMIT STATE DESIGN -------------------------------------------------------------------------- 8
5.7.1
5.7.2
5.7.3
5.7.4
5.7.5
5.7.6
5.7.7
General ------------------------------------------------------------------------------------------------------------- 8
Overall stability ---------------------------------------------------------------------------------------------------- 8
Foundation failure of gravity walls ---------------------------------------------------------------------------- 8
Rotational failure of embedded walls ------------------------------------------------------------------------ 8
Vertical failure of embedded walls --------------------------------------------------------------------------- 9
Structural design of retaining structures -------------------------------------------------------------------- 9
Failure by pull-out of anchorages ----------------------------------------------------------------------------- 9
5.8
SERVICEABILITY LIMIT STATE DESIGN ----------------------------------------------------------------- 9
5.8.1
5.8.2
General ------------------------------------------------------------------------------------------------------------- 9
Displacements ---------------------------------------------------------------------------------------------------- 9
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RETAINING STRUCTURES
5.1
GENERAL
The provisions of this Part 5 apply to retaining structures in general. These are structures
used to retain ground comprising soil, rock or backfill and water and this at an angle steeper
than the angle they would normally adopt without the presence of those structures. Common
retaining structures used within the state of Qatar taking into account the prevailing geologic
conditions are:
Sheet Piles
(b)
Bored and Cast in Place Concrete Piles
Secant Piles
(c)
Diaphragm Walls
(d)
Composite Shoring Systems
(e)
Concrete Retaining Walls
(ii)
Counter Fort Retaining Wall
(iii)
Gravity Retaining Wall
(iv)
Buttressed Retaining Wall
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Cantilever Retaining Wall
Reinforced Soil Retaining Structures

Geogrid and Geotextile Reinforced Earth Systems
(ii)
Galvanized Strips Reinforced Earth System
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Soil and Rock Nailing Systems
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Contiguous Piles
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(a)
This revision of Section 4 Part 5 is considered preliminary and shall be reviewed and
amended as needed in the next revision to elaborate on various subjects not covered herein.
This revision of Section 4 Part 5 is based generally on EN1997-1:2004+A1:2013

Eurocode 7.
Section 4 Part 5 will cover at this stage the general design aspects knowing that the
construction procedures shall be added in future revisions of this Section. Hence, at this
stage, the construction related subjects of the retaining structures will follow relevant Parts of
the QCS.
5.2
LIMIT STATES
During the design of retaining structures the following typical limit states should be
considered:
5.2.2
Ultimate Limit State
Loss of overall stability: it should be demonstrated that an overall stability failure is unlikely.
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Foundation failure of retaining structures with footings: it should be demonstrated that the
foundation pressures (lateral and vertical) do not exceed neither the ground allowable
bearing capacity nor the sliding resistance. Uplift pressures under the foundation due to
water seepage should also be included in the analysis.
Foundation failure of gravity walls, which is the loss of equilibrium of the wall considered as a
rigid body.
Failure of embedded walls by rotation or horizontal translation or by lack of vertical

equilibrium.
Failure of a structural element such as a wall, anchorage, wale or strut, including failure of
the connection between those elements.
Failure of a retaining structure by hydraulic heave, internal erosion or piping, unacceptable

leakage of water, or transport of soil particles through or under the wall caused by excessive
hydraulic gradients.
5.2.3
Serviceability Limit State
Unacceptable movement of the retaining structure, which may affect the appearance or
functionality of the structure itself, or other neighbouring structures or utilities influenced by
the movement.
Unacceptable change in the groundwater regime.
5.3
ACTIONS AND GEOMETRICAL DATA
5.3.1
Actions
Generally, the forces exerted on retaining structure with values assumed known at the
beginning of the calculation are considered as 'actions', while forces with initially unknown
values, to be determined by the interaction of the retaining structure with support elements
(ground springs, anchorages, struts, etc.), are considered as 'reactions'. The following
actions are to be taken into account:
Weight of backfill material
(a)
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(b)
Surcharges
(c)
Weight of water
(d)
Wave forces for marine projects
(e)
Seepage forces
(f)
Collision forces
(g)
Temperature effects
(h)
Forces from propping elements (i.e. post-tensioned anchors)
(i)
Siesmic related effects
The above actions should result in the determination of various earth pressures acting on the
retaining structure.
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5.3.2
Geometrical data
This paragraph covers the uncertainties in the geometrical data namely excavation and water
levels. In general, small variations in geometrical data are considered to be covered by the
safety factors included in the calculations. However, since the design of retaining structures
is sensitive to ground and water levels, special requirements are included in this paragraph,
mainly for unforeseen over-dig in front of the wall and groundwater levels change on both
sides of the wall.
Unforeseen over-dig in front of the wall
Equal to 10% of the wall height above excavation level (up to a maximum of 0.5 m), for
cantilever walls;
(b)
Equal to 10% of the distance between the lowest support and the excavation level (up
to a maximum of 0.5 m), for supported walls.
Groundwater levels in front of and behind the wall
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In Ultimate Limit State design calculations, where the wall stability depends on the earth
resistance in front of the wall, the level of the resisting soil should be lowered below the
nominally expected level by an amount which depends on the degree of control on the
excavation level. With a normal degree of control the expected difference in resisting soil
level should be:
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The selection of the levels of the phreatic surfaces in front of and behind the wall must
consider long-term variations of the groundwater regime and/or the ground permeability, the
presence of perched or artesian aquifers and the possibility that drainage behind the wall
may cease to function with time.
Design Situations
The following conditions shall be considered during the design of retaining structures:
Anticipated variations in soil properties
(b)
Variations in actions and the ways they are combined
(c)
Excavation, scour or erosion in front of the retaining structure

The effect of compaction of the backfill behind the retaining structure
(d)
(a)
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5.3.3
(e)
The effect of anticipated future structures and surcharge loads/unloads
(f)
Anticipated ground movements
(g)
Inclination of the wall to the vertical
(h)
Variations in groundwater table and the seepage forces in the ground
(i)
Horizontal as well as vertical equilibrium for the entire retaining structure
(j)
The shear strength and weight density of the ground
(k)
The rigidity of the wall and the supporting system
(l)
The wall roughness
(m)
Seismic effect on the various forces
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5.4
DESIGN AND CONSTRUCTION CONSIDERATIONS
The design of retaining structures requires consideration of all relevant Ultimate Service
States and Service Limit States.
For retaining structures without strict serviceability requirements, the geometry is usually
determined by Ultimate Limit State design calculations and checked by Service Limit State
calculations (if relevant). For the retaining structures with strict serviceability requirements,
the Service Limit State requirements often govern the design.
The design and construction considerations should cover the following:

Demonstrate that vertical equilibrium can be achieved for the assumed pressure
distributions and actions on the wall.
(b)
Verification of vertical equilibrium may be achieved by reducing the wall friction

parameters.
(c)
Retaining walls should be designed in such a way that there are visible signs of the
approach of an ultimate limit state. The design should prevent brittle failure of the
structure, e.g. sudden collapse without conspicuous preliminary deformations.
(d)
A critical limit state should be considered to occur if the wall has displaced enough to
cause damage to nearby structures or services. Although collapse of the wall may not
be imminent, the degree of damage may considerably exceed a serviceability limit
state in the supported structure.
(e)
The design methods and partial factor values recommended by EN19971:2004+A1:2013 are usually sufficient to prevent the occurrence of ultimate limit
states in nearby structures, provided that the soils involved are of at least medium
density or firm consistency and adequate construction methods and sequences are
adopted. Special care should be taken, however, with some highly over-consolidated
clay deposits in which large at rest horizontal stresses may induce substantial
movements in a wide area around excavations.
(f)
The complexity of the interaction between the ground and the retaining structure
sometimes makes it difficult to design a retaining structure in detail before the actual
execution starts. In this case, use of the observational method for the design should be
considered. The observational method consists of setting criteria enabling monitoring
during construction, allowing necessary corrective actions to be taken to rectify the
design. Hence, the following requirements shall be set before construction:
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(a)
(g)
(i)
Acceptable limits of behaviour
(ii)
The range of potential behaviour shall be analysed showing acceptable

probability that the actual behaviour will be within the acceptable limits
(iii)
A plan of monitoring shall be established (including necessary instruments and

procedures) enabling the comparison of the actual behaviour to the acceptable
limits. The monitoring shall allow early detection of nonconformities, allowing
enough time for corrective actions to be taken successfully.
(iv)
A list of contingency actions shall be established which could be used if the

actual observed behaviour is outside of the acceptable limits.
The effects of constructing the wall, including:

(i)
The provision of temporary support to the sides of excavations;
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(ii)
The changes of in situ stresses and resulting ground movements caused both
by the wall excavation and its construction;
(iii)
Disturbance of the ground due to driving or boring operations;
(iv)
Provision of access for construction;
The required degree of water tightness of the finished wall;
(i)
The practicability of constructing the wall to reach a stratum of low permeability, so

forming a water cut-off. The resulting equilibrium ground-water flow problem shall be
assessed;
(j)
The practicability of forming ground anchorages in adjacent ground;
(k)
The practicability of excavating between any propping of retaining walls;
(l)
The ability of the wall to carry vertical load;
(m)
The ductility of structural components;
(n)
Access for maintenance of the wall and any associated drainage measures;
(o)
The appearance and durability of the wall and any anchorages;
(p)
For sheet piling, the need for a section stiff enough to be driven to the design
penetration without loss of interlock;
(q)
The stability of borings or slurry trench panels while they are open;
(r)
For fill, the nature of materials available and the means used to compact them
adjacent to the wall.
(s)
Drainage systems
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If the safety and serviceability of the designed structure depend on the successful
performance of a drainage system, the consequences of its failure shall be
considered, taking into account both safety and cost of repair. One of the following
conditions (or a combination of them) shall apply:
A maintenance program for the drainage system shall be specified and the
design shall allow access for this purpose;
(ii)
It shall be demonstrated both by comparable experience and by assessment of

any water discharge that the drainage system will operate adequately without
maintenance.
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(i)
The quantities, pressures and eventual chemical content of any water discharge
should be taken into account.
5.5
DETERMINATION OF EARTH PRESSURES
5.5.1
General
The Determination of the earth pressures shall take into account the acceptable mode and
amount of any movement and strain, which may occur at the limit state under consideration.
In the following context the words "earth pressure" should also be used for the total earth
pressure from soft and weathered rocks and should include the pressure of ground-water.
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Calculations of the magnitudes of earth pressures and directions of forces resulting from
them shall take account of the issues highlighted under paragraph 5.3.3.
The amount of mobilized wall friction and adhesion should be considered as a function of:
The strength parameters of the ground
(b)
The friction properties of the wall-ground interface
(c)
The direction and amount of movement of the wall relative to the ground
(d)
The ability of the wall to support any vertical forces resulting from wall friction and
adhesion
A concrete wall or steel sheet pile wall supporting sand or gravel may be assumed to have a
design wall ground interface parameter d k. cv ;d . k should not exceed 2/3 for precast
(a)
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concrete or steel sheet piling. For concrete cast against soil, a value of k = 1.0 may be
assumed. For a steel sheet pile in clay under undrained conditions immediately after driving,
no adhesive or frictional resistance should be assumed. Increases in these values may take
place over a period of time.
In the case of structures retaining rock masses, calculations of the ground pressures shall
take into account the effects of discontinuities, with particular attention to their orientation,
spacing, aperture, roughness and the mechanical characteristics of any joint filling material.
Account shall be taken of any swelling potential of the ground when calculating the pressures
on the retaining structure.
5.5.2
At rest values of earth pressure
When no movement of the wall relative to the ground takes place, the earth pressure shall be
calculated from the at rest state of stress. The determination of the at-rest state shall take
into account the stress history of the ground.
5.5.3
Limiting values of earth pressure
Limiting values of earth pressures shall be determined taking into account the relative
movement of the soil and the wall at failure and the corresponding shape of the failure
surface.
5.5.4
Intermediate values of earth pressure
Intermediate values of earth pressure occur if the wall movements are insufficient to mobilize
the limiting values. The determination of the intermediate values of earth pressure shall take
into account the amount of wall movement and its direction relative to the ground.
The intermediate values of earth pressures may be calculated using, for example, various
empirical rules, spring constant methods or finite element methods.
5.5.5
Compaction effects
The determination of earth pressures acting behind the wall shall take into account the
additional pressures generated by any placing of backfill and the procedures adopted for its
compaction.
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WATER PRESSURES
Determination of characteristic and design water pressures shall take account of water levels
both above and in the ground.
When checking the ultimate and serviceability limit water pressures shall be accounted for in
the combinations of actions considering the possible risks of flooding or change in
groundwater levels from either sides of the retaining structure.
For structures retaining earth of medium or low permeability (silts and clays), water pressures
should normally be assumed to act behind the wall. Unless a reliable drainage system is
installed, or infiltration is prevented, the values of water pressures should normally
correspond to a water table at the surface of the retained material.
Where sudden changes in a free water level may occur, both the non-steady condition
occurring immediately after the change and the steady condition shall be examined.
Where no special drainage or flow prevention measures are taken, the possible effects of
water-filled tension or shrinkage cracks shall be considered.
5.7
ULTIMATE LIMIT STATE DESIGN
5.7.1
General
The design of retaining structures shall be checked at the ultimate limit state for the design
situations appropriate to that state, as specified in 5.3.3, using the design actions or action
effects and design resistances.
All relevant limit modes shall be considered. These will include, as a minimum, limit modes of
the types illustrated in Figures 5.1 to 5.6 for the most commonly used retaining structures.
Calculations for ultimate limit states shall establish that equilibrium can be achieved using the
design actions or effects of actions and the design strengths or resistances. Compatibility of
deformations shall be considered in assessing design strengths or resistances.
5.7.2
Overall stability
Principles and calculations should be used as appropriate to demonstrate that an overall

stability failure will not occur and that the corresponding deformations are sufficiently small
taking into account progressive failure and liquefaction into account as relevant.
5.7.3
Foundation failure of gravity walls
The principles of foundation design shall be used as appropriate to demonstrate that a

foundation failure is sufficiently remote and that deformations will be acceptable. Both
bearing resistance and sliding shall be considered. Failure modes shown in Figure 5.2 should
be verified as a minimum.
5.7.4
Rotational failure of embedded walls
It shall be demonstrated by equilibrium calculations that embedded walls have sufficient

penetration into the ground to prevent rotational failure. As a minimum, limit modes of the
types illustrated in Figure 5.3 should be considered.
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5.6
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The design magnitude and direction of shear stress between the soil and the wall shall be
consistent with the relative vertical displacement, which would occur in the design situation.
5.7.5
Vertical failure of embedded walls
It shall be demonstrated that vertical equilibrium can be achieved using the design soil
strengths or resistances and design vertical forces on the wall. As a minimum, the limit mode
of the type illustrated in Figure 5.4 should be considered.
Where downward movement of the wall is considered, upper design values shall be used in
the calculation of pre-stressing forces, such as those from ground anchorages, which have a
vertical downward component. The design magnitude and direction of shear stress between
the soil and the wall shall be consistent with the check for vertical and rotational equilibrium.
If the wall acts as the foundation for a structure, vertical equilibrium shall be checked using
the principles of Pile Foundations Design.
5.7.6
Structural design of retaining structures
Retaining structures, including their supporting structural elements such as anchorages and
props, shall be verified against structural failure in accordance with EN1997-1:2004+A1:2013
2.4 Geotechnical Design by Calculation and EN1992, EN1993, EN1995 and EN1996. As a
minimum, limit modes of the types illustrated in Figure 5.5 should be considered.
5.7.7
Failure by pull-out of anchorages
It shall be demonstrated that equilibrium can be achieved without pull-out failure of ground
anchorages. Anchors shall be designed in accordance with Anchorage Design procedures
with minimum the limit modes of the types illustrated in Figure 5.6 (a, b) should be
considered. For dead-man anchors, the failure mode illustrated in Figure 5.6 (c) should also
be considered.
5.8
SERVICEABILITY LIMIT STATE DESIGN
5.8.1
General
The design of retaining structures shall be checked at the serviceability limit state using the
appropriate design situations as specified in 5.3.3. The assessment of design values of earth
pressures should take account of the initial stress, stiffness and strength of the ground and
the stiffness of the structural elements.
The design values of earth pressures should be derived taking account of the allowable
deformation of the structure at its serviceability limit state. These pressures need not
necessarily be limiting values.
5.8.2
Displacements
Limiting values for the allowable displacements of walls and the ground adjacent to them
shall be established for a particular deformation is the value at which a serviceability limit
state, such as unacceptable cracking or displacement of adjacent structures or utilities, is
deemed to occur. This limiting value shall be agreed during the design, taking into account
the tolerance to displacements of supported structures and services.
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Part
Page 10
If the initial cautious estimate of displacement exceeds the limiting values, the design shall be
justified by a more detailed investigation including displacement calculations.
It shall be considered to what extent variable actions, such as vibrations caused by traffic
loads behind the retaining wall, contribute to the wall displacement.
Displacement calculations should also be considered in the following cases:

(a)
where the wall retains more than 6m of cohesive soil of low plasticity,
(b)
where the wall retains more than 3m of soils of high plasticity;
(c)
where the wall is supported by soft clay within its height or beneath its base.
Displacement calculations shall take into account the stiffness of the ground and structural
elements and the sequence of construction.
The effect of vibrations on displacements shall be considered with regard to the following:
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Foundations for structures subjected to vibrations or to vibrating loads shall be

designed to ensure that vibrations will not cause excessive settlements.
(b)
Precautions should be taken to ensure that resonance will not occur between the
frequency of the dynamic load and a critical frequency in the foundation-ground
system, and to ensure that liquefaction will not occur in the ground.
(c)
Vibrations caused by earthquakes shall be considered using the guidelines of the

designated section of the QCS.
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(a)
Figure 5.1 Examples of Limit Modes for Overall Stability of Retaining Structures
(EN 1997-1:2004+A1:2013)

Part
Page 11
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Figure 5.2 Examples of Limit Modes for Foundation Failures of Gravity Walls
(EN 1997-1:2004+A1:2013)
Figure 5.3 Examples of Limit Modes for Rotational Failures of Embedded Walls
(EN 1997-1:2004+A1:2013)

Part
Page 12
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Figure 5.4 Example of a Limit Mode for Vertical Failure of Embedded Walls
(EN 1997-1:2004+A1:2013)
Figure 5.5 Examples of Limit Modes for Structural Failure of Retaining Structures
(EN 1997-1:2004+A1:2013)

Part
Page 13
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Figure 5.6 Examples of Limit Modes for Failure by Pull-out of Anchoes

(EN 1997-1:2004+A1:2013)
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END OF PART
QCS 2014
Section 05: Concrete

Part
01: General
Page 1
GENERAL------------------------------------------------------------------------------------------------------------ 2
1.1
1.1.1
1.1.2
1.1.3
1.1.4
INTRODUCTION --------------------------------------------------------------------------------------------------- 2
Scope ----------------------------------------------------------------------------------------------------------------- 2
References----------------------------------------------------------------------------------------------------------- 2
Definitions ------------------------------------------------------------------------------------------------------------ 3
Approved Products ------------------------------------------------------------------------------------------------ 4
1.2
1.2.1
1.2.2
1.2.3
1.2.4
IMPLEMENTATION ----------------------------------------------------------------------------------------------- 4
Approved Installers ------------------------------------------------------------------------------------------------ 4
Field Quality Control ----------------------------------------------------------------------------------------------- 4
Rejected materials ------------------------------------------------------------------------------------------------- 5
Records --------------------------------------------------------------------------------------------------------------- 5
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QCS 2014

Part
01: General
Page 2
GENERAL
1.1
INTRODUCTION
1.1.1
Scope
This Section includes the requirements for concrete work for pipelines, roadworks, runways,
structures, water retaining structures, foundations and bases for structures and equipment.
This Part includes relevant standards, definitions, abbreviations, and requirements for testing
facilities, rejected materials, and record keeping.
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Aggregates
Water
Admixtures
Concrete Plants
Transportation and Placing of Concrete
Formwork
Curing
Reinforcement
Construction Joints
Inspection and Testing of Hardened Concrete
Protective Coatings to Concrete
Hot Weather Concrete
Miscellaneous
Precast Concrete
Water Retaining Structures
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This Section:
Part 2,
Part 3,
Part 4,
Part 5,
Part 6,
Part 7,
Part 8,
Part 9,
Part 10,
Part 11,
Part 12,
Part 13,
Part 14,
Part 15,
Part 16,
Part 17,
Part 18,
Part 19,
Section 1,
Section 2,
Section 4,
Section 6,
Section 8,
Section 9,
General
Roadworks
Drainage Works
1.1.2
References

ASTM C31 ..................Standard Practice for Making and Curing Concrete Test Specimens in
the Field
ASTM C39 ..................Standard Test Method for Compressive Strength of Cylindrical
Concrete Specimens
ASTM C143 ................Standard Test Method for Slump of Hydraulic-Cement C Concrete
ASTM C1064 ..............Standard Test Method for Temperature of Freshly Mixed HydraulicCement Concrete
QCS 2014

Part
01: General
Page 3
BS 6100, ....................Glossary of Building and civil engineering terms

BS EN 932-1 ..............Tests for general properties of aggregates. Methods for sampling
BS EN 932-2 ..............Tests for general properties of aggregates. Methods for reducing
laboratory samples
BS EN 12350-1 ..........Method of sampling fresh concrete in site
BS EN 12350-2 ..........Testing fresh concrete. Slump-test
BS EN 12390-1 ..........Shape, dimensions and other requirements for specimens and moulds
BS EN 12390-2 .......... Making and curing specimens for strength tests
GSO ISO 1920-1 ........Testing of concrete Part 1: Sampling of fresh concrete
GSO ISO 1920-2 ........Testing of concrete Part 2: Properties of fresh concrete
GSO ISO 1920-3 ........Testing of concrete Part 3: Making and curing test specimens
Definitions
Definitions used in this Section.
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1.1.3
The following are terms and abbreviations used:
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degree Celsius
calorie
centimetre
day
Characteristic compressive strength of concrete determined by testing cylinders
Compressive strength of concrete determined by testing cylinders
Characteristic compressive strength of concrete determined by testing cubes
Compressive strength of concrete determined by testing cubes
Mean compressive strength of concrete
Mean compressive strength of concrete at the age of (j) days
ground granulated blast furnace slag
guaranteed ultimate tensile strength
hour
kilogram
kilojoule
kilonewton
litre
metre
square metre
cubic metre
milligram
minute
millimetre
square millimetre
months
mega Pascal
kilo Pascal
moderate sulphate resisting Portland cement
ordinary Portland cement
pulverised fuel ash
polyvinylchloride
second
silica fume
sulphate resisting Portland cement
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C
cal
cm
d
fck,cyl
fc,cyl
fck,cube
fc,cube
fcm
fcm,j
GGBS
GUTS
h
kg
kJ
kN
l
m
2
m
3
m
mg
min
mm
2
mm
months
MPa
kPa
MSRPC
OPC
PFA
PVC
s
SF
SRPC
QCS 2014
ton
ppm
1000 kg
part per million
micron
10
10 meter
Page 4
-6
-6

accordance with the following abbreviations.
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American Society for Testing and Materials
British Standard
British Standard Code of Practice
British Standards Institution
Construction Industry Research and Information Association
Concrete Society
Deutsches Institut fur Normung e.V.
Euro Norm
GCC Standardization Organization
Qatar Construction Specifications
Qatar Standards
United Kingdom Department for Transport
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AASHTO
ACI
ASTM
AWS
BS
BSCP
BSI
C & CA
CIRIA
CRSI
CS
DIN
EN
FHWA
GSO
ICE
ISO
PCI
QCS
QS
UK DfT
Products
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Part
01: General
Approved Products
The contract specific documentation may identify approved products and approved or
prequalified manufacturers and suppliers of products used in concrete work.
1.2
IMPLEMENTATION
1.2.1
Approved Installers
The contract specific documentation may identify approved or prequalified providers of

concrete construction services.
1.2.2
Field Quality Control
The Contractor shall carry out the test procedures required by this Section and any other
tests and test procedures as directed by the Engineer from time to time. The test procedures
shall be carried out using the facilities of an approved independent testing laboratory.
Supply, storage, sampling and testing of all materials shall be the responsibility of the
Contractor, unless the Contract specifies otherwise.
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1.1.4
QCS 2014

Part
01: General
Page 5
The Engineer may also require the Contractor to take samples of materials and deliver them
to the Central Materials Laboratory for additional tests to be carried out by the Employer.
Sampling procedures shall be in accordance with BS EN 932 or relevant ASTM Standards,
and sample sizes shall conform to the requirements shown in Table 1.1.
The minimum equipment required for testing on Site is given in Table 1.2. This equipment
shall be maintained on Site at all times during concreting operations together with the
necessary scoops, buckets, sample containers, and other items required for sampling. The
cube curing tank shall be located in an air-conditioned area as stated in part 06.
1.2.3
Rejected materials
Any material rejected by the Engineer, in particular cement which has deteriorated or
aggregates which have segregated or become contaminated, shall be immediately removed
from the Site.
1.2.4
Records
The Contractor shall maintain on the Site full records of all work carried out accurately
related to the location of the work on site, which shall include:
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formwork props were fully removed

all cubes and other tests
(c)
daily maximum and minimum temperatures.
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One copy of all test results shall be sent to the Engineer immediately upon completion of the
tests
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Table 1.1
Sampling Procedure and
Minimum Sample Sizes for Central Materials Laboratory
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Cement
Material
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the time and date when all concrete was poured, formwork removed and when
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(a)
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Aggregate
Reinforcement
Water
Test
Min. Sample
Full range of tests
Composite sample of 7 kg
taken from at least 12 bags
Full range of tests
200 kg
Sieve analysis
Chemical analysis
Soundness test
Water absorption
Particle density
Flakiness index
Fines content
LA Abrasion value
50 kg
Tensile test
500 mm
Bend test
300 mm
Full range of tests
5 litres
QCS 2014

Part
01: General
Page 6
Table 1.2
Minimum Testing Equipment for Each Site*
Test
Equipment to be Provided
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ASTM C1064
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Cube curing
BS EN
12390-2
or
GSO ISO 1920-3
or ASTM C39
Hessian or sacking, impervious sheet

Maximum/minimum thermometer
Waterproof marking crayon/paint or
equivalent
Curing tank (in air conditioned room)
Supply of packing materials for sending
cubes to commercial laboratory
Concrete thermometer
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Cube making
BS EN 12390-1
and
BS EN 12350-1:2000
or
GSO ISO 1920-1
and
GSO ISO 1920-3
or ASTM C31 and C39
Slump cone with base plate

Compacting rod, circular cross-section
and round ends
Remixing container, 300 mm ruler,
moist cloth
Scoop and shovel
Timer
100 or 150 mm cubical or cylindrical
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moulds
Compacting rod or bar Set of tools for
assembling and stripping moulds
Remixing container
Trowel, Scoop, Shovel and Mallet
Mould release agent in closed
container with brush
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Slump test BS EN
12350-2
or
GSO ISO 1920-2
or
ASTM C143
Minimum Number
Required
1
1
1
1
1
6
1
1
1
lot
1
1
1
Lot
1
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1 - The use of 100 mm cube and cylinder moulds are permitted when the nominal maximum aggregate
size is not greater than 20mm
END OF PART
QCS 2014

Part
10: Curing
Page 1
CURING .................................................................................................................. 2
10.1
10.1.1
10.1.2
10.1.3
10.1.4
10.1.5
GENERAL ............................................................................................................... 2
Scope
2
References
2
Submittals
2
Quality Assurance
2
Storage
2
10.2
10.2.1
10.2.2
10.2.3
10.2.4
10.2.5
10.2.6
10.2.7
10.2.8
10.2.9
10.2.10
10.2.11
10.2.12
CURING .................................................................................................................. 2
General
2
Water for Curing
3
3
Curing of Formed Surfaces
4
Curing of Unformed Surfaces
4
Moisture Curing
4
Moisture Retaining Cover Curing
4
Liquid Membrane Curing
5
Steam Curing
5
Pavements and other slab on ground
5
Buildings, bridges, and other structures
5
Mass concrete
6
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10
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Part
10: Curing
Page 2
10
CURING
10.1
GENERAL
10.1.1
Scope
This part covers the requirements for the curing of concrete.
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References
AASHTO M 148.74, ...Liquid Membrane Curing
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ACI 308 ..................... Guide to Concrete Curing
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10.1.2
This Section
Part 1, ............ General
Part 4, ............ Water
Part 6, ............ Property Requirements
Part 15, ........... Hot Weather Concreting
Part 16, ........... Miscellaneous.
ASTM C 309, .............. Specification for Liquid Membrane-forming Compounds for Curing
Concrete
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BS 7542,..................... Method of test for curing compounds for concrete.

Quality management systems -- Requirements
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ISO 9001: 2008

Submittals
The Contractor shall submit to the Engineer the proposed method of curing for approval.
10.1.4
Quality Assurance
The Contractor shall submit to the Engineer for approval the details of proposed curing
media, if any. Details shall include chemical tests for the product in accordance with
BS 7542 and details of quality assurance procedures, including ISO 9001 certificates if held.
10.1.5
Storage
Chemical curing compounds shall be stored in accordance with manufacturer's

recommendations.
10.2
CURING
10.2.1
General
The Contractor shall ensure that curing is provided for 24 hours per day including holidays
and that all related necessary plant and labour resources are also available.
Special attention shall be given to the curing of vertical and overhanging surfaces to ensure
satisfactory curing.
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10.1.3
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Part
10: Curing
Page 3
The Contractor shall adopt curing measures that preclude the possibility of thermal shock to
the concrete during curing. This may be achieved by ensuring that the temperature of the
water used for curing does not differ from that of the concrete by more than 15 C.
Curing shall continue for at least 7 days and until it attains an in-place compressive strength
of the concrete of at least 70% of the specified compressive or flexural strength, whichever
period is longer. Curing shall not stop unless otherwise approved by the Engineer.
When low W/cm is used, the concrete shall be preferably cured by water.
10.2.2
Water for Curing
Water used for any curing purposes shall conform to the requirements of Part 4 of this
Section.
10.2.3
Freshly placed concrete shall be protected from sun, wind, rain, exposure and excessive
drying out.
All concrete shall be cured for a period of time required to obtain the full specified strength,
but not less than seven consecutive days. The method of curing shall be by water for the first
seven days and by water or membrane until the concrete has reached the full specified
strength.
For mixtures with a low to zero bleeding rate, or in the case of aggressively evaporative
environments, or both, the curing shall start at early anytime between placement and final
finishing of the concrete. The curing shall be by reducing the moisture loss from surface
using fogging systems and the use of evaporation reducers such as monomolecular water
curing compound.
Exposed surfaces shall be protected from air blown contamination until 28 d after the
concrete is placed.
The method of curing shall ensure that sufficient moisture is present to complete the
hydration of the cement, and shall be to the approval of the Engineer. The method of curing
shall not:
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(a)
disfigure permanently exposed surfaces
(b)
affect bonding of subsequent coatings
(c)
increase the temperature of the concrete.
During the curing period, exposed concrete surface shall be protected from the direct rays of
the sun.
When liquid membrane is used to cure the concrete, it shall not be applied if bleeding water
is present on the surface of the concrete.
The applied film of the liquid membrane shall be continuous and protected from rain and any
damages for at least 14 days.
QCS 2014

Part
10: Curing
Page 4
Formed surfaces, including the underside of beams, girders, supported slabs and the like, by
moist curing with the forms in place for the full curing period, or until the forms are removed.
When the forms are stripped, curing shall continue by any approved method.
When liquid membrane curing is used, it shall be applied immediately after de-shuttering. In
such cases the concrete surface shall be prepared prior to the application of the membrane
as recommended by the manufacturer.
Water curing is not required when liquid membrane is used.
10.2.5
Unformed surfaces shall be protected as soon as possible after the concrete has been
placed by polythene sheeting. When sufficiently hard, hessian or other absorbent material
shall be placed on the concrete surface and shall be kept wet for the required period. The
hessian shall be overlaid with a sheet of 1000 gauge polythene to assist in the retention of
water. Alternatively a curing method approved by the Engineer may be used.
Once the concrete is sufficiently hard, the top exposed surface of walls, columns and beams
shall be water cured and covered with wet hessian for the required curing period.
10.2.6
Moisture Curing
Moisture curing shall be performed by :
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10.2.4
covering the surface of the concrete with water and keeping it continuously wet
(b)
continuous use of fine fog water sprays
(c)
covering the surface with a saturated absorptive cover and keeping it continuously
wet.
(d)
Burlap, cotton mats, and other absorbent materials can be used to hold water on
horizontal or vertical surfaces.
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Wet straw or hay can be used for wet-curing small areas, but there is the danger that
wind might displace it unless it is held down with screen wire, burlap, or other means
(e)
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(a)
Where method (a) is employed, the bunds used shall not be made from fill from excavations
or any other areas where there is the possibility of chloride contamination.
10.2.7
The concrete surface shall be covered with a suitable absorptive covering, such as wet
hessian.
The absorptive covering shall be overlaid with a 1000 gauge polythene sheet.
The cover shall be in the widest practical widths and shall have 100 mm side and end laps.
Any penetrations or tear in the covering shall be shall be repaired with the same material and
waterproof tape.
QCS 2014

Part
10: Curing
Page 5
Liquid membrane curing shall be in accordance with the requirements of BS 7542, ASTM
C 309 or C1315 when tested at the rate of coverage use on the job.
ASTM C 156 shall be used as a test method to evaluate water-retention capability of liquid
membrane forming compounds. ASTM C 1151 provides an alternative laboratory test for
determining the efficiency of liquid membrane-forming compounds.
Membrane forming curing compounds shall be applied in accordance with the manufacturer's
recommendations immediately after any water sheen which may develop after finishing has
disappeared from the surface and within 2 h of stripping formwork on formed surfaces.
Membrane forming curing compounds shall not be used on surfaces against which additional
concrete or other material is to be bonded unless:
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10.2.8
it is proven that the curing compound will not prevent bond, or
(b)
positive measures are taken to remove it completely from those areas which are to
receive bonded applications
(c)
on fair faced concrete surfaces.
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(a)
Steam Curing
An enclosure shall be formed around the concrete using tarpaulin or other suitable means.
Application of steam shall not be commenced until at least 2 h after final placement of
concrete.
Steam shall be applied at a temperature between 65 C and 80 C.
Excessive rates of heating and cooling shall be prevented during steam curing and
temperatures in the enclosure shall not be allowed to increase or decrease by more than
22 C per hour.
The maximum steam temperature shall be maintained in the enclosure until concrete has
reached its specified strength.
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10.2.9
10.2.10 Pavements and other slab on ground

1
Curing shall ensure that no plastic shrinkage crack will occur, this can be done by protective
measures such as sun shields, wind breaks, evaporation reducers, or fog spraying should be
initiated immediately to reduce evaporation.
Mats used for curing can either be left in place and kept saturated for completion of the
curing, or can be subsequently replaced by a liquid membrane-forming curing compound,
plastic sheeting, reinforced paper, straw, or water
10.2.11 Buildings, bridges, and other structures

1
Additional curing shall be provided after the removal of forms
QCS 2014

Part
10: Curing
Page 6
After the concrete has hardened and while the forms are still in place on vertical and other
formed surfaces, form ties may be loosened when damage to the concrete will not occur and
water applied to run down on the inside of the form to keep the concrete wet.
Care shall be taken to prevent thermal shock and cracks when using water that is
significantly cooler than the concrete surface. Curing water should not be more than about
o
11 C cooler than the concrete.
Immediately following form removal, the surfaces shall be kept continuously wet by a water
spray or water-saturated fabric or until the membrane-forming curing compound is applied.
Curing
10.2.12 Mass concrete

Mass concrete is often cured with water for the additional cooling benefit in warm weather;
however, this can be counterproductive when the temperature gradient between the warmer
interior and the cooler surface generates stress in the concrete.
Horizontal or sloping unformed surfaces of mass concrete can be maintained continuously

wet by water spraying, wet sand, or water saturated fabrics.
For vertical and other formed surfaces, after the concrete has hardened and the forms are
still in place, the form ties may be loosened and water supplied to run down the inside of the
form to keep the concrete wet
o
Curing shall start as soon as the concrete has hardened sufficiently to prevent surface
damage.
For unreinforced massive sections not containing ground granulated blast-furnace slag or
pozzolan, curing shall be continued for not less than 2 weeks. Where ground granulated
blast-furnace slag or pozzolan is included in the concrete, the minimum time for curing shall
be not less than 3 weeks.
For reinforced mass concrete, curing shall be continuous for a minimum of 7 days or until
70% of the specified compressive strength is obtained, if strength is the key concrete
performance criterion. For construction joints, curing shall be continued until resumption of
concrete placement or until the required curing period is completed.
Curing shall not stop until favourable differential temperature is attained and at the approval
of the Engineer.
For mass concrete, thermocouples shall be used to monitor the temperature differential of
the concrete.
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END OF PART
QCS 2014

Part
11: Reinforcement
Page 1
REINFORCEMENT ................................................................................................. 2
11.1
11.1.1
11.1.2
11.1.3
11.1.4
11.1.5
GENERAL ............................................................................................................... 2
Scope
2
References
2
Submittals
3
Quality Assurance
3
Delivery Storage and Handling
3
11.2
11.2.1
11.2.2
11.2.3
REINFORCING MATERIALS .................................................................................. 4

Reinforcing Bars
4
Welded Steel Wire Fabric
4
Tie Wire
5
11.3
11.3.2
11.3.3
INSPECTION, SAMPLING AND TESTING.............................................................. 5

Sampling
5
Testing
6
11.4
CUTTING AND BENDING OF REINFORCEMENT ................................................. 6
11.5
11.5.1
11.5.2
11.5.3
11.5.4
11.5.5
11.5.6
11.5.7
11.5.8
11.5.9
11.5.10
11.5.11
FIXING OF REINFORCEMENT ............................................................................... 6

General
6
Welding
7
Mechanical Splices
8
Bundling and Splicing of Bundled Bars
8
Examination
8
Electrolytic Action
8
Cover
8
Reinforcement
8
Forms and Linings
9
Tanking
9
Adjustment and Cleaning
9
11.6
11.6.2
11.6.3
11.6.4
PROTECTIVE COATINGS TO REINFORCEMENT ................................................ 9

Epoxy Coated Reinforcing Bars
9
Handling of Epoxy Coated Reinforcement
11
Testing of Epoxy Coated Reinforcement
11
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11
QCS 2014

Part
11: Reinforcement
Page 2
11
REINFORCEMENT
11.1
GENERAL
11.1.1
Scope
This Part includes tension, compression, and temperature reinforcing steel, including welded
wire fabric, and epoxy coated reinforcing. The work includes furnishing, fabrication, and
placement of reinforcement for cast-in-place concrete, including bars, welded wire fabric,
ties, and supports.

This Section
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References
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ASTM A416/A416M....Standard Specification for Steel Strand, Uncoated Seven-Wire for

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ASTM 615/615M ........Standard Specification for Deformed and Plain Carbon-Steel Bars for
Concrete Reinforcement
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ASTM A706, ...............Specification for Low-allow Steel Deformed Bars for Concrete
Reinforcement
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ASTM A881/A881M ...Standard Specification for Steel Wire, Deformed, Stress-Relieved or

Low-Relaxation for Prestressed Concrete Railroad Ties
Filled
Epoxy-Coated
Seven-Wire
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ASTM A882/A882M- ..Standard Specification for

Prestressing Steel Strand
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ASTM A955/A955M-14 Standard Specification for Deformed and Plain Stainless-Steel Bars
for Concrete Reinforcement
ASTM A1022/A1022M-14a Standard Specification for Deformed and Plain Stainless Steel
Wire and Welded Wire for Concrete Reinforcement
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ASTM A1035/ A1035M Deformed and Plain, Low-carbon, -Chromium, -Steel Bars for
Concrete Reinforcement:
11.1.2
Part 16 ............. Miscellaneous

Part 17 ............. Structural Precast Concrete
BS 4449 : 2005...........Specification for Carbon steel bars for the reinforcement of concrete
BS 4482: 2005,...........Specification for Cold reduced steel wire for the reinforcement of
concrete
BS 4483: 2005............Steel fabric for the reinforcement of concrete
BS 5896,.....................Specification for high tensile steel wire and strand for the prestressing
of concrete.
BS 8666,.....................Specification for scheduling, dimensioning, bending and cutting of
steel reinforcement for concrete
EN 1011, ....................Welding. Recommendation for welding of metallic materials
EN 1992-1-1 Eurocode 2: Design of concrete structures. General rules and rules for buildings
ISO 14654, .................Epoxy- coated steel for the reinforcement of concrete
ISO 14656, .................Epoxy powder and sealing material for the coating of steel for the
reinforcement of concrete
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Part
11: Reinforcement
Page 3
ISO 3766 ...................Construction drawings -- Simplified representation of concrete

reinforcement
ISO 9000, ..................Quality management systems. Fundamentals and vocabulary
QS ISO 6935-1:2007, .Steel for the reinforcement of concrete -Part 1: Plain bars
QS ISO 6935-2:2007 ..Steel for the reinforcement of concrete Part 2: Ribbed bars
QS ISO 6935-3:2007 ..Steel for the reinforcement of concrete Part 3: Welded fabric
Submittals
Product data including the manufacturers specification and installation instructions for
proprietary materials and reinforcement accessories shall be provided.
The Contractor shall submit the manufacturers records of chemical and physical properties
of each batch of billet steel bars and a certificate that the respective material furnished meets
the requirements for the steel reinforcement specified. The manufacturers records shall
include certificates of mill as well as analysis, tensile and bend tests of the reinforcement.
Three copies of the steel test report shall be furnished with each consignment of steel
reinforcement. The steel shall be tagged and cross-referenced with mill certificates.
11.1.4
Quality Assurance
The Contractor shall submit to the Engineer for source approval details of the proposed
source of supply of the reinforcement. Details shall include chemical and physical tests for
the past six months production and any independent test results for this period. Details of
quality assurance procedures, including ISO 9000 certificate if held, shall also be given.
The Contractor shall furnish the Engineer with a certificate of compliance for each shipment
of epoxy coated bars. The certificate of compliance shall state that representative samples of
the epoxy coated bars have been tested and that the test results comply with the
requirements herein specified. Test results shall be retained by the Contractor for seven
years. A complete set of test results shall also be handed to the client at the completion of
reinforcement works, and shall be made available to the Engineer upon request.
11.1.5
On delivery, bars in each lot shall be legibly tagged by the manufacturer. The tag shall show
the manufacturers test number and lot number and other applicable data that will identify the
material with the certificate issued for that lot of steel. The fabricator shall furnish three
copies of a certification which shows the batch number or numbers from which each size of
bar in the shipment was fabricated.
Storage of reinforcement shall be on suitable structures a minimum of 450 mm above the

ground surface to prevent damage and accumulation of dirt, rust and other deleterious
matter. Storage facilities shall be such as to permit easy access for inspection and
identification. Reinforcement bundles shall be clearly tagged with bar schedule and bar mark
reference.
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11.1.3
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Page 4
The reinforcement shall not be roughly handled, dropped from a height, or subjected to shock
loading or mechanical damage. Steel reinforcing bars shall be kept clean and shall be free
from pitting, loose rust, mill scale, oil, grease, earth, paint, or any other material which may
impair the bond between the concrete and the reinforcement. The reinforcement shall be
covered to ensure protection from wind blown dust, condensation and other deleterious
materials.
11.2
REINFORCING MATERIALS
11.2.1
Reinforcing Bars
Reinforcement shall be from an acceptable source. All steel reinforcement bars shall comply
with the requirements of:
QS ISO 6935 with minimum grade of B500 MPa or
(ii)
BS 4449 with minimum grades of B500 MPa ; or..
(iii)
ASTM A615 / A615M with minimum grade of 75 [520MPa]; or
(iv)
Deformed and Plain, Low-carbon-Chromium-Steel

Reinforcement: ASTM A1035/ A1035M
(v)
ASTM A1022/A1022M-14a Standard Specification for Deformed and Plain

Stainless Steel Wire and Welded Wire for Concrete Reinforcement
(vi)
ASTM A955/A955M-14 Standard Specification for Deformed and Plain

Stainless-Steel Bars for Concrete Reinforcement
(vii)
Other types of reinforcement, as approved by Qatar Standards
Bars
for
Concrete
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(i)
As per project design, other steel grades of less than B500MPa may be used only for stirrups
and secondary reinforcement of diameter of 10mm or less.
If the steel has excessive surface rust, dust or other deleterious material then the steel shall
be sand blasted. Sand for blasting shall not contain materials deleterious to the durability of
the reinforcement or concrete. Dune sand shall not be used for the sandblasting of
reinforcement.
For extreme exposure class X5; protection measures such as epoxy coated bars; Lowcarbon-chromium-steel bars; or Stainless Steel may be considered.
11.2.2
Steel fabric reinforcement shall comply with the requirements of QS ISO 6935-3 or BS 4483
and shall be delivered to Site in flat mats.
Welded intersections shall not be spaced more than:
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(a)
300 mm for plain round bars
(b)
400 mm apart for deformed high yield bars in direction of calculated stress except
when used as stirrups.
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Tie Wire
Tie wire shall conform to the requirements of BS 4482.
1.6 mm black annealed mild steel shall be used for tie wire.
No wires smaller than size D-4 shall be used.
11.3
INSPECTION, SAMPLING AND TESTING
Inspection of reinforcing steel and the installation thereof will be conducted by the Engineer.
The Contractor shall give 24 hour notice to the Engineer before closing forms or placing
concrete.
The Engineer may instruct the Contractor to break out and remove completely all sections of
the work already constructed under any of the following circumstances:
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11.2.3
reinforcing steel sample under test fails to meet the specification requirements at any
time
(b)
the Engineer considers that samples which were presented to him for test were not
truly representative
(c)
a previously rejected reinforcing steel has been used in the Works.
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(a)
Sampling
Representative samples of all reinforcing steel proposed for use in the Works must be
submitted by the Contractor, before work is commenced, to the Engineer for his written
approval.
Manufacturer's certificates stating clearly for each sample:

(a)
place of manufacture
expected date and size of deliveries to site
(b)
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11.3.2
(c)
all relevant details of composition, manufacture, strengths and other quality of the
steel.
The Engineer reserves the right to sample and inspect reinforcement steel upon its arrival at
the work site.
Frequency of sampling and the method of quality control shall be in accordance with steel
bars manufactured standard QS ISO 6935 or BS 4449 .
Where epoxy coated steel is used, a sample of the coating material shall be supplied with
each batch in an airtight container and identified by the batch number.
Allow 14 days for Engineers review of samples.
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Testing
Tests shall be carried out when directed by the Engineer.
Tests shall be carried out in accordance with QS ISO 6935 or BS 4449.
The following information shall be provided with each delivery of reinforcement:

elastic limit
(b)
ultimate strength
(c)
stress/strain curve
(d)
cross-sectional area
(e)
deformation/bond characteristics of deformed bars.
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(a)
11.3.3
The Contractor shall allow for dimensions and weight measurements, tensile, bend and/ or
rebend tests at own cost, for each size of bar to be used in the concrete construction.
Test results for each bar size shall be submitted to the Engineer three weeks before concrete
work commences on Site.
Full testing shall be required if the source of supply of reinforcement changes, in which case
the cost of such extra testing will be borne by the Contractor.
When any test results do not conform to the relevant standard the reinforcement steel shall
be removed from the Site and all costs resulting therefrom shall be borne by the Contractor.
11.4
CUTTING AND BENDING OF REINFORCEMENT
Cutting and bending of reinforcement shall be in accordance with ISO 3766 or BS 8666 and
shall be done without the application of heat. Bends shall have a substantially constant
curvature. For epoxy coated steel the provisions of Clause 11.6.1 of this Part shall apply
Steel bars manufactured according to the approved ASTM standards shall be bent according
to the same standard.
Reinforcement shall not be straightened or rebent without the approval of the Engineer. If
permission is given to bend projecting reinforcement care shall be taken not to damage the
concrete and to ensure that the radius is not less than the minimum specified in ISO 3766 or
BS 8666.
11.5
FIXING OF REINFORCEMENT
11.5.1
General
All reinforcement shall be securely and accurately fixed in positions shown on the Drawings
to ensure that the reinforcement steel framework as a whole shall retain its shape. The
framework shall be supported to retain its correct position in the forms during the process of
placing and consolidating the concrete.
The ends of all tying wires shall be turned into the main body of the concrete and not allowed
to project towards the surface.
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No part of the reinforcement shall be used to support access ways, working platform or for
the conducting of an electric current.
The Contractors specific attention is drawn to the following general requirements:

(a)
lapped joints shall be as indicated on the Drawings and/or in accordance with the
requirements of EN 1992-1-1 or BS 8666
(b)
hooks shall be semicircular with a straight length of at least:

(i)
four bar diameters for mild steel
(ii)
six bar diameters for high yield steel.
Welding
Welding shall not be used unless authorised by the Engineer and recommended by the
reinforcement manufacturer.
Where welding is approved it shall be executed under controlled conditions in a factory or

workshop.
Welding shall not take place on site without the approval of the Engineer and unless suitable
safeguards and techniques are employed and the types of steel employed have the required
welding properties.
Welding if approved, may be used for:
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11.5.2
fixing crossing or lapping reinforcement in position
(b)
fixing bars to other steel members
(c)
structural welds involving transfer of loads between reinforcement or between bars

and other steel members.
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The length of run deposited in a single pass shall not exceed five times the bar diameter. If a
longer welded length is required, the weld shall be divided into sections with the space
between runs made not less than five times the bar diameter.
Butt welds shall be formed by flash butt welding or metal-arc welding. Other methods may be
approved, subject to their satisfactory performance in trial joints.
Metal-arc welding or electrical resistance welding may be used for fixing suitable steels or for
lapped joints.
Flash butt welding shall be executed with the correct combination of flashing, heating,
upsetting and annealing, using only machines which automatically control this cycle of
operations.
Metal-arc welding shall comply with EN 1011 and the recommendations of the reinforcement
manufacturer.
10
Welded joints shall not be made at bends in the reinforcement. Joints in parallel bars of
principle reinforcement shall be staggered, unless otherwise approved. The distance
between staggered joints shall be not less than the end anchorage length joints.
11
Weldable reinforcement where shown on the Drawings shall conform to ASTM A706.
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Mechanical Splices
Mechanical splices shall comply with EN 1992-1-1 or BS 8666, and shall be used as and
where indicated on the Drawings.
Details of mechanical splices shall be submitted to the Engineer for approval.
11.5.4
Bundling and splicing of bundled bars shall be in accordance with EN 1992-1-1 or BS 8666.
Splicing, except where indicated on the Drawings or approved shop drawings, will not be
permitted without the approval of the Engineer.
11.5.5
Examination
The Contractor shall notify the Engineer at least 24 hours before commencing the fixing of
reinforcement in order to facilitate the inspection of formwork.
The Contractor shall ensure that areas to receive reinforcement are cleaned before fixing.
11.5.6
Electrolytic Action
Reinforcement shall not be fixed or placed in contact with non-ferrous metals.
11.5.7
Cover
Correct concrete cover to reinforcement shall be maintained with the aid of approved spacer
pieces.
The cover shall not be less than given in Section 5 Part 6.
Spacers, chairs and other supports shall be provided as necessary to maintain the
reinforcement in its correct position.
In a member where the nominal cover is dimensioned to the links, spacers between the links
and formwork shall be the same dimension as the nominal cover.
Spacer bars shall be of the same diameter as longitudinal bars, but not less than 25 mm in
diameter, and shall be fixed between two layers at 1.5 m centres except where bundled bars
are detailed.
Spacers, chairs and other supports shall be made of concrete, plastic or other material to the
approval of the Engineer. Where supports are made of concrete they shall have at least the
same cube strength as the concrete in the host member.
11.5.8
Reinforcement
Placing of all reinforcement steel bars will be checked by the Engineer and in no case is
concrete to be placed around any reinforcement steel that has not been approved by the
Engineer. Insertion of bars into or the removal of bars from concrete already placed will not
be permitted.
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11.5.3
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Part
11: Reinforcement
Page 9
Reinforcement steel temporarily left projecting from the concrete at the joints shall not be
bent without the prior approval of the Engineer.
11.5.9
Forms and Linings
Damage to forms and linings shall be avoided.
11.5.10 Tanking
1
Reinforcement shall not be fixed until completion of placing tanking (membrane) protection.
11.5.11 Adjustment and Cleaning
Check position of reinforcement before and during placing concrete:

pay particular attention to the position of top reinforcement in cantilever sections
(b)
ensure that reinforcement is clean and free from corrosive pitting, loose rust, loose mill
scale, oil and other substances which may adversely affect reinforcement, concrete, or
the bond between the two.
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Protect projecting reinforcement from the weather where rust staining of exposed concrete
surfaces may occur.
At the time of concreting, all reinforcement steel shall have been thoroughly cleaned and
freed from all mud, oil or any other coatings that might destroy or reduce the bond:
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clean all set or partially set concrete which may have been deposited thereon during
the placing of a previous lift of concrete
(b)
all uncoated rust bars shall be again sand blasted and pressure washed.
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Immediately before concrete placing the reinforcing steel shall be washed thoroughly with
high pressure potable water jets to remove any deposited salts.
11.6
PROTECTIVE COATINGS TO REINFORCEMENT
All the forgoing clauses of this part apply equally to epoxy coated reinforcing bars.
11.6.2
Reinforcing steel which are to be coated shall be free of slivers, scabs, excessive pitting,
rust, grease, oil and other surface defects detrimental to proper coating.
The surface shall be prepared in accordance with ISO 14654.
Coating shall be applied to the cleaned surface as soon as possible after cleaning and before
any visible oxidation to the surface occurs.
Reinforcing steel shall not have surface defects that would be detrimental to coating.
Coating material shall be epoxy resin powders as specified in ISO 14654 and ISO 14656 for
coating of reinforcing bars and as follows:
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epoxy resin powders which do not meet the above requirements must be tested by an
approved independent testing laboratory and accepted by the Engineer before use
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Part
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(b)
only fusion bonded epoxy-coated reinforcing steel will be accepted
(c)
no other means of epoxy coating will be approved.
Patching material shall be:

(a)
furnished by the epoxy coating manufacturer
(b)
compatible with the coating
(c)
inert in concrete
(d)
suitable for repairs to the coated reinforcing bars to be made by the coating applicator
and the Contractor at the project site.
Fabrication shall be performed before coating except as hereinafter specified for bent bars
and straight bars less than 7.6 m long.
Bent reinforcing steel bars shall be coated after bending, unless the fabricator can show that
satisfactory results can be obtained by coating before bending.
Any visible cracks in the coating on the outside of the bend or damage to coating resulting in
debonding of the coating after bending shall be rejected.
10
Bars less than 7.6 m long may be sheared or sawn to length after coating, provided:
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end damage to coating does not extend more than 12 mm back
(b)
cut end is patched before any visible oxidation appears.
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(a)
Flame cutting will not be permitted.
12
Epoxy coating shall be checked visually after cure for continuity of coating and shall be free
from holes, contamination, cracks and damaged areas.
13
There shall not be more than two holidays (pinholes not visually discernible) in any 300 mm
of the epoxy coated bar.
14
A holiday detector shall be used in accordance with the manufacturer's instruction to check
the epoxy coating for holidays. A 67.5 V detector such as the Tinker and Rasor Model M-1 or
its approved equivalent shall be used.
15
Patching of holidays is not required if there are less than three holidays per 300 mm length.
Bars having three or more holidays per 300 mm shall be cleaned and recoated or replaced
as directed by the Engineer.
16
Epoxy coating film shall be cured and/or post cured to a fully cured condition. A
representative proportion of each production lot shall be checked by the epoxy coating
applicator, using the method most effective for measuring cure to ensure that the entire
production lot of epoxy coating is supplied in the fully cured condition.
17
Contractor shall repair all coating damaged by fixtures used to handle or support the bars in
the coating process as follows:
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11
(a)
patching shall be done as soon as possible and before visible oxidation occurs
(b)
excessive patching from other causes will not be permitted
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(c)

Part
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Page 11
satisfactory correction shall consist of proper adjustment of process, and rerunning

the bars through the plant.
The Engineer reserves the right for access to the epoxy coating applicators plant to witness
epoxy coating processes for project work and to obtain specimens from test bars for any
testing desired.
19
All chairs, tie wires and other devices used in connecting, supporting, securing or fastening
epoxy coated reinforcement steel shall be made of or coated with a dielectric material.
20
Before the reinforcement is lowered into place and before placement of the concrete, the
coated bars shall be inspected by the Engineer for damage to the epoxy coating.
21
Sheared ends of bars and other areas requiring limited repair due to scars and minor defects
shall be repaired, using the specified patching or repair materials.
11.6.3
Reinforcement steel bars shall be handled and stored in a manner to prevent damage to bars
or, where used, the epoxy coating.
Bars, or where used epoxy coating, damaged in handling or other operations shall be
satisfactorily repaired at no additional cost to the Employer.
Where epoxy coated bars are used all handling systems shall have plastic mandrel and
padded contact areas wherever possible.
Where epoxy coated bars are used all bundling bands shall be padded.
All bundles shall be lifted with a strongback, multiple supports or a platform bridge so as to
prevent bar to bar abrasion from sags in the bar bundle.
Bars or bundles shall not be dropped or dragged.
During vibration care shall be taken to ensure that the epoxy-coated reinforcement is not
damaged by the pokers.
11.6.4
Adhesion and flexibility of the epoxy coating shall be evaluated on test bars coated with each
production lot.
At least 1 % of the length or 6 m, whichever is less, of each size of bar to be coated shall be
furnished as test bars.
Test bars may be in one length or multiple lengths as required to have one test bar of each
size with each production lot.
The production epoxy coated test bars shall be evaluated by bending 120 (after rebound)
around a mandrel of a diameter corresponding to size of bar indicated in Table 11.1.
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Part
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Table 11.1
Mandrel Diameter for Bar Diameter for
Evaluation Test of Epoxy Coated Test Bars
Diameter of Mandrel
(mm)
10
12
13
14
16
18
20
22
24
25
26
28
30
32
34
36
79
95
103
111
127
143
159
175
191
198
206
222
238
254
270
286
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Bar Diameter
(mm)
Bend shall be made at a uniform rate and may take up to one minute to complete.
Bend test shall be conducted at a room temperature of between 20 C and 30 C after the
specimen has been exposed to room temperature for a sufficient time to ensure that it has
reached thermal equilibrium.
No cracking of the epoxy coating shall be visible to the naked eye on the outside radius of the
bent bar.
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END OF PART
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Part
12: Joints
Page 1
JOINTS.................................................................................................................... 2
12.1
12.1.1
12.1.2
12.1.3
12.1.4
12.1.5
GENERAL ............................................................................................................... 2
Scope
2
References
2
Submittals
2
Quality Assurance
3
Definitions
3
12.2
12.2.1
12.2.2
CONSTRUCTION JOINTS ...................................................................................... 4

General
4
Construction Joints in Water Retaining Structures
4
12.3
12.3.1
12.3.2
12.3.3
MOVEMENT JOINTS .............................................................................................. 5

General
5
Joint Filler
6
Joint Sealants
6
12.4
12.4.1
SLIP BEARINGS ..................................................................................................... 7

General
7
12.5
12.5.1
12.5.2
12.5.3
12.5.4
WATERSTOPS ....................................................................................................... 7
General
7
Waterstops
7
Butyl Rubber Waterstops
8
Water Swelling Gaskets
8
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12
JOINTS
12.1
GENERAL
12.1.1
Scope
This part deals with movement and construction joints, slip bearings, waterstops and
associated sealants and filler materials.
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12.1.2
This Section
Part 1 ............... General
Part 10, ............ Curing
Part 15, ............ Hot Weather Concreting
Part 16, ............ Miscellaneous
References
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ASTM D1751 ..............Standard Specification for Preformed Expansion Joint Filler for
Concrete Paving and Structural Construction (Non-extruding and
Resilient Bituminous Types)
ASTM D2240 ..............Standard Test Method for Rubber PropertyDurometer Hardness
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ASTM D3575 ..............Standard Test Methods for Flexible Cellular Materials Made From
Olefin Polymers
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BS 903........................Physical testing of rubber

BS 2571......................General purpose flexible PVC compounds for moulding and extrusion
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BS 2782,.....................Methods of testing plastics

BS 6093,.....................Design of joints and joining in building construction
BS 7164,.....................Chemical tests for raw and vulcanized rubber
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BS EN 1992-3 ............Eurocode 2. Design of concrete structures. Liquid retaining and

containing structures
BS EN ISO 7214 ........Cellular plastics. Polyethylene. Methods of test

CRD-C572 ..................Corps of Engineers Specifications for Polyvinylchloride Waterstop
ISO 9001 ....................Quality management systems. Requirements
12.1.3
Submittals
The Contractor shall submit for approval by the Engineer as soon as practicable after
acceptance of his Tender and not less than three weeks before commencement of
concreting, drawings showing his proposals for the position of construction joints having due
regard to any that may be shown on the Contract Drawings.
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Page 3
For slide bearings the Contractor shall provide at least three samples of the proposed
material, together with the manufacturer's technical specifications and recommendations in
respect of application and performance.
For slip joints the Contractor shall provide at least three samples of materials proposed,
together with manufacturer's technical specifications and recommendations in respect of
application and performance.
For waterstops the Contractor shall provide at least three samples of proposed types,
including prefabricated joints and junctions, if applicable. If joints are to be made up on site,
provide worked samples, including samples for each make of waterstop, where samples
from different manufacturers are provided.
The Contractor must supply a certificate of compliance for the joint sealant, stating that it
meets the requirements of the specification. The Contractor shall also supply the
Manufacturers technical and installation data for the proposed material. The Contractor shall
provide details of previous installations of the product, with the client name, structure name,
type of joint and value of contract.
The Contractor shall prepare shop drawings that show the layout of the waterstops, specials
and joints.
12.1.4
Quality Assurance
The joint sealant, including primers and debonding materials shall be compatible with each
other and shall be supplied from a manufacturer operating the ISO 9001 or 9002 Quality
Assurance Scheme.
12.1.5
Definitions
Construction Joint: The surface where two successive placements of concrete meet, across
which it is desirable to develop and maintain bond between the two concrete placements, and
through which any reinforcement which may be present is not interrupted.
Contraction Joint: Formed, sawed, or tooled groove in a concrete structure to create a

weakened plane and regulate the location of cracking resulting from the dimensional change
of different parts of the structure. (See also Isolation Joint.)
Expansion Joint: A separation between adjoining parts of a concrete structure which is

provided to allow small relative movements such as those caused by thermal changes to
occur independently.
Isolation Joint: A separation between adjoining parts of a concrete structure provided to

isolate and element and thus allow independent movement.
Joints Fillers: Materials that are used to fill space within movement joints during construction.
They may provide support to a sealant applied subsequently.
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Page 4
CONSTRUCTION JOINTS
12.2.1
General
Where construction joints are required in slabs or beams (designed by Direct Design Method
DDM) they shall be located within the middle third of their spans, and at one-third to onequarter of span in slabs and beams subject to a maximum spacing of approximately 9
metres. Where slabs are supported by beams then the beams and slabs shall be constructed
in one operation.
In all cases vertical stop boards of a form to be approved by the Engineer shall be provided
by at the end of each section of work which is to be concreted in one operation and the
concrete shall be thoroughly compacted against these stop boards.
Where slabs, beams and walls incorporate construction joints, panels shall generally be
constructed consecutively. Where this is not possible a gap not exceeding one metre shall be
formed between adjacent panels. This gap shall not be concreted until a minimum interval of
7 d has expired since the casting of the most recent panel.
The size of bays for reinforced floors, walls and roofs shall be as shown on the drawings but
in no event shall they exceed 7.5 m in either direction and 6 m when unreinforced or with
nominal reinforcement.
Horizontal construction joints in walls will only be permitted when the wall is continuous with
the floor slab. Walls shall be keyed on cast kickers 150 mm high or on the tops of walls
meeting the soffits of suspended members.
Construction joints in monolithic structures shall be aligned with each other whenever
practicable.
Before placing new concrete against concrete which has already set the latter shall be
treated to expose the aggregate over the full section and leave a sound irregular surface.
This shall be done while the concrete is still fresh by means of water spray and light brushing
or other means approved by the Engineer.
Immediately before the new concrete is placed all foreign matter shall be cleaned away and
the surface moistened.
If during the course of the Contract it should become apparent that the Contractors methods
of forming construction joints are not proving effective the Engineer may order the Contractor
to execute at the Contractors expense such preventative measures as the Engineer may
consider necessary to ensure the watertightness of the construction joints in further work.
12.2.2
The floor may be designed as fully restrained against shrinkage and thermal contraction and
should be cast directly onto the blinding concrete.
In large structures, the floor shall be designed as a series of continuous strips with transverse
induced contraction joints provided to ensure that cracking occurs in predetermined
positions. Longitudinal joints between the strips should form contraction joints.
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12.2
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Page 5
Waterstops shall be incorporated into construction joints, crack induced joints, contraction
joints and expansion joints in water retaining structures. The Contractor shall ensure that all
such joints are watertight and any joints which may leak or weep shall be rectified by the
Contractor to the Engineers satisfaction.
The spacing of construction joints, crack induced joints, contraction joints and expansion
joints in water retaining structures shall be shown on the design drawings.
Where the positions or type of joints are not indicated on the drawings, the spacing of
construction joints or crack induced joints in water retaining structures shall not exceed 5 m.
Where the positions or type of joints are not indicated on the drawings in the ground floor
slab, construction joints, crack induced joints, contraction joints and expansion joints shall be
incorporated into the works as appropriate. for slabs on grade, construction joints or crack
induced joints should be provided at areas where differences in subgrade and slab support
may cause cracks. The slab shall be cast in strips not more than 15 metres wide across the
width of the building. Within each strip for both directions, crack induced joints shall be
provided at areas where cracks are expected and not more than 5.0 metre spacing, and
construction or contraction joints shall be provided at not more than 15.0m spacing.
Construction or contraction joints shall be provided between adjacent strips.
Waterstops of a type acceptable to the Engineer shall be embedded in the concrete. The
waterstop should be made of a high quality material, which must retain its resilience through
the service life of the structure for the double function of movement and sealing. The surface
of waterstops should be carefully rounded to ensure tightness of the joint even under heavy
water pressure. To ensure a good tightness with or without movement of the joints, the
waterstop should be provided with anchor parts. The cross-section of the waterstops should
be determined in accordance with the presumed maximum water pressure and joint
movements. The complete works of fixed and welded connections must be carried out
strictly in accordance with the manufacturers instructions.
Engineers acceptance shall be obtained by the Contractor, prior to start of work, on the
casting sequence and the layout of joints.
12.3
MOVEMENT JOINTS
12.3.1
General
Movement joints for expansion and contraction shall be constructed in accordance with the
details and to the dimension shown on the Drawings or where otherwise ordered by the
Engineer and shall be formed of the elements specified.
Movement Joints in Water Retaining Structures shall be in accordance with the details and to
the dimension shown on the Drawings and EN 1992-3.
The Contractor shall pay particular attention to the effects of climatic extremes on any
material which he may desire to use on any movement joint and shall submit for approval by
the Engineer his proposals for the proper storage, handling and use of the said materials
having due regard for any recommendations made by the manufacturer in this connection.
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Part
12: Joints
Page 6
Joint Filler
Joint fillers shall conform to the requirements of BS 6093 or ASTM D1751 or equivalent if
they are bituminous type or to the requirements of ASTM D3575 or BS EN ISO 7214 or
equivalent if they are polymer foam type.
The joint filler shall be fixed to the required dimensions of the joint cross-section and shall
provide a firm base for the joint sealer.
When required between two concrete surfaces as a resilient movement joint, the filler shall
be an approved granulated cork bound with insoluble synthetic resin.
When required between blockwork and concrete as a low density movement joint filler or for
building details it shall be an approved bitumen impregnated fibreboard or preformed closed
cell polyethylene.
12.3.3
Joint Sealants
All joints to be sealed shall be formed and the groove grit blasted to remove all traces of
deleterious materials such as form oil or curing compounds and also to remove any surface
laitance from the sides of the joint. The joint shall be dry prior the application of priming.
Where the use of grit blasting is not possible the Contractor may propose alternative
methods subject to the approval of the Engineer.
The back of the joint shall receive a debonding tape or polyethylene foam backer cord in
order to provide the correct depth to width ratio and prevent three sided adhesion.
The areas adjacent to the joint shall be protected using masking tape.
The sides of the joint shall be primed with the relevant primer as recommended by the
sealant manufacturer and the sealant material applied in accordance with the manufacturers
instructions.
The sealant material shall be a non-biodegradable multicomponent pitch polyurethane

elastomeric joint sealant, carefully selected as appropriate for the specific climatic and
environmental exposure conditions expected. Alternative types of sealant will be considered,
including epoxy-polyurethane, rubber bitumen and acrylic, subject to the requirements of the
specification and the approval of the Engineer.
Where the joint sealant is to be in contact with a protective coating the Contractor shall
satisfy the Engineer that the sealant and protective coating are compatible
Sealants shall exhibit the following properties:
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12.3.2
(a)
Movement accommodation factor
25 %
(b)
Shore A hardness
(c)
Solids content
(d)
Service temperature range
(e)
Chemical resistance to Sewage, Sabkha, Mineral acids and Alkalis
(f)
Width to depth ratio
20 - 25
100 %
2:1
0 C to 90 C
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Part
12: Joints
Page 7
Where shown on the Drawings sealants shall also be suitable for use with potable water.
All surface preparation, priming, mixing and application shall be carried out in strict
accordance with the manufacturers instructions.
10
The sealant shall have a proven track record of no less than ten years under similar local
conditions.
12.4
SLIP BEARINGS
12.4.1
General
Slip bearings shall be preformed low friction bearing strips to form a thin sliding joint.
They shall be extruded from specially formulated polyethylene to form a durable lamina
resistant to sewage, mineral acids and alkalis, solvents and weathering.
Slip bearings shall be applied in two layers with the bottom layer bonded to the substrate with
a high quality solvent borne adhesive based on polychloroprene rubber. The substrate shall
be clean and free from deleterious materials such as form oil or curing compounds and
surface laitance. The surface shall be level and even along the full length of the joint
The applied loads for slip bearings shall not exceed 0.7 MPa.
Operating temperatures shall be up to 80 C
The coefficient of friction shall not exceed 0.15
12.5
WATERSTOPS
12.5.1
General
Waterstops and associated materials shall be by a manufacturer with a minimum of ten years
experience in the field of engineering waterproof products.
PVC waterstops shall be suitable for storage, handling, installation and service within a range
of 15 C to 65 C.
12.5.2
Waterstops
The waterstop shall be a high performance system forming a continuous network as shown
on the Drawings.
Site jointing is to be limited to butt joints and shall be performed strictly in accordance with
the manufacturers instructions.
Centrally placed waterstops shall employ centre bulbs/shutter stop with ribs on the web
sections.
Externally placed waterstops shall have ribs on either side of the centre of the waterstop. The
water bar used at the location of expansion joints shall have a bulb in the centre to
accommodate the movements.
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Part
12: Joints
Page 8
Waterstops shall have a minimum thickness of 3 mm.
The minimum test performance data for PVC waterstops shall be as follows:
Tensile strength
Elongation at break
Hardness
>12 MPa
300 %
Shore A 80 to 90
The materials shall be tested in accordance with BS 2571 or BS 2782 or CRDC572 or

ASTM D2240.
12.5.3
Butyl rubber waterstops shall have the properties stated in Table 12.1 when tested in
accordance with BS 903.
Property
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BS 903
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Table 12.1
Properties Requirements of Butyl Rubber Waterstops
Requirements
3
Density
Part A26
Handness
Part A2
Tensile Strength
Part A2
Elongation at break point
Not less than 450 %
Part A/6
Water Absosption (48 hours immersion)
Not exceeding 5 %
1100 kg/m ( 5 %)
60-70 IRHD
Not less than 17.5 N/mm
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Part A1
Butyl rubber waterstops shall be suitable for storage, handling, installation and service within
a temperature of 0 C to 40 C
12.5.4
Where active sealing is required for critical areas, waterstops shall be hydrophilic polymer
modified chloroprene rubber strips. The rubber strips shall conform to the following properties
as applicable:
Water pressure resistance
(a)
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(b)
Expansion in contact with water :
(c)
Reversible
- 30 to + 70 C
(d)
5 Bar (50 m)
Application Temperatures
2 x original SRE
The selected rubber strips shall be available for three exposures:

(a)
Fresh Water
(b)
Seawater
(c)
Chemicals (if the condition demands or upon the Engineers request)
The supplier shall furnish references upon request of the Engineer.

END OF PART
QCS 2014

Part
13: Inspection and Testing of Hardened Concrete
Page 1
INSPECTION AND TESTING OF HARDENED CONCRETE .................................. 2
13.1
13.1.1
13.1.2
13.1.3
13.1.4
13.1.5
13.1.6
GENERAL ............................................................................................................... 2
Scope
2
References
2
Submittals
2
Quality Assurance
3
Non-Compliance of Work
3
General Fieldwork Requirements
4
13.2
13.2.1
13.2.2
13.2.3
13.2.4
CONCRETE CORES ............................................................................................... 4

General
4
Drilling Cores
5
Testing for Strength
6
Assessment of Strength
7
13.3
REINFORCEMENT COVER MEASUREMENTS ..................................................... 7
13.4
13.4.1
13.4.2
13.4.3
13.4.4
ULTRASONIC PULSE MEASUREMENTS .............................................................. 8

General
8
Selection of Test Locations
8
Execution of Tests
8
Estimated In-Situ Cube Strength
9
13.5
RADIOGRAPHY OF CONCRETE ........................................................................... 9
13.6
13.6.1
13.6.2
13.6.3
13.6.4
SURFACE HARDNESS ........................................................................................... 9

General
9
Method of Test
9
Equipment
10
Reporting
10
13.7
13.7.1
13.7.2
CHEMICAL CONTENT .......................................................................................... 10

Sampling
10
Laboratory Testing
11
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13
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Part
Page 2
13
INSPECTION AND TESTING OF HARDENED CONCRETE
13.1
GENERAL
13.1.1
Scope
This Part of the specification covers the inspection, sampling and testing of hardened
concrete.
Related Section and Parts are as follows:
This Section
Part 6 ............... Property Requirements
References
The following standards are referred to in this part of the specification:
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13.1.2
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ACI 214.4R .................Guide for Obtaining Cores and Interpreting Compressive Strength
Results
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ACI 318 ERTA ............Building Code Requirements for Structural Concrete (ACI 318-08) and
Commentary
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ASTM C42 ..................Standard Test Method for Obtaining and Testing Drilled Cores and
Sawed Beams of Concrete
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ASTM C823 ................Standard Practice for Examination and Sampling of Hardened

Concrete in Constructions
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BS 1881-124 ..............Testing concrete. Methods for analysis of hardened concrete
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BS 1881-204, .............Testing concrete. Recommendations on the use of electromagnetic

covermeters
BS EN 12350..............Testing fresh concrete
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BS EN 12504-1 ..........Testing concrete in structures cored specimens taking, examining and

testing in compression
BS EN 12504-2 ..........Non-destructive testing. Determination of rebound number
BS EN 12504-3:2005 Testing concrete in structures. Determination of pull-out force

BS EN 12504-4 ..........Determination of ultrasonic pulse velocity
BS EN 13791..............Assessment of in-situ compressive strength in structures and precast
concrete components
GSO ISO 1920-6 ........ Testing of concrete part 6: sampling, preparing and testing of
concrete core .
13.1.3
Submittals
The Contractor shall submit to the Engineer his quality assurance procedures for the
particular parts of the testing work that will be carried out.
The Contractor shall submit for the Engineers approval the curriculum vitae (CV) of the
supervisor proposed for the work.
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Part
Page 3
The Contractor shall through testing agency prepare a factual report that identifies the test
methods used and the test results. The report shall also identify any unusual results or
pertinent information relating to the testing. The report shall be presented in hard and
electronic copies.
For each of the test results the Contractor shall identify the precision or repeatability of the
particular sampling and testing method. This shall be as given from experience of the
particular test by the laboratory or as expected from information in the particular test
standard.
In-place tests will be valid only if the tests have been conducted using properly calibrated
equipment in accordance with recognized standard procedures and acceptable correlation
between test results and concrete compressive strength has been established and is
submitted.
Non-destructive tests shall not be used as the sole basis for accepting or rejecting concrete,
but they may be used to evaluate concrete when the standard-cured strengths fail to meet
the specified strength criteria
13.1.4
Quality Assurance
All field and laboratory testing of concrete shall be carried out by an independent laboratory
The evaluation of concrete in structure is needed when an existing structure is to be modified

or redesigned; to assess structural adequacy when doubt arises about the compressive
strength in the structure due to defective workmanship, deterioration of concrete due to fire or
other causes;when an assessment of the in-situ concrete strength is needed during
construction; to assess structural adequacy in the case of non-conformity of the compressive
strength obtained from standard test specimens; assessment of conformity of the in-situ
concrete compressive strength when specified in a specification or product standard.
13.1.5
If the 28 d works test cubes as defined in clause 6.6 of this Section fail to meet the minimum
criteria, the Engineer shall direct the Contractor to carry out in-place methods to estimate the
concrete strength by non-destructive testing, in-situ drilling of concrete cores or load testing.
The parts or elements of the structure made from the defective batch or batches of concrete
as represented by the works test cubes shall be identified by the Engineer and based on this
information the Engineer shall instruct the Contractor on the required number and position of
concrete cores.
The Engineer shall review the concrete core test results in conjunction with BS EN 13791 or
ACI 318 whichever is applicable to the structural design.
Based on this assessment the Engineer shall decide the acceptability of the concrete in the
structural element and may either:
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(a)
accept the concrete
(b)
instruct that certain remedial works are carried out
(c)
instruct that the element is replaced.
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Part
Page 4
The Contractor shall make all arrangements to provide safe stable access to testing
locations.
When gaining access to testing locations and whilst testing the Contractor shall take care not
to damage the structure or leave it in an untidy or unclean state.
The Contractor shall take precautions to ensure that cooling water from concrete coring/other
operations is discharged such as not to cause a mess or damage the interior or exterior parts
of the structure.
The Contractor shall be responsible for arranging the water supply required for testing.
The Contractor shall arrange for a suitable power supplies. Where testing is being carried out
on an occupied structure a power supply from the building services may not available and the
Contractor shall make arrangements for power supply and extension leads of adequate
length.
The Contractor shall appoint a qualified field supervisor to co-ordinate and manage the field
work. The supervisor shall have not less than five years experience of such work.
Before starting the work, the Engineer with the Contractors supervisor will mark the positions
where field testing is to be carried out. A unique referencing system to identify each sample
or testing location will be adopted, and this will either be referenced on sketch plans or
drawings or by a detailed description used throughout the report to identify test locations.
If testing is being carried out on an occupied structure the Contractor shall co-ordinate with
the owner or operator of the structure to arrange the detailed programme for the works and
gain access to the various parts of the structure.
As soon as laboratory test results are available these shall be submitted by hand or faxed to
the Engineer in draft form. The testing laboratory, or technical bureau assigned by the testing
agency, assigned by the contractor shall provide a technical report providing visual
information and analysing the tests conducted.
10
All core holes, dust sample holes and exploratory investigation areas shall be reinstated with
a proprietary non shrink cementitious repair mortar. The preparation of the hole or area
before reinstatement shall be carried out as per the recommendation of the repair mortar
supplier.
11
Before filling any core holes, dust sample holes or exploratory investigation areas, the
Contractor shall allow the Engineer time to inspect these areas and obtain written
confirmation from the Engineer before filling.
13.2
CONCRETE CORES
13.2.1
General
The drilling and testing of cores shall be carried out in accordance with BS EN 13791 & BS
EN 12504-1, or GSO ISO 1920-6 or ASTM C42 and ACI 214.4 whichever is applicable to the
structural design.
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13.1.6
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Part
Page 5
All of the supplementary information listed by the relevant standards shall be included in the
test report with photographs of the cores.
An assessment of in-situ compressive strength for a particular test region shall be based on
at least 3 cores. Consideration shall be given to any structural implications resulting from
taking cores. The diameter of concrete core shall be at least 100 mm for strength evaluation
unless clear spacing of reinforcement is less than 100 mm and approved by Engineer.
The preferred minimum core diameter is three times the nominal maximum size of the
coarse aggregate, but it shall be at least two times the nominal maximum size of the coarse
aggregate
The Engineer will advise the required number and locations of cores. If the results of the
initial coring are inconclusive, the Engineer may instruct that further cores be taken at certain
locations.
Unless otherwise directed by the Engineer, the Contractor shall ensure that coring does not
cut through any reinforcing steel. The required diameter and depth of concrete cores shall be
as stated in table 13.1
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Table 13.1
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Minimum Depth of Sampling of Concrete for Testing Purposes (ASTM C823)

Thickness of
Section, m
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Types of Construction
0.3 or less
0.3 or greater
entire depth
0.3
0.15 or less
entire depth
0.15 0.6
one half the thickness or

0.15 whichever is greater
0.6 or greater
0.6
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Slabs, pavements, walls, linings, foundations,

structural elements accessible from one side
only
2
Suspended slabs , walls, conduits,
foundations, structural elements exposed to
the atmosphere at two or more sides;
concrete products
Massive sections
Minimum Depth to Be
Sampled, m
1 The requirements of table 13.2.1 may not provide the quantities or dimensions of samples
that are required for all tests, in that case, the necessary additional quantity of concrete in
pieces of appropriate minimum size should be taken at each sampling location.
2 When suspended slabs are cored, it is desirable to leave the lower 25 mm uncored, so as
not to lose the core by its falling from the barrel and to make it easier to patch the core hole.
13.2.2
Drilling Cores
Before beginning coring operations the Contractor shall use a proprietary cover meter to
identify the position of steel reinforcing bars at the testing location.
QCS 2014

Part
Page 6
The Engineer may instruct that the core is taken through the concrete without hitting any
reinforcement or the Engineer may instruct that the core is taken in a position where it is
expected reinforcement will be cut in order to provide a sample of the reinforcement to check
its condition. The locations of all drilling points shall be chosen so that the core contains no
steel parallel to its length.
Before capping, the core shall have a length of at least 95 % of its diameter. Once prepared
for test the core shall have a length at least equal to the diameter and not more than 1.2
times its diameter.
Cores of both 100 mm and 150 mm nominal diameters may be tested provided that the
aggregate size does not exceed 20 mm and 40 mm respectively. Where possible 150 mm
cores should be taken to reduce the variability due to drilling and increase the reliability of the
testing, unless reinforcement is congested and the use of 100 mm cores will reduce the
possibility that the core will contain steel or it is necessary to restrict the sampling to a length
of less than 150 mm.
Where the size of the section precludes the use of 100 mm or 150 mm cores, smaller cores
may be used with the permission of the Engineer.
During drilling operations, a log of observations that may affect the interpretation of core
samples shall be prepared.
If instructed by the Engineer, immediately after the core has been cut and removed and the
structure a carbonation test will be carried out by using a 1 or 2 % solution of phenolphthalein
poured over the cut surface. A photograph shall be taken of the cut core with the
phenolphthalein solution applied to provide a record of the test.
If during the drilling of the core, the core collapses due to weak honeycombed or defective
concrete, the Contractor shall stop the drilling operation and carry out testing at an adjacent
location as advised by the Engineer. If when testing at the second location, the core again
breaks due to honeycombed or defective concrete the freshly cut core shall be retained for
reference and a note made of the condition.
13.2.3
The compressive strength of field concrete cores shall be assessed in accordance with BS
EN 13791.
The details of the concrete core in accordance with BS EN 13791 shall be recorded and two
photographs on either side of the core taken.
Where there is reinforcement in the core, the size and the type of bar shall be noted along
with its cover to the concrete surface, the condition of reinforcing bars shall be noted with a
detailed description of any corrosion of the reinforcement.
Before carrying out the compressive strength testing of the cores, the Contractor shall inform
the Engineer to allow him to witness the testing if required.
Crushed core samples shall be retained by the laboratory and only disposed of after written
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The estimated in-situ strength of the concrete shall be calculated from the core result using
BS EN 13791, ACI 214.4 or ACI 318 whichever is applicable by the structural design.
13.3
REINFORCEMENT COVER MEASUREMENTS
The measurement of cover to reinforcing steel and other metallic items in concrete shall be
carried out in accordance with BS 1881 Part 204 using an electromagnetic device that
estimates the position depth and size of the reinforcement.
The locations for checking cover and the spacing between measurements shall be advised
by the Engineer based on the objective of the investigation. The Contractor shall carry out
calibrations of the electric magnetic device for a particular bar size to allow the bar diameter
to be measured.
While testing, the orientation of steel bars shall be checked.
The electromagnetic device shall incorporate scale or digital display range and shall be
calibrated in accordance with BS 1881 Part 204. When calibrated in this manner the
indicated cover to steel reinforcement shall be accurate to within 5 % or 2 mm which ever
is the greater over the working range given by the manufacturer.
The cover meter shall be used in accordance with the manufacturers instructions and checks
on the zero carried out as specified.
The search head shall be traversed systematically across the concrete, and, where
reinforcement is located, rotated until the maximum disturbance with electromagnetic field is
indicated by the meter.
The cover to the reinforcement shall be noted along with the axis of the reinforcement. The
cover shall also be recorded on the concrete surface with chalk or a suitable non-permanent
marking pen.
Care should be taken to avoid interference from other metallic sources or magnetic material.
The cover meter checks shall be carried out by an operator with five years experience.
10
The test report on cover shall include the following information:
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13.2.4
(a)
date
(b)
time and place of test
(c)
description of the structure or component under investigation
(d)
location of test areas
(e)
make and type of cover meter used
(f)
date of last laboratory calibration of cover meter
(g)
details of site calibration of cover meter, indicated values of cover
(h)
estimated accuracy of quantitative measurements
(i)
configuration of steel reinforcement
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Part
Page 8
ULTRASONIC PULSE MEASUREMENTS
13.4.1
General
The ultrasonic velocity test equipment shall be capable of measuring the transit time of a
pulse vibration through concrete. The length of the pulse part between the transducer
equipment shall be measured, and the pulse velocity calculated.
Ultrasonic pulse velocity testing shall be carried out in accordance with the provisions of BS
EN 12504-4.
Velocities shall be measured at a number of locations around a structure and a velocity

contour of the structure established. A minimum of 40 velocities shall be measured for each
structural element.
13.4.2
Wherever possible direct transmission arrangements shall be used. The transducers shall be
mounted on a specially formed moulded surface.
The minimum path length shall be 100 mm for concrete in which the nominal maximum size
of aggregate is 20 mm or less and 150 mm for concrete in which the nominal maximum size
of aggregate is between 20 mm and 40 mm. but the path length shall not be longer than
required to detect small regions of bad concrete.
Where concrete contains steel the pulse velocity shall be adjusted in accordance with the
requirement of BS EN 12504-4.
Locations that contain reinforcement directly along or close to the pulse paths shall be
avoided.
Where repositioning is not possible the semi-direct transmission measurement, where

transducers are placed on adjacent faces of the concrete, may be used.
13.4.3
Execution of Tests
Positions chosen for the test locations shall be clearly and accurately marked on the surface
of the concrete.
The surface of the concrete shall be shall be cleaned and free from grit and dust. Path
lengths shall be determined to an accuracy of 1 % and a suitable couplant (such as grease)
applied to each of the test points.
Pulse transit times shall be measured by a skilled operator, with a minimum of five years
experience in the use of the equipment.
Pulse velocity measurement equipment shall be in accordance with the requirements of BS

EN 12504-4.
Test results shall be examined and any unusual readings repeated carefully for verification or
amendment.
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13.4
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A correlation shall be established between the cube crushing strength of the particular mix
used in the structure and the pulse velocity.
Where it is not possible to obtain cubes with the same mix design as the original structure a
combination of coring and ultrasonic pulse velocity testing may be carried out at the direction
of the Engineer, where the cores are used to provide the correlation information required for
the interpretation of the ultrasonic pulse velocity tests.
13.5
RADIOGRAPHY OF CONCRETE
Gamma rays and high energy X-rays, which illustrate by radiographs the concrete defects:
The testing shall be carried out in accordance with the requirements of BS 1881-205 or
equivalent.
13.6
SURFACE HARDNESS
13.6.1
General
Testing of concrete surfaces for hardness using rebound hammers shall be carried out in
accordance with BS EN 12504-2.
The rebound hammer shall only be used for estimation of concrete strength where a specific
correlation is carried out of the concrete from the structure being tested; this shall be from
works test cubes or cores taken from the structure.
The correlation between concrete strength and the rebound number shall be carried out in
accordance with BS EN 12504-2. The precision of the correlation curve between the mean
rebound number and strength shall be stated and this shall be used when reporting any
strength interpretations from surface hardness readings. The use of general manufacturers
correlation or calibration curve for strength shall not be used.
It should be noted that the rebound hammer number only provides information on a surface
layer of approximately 30 mm in depth of the concrete and that this should be quoted in the
test report.
The rebound hammer maybe used to establish the uniformity of the finish products or similar
elements in a structure at a constant age, temperature, maturity and moisture condition.
13.6.2
Method of Test
A minimum of 12 readings shall be taken to establish a single surface hardness at a

particular location.
The reading shall be on a regular grid between 20 mm to 50 mm spacing over an area not
exceeding 300 mm by 300 mm.
The mean of each set of readings shall be calculated including abnormally high and
abnormally low results unless there is good reason to doubt the validity of a particular
reading.
The coefficient of variation and the standard deviation of the readings shall be reported.
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13.4.4
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Equipment
The rebound hammer shall be a proprietary type that has been used successfully and
serviced for a minimum of five years.
The hammer shall comprise of a mass propelled by a spring that strikes a plunger in contact
with the surface.
The manufacturers literature shall identify the impact energy and contact area of the plunger
for the hammer.
13.6.4
Reporting
The test report shall affirm that the hardness was determined in accordance with BS EN
12504-2 and shall provide the following information:
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13.6.3
date time and place of test
(b)
description of structure and location of test
(c)
details of concrete
(d)
type of cement
(e)
cement content
(f)
type of aggregate
(g)
type of curing
(h)
age of concrete
(i)
type of compaction of concrete
(j)
forming of surface
(k)
moisture condition of the surface
(l)
carbonation state of surface
(m)
any suspected movement of the concrete under test
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(n)
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(a)
(o)
any other factors that are considered significant in influencing the hardness readings.
The details of the rebound hammer correlation with strength including the mean, range,
standard deviation and coefficient and variation of each reading shall also be included.
13.7
CHEMICAL CONTENT
13.7.1
Sampling
The Engineer shall instruct the depth increments over which the dust samples are to be
taken, the types of chemical testing to be carried out and the quantity of sample required.
The depth of sample shall not be less than the concrete cover to the reinforcement and at
least 50 mm from the surface of concrete. In presence of reinforcement, the chemical
content shall be tested at least at two levels before and after the depth of reinforcement from
the surface of concrete.
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To provide uniform samples of cement matrix and aggregate, three separate holes shall be
drilled at one location. The diameter of the holes shall be between 12 and 20 mm.
Care shall be taken to discard the material from any render or finish unless this is specifically
required under the investigation.
Care shall be taken to ensure that dust increments are accurately measured by marking the
drill bit.
The dust samples increments shall be carefully transferred to plastic bags and sealed to
avoid contamination. Each sealed bag shall be uniquely identified by the sample identification
and depth increment.
13.7.2
Laboratory Testing
Residual split samples of dust from the field investigation shall be retained until the Engineer
has reviewed the chloride test results. The Engineer may instruct that repeat tests are carried
out on certain samples.
Chloride testing of concrete dust samples shall be by an acid soluble method in accordance
with BS 1881 Part 124. The results shall be reported to two decimal places.
Sulphate testing of concrete dust samples shall be in accordance with BS 1881 Part 124,
using an acid soluble method.
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END OF PART
QCS 2014

Part
14: Protective Treatments for Concrete
Page 1
PROTECTIVE TREATMENTS FOR CONCRETE ................................................... 2
14.1
14.1.1
14.1.2
14.1.3
14.1.4
14.1.5
14.1.6
14.1.7
14.1.8
14.1.9
GENERAL ............................................................................................................... 2
Scope
2
References
2
Submittals
2
Quality Assurance
3
Preinstallation and Co-ordination
4
4
Protection
4
General Requirements for all Treatments
5
Final Inspection
5
14.2
14.2.1
14.2.2
14.2.3
14.2.4
EPOXY COATING ................................................................................................... 5

General
5
Surface Preparation
5
Materials
6
Application
6
14.3
14.3.1
14.3.2
14.3.3
14.3.4
WATERPROOF MEMBRANE ................................................................................. 6

General
6
Materials
7
Waterproof Membrane
7
Application
7
14.4
14.4.1
14.4.2
14.4.3
14.4.4
PENETRATIVE PRIMER ......................................................................................... 8

General
8
Material
8
Surface Preparation
8
Application
8
14.5
14.5.1
14.5.2
14.5.3
14.5.4
PROTECTIVE COATING ........................................................................................ 9

General
9
Surface Preparation
9
Material
10
Application
10
14.6
14.6.1
14.6.2
14.6.3
14.6.4
14.6.5
14.6.6
14.6.7
14.6.8
14.6.9
14.6.10
14.6.11
PLASTIC SHEET LINER FOR CONCRETE STRUCTURES ................................. 11

General
11
Shop Drawings and Submittals
11
Liner Material Requirements
11
Plastic Sheet Liner Strip Properties
12
Basic Sheet Dimensions
12
Liner Details
12
Installation
13
Testing Requirements
13
Special Requirements
14
Joints in Lining for In-Situ Concrete Structures
15
Testing and repairing damaged surfaces
15
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14
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Page 2
14
PROTECTIVE TREATMENTS FOR CONCRETE
14.1
GENERAL
14.1.1
Scope
This Part covers the materials and application requirements for coatings for concrete
surfaces including epoxy coatings, waterproof membranes, penetrative primers, protective
coatings, and coatings and treatments for specialist applications where there is a harsh
environment.
References
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14.1.2
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This Section
Part 1, ............. General
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ASTM D412 ................Test Methods for Vulcanized Rubbers and Thermoplastic Elastomers
Tension
ASTM D543 ................Test Method for Resistance of Plastics to Chemical Reagents
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ASTM D570 ................Test Method for Water Absorption of Plastics

ASTM D638 ................Test Method for Tensile Properties of Plastics (Metric)
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ASTM D746 ................Test Method for Brittleness Temperature of Plastics and Elastomers
by Impact
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ASTM D882 ................Test Methods for Tensile Properties of Thin Plastic Sheeting
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ASTM D1000 ..............Test Method for Pressure Sensitive Adhesive Coated Tapes Used for
Electrical and Electronic Applications
ASTM D1004 ..............Test Method for Initial Tear Resistance of Plastic Film and Sheeting
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ASTM D4541 ..............Test Method for Pull Off Strength of Coatings Using Portable Adhesion
Testers
ASTM E 96 .................Test Methods for Water Vapor Transmission of Materials
ASTM E154 ................Test Methods for Water Vapor Retarders Used in Contact with Earth
Under Concrete Slabs, on Walls, or as Ground Cover
BS 1881......................Testing Concrete
CIRIA Technical Note 130, Protection of Reinforced Concrete by Surface Treatments.
ISO 9000 ....................Quality management and quality assurance standards
ISO 9001 ....................Quality systems - Model for quality assurance in design, development,
production, installation and servicing
14.1.3
Submittals
The Contractor shall submit manufacturers' specifications, installation instructions and other
data to show compliance with the requirements of this part of the specification and the
Contract Documents.
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Part
Page 3
The Contractor shall submit samples of all materials to be used in the works before delivery
of material to Site. Samples of membrane waterproofing shall be 300 mm square. Samples
of liquid components shall be a minimum of one litre.
The Contractor shall submit comprehensive test results for the protective coating system as
per the tests in the specification which shall clearly indicate whether the values are mean
values measured in current production or minimum values which the property does not fall
below.
The Contractor shall clearly state the chemical composition of the material and the process
by which protection is given to the concrete.
In addition to the test methods identified in this clause of this specification, the Engineer may
require the Contractor to carry out further tests to different standards.
If the Contractor wishes to propose a material which has been tested to alternative
standards, the Contractor shall submit correlation tests showing the comparable values of the
two test methods. These test results shall be comprehensive giving full details of the sample
conditioning, preparation, method of test, criteria for assessment etc.
The Contractor shall submit comprehensive information of previous applications of the

material in similar conditions and environments. This information shall include: project name,
type/grade of material used, quantity of material used, name of client, name of consultant,
name of Contractor. If requested by the Engineer, the Contractor shall supply the contact
details of the client, consultant or Contractor where the material was previously installed.
The Contractor shall submit a guaranty for the protective coating system and the
workmanship. The guaranty shall be worded to reflect the required performance of the
material and shall be approved by the Engineer. The guaranty shall be worded to include the
phrase the Contractor shall, at the convenience of the Employer, effect all repairs and
replacements necessary to remedy defects all to the complete satisfaction of the Engineer.
Unless stated otherwise in the contract specific documentation, the performance guaranty
shall be for a period of ten years except for the penetrative primer which shall be for a period
of five years.
The use of alternatives may be considered by the Engineer. If the Contractor wishes to
propose such systems, a technical submission shall be made which shall include a
comprehensive justification giving an explanation of why the proposed system is equivalent
or superior to the one designated.
14.1.4
Quality Assurance
The protective coating system shall be supplied by a manufacturer who is certified to the
ISO 9000 series of quality standards. The Contractor shall submit to the Engineer a copy of
the ISO 9000 series certificate that clearly states the scope of the certification.
The protective coating system shall be supplied by a manufacturer who provides technical
assistance on the suitability for the application and installation for the material. For the initial
use of the material on Site, the Contractor shall arrange for the technical representative of
the manufacturer to be present to demonstrate the correct use of the material.
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The protective coating system shall be applied by a contractor or subcontractor who is

certified to the ISO 9000 series of quality standards. The Contractor shall submit to the
Engineer a copy of the ISO 9000 certificate that clearly states the scope of the certification.
the Engineer may permit the use of an applicator who is not certified to ISO 9000 if the
applicator works to a quality system that is approved by the Engineer.
The works shall be executed by an approved specialist subcontractor having a minimum of 5

years successful experience in the installation of the specified material. Only tradesmen
experienced with the installation of the materials specified shall be used.
14.1.5
After approval of all materials and before installation, a prework conference with the Engineer
shall be held at the Site. The meeting shall be attended by representatives of the Engineer,
Contractor, subcontractor, and manufacturer.
The parties shall:
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review drawings, specifications and approved materials
(b)
correct conflicts, if any, between approvals and specification requirements
(c)
examine Site conditions, including inspection of substrate, material labels and

methods of storing materials
(d)
review installation procedures and scheduling
(e)
review protection methods for finished work from other trades.
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(a)
Before applying the coating system to the permanent works the Contractor shall carry out a
small trial of the coating system for the review and approval of the Engineer.
14.1.6
Materials shall be delivered in their original, tightly sealed containers or unopened packages,
all clearly labelled with the manufacturer's name, brand name, and number and batch
number of the material where appropriate. Materials and equipment shall be stored as
directed in a neat and safe manner.
Storage areas shall comply with the manufacturers requirements with regard to shade,
ventilation and temperature limits and shall be located away from all sources of excess heat,
sparks or open flame. Containers of liquid material shall not be left open at any time in the
storage area.
Materials not conforming to these requirements will be rejected by the Engineer and shall be
removed from the Site and replaced with approved materials.
The Contractor shall deliver materials to Site in ample time to avoid delay in job progress and
at such times as to permit proper co-ordination of the various parts.
14.1.7
Protection
The Contractor shall protect the protection system installation from damage during the
construction period so that it will be without any indication of abuse, defects or damage at the
time of completion.
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The Contractor shall protect the building/structure from damage resulting from spillage,
dripping and dropping of materials.
The Contractor shall prevent any materials from running into and clogging drains.
Materials and plant shall not be stored on any newly constructed floor without the permission
of the Engineer.
Impervious membranes shall be laid as protection to all concrete surfaces in contact with the
soil and shall consist of tanking or similar accepted material, based on soil investigation
report.
All foundations shall be provided with protection such as epoxy coatings or similar other
accepted equivalents so that concrete is not exposed to harmful effects of soil, chlorides etc.
14.1.8
Protective treatments shall be applied where designated in the contract specific

documentation.
All protective coating systems to be used shall be applied strictly in accordance with the
manufacturers recommendations.
The Contractor shall take all necessary precautions against fire and other hazards during
delivery, storage and installation of flammable materials specified herein and comply any
regulations imposed by the Civil Defence Department of the Ministry of the Interior in respect
of the storage and use of hazardous materials required under this section.
The Engineer shall specify the required final colour of the coating and the Contractor shall
submit samples showing the colour before ordering the materials.
14.1.9
Final Inspection
Upon completion of the installation, an inspection shall be made by a representative of the

material manufacturer in order to ascertain that the system has been properly installed.
14.2
EPOXY COATING
14.2.1
General
The coating shall be a decorative flexible high solids, epoxy polyurethane coating applied in
two coats to a dry film thickness of 200 m minimum.
14.2.2
Surface Preparation
The surface of the concrete shall be free from oil, grease, loose particles, decayed matter,
moss or algae growth and general curing compounds. All surface contamination and surface
laitance shall be removed by high pressure water jetting or sweep blasting.
Blow holes and areas of substantial pitting shall then be filled with a solvent free thixotropic
epoxy resin fairing coat. The mixing and application of this coat shall be in accordance with
the product manufacturers recommendations.
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Where surface cracking is apparent these cracks shall be chased, by an approved

mechanical means, to the depth of the crack. A thixotropic epoxy resin shall be applied using
a trowel, scraper or filling knife ensuring that full compaction is achieved into the chased
section and providing a flush finish with the concrete surface. A minimum period of 24 h shall
be allowed before applying any subsequent protective coating systems.
14.2.3
Materials
External above ground coating materials shall provide protection against chlorides and
carbonation, and be UV and abrasion resistant.
The above ground coating shall be applied over the below ground coating and shall continue
for a minimum of 150 mm above the ground level.
The epoxy coating shall be UV stable.
The finished coating shall be pinhole free and have a total minimum dry film thickness of
200 m.
The materials used in the coating system shall comply with the following requirements:
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> 85 %
-20 C to 70 C
4 MPa
6 MPa
greater than 3.5 MPa
90 MPa (neat resin)
6-8 % (neat resin)
Nil
50 mg
97 MPa @ 7 days
-6
46.8 x 10 mm/mm/degree C
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Solids content
Service temperature
Tensile strength (DIN 53504)
Resistance against crack (DIN 53515)
Adhesion to concrete (ASTM D-4541)
Compressive strength (ASTM D-695)
Tensile elongation (ASTM D-638)
Water absorption (MIL D-24613)
Abrasion resistance (ASTM C-501)
Compressive strength (ASTM C-579)
Thermal coefficient of expansion (ASTM C-531)
Application
Where required by the Engineer, trial areas not exposed in the finished work shall first be
treated using the selected materials.
The exposed concrete surfaces as defined in the documents or as agreed with the Engineer
shall be treated with the material.
The coating shall be applied by spray, roller or brush to achieve a finish acceptable to the
Engineer.
In all operations of storage, mixing and application, the Contractor is to comply with the
health and safety recommendations of the manufacturer and governing authorities.
14.3
WATERPROOF MEMBRANE
14.3.1
General
This Subpart covers the use of waterproof membrane for general protection to buried
concrete.
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14.2.4
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Where indicated on the Drawings or directed by the Engineer, concrete in contact with the
ground shall be protected by a preformed flexible self-adhesive bituminous type membrane.
The laying, lapping and sealing of the membrane shall be in accordance with the
manufacturers instructions.
14.3.2
Materials
The material shall be an externally applied waterproof membrane shall be an impervious,

cold applied flexible laminated sheet, consisting of multilayer high density cross-laminated
polyethylene film with a backing of self-adhesive rubber bitumen compound, protected with
silicone coated release paper.
Primer for Sheet Membrane: As recommended by the manufacture of the sheet membrane.
Protection Board: Provide a minimum 6 mm thick asphalt protection board manufactured

from selected aggregates, bound in modified bitumen encased between two layers of
strengthened asphalt paper. The bituminous material shall be a minimum of 1.0 mm thick
and the membrane shall be capable of bridging crack widths in the substrate up to 0.6 mm
wide.
14.3.3
Waterproof Membrane
The material shall be suitable for use in the Gulf region the compound shall be specially
formulated for hot climates and shall have proven experience in the Middle East.
The waterproofing material shall conform to the standards detailed in Table 14.1
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Table 14.1
Waterproof Membrane Property Requirements
Property
Standard
ASTM D638
Tear resistance
ASTM D1004
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Elongation Film
Value
Longituduial 210 %
Transverse 160 %
Longitudinal 340 MPa
Transverse 310 MPa
Adhesion to primed concrete
ASTM D1000
1.8 MPa
Elongation compound
ASTM D1000
1.8 MPa
Puncture resistance
ASTM E154
220 N over 65 mm
Water resistance
ASTM D570
After 24 h. 0.14 %
After 35 d 0.95 %
Environmental resistance
Moisture vapour transmission rate
ASTM D543
ASTM E96
Minimum thickness
0.3g/M 24 h
1.0 mm.
14.3.4
Application
Waterproofing membranes placed on vertical concrete faces shall be protected by preformed

asphalt board.
QCS 2014

Part
Page 8
Boards shall be bonded onto position with high quality solvent borne contact adhesive based
on polychloroprene rubber.
The Contractor shall co-ordinate the installation of waterproofing membrane with floor drains,
equipment bases and other adjacent work and mask adjacent work to prevent soil marks.
Areas where waterproofing is applied shall be protected from all traffic and where necessary
backfilling. All damage to finished portions of the waterproofing membrane shall be either
repaired or replaced, or both, in a manner acceptable to the Engineer.
14.4
PENETRATIVE PRIMER
14.4.1
General
The system shall be a penetrating hydrophobic treatment that protects concrete from both
water and chloride intrusion, while permitting water vapour transmission.
The treatment shall significantly reduce the absorption of water and water borne salts but
allow the transmission of water vapour from the substrate.
The treatment shall not produce any discoloration of the substrate and shall have excellent
resistance to weathering.
14.4.2
Material
The material shall be a low viscosity silane-siloxane system which penetrates deeply into a
porous substrate and reacts to produce a bonded hydrophobic lining to the pores.
The material shall be resistant to petrol, oil, and atmospheric contaminants such as car
exhaust fumes and industrial exhausts.
14.4.3
Surface Preparation
The surface shall be dry, free from oil and grease, loose particles, decayed matter, algae
growth and curing compounds.
If the concrete surface is newly cast and has a very smooth finish, the surface shall be
roughened by sand or grit blasting, water blasting or some mechanical means. The Engineer
shall decide if this means of preparation is required.
Moss or algae growth on the surface shall be removed using a proprietary fungicidal wash in
accordance with the manufacturers recommendations.
Concrete finishing required shall be completed before the application of the treatment.
Cracks of width greater than 0.2 mm shall be filled in accordance with the manufacturers
recommendations.
14.4.4
Application
Unless directed otherwise by the Engineer the treatment shall be applied a minimum period
of 24 h after the wet curing period, and shall be surface dry.
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The Contractor shall carry out tests to verify the depth of penetration of the material. These
tests shall be carried out on specimens of the actual mix design and shall use coloured dyes
to trace the penetration of the material.
Where fine cracking has occurred in the concrete (at a width not greater than 0.3 mm for
reinforced concrete and 0.2 mm for water retaining structures) an additional four 'stripe coats'
of the treatment shall be applied before the main treatment.
The application of the material on surfaces shall be by a low pressure spray direct from the
can. Under no circumstances should thinning of the material be carried out.
The rate of application shall ensure that the surface is completely saturated. The
impregnated coating shall be applied to two or more flood coats each flood coat shall be a
2
minimum of 0.4 l/m .
The material shall be applied strictly in accordance with the manufacturers instructions and
as follows:
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the material shall be applied by a fine nozzle spray
(b)
application will not be permitted when the ambient air temperature is above 35 C or
in windy conditions
(c)
the surface shall be cleaned by a stiff brush or compressed air to remove all loose
deposits
(d)
concrete to be treated shall be surface dry for a minimum period of 24 h before

impregnation
(e)
membranes, joint sealers and cast in concrete ancillaries shall be masked off before
treatment
(f)
application shall be made by saturation flooding
(g)
the interval between application shall be at least 6 h
(h)
treated areas shall be protected from sea water and rain for 6 h after treatment.
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(a)
PROTECTIVE COATING
14.5.1
General
The coating system shall be used for the protection of new or existing reinforced concrete
structures against carbonation or chloride induced corrosion.
The system shall comprise of a penetrating, reactive primer and an acrylic polymer top coat
system to minimise ingress of acidic gases, chlorides and water.
14.5.2
Surface Preparation
Before application, all surfaces must be dry and free from oil, grease, loose particles,
decayed matter, moss or algae growth and general curing compounds.
All such contamination and laitence must be removed by the use of grit blasting, high
pressure water jetting or equivalent mechanical means.
14.5
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Before proceeding to apply the protective coatings, all surfaces which are not to be coated
but which may be affected by the application of the coating shall be fully masked and, in
particular, flora and fauna shall be protected.
Blow holes and areas of pitting shall be made good with a one part modified cementitious
material and allowed to cure in accordance with the manufacturer's recommendations. In
particular, the application shall be in accordance with the manufacturer's recommendations,
with respect to the maximum application thickness.
14.5.3
Material
The materials are required to provide in-depth protection against carbonation and chloride
penetration whilst permitting water vapour transmission from the concrete.
The primer shall be a low viscosity silane-siloxane system which penetrates deeply into a
The material employed for the coating shall comply with the following requirements:
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400 m
200 m
R Value at 325 microns > 161 metres.
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Wet film thickness

Dry film thickness
Carbon Dioxide diffusion resistance
(Taywood Engineering Laboratories)
Water vapour transmission
Reduction in chloride ion penetration
(BS 1881 : Part 124)
Tear Resistance (ASTM D624)
Crack bridging (BRE Method)
Chloride Ion Diffusion
(Taywood Engineering Labororatories)
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Shall be more than 13 g/m .d

94 % minimum at 28 d
7.3 kN/mm
5.1 mm
-10
3.63 x 10
cm /sec.
Where test methods are not specified, the procedure for establishing compliance with the
above criteria shall be agreed with the Engineer.
The Contractor is required to adhere strictly to the manufacturer's recommendations

regarding the use, storage, application and safety rules in respect of the approved materials.
14.5.4
Application
treated using the selected materials. These trial areas shall be noted on the Drawings and
shall be carried out using the type of materials, mixing procedures and applications that will
be used on the contract and shall be approved by the Engineer before the Contractor
commences with the general work.
shall be conditioned by the application of a penetrating hydrophobic treatment. The primer
shall be allowed to dry in accordance with the manufacturer's requirements.
The Contractor shall then apply two coats of pigmented topcoat in accordance with the
manufacturer's instructions. The finished coating shall be pinhole free and have a total
minimum dry film thickness of 150 m. The colour and finish is to be as agreed with the
Engineer.
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Engineer.
In all operations of storage, mixing and application the Contractor shall comply with the health
and safety recommendations of the manufacturer and governing authorities.
14.6
PLASTIC SHEET LINER FOR CONCRETE STRUCTURES
14.6.1
General
This Subpart covers the supply and installation of sheet liners in reinforced concrete
structures.
The liner must be continuous and free of pinholes both across the joints and in the liner itself.
All work for and in connection with the installation of the lining in concrete pipe and structure,
and the field sealing and welding of joints, will be done in strict conformity with all applicable
specifications, instructions, and recommendations of the lining manufacturer.
14.6.2
The Contractor shall submit to the Engineer for approval the following:
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liner schedule
(b)
material certifications
(c)
test results
(d)
material samples
(e)
the manufacturer of the lining will submit an affidavit attesting to the successful use
of its material as a lining for sewer pipes and structures for a minimum period of
five years in service conditions recognised as corrosive or otherwise detrimental to
concrete.
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(a)
The sheet liner shall be manufactured from, high molecular weight PVC or PE resin and
other components necessary to make a material of permanent flexibility suitable for a liner in
concrete pipes and structures in sewerage service. The weld strips and the joint strips shall
be made from like material. For PVC and PE sheet liners, the actual resin used in
manufacture must constitute not less than 99 % of the resin used in the formulation.
Copolymer resins will not be permitted.
All plastic sheets including locking extensions, all joints and welding strips shall be free of
cracks, asperities and other defects that may affect the protective properties of the material.
The properties of PVC and PE sheet are shown in Table 14.2
14.6.3
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Table 14.2
Properties of PVC and PE Sheet Liners
Property
Test Method
PVC
Elongation at break
Tensile Strength
Low Temp. Brittleness
PE
Elongation at break
Tensile Strength
Requirement
ASTM D638/882
ASTM D638/412
ASTM D746
300 %
15 MPa
0C
ASTM D638/882
ASTM D638/412
ASTM D746
Exceeds 600 %
10-20 MPa
-75 C
Except at shop welds, all plastic sheet liners and strips shall have the properties shown in
Table 14.3 when tested at 25 C.
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14.6.4
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Table 14.3
Properties of Plastic Sheet Liner Strips
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Property
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Shore Durometer
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Weight change
15 MPa
200 %
1 s 50 - 60 5 (with respect to 10 s
35 - 50 5)
1.5 %
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Tensile strength
Elongation at break
Requirement
The minimum thickness of the material shall be as shown in Table 14.4
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14.6.5
Table 14.4
Plastic Sheet Liner Minimum Dimensions
Material Thickness
Sheet with locking extensions

Sheet, plain
Joint strip
Weld strip
Structures
4.0 mm
2.3 mm
1.9 mm
2.4 mm
14.6.6
Liner Details
Locking extensions (T-shaped) shall be of the same materials as that of the liner and shall be
integrally extruded with the sheet.
Locking extensions shall be approximately 65 mm apart and shall be at least 10 mm high.
Sheets not used for shop fabrication into larger sheets shall be shop tested for pinholes using
an electrical spark tester set at 9000 V per 1.0 mm thickness of lining minimum. Holes shall
be repaired and retested.
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14.6.7
Installation
Installation of the lining, including preheating of sheets in cold weather and the welding of all
joints, shall be performed in accordance with the recommendations of the manufacturer.
The lining to be held snugly in place against inner forms by means of steel banding straps or
other means recommended by the manufacturer.
Concrete that is to be poured against the lining shall be vibrated, spaded, or compacted in a
careful manner to protect the lining and produce a dense, homogenous concrete, securely
anchoring the locking extensions into the concrete.
In removing forms care shall be taken to protect the lining from damage. In particular:
(b)
when forms are removed, any nails that remain in the lining to be pulled, without
tearing the lining, and the resulting holes clearly marked.
(c)
form tie holes to be marked before ties are broken off and all areas of serious
abrasion or damage shall be marked.
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sharp instruments not to be used to pry forms from lined surfaces.
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All nail and tie holes and all cut, torn, and seriously abraded areas in the lining shall be
patched as follows:
patches made entirely with welding strip to be fused to the liner over the entire patch
area
(b)
larger patches may consist of smooth liner sheet applied over the damaged area with
adhesive
(c)
all edges must be covered with welding strip fused to the patch and the sound lining
adjoining the damaged area.
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(a)
Hot joint compounds, such as coal tar, shall not be poured or applied to the lining.
The Contractor shall take all necessary measures to prevent damage to the installed lining
from equipment and materials used in or taken through the work.
14.6.8
Samples taken from sheets, joints or weld strips shall be tested to determine material
properties. Determination of tensile strength and elongation shall be in accordance with
ASTM D 412 using Die B. Determination of indentation hardness shall be in accordance with
ASTM D 2240 using a Type D Durometer, except that a single thickness of material and
indentation hardness shall be made on 25 mm by 75 mm specimens. Thickness of
specimens shall be the thickness of the sheet or strip.
The measurement of initial physical properties for tensile strength, weight, elongation and
indentation hardness shall be determined before chemical resistance tests.
Chemical resistance tests shall be carried out to determine the physical properties of the
specimens after exposure to chemical solutions. Test specimens shall be conditioned to
constant weight at 43 C before and after submersion in the solutions detailed in Table 14.5
for a period of 112 d at 25 3 C.
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Volumetric percentages of concentrated reagents of CP grade: At 28 day intervals,

specimens shall be removed from each chemical solution and tested. If any specimen fails to
meet the 112 day exposure, the material will be subject to rejection.
Pull test for locking extensions: Liner locking extensions embedded in concrete shall
withstand a test pull of at least 18 kN/m, applied perpendicularly to the concrete surface for a
period of 1 min, without rupture of the locking extensions or withdrawal from embedment.
This test shall be made at a temperature between 21 C to 27 C inclusive.
Shop-welded joints: Shop-welded joints, used to fuse individual sections of liner together,
shall be a least equal to the minimum requirements of the liner for thickness, corrosion
resistance and impermeability. Welds shall show no cracks or separations and shall be
tested for tensile strength. Tensile strength measured across the welded joint in accordance
with ASTM D 412 using Die B shall be at least 15 MPa. Test temperature shall be 25 3 C
and the measured minimum width and thickness of the reduced section shall be used.
Spark test: All liner shall be shop tested for holes with a spark tester set to provide from
15 000 to 20 000 V. Sheets having holes shall be satisfactorily repaired in the shop before
shipment from the manufacturers plant.
The Contractor shall provide the Engineer with certified copies of test reports before the
shipment of the product to the Site.
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Table 14.5
Chemical Resistance Tests
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Chemical Solutions
Sodium Hydroxide
Nitric Acid
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Soap
5%
1%
1%
Ferric Chloride
5%
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Ammonium Hydroxide
20 %
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Sulphuric Acid
Concentration
0.1 %
Detergent (Linear alkyl benzyl sulphonate or LAS)
0.1 %
BOD not less than 700 mg/l
Bacteriological
Phosphoric Acid
14.6.9
Liner sheets to be closely fitted and properly secured to the inner forms.
50 %
(a)
sheets that are to be cut to fit curved and warped surfaces shall use a minimum
number of separate pieces
(b)
a 50 mm wide water resistant tape or welding strip shall be welded on the back of butt
joints to prevent wet concrete from flowing around the edges.
Unless otherwise shown on the Drawings, the lining will be returned at least 75 mm at the
surfaces of contact between the concrete structure and items not of concrete and
(a)
the same procedure will be followed at joints where the type of protective lining is
changed or the new work is built to join existing unlined concrete
QCS 2014

Part
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(b)
at each return, the returned liner will be sealed to the item in contact with the plastic
lined concrete with an adhesive system
(c)
if the liner cannot be sealed with this adhesive because of the joint at the return being
too wide or rough or because of safety regulations, the joint space shall be densely
caulked with lead wool or other approved caulking material to a depth of 50 mm and
finish with a minimum of 25 mm of an approved corrosion resistant material.
14.6.10 Joints in Lining for In-Situ Concrete Structures

Field joints and Lining at joints shall be free of all mortar and other foreign material and shall
be clean and dry before joints are made.
All welding is to be in strict conformance with the specifications of the lining manufacturer.
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all welds shall be physically tested by a non-destructive probing method
(b)
all patches over holes, or repairs to the liner wherever damage has occurred.
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Each transverse welding strip which extends to a lower edge of the liner will be tested by an
approved testing agency at the cost of the Contractor.
the welding strips will extend 50 mm below the liner to provide a tab.
(b)
a 5 kg pull will be applied to each tab. The force will be applied normal to the face of
the structure by means of a spring balance
(c)
liner adjoining the welding strip will be held against the concrete during application of
the force
(d)
the 5 kg pull will be maintained if a weld failure develops until no further separation
occurs.
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(a)
(e)
(f)
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All surfaces covered with lining, including welds, will be tested with an approved electrical
holiday detector with the instrument set at 9000 V per 1.0 mm of lining minimum:
defective welds will be retested after repairs have been made

tabs shall be trimmed away neatly by the installer of the liner after the welding strip has
passed inspection.
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14.6.11 Testing and repairing damaged surfaces
(g)
inspection will be made within two days after joints has been completed in order to
prevent tearing the projecting weld strip and consequent damage to the liner from
equipment and materials used in or taken through the work.
END OF PART
QCS 2014

Part
15: Hot Weather Concreting
Page 1
HOT WEATHER CONCRETING ............................................................................. 2
15.1
15.1.1
15.1.2
15.1.3
15.1.4
15.1.5
GENERAL ............................................................................................................... 2
Scope
2
References
2
Definition of Hot Weather
2
System Description
3
Submittals
3
15.2
PLACING TEMPERATURE ..................................................................................... 3
15.3
PLANNING CONCRETING ..................................................................................... 4
15.4
MIX DESIGN ........................................................................................................... 4
15.5
15.5.1
15.5.2
15.5.3
15.5.4
15.5.5
15.5.6
TEMPERATURE CONTROL ................................................................................... 4

General
4
Aggregates
4
Water
5
Cement
5
Addition of Ice
5
Liquid Nitrogen
6
15.6
BATCHING AND MIXING ........................................................................................ 6
15.7
TRANSPORTATION ............................................................................................... 6
15.8
PLACING AND FINISHING ..................................................................................... 6
15.9
CURING AND PROTECTION.................................................................................. 7
15.10
INSPECTION AND TESTING .................................................................................. 7
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HOT WEATHER CONCRETING
15.1
GENERAL
15.1.1
Scope
This Part covers the precautions to be taken for hot weather concreting for all structural
concrete except blinding concrete, where a minimum compressive strength is specified.
15.1.2
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This Section
Part 6, .............. Property Requirements
Part 7, .............. Concrete Plants
Part 8 .............. Transportation and Placing of Concrete
Part 10 ............. Curing
15
References
ta
ACI 305R-91...............American Concrete Institute , Hot Weather Concreting
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ASTM C1064 ..............Measuring the Temperature of Concrete
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BS EN 1992-1-1 .........Eurocode 2, Design of concrete structures. General rules and rules for
buildings
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BS EN 480..................Admixtures for concrete, mortar and grout. Test methods
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BS EN 934..................Admixtures for concrete, mortar and grout

The requirements of the following clauses of the specification are applicable during the hot
weather period in Qatar.
The hot weather period shall be defined as starting when the maximum ambient air shade
temperature on the Site exceeds 35 C for three consecutive days. The end of the hot
weather period shall be defined as the period when the maximum air shade temperature is
below 35 C on three consecutive days.
The Contractor shall establish a thermometer on Site that records the ambient air shade
temperature. The thermometer shall be established at a position to provide representative air
temperature for the Site conditions. If requested by the Engineer the Contractor shall arrange
for the calibration of the Site thermometer.
Hot Weather shall mean any combination of the following conditions that tends to impair the
quality of freshly mixed or hardened concrete by accelerating the rate of moisture loss and
rate of cement hydration, or otherwise causing detrimental results such as:
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15.1.3
(a)
High ambient temperature (when the shade temperature is above 40 deg C on a rising
thermometer, 43 deg C on a falling thermometer),
(b)
High concrete temperature,
(c)
Low relative humidity,
(d)
High wind speed
QCS 2014

Part
(e)
the rate of evaporation exceeds 0.75 kg/m /h
Page 3
15.1.4
System Description
The Contractor shall undertake hot weather concreting procedures that are effective in
controlling the following potential problems associated with concreting in hot weather:
increased water demand of the mix
(b)
increased rate of slump loss
(c)
increased rate of setting
(d)
increased tendency for plastic shrinkage cracking
(e)
decreased long-term strength
(f)
increase tendency for drying shrinkage and cracking
(g)
increased tendency for differential thermal effects with consequent cracking
(h)
decreased durability from cracking where there is increased permeability.
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(a)
Submittals
The Contractor shall prepare weekly in advance his proposed concreting programme
showing the quantities to be placed and the anticipated placing hours.
At least one month before the start of the hot weather period the Contractor shall submit his
specific proposals for the control of the concrete temperature for the constituent materials;
cement, water aggregates.
Where required the Contractor shall submit to the Engineer his proposals for the use of liquid
nitrogen for cooling which shall include details of previous project application and the
intended methods to be used and quantities of liquid nitrogen.
15.2
PLACING TEMPERATURE
This Subpart of the specification applies at all times of the year and at all times of the day.
Maximum fresh concrete temperature (at placement) shall not exceed 32C unless
construction testing to verify a proposed concrete mixture will function satisfactorily at a
concrete temperature greater than 32C. No concrete shall be placed if the concrete
temperature is above 35C
Concrete shall not be placed if the shade temperature exceeds 40C.
The temperature of each truck of concrete shall be measured using either a glass, dial type
or electronic thermometer, just before the placing of the concrete and the temperature
recorded on the delivery ticket. The maximum temperature at placing shall apply to the entire
load of concrete in the truck or conveyer.
The Contractor shall allow for the increase in concrete temperature in the period from
dispatch from the plant while in transportation or whilst awaiting placement on Site and take
adequate measures to ensure the maximum temperature is not exceeded.
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15.1.5
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PLANNING CONCRETING
During the hot weather period as defined in Clause 15.1.3 of this Part, the Contractor shall
plan concreting operations such that no concreting takes place between the hours of
10:00 hours and 17:00 hours.
The Contractor shall arrange concrete pours such that the programme of works can be
achieved without concreting during the period from 10:00 hours to 17:00 hours.
The Contractor shall nominate one member of his staff to be the co-ordinator for the supply
of concrete. The co-ordinators responsibilities shall include ensuring the batched rate
matches that of delivery and placement and the preparations needed before commencing a
concrete pour.
15.4
MIX DESIGN
In the hot weather period, the Contractor shall review all concrete mix designs to ensure that
the design slump or workability specified is achieved without increase in the mix water
content. The Contractor shall make modifications to the mix design to allow for increased
slump loss during transportation in hot weather.
This shall be achieved by adjusting the proportion of admixture, plasticiser or super

plasticiser. The permitted range of admixture shall be clearly stated on the concrete mix
design with nominal values for cold weather and hot weather use.
Under no circumstances will the addition of extra water that increases the water cement ratio
be permitted during hotter weather.
All concrete materials and proportions used in periods of hot weather shall be those that have
a satisfactory record of use in such conditions.
15.5
TEMPERATURE CONTROL
15.5.1
General
The Contractors specific proposals for the control of the concrete temperature shall include
extent and type of shading of aggregates, method of chilling mix water and procedures for
batching and mixing, transportation, placing and finishing, curing and protection.
These shall include calculations in accordance with ACI 305R, clause 3.1 estimating
concrete temperature. The Contractor shall calculate the temperature of freshly produced
concrete based on the input temperatures of the constituent materials and the weights from
particular mix designs. The calculations shall make allowance for the rise in temperature
between mixing and placing due to the transportation and waiting period. The calculations
shall successfully demonstrate that the temperature can be maintained below 32 C at the
point of placing.
15.5.2
Aggregates
All practical means shall be employed to keep the aggregates as cool as possible.
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15.3
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Stockpiles of aggregates shall be shaded from direct sunlight. Shades shall extend beyond
the edge of aggregate storage areas and stockpile layouts shall be such that direct sunlight is
not incident on the aggregates. Shades shall be constructed to allow access for mechanical
shovels or means of conveyance. Shades and stockpiles shall be constructed so as to permit
the free flow of air over the aggregates. Embedded cooling pipes may also be used to cool
the aggregate.
Sprinkling of coarse aggregates to reduce temperature by evaporation or direct cooling shall

not be permitted.
15.5.3
Water
Mix Water shall be cooled by storing in underground tanks or insulated tanks above ground.
The water shall be chilled by the use of proprietary chillers or the addition of ice to the water
tank. Measures shall be taken to ensure that ice pieces are not inadvertently deposited
directly into the mixer.
Water shall not be chilled below a temperature of 5 C.
Tanks, pipes or trucks used for the storage or transportation of water shall be insulated and
painted white.
The mechanical refrigeration equipment and insulated water storage shall be adequate for
the anticipated hourly and daily production rates of concrete during the hot weather period.
Mixing water may also be chilled by injection of liquid nitrogen into an insulated holding tank,
such procedures shall be to the approval of the Engineer.
Ice shall be completely melted in mixing water prior to adding water to the mixer.
15.5.4
Cement
The use of freshly ground cement at very high temperatures is not permitted.
The cement shall be kept below the temperature which there is a tendency of false set.
Under no conditions shall the temperature of the cement exceed 75 C when it enters the
mixture.
The Contractor shall make arrangements for storage on Site to allow cooling of freshly
ground and delivered cement.
15.5.5
Addition of Ice
Crushed shaved or chipped ice can be used as part of the mixing water for reducing the
concrete temperature.
The maximum nominal size of ice particles shall be 10 mm and all the ice must be melted
before the completion of mixing of the concrete in the pan.
To ensure proper concrete mixing the maximum proportion by substitution shall be 75 % of

the batch water requirement.
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Crushed ice shall be stored at a temperature that will prevent lumps from forming by
refreezing of particles.
The batching plant shall incorporate a mechanical system for correctly proportioning and
weighing the ice to be added to the mixture.
The quantity of ice shall be deducted from the total batch water.
The Contractor shall ensure there are adequate quantities of ice in suitable refrigerated
storage on the Site at the plant to meet the anticipated daily and hourly production rates of
concrete during the hot weather period.
15.5.6
Liquid Nitrogen
Freshly mixed concrete maybe cooled by the injection of liquid nitrogen.
Care shall be taken to ensure that the concrete directly adjacent the injection nozzle is not
frozen.
The use of liquid nitrogen for cooling concrete shall include a nitrogen supply vessel and
injection facility for the batching plant or one or more injection stations for truck mixers.
The system may be set up at the Site for injection just before placing.
Proper safety precautions as advised by the supplier of the liquid nitrogen shall be used.
15.6
BATCHING AND MIXING
The drums of concrete mixer trucks shall be painted white to minimise solar heat gain.
Where a truck mixer has been left standing in the sun, the empty drum shall be sprayed with
water and the drum flushed out with cold water before batching. Care shall be taken to
ensure all water is removed from the drum before batching.
The temperature of the concrete shall be checked after discharge from the mixer and written
on the delivery ticket. Temperature check shall be carried out at the plant on the concrete
3
floor for every 50 m produced or every hour which ever is the minimum.
A water-reducing, set-retarding chemical admixture conforming to the requirements of BS EN

480 Parts 1, 2 and 4 may be used in varying proportions under different air temperature
conditions.
15.7
TRANSPORTATION
The transportation, placing, compaction and finishing of concrete shall be at the fastest
possible rate. Delivery of concrete to the Site shall be properly scheduled to match the rate of
placement and compaction.
15.8
PLACING AND FINISHING
If the temperature of the first truck of concrete of a particular pour is above the specification
maximum temperature limit then placing shall not commence.
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If a pour is in progress and the temperature of a particular truck exceeds the maximum
permitted temperature the placing may be allowed to continue at the discretion of the
Engineer in order to avoid the possible development of a cold joint.
However, no further concreting pours shall take place until the Contractor has submitted
revised calculations, in accordance with ACI 305R clause 3.1 to demonstrate that the
maximum temperature will not be exceeded in the future. Before beginning new pours the
temperature of the concrete constituent materials shall be monitored to verify that they meet
the assumptions of the calculations.
15.9
CURING AND PROTECTION
Curing and protection shall conform to the requirements of Part 10 of this Section.
Evaporation shall be minimised, particularly during the first few hours subsequent to placing
concrete, by suitable means such as applying moisture by fog spraying or any other means
acceptable to the Engineer.
15.10
INSPECTION AND TESTING
All thermometers used for the measurement of concrete temperature shall be calibrated
weekly against a glass mercury thermometer. Calibration shall be carried out over the
temperature range of 10 C to 100 C using a water bath with ice or heating.
The method used to determine acceptance of temperature controlled concrete should be in

accordance with ASTM C1064.
All concrete test specimens for strength or other purposes shall be carefully protected and
cured.
Specimens shall be protected from accidental damage by plant personnel or equipment on

Site.
Specimens shall be kept moist by the addition of water or covering by suitable curing
materials.
The exact time of preparation of the specimen on Site shall be noted and the time when it is
transferred to the laboratory. These times shall be written on the test report.
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END OF PART
QCS 2014

Part
16: Miscellaneous
Page 1
MISCELLANEOUS .................................................................................................. 2
16.1
16.1.1
16.1.2
GENERAL ............................................................................................................... 2
Scope
2
References
2
16.2
16.2.1
16.2.2
16.2.3
16.2.4
16.2.5
16.2.6
16.2.7
16.2.8
PAVEMENT QUALITY CONCRETE ........................................................................ 3

Scope
3
Mix Designs
3
Cement
4
Water
4
Aggregates
5
Admixtures
5
Air content
5
Density
5
16.3
16.3.1
16.3.2
16.3.3
CEMENTITIOUS GROUT ........................................................................................ 6

General
6
Material
6
Workmanship
6
16.4
16.4.1
16.4.2
SCREEDS ............................................................................................................... 7
Scope
7
General
7
16.5
CELLULAR CONCRETE ......................................................................................... 9
16.6
16.6.1
16.6.2
16.6.3
REPAIR OF CONCRETE ........................................................................................ 9

General
9
Honeycombing or Spalling
9
Crack injection
11
16.7
POLYESTER RESIN CONCRETE (PRC) - PIPING SYSTEMS FOR NONPRESSURE DRAINAGE AND SEWERAGE ......................................................... 13
General
13
Resin
13
Minimum strength
14
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16.7.1
16.7.2
16.7.3
16
QCS 2014

Part
16: Miscellaneous
Page 2
16
MISCELLANEOUS
16.1
GENERAL
16.1.1
Scope
This Part deals with miscellaneous items related to concrete works including pavement
quality concrete, no fines concrete, lightweight concrete, cementitious grout, screeds, repair
of concrete and guniting.
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Part 2, .............. Aggregate

Part 3, .............. Cementitious Material
Part 4, .............. Water
Part 5, .............. Admixture
Part 8, .............. Transportation and Placing of Concrete
Part 9, .............. Formwork
Part 10, ............ Curing
Part 15, ............ Hot Weather Concreting.
This Section
References
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16.1.2
ACI 506, .....................Guide to Shotcrete
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ASTM C989 10, ........Standard Specification for Slag Cement for Use in Concrete and
Mortars
BS 146,.......................Portland-blast furnace cement
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BS 812,.......................Testing aggregates
BS 1881,.....................Testing concrete

BS 3892,.....................Pulverised fuel ash
BS 4551,.....................Methods of testing mortars, screeds and plasters
BS 5075,.....................Concrete admixtures
BS 6319,.....................Testing of resin and polymer / cement compositions for use in
construction
BS 6610,.....................Specification for pozzolanic pulverised-fuel ash cement.
BS 8203,.....................Code of practice for installation of resilient floor coverings.
BS 8500,.....................Concrete
BS EN 197-1, .............Cement. Composition, specifications and conformity criteria for
common cements
BS EN 480,.................Admixtures for concrete, mortar and grout. Test methods (parts: 1, 2,
4, 5, 6, 8, 10, 11, and 12)
BS EN 934,.................Admixtures for concrete, mortar and grout (parts: 2, 6)
BS EN 998,.................Specification for mortar for masonry
QCS 2014

Part
16: Miscellaneous
Page 3
BS EN 1744-1, ...........Tests for chemical properties of aggregates. Chemical analysis

BS EN 12350,.............Testing fresh concrete
BS EN 12390-5, .........Flexural strength of test specimens
BS EN 12620,............. Aggregates for concrete
EN 197-4:2004 ...........Cement. Composition, specifications and conformity criteria for low
early strength blastfurnace cements
EN 197-4, ...................Cement. Composition, specifications and conformity criteria for low
EN 12350, ..................Testing fresh concrete
EN 1744-1, .................Tests for chemical properties of aggregates. Chemical analysis
GSO EN 206-1, ..........Concrete Specification, performance, production and conformity
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SHW 1000 ..................Specification for Highway Works UK ROAD PAVEMENTS

CONCRETE MATERIALS
PAVEMENT QUALITY CONCRETE
16.2.1
Scope
This Subpart covers the mix design for concrete used for aircraft aprons and roadworks as
surface slabs, continuously reinforced concrete roadbase, and wet lean mix except cement
bound granular material used as a roadbase or sub-base or as a backfill material for
excavations.
16.2.2
Mix Designs
Concrete in rigid or composite pavements shall be one of the grades given in Table 16.1
below, in accordance, with the pavement design shown on the Drawings or as directed by the
Engineer.
All concrete for use in pavements shall be designed mixes or equivalent standard mixes in
accordance with the relevant clauses of BS 8500 and GSO EN 206-1, except where
otherwise specified.
Prescribed mixes may be used for rapid construction with the approval of the Engineer.
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16.2
Table 16.1
Pavement Grades
Pavement Layer
BS 8500 and
GSO EN 2061Designed
Mix
Surface Slabs
Unreinforced Concrete
C40
Jointed Reinforced Concrete ( JRC )
C40
Continuously Reinforced Concrete Pavement ( CRCP )
C40
Continuously Reinforced Concrete Roadbase ( CRCR )
C40
Ground Anchorage Beam
C40
BS 8500 and
GSO EN 206-1
Standard Mix
QCS 2014

Part
16: Miscellaneous
Page 4
BS 8500 and
GSO EN 2061Designed
Mix
BS 8500 and
GSO EN 206-1
Standard Mix
Wet Lean Mix Concrete 4
C20
ST4
C15
ST3
C10
ST2
C7.5
ST1
Pavement Layer
Cement
The general term 'cement' in this Part means the materials shown below.
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16.2.3
Complying with
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Cement
EN 197-1
Specification for pozzolanic pulverised-fuel ash cement (grades

C20 or below)
BS 6610
BS 146 or EN 197-4
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Cement. Composition, specifications and conformity criteria for

common cements
Portland blast furnace cement
The use of a combination of Portland cement and ground granulated blast furnace slag is
permitted subject to the approval of the Engineer. In such cases, the Engineer will stipulate
the minimum combined cementitious material content required for the mix.
The use of a combination of Portland cement and pulverised fuel ash (PFA) is permitted
subject to the approval of the Engineer. In such cases, the Engineer will stipulate the
minimum combined cementitious material content required for the mix. PFA shall be in
The use of microsilica in the mix designs will be permitted if approved by the Engineer.
The Engineer will stipulate the minimum combined cementitious material content required for
the mix where PFA or GGBFS are used.
The maximum proportion of ground granulated blastfurnace slag with Portland cement shall
be as per Table 6.6 of Part 5.6.
In combination with Portland cement, the proportion of PFA by mass to the total cement shall
The limit of chloride content of the concrete shall be as stated in Table 6.5 of Part 5.6.
The minimum cement content for concrete pavements shall be preapproved by Qatar
Standards.
16.2.4
Water
Water for use in the making and curing of concrete shall conform to the requirements of Part
4 of this Section.
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Part
16: Miscellaneous
Page 5
The water content shall be the minimum required to provide the agreed workability for full
compaction of the concrete to the required density, as determined by trial mixes or other
means approved by the Engineer..
16.2.5
Aggregates
The requirements of Part 2 of this specification will govern, except as modified below.
Aggregates for all pavement concrete shall be complying with BS EN 12620
Alternatively coarse aggregate of recycled and secondary aggregate materials may be used
to replace up to 50% by mass of coarse aggregate
The nominal size of coarse aggregate shall not exceed 40 mm. When the spacing between
longitudinal reinforcement is less than 90 mm, the nominal size of coarse aggregate shall not
exceed 20 mm.
If requested by the Engineer, the Contractor shall carry out tests on the proposed aggregate
combination to check for the possibility of alkali silica reaction. Such tests shall be carried out
in accordance with the procedure laid down in Part 2 of this Section.
16.2.6
Admixtures
Plasticisers or water reducing admixtures shall comply with BS 5075, BS EN 480 and BS EN
934. Admixtures containing calcium chloride shall not be used.
Other chloride-free admixtures may be used with the approval of the Engineer.
16.2.7
Air content
The total quantity of air in air-entrained concrete as a percentage of the volume of the mix
shall be 5 1.5 % for mixes of nominal aggregate size 20 and be 4 1.5 % for mixes of
nominal aggregate size 40.
The air content shall be determined at the point of delivery by a pressure type air meter in
accordance with BS EN 12350-7, at the rate of one determination per 300 m2 of slab or at
least six times per day whichever is the greater, in conjunction with tests for workability and
strength. For areas less than 300 m2, the rate shall be at least one determination to each 20
m length of slab or less constructed at one time or at least three times per day. If the air
content is outside the specified limits, a further determination shall be made immediately on
the next available load of concrete before discharging. If the air content is still outside the
limit, the Contractor shall immediately adjust the air content of the concrete to improve its
uniformity, before further concrete is used in the Works.
The air-entraining agent shall be added at the mixer, by an apparatus capable of dispensing
the correct dose within the tolerance for admixtures given in EN 206-1, and so as to ensure
uniform distribution of the agent throughout the batch during mixing.
16.2.8
Density
The density of concrete Grades greater than C30 shall be such that without air-entrainment
the total air voids are not more than 3 %. With air entrainment, the total air voids shall be not
more than 8 %, for 20 mm aggregate or 7 % for 40 mm aggregate.
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The density of concrete Grades B15 and B20, mix ST4 or below shall be at least 95 %, of the
theoretical maximum dry density.
16.3
CEMENTITIOUS GROUT
16.3.1
General
This Subpart covers a general purpose non-shrink cementitious grout. The grout shall be
used to where it is necessary to eliminate shrinkage when filling the void between a base
plate and a substrate such as in the grouting of stanchion bases, anchorage fixings, including
masts, anchor bolts and fence posts.
The grout shall be supplied by a reputable construction chemical company as a single pack
prepackaged cement based product which is chloride free.
For a particular application, the Contractor shall submit a method statement detailing how the
formwork will be placed and the points where the grout will be poured.
Before beginning work on large repetitive works, the Contractor shall arrange for a site trial of
the materials and methods with the suppliers representative being present to train the
Contractors personnel in the correct use of the material.
16.3.2
Material
The grout shall be suitable for filling gaps of thickness up to 100 mm and shall be free flowing
and non shrink.
Positive volumetric expansion shall take place while the grout is plastic by means of gaseous
expansion to avoid shrinkage and cracking.
The compressive strength of the grout when tested in accordance with BS EN 12390-3 shall
be a minimum of 25 MPa at 24 h, 40 MPa at 7 d and 50 MPa at 28 d.
The grout shall exhibit a high early strength gain yet not be subject to cracking or other
detrimental effects.
At ambient temperatures above 35 C, cool water shall be used for mixing the grout before
placing.
16.3.3
Workmanship
The storage handling and pouring of the grout shall be in strict accordance with the
The substrate surface shall be free from oil grease or loose or partially bonded material.
If the concrete surface is defective or has laitance it shall be cut back to a sound base.
Bolt holes and fixing pockets shall be blown clean of dirt or debris.
The substrate shall be soaked with fresh potable water before grouting, although immediately
before grouting, free water shall be removed and blown out of bolt holes or pockets.
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Grout shall not be placed in a gap of less than 25 mm for base plates larger than 1 m wide.
For larger base plates or flow areas the manufacturers instructions shall be followed.
Base plates and metallic items shall be clean and free from oil, grease, or scale.
Vent holes shall be provided to allow the release of air from isolated spots.
Formwork shall be made leak proof by the use of form rubber strip or mastic sealant between
the constructive formwork and joints. Formwork shall extend above the required pour height
and if necessary shall be extended to allow a hydrostatic head to aid placement.
10
The grout shall be mixed mechanically with a slow speed drill fitted with a high-shear mixer.
11
The quantity of water to be added to the preweighed bags shall be enough to give the
desirable consistency as trowelable or flowable.
12
Mixing shall take place for a minimum of 5 min.
13
The grout shall be placed within the time limit specified by the manufacturer depending on
the actual application temperature.
14
Grout shall be poured from one side and it shall be verified that the grout has flowed under all
of the base plate with no voids. Pouring from several sides shall not be permitted.
15
Exposed areas of grout shall be thoroughly cured in accordance with Part 10 of this Section.
16.4
SCREEDS
16.4.1
Scope
This Subpart covers screeds that provide by means of a layer of mortar a level surface in
flooring applications and to provide falls on flat concrete roofs.
16.4.2
General
Screeds shall be suitable for application onto a concrete substrate.
The screeds shall be suitable for receiving surface finishes which may arrange from thin
flexible sheeting to ceramic tiling. The screed is not intended to be the final wearing surface.
Screed mortars shall generally comprise sand and cement modified by additives or
substituted by other materials such as polymers in order to provide specific performance
requirements.
For screeds of thickness greater than 40 mm it is permissible to incorporate a proportion of

10 mm aggregate.
Aggregates used for screeds shall not contain deleterious materials such as coal or iron
particles which may affect the finish the surface of the screed.
Admixtures for mortar screeds shall assist workability or alter rates of setting and hardening
and shall comply with the appropriate part of BS EN 480 and BS EN 934.
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Polymer based additives may be used to improve adhesion and strength of thin or featured
screeds, these shall be based on polyvinyl acetate (PVA) styrene bituene rubber (SPR) or
acrylic polymers.
Ready to use sand cement screeds shall comply with the material requirements BS EN 998.
Screeds with a rapid drying time to enable earlier floor finishes to be applied shall be used
10
The interface of the screed in the concrete substrate shall be specified as one of the
following options by the Engineer:
Monolithic with the concrete base: The screed shall be applied within 3 hours of
placing the concrete base.
(b)
Bonded to the concrete base: Screed shall be laid onto a concrete base which is
hardened and is subsequently been prepared to receive the screed, the minimum
thickness of the screed shall be 25 mm and the maximum thickness 40 mm.
(c)
As an unbonded screed: The screed shall be laid on a separating layer.
(d)
As a floating screed: The screed shall be laid on an insulating material.
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The cement and sand screed mix shall have the minimum amount of water added to give
sufficient workability and allow the material to be thoroughly compacted.
12
Pan type mixes shall be used to ensure efficient mixing of materials, the cement to aggregate
ratio shall be between 1 to 3 and 1 to 4.5 by weight. The mixing of the sand cement, water
and admixtures shall ensure a thorough homogeneous mixture with no balling up of the
cement.
13
Screeds shall be laid either between carefully levelled and trued batons or between strips of
screed laid and compacted to a finished level.
14
For bonded screed where a high degree of bond is required the surface laitance of the
concrete base shall be mechanically removed to expose the coarse aggregate. A thin layer
of neat cement grout shall be applied to the prewetted or dampened concrete and the screed
applied and compacted while the grout is wet.
15
Screeds shall be fully compacted by heavy hand or mechanical tamping. The screed at joints
around the perimeter shall be particularly well compacted to avoid breaking out and curling.
16
Screeds thicker than 50 mm shall be laid in two approximately equal layers; screed shall be
kept protected by waterproof sheeting for at least 7 days after laying.
17
Sheet and non ceramic tiling finishes shall only be applied after the screed has cured and
necessary strength achieved.
18
If requested by the Engineer the Contractor shall carry out a soundness and impact test in
19
Screeds shall be laid in bays of a size to minimise thermal moisture contraction. Contraction
or movement joints shall be provided as appropriate, where shown on the drawings or as
directed by the Engineer. Bays shall be laid alternatively.
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Bay sizes shall be approximately 15 m2 for 100 mm thick screed and 12 m2 for 75 mm thick
screed.
16.5
CELLULAR CONCRETE
Cellular Concrete (CC) is conventional concrete, where natural aggregate (gravel) is

exchanged for an insulation medium, namely air, embedded in an organic and biodegradable foam. It behaves, like conventional concrete, in particular concerning curing,
hardening and most important "ageing ". CC infinitely increases its strength by hydration as
long as exposed to humidity in the atmosphere.
CC offer more thermal insulation and a substantially higher fire-rating than conventional
concrete.
Minimum compressive strengths shall be 4.0 MPa.
The required density and strength of the CC shall be specified on the drawings and approved
by the Engineer.
The method of production of Cellular Concrete shall be shown on the drawings or directed by
the Engineer. The Contractor shall submit full technical details of the materials and method of
production for the CC along with a list of previous projects where the particular system has
been used.
After source approval of the material and system the Contractor shall submit a mix design for
the CLC for the approval of the Engineer. After the review and approval of the mix theoretical
mix design the Contractor shall carry out a trial mix to check the workability of the fresh
concrete and to allow samples to be made for compressive strength and density.
The Engineer may also instruct that tests are carried out for abrasion resistance and thermal
insulation properties.
Cellular Concrete shall not be used for structural reinforced members.
16.6
REPAIR OF CONCRETE
16.6.1
General
The extent and nature of the defects in concrete shall be established in accordance with Part
15 of this Section. Based on these results the Engineer shall confirm the acceptability of the
work and whether remedial works are required.
If remedial works are required the Contractor shall submit a detailed method statement
identifying the specific materials to be used and the sequence of activities for the repair.
Only proprietary proven materials that form part of a standard repair system shall be used.
16.6.2
Where there is honeycombed concrete or concrete damaged by physical forces such as

impact that has caused spalling, the concrete shall be replaced using a high strength free
flowing cementitious micro-concrete.
The areas of repair shall be marked out and agreed with the Engineer.
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All honeycombed, loose, cracked or friable concrete in these areas shall be removed until
sound concrete is reached. Due account shall be taken of propping or other instructions
given by the Engineer regarding sequences of removal and repair.
The equipment and methods used to break out the concrete shall be such that no reinforcing
steel or other embedded items such as conduits, lifting sockets, or other inserts are loosened
or damaged unless so directed by the Engineer.
Where the removal of concrete by mechanical means is difficult due to reinforcement

congestion, then the use of high pressure water jetting shall be considered and necessary
provisions for protecting the rest of the structure shall be made.
The prepared void shall be profiled so that entrapment of air is avoided during the repair
process using fluid micro-concrete.
The minimum depth of repair shall be 40 mm throughout. The perimeter of the area to be
repaired shall first be cut to a depth of 10 mm using a suitable tool. Feather edges will not be
accepted.
The prepared concrete surface shall be sound and clean and free of loose particles, dust and
debris.
Where exposed reinforcement is sound, it shall be mechanically cleaned of rust and loose
millscale.
10
Reinforcement damaged during the removal of concrete or the preparation process shall, if
required by the Engineer, be repaired or replaced.
11
Adequate formwork shall be provided in accordance with of Part 9 of this Section. This shall
be securely fixed to withstand the hydraulic pressures of the fluid micro-concrete repair
material without distortion or movement during placement.
12
The formwork shall be watertight at all joints between panels and between the formwork and
the existing concrete surface so as to prevent grout leakage.
13
The formwork shall be constructed from appropriate materials as agreed with the Engineer to
achieve the required finish.
14
Formwork surfaces that are to be in contact with the repair micro-concrete shall be treated
with a suitable mould release agent. This shall be used in accordance with the
manufacturer's recommendations.
15
The entry point of the feed pipe into the form shall be at the lowest point of the void. Sufficient
hydrostatic head or pumping pressure shall be maintained to ensure that the void is filled
completely and no air remains entrapped.
16
Where necessary, provision shall be made for controllable bleed points to prevent air
entrapment and enable the extent of flow of the repair material to be assessed.
17
The formwork shall be inspected by the Engineer and, if approved, filled with clean water
which demonstrates that the formwork is grout-tight and saturates the prepared concrete
surfaces. The formwork shall be then be completely drained and resealed
18
In situations where the completed repair will be subjected to constant immersion an epoxy
bonding agent shall be applied in accordance with the manufacturers instructions.
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19
Both the Compressive strength and Flexural strength shall be at a water:powder ratio of 0.18
and tested at 20 oC
20
The thermal conductivity and the elastic modulus of the repair material shall be compatible
with the host concrete.
21
If requested by the Engineer, recent test results of the material for the following properties
shall be submitted:
(a)
thermal conductivity
(b)
elastic modulus, BS 1881
(c)
expansion characteristics, ASTM C 827, CRD 621-82A
(d)
flow characteristic, UK DOT BD 27/86 paragraph 4.6 B.
The micro-concrete shall be mixed and placed in accordance with the manufacturer's
recommendations, particularly with regard to water content, mixing equipment and placing
time.
23
As far as possible the placing of the micro-concrete shall be continuous. The mixing
operation shall be timed so that there is minimal interruption in the material flow. If, however,
placing is interrupted, the operation shall recommence as soon as possible while the repair
material retains its flow characteristics.
24
The formwork shall not be removed until the repair micro-concrete has achieved a
compressive strength of at least 10 MPa or as directed by the Engineer.
25
Immediately after removal of the formwork the repair area shall be cured in accordance with
Part 10 of this Section.
26
The repair material shall:
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22
be shrinkage compensated in both liquid and cured states
(b)
contain no metallic expansion system
(c)
be prepacked and factory quality controlled
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be a free-flowing cementitious material that has a coefficient of thermal expansion fully

compatible with the host concrete and which complies with the requirements of Table
16.3.
(d)
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(a)
Table 16.3
Property requirements of micro concrete
Property
Test Method
Minimum Value
Compressive strength
BS EN 12390-3 @ 28 d
50 MPa
Flexural strength
BS 4551 @ 28 d
10 MPa
Anchorage bond
BS 8110
Passes
16.6.3
Crack injection
This clause of the specification covers non-active cracks within concrete elements caused by
shrinkage or other structural movement. Non-active cracks shall be injected with a lowviscosity epoxy resin to fill and seal the crack and restore the structural integrity.
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Before to starting the injection operation it shall be established by testing and investigation
work that cracks manifest within concrete elements due to either or both shrinkage or
structural movement are non-active.
The extent of the cracks to be filled will be as directed by the Engineer. The cracks to be
filled shall be marked out in detail on the concrete elements by the Contractor and agreed
with the Engineer before proceeding.
The extent of the work may be adjusted by the Engineer as the project proceeds, according
to the conditions found.
Grease, oil or other contaminants shall be removed. Algae and other biological growth shall
also be removed by scrubbing with bactericide or detergent and clean water. If necessary,
wire brushes shall be used.
Loose or spalling areas of concrete, laitance, traces of paint or other coating materials within
the marked out scope of the work shall be removed.
All cracks shall be thoroughly cleaned out using clean, oil-free compressed air. Both the
concrete surface and the cracks shall be allowed to dry thoroughly before continuing.
The injection nipples shall be fixed at intervals along the length of each crack. The distance
between each nipple will depend on the width and depth of the crack.
Spacing shall be close enough to ensure that the resin will penetrate along the crack to the
next point of injection. This will normally be between 200 mm and 100 mm.
10
Each nipple shall be firmly bonded to the concrete surface by using a sealant. The sealant
shall be supplied in two pans (liquid base and hardener system). The two components shall
be thoroughly mixed together for 3 to 4 min until a putty-like consistency is achieved.
11
The mixed sealant shall be applied to the metal base of each surface-fixed nipple. They shall
be pressed firmly into place and held for several seconds until secure. The mixed sealant
shall be applied around each embedded nipple, ensuring a complete seal is made. In this
way, all the nipples shall be fixed along the length of the crack.
12
In the case of a wall or slab which is cracked all the way through, nipples shall be located on
both sides with those at the back placed at midway points between those it the front.
13
The surface of the cracks between the nipples shall be sealed with a band of sealant 30 to
40 mm wide and 2 to 3 mm thick. Both sides if cracks which go all the way through a wall or
slab shall be sealed in this way.
14
The prepared cracks shall be allowed to cure for 12 to 24 h. At low ambient temperatures
(5 C to 12 C) the curing time will be extended and the Contractor shall ensure that the
surface sealant has adequately cured before continuing.
15
One end of the injection hose shall be attached to the lowest nipple on vertical cracks or to
either end of horizontal cracks.
16
Each crack shall be treated in a single, continuous operation. Sufficient material shall
therefore be made ready before the commencement of the work.
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The Contractor shall to ensure that sufficient cracks are prepared to provide effective use of
the mixed material.
18
The preparation, mixing and application of the materials shall be undertaken in strict
accordance with the manufacturer's recommendations. The Contractor is to ensure that all
necessary tools and equipment are on Site.
19
Both the compressive strength and flexural strength shall be tested at 7 d.
20
The material shall exhibit excellent bond to concrete and when tested for tensile adhesion the
failure shall be in the concrete and not at the interface.
21
The injection resin shall be of a prepackaged or preweighed type and only the use of full units
will be allowed. No part packs or on-Site batching will be allowed under any circumstances.
22
In all operations of storage, mixing and application, the Contractor shall comply with the
23
The injected system shall be allowed to cure for 24 h and shall be left undisturbed for this
time.
24
The nipples and bands of surface sealant shall then be removed and damaged areas made
good to the satisfaction of the Engineer.
25
The injection material shall be compatible with the host concrete and shall have the
properties shown in Table 16.4 when tested in accordance with the relevant standards.
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Property
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Table 16.4
Property Requirement for Epoxy Crack Injection Material
Method
BS 4551, BS 2782 BS 6319
Flexural strength
BS EN 12390-5
70 MPa
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Minimum Value
POLYESTER RESIN CONCRETE (PRC) - PIPING SYSTEMS FOR NONPRESSURE DRAINAGE AND SEWERAGE
16.7.1
General
Polyester resin concrete is a mixture formed from aggregates and fillers which are bound
together using a polyester resin (also called Polymer concrete pipes), as defined in ISO
18672-1 or ASTM D 6783 with the amendments given below.
Polyester resin concrete is permitted for use in infrastructure drainage and sewage systems
(pipes, manhalls, soakways).
16.7.2
Resin
The resin used in the pipe system and manufactured as per ISO 18672-1shall have a
temperature of deflection of at least 85 C, when tested in accordance with Method A of
ISO 75-2 with the test specimen in the edgewise position. It shall also conform to the
applicable requirements of EN 13121-1.
16.7
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Page 14
The resin used in the pipe system and manufactured as per ASTM D 6783 shall have a
minimum deflection temperature of 85C when tested at 1.82 MPa following Test Method
D648. The resin content shall not be less than 7 % of the weight of the sample as determined
by Test Method D2584.
16.7.3
Minimum strength
The minimum strength classes for different pipe shapes are given below.
Table 16.4
Minimum strength classes for pipes designated PRC-OC or PRC-TC

Strength class
Sc
Nominal size
N/mm
DN
PRC-TC
150 DN 500
180
180
600 DN 1000
145
1200 DN 3000
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Table 16.5
Minimum strength classes for pipes designated PRC-OE or PRC-TE
Strength class
Sc
N/mm
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Nominal width/height
WN/HN
PRC-TE
300/450 WN/HN 600/900
180
180
700/1050 WN/HN 1000/1500
145
160
120
145
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PRC-OE
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1200/1800 WN/HN 1400/2100
Table 16.6
Minimum strength classes for pipes designated PRC-OK or PRC-TK
Strength class
Sc
N/mm
Nominal size
DN
PRC-OK
PRC-TK
800 DN 1000
145
160
1200 DN 1800
120
145
END OF PART

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CONTRACTORS INSPECTION AND TEST PLAN TEMPLATE
15.2

Part
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QUALITY NON-CONFORMANCE TEMPLATE
15.3

Part
END OF PART
Page 17
QCS 2014

Part
02: Submittals
Page 1
SUBMITTALS .......................................................................................................... 2
2.1
2.1.1
2.1.2
2.1.3
2.1.4
2.1.5
2.1.6
2.1.7
GENERAL ............................................................................................................... 2
2
3
4
Quality Checklists
5
5
Method Statements
6
Commissioning Plan
6
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Page 2
SUBMITTALS
2.1
GENERAL
2.1.1
The Contractor shall prepare the necessary Contract specific Project Quality Plan as
specified in this Section, the Contract Documents and as a minimum meeting the
requirements ISO 9001 and ISO 10005 and submit them to the Engineer for review and
approval within 30 days of the award of Contract. The Contractor is not permitted to Work on
the worksite until such time as the plan has been approved by the Engineer.
The Contractor shall regularly review the suitability of the Project Quality Plan. The Contractor
shall undertake a full formal review of the quality plans annually with reference to the date of
award of the Contract and submit the findings of the review to the Engineer within 14 days of
that date along with an amended plan should any amendments be required.
The Project Quality Plan shall describe the Contractors Quality Management System that will
be used throughout the Contract and the contents shall include but not be limited to the
following:
Front Cover
(b)
Table of Contents
(c)
Project Scope, Requirements and Quality Objectives
(d)
Quality Policy and ISO 9001 Certificate (if applicable)
(e)
Control of Project Quality Plan
(f)
(g)
Project Management, Planning and Resources
(h)
Management, Organisation and Responsibilities
(i)
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Contract Review
Project Deliverables
(j)
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(a)
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(k)
Communication with the Engineer
(l)
Management of Documents, Data and Records
(m)
Design (Including Temporary Works)
(n)
Procurement of Services, Equipment and Materials
(o)
Method Statements
(p)
Inspection and Test
(q)
Product Identification and Traceability
(r)
Owner Supplied Product
(s)
Handling, Storage, Packaging and Delivery
(t)
(u)
Control of Inspection, Measuring and Test Equipment
QCS 2014

Part
02: Submittals
Audits
(w)
Training
(x)
(y)
Management Review
(z)
Quality Meetings
(aa)
Monthly Quality Report
(bb)
Commissioning
(cc)
Interface Management
(dd)
Project Completion and Handover
(ee)
Appendices
rw
And include as a minimum:
a detailed description of procedures, instructions, and reports to be used to ensure

compliance with the Project Documentation
(b)
a detailed description of procedures for reviewing shop drawings, samples, certificates

and other submittals necessary for compliance with the Project Documentation
(c)
a detailed description of procedures used to identify, report and resolve problems
(d)
a description of the services provided by outside organisations such as testing

laboratories, architects, and consulting engineers
(e)
a detailed description of inspections and tests required
(f)
copies of forms and reports to be used to document quality assurance operations
(g)
the names of personnel responsible for each part of the Works
(h)
a submittal status log listing required submittals and action required by the Contractor
and Engineer
(i)
a detailed description of document and submittal control procedures
(j)
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an inspection and test schedule keyed to the construction programme

procedures to identify and control the use of items and materials
(k)
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(a)
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(v)
Page 3
No construction shall begin and no requests for payment from the Contractor shall be
processed until the Contractors Project Quality Plan is approved.
A Contractors Project Quality Plan Template with guidance notes is included in Part 15
Appendix B of this Section. The format of the Contractors Project Quality Plan must follow
this template including all clauses contained within.
2.1.2
The Contractor shall submit a Quality Organisation Plan to the Engineer for approval no later
than thirty (30) days from the start of the Contract.
The Quality Organisation Plan shall provide the names, qualifications, experience and skills
of all the QA/QC Team including Corporate QA/QC Manager, Quality Management
Representative and key support staff.
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Part
02: Submittals
Page 4
The Quality Organisation Plan shall show the organisation of Contractors quality team and
shall include, but not be limited to, the following:
(a)
an organisation chart identifying all personnel responsible for quality
(b)
Identify the quality team showing that the team is independent of the job supervisory
staff with clear lines of authority to top tier management.
(c)
Indicate and describe the area of responsibility and authority of each individual in the
quality assurance team.
The Quality Organisation Plan should also define quality responsibilities of any of the
Contractors team with responsibilities under the Contractors Project Quality Plan.
The Contractors Quality staff shall have relevant educational and professional qualifications,
and training as defined in 3.1.7 (1). The Contractor is not permitted to execute any form of
the works at the worksite until such time as approved quality personnel have been deployed
on a fulltime basis to the worksite. The Contractor shall not remove or replace the appointed
quality personnel without prior approval from the Engineer.
The Quality Organisation Plan may form part of the Project Quality Plan or be prepared as a
standalone document and cross-referenced within the Project Quality Plan.
2.1.3
As part of the Project Quality Plan the Contractor shall submit an Inspection and Test Plan
Schedule to the Engineer for approval no later than thirty (30) days from the start of the
Contract.
The Inspection and Test Plan schedule shall define the Inspection and Test Plans to be
prepared for the Works and the target dates for their submission to the Engineer for his
approval.
The Inspection and Test Plans shall consider the requirements of each Section of the
Specification and shall identify, as a minimum, the following:
(b)
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(c)
the required inspection and testing frequency
(d)
the acceptance/rejection criteria
(e)
whom from the Contractors team is responsible and qualified to perform the inspection
or test
(f)
Quality Records to be generated
(g)
Hold, Witness, surveillance and Record Review points of the Contractors team, the
Engineer and any other agencies having jurisdictional authority over the work relating
to each inspection and test to be performed.
Details each activity, inspection and test to be performed

Reference to specifications, standards etc.
(a)
Each inspection and test shall have a unique reference number.
Inspection and Test Plans are required to address the Contractors on and off site Work and
preparation, submission and approval of related documentation.
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Part
02: Submittals
Page 5
Inspection and Test Plans are required for all operations including major temporary works
and commissioning.
No work covered by the Inspection and Test Plan shall begin until the plan has been
A Contractors Inspection and Test Plan Template with guidance notes is included in
Appendix B of this Section and must be used by the Contractor
2.1.4
Quality Checklists
The Contractor shall develop specific quality checklists for all activities to be checked as per
the Inspection and Test Plans and submit to the Engineer for the approval with the Inspection
Test Plans submission prior to the start of the activity.
The Contractor shall inspect the work and sign off the relevant checklist and Inspection
Request prior to the final inspection with the Engineer.
The checklist shall be attached with the Inspection Request and other relevant attachments
and submitted to the Engineer.
2.1.5
The Contractor shall develop and report Key Performance Indicators (KPIs). KPIs are a set
of quantifiable measures that are used to gauge performance of the Contractors
Performance.
The KPIs shall be defined in the Contractors Project Quality Plan and be subject to
Engineers approval.
The Contractor is responsible for developing his own KPIs for all elements of his contract
(Contractual, Commercial, Safety etc.) but as a minimum shall address the following KPIs.
Time between opening and closure of Nonconformance Reports (NCR) and Corrective
Action Requests (CAR).
(b)
Time between identification of a Nonconformance or Corrective Action and actual

raising on the system.
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(c)
NCR and CAR statistics per areas, sections, discipline, subcontractor etc.
(d)
Percentage of reoccurring NCRs and CARs Trends on NCRs and CARs.
(e)
Approval status of critical documentation for the progress of the works (Method
Statements, ITPs etc.).
(f)
Statistical data from inspections as per the Inspection & Test Plans (Pass vs failed,
pass first time, etc.).
(g)
Completion packages (As-Built folders) progress.
Reporting of the KPIs shall include a graphical bar chart representation on a month by month
basis from the start of the Contract.
QCS 2014

Part
02: Submittals
Page 6
Method Statements
Contractor shall ensure that Method Statements address quality issues. Refer to Section 11
Part 1 (Regulatory Document) in particular section 1.1.7 and Section 11 Part 2 (SAMAS) in
particular section 2.4
2.1.7
Commissioning Plan
The Contractor shall submit a Commissioning Plan to the Engineer for approval no later than
sixty (60) days unless agreed otherwise with the engineer before the start of the
commissioning of the Works or any part thereof.
The Commissioning Plan shall consider the requirements of each Section of the Specification
in turn and shall identify the following:
2.1.6
all required commissioning work required by that Section of the Specification
(b)
any prerequisites to commissioning
(c)
a list of the commissioning procedure
(d)
a detailed description of the duties and responsibilities on the personnel involved in the
commissioning process
(e)
a detailed list of the tests/checks/activities that will be performed, linked to the relevant
construction activities and referenced to any links/documents to the ITPs performed
during the construction
(f)
specific reference to the witness/hold and review points of the engineer
(g)
a detailed list of the standards /specifications/regulatory requirements that need to be

performed
(h)
a detailed description of the interactions/communication

organization/public service or other legal/regulatory institutions
(i)
a detailed description of the test/activities of the maintenance needed during the life
time of the project, with reference to any special requirements/qualifications of the
personnel involved in the maintenance activities
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a detailed description of any spare parts/equipment/fixtures and other type of the of

consumables that might be needed, with an estimation of quantities, for the life time of
the project
(j)
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(a)
(k)
a detailed description of the as built project file that will be created after the
commission phase
(l)
a procedure for up-date and revision of the commissioning plan
No work covered by the Commissioning Plan shall begin until the plan has been approved.
END OF PART
QCS 2014

Part
Page 1
CONTRACTORS QUALITY PERSONNEL ............................................................. 2
3.1
3.1.1
3.1.2
3.1.3
3.1.4
3.1.5
3.1.6
3.1.7
3.1.8
INTRODUCTION ..................................................................................................... 2
General
2
2
2
Quality Engineer
2
Quality Inspector
3
3
3
5
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Part
Page 2
CONTRACTORS QUALITY PERSONNEL
3.1
INTRODUCTION
3.1.1
General
Contractor shall, throughout the execution and completion of the Works and the remedying
defects therein have on his staff at the Site office(s) a dedicated Quality Team dealing only
with matters regarding the quality and protection against damage before, during and after
execution of Works as specified in this section. This team shall be qualified and experienced
in their work and shall have the authority to issue instructions and shall take protective
measures to prevent execution of Works that do not comply with the Specifications.
The Contractor shall notify the Engineer in writing prior to re-assigning or replacement of any
of the quality team designated in the Quality Organisation Plan.
The Contractor shall have adequate quality personnel on the site during all production
operations, including adequate coverage during night shift operations and off site work.
The Contractor's quality team shall have the authority to stop any portion of the work which
does not comply with the requirements of the Project Documentation.
Minimum qualifications and experience of the Contractors Quality Personnel shall be as

defined in the Contract.
3.1.2
Assurance Manager who shall be responsible for overseeing the implementation and
operation of the Project Quality Plan at all levels. The Quality Assurance Manager shall report
directly to Top Tier Management and be independent of the Contractors organisation
responsible for construction.
3.1.3
Control Manager who reports directly to the Quality Assurance Manager and shall be
responsible for supervision of the construction quality control management activities and
ensuring compliance with the Contractors Inspection and Test Plans and associated
specification and contract documentation.
3.1.4
Quality Engineer
Where required by this section, the Contractor shall designate and assign a Quality Engineer
who reports directly to the Quality Assurance Manager or Quality Control Manager and shall
be responsible for assisting
them with their day to day responsibilities and may be
assigned to cover several locations or areas of work relating to the Contract. Where a Quality
Assurance Manager or Quality Control Manager are not required by this section the Quality
Engineer shall be assigned all the responsibilities defined in clause 3.1.2, 3.13, and 3.1.7.
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QCS 2014

Part
Page 3
Quality Inspector
The Contractor shall designate and assign a Quality Inspector for each shift for each location
where work is being performed. Each Quality Inspector shall be qualified by training and
experience in all the construction or fabrication activities being conducted at the location of
work and is directly responsible for ensuring compliance with the Contractors Inspection and
Test Plans and associated specification and contract documentation.
3.1.6
The Contractor shall identify activities requiring qualified production, inspection, and test
personnel and establish their minimum competence level.
The Contractor shall maintain records of personnel qualifications as quality records.
3.1.7
Unless otherwise specified by the Engineer the Contractor shall employ fulltime qualified
quality personnel for the Work as per below tables.
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3.1.5
No of workers on Worksite
Requirement
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No
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1 Quality Inspector (Part time, 15 hours of duty per

week)
Less than 10
2.
3.
4.

More than 1501

1 Quality Control Manager and
1 Quality Inspector
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1 Quality Engineer and

QCS 2014

Part
Page 4
Quality Management and Control staff Qualifications & Experience Matrix

Minimum Qualifications
Required
Position
Minimum Years of
Experience
Minimum Key
Competencies
Degree in relevant
Engineering discipline and Management Level and 3
years Regional experience
Qualified Professional who

can manage a Quality
Management System and
coordinate specialised
activities. Excellent written
& verbal communication
skills in English
Quality Control
Manager
Degree in relevant
Excellent written & verbal
Engineering discipline and Management Level and 3 communication skills in
years Regional experience English
Quality Engineer
Degree in relevant
Engineering discipline.
Quality Inspector
Certificate or Diploma in
the appropriate
engineering discipline
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Quality
Assurance
Manager

communication skills in
English
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related Quality Control
Activities and 3 years
Regional experience
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related Quality Control and communication skills in
Materials Testing activities English
along with 2 years
Regional Experience
The Contractor shall appoint deputy quality personnel who are capable of performing all the
duties of the quality personnel in the event of their absence.
The Contractor shall appoint support staff in sufficient numbers to ensure the effective
function of the quality related work within the Contractors organisation.
The Contractor shall ensure that every Sub-contractor employed on the Worksite appoints
suitably qualified quality staff to ensure the effective function of the quality related issues
within the Sub-contractors organisation. The Sub-contractor shall appoint and deploy fulltime
on the Worksite one Quality Inspector for every 100 workers that they employ at the
Worksite. Any Sub-contractor that employs more than 100 workers will appoint a Quality
Engineer. This shall be in addition to the Contractors Quality Team.
QCS 2014

Part
Page 5
The Contractor shall conduct quality training including Contract specific induction, pre-work
briefings, skills training, tool box talks and formal training conducted by training professionals
or agencies for all the Contractors employees. The Contract specific induction will be at least
1 hour duration, approved by the Engineer and provided for all persons involved in the
Works. Such induction training will be reviewed, revised and repeated at intervals not
exceeding 12 months throughout the duration of the Work. All training shall be provided in the
languages preferred by the recipients of the training. Training shall focus on improving
competency and skill for those performing activities that impact quality.
The Contractor must conduct regular tool box talks to his Labour workforce Such training
should include as a minimum Health and Safety issues and Construction Method best
practice.
The Owner may organise quality related training, meetings, seminars, workshops or similar
events at any time throughout the Contract Period. The Contractor is required to participate
in such events when requested at his own expense.
The Contractor shall maintain records of all training conducted including details of the training
given and a list of attendees, including attendees signature and ID numbers.
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END OF PART
QCS 2014

Part
Page 1
DOCUMENT & DATA CONTROL ............................................................................ 2
4.1
4.1.1
4.1.2
4.1.3
INTRODUCTION ..................................................................................................... 2
General
2
2
2
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Part
Page 2
DOCUMENT & DATA CONTROL
4.1
INTRODUCTION
4.1.1
General
The Contractor shall establish and maintain documented procedures to control all documents
and data that relate to the requirements of the Specification. Documents and data can be in
the form of any type of media, such as hard copy or electronic media.
to the Contract.
4.1.2
The documents and data shall be reviewed and approved for adequacy by authorised
personnel prior to issue. A master list or equivalent document control procedure identifying
the current revision status of documents shall be established and be readily available to
preclude the use of invalid and/or obsolete documents. This control shall ensure that:
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The pertinent issues of appropriate documents are available at all locations where
operations essential to the effective functioning of the quality system are performed
(b)
Invalid and/or obsolete documents are promptly removed from all points of issue or
use, or otherwise assured against unintended use
(c)
Any obsolete documents retained for legal and/or knowledge preservation purposes
are suitably identified
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(a)
Where practicable, the nature of the change shall be identified in the document or
appropriate attachments.
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4.1.3
END OF PART
QCS 2014

Part
05: Quality Records
Page 1
QUALITY RECORDS..................................................................................... 2
5.1
5.1.1
INTRODUCTION ........................................................................................... 2
General
2
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Part
05: Quality Records
Page 2
QUALITY RECORDS
5.1
INTRODUCTION
5.1.1
General
The Contractor shall establish and maintain documented procedures for identification,
collection, indexing, access, filing, storage, maintenance and disposition of quality records.
The Contractor shall supplement these quality records as necessary to monitor quality
throughout the Contract period.
Quality records shall be maintained to demonstrate conformance of materials and equipment

to specified technical requirements and the effective operation of the quality system.
All quality records shall be legible and shall be stored and retained in such a way that they
are readily retrievable in facilities that provide a suitable environment to prevent damage or
deterioration and to prevent loss.
As a minimum, the quality record for any particular item shall include:
name of item
(b)
item number
(c)
item description
(d)
suppliers name
(e)
serial number or other identification (where applicable)
(f)
Specification reference (where applicable)
(g)
verification of receipt of all required supporting documentation
(h)
quantity of items
(i)
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(j)
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(a)
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(k)
non-conformance number (if applicable)
(l)
Observations / comments.
(m)
Signatures of responsible person
END OF PART
QCS 2014

Part
06: Quality Audits
Page 1
QUALITY AUDITS ................................................................................................... 2
6.1
6.1.1
6.1.2
GENERAL ............................................................................................................... 2
2
2
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Part
06: Quality Audits
Page 2
QUALITY AUDITS
6.1
GENERAL
6.1.1
The Contractor shall establish and maintain documented procedures in line with ISO 190011
for planning and implementing internal quality audits to verify whether quality activities and
related results comply with planned arrangements and to determine the effectiveness of the
quality system.
Internal quality audits shall be scheduled on the basis of the status and importance of the
activity to be audited and shall be carried out by personnel independent of those having direct
responsibility for the activity being audited. Unless otherwise agreed with the Engineer in
writing, the Contractor shall carry out a full system quality audit every three months.
The results of the audits shall be recorded and brought to the attention of the personnel
having responsibility in the area audited. The management personnel responsible for the
area shall take timely corrective action on deficiencies found during the audit.
Follow-up audit activities shall verify and record the implementation and effectiveness the
corrective action taken.
The results of the Contractors quality audits shall be made available for review by the
Engineer. The Contractor shall implement any recommendations made by the Engineer
based on the results of the internal audit.
The Contractor shall allow the Engineer to observe the Contractors internal audit upon
request.
Quality audits must be undertaken by suitably qualified personnel with an internationally

recognized audit qualification to recognized standards.
6.1.2
The Engineer may undertake a quality audit of any of the Contractors activities at any time
during the course of the Contract. The Contractor shall make all personnel and facilities
available to the Engineer as necessary to undertake quality audits.
The Engineer shall make the results of his quality audit available to the Contractor for review.
The Contractor shall implement any recommendations made by the Engineer based on the
results of the Engineers quality audit.
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END OF PART
QCS 2014

Part
Page 1
INSPECTION AND TEST ........................................................................................ 2
7.1
7.1.1
7.1.2
7.1.3
7.1.4
7.1.5
7.1.6
7.1.7
INTRODUCTION ..................................................................................................... 2
General
2
2
3
3
4
Workmanship
4
4
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QCS 2014

Part
Page 2
INSPECTION AND TEST

INTRODUCTION
7.1.1
General
The Contractor shall provide equipment, instruments, qualified personnel, and facilities
necessary to inspect the work and perform the tests required by the Project Documentation.
The Contractor shall repeat tests and inspections after correcting non-conforming work until
all work complies with the requirements. All re-testing and re-inspections shall be performed
at no additional cost to the Client.
The Engineer may elect to perform additional inspections and tests at the place of the
manufacture or the shipping point to verify compliance with applicable Specifications.
Inspections and tests performed by the Engineer shall not relieve the Contractor of his
responsibility to meet the Specifications. Inspections and tests by the Engineer shall not be
considered a guarantee that materials delivered at a later time will be acceptable. All costs
associated with the foregoing shall be borne by the Contractor.
Inspections and tests conducted by persons or agencies other than the Contractor, shall not
in any way relieve the Contractor of his responsibility and obligation to meet all Specifications
and referenced standards.
7.1.2
All inspections and tests shall be conducted in accordance with written test procedures as
detailed in the Project Quality Plan and Inspection and Test Plans that have been reviewed
and approved by the Engineer.
Mandatory Products and Materials Sampling and Testing Frequencies are included in Part
14, Appendix A of this section. The Contractor shall follow the Sampling and Testing
Frequencies stipulated in Appendix A unless otherwise stated in the Contract. The table in
Appendix A shall be read and understood in tandem with the footnotes in Appendix A.
Inspection and test procedures submitted for approval shall include, but not be limited to, the
following:
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7.1
(a)
(b)
references to Clauses of this Specification and other standards along with applicable
inspection/test levels specified therein
(c)
prerequisites for the given inspection/test
(d)
required tools, equipment
(e)
necessary environmental conditions
(f)
acceptance criteria
(g)
data to be recorded
(h)
reporting forms
(i)
Identification of items inspected and tested.
(j)
Contractors and Engineers Hold, Witness, Surveillance and Record Review Points
QCS 2014

Part
Page 3
Approved procedures and instructions shall be readily available and used by inspection and
test personnel at the time of inspection or test. All revisions to these procedures and
instructions shall be approved prior to being used to inspect or test the work. No deviations
from the approved procedures and instructions shall be allowed without written authorisation
from the Engineer.
Inspection and testing work shall be performed by personnel designated by the Contractor.
Such personnel shall not be the same as those performing the work.
The Contractor shall furnish the Engineer with a signed inspection report for each item of
work inspected and tested. The report shall indicate whether the item of work, material
and/or equipment complies with all the inspection/test criteria. The Contractor shall submit
inspection/test results to the Engineer prior to incorporating the item(s) into the work.
Inspection/test failures shall be reported to the Engineer immediately.
Inspection and test reports shall, as a minimum, identify the following:

(b)
name of inspector/tester
(c)
observations/comments
(d)
specified requirements
(e)
acceptability
(f)
deviations/non-conformance
(g)
corrective action
(h)
evaluation of results
(i)
authorised signature
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The Contractor shall clearly document and identify the inspections and test status of
all materials and equipment throughout construction. Identification may be by means of
stamps, tags, or other control devices attached to, or accompanying, the material or
equipment.
7.1.3
The inspection and test status of materials, equipment and construction work shall be
identified by suitable means, which indicates the conformance or non-conformance of
materials, equipment and construction work with regard to inspection and tests performed.
The identification of inspection and test status shall be maintained, as defined in the Quality
Assurance Plan and/or documented procedures, throughout the course of construction to
ensure that only materials, equipment and construction work that have passed the required
inspections and tests are used or installed.
7.1.4
The Contractors Inspection and Test Plans will define Hold, Witness, Surveillance and
Record Review points for the Engineer during construction. The contractor shall prepare,
document and implement a Request for Inspection system that defines how the Engineer will
be given sufficient notice to inspect the works in accordance with the Inspection and Test
Plans.
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QCS 2014

Part
Page 4
The Engineer will give the Contractor due notice of his intention to carry out any inspections
during the defects liability period.
The Contractor shall arrange for a responsible representative to be present at the times and
dates named by the Engineer.
The Contractors representative shall render all necessary assistance and take note of all
matters to which his attention is directed by the Engineer
7.1.6
Workmanship
The Contractor shall comply with industry standards except when more restrictive tolerances
or specified requirements indicate more rigid standards or more precise workmanship.
Only persons qualified to produce workmanship of the required quality shall perform works
The Contractor shall comply with manufactures published installation instructions / guides in
full, including each step in sequence. Should instructions conflict with project documentation,
the Contractor shall request clarification from the Engineer before proceeding.
7.1.7
The Contractor shall establish and maintain documented procedures which conform to
accepted and approved national or international standards to control, calibrate and maintain
inspection, measuring and test equipment used by the Contractor to demonstrate the
conformance of materials, equipment and/or construction work with the requirements of the
Inspection, measuring and test equipment shall be used in a manner which ensures that the
measurement uncertainty is known and is consistent with the required measurement
capability
The Contractor shall establish a unique identification number for each item of measuring and
test equipment. This unique identification number shall be permanently affixed to each item
of measuring and test equipment
The Contractor shall ensure that each item of inspection, measuring and test equipment is
calibrated at intervals recommended by the manufacturer. Valid calibration certificates for
measuring and testing equipment shall be present and available for inspection during
The Contractor shall establish a log of all measuring and test equipment and record:
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7.1.5
(a)
equipment description
(b)
identification number
(c)
date of the last calibration
(d)
date that the next calibration is due.
QCS 2014
Page 5
The Contractor shall assess and record the validity of the previous measuring results when
the equipment is subsequently found not to confirm to requirements. The Contractor shall
take appropriate action on the equipment and any product affected.
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END OF PART

Part
QCS 2014

Part
08: Materials
Page 1
MATERIALS .................................................................................................. 2
8.1
8.1.1
8.1.2
8.1.3
GENERAL ...................................................................................................... 2
2
2
2
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QCS 2014

Part
08: Materials
Page 2
MATERIALS
8.1
GENERAL
8.1.1
All Plant, materials, goods and workmanship shall be of the respective kinds described in the
Contract with necessary approvals from the concerned authorities and in accordance with the
Engineer's instructions and shall be subjected from time to time to such tests as the Engineer
may direct at the place of manufacture or fabrication or on the Site or at all or any such
places. The Contractor shall provide such assistance, instruments, machines, labour and
material as are normally required for examining, measuring and testing any work and the
quality, weight or quantity of any materials used and shall supply samples of materials before
incorporation in the Works for testing as may be selected and required by the Engineer.
8.1.2
The Contractor shall establish procedures for handling and storage of materials and
equipment.
The Contractors storage and handling procedures shall be designed to prevent damage,
deterioration, distortion of shape or dimension, loss, degradation, loss of identification, or
substitution.
The handling procedures shall address the use, inspection and maintenance of special
devices such as crates, boxes, containers, dividers, slings, material handling and
transportation equipment and other facilities.
The Contractor shall identify equipment and/or material requiring special handling or storage.
8.1.3
The Contractor shall establish control procedures to ensure that equipment and materials are
properly used and installed.
The Contractor shall identify all items and materials so that they are traceable throughout all
inspections, test activities, and records. For stored items, the identification method shall be
consistent with the expected duration and type of storage.
The Contractor shall record equipment and material identifications and ensure that they are
traceable to the location where they are incorporated into the Works.
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END OF PART
QCS 2014

Part
Page 1
NONCONFORMANCE MONITORING .................................................................... 2
9.1
9.1.1
9.1.2
9.1.3
9.1.4
9.1.5
9.1.6
INTRODUCTION ..................................................................................................... 2
General
2
2
Corrective Action
3
3
4
4
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QCS 2014

Part
Page 2
NONCONFORMANCE MONITORING
9.1
INTRODUCTION
9.1.1
General
The Contractor shall ensure that product which does not conform to Specification
requirements is identified and controlled to prevent its unintended use or delivery. A
documented procedure shall be established to define the controls and relate responsibilities
and authorities for dealing with nonconforming product:
by taking action to estimate the detected nonconformity
(b)
by authorizing its use, release or acceptance under concession by the Engineer
(c)
by taking action to preclude its original intended use or application
(d)
by taking action appropriate to the effects, or potential effects, of the nonconformity

when nonconformity product is detected after delivery or use has started .
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(a)
When Conforming product is corrected it shall be subject to re-verification to demonstrate

conformity to requirements.
Records of the nature of nonconformities and any subsequent actions taken, including
concessions obtained by the engineer, shall be maintained.
The monitoring system shall apply to material and equipment as well as installation and
construction which fail to conform to the Contract.
A Contractors Quality Nonconformance Template is included in Part 15 Appendix B of this

Section and must be used for recording Nonconformance.
9.1.2
The responsibility for review and authority for the disposition of nonconforming items shall be
defined in the Quality Plan.
Nonconforming items shall be reviewed in accordance with documented procedures. A

nonconforming item may be:
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(a)
reworked to meet the specified requirements
(b)
accepted with or without repair if agreed in writing by the Engineer
(c)
re-graded for alternative applications
(d)
rejected or scrapped.
The proposed use or repair of an item which does not conform to the requirements of the
Project Documentation shall be reported to the Engineer.
The description of the
nonconformity and of repairs shall be recorded to denote the actual condition.
Repaired and/or reworked products shall be inspected in accordance with the Quality
Assurance Plan and/or documented procedures
QCS 2014

Part
Page 3
9.1.3
Corrective Action
The Contractor shall take action to eliminate the causes of nonconformities in order to
prevent recurrence. Corrective actions shall be appropriate to the effects of the
nonconformity encountered.
A documented procedure shall be established to define requirements for:
Reviewing nonconformities (including Engineer complaints)
(b)
Determining the causes of nonconformities
(c)
Evaluating the need for action to ensure that conformities do not occur
(d)
Determining and implementing actions needed
(e)
Records of the results of action taken and
(f)
Reviewing the effectiveness of the corrective action taken
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(a)
Any corrective or preventive action taken to eliminate the causes of actual or potential
nonconformities shall be to a degree appropriate to the magnitude of problems and
commensurate with the risks encountered.
The Contractor shall implement and record any changes to the documented procedures for
implementing corrective and preventive action.
The Contractor shall take prompt action to identify the causes of each nonconformance and
the corrective action necessary prevent recurrence. The results of failure and discrepancy
report summaries, Contractor evaluations, and any other pertinent applicable data shall be
used for determining corrective action. Information developed during construction, tests, and
inspections that support the implementation of required improvements and corrections shall
be used to support the adequacy of corrective action taken.
The procedures for preventive action shall include:
determination of the steps needed to deal with any problems requiring preventive
action
(b)
the use of appropriate sources of information such as processes and work operations
which affect product quality, concessions, audit results, quality records and service
reports to detect, analyse and eliminate potential causes of nonconformities
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(c)
initiation of preventive action and application of controls to ensure that it is effective
(d)
ensuring that relevant information on actions taken is submitted for management

review
9.1.4
The Contractor shall clearly identify each nonconforming item with a status tag or other
distinguishing mark. The Contractor shall establish procedures for installing, monitoring, and
removing these status tags and identify personnel authorised to remove status tags.
QCS 2014

Part
Page 4
9.1.5
Acceptance of the Contractors proposed disposition of Nonconforming items should be his

obtained in writing from the Engineer prior to the undertaking of any remedial works by the
his Contractor.
Close out of Nonconforming items must be agreed in writing by the Engineer.
9.1.6
The Contractor shall provide the Engineer with the following information for each
nonconformance:
(b)
(c)
evaluation of nonconformance to establish the cause
(d)
recommended corrective action
(e)
date nonconformance was identified
(f)
date corrective action was completed
(g)
description of final corrective action.
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identification of nonconformance
unique sequential reference number
(b)
date issued
(c)
originator
(d)
description of item deemed to be in nonconformance
(e)
(f)
(g)
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The Contractor shall establish and maintain a nonconformance log. The log shall contain the
following information as a minimum:
Contractors recommended and final disposition

Engineers acceptance of Contractors recommended and final disposition
(a)
(h)
date closed
(i)
remarks, as applicable
END OF PART
QCS 2014

Part
01: General
Page 1
GENERAL ............................................................................................................... 2
1.1
1.1.1
1.1.2
1.1.3
INTRODUCTION ..................................................................................................... 2
Scope
2
References
2
Definitions
2
1.2
1.2.1
1.2.2
1.2.3
1.2.4
1.2.5
1.2.6
1.2.7
SUBMITTALS .......................................................................................................... 3
Programme of Works
3
Preliminary Logs
3
4
5
Digital Data
5
Form of Report
5
Approval of Report
6
1.3
QUALITY ASSURANCE .......................................................................................... 6
1.4
1.4.1
1.4.2
1.4.3
1.4.4
1.4.5
1.4.6
1.4.7
1.4.8
1.4.9
1.4.10
1.4.11
1.4.12
1.4.13
1.4.14
1.4.15
1.4.16
GENERAL PROJECT/SITE CONDITIONS .............................................................. 7

General
7
Working Areas
7
Turf and Topsoil
7
Paved Areas
7
7
Claims for Damage
8
8
8
8
Exploratory Work
8
8
9
9
9
Photographs
9
10
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Part
01: General
Page 2
GENERAL
1.1
INTRODUCTION
1.1.1
Scope
General requirements and information for the execution of ground investigations.
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Section 1 ......... General

Section 2 ......... Quality Assurance and Quality Control
Section 4 ......... Foundations and Retaining Structures
Section 6 ......... Roadworks
Section 8 ......... Drainage Works
Section 12 ....... Earthworks Related to Buildings
References
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1.1.2
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Purposes
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Deere D. U. et al., Design of surface and near-surface construction in rock. Proc. 8th US
symposium on rock mechanics. AIME, New York, 1967
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Government.
Definitions
Topsoil: the surface layer of earth that contains organic material and can also support
vegetation.
Soil: earthen material not classified herein as topsoil or hard stratum.
Hard stratum and obstruction: The words 'hard stratum' and 'obstruction' shall mean
natural or artificial material, including rock, which cannot be penetrated except by the use of
chiselling techniques, rotary drilling, blasting or powered breaking tools. The term 'hard
stratum' shall apply during boring, where it is shown that condition (1) or condition (2) below
are fulfilled, provided that the boring rig involved is in good working order and is fully manned:
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(a)
Condition (1) 100 mm diameter undisturbed sample tubes cannot be driven more
than 300 mm
(b)
Condition (2) a standard penetration resistance test shows a resistance in excess

of 35 blows/75 mm.
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Page 3
Fill: deposits or embankments which have been formed by persons, as distinct from
geological agencies.
Exploratory Hole/Trench/Excavation: any boring, pit trench, ditch or shaft formed for the
purpose of ground investigation.
Boring: hole in earth, excavated by either percussion or auger equipment.
Drilling: any hole in rock, excavated by rotary equipment.
Borehole: exploratory hole excavated by boring or drilling techniques.
1.2
SUBMITTALS
1.2.1
Programme of Works
The Geotechnical Investigation Contractor shall prepare a programme of works for the
investigation which will give a detailed schedule showing proposed time schedule for all
aspect of the work, details of all plant and equipment to be used in addition to a list of
personnel who will work on the project.
1.2.2
Preliminary Logs
The Geotechnical Investigation Contractor shall prepare a preliminary log of each exploratory
hole. For trial pits and trenches, a trial pit or trench map showing each face of the pit or
trench shall be provided, as appropriate. Preliminary logs shall be submitted to the Engineer
in duplicate within seven working days of completion of the explorations to which they refer
to, and shall contain the information required for the exploratory hole logs.
Geotechnical Investigation Contractor activities shall fully comply with Ministry of Environment
(MOE) requirements and/or those of other Government Departments, Ministries and
Statutory Organizations.
The Geotechnical Investigation Contractor shall obtain all necessary work permits and
security permits prior to commencement of Geotechnical investigation of the site.
The investigation shall provide detailed information on the nature of the sub-strata, superficial
deposits and ground water table at the site together with general recommendations for
designing foundations and earthworks, new road pavements, culverts, retaining walls, etc.
The geotechnical investigation Exploratory Boreholes shall be spaced as mentioned in

Section 2.
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Part
01: General
Page 4
The geotechnical investigation Exploratory Boreholes depths shall be as mentioned in Table

1.1.
Table 1.1: Minimum Depth of Boreholes
No of floors
Depth of Boreholes (m)
3 or Less
10
12
13
0.7
3S
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>8
2m below the inverted level;

1.5width of excavation.
2D (D=Diameter or equivalent diameter of the tunnel/underground structure.
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For trenches, pipeline and Tunnels, the depth of Boreholes shall be the larger value of:
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Notes:
The depth of boreholes is measured from foundation level.
S is the number of floors.
For structures small in plan area, exploration should be made at a minimum of three points,
unless other reliable information is available in the immediate vicinity. Where a structure
consists of a number of adjacent units, one exploration point per unit may suffice.
For piles the depth of Boreholes is at least below the depth of pile tip by 5m or 5D (D is the
diameter of the pile at the toe) whichever is greater.
For roads, the depth of Boreholes shall be greater than 2m below the proposed formation
Level.
The exploratory hole logs shall be prepared and presented to a suitable vertical scale. The
logs shall include all the information that follows, such information having been updated as
necessary in the light of laboratory testing and further examination of samples and cores.
Information for exploratory hole logs:
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1.2.3
Drilling
Pit and
Trench
Static
and
Dynamic
Probing
National grid co-ordinates
Ground level related to the datum
Elevation of each stratum referred to the datum
()
Rotary
Borehole
All the designated information
QCS 2014

Part
01: General
Page 5
Drilling
Pit and
Trench
Static
and
Dynamic
Probing
()
Details of groundwater observations
()
Symbolic legend of strata in accordance with BS

5930
()
Rotary
Borehole
Description of each stratum in accordance with BS
5930 and initials of person who carried out the
logging (and responsible Supervisor if under
training)
Core recovery as percentage of each core run
Rock Quality Designation, RQD (Deere et al. 1967)
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Note: means information required; () means information required if applicable.
Laboratory test results shall be submitted to the Engineer in batches at the completion of
each week's testing. Legible photocopies of work sheets are acceptable.
1.2.5
Digital Data
Data from the investigation shall be provided in digital form to the approval of the Engineer.
1.2.6
Form of Report
The report shall comprise of a factual or interpretative or both types of reports as required by
the Employer or Engineer. Reports shall begin with a cover page showing the name of the
Contract and the names of the Employer, Engineer and Geotechnical Investigation
Contractor. Report pages shall be numbered consecutively.
The factual report shall contain, as a minimum, the following information:

A statement from the Engineer on the purpose and rationale of the investigation.
(a)
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1.2.4
(b)
A description of the work carried out, including reference to specification and

standards adopted and any deviations from them.
(c)
Exploratory hole logs.
(d)
In-situ test records.
(e)
Laboratory test results.
(f)
Plan with locations of exploratory holes.
(g)
Site location plan.
(h)
Geological cross-sections (if appropriate).
The plans shall be to a stated scale and shall include a north arrow. Additional information
shall be provided as designated.
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Part
01: General
Page 6
The interpretative report shall contain the following information:

(a)
A written appraisal of the ground and water conditions.
(b)
Analysis and recommendations as designated.
When so designated, the Geotechnical Investigation Contractor shall supply the calculations
and analyses on which recommendations are based.
Approval of Report
A draft copy of the factual report and the interpretative report shall be submitted to the
Engineer for approval before submission of the final report.
1.3
QUALITY ASSURANCE
Only Geotechnical Investigation Contractors holding a current approval certificate from the
Central Materials Laboratory shall be permitted to carry out ground investigations.
The work shall be carried out in accordance with the relevant British Standards or equivalent.
Where specifically designated, all work shall be carried out in accordance with a quality
management system established in accordance with Section 2 Quality Assurance and Quality
Control of the QCS. Records to indicate compliance with quality management shall be made
available to the Engineer on request.
The Geotechnical Investigation Contractor shall provide full time professional attendance on
site. The professional attendant shall be approved by the Engineer, and shall be responsible
for the technical direction of all fieldwork.
The Geotechnical Investigation Contractors geotechnical and environmental personnel

employed on the Contract shall be competent to undertake the work required. Categories of
personnel who may be required by the Contract are as follows:
(b)
Graduate Engineer/Geologist/Environmental Scientist.

Graduate Engineer/Geologist/Environmental Scientist with at least three years of
(c)
Technician.
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1.2.7
relevant experience since graduation.
(d)
Professional Engineer/Geologist/Environmental Scientist with at least five years of

(e)
Professional Engineer/Geologist/Environmental Specialist with at least ten years of

All drillers employed on the Contract shall be experienced and competent in percussion or
auger boring or rotary drilling, to the complete satisfaction of the Engineer. One competent
drilling supervisor per site shall be permanently on the Site during borehole operations.
QCS 2014

Part
01: General
Page 7
GENERAL PROJECT/SITE CONDITIONS
1.4.1
General
Geotechnical Investigation Contractor shall only use access routes to and between
exploration sites that are approved by the Engineer.
Where the presence of underground services is likely, exploratory holes shall be started by
means of a hand excavated inspection pit.
In addition to any designated notice, at least one working day's notice of the intended time of
entry shall be given to the land owner and occupier of the exploration site.
All work shall be carried out with the least possible damage to the Site and its environs.
All barriers breached or otherwise disturbed during the execution of site operations shall be
immediately repaired or replaced to the same standard.
Working hours shall be restricted to those designated.
Daily allocation sheets detailing the work carried out shall be submitted in duplicate at the
end of each days work.
1.4.2
Working Areas
Operations shall be confined to the minimum area of ground required for the Works. Unless
otherwise designated, on completion of each exploration all equipment, surplus material and
rubbish of every kind shall be cleared away and removed from the Site. Damage to land or
property in the vicinity of the exploratory hole and on access routes shall be made good. The
whole of the Site and any ancillary works shall be left in a clean and tidy condition.
1.4.3
Turf and Topsoil
Turf and topsoil shall be stripped from the site of each exploration and stockpiled for future
replacement. Vegetation and topsoil adjacent to the exploration which may be damaged by
the operations shall either be removed and stockpiled as above, or otherwise protected from
damage. After completion of the exploration all topsoil shall be replaced and the Site
restored to its original condition.
1.4.4
Paved Areas
Pavement from paved areas (other than paving slabs and blocks) shall be broken out to the
minimum extent necessary for each exploration. After completion of the exploration and
backfill of the excavation, the disturbed subgrade shall be compacted and the paving
replaced.
Restoration of highway pavement shall be in accordance with the current Code of Practice
and Specification for Road Openings in the Highway issued by the Government.
1.4.5
Paving slabs and blocks shall be removed from the Site, as required for each exploration,
and stored for reuse.
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1.4
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Part
01: General
Page 8
Contiguous paving slabs and blocks which are liable to be damaged by the operations shall
either be removed and stored as above or otherwise protected from damage.
After completion of the exploration and backfill of the excavation, the disturbed subgrade
shall be compacted and the paving slabs and blocks relayed.
1.4.6
Claims for Damage
Any damage, or claim for compensation for damage by owners or occupiers of the Site, shall
be reported to the Engineer.
1.4.7
In addition to the provision of the designated personnel by the Geotechnical Investigation

Contractor, the Engineer may specifically require the services of geotechnical and
environmental personnel for advice, assistance or preparation of interpretative reports. The
form of interpretative reports shall be agreed with the Engineer. Details of the qualifications
and experience of the personnel shall be supplied to the Engineer.
1.4.8
The location of each exploratory hole shall be measured from an approved grid co-ordinate
system, and shall be accurate to within 1 m, and the position recorded on a plan as
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designated.
The elevation of the ground at each exploratory hole shall be established, on the basis of the
Qatar National Datum unless otherwise designated or approved by the Engineer, to the
nearest 0.05 m.
1.4.10
Exploratory Work
The location and depth of each exploratory hole shall be as designated. The Engineer may,
after consultation with the Geotechnical Investigation Contractor, vary the location and depth
of any exploratory hole and the sequence or quantity of in-situ testing depending on the
actual ground conditions encountered. When the position of an exploratory hole has been
varied, the Geotechnical Investigation Contractor shall take all necessary measurements and
shall inform the Engineer of the revised co-ordinates and ground elevation or other
measurements required to locate the exploratory hole.
1.4.11
The Engineer will have the option to require any of the following methods of investigation.
These options will comprise, but not necessarily be limited to, the following:
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1.4.9
(a)
Desk study.
(b)
Geological mapping.
(c)
Topographic survey.
(d)
Aerial photographs.
or any other methods described in this Section.
QCS 2014

Part
01: General
Page 9
The Geotechnical Investigation Contractor shall submit detailed Job Hazard Analysis (JHA)
to all site activities including but not limited to potential hazard, who/what might be harmed,
control/ recovery measure, responsible personetc.
The presence and nature of known areas of hazardous or contaminated ground are
designated, based on available records. If evidence of further hazardous or contaminated
ground is encountered, the Geotechnical Investigation Contractor shall immediately so inform
the Engineer. If required by the Engineer, the Geotechnical Investigation Contractors work
plan shall be revised appropriately to take into account the nature and level of contamination
encountered. Where contaminated land is present or suspected the Geotechnical
Investigation Contractor shall take the appropriate health and safety precautions as directed
by the Engineer and where appropriate by the Civil Defence Department of the Government.
Care shall be taken to avoid contaminating the egress from the Site.
A method statement indicating the safety procedures to be followed during the investigation
of hazardous or contaminated ground shall be provided by the Geotechnical Investigation
Contractor before beginning the investigation in the hazardous or contaminated ground.
Traffic safety and management measures shall be provided, in accordance with the
provisions of traffic control of Section 1, General. Where the circumstances of any particular
case are not designated, proposals for dealing with such situations shall be submitted to the
1.4.13
Where anomalous or unexpected features are revealed, the Geotechnical Investigation

Contractor shall immediately inform the Engineer.
1.4.14
Surface water or other water shall be prevented from entering the exploratory hole, except as
permitted by the Engineer.
1.4.15
Photographs
Colour photographs shall be taken and supplied by the Geotechnical Investigation Contractor
as designated. Each photograph shall clearly show all necessary details, and shall have its
scale identified.
A single gloss colour print (size 150 mm by 100 mm) copy of each photograph shall be
submitted to the Engineer for his approval, within seven working days of the photography. In
the event that the photographs are of a quality unacceptable to the Engineer, they shall be
retaken.
On acceptance of the quality of the photograph, two complete sets of prints of all the
photographs shall be presented, annotated and submitted in bound volumes, together with
the original photograph digital format with the factual report.
Particular requirements for photographs of cores and pits and trenches are given in Parts 3
and 4
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1.4.12
QCS 2014

Part
01: General
Page 10
1.4.16
When required by the particular contract documentation, facilities to the designated standard
shall be provided for the use of the Engineer, as described in Section 1.
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END OF PART
QCS 2014

Part
02: Boreholes
Page 1
BOREHOLES .......................................................................................................... 2
2.1
2.1.1
2.1.2
GENERAL ............................................................................................................... 2
Scope
2
References
2
2.2
2.2.1
2.2.2
2.2.3
BOREHOLES GENERALLY .................................................................................... 2

Method and Diameter
2
3
Backfilling
3
2.3
2.3.1
PERCUSSION BORING .......................................................................................... 3

3
2.4
2.4.1
2.4.2
2.4.3
AUGER BORING ..................................................................................................... 3

Hand Auger
3
3
3
2.5
2.5.1
2.5.2
2.5.3
2.5.4
2.5.5
2.5.6
ROTARY DRILLING ................................................................................................ 3

General
3
Drilling Fluid
4
4
6
Backfilling
6
Photographs
6
2.6
BOREHOLES OVERWATER .................................................................................. 6
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Part
02: Boreholes
Page 2
BOREHOLES
2.1
GENERAL
2.1.1
Scope
Advancement of boreholes by percussion boring, auger boring, and rotary drilling.

This Section
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Section 4, ........ Foundations and Retaining Structures

Part 1 ............... General
References
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2.1.2
BS 5930 ......................Code of practice for site investigations.
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Purposes
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Engineering Group of the Geological Society Working Party Report The logging of rock cores
for engineering purposes (1970).
BOREHOLES GENERALLY
2.2.1
Method and Diameter
The method of advancement and the diameter of a borehole shall be such that the boring
can be completed and logged to the designated depth, and samples of the designated
diameter can be obtained, in-situ testing carried out and instrumentation installed.
The following methods may be employed for advancement of a borehole unless otherwise
designated:
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2.2
(a)
Percussion boring.
(b)
Auger boring (If hollow stem augering is proposed, the Contractor shall satisfy the
Employer that the SPT values obtained are not effected by disturbance of the soil by
the auger head, or the presence of material within the hollow stem.).
(c)
Rotary drilling.
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Part
02: Boreholes
Page 3
Jetting with water shall not be used to assist the advance of the borehole, except where
approved by the Engineer. Where the borehole penetrates below the water table and
disturbance of the soils is likely, a positive hydraulic head shall be maintained in the borehole.
2.2.3
Backfilling
The Contractor shall backfill boreholes in such a manner as to minimise subsequent

depression at the ground surface due to settlement of the backfill. In some circumstances,
grout or special infilling may be required by the Engineer. Where artesian or other water
conditions make normal backfilling impracticable, the Contractor shall consult and agree with
the Engineer a procedure for sealing the borehole.
2.3
PERCUSSION BORING
2.3.1
In a borehole where percussion boring is employed and a hard stratum or obstruction is

encountered, the Contractor shall employ chiselling techniques for a period of up to 1 h.
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2.2.2
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Should this not penetrate through the hard stratum or obstruction the Contractor shall inform
the Engineer, who may instruct the use of one or more of the following:
continuation of chiselling techniques
(b)
rotary or other approved drilling until the stratum is penetrated
(c)
abandonment of the borehole.
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(a)
AUGER BORING
2.4.1
Hand Auger
Hand auger boring may be appropriate in suitable self-supporting strata.
2.4.2
Where continuous flight auger boring is used, it shall be carried out under the full-time
supervision of a person meeting the requirements of Part 1 Clause 1.5 Paragraph 5 Item (c)
who shall produce, as boring proceeds, a record of the material and groundwater
encountered.
2.4.3
Where hollow stem flight auger boring is used, the equipment used shall be such as to bore
and recover samples as designated. Sampling shall be carried out through the hollow stem.
2.5
ROTARY DRILLING
2.5.1
General
Rotary drilling may be required for the recovery of cores, or for the advancement of a hole in
rock, with or without core recovery.
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Part
02: Boreholes
Page 4
Drilling Fluid
The drilling fluid shall normally be clean water, air or air mist. However, with the approval of
the Engineer, drilling muds, additives or foam may be used.
2.5.3
Unless otherwise designated rotary core drilling shall be carried out by a double or triple tube
coring system incorporating a removable inner liner or split tube. The triple tube system may
be affected by use of a double tube barrel with an approved semi-rigid liner.
Rotary core drilling shall produce cores of not less than the designated diameter throughout
the core length. Care shall be exercised in the drilling so as to optimise core recovery.
The first drill run in each hole shall not exceed 1 m in length. Subsequent drill runs shall not
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2.5.2
normally exceed 3 m in length and the core barrel shall be removed from the drill hole as
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Removal of cores and labelling of liners shall be carried out as follows:

All operations entailed in recovering the cores from the ground after completion of
drilling shall be carried out in a manner such as to minimise disturbance to the cores.
(b)
Core barrels or inner tube in case of wireline shall be held horizontally while the
innermost liner containing the core is removed without vibration and in a manner to
prevent disturbance to the core. The core should be rigidly supported at all times while
it is being extruded and during subsequent handling, and the liner containing the core
must not be allowed to flex
(c)
Immediately after removing the liner the top and bottom shall be marked in indelible
ink. The ends of liners shall be capped and sealed using adhesive tape. Liners shall
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often as is required to obtain the best possible core recovery or alternatively the core
samples shall be retrieved by means of wireline. The Engineer may designate in-situ testing
between drill runs.
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be cut to the length of the enclosed core. Alternatively, should a metallic split tube be
used, the samples shall be placed in half cut PVC pipes sealed with the second half
after core samples description with marking of the core run on the PVC tube and the
core box.
(d)
Where the length of core recovered from any single core run is such that it cannot be
accommodated in one channel of the core box, the liner shall be cut to coincide, if
possible, with existing fractures. The liner either side of the cut shall be marked 'cut'
and the ends capped as above.
(e)
Each section of liner shall be marked with the contract title, exploratory hole reference
number, date and the depths of the top and bottom of the drill run.
(f)
Core obtained without a liner and that from within the core catcher but not inside the
liner shall be wrapped in two layers of plastic cling film and labelled to indicate the
depth and exploratory hole reference number.
Core boxes, packing, labelling, storing shall be carried out as follows:

(a)
Core boxes shall be soundly constructed and fitted with stout carrying handles,
fastenings and hinged lids. The total weight of the cores and box shall together not
exceed 60 kg.
QCS 2014

Part
02: Boreholes
Page 5
Cores shall be rigidly and securely packed at the site of drilling and during all
subsequent handling and storage the cores shall remain packed unless required for
examination or testing. Cores shall be placed in the box, in their liners where used,
with the shallowest core to the top left hand corner, the top being considered adjacent
to the hinged section. Cores from the core catcher shall also be placed in the core
boxes at the correct relative depth.
(c)
Depth shall be indicated on the core box by durable markers at the beginning and end
of each drill run. Rigid core spacers shall be used to indicate missing lengths. The
contract title, exploratory hole reference number and the depth of coring contained in
each bore shall be clearly indicated in indelible ink inside, on top and on the right-hand
end of the box and on the inside of the box lid.
(d)
Core boxes containing core shall be kept horizontal and moved and handled with care
at all times. Cores shall be protected from direct sunlight. At the end of each day's
work, core boxes shall be stored secure from interference and protected from the
weather.
Cores shall be prepared for examination as follows:

(a)
Cores shall be prepared for examination by the removal of sealing materials and
splitting of liners in such a way as not to damage the cores. Plastic liners shall be cut
lengthways such that at least half the core circumference is exposed. If half PVC is
used, care should be taken while removing and replacing the split half.
(b)
Before examination of the core, the Contractor shall photograph the cores. The time
between beginning preparation and the examination of the prepared and photographed
cores shall be minimised to prevent loss of moisture from the core samples.
(c)
Cores shall be examined and described on site by a person meeting the requirements
of Part 1 Clause 1.5 Paragraph 5 Item (c) in accordance with BS 5930 or ASTM D
2488 and the recommendations of the Engineering Group of the Geological Society
Working Party Report The logging of rock cores for engineering purpose (1970).
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(b)
When the examination of the cores has been completed, the Contractor may be required to
retain separately designated core sub-samples for possible laboratory testing. The Contractor
shall cut the liner and cap and seal the core sub-samples in such a way as to prevent loss of
moisture and sample disturbance. They shall be clearly labelled so that the location, depth
and origin of the sub-samples can be readily identified. Cores in their liners remaining after
the designated sub-samples have been removed shall be end-capped and resealed and
replaced in the original core box location. Rigid spacers shall be placed in the spaces in the
cores boxes previously occupied by the core sub-samples to prevent movement of adjacent
cores and these shall be labelled identically to the core sub-samples that they replace. The
core sub-samples shall be retained in separate core boxes clearly marked to indicate the
origin of the cores contained within.
The Contractor shall protect all cores and transport them including loading and unloading to
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(a)
The Contractor's premises.
(b)
For a number of selected cores, to the designated address.
After submittal of the approved final report, the Contractor shall retain cores, other than those
delivered to the designated address, for a period of time required by the Engineer. The
Engineer's written permission shall be obtained before disposal of the cores, but the required
retention period will normally not exceed three months.
QCS 2014

Part
02: Boreholes
Page 6
2.5.4
Rotary blind bit or rotary percussive drilling may be used to advance a hole. The hole
diameter shall be as designated.
When used for the purpose of locating mineral seams, mineworkings, adits, shafts, other
cavities or anomalous conditions, drilling shall be under the full-time supervision of a person
meeting the requirements of Part 1 Clause 1.5 Paragraph 5 Item (c). As drilling proceeds a
systematic record shall be made of the drilling methods, rate of penetration, loss of flushing
medium, the material penetrated and any cavities or broken ground encountered.
Backfilling
Except where otherwise designated, the Contractor shall backfill rotary drill holes with clean,
well graded aggregate. The aggregate size and gradation shall be approved by the Engineer.
Under special circumstances grout may be required to backfill the holes. The grout shall
consist of equal portions by weight of ordinary Portland cement and bentonite mixed by
machine or hand to a uniform colour and consistency before placing, with a moisture content
not greater than 250 %. The grout shall be introduced at the bottom of the hole by means of
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2.5.5
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a tremie pipe, which shall be raised but kept below the grout surface as the filling proceeds.
Where artesian water conditions or voids make normal grouting impracticable, the Contractor
shall consult and agree with the Engineer a procedure for sealing the drill hole.
2.5.6
Photographs
In addition to the requirements of Part 1, the Contractor shall photograph cores where
required in a fresh condition before logging and ensure that the following criteria are fulfilled:
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A graduated scale in centimetres is provided.
(b)
Labels and markers are clearly legible in the photograph.
(c)
A clearly legible reference board identifying the project title, exploratory hole number,
date, and depth of drill runs shall be included in each photograph.
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Core boxes are evenly and consistently lit.
(d)
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(a)
(e)
The length of the core box in each photograph fills the frame.
(f)
The focal plane of the camera and the plane of the core box are parallel.
(g)
The camera is placed in the same position with respect to the core box in every
photograph.
(h)
The resolution of the camera is not less than 8Mpixels.
(i)
The photograph taken should be in focus along all the core samples length.
2.6
BOREHOLES OVERWATER
When boreholes are required overwater the method of drilling and sampling shall comply in
general with the other requirements given in this Section, with the exception of backfilling.
Overwater boreholes shall be undertaken by the use of overwater staging, work over platform
(WOP) jack-up vessels, anchored floating vessels or any other methods agreed with the
Engineer.
QCS 2014

Part
02: Boreholes
Page 7
Control of the elevation related to the borehole/seabed surface or varying stratums shall be
related to the top of the casing installed. Anchored floating vessels will keep a constant
record of tidal movement between the vessel and the fixed casing elevation and make any
allowances necessary.
Boring or drilling operations will cease when the wave height exceeds the designated
maximum value relating to standing time due to inclement weather, if this item is applicable
to the Contract under the contract specific documentation.
An accurate method of measuring wave height from trough to crest will be installed on the
drilling vessel or platform and calibrated and approved by the Engineer before beginning
drilling operations.
All overwater operations will comply with all local government regulations related to such
work and will also comply fully with any Safety of Lives at Sea (SOLAS) regulations in force at
the time.
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END OF PART
QCS 2014

Part
Page 1
PITS AND TRENCHES ........................................................................................... 2
3.1
3.1.1
3.1.2
3.1.3
GENERAL ............................................................................................................... 2
Scope
2
References
2
Quality Assurance
2
3.2
3.2.1
3.2.2
3.2.3
3.2.4
3.2.5
3.2.6
PITS AND TRENCHES GENERALLY ..................................................................... 2

2
Contaminated Ground
2
Groundwater
3
3
3
Photographs
3
3.3
3.3.1
3.3.2
3.3.3
INSPECTION PITS .................................................................................................. 3

Excavation Method
3
Services
3
Sidewall Stability
4
3.4
3.4.1
3.4.2
3.4.3
3.4.4
TRIAL PITS AND TRENCHES ................................................................................ 4

Excavation Method
4
Services
4
Sidewall Stability
4
4
3.5
3.5.1
3.5.2
3.5.3
OBSERVATION PITS AND TRENCHES ................................................................. 4

Excavation Method
4
Services
5
Sidewall Stability
5
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QCS 2014

Part
Page 2
PITS AND TRENCHES
3.1
GENERAL
3.1.1
Scope
Inspection pits, trial pits and trenches, observation pits and trenches.

This Section
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Section 1, ....... General

Section 4, ....... Foundations and Retaining Structures
Section 6, ....... Roadworks
Section 8, ....... Drainage Works
Section 12, ..... Earthworks Related to Buildings.
Part 1, .............. General
References
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3.1.2
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BS 5930 ...................... Code of practice for site investigations
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Purposes
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Government.
Quality Assurance
Trial pits and trenches and observation pits and trenches shall be examined and described
by a geotechnical person meeting the requirements of Part 1 Clause 1.5 Paragraph 5 Item
(c) and photographed, if required.
3.2
PITS AND TRENCHES GENERALLY
3.2.1
Unless otherwise designated
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3.1.3
2.
(a)
Trial pits and observation pits shall have a minimum base area of 1.5 m
(b)
Trial trenches and observation trenches shall not be less than 1 m wide.
3.2.2
Contaminated Ground
Ground that is suspected of being contaminated shall be described by an environmental or

geotechnical person, as appropriate, meeting the requirements of Part 1 Clause 1.5
Paragraph 5 Item (c).
QCS 2014

Part
Page 3
Groundwater
The Contractor shall divert surface water runoff from entering pits and trenches.
Groundwater shall be controlled by the use of wellpoints or sump pumps to permit continuous
work if required.
3.2.4
Where pits and trenches are required to be left open and unattended, the Contractor shall
provide fencing together with all necessary lighting and signing.
Precautions shall be taken to protect the pits and trenches from the adverse effects of
weather during this period.
3.2.5
Pits and trenches shall be backfilled as soon as practicable and reinstated to their original
condition.
The backfill shall be placed in lifts of 150 mm thickness and compacted in such a manner as
to minimise any subsequent settlement of the ground surface.
The use of sand backfill compacted by flooding may be permitted, but this method requires
In paved areas, the pavement shall be restored.
3.2.6
Photographs
In addition to the requirements of Part 1, photographs shall clearly show details of the ground
conditions in the pit and trench with any support in place and shall contain a graduated scale.
Material derived from the excavation shall be photographed, when directed by the Engineer.
Artificial lighting shall be used where necessary.
Unless directed otherwise by the Engineer, three photographs will normally be required at
every pit and trench.
3.3
INSPECTION PITS
3.3.1
Excavation Method
Inspection pits for the location of underground services shall be excavated by hand to a
depth of 1.2 m unless otherwise designated.
Hand-operated power tools may be used to assist excavation where necessary.
3.3.2
Services
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3.2.3
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Part
Page 4
Sidewall Stability
3.4
TRIAL PITS AND TRENCHES
3.4.1
Excavation Method
Trial pits and trenches shall be excavated by hand to a maximum depth of 1.2 m or by
machine to the required depth to enable visual examination and sampling from outside the pit
or trench as required.
Where dewatering is required, the pumping equipment used shall be adequate to lower the
water table to the required level.
3.4.2
Services
3.4.3
Sidewall Stability
Excavations deeper than 1.2 m shall be braced if necessary.
3.4.4
All recovered materials from the Trial Pits shall be examined in accordance with BS 5930 or
ASTM D 2488 and the recommendations of the Engineering Group of the Geological Society
Working Party.
Disturbed samples shall be obtained from the trial pits for laboratory testing and geological
description purposes. The samples shall be taken to be representative of the actual site
Color photographs shall be taken for each excavated trial pit with a metric scale laid into the
pit after cleaning it, indicating the pits details such as trial pit number, date and depth.
3.5
OBSERVATION PITS AND TRENCHES
3.5.1
Excavation Method
Observation pits and trenches shall be excavated by hand or machine and shall be
adequately supported to enable personnel to enter safely and to permit in-situ examination,
soil sampling and testing as required. In areas where dewatering is required, the equipment
and methods proposed must be approved by the Engineer before beginning the work.
All recovered materials from the pit/trench shall be examined in accordance with BS 5930 or
ASTM D 2488.
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3.3.3
QCS 2014

Part
Page 5
Disturbed samples shall be obtained for laboratory testing and geological description
purposes (if required). The samples shall be taken to be representative of the actual site
Color photographs shall be taken for each excavated pit with a metric scale laid into the pit
after cleaning it, indicating the pits details such as trial pit number, date and depth.
3.5.2
Services
3.5.3
Sidewall Stability
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END OF PART
QCS 2014

Part
04: Soil Sampling
Page 1
SOIL SAMPLING ..................................................................................................... 2
4.1
4.1.1
4.1.2
GENERAL ............................................................................................................... 2
Scope
2
References
2
4.2
4.2.1
4.2.2
4.2.3
4.2.4
4.2.5
SAMPLING GENERALLY ........................................................................................ 2

2
3
3
3
3
4.3
4.3.1
4.3.2
4.3.3
4.3.4
SOIL SAMPLES....................................................................................................... 3
3
3
4
4
4.4
GROUNDWATER SAMPLES .................................................................................. 4
4.5
SAMPLES OF SUSPECTED CONTAMINATED GROUND, GROUNDWATER AND

LEACHATE FOR CHEMICAL ANALYSIS ................................................................ 4
4.6
GAS SAMPLING...................................................................................................... 5
4.7
SPECIAL SAMPLING .............................................................................................. 5
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QCS 2014

Part
04: Soil Sampling
Page 2
SOIL SAMPLING
4.1
GENERAL
4.1.1
Scope
Taking of samples of soil, groundwater, gas and contaminants. Sample handling,

transportation, storage, retention and disposal.

This Section
References
The following documents are referred to in this Part:
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Part 1, .............. General

Part 2, .............. Boreholes
Part 3, .............. Pits and Trenches.
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Purposes
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BS 5930 ......................Code of practice for site investigations
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BSI DD 175 ..............Code of practice for the identification of potentially contaminated land
and its investigation (draft for development).
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BS EN 1997--- ............ Ground Investigation and testing
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ICE et al, Soil Investigation Steering Group (SISG) Publication, Soil investigation in
construction, Part 4, Guidelines for the safe investigation by drilling of landfills and
contaminated land, Thomas Telford, (1993).
SAMPLING GENERALLY
4.2.1
The frequency of sampling and in-situ testing is dependent on the ground conditions. In the
absence of designated requirements the intervals observed shall be as follows:
4.2
(a)
(b)
in boreholes
(i)
first open tube sample (generally in clay soils) or standard penetration test
(SPT) (generally in granular soils) at 0.5 m depth, the next at 1.0 m depth,
thereafter at 1 m intervals to 5 m depth then at 1.5 m intervals.
(ii)
small disturbed samples shall be taken from the topsoil, at each change in soil
(iii)
type or consistency and midway between successive open tube samples or

SPTs.
(iv)
Bulk disturbed samples shall be taken of each soil type.
in pits and trenches
QCS 2014

Part
04: Soil Sampling
Page 3
(i)
Small disturbed samples shall be taken of the topsoil, at each change in soil
type or consistency and between successive bulk disturbed samples.
(ii)
Bulk disturbed samples shall be taken at 1 m depth intervals, with at least one
large bulk disturbed sample of each soil type.
The depths below ground level at which samples are taken shall be recorded. For open tube
and piston samples the depth to the top and bottom of the sample, and the length of sample
obtained shall be given. For bulk samples the limits of the sampled zone shall be recorded.
4.2.3
All samples shall be examined and described by a geotechnical person meeting the
requirements of Part 1, Clause 1.3.1, Paragraph 5 Item (c) in accordance with BS 5930.
Samples of suspected contaminated ground and leachate shall be described by an
environmental or geotechnical person meeting the requirements of Part 1, Clause 1.5,
Paragraph 5 Item (c) in accordance with DD 175. Descriptions shall include colour and smell
with reference to specific inclusions.
4.2.4
Samples shall be clearly labelled in accordance with BS 5930. Samples of fill, groundwater,
leachate or contaminated ground suspected to be toxic or hazardous shall be tagged with a
red label.
Samples shall be protected from direct heat and sunlight.
Samples shall be transported to the Contractor's premises. Where required by the Engineer,
selected samples shall be delivered to the designated address.
4.2.5
Samples shall be kept for the designated period after submission of the approved final report.
This period shall not exceed three months, unless specifically designated otherwise. The
Contractor shall ultimately dispose of all samples other than those delivered to the
designated address.
4.3
SOIL SAMPLES
4.3.1
Small disturbed samples shall weigh not less than 0.5 kg. They shall be placed immediately
in airtight containers, which they should sensibly fill.
4.3.2
Bulk disturbed samples shall be representative of the zone from which they have been taken.
Normal bulk disturbed samples shall weigh not less than 10 kg.
Large bulk disturbed samples shall weigh not less than 30 kg.
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4.2.2
QCS 2014

Part
04: Soil Sampling
Page 4
Open tube and piston samples shall be taken using the sampling equipment and procedures
as described in BS 5930. The diameter shall be 100 mm unless otherwise designated.
Before an open tube or piston sample is taken, the bottom of the hole shall be carefully
cleared of disturb materials and where a casing is being used the sample shall be taken
below the bottom of the casing. Following a break in the work exceeding one hour, the
borehole shall be advanced by 250 mm before open tube or piston sampling is resumed.
Where an attempt to take an open tube or piston sample is unsuccessful the hole shall be
cleaned out for the full depth to which the sampling tube has penetrated and the recovered
soil saved as a bulk disturbed sample. A fresh attempt shall then be made from the level of
the base of the unsuccessful attempt. Should this second attempt also prove unsuccessful
the Contractor shall agree with the Engineer as to alternative means of sampling.
The samples shall be sealed immediately to preserve their natural moisture content and in
such a manner as to prevent the sealant from entering any voids in the sample.
Soil from the cutting shoe of an open tube shall be retained as an additional small disturbed
sample.
4.3.4
When a standard penetration test (SPT) is made, the sample from the split barrel sampler
shall be retained as a small disturbed sample.
4.4
GROUNDWATER SAMPLES
Groundwater samples shall be taken from each exploratory hole where groundwater is
encountered. Where more than one groundwater level is found, each one shall be sampled
separately. Where water has been previously added, the hole shall be bailed out before
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4.3.3
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sampling so that only groundwater is present. The sample volume shall be not less than 0.25
l.
SAMPLES OF SUSPECTED CONTAMINATED GROUND,

GROUNDWATER AND LEACHATE FOR CHEMICAL ANALYSIS
Samples of suspected contaminated ground, groundwater and leachate shall be taken in

accordance with DD 175 and the SISG publication under the supervision of an environmental
or geotechnical person meeting the requirements of Part 1, Clause 1.5, Paragraph 5 Item (c).
The size and type of sample and container, method of sampling and time limitations for
carrying out specific analyses shall be commensurate with the range of analyses to be
carried out or as designated.
4.5
QCS 2014

Part
04: Soil Sampling
Page 5
GAS SAMPLING
Samples of gas for chromatographic analysis shall be obtained from exploratory holes or
standpipes in accordance with DD 175 and the SISG publication. The sampling method shall
relate to the volume of gas available and the type of laboratory analysis. The sampler
receptacle shall be airtight and may include lockable syringes, Teflon-lined bags or gas
bombs.
4.7
SPECIAL SAMPLING
The Engineer may require special sampling. This work will normally require supervision on
site by a geotechnical person and shall be carried out in accordance with BS 5930 or as
designated.
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4.6
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END OF PART
QCS 2014

Part
Page 1
IN-SITU TESTING, INSTRUMENTATION AND MONITORING............................... 2
5.1
5.1.1
5.1.2
GENERAL ............................................................................................................... 2
Scope
2
References
2
5.2
5.2.1
5.2.2
TESTING, INSTRUMENTATION AND MONITORING GENERALLY ...................... 2

Testing
2
3
5.3
5.3.1
5.3.2
5.3.3
5.3.4
5.3.5
5.3.6
TESTS ..................................................................................................................... 3
3
4
4
4
5
5
5.4
5.4.1
5.4.2
5.4.3
INSTRUMENTATION AND MONITORING .............................................................. 6

Groundwater
6
6
6
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QCS 2014

Part
Page 2
IN-SITU TESTING, INSTRUMENTATION AND MONITORING
5.1
GENERAL
5.1.1
Scope
Testing of soils in place, and provision of instrumentation and monitoring of groundwater and
subsurface gases.

This Section
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Part 1 ............... General

Part 2 ............... Boreholes
Part 3 ............... Pits and Trenches.
References
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5.1.2
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Purposes
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BS 7022......................Geophysical logging of boreholes for hydrogeological purposes
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The Geological Society Engineering Group Working Party Report on Engineering

Geophysics, Quarterly Journal of Engineering Geology, 21, pp. 207-271, 1988.
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Clarke B.G. and Smith A., A model specification for radial displacement measuring
pressuremeters, Ground Engineering, Volume 25, No. 2, March, 1992.
TESTING, INSTRUMENTATION AND MONITORING GENERALLY
5.2.1
Testing
The following information shall be submitted for each test record to be included in the daily
report, preliminary log and factual report:
5.2
(a)
Date of test.
(b)
Project name, exploratory hole number and location.
(c)
Depth and location of test or depths covered by test.
(d)
Information on water levels in exploratory hole during testing.
(e)
Original ground level at test site.
(f)
Soil type and description as identified from the sample.
All results shall be reported in SI units.
QCS 2014

Part
Page 3
Where load, displacement or other measuring equipment is used which necessitates regular
calibration, then this shall be carried out in accordance with the relevant standard (the
preferred method) or the manufacturer's instructions, by a calibration service approved by the
Central Materials Laboratory. Evidence of calibrations and copies of calibration charts shall
be supplied to the Engineer prior to commencing work and when otherwise requested.
5.2.2
The top of each standpipe, gas monitoring standpipe and piezometer tube shall be protected
by a cover. The type of protective cover shall be approved by the Engineer.
When instructed by the Engineer, the Contractor shall install a protective fence around the
top of a standpipe or piezometer. The fence shall be constructed of corrosion treated angle
iron, galvanised wire, and corrosion resistant wire mesh fencing suitable for use in the
climate of Qatar or a fence as a agreed upon with the Engineer.
Daily readings of depths to water in groundwater monitoring standpipes and piezometers

shall be made by the Contractor, with an instrument approved by the Engineer.
Where the presence of gas is suspected or when directed by the Engineer, gas
measurements, using an approved in-situ meter, shall be made by the Contractor during
construction of exploratory holes and in gas monitoring standpipes. The depth to water and
barometric pressure shall be measured immediately after each gas measurement.
Unless otherwise designated, piezometers, and standpipes protection shall not be removed
from the site.
Other instrumentation and monitoring shall be carried out as designated.
5.3
TESTS
5.3.1
The following in-situ tests shall be carried out and reported in accordance with BS 1377 or
BS EN 1997:
in-situ density by
(a)
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(i)
Small pouring cylinder method.
(ii)
Large pouring cylinder method.
(iii)
Water replacement method.
(iv)
Core cutter method.
(v)
Nuclear method.
(b)
Static cone penetration test (CPT), capacity to suit scheduled depths unless otherwise
designated
(c)
Dynamic probing (DPH or DPSH).
(d)
Standard penetration test (SPT).
(e)
Plate loading test.
(f)
Shallow pad maintained load test.
QCS 2014

Part
(g)
California bearing ratio (CBR).
(h)
Vane shear strength.
(i)
Apparent resistivity of soil.
(j)
Redox potential.
(k)
Pressurementer or Self-boring Pressuremeter (PMT)
(l)
Pocket Penetrometer.
Page 4
5.3.2
The following in-situ tests shall be carried out where applicable and reported in accordance
with BS 5930:
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Constant head permeability test.

Variable head permeability test.
Packer permeability test.
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(a)
(b)
(c)
Geophysical testing shall be carried out as designated. The Contractor shall submit to the
Engineer a full description of equipment and procedure for each geophysical method
required.
The equipment and procedure, and information to be submitted for the following geophysical
methods of investigation, shall be as described in BS 5930, BS 7022 and the Geological
Society Engineering Group Working Party Report on Engineering Geophysics:
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5.3.3
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electrical resistivity method
(b)
seismic refraction and reflection method
(c)
magnetic method
(d)
gravity method
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electromagnetic method
(e)
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(a)
(i)
Ground conductivity.
(ii)
Transient electromagnetic.
(iii)
Ground probing radar (optional).
(f)
Borehole geophysical logging.
(g)
Cross-hole seismic method.
(h)
Multi Channel Analysis of Surface Waves (MASW)
(i)
Refraction Microtremor (ReMi)
5.3.4
Special in-situ testing shall be carried out as designated.
The Contractor shall allow for the excavation of boreholes, trenches or trial pits necessary for
the execution of inspection tests.
QCS 2014

Part
Page 5
Inspection tests shall be decided as directed by the Engineer. These tests shall include but
not limited to those in Table 3.2.
Table 3.2: Quality Assurance Tests for Completed Work
Recommended Test per Layer
Deep Fill
(boreholes)
In-situ CBR
Field density
Plate load Test
Layer Thickness
Field density
DCP Test
Layer Thickness
SPT
DCP Test
Pressure meter
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Shallow Fill
(trench or test pit)
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Large Scale Loading

Hand penetrometer and hand vane tests shall be carried out where required to give a
preliminary estimate of undrained shear strength of the soil tested.
Hand (or pocket) penetrometer equipment shall be of an approved proprietary make with
2
stainless steel tip of end area 31 mm with an engraved penetration line 6 mm from the tip.
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5.3.5
Hand vane equipment shall be of an approved proprietary make with stainless steel vanes
having a length of 19 mm or 33 mm and a length-to-diameter ratio of 2:1. The scale shall be
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The scale shall be suitably graduated. The procedure for the test shall be in accordance with
the manufacturer's instructions. Both unconfined compressive strength and estimated shear
strength shall be reported for the soil tested.
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suitably graduated. The procedure for test shall be in accordance with BS 5930 and the
manufacturer's instructions. Peak shear strength and residual shear strength shall be
recorded.
4
The reported shear strengths for the hand penetrometer and handvane shall be the average
of 3 tests in close proximity. Tests giving inconsistent results shall be reported and
comments on the relevance of the tests noted.
5.3.6
The equipment shall be of the Cambridge type (soft ground) self-boring pressuremeter (SBP)
unless otherwise designated. The instruments, calibration, operator, installation, testing
procedure, on-site data processing and analysis, information to be submitted, report data
processing and analysis and information to be submitted in the report shall be as described
by Clarke and Smith (1992) and as designated..
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Part
Page 6
5.4
INSTRUMENTATION AND MONITORING
5.4.1
Groundwater
When groundwater is encountered in exploratory holes, the depth from ground level of the
point of entry shall be recorded together with depth of any casing. Exploratory hole
operations shall be stopped and the depth from ground level to water level recorded with an
approved instrument at 5 minutes intervals for a period of 20 minutes. If at the end of the
period of 20 minutes the water level is still rising, this shall be recorded together with the
depth to water below ground level, unless otherwise instructed by the Engineer, and the
exploratory hole shall then be continued. If casing is used and this forms a seal against the
entry of groundwater, the Contractor shall record the depth of casing at which no further entry
or only insignificant infiltration of water occurred.
Water levels shall be recorded as required by the Contract and at the beginning and end of
each shift. On each occasion when groundwater levels are recorded, the depth of the
exploratory hole, the depth of any casing and the time shall also be recorded.
Where artesian conditions are encountered, the Contractor shall immediately inform the
Engineer and agree a method for dealing with the conditions.
5.4.2
Standpipes for monitoring groundwater levels and changes in groundwater levels shall be
installed in exploratory holes, as instructed by the Engineer. They shall be to the designated
form and detail, and appropriate dimensions and depths shall be recorded at the time of
installation.
Standpipe piezometers for monitoring groundwater levels in exploratory holes shall be

installed as instructed by the Engineer. They shall be to the designated form and detail, and
appropriate dimensions. The installation details of the standpipe piezometers shall be
recorded.
The Contractor shall install piezometers of the hydraulic, electrical or pneumatic type
described in BS 5930 or as designated by the Engineer.
5.4.3
Standpipes for monitoring gas concentration in exploratory holes shall be installed as

instructed by the Engineer. Warning signs or other safety measures required by the Civil
Defence Department of the Government shall be complied with. Standpipes shall be of the
designated form and detail. All dimensions and depths shall he recorded at the time of
installation.
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END OF PART
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Part
Page 1
LABORATORY TESTING ........................................................................................ 2
6.1
6.1.1
6.1.2
GENERAL ............................................................................................................... 2
Scope
2
References
2
6.2
SCHEDULE OF TESTS ........................................................................................... 2
6.3
6.3.1
6.3.2
6.3.3
6.3.4
TESTING PROCEDURES ....................................................................................... 3

General
3
3
Soil Testing
3
Rock Testing
3
6.4
6.4.2
6.4.3
CHEMICAL TESTING FOR CONTAMINATED GROUND ....................................... 4

6
6
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Page 2
LABORATORY TESTING
6.1
GENERAL
6.1.1
Scope
Geotechnical tests and testing procedures carried out in the laboratory or, when designated,
on site.

This Section
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Part 1, .............. General

Part 3, .............. Soil Sampling
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References
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6.1.2
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Purposes
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ASTM SP 402.............Special Technical Publications No. 402
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BS 1377 ......................Methods of tests for soils for civil engineering purposes

BS 1881 ......................Analysis of hardened concrete
BS 812 ........................Testing aggregates
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BS EN 1997--------- .....Ground Investigation and testing
Brown E.T. (Editor). Rock characterisation testing and monitoring. International Society for
Rock Mechanics Suggested Methods. 1981. Pergamon Press.
C2 through C25 and C27 through C31, Methods for examination of waters and associated
materials, HMSO
IRSM Commission on Testing Methods. Suggested method for determining Point Load
Strength (revised version). Int. J. Rock Mech. Min. Sci. and Geomech. Abst., 22,
51-60 (1985).
6.2
SCHEDULE OF TESTS
The Contractor shall prepare a schedule of tests for approval by the Engineer. It may be
necessary to designate additional testing after the results of the original tests are available.
Unless otherwise agreed, testing schedules are to be provided within six working days of the
receipt by the Engineer of the relevant preliminary logs. The Contractor shall inform the
Engineer within six working days from the receipt of the approved testing schedule if a
sample referred to in the schedule is not available for testing.
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Part
Page 3
TESTING PROCEDURES
6.3.1
General
Where applicable, all preparation, testing and reporting shall be in accordance with the
relevant Qatar National Standard or British Standards or ASTM Standards. Where tests are
not covered by these Standards, they shall be performed in accordance with the procedures
in the references or as designated.
Calibration of load-displacement or other measuring equipment shall be carried out in

accordance with the relevant standard (the preferred method) or the manufacturers
instructions by a calibration service approved by the Central Materials Laboratory. Evidence
of current calibrations shall be supplied to the Engineer.
6.3.2
Where geotechnical testing is required on samples of suspected contaminated material,

indicative chemical testing shall be carried out and a safe method of working approved by the
Engineer before any such work is started. It should be noted that this may include but is not
limited to the safe storage, transportation and handling of all suspect material.
6.3.3
Soil Testing
Soil testing shall be carried out and reported in accordance with BS 1377 or ASTM Standards
6.3.4
Rock Testing
Rock testing shall be carried out and reported in accordance with the following references
and as designated:
Classification.
Natural water content - Brown (1981).
(ii)
Porosity/density - Brown (1981).
(iii)
Void index - Brown (1981).
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6.3
(b)
(c)
(d)
(iv)
Carbonate content - BS 1881.
(v)
Petrographic description -Brown (1981).
Durability.
(i)
Slake durability index - Brown (1981).
(ii)
Soundness by solution of magnesium sulphate - BS 812.
Hardness.
(i)
Shore sclerometer -Brown (1981).
(ii)
Schmidt rebound hardness - Brown (1981).
Aggregates.
(i)
Aggregate crushing value - BS 812.
(ii)
Ten percent fines - BS 812.
(iii)
Aggregate impact value - BS 812.
(iv)
Aggregate abrasion value - BS 812.
(v)
Polished stone value - BS 812.
(vi)
Aggregate frost heave - BS 812.
Strength.
(i)
Uniaxial compressive strength - Brown (1981).
(ii)
Deformability in uniaxial compression -Brown (1981).
(iii)
Tensile strength-Brown (1981).
Direct tensile strength.

Indirect tensile strength by the Brazilian method.
Undrained triaxial compression without measurement of porewater pressureBrown (1981).
(v)
Direct shear strength - Brown (1981).
(vi)
Swelling pressure - Brown (1981).
(vii)
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Swelling pressure index under conditions of zero volume change.

Swelling strain index for a radially confined specimen with axial surcharge.
Swelling strain developed in an unconfined rock specimen.
Point load test - IRSM Commission on Testing Methods (1985).
Geophysical.
Seismic velocity-Brown (1981).
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(iv)
(f)
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CHEMICAL TESTING FOR CONTAMINATED GROUND
Chemical testing for contaminated ground shall be carried out and reported in accordance
with the following references and as designated:
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Primary contaminants in soil.

Arsenic total - C4.
(ii)
Cadmium total - C2.
(iii)
Chromium total - C2.
(iv)
hexavalent chromium (undertaken if total chromium content >25 mg/kg dry
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6.4
Mass) -C2.
(v)
Lead total - C2.
(vi)
Mercury total - C3.
(vii)
Selenium total - C4.
(viii)
Boron, water-soluble - C5.
(ix)
Copper total - C2.
(x)
Nickel total - C2.
(xi)
Zinc total - C2.
(xii)
Cyanide total (alkali extraction methods) - C6.
(xiii)
(xiv) Cyanide free - C6.

(xv)
Thiocyanate - C6.
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Page 5
(xvi) (Tests xiii, xiv and xv undertaken if total cyanide >25 mg/kg dry mass. Methods
shall follow alkali extraction.)
(xvii) Phenols total - C7.
(xviii) Sulphide - C8.
(xix) Sulphate - total, acid, soluble - C9.
(xx)
Sulphate - water soluble, 2 : 1 extract - C9.
(xxi) Sulphur free - C10.

(xxii) PH value - C9.
(xxiii) Toluene extractable matter - Cl1.
(xxiv) Coal tar/polyaromatic hydrocarbons (undertaken if toluene extractable matter>

2000 g/kg dry mass of soil) - C12.
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Antimony total - C13.
(ii)
Barium total - C13.
(iii)
Beryllium total - C15.
(iv)
Vanadium total - C13.
(v)
Cyclohexane extractable matter - C14.
(vi)
Freon extractable matter - C15.
(vii)
Mineral oils - C31.
(viii)
Chloride - C9.
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(i)
Contaminants in water.
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(c)
Secondary contaminants in soil.
(i)
Arsenic - C4.
(ii)
Cadmium - C2 and C23.

Chromium - C2 and C24.
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(b)
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(xxv) Asbestos. Asbestos content determination shall be carried out by visual

examination and polarised light microscopy.
Hexavalent chromium - C2.
(v)
Lead - C2 and C25.
(vi)
Mercury - C3.
(vii)
Selenium - C4.
(viii)
Boron - C5 and C6.
(ix)
Copper - C2 and C27.
(x)
Nickel - C2 and C28.
(xi)
Zinc - C2 and C29.
(xii)
Cyanide total - C6.
(xiii)
(xiv)
Cyanide free - C6.
(xv)
Thiocyanate - C6.
(xvi)
Phenols total - C7.
(xvii)
Sulphide - C8.
(iv)

Part
Page 6
Sulphate - C9.
(xix)
Sulphur free - C10.
(xx)
PH value - C9.
(xxi)
Polyaromatic hydrocarbons - C 12.
(xxii)
Antimony-C13.
(xxiii)
Barium-C13.
(xxiv)
Beryllium-C15.
(xxv)
Vanadium - C 13.
(xxvi)
Chloride - C9.
(xxvii)
Ammoniacal nitrogen - C16.
(xxviii)
Nitrate nitrogen - Cl7.
(xxix)
Chemical oxygen demand - C18.
(xxx)
Biochemical oxygen demand - C19.
(xxxi)
Total organic carbon - C20.
(xxxii)
Volatile fatty acids - C21.
(xxxiii)
Iron - C22.
(xxxiv)
Manganese - C22.
(xxxv)
Calcium - C31.
(xxxvi)
Sodium - C31.
(xxxvii)
Magnesium - C31.
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Constituents of gas samples.

Carbon dioxide - C30.
(ii)
Hydrogen - C30.
(iii)
Hydrogen sulphide - C30.
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(xxxviii) Potassium - C21.
Methane - C30.
(v)
Nitrogen - C30.
(vi)
Oxygen - C30.
(vii)
Ethane- C30.
(viii)
Propane- C30.
(ix)
Carbon monoxide - C30.
(iv)
6.4.2
When designated, tests listed under laboratory testing shall be carried out on site.
6.4.3
When designated, special laboratory testing shall be carried out.

END OF PART
QCS 2014

Part
Page 1
GENERAL REQUIREMENTS FOR PILING WORK ................................................. 2
1.1
1.1.1
1.1.2
1.1.3
1.1.4
1.1.5
GENERAL ............................................................................................................... 2
Scope
2
References
2
2
Submittals
3
Records
3
1.2
1.2.1
1.2.2
GROUND CONDITIONS ......................................................................................... 3

3
4
1.3
1.3.1
1.3.2
1.3.3
MATERIALS AND WORKMANSHIP........................................................................ 4

General
4
Sources of Supply
4
Rejected materials
5
1.4
1.4.1
1.4.2
1.4.3
1.4.4
1.4.5
1.4.6
INSTALLATION TOLERANCES .............................................................................. 5

Setting Out
5
Position
6
Verticality
6
Rake
6
6
6
1.5
1.5.1
1.5.2
1.5.3
1.5.4
NUISANCE AND DAMAGE ..................................................................................... 6

6
7
Damage to Piles
7
Temporary Support
7
1.6
1.6.1
1.6.2
1.6.3
SAFETY .................................................................................................................. 7
General
7
7
Driving
7
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Page 2
GENERAL REQUIREMENTS FOR PILING WORK
1.1
GENERAL
1.1.1
Scope
This Part is concerned with all works associated with installation of piles by any of the
recognised techniques.
1.1.2
References
The following standards and codes of practice are referred to in this Part:
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BS 5228......................Noise control on construction and open sites
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Part I, Code of practice for basic information and procedures for noise
control
Part IV, Code of practice for noise and vibration control applicable to
piling operations
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BS EN 1997................Eurocode 7, Geotechnical Design.
The following matters, where appropriate, are described in the contract specific
documentation for the Works:
general items related to Works
Nature of the Works.
(ii)
Classes of loads on piles.
(iii)
Contract drawings.
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1.1.3
(b)
(iv)
Other works proceeding at the same time.
(v)
Working area.
(vi)
Order of the Works.
(vii)
Datum.
(viii)
Offices for the Engineer's Representative.
(ix)
Particular facilities and attendance items where not included in this section.
(x)
Details of soil investigation reports.
specific items related to particular type of pile

(i)
Soil sampling, laboratory testing and in-situ soil testing.
(ii)
Designed concrete or grout mixes, grades of concrete or grout, type of cement

and aggregate, grout or concrete admixtures, concreting of piles.

Part
Page 3
Grades and types of reinforcement and prestressing tendons.
(iv)
Pile dimensions, length and marking of piles.
(v)
Type and quality of pile shoe/splice.
(vi)
Type and quality of permanent casing.
(vii)
Specified working loads.
(viii)
Sections of proprietary types of pile, grades of steel, minimum length to be

supplied, thickness of circumferential weld reinforcement.
(ix)
Surface preparation, types and thickness of coatings.
(x)
Test piles, driving resistance or dynamic evaluation and penetration.
(xi)
Detailed requirements for driving records.
(xii)
Acceptance criteria for piles under test.
(xiii)
Disposal of cut-off lengths.
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QCS 2014
(xiv) Preboring.
Submittals
The Contractor shall supply for approval all relevant details of the method of piling and the
plant he proposes to use. Any alternative method to that specified shall be subject to
approval.
The Contractor shall submit to the Engineer on the first day of each week, or at such longer
periods as the Engineer may from time to time direct, a progress report showing the current
rate of progress and progress during the previous period on all important items of each
section of the Works.
The Contractor shall inform the Engineer each day of the intended programme of piling for
the following day and shall give adequate notice of his intention to work outside normal hours
and at weekends.
1.1.5
Records
The Contractor shall keep records, as indicated by an asterisk in Table 1.1, of the installation
of each pile and shall submit two signed copies of these records to the Engineer not later
than noon of the next working day after the pile is installed. The signed records will form a
record of the work. Any unexpected driving or boring conditions shall be noted briefly in the
records.
1.2
GROUND CONDITIONS
1.2.1
Factual information and reports on site investigations for the Works and on the previous
known uses of the Site will be provided by the Engineer where they exist as part of the
specific contract documentation. However, even if a full report is given, including
interpretations, opinions or conclusions, no responsibility is accepted by the Engineer for any
opinions or conclusions which may be given in the reports.
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1.1.4
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Part
Page 4
Before the start of work the Contractor shall be given a copy of any subsequent information
which may have been obtained relating to the ground conditions and previous uses of the
Site.
1.2.2
The Contractor shall report immediately to the Engineer any circumstance which indicates
that in the Contractor's opinion the ground conditions differ from those reported in or which
could have been inferred from the site investigation reports or test pile results.
1.3
MATERIALS AND WORKMANSHIP
1.3.1
General
All materials and workmanship shall be in accordance with the appropriate British Standards,
codes of practice and other approved standards current at the date of tender except where
the requirements of these standards or codes of practice are in conflict with this Section in
which case the requirements of this Section shall take precedence.
1.3.2
Sources of Supply
The sources of supply of materials shall not be changed without prior approval.
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Table 1.1
Driven segmental
concrete piles
concrete piles
Bored cast-in-place
concrete piles
Continuous flight
auger concrete or
grout piles
Nominal cross-sectional dimensions or diameter
Nominal diameter of underream/base
Length of preformed pile
Standing groundwater level from direct observation or given site

investigation data.
Date and time of driving, redriving or boring
Date of concreting
Ground level/sea bed level at pile position at commencement of

installation of pile (commencing surface)
Working elevation of pile driver
Depth from ground level at pile position to pile tip
Tip elevation
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concrete and steel
sheet piles
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Records to be Kept (Indicated by an Asterisk)
Contract
Pile type
Pile reference number (location)
Bored cast-in-place
concrete piles
Continuous flight
auger concrete or
grout piles
Pile head elevation, as constructed
Pile cut-off elevation
Length of temporary casing
Length of permanent casing
Type, weight, drop and mechanical condition of hammer and

equivalent information for other equipment
Number and type of packings used and type and condition of

dolly used during driving of the pile
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Set of pile or pile tube in millimetres per 10 blows or number of

blows per 25 mm of penetration
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Data
concrete piles
Page 5
Driven segmental
concrete piles

Part
concrete and steel
sheet piles
QCS 2014
If required, temporary compression of ground and pile from time

of a marked increase in driving resistance until pile reached its
final level
Soil samples taken and in-situ tests carried out during pile
installation
Length and details of reinforcements
Concrete mix
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If required, the sets taken at intervals during the last 3 m of

driving
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If required, driving resistance taken at regular intervals over the

last 3 m of driving
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Volume of concrete supplied to pile

obstructions
delays
All information regarding

interruptions to the work
and
other
1.3.3
Rejected materials
Rejected materials are to be removed promptly from the Site.
1.4
INSTALLATION TOLERANCES
1.4.1
Setting Out
Setting out of the main grid lines shall be by the Contractor. The installation of marker pins at
pile positions, as required by the Contract, shall be located by the Contractor from the main
grid lines of the proposed structure. Before installation of the pile, the pile position relative to
the main grid lines shall be verified.
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Part
Page 6
Position
For a pile cut off at or above ground level the maximum permitted deviation of the pile centre
from the centre-point shown on the drawings shall be 75 mm in any direction. An additional
tolerance for a pile head cut off below ground level will be permitted in accordance with
Clauses 1.4.3 and 1.4.4.
1.4.3
Verticality
At the commencement of installation, the pile, or pile-forming equipment in the case of a

driven pile, or the relevant equipment governing alignment in the case of the bored pile, shall
be made vertical to a tolerance of within 1 in 100. The maximum permitted deviation of the
finished pile from the vertical is 1 in 75.
1.4.4
Rake
As in clause 1.4.3, the pile, or driving or other equipment governing the direction and angle of
rake shall be set to give the correct alignment of the pile to within a tolerance of 1 in 50. The
piling rig shall be set and maintained to attain the required rake. The maximum permitted
deviation of the finished pile from the specified rake is 1 in 25 for piles raking up to 1:6 and 1
in 15 for piles raking more than 1:6.
1.4.5
In exceptional circumstances where these tolerances are difficult to achieve, the tolerances
of Clauses 1.4.2, 1.4.3 and 1.4.4 may be relaxed by the Engineer, subject to consideration of
the implications of such action.
1.4.6
Forcible corrections to concrete piles to overcome errors of position or alignment shall not be
made. Forcible corrections may be made to other piles only if approved and where the pile
shaft is not fully embedded in the soil.
1.5
NUISANCE AND DAMAGE
1.5.1
The Contractor shall carry out the work in such a manner and at such times as to minimise
noise, vibration and other disturbance in order to comply with current environmental
legislation.
The Contractor shall endeavour to ascertain the nature and levels of noise produced by the
mechanical equipment and plant that will be used. He shall than take steps to reduce either
the level or the annoying characteristics, or both, of the noise. Reference should be made to
BS 5228 Part 1 for prediction of noise level due to different types of mechanical equipment
and plant, and to BS 5228 Part 4 for noise and vibration control techniques applicable to
piling operations.
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1.4.2
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Page 7
If in the opinion of the Contractor, damage will be, or is likely to be, caused to mains, services
or adjacent structures, he shall submit to the Engineer his proposals for making
preconstruction surveys, monitoring movements or vibrations, and minimising or avoiding
such damage.
1.5.3
Damage to Piles
The Contractor shall ensure that during the course of the work, displacement or damage
which would impair either performance or durability does not occur to completed piles.
The Contractor shall submit to the Engineer his proposed sequence and timing for driving or
boring piles, having the intent of avoiding damage to adjacent piles.
1.5.4
Temporary Support
The Contractor shall ensure that where required, any permanently free-standing piles are
temporarily braced or stayed immediately after driving to prevent loosening of the piles in the
ground and to ensure that the pile will not be damaged by oscillation, vibration or ground
movement.
1.6
SAFETY
1.6.1
General
A competent person, properly qualified and experienced, should be appointed to supervise

the piling operations. This person should be capable of recognising and assessing any
potential dangers as they arise; e.g., unexpected ground conditions that may require a
change in construction technique, or unusual smells which may indicate the presence of
noxious or dangerous gases.
Safety precautions throughout the piling operations shall comply with BS 8008 and BS EN
1997. Refer Section 1 for general safety standards to be adopted at a construction site.
1.6.2
The Contractor shall provide and maintain on the Site sufficient, proper and efficient lifesaving appliances to the approval of the Engineer. The appliances must be conspicuous and
available for use at all times.
Site operatives shall be instructed in the use of safety equipment and periodic drills shall be
held to ensure that all necessary procedures can be correctly observed.
1.6.3
Driving
Before any pile driving is started, the Contractor shall supply the Engineer with two copies of
the code of signals to be employed, and shall have a copy of the code prominently displayed
adjacent to the driving control station on the craft, structure or site from which the piles will be
driven.
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1.5.2
END OF PART
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Part
Page 1
CONCRETE WORKS FOR PILING ......................................................................... 2
2.1
2.1.1
2.1.2
GENERAL ............................................................................................................... 2
Scope
2
References
2
2.2
2.2.1
2.2.2
2.2.3
2.2.4
2.2.5
MATERIALS ............................................................................................................ 2
Cementitious
2
Aggregate
2
Water
2
Admixtures
2
2
2.3
2.3.1
2.3.2
2.3.3
2.3.4
2.3.5
CONCRETE MIXES FOR PILING WORK ............................................................... 3

General
3
Grade Designation
3
Designed Mix
3
Durability
3
Exposure Classes
3
2.4
2.4.1
2.4.2
2.4.3
2.4.4
2.4.5
2.4.6
2.4.7

General
3
Inspection
4
4
4
Compaction
4
5
5
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Part
CONCRETE WORKS FOR PILING
2.1
GENERAL
2.1.1
Scope
This part applies to cast in-situ as well as precast concrete work.
Section 5
Concrete.
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Shallow Foundations
Deep Foundations
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This Section
Part 1,
Part 3
Part 4
Part 5
Page 2
References
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All Standards mentioned in Section 5
MATERIALS
2.2.1
Cementitious
All cementitious materials shall comply with the requirements of Section 5, Part 3.
All cementitious materials shall be stored in separate containers according to type in

waterproof stores or silos.
2.2.2
Aggregate
Aggregates shall comply with the requirements of Section 5, Part 2.
2.2.3
Water
If water for the Works is not available from a public supply, approval shall be obtained
regarding the source of water. For quality of water refer to Section 5, Part 4.
2.2.4
Admixtures
Admixtures shall comply with the requirements of Section 5, Part 5
2.2.5
Steel reinforcement shall be stored in clean and dry conditions. It shall be clean, and free
from loose rust and loose mill scale when installed in the Works. For requirements of steel
reinforcement refer to Section 5, Part 11.
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2.2
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Part
Page 3
The number of joints in longitudinal steel bars shall be kept to a minimum. Joints in
reinforcement shall be such that the full strength of each bar is effective across the joint and
shall be made so that there is no detrimental displacement of the reinforcement during the
construction of the pile.
For requirements of prestressing steel refer to Section 5, Part 18.
2.3
CONCRETE MIXES FOR PILING WORK
2.3.1
General
For general requirements of concrete mixes, trial mixes, batching, mixing and transportation
of fresh concrete and testing of hardened concrete refer to Section 5.
2.3.2
Grade Designation
Grades of concrete shall be as given in Section 5, Part 6.
2.3.3
Designed Mix
The Contractor shall be responsible for selecting the mix proportions to achieve the required
strength and workability..
Complete information on the mix and sources of aggregate for each grade of concrete and
the water/cementitious ratio and the proposed degree of workability shall be approved before
work commences.
Where low-alkali, sulphate-resisting cement to BS EN 197 is specified, the alkali content

(equivalent sodium oxide) of the cement shall not exceed 0.6 % by weight.
The Contractor shall submit the slump value for approval before work commences.
2.3.4
Durability
For piles exposed to aggressive ground or groundwater, approved measures shall be taken
to ensure durability. Reference shall be made to Section 5, Part 6.
2.3.5
Exposure Classes
The minimum cementitious content and type and the concrete grades shall be specified
based on the exposure classes as given in Table 6.8, Section 5, Part 6.
2.4
PLACING CONCRETE
2.4.1
General
The workability and method of placing and vibrating the concrete shall be such that a
continuous monolithic concrete shaft of the full cross-section is formed.
The concrete shall be placed without such interruption as would produce a cold joint in the
pile. The method of placing shall be approved.
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The Contractor shall take all precautions in the design of the mix and placing of the concrete
to avoid arching of the concrete in a temporary casing. No soil, liquid or other foreign matter
which would adversely affect the performance of the pile shall be permitted to contaminate
the concrete.
2.4.2
Inspection
directly or indirectly before to concrete is placed in it. This inspection shall be carried out from
the ground surface in the case of piles of less than 750 mm diameter. Torches or other
approved means of lighting, measuring tapes, and a means of measuring verticality shall be
provided. For piles of 750 mm diameter or larger, equipment shall be provided by the
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Contractor to enable his representatives and the Engineer to descend into the bore for the
purpose of inspection. Any method of descent and the equipment used shall comply with the
On completion of boring and where inspection of a dry pile bore indicates the necessity,
loose, disturbed or softened soil shall be removed from the bore. Where pile bores contain
water or drilling fluid, a cleaning process shall be employed before concrete is placed, or the
concrete shall be placed by tremie method. Large debris or accumulated sediment, or both
of them, shall be removed using appropriate approved methods, which shall be designed to
clean while at the same time minimising ground disturbance below the pile bases. Water or
drilling fluid shall be maintained at such levels throughout and following the cleaning
operation that stability of the bore is preserved.
2.4.4
Slump measured at the time of discharge into the pile bore shall be in accordance with the
standards shown in Table 2.1.
2.4.5
Compaction
Internal vibrators may be used to compact concrete, with the approval of the Engineer
obtained in advance for each specific use.
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2.4.3
Piling mix
workability
Table 2.1
Standards for Concrete Slump
Slump
Minimum
Range
mm
mm
Typical conditions of use
75
75-150
Placed into water-free unlined or permanently lined bore

of 600 mm diameter or over, or where concrete is placed
below temporary casing, and where reinforcement is
widely spaced leaving ample room for free movement of
concrete between bars.
100
100-200
Where reinforcement is not spaced widely, where

concrete is placed within temporary casings, where pile
bore is water-free, and the diameter less than 600 mm
150
150 or more
Where concrete is to be placed by tremie under water or

drilling mud, or by pumping
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Approved measures shall be taken to ensure that the structural strength of the concrete
placed in all piles is not impaired through grout loss, segregation or bleeding.
Concrete shall be placed by elephant trunk, and the free fall shall not exceed 1.2 m.
2.4.7
Before placing concrete, measures shall be taken in accordance with Clause 2.4.3 to ensure
that there is no accumulation of silt or other material at the base of the boring, and the
Contractor shall ensure that heavily contaminated bentonite suspension, which could impair
the free flow of concrete from the tremie pipe, has not accumulated in the bottom of the hole.
Concrete to be placed under water or drilling fluid shall be placed by tremie and shall not be
discharged freely into the water or drilling fluid. Pumping of concrete may be approved where
appropriate.
A sample of the bentonite suspension shall be taken from the base of the boring using an
approved sampling device. If the specific gravity of the suspension exceeds 1.20 the placing
of concrete shall not proceed. In this event the Contractor shall modify or replace the
bentonite as approved to meet the specification.
The concrete shall be a rich, coherent mix and highly workable, and cement content shall be
in accordance with Clause 2.3.5.
The concrete shall be placed in such a manner that segregation does not occur.
The hopper and pipe of the tremie shall be clean and watertight throughout. The pipe shall
extend to the base of the bore and a sliding plug or barrier shall be placed in the pipe to
prevent direct contact between the first charge of concrete in the tremie and the water or
drilling fluid. The pipe shall at all times penetrate the concrete which has previously been
placed and shall be withdrawn at a rate such that there shall be a minimum concrete cover of
2 m over the end of the tremie pipe, until completion of concreting. A sufficient quantity of
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2.4.6
concrete shall be maintained within the pipe to ensure that the pressure from it exceeds that
from the water or drilling fluid. The internal diameter of the tremie pipe shall be not less than
150 mm, and the maximum sized aggregate shall be 20 mm. It shall be so designed that
external projections are minimised, allowing the tremie to pass within reinforcing cages
without causing damage. The internal face of the pipe of the tremie shall be free from
projections.
END OF PART
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Page 1
SHALLOW FOUNDATIONS .................................................................................... 2
3.1
3.1.1
3.1.2
3.1.3
3.1.4
GENERAL ............................................................................................................... 2
Scope
2
Definition
2
References
2
2
3.2
3.2.1
3.2.2
3.2.3
3.2.4
3.2.5
3.2.6
DESIGN CONSIDERATIONS .................................................................................. 3

General
3
3
3
Pad foundations
4
Strip foundations
4
Raft foundations
5
3.3
3.3.1
3.3.2
3.3.3
BASIS OF GEOTECHNICAL DESIGN .................................................................... 5

Design Requirements
5
Design Situations
7
Durability
8
3.4
3.4.1
3.4.2
3.4.3
3.4.4
3.4.5
3.4.6
3.4.7
3.4.8
3.4.9
3.4.10
3.4.11
GEOTECHNICAL DESIGN BY CALCULATION ...................................................... 9

General
9
Actions
10
Ground Properties
12
Geometrical Data
13
13
13
14
14
15
15
16
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SHALLOW FOUNDATIONS
3.1
GENERAL
3.1.1
Scope
The provisions of this Section apply to shallow foundations including isolated, pads, strips and
rafts.
3.1.2
Definition
Shallow foundations are taken to be those where the depth below finished ground level is
less than 3 m and include isolated, pad, strip and raft foundations. The choice of 3 m is
arbitrary; shallow foundations where the depth/breadth ratio is high may need to be designed
as deep foundations.
3.1.3
References
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BS 8004,.....................Code of practice for foundations.
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BS EN 1990................Eurocode 0: Basis of Structural Design

BS EN 1991................Eurocode 1: Actions on structures
BS EN 1992................Eurocode 2: Design of concrete structures -
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BS EN 1993................Eurocode 3: Design of steel structures
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BS EN 1994................Eurocode 4: Design of composite steel and concrete structures

BS EN 1995................Eurocode 5: Design of timber structures
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BS EN 1996................Eurocode 6: Design of masonry structures
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BS EN 1997-1 ............Eurocode 7, Geotechnical design Part 1: General Rules

BS EN 1997-2 ............Eurocode 7, Geotechnical design Part 2: Ground investigation and
testing
BS EN 1998................Eurocode 8: Design of structures for earthquake resistance
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BS 5930......................Code of Practice for Site Investigation

3.1.4
(a)
(b)
Bearing resistance failure, punching failure, squeezing;
(c)
Failure by sliding;
(d)
Combined failure in the ground and in the structure;
(e)
Structural failure due to foundation movement;
(f)
Excessive settlements;
(g)
Excessive heave due to swelling, frost and other causes;
(h)
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3.2
DESIGN CONSIDERATIONS
3.2.1
General
The depth to which foundations should be carried depends on two principal factors:
(a)
Reaching an adequate bearing stratum;
(b)
Penetration below the zone in which trouble may be expected from seasonal weather
changes.
Other factors such as ground movements, changes in groundwater conditions, long-term

stability and heat transmitted from structures to the supporting ground may be important.
Shallow foundations are particularly vulnerable to certain soil conditions, e.g. loose waterbearing sands and soils that change structure when loaded. Specialist advice should be
sought where such conditions are indicated by ground investigation.
3.2.2
The center of area of a foundation or group of foundations should be arranged vertically

under the centre of gravity of the imposed loading. If this is not possible, the effects on the
structure of rotation and settlement of the foundation need to be considered.
Where foundation support is provided by a number of separate bases these should, as far as
practicable, be proportioned so that differential settlement is minimal.
3.2.3
The selection of the appropriate type of shallow foundation will normally depend on the
magnitude and disposition of the structural loads, the bearing capacity and settlement
characteristics of the ground and the need to found in stable soil.
A pad foundation is used for the purpose of distributing concentrated loads. Unless special
conditions control the design, relatively heavy column loads make it advantageous to use pad
foundations.
Strip foundations may be more appropriate where column loads are comparatively small and
closely spaced or where walls are heavy or heavily loaded.
Adjacent pad foundations can be combined or joined together with ground beams to support
eccentric loads, to resist overturning or to oppose horizontal forces. Walls between columns
may be carried on ground beams spanning between the pad foundations.
Where the allowable bearing pressure would result in large isolated foundations occupying
the majority of the available area, it may be logical to join them to form a raft and spread the
loads over the entire area. The combination of isolated foundations to form a raft sometimes
results in a complex design and a large increase in the reinforcement requirement.
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In connection with the provision of foundations to an extension of an existing building,

allowance should be made for differential movement of the foundations between the new and
existing structure; such movement affects the structure above foundations. Where a degree
of cracking and subsequent remedial work is not acceptable, provision for a joint between the
extension and existing building should be considered. Where the foundations of an extension
about the foundations of the existing building, the stability of the existing foundations should
be ensured.
3.2.4
Pad foundations
For buildings such as low rise dwellings and lightly framed structures, pad foundations may
be of unreinforced concrete provided that the angle of spread of load from the pier or base
plate to the outer edge of the ground bearing does not exceed one (vertical) in one
(horizontal) and that the stresses in the concrete due to bending and shear do not exceed
tolerable limits. For buildings other than low rise and lightly framed structures, it is customary
to use reinforced concrete foundations.
The thickness of the foundation should under no circumstances be less than 150 mm and will
generally be greater than this to maintain cover to reinforcement where provided.
Where concrete foundations are used they should be designed in accordance with the design
method appropriate to the loading assumptions.
3.2.5
Strip foundations
Similar considerations to those for pad foundations apply to strip foundations. On sloping
sites strip foundations should be on a horizontal bearing, stepped where necessary to
maintain adequate depth.
In continuous wall foundations it is recommended that reinforcement be provided wherever

an abrupt change in magnitude of load or variation in ground support occurs. Continuous wall
foundations will normally be constructed in mass concrete provided that the angle of spread
of load from the edge of the wall base to the outer edge of the ground bearing does not
exceed one (vertical) in one (horizontal). Foundations on sloping ground, and where
regarding is likely to take place, may require to be designed as retaining walls to
accommodate steps between adjacent ground floor slabs or finished ground levels. At all
changes of level unreinforced foundations should be lapped at the steps for a distance at
least equal to the thickness of the foundation or a minimum of 300mm. Where the height of
the step exceeds the thickness of the foundation, special precautions should be taken. The
thickness of reinforced strip foundations should be not less than 150mm, and care should be
taken with the excavation levels to ensure that this minimum thickness is maintained. For the
longitudinal spread of loads, sufficient reinforcement should be provided to withstand the
tensions induced. It will sometimes be desirable to make strip foundations of inverted tee
beam sections, in order to provide adequate stiffness in the longitudinal direction. At corners
and junctions the longitudinal reinforcement of each wall foundation should be lapped.
Where the use of ordinary strip foundations would overstress the bearing strata, wide strip
foundations designed to transmit the foundation loads across the full width of the strip may be
used. The depth below the finished ground level should be the same as for ordinary strip
foundations.
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Where the nature of the ground is such that narrow trenches can be neatly cut down to the
bearing stratum, an economical foundation may be achieved by filling the trenches with
concrete. When deciding the trench width, account should be taken of normal building
tolerances in relation to setting out dimensions. Where the thickness of such a foundation is
500mm or more, any step should be not greater than the concrete thickness and the lap at
such a step should be at least 1 m or twice the step height, whichever is the greater?
Where fill or other loose materials occur above the bearing stratum adequate support is
required to any excavation. Consideration may be given to the use of lean mix mass concrete
replacement under ordinary strip footings placed at shallow depth. This mass concrete can
be poured against either permanent or recoverable shuttering. This form of foundation
provides a method of dealing with local areas where deeper foundations are required.
3.2.6
Raft foundations
General. Suitably designed raft foundations may be used in the following circumstances.
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For lightly loaded structures on soft natural ground where it is necessary to spread the
load, or where there is variable support due to natural variations, made ground or
weaker zones. In this case the function of the raft is to act as a bridge across the
weaker zones. Rafts may form part of compensated foundations.
(b)
Where differential settlements are likely to be significant. The raft will require special
design, involving an assessment of the disposition and distribution of loads, contact
pressures and stiffness of the soil and raft.
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(a)
BASIS OF GEOTECHNICAL DESIGN
3.3.1
Design Requirements
For each geotechnical design situation it shall be verified that no relevant limit state is
exceeded.
When defining the design situations and the limit states, the following factors should be
considered:
Site conditions with respect to overall stability and ground movements;
(a)
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3.3
(b)
Nature and size of the structure and its elements, including any special requirements
such as the design life;
(c)
Conditions with regard to its surroundings (e.g.: neighboring structures, traffic, utilities,
vegetation, hazardous chemicals);
(d)
Ground conditions;
(e)
Ground-water conditions;
(f)
Regional seismicity;
(g)
Influence of the environment (hydrology, surface water, subsidence, seasonal changes

of temperature and moisture).
Limit states can occur either in the ground or in the structure or by combined failure in the
structure and the ground.
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Limit states should be verified by any appropriate method such as calculation method as
described in 3.4;
In practice, experience will often show which type of limit state will govern the design and the
avoidance of other limit states may be verified by a control check.
Buildings should normally be protected against the penetration of ground-water or the

transmission of vapor or gases to their interiors.
If practicable, the design results should be checked against comparable experience.
In order to establish minimum requirements for the extent and content of geotechnical
investigations, calculations and construction control checks, the complexity of each
geotechnical design shall be identified together with the associated risks. In particular, a
distinction shall be made between:
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L ight and simple structures and small earthworks for which it is possible to ensure that
the minimum requirements will be satisfied by experience and qualitative geotechnical
investigations, with negligible risk;
(b)
Other geotechnical structures.
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(a)
For structures and earthworks of low geotechnical complexity and risk, such as defined
above, simplified design procedures may be applied.
10
To establish geotechnical design requirements, three Geotechnical Categories, 1, 2 and 3,

may be introduced.
11
A preliminary classification of a structure according to Geotechnical Category should

normally be performed prior to the geotechnical investigations. The category should be
checked and changed, if necessary, at each stage of the design and construction process.
12
The procedures of higher categories may be used to justify more economic designs, or if the
designer considers them to be appropriate.
13
The various design aspects of a project can require treatment in different Geotechnical
Categories. It is not required to treat the whole of the project according to the highest of these
categories.
14
Geotechnical Category 1 should only include small and relatively simple structures:
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(a)
For which it is possible to ensure that the fundamental requirements will be satisfied on
the basis of experience and qualitative geotechnical investigations;
(b)
With negligible risk.
15
Geotechnical Category 1 procedures should be used only where there is negligible risk in
terms of overall stability or ground movements and in ground conditions, which are known
from comparable local experience to be sufficiently straightforward. In these cases the
procedures may consist of routine methods for foundation design and construction.
16
Geotechnical Category 1 procedures should be used only if there is no excavation below the
water table or if comparable local experience indicates that a proposed excavation below the
water table will be straightforward.
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17
Geotechnical Category 2 should include conventional types of structure and foundation with
no exceptional risk or difficult soil or loading conditions
18
Designs for structures in Geotechnical Category 2 should normally include quantitative

geotechnical data and analysis to ensure that the fundamental requirements are satisfied.
19
Routine procedures for field and laboratory testing and for design and execution may be used
for Geotechnical Category 2 designs.
the following are examples of conventional structures or parts of structures complying
with Geotechnical Category 2:
Shallow foundations;
(ii)
Pile foundations;
(iii)
Walls and other structures retaining or supporting soil or water;
(iv)
Excavations;
(v)
Bridge piers and abutments;
(vi)
Embankments and earthworks;
(vii)
Ground anchors and other tie-back systems;
(viii)
Tunnels in hard, non-fractured rock and not subjected to special water tightness
or other requirements.
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(i)
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(a)
Geotechnical Category 3 should include structures or parts of structures, which fall outside
the limits of Geotechnical Categories 1 and 2.
21
Geotechnical Category 3 should normally include alternative provisions and rules to those in
this standard.
Geotechnical Category 3 includes the following examples:
Very large or unusual structures;
(ii)
Structures involving abnormal risks, or unusual or exceptionally difficult ground

or loading conditions;
(iii)
Structures in highly seismic areas;
(iv)
Structures in areas of probable site instability or persistent ground movements

that require separate investigation or special measures.
(i)
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3.3.2
Design Situations
Both short-term and long-term design situations shall be considered.
In geotechnical design, the detailed specifications of design situations should include, as

appropriate:
(a)
The actions, their combinations and load cases;
(b)
The general suitability of the ground on which the structure is located with respect to
overall stability and ground movements;
(c)
The disposition and classification of the various zones of soil, rock and elements of
construction, which are involved in any calculation model;
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Part
(d)
Dipping bedding planes;
(e)
Mine workings, caves or other underground structures;
(f)
In the case of structures resting on or near rock:

(i)
inter bedded hard and soft strata;
(ii)
faults, joints and fissures;
(iii)
possible instability of rock blocks;
(iv)
solution cavities, such as swallow holes or fissures filled with soft material, and
continuing solution processes;
The environment within which the design is set, including the following:
(i)
effects of scour, erosion and excavation, leading to changes in the geometry of

the ground surface;
(ii)
effects of chemical corrosion;
(iii)
effects of weathering;
(iv)
effects of long duration droughts;
(v)
variations in ground-water levels, including, e.g. the effects of dewatering,

possible flooding, failure of drainage systems, water exploitation;
(vi)
the presence of gases emerging from the ground;
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(g)
Page 8
Earthquakes;
(i)
Ground movements caused by subsidence due to mining or other activities;
(j)
The sensitivity of the structure to deformations;
(k)
The effect of the new structure on existing structures, services and the local
environment.
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(h)
Durability
At the geotechnical design stage, the significance of environmental conditions shall be

assessed in relation to durability and to enable provisions to be made for the protection or
adequate resistance of the materials.
In designing for durability of materials used in the ground, the following should be considered:
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3.3.3
(a)
For concrete:
(i)
(b)
Aggressive agents in the ground-water or in the ground or fill material, such as

acids or sulfate salts;
For steel:
(i)
Chemical attack where foundation elements are buried in ground that is

sufficiently permeable to allow the percolation of ground-water and oxygen;
(ii)
Corrosion on the faces of sheet pile walls exposed to free water, particularly in
the mean water level zone;
(iii)
The pitting type of corrosive attack on steel embedded in fissured or porous

concrete, particularly for rolled steel where the mill scale, acting as a cathode,
promotes electrolytic action with the scale-free surface acting as an anode;
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Part
For timber:
(i)
(d)
Page 9
Fungi and aerobic bacteria in the presence of oxygen;
For synthetic fabrics:

(i)
The ageing effects of UV exposure or ozone degradation or the combined

effects of temperature and stress, and secondary effects due to chemical
degradation.
Reference should be made to durability provisions in construction materials standards.
3.4
GEOTECHNICAL DESIGN BY CALCULATION
3.4.1
General
Design by calculation shall be in accordance with the fundamental requirements of EN 1990

and with the particular rules of this specification. Design by calculation involves:
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Actions, which may be either imposed loads or imposed displacements, e.g. from
ground movements;
(b)
Properties of soils, rocks and other materials;
(c)
Geometrical data;
(d)
Limiting values of deformations, crack widths, vibrations etc;
(e)
Calculation models.
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(a)
It should be considered that knowledge of the ground conditions depends on the extent and
quality of the geotechnical investigations. Such knowledge and the control of workmanship
are usually more significant to fulfilling the fundamental requirements than is precision in the
calculation models and partial factors.
The calculation model shall describe the assumed behavior of the ground for the limit state
under consideration.
If no reliable calculation model is available for a specific limit state, analysis of another limit
state shall be carried out using factors to ensure that exceeding the specific limit state
considered is sufficiently improbable. Alternatively, design by prescriptive measures,
experimental models and load tests, or the observational method, shall be performed.
The calculation model may consist of any of the following:
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(a)
An analytical model;
(b)
A semi-empirical model;
(c)
A numerical model.
Any calculation model shall be either accurate or err on the side of safety.
A calculation model may include simplifications.
If needed, a modification of the results from the model may be used to ensure that the design
calculation is either accurate or errs on the side of safety.
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If the modification of the results makes use of a model factor, it should take account of the
following:
(a)
The range of uncertainty in the results of the method of analysis;
(b)
Any systematic errors known to be associated with the method of analysis.
10
If an empirical relationship is used in the analysis, it shall be clearly established that it is

relevant for the prevailing ground conditions.
11
Limit states involving the formation of a mechanism in the ground should be readily checked
using a calculation model. For limit states defined by deformation considerations, the
deformations should be evaluated by calculation or otherwise assessed.
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NOTE: many calculation models are based on the assumption of a sufficiently ductile
performance of the ground/structure system. A lack of ductility, however, will lead to an
ultimate limit state characterized by sudden collapse.
Numerical methods can be appropriate if compatibility of strains or the interaction between
the structure and the soil at a limit state are considered.
13
Compatibility of strains at a limit state should be considered. Detailed analysis, allowing for
the relative stiffness of structure and ground, may be needed in cases where a combined
failure of structural members and the ground could occur. Examples include raft foundations,
laterally loaded piles and flexible retaining walls. Particular attention should be paid to strain
compatibility for materials that are brittle or that have strain-softening properties.
14
In some problems, such as excavations supported by anchored or strutted flexible walls, the
magnitude and distribution of earth pressures, internal structural forces and bending
moments depend to a great extent on the stiffness of the structure, the stiffness and strength
of the ground and the state of stress in the ground.
15
In these problems of ground-structure interaction, analyses should use stress-strain

relationships for ground and structural materials and stress states in the ground that are
sufficiently representative, for the limit state considered, to give a safe result.
3.4.2
Actions
The definition of actions shall be taken as:
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12
(a)
Set of forces (loads) applied to the structure (direct action);
(b)
Set of imposed deformations or accelerations caused for example, by temperature

changes, moisture variation, uneven settlement or earthquakes (indirect action).
The values of actions shall be taken from EN 1991 or equivalent international standard,
where relevant.
2
The values of geotechnical actions to be used shall be selected, since they are known before
a calculation is performed; they may change during that calculation.
NOTE: Values of geotechnical actions may change during the course of calculation. In such
cases they will be introduced as a first estimate to start the calculation with a preliminary,
known value.
Any interaction between the structure and the ground shall be taken into account when
determining the actions to be adopted in the design.
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In geotechnical design, the following should be considered for inclusion as actions:

the weight of soil, rock and water;
(b)
stresses in the ground;
(c)
earth pressures and ground-water pressure;
(d)
free water pressures, including wave pressures;
(e)
ground-water pressures;
(f)
seepage forces;
(g)
dead and imposed loads from structures;
(h)
surcharges;
(i)
mooring forces;
(j)
removal of load or excavation of ground;
(k)
traffic loads;
(l)
movements caused by mining or other caving or tunneling activities;
(m)
swelling and shrinkage caused by vegetation, climate or moisture changes;
(n)
movements due to creeping or sliding or settling ground masses;
(o)
movements due to degradation, dispersion, decomposition, self-compaction and

solution;
(p)
movements and accelerations caused by earthquakes, explosions, vibrations and

dynamic loads;
(q)
temperature effects, including frost action;
(r)
imposed pre-stress in ground anchors or struts;
(s)
down drag.
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Consideration shall be given to the possibility of variable actions occurring both jointly and
separately.
The duration of actions shall be considered with reference to time effects in the material
properties of the soil, especially the drainage properties and compressibility of fine-grained
soils.
Actions, which are applied repeatedly, and actions with variable intensity shall be identified
for special consideration with regard to, e.g. continuing movements, liquefaction of soils,
change of ground stiffness and strength.
Actions that produce a dynamic response in the structure and the ground shall be identified
for special consideration.
Actions in which ground- and free-water forces predominate shall be identified for special
consideration with regard to deformations, fissuring, variable permeability and erosion.
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NOTE Unfavorable (or destabilizing) and favorable (or stabilizing) permanent actions may in
some situations be considered as coming from a single source. If they are considered so, a
single partial factor may be applied to the sum of these actions or to the sum of their effects.
QCS 2014

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Page 12
Ground Properties
Properties of soil and rock masses, as quantified for design calculations by geotechnical
parameters, shall be obtained from test results, either directly or through correlation, theory
or empiricism, and from other relevant data.
Values obtained from test results and other data shall be interpreted appropriately for the limit
state considered.
Account shall be taken of the possible differences between the ground properties and
geotechnical parameters obtained from test results and those governing the behavior of the
geotechnical structure.
The above differences can be due to the following factors:

many geotechnical parameters are not true constants but depend on stress level and
mode of deformation;
(b)
soil and rock structure (e.g. fissures, laminations, or large particles) that may play a
different role in the test and in the geotechnical structure;
(c)
time effects;
(d)
the softening effect of percolating water on soil or rock strength;
(e)
the softening effect of dynamic actions;
(f)
the brittleness or ductility of the soil and rock tested;
(g)
the method of installation of the geotechnical structure;
(h)
the influence of workmanship on artificially placed or improved ground;
(i)
the effect of construction activities on the properties of the ground.
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(a)
When establishing values of geotechnical parameters, the following should be considered:
the value of each geotechnical parameter compared with relevant published data and
local and general experience;
(b)
published and well recognized information relevant to the use of each type of test in
the appropriate ground conditions;
(a)
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3.4.3
(c)
the variation of the geotechnical parameters that are relevant to the design;
(d)
the results of any large scale field trials and measurements from neighboring
constructions;
(e)
any correlations between the results from more than one type of test;
(f)
any significant deterioration in ground material properties that may occur during the
lifetime of the structure.
Calibration factors shall be applied where necessary to convert laboratory or field test results
according to EN 1997-2 into values that represent the behavior of the soil and rock in the
ground, for the actual limit state, or to take account of correlations used to obtain derived
values from the test results.
QCS 2014

Part
Page 13
Geometrical Data
The level and slope of the ground surface, water levels, levels of interfaces between strata,
excavation levels and the dimensions of the geotechnical structure shall be treated as
geometrical data.
3.4.5
Characteristic and representative values of actions shall be derived in accordance with EN

1990:2002 and the various parts of EN 1991.
3.4.6
The selection of characteristic values for geotechnical parameters shall be based on results
and derived values from laboratory and field tests, complemented by well-established
experience.
The characteristic value of a geotechnical parameter shall be selected as a cautious estimate

of the value affecting the occurrence of the limit state.
The selection of characteristic values for geotechnical parameters shall take account of the
following:
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3.4.4
geological and other background information, such as data from previous projects;
(b)
the variability of the measured property values and other relevant information, e.g.
from existing knowledge;
(c)
the extent of the field and laboratory investigation;
(d)
the type and number of samples;
(e)
the extent of the zone of ground governing the behavior of the geotechnical structure
at the limit state being considered;
(f)
the ability of the geotechnical structure to transfer loads from weak to strong zones in
the ground.
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(a)
Characteristic values can be lower values, which are less than the most probable values, or
upper values, which are greater.
For each calculation, the most unfavorable combination of lower and upper values of
independent parameters shall be used.
The zone of ground governing the behavior of a geotechnical structure at a limit state is
usually much larger than a test sample or the zone of ground affected in an in situ test.
Consequently the value of the governing parameter is often the mean of a range of values
covering a large surface or volume of the ground. The characteristic value should be a
cautious estimate of this mean value.
If the behavior of the geotechnical structure at the limit state considered is governed by the
lowest or highest value of the ground property, the characteristic value should be a cautious
estimate of the lowest or highest value occurring in the zone governing the behavior.
QCS 2014

Part
Page 14
When selecting the zone of ground governing the behavior of a geotechnical structure at a
limit state, it should be considered that this limit state may depend on the behavior of the
supported structure. For instance, when considering a bearing resistance ultimate limit state
for a building resting on several footings, the governing parameter should be the mean
strength over each individual zone of ground under a footing, if the building is unable to resist
a local failure. If, however, the building is stiff and strong enough, the governing parameter
should be the mean of these mean values over the entire zone or part of the zone of ground
under the building.
If statistical methods are employed in the selection of characteristic values for ground
properties, such methods should differentiate between local and regional sampling and
should allow the use of a prior knowledge of comparable ground properties.
10
If statistical methods are used, the characteristic value should be derived such that the
calculated probability of a worse value governing the occurrence of the limit state under
consideration is not greater than 5%.
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NOTE : In this respect, a cautious estimate of the mean value is a selection of the mean
value of the limited set of geotechnical parameter values, with a confidence level of 95%;
where local failure is concerned, a cautious estimate of the low value is a 5% fractal.
When using standard tables of characteristic values related to soil investigation parameters,
the characteristic value shall be selected as a very cautious value.
3.4.7
Characteristic values of the levels of ground and ground-water or free water shall be
measured, nominal or estimated upper or lower levels.
Characteristic values of levels of ground and dimensions of geotechnical structures or

elements should usually be nominal values.
3.4.8
The assumptions, data, methods of calculation and results of the verification of safety and
serviceability shall be recorded in the Geotechnical Design Report.
The level of detail of the Geotechnical Design Reports will vary greatly, depending on the
type of design. For simple designs, a single sheet may be sufficient.
The Geotechnical Design Report should normally include the following items, with crossreference to the Ground Investigation Report :
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(a)
a description of the site and surroundings;
(b)
a description of the ground conditions;
(c)
a description of the proposed construction, including actions;
(d)
design values of soil and rock properties, including justification, as appropriate;
(e)
statements on the codes and standards applied;
(f)
statements on the suitability of the site with respect to the proposed construction and
the level of acceptable risks;
(g)
geotechnical design calculations and drawings;
QCS 2014

Part
Page 15
(h)
foundation design recommendations;
(i)
a note of items to be checked during construction or requiring maintenance or

monitoring.
The Geotechnical Design Report shall include a plan of supervision and monitoring, as
appropriate. Items, which require checking during construction or, which require maintenance
after construction shall be clearly identified. When the required checks have been carried out
during construction, they shall be recorded in an addendum to the Report.
In relation to supervision and monitoring the Geotechnical Design Report should state:
the purpose of each set of observations or measurements;
(b)
the parts of the structure, which are to be monitored and the locations at which
observations are to be made;
(c)
the frequency with which readings is to be taken;
(d)
the ways in which the results are to be evaluated;
(e)
the range of values within which the results are to be expected;
(f)
the period of time for which monitoring is to continue after construction is complete;
(g)
the parties responsible for making measurements and observations, for interpreting
the results obtained and for maintaining the instruments.
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(a)
An extract from the Geotechnical Design Report, containing the supervision, monitoring and
maintenance requirements for the completed structure, shall be provided to the owner/client.
3.4.9
Design situations shall be selected in accordance with 3.3.2.
The actions listed in 3.4.2(4) should be considered when selecting the limit states for
calculation.
If structural stiffness is significant, an analysis of the interaction between the structure and
the ground should be performed in order to determine the distribution of actions.
3.4.10
When choosing the depth of a shallow foundation the following shall be considered:
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(a)
reaching an adequate bearing stratum;
(b)
the depth above which shrinkage and swelling of clay soils, due to seasonal weather
changes, or to trees and shrubs, may cause appreciable movements;
(c)
the level of the water table in the ground and the problems, which may occur if
excavation for the foundation is required below this level;
(d)
possible ground movements and reductions in the strength of the bearing stratum by
seepage or climatic effects or by construction procedures;
(e)
the effects of excavations on nearby foundations and structures;
(f)
anticipated excavations for services close to the foundation;
(g)
high or low temperatures transmitted from the building;
QCS 2014

Part
Page 16
(h)
the possibility of scour;
(i)
the effects of variation of water content due to long periods of drought, and subsequent
periods of rain, on the properties of volume-unstable soils in arid climatic areas;
(j)
the presence of soluble materials, e.g. limestone, clay stone, gypsum, salt rocks;
In addition to fulfilling the performance requirements, the design foundation width shall take
account of practical considerations such as economic excavation, setting out tolerances,
working space requirements and the dimensions of the wall or column supported by the
foundation.
One of the following design methods shall be used for shallow foundations:
a direct method, in which separate analyses are carried out for each limit state. When
checking against an ultimate limit state, the calculation shall model as closely as
possible the failure mechanism, which is envisaged. When checking against a
serviceability limit state, a settlement calculation shall be used;
(b)
an indirect method using comparable experience and the results of field or laboratory
measurements or observations, and chosen in relation to serviceability limit state loads
so as to satisfy the requirements of all relevant limit states;
(c)
a prescriptive method in which a presumed bearing resistance is used.
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(a)
The design of shallow foundations on rock shall take account of the following features:
the deformability and strength of the rock mass and the permissible settlement of the
supported structure;
(b)
the presence of any weak layers, for example solution features or fault zones, beneath
the foundation;
(c)
the presence of bedding joints and other discontinuities and their characteristics (for
example filling, continuity, width, spacing);
(d)
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3.4.11
disturbance of the natural state of the rock caused by construction activities, such as,
for example, underground works or slope excavation, being near to the foundation.
(e)
the state of weathering, decomposition and fracturing of the rock;
Shallow foundations on rock may normally be designed using the method of presumed
bearing pressures. For strong intact igneous rocks, gneissic rocks, limestone and
sandstones, the presumed bearing pressure are limited by the compressive strength of the
concrete foundation.
The settlement of a foundation may be assessed on the basis of comparable experience

related to rock mass classification.
END OF PART
QCS 2014

Part
Page 1
DEEP FOUNDATIONS ............................................................................................ 4
4.1
4.1.1
4.1.2
4.1.3
4.1.4
4.1.5
4.1.6
4.1.7
4.1.8
4.1.9
PRECAST REINFORCED AND PRESTRESSED CONCRETE PILES .................... 4

General
4
4
4
5
Prestressing
7
Driving Piles
8
Risen Piles
10
10
10
4.2
4.2.1
4.2.2
4.2.3
4.2.4
4.2.5
4.2.6
4.2.7
4.2.8
4.2.9
4.2.10
4.2.11
PRECAST REINFORCED CONCRETE SEGMENTAL PILES............................... 10

Scope
10
References
11
Submittals
11
Quality Assurance
11
11
12
12
Driving piles
13
Risen Piles
14
15
15
4.3
4.3.1
4.3.2
4.3.3
4.3.4
4.3.5
4.3.6
BORED CAST IN PLACE PILES ........................................................................... 15

Scope
15
References
16
Quality Assurance
16
Materials
16
Boring
17
19
4.4
4.4.1
4.4.2
4.4.3
4.4.4
4.4.5
BORED PILES CONSTRUCTED USING CONTINUOUS FLIGHT AUGERS AND

CONCRETE OR GROUT INJECTION TROUGH HOLLOW AUGER STEMS ....... 21
Scope
21
Materials
21
Boring
22
23
23
4.5
4.5.1
4.5.2
4.5.3
4.5.4
4.5.5
4.5.6
DRIVEN CAST IN PLACES PILES ........................................................................ 23

Scope
23
Submittals
24
Quality Assurance
24
Materials
24
Driving piles
25
Risen Piles
26
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Page 2
26
4.6
4.6.1
4.6.2
4.6.3
4.6.4
4.6.5
4.6.6
4.6.7
4.6.8
4.6.9
4.6.10
4.6.11
STEEL PILES ........................................................................................................ 28

Scope
28
References
28
Submittals
28
Quality Assurance
28
29
Materials
29
30
31
Driving of piles
31
Risen Piles
33
33
4.7
MICROPILES (TO BE ADDED LATER) ................................................................. 33
4.8
4.8.1
4.8.2
4.8.3
4.8.4
4.8.5
REDUCTION OF FRICTION ON PILES ................................................................ 33

Scope
33
Submittals
33
33
Inspection
34
Driving resistance
35
4.9
4.9.1
4.9.2
4.9.3
4.9.4
4.9.5
4.9.6
4.9.7
4.9.8
PILE LOAD TESTING ........................................................................................... 35

35
45
47
48
48
48
Lateral Load Test
48
48
4.10
4.10.1
4.10.2
4.10.3
DESIGN METHODS AND DESIGN CONSIDERATIONS ...................................... 51

Design method
51
51
51
4.11
4.11.1
4.11.2
4.11.3
4.11.4
4.11.5
4.11.6
4.11.7
4.11.8
4.11.9
4.11.10
AXIALLY LOADED PILES ..................................................................................... 52

Limit state design
52
53
54
55
56
56
56
57
57
Ultimate tensile resistance from ground test results
57
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4.5.7
QCS 2014

Part
Page 3

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TRANSVERSELY LOADED PILES ....................................................................... 58

Design method
58
59
Transverse load resistance from ground test results and pile strength parameters 59
60
4.12
4.12.1
4.12.2
4.12.3
4.12.4
58
58
58
QCS 2014

Part
Page 4
DEEP FOUNDATIONS
4.1
PRECAST REINFORCED AND PRESTRESSED CONCRETE PILES
4.1.1
General
The provisions of this Part apply to end-bearing piles, friction piles, tension piles and
transversely loaded piles installed by driving, by jacking, and by screwing or boring with or
without grouting.
4.1.2
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(b)
bearing resistance failure of the pile foundation;
(c)
Uplift or insufficient tensile resistance of the pile foundation;
(d)
Failure in the ground due to transverse loading of the pile foundation;
(e)
Structural failure of the pile in compression, tension, bending, buckling or shear;
(f)
combined failure in the ground and in the pile foundation;
(g)
combined failure in the ground and in the structure;
(h)
Excessive settlement;
(i)
Excessive heave;
(j)
Excessive lateral movement;
(k)
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(a)
Scope
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This Part applies to precast concrete driven piles usually supplied for use in a single
length without facility for joining lengths together.
(a)
4.1.3
(b)
2
References
(a)

3
Submittals
(a)
Engineer's approval before placing the order. When preliminary piles are specified,
the approval of the piles for the main work will not necessarily be given until the results
of the driving and loading tests on preliminary piles have been received and evaluated.
QCS 2014
Page 5
Quality Assurance
(a)

Part
After a pile has been cast, the date of casting, reference number, length and, where
appropriate, the prestressing force shall be clearly inscribed on the top surface of the
pile and also clearly and indelibly marked on the head of the pile. Lifting positions shall
be marked at the proper locations on each pile.

(a)
The cross-sectional dimensions of the pile shall be not less than those specified and
shall not exceed them by more than 6 mm. Each face of a pile shall not deviate by
more than 6 mm from any straight line 3 m long joining two points on that face, nor
shall the centre of area of the pile at any cross section along its length deviate by more
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than 1/500 of the pile length from a line joining the centres of area at the ends of the
pile. Where a pile is less than 3 m long, the permitted deviation from straightness shall
Handling, Transportation and Storage of Piles
The method and sequence of lifting, handling, and storage of piles transporting and
storing piles shall be such as to avoid shock loading and to ensure that the piles are
not damaged. Only the designated lifting and support points shall be used. During
transport and storage, piles shall be appropriately supported under the marked lifting
points or fully supported along their length.
(b)
All piles within a stack shall be in groups of the same length. Packing of uniform
(c)
Concrete shall at no time be subjected to loading, including its own weight, which will
induce a compressive stress in it exceeding 0.33 of its strength at the time of loading
or of the specified strength, whichever is the lesser. For this purpose the assessment
of the strength of the concrete and of the stresses produced by the loads shall be
subject to the agreement of the Engineer.
(d)
Pile may be rejected when the width of any transverse crack exceeds 0.3 mm. The
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(a)
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be reduced below 6 mm on a pro rata basis in accordance with actual length.
measurement shall be made with the pile in its working attitude.
4.1.4
(a)
Pile Toes
(a)
In the manufacture of precast concrete piles, fabricated steel components shall comply
with BS 7613 grades 43A or 50B, cast steel components with BS 3100 grade A, and
ductile iron components with BS 2789.
during installation. Where positional fixity is required on an inclined rock surface or in
other circumstances, an approved shoe may be required.

(a)
The head of each pile shall be so reinforced or banded as to prevent bursting of the
pile under driving conditions.
QCS 2014

Part
Page 6
Main Reinforcement
(a)
The main longitudinal reinforcing bars in piles not exceeding 12 m in length shall be in
one continuous length unless otherwise specified. In piles more than 12 m long, lap
splicing will be permitted in main longitudinal bars at 12 m nominal intervals, with no
more than 25 % of the bars lapped at one location, and laps staggered by a minimum
of 1.2 m. Laps in reinforcement shall be such that the full strength of the bar is
effective across the joint.
Lap or splice joints shall be provided with sufficient link bars to resist eccentric forces.
(c)
Sufficient reinforcement shall be provided for lifting and handling purposes.
Unless otherwise agreed by the Engineer, concrete shall be compacted with the
assistance of vibrators. Internal vibrators shall be capable of producing not less than
150 Hz and external vibrators not less than 50 Hz. Internal vibrators shall operate not
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(a)
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Concrete
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closer than 75 mm to shuttering.
Vibrators shall be operated in such a manner that neither segregation of the concrete
mix constituents nor displacement of reinforcement occurs.
(c)
Immediately after compaction, concrete shall he adequately protected from the harmful
effects of the weather, including wind, rain, rapid temperature changes and frost. It
shall be protected from drying out by an approved method of curing.
(d)
Piles shall not be removed from formwork until a sufficient pile concrete strength has
been achieved to allow the pile to be handled without damage.
(e)
The period of curing at an ambient temperature of 10 C shall not be less than that
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(b)
shown in Table 4.1. If the temperature is greater or less than 10 C, the periods given
When steam or accelerated curing is used the curing procedure shall be approved.
Four hours must elapse from the completion of placing concrete before the
temperature is raised. The rise in temperature within any period of 30 min shall not
exceed 10 C and the maximum temperature attained shall not exceed 70 C. The rate
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(f)
shall be adjusted accordingly and shall be approved.
(b)
of subsequent cooling shall not exceed the rate of heating.

Table 4.1
Period of Curing at 10 C
Type of cement
Wet curing time after

completion of placing concrete, d
Ordinary Portland
Sulphate-resisting Portland
Portland blast-furnace
Super-sulphated
Rapid-hardening Portland
QCS 2014

Part
Page 7
Formwork
(a)
shaped point or shoe, then the end of the pile shall be symmetrical about the
longitudinal axis of the pile. Holes for handling or pitching, where provided in the pile,
shall be lined with steel tubes; alternatively, approved inserts may be cast in.
(b)

aggregate from the wet concrete and ensure the production of uniform pile sections,
free from defects. The piles are to be removed from the formwork carefully so as to
prevent damage.
4.1.5
Prestressing
General
Tensioning shall be carried out only when the Engineer is present, unless otherwise
approved. In cases where piles are manufactured off site, the Contractor shall ensure
that the Engineer is given adequate notice and every facility for inspecting the
(b)
Prestressing operations shall be carried out only under the direction of an experienced
and competent supervisor. All personnel operating the stressing equipment shall have
been trained in its use.
(c)
The calculated extensions and total forces, including allowance for losses, shall be
agreed with the Engineer before stressing is commenced.
(d)
Stressing of tendons and transfer of prestress shall be carried out at a gradual and
steady rate. The force in the tendons shall be obtained from readings on a recently
calibrated load cell or pressure gauge incorporated in the equipment. The extension of
the tendons under the agreed total forces shall be within 5 % of the agreed calculated
extension.
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Concrete Strength
The Contractor shall cast sufficient cubes, cured in the same manner as the piles, to
be able to demonstrate by testing two cubes at a time, with approved intervals between
pairs of cubes, that the specified transfer strength of the concrete has been reached.
(b)
(a)
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(a)
Post-Tensioned Piles
(a)
Unless otherwise permitted, concrete shall not be stressed until two test cubes attain
the specified transfer strength.
Ducts and vents in post-tensioned piles shall be grouted after the transfer of prestress.
Grouting Procedure
(a)
Grout shall be mixed for a minimum of 2 min and until a uniform consistency is
obtained.
(b)
Ducts shall not be grouted when the air temperature in the shade is lower than 3 C.
(c)
Before grouting is started all ducts shall be thoroughly cleaned by means of

compressed air.
(d)
Grout shall be injected near the lowest point in the duct in one continuous operation
and allowed to flow from the outlet until the consistency is equivalent to that of the
grout being injected.
(e)
Vents in ducts shall be provided in accordance with Clause 8.9.2 of BS 8110.
QCS 2014
Page 8
Grout
(a)
Unless otherwise directed or agreed by the Engineer

(i)
the grout shall consist only of ordinary Portland cement, water and approved
admixtures; admixtures containing chlorides or nitrates shall not be used
(ii)
the grout shall have a water/cement ratio as low as possible consistent with the
necessary workability, and the water/cement ratio shall not exceed 0.45 unless
an approved mix containing an expanding agent is used
(iii)
the grout shall not be subject to bleeding in excess of 2 % after 3 h, or in excess

of 4% maximum, when measured at 18 C in a covered glass cylinder
approximately 100 mm in diameter with a height of grout of approximately 100
mm, and the water shall be reabsorbed after 24 h.
Records
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Part
The Contractor shall keep detailed records of times of tensioning, measured

extensions, pressure gauge readings or load cell readings and the amount of pull-in at
each anchorage. Copies of these records shall be supplied to the Engineer within
such reasonable time from completion of each tensioning operation as may be
required, and in any case not later than noon on the following working day.
(b)
The Contractor shall keep records of grouting, including the date, the proportions of
the grout and any admixtures used, the pressure, details of interruption and topping up
required. Copies of these records shall be supplied to the Engineer within such
reasonable time after completion of each grouting operation as may be required, and
in any case not later than noon on the following working day.
Driving Piles
Strength of Piles
(a)
Piles shall not be driven until the concrete has achieved the specified strength.
occur.
(a)
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(a)

(a)
energy of the driving equipment. Where designated, dynamic evaluation and analysis
shall be provided.
(b)
such a manner as to cause instability of the craft or damage to the pile.
Length of Piles
(a)
The length of pile to be driven in any location shall be approved prior to the
commencement of driving.
QCS 2014

Part
Page 9

(a)
the pile will be accepted provided it can subsequently be driven to the specified depth
or resistance (set), or both, without damage. A follower shall not be used unless
approved, in which case the Engineer will require the set where applicable to be
revised in order to take into account reduction in the effectiveness of the hammer blow.
(b)
(c)
At the start of the work in a new area or section, a detailed driving record shall be
made over the full length of the first pile and during the last 3 m of subsequent piles
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until consistency of behaviour is established. Where required, detailed driving records

shall also be made for 5 % of the piles driven, the locations of such piles being
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(e)
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Final Set
(a)
penetration in millimetres per 10 blows or as the number of blows required to produce
(b)
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(d)
The exposed part of the pile shall be in good condition without damage or
distortion.
(ii)
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(i)
(iii)
(iv)
(v)
The temporary compression of the pile shall be recorded, if required.
Preboring
(a)
be flat and at right angles to the pile and hammer axis, and the head of the pile
protected against damage from hammer impact.
Jetting
(a)
approved.
QCS 2014
Page 10
Risen Piles
(b)
(c)
unimpaired. If required, the Contractor shall make proposals for correcting
detrimentally affected piles and for avoidance or control of heave effects in subsequent
work.
4.1.8
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out such repair in an approved way which allows the pile-driving to be completed
load.
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Lengthening of Reinforced and Prestressed Concrete Piles

Any provision for lengthening piles incorporated at the time of manufacture shall be as
designed or approved.
(b)
If no provision for lengthening piles was incorporated at the time of manufacture, any
method for lengthening shall be such that splices are capable of safely resisting the
stresses during driving and under service load and shall be subject to approval.
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(a)
Driving Repaired or Lengthened Piles

Repaired or lengthened piles shall not be driven until the added concrete has reached
the specified strength of the concrete of the pile.
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(a)
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(a)
(a)
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4.1.7

Part
Unless otherwise directed by the Engineer, when the driving of a pile has been approved the
concrete of the head of the pile shall be cut off to the designated level. The length of splice
reinforcing bars projecting above this level shall be as designated.
4.2
PRECAST REINFORCED CONCRETE SEGMENTAL PILES
4.2.1
Scope
This Part applies to piles made of elements cast at a precasting works away from the site,
where work cannot normally be closely supervised by the Engineer. The elements are joined
together as necessary on site during driving using special proven steel joints incorporated
into the pile elements when cast.
4.1.9
QCS 2014

Part
Page 11

This Section
Section 5,
Concrete.
4.2.2
References

Eurocode 7, EN1997-1, Section 7 Pile foundation
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Submittals
Engineer's approval before placing the order. When preliminary piles are specified the
approval for the piles for the main work will not necessarily be given until the results of the
driving and tests on preliminary piles have been received and evaluated.
4.2.4
Quality Assurance
A certificate of quality from the pile manufacturer shall be provided to the Engineer when
required stating that the designated requirements have been fulfilled during manufacture.
Each pile element shall be marked in such a manner that it can be identified with the records
of manufacture, which shall state the date of casting, the cement type, concrete grade,
element length and any other relevant data. On delivery, the pile elements shall be
accompanied by records of manufacture.
4.2.5
The cross-sectional dimensions of the pile shall be not less than those designated.
The head of a pile element or the end of the pile upon which the hammer acts shall be
square to the pile axis within a tolerance of 1 in 50.
Each pile joint shall be square to the axis of the pile within a tolerance of 1 in 150. The
centroid of the pile joint shall lie within 5 mm of the true axis of the pile element.
Each face of a pile element shall not deviate by more than 6 mm from any straight line 3 m
long joining two points on that face, nor shall the centre of area of the pile at any crosssection along its length deviate by more than 1/500 of the pile length from a line joining the
centres of area at the ends of the element. Where a pile element is less than 3 m long the
permitted deviation from straightness shall be reduced below 6 mm on a pro rata basis in
accordance with actual length.
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4.2.3
QCS 2014

Part
Page 12
The method and sequence of lifting, handling, transporting and storing piles shall be such as
to avoid shock loading and to ensure that the piles are not damaged. Only designed lifting
and support points shall be used. During transport and storage, piles shall be appropriately
supported under the marked lifting points or fully supported along their length.
All pile elements within a stack shall be in groups of the same length. Packing of uniform
Concrete shall at no time be subjected to loading, including its own weight, which will induce
a compressive stress in it exceeding 0.33 of its strength at the time of loading or of the
specified strength, whichever is the less. For this purpose the assessment of the strength of
the concrete and of the stresses produced by the loads shall be subject to the approval of the
Engineer.
A pile element shall be rejected when the width of any transverse crack exceeds 0.3 mm.
The measurement shall be made with the pile in its working attitude.
4.2.7
ta
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In the manufacture of jointed precast concrete segmental piles, fabricated steel

components shall comply with BS 7613 grades 43A or 50A, cast steel components
with BS 3100 grade A, and ductile iron components with BS 2789.
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Pile Splices
(a)
The splice joints shall be close-fitting face to face and the locking method shall be
such as to hold the faces in intimate contact. The design and manufacture of the
splicing system shall be approved by the Engineer prior to the commencement of the
Contract.
(b)
A spliced pile shall be capable of withstanding the same driving stresses or service
axial loads, moments and shear stresses as a single unspliced pile of the same crosssectional dimensions and materials.
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4.2.6
(c)
Pile Toes
(a)
during installation. Where fixity is required or socketing into rock, or in other
circumstances, an approved shoe may be required.

(a)
The welding of a joint to main reinforcement in lieu of a lapped connection with

projecting bars affixed to the joint will not be permitted.
Where the pile head is not furnished with a joint, it shall be so reinforced or banded as
to prevent bursting of the pile under driving conditions.
Main Reinforcement
(a)
The main longitudinal reinforcing bars shall be in one continuous length. Splicing of
bars will not be permitted except at element ends.
QCS 2014
Page 13
(b)
Concrete cover to steel reinforcement shall be in accordance with the requirements of

BS 8110.
(c)
In very aggressive ground or exposure conditions, cover greater than 25 mm may be

required, but alternative protection methods may be approved.
Formwork
(a)
If a pile is constructed with a shaped point or shoe, then the end of the pile shall be
symmetrical about the longitudinal axis of the pile.
(b)
Holes for handling or pitching, where provided in the pile, shall be lined with steel
tubes; alternatively, approved inserts may be cast in.
(c)

aggregate from the wet concrete and ensure the production of uniform pile sections.
The piles are to be removed from the formwork carefully so as to prevent damage.
Driving piles
Strength of Piles
occur.
energy of the driving equipment. Where required in the particular specification,
dynamic evaluation and analysis shall be provided.
the pile at the moment of driving unless otherwise approved by the Engineer. For
other types of hammer, the energy delivered to the pile per blow shall be at least
equivalent to that of a drop hammer of the stated mass. Drop hammers shall not be
used from floating craft in such a manner as to cause instability of the craft or damage
to the pile.
(b)
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(a)
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Piles shall not be driven until the concrete has achieved the specified characteristic
strength.
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(a)
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4.2.8
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Part
Length of Piles
(a)
The length of pile supplied to be driven in any location and any additional lengths to be
added during driving shall he approved prior to the commencement of pile-driving.
During the execution of the Works, any changes to the supplied lengths shall be
approved.
QCS 2014
Page 14

(a)
Except when making field splices, the driving of each pile shall he continuous until the
specified depth or resistance (set), or both, has been reached. In the event of
unavoidable interruption to driving, the pile will be accepted provided it can
subsequently be driven to the specified depth or resistance (set), or both, without
damage. A follower shall only be used when approved, in which case the Engineer will
require the set where applicable to be revised in order to take into account reduction in
the effectiveness of the hammer blow.
(b)
(c)
over the full length of the first pile and during the last 3 m of subsequent piles until
consistency of behaviour is established. Where required, detailed driving records shall
also be made for 5 % of the piles driven, the positions of such piles being specified by
the Engineer.
(d)
(e)
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Final Set
(b)
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(a)
distortion.
(ii)
(iii)
(i)
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Part
(v)
The temporary compression of the pile shall be recorded if required.
Jetting
(a)
4.2.9
Preboring
(a)
(iv)
approved.
Risen Piles
(a)

QCS 2014

Part
Page 15
(b)
(c)
unimpaired. If required, the Contractor shall make proposals for correcting piles
detrimentally affected and for avoidance or control of heave effects in subsequent
work.
4.2.10

out such repair in an approved way which allows the driving of the pile to be completed
load.
Where piles are required to be driven to depths exceeding those expected, leaving
insufficient projection for bonding into the following works, the piles shall be extended
or replaced as required by the Engineer using approved materials and methods.
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(a)
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Lengthening of Piles
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(a)
Unless otherwise specified, when the driving of a pile has been approved the concrete of the
head of the pile shall be cut off to the designated level. The length of splice reinforcing bars
projecting above this level shall be as designated.
4.3
BORED CAST IN PLACE PILES
4.3.1
Scope
This Part applies to bored piles in which the pile bore is excavated by rotary or percussive
means, or both, using short augers, buckets, grabs or other boring tools to advance the open
bore. Where the open bore is unstable, temporary or permanent casing or bentonite
suspension may be used to support the wall of the bore prior to concreting.
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4.2.11
This Section
Section 3, Ground Investigation
Section 5, Concrete
QCS 2014

Part
4.3.2
References
The following codes of practice are referred to in this Part:
Page 16
BS 5573,.....................Code of practice for safety precautions in the construction of large

diameter boreholes for piling and other purposes
BS 5930,.....................Code of practice for site investigation.
4.3.3
Quality Assurance
Inspection
directly or indirectly prior to concrete being placed in it. This inspection shall be carried
out from the ground surface in the case of piles of less than 750 mm diameter.
Torches or other approved means of lighting, measuring tapes, and a means of
measuring verticality shall be provided. For piles of 750 mm diameter or larger,
equipment shall be provided, by the Contractor to enable his representatives and the
Engineer to descend into the bore for the purpose of inspection. Any method of
descent and the equipment used shall comply with the requirements of BS 5573.
Cleanliness of pile bases
On completion of boring and where inspection of a dry pile bore indicates the
necessity, loose, disturbed or softened soil shall be removed from the bore. Where
pile bores contain water or drilling fluid, a cleaning process shall be employed before
concrete is placed. Large debris and accumulated sediment shall be removed using
appropriate approved methods, which shall be designed to clean while at the same
time minimising ground disturbance below the pile bases. Water or drilling fluid shall
be maintained at such levels throughout and following the cleaning operation that
stability of the bore is preserved.
Samples and Testing
The taking of samples and all subsequent handling, transporting and testing shall be
carried out in accordance with Section 3, Ground Investigation.
(b)
If required in the Contract, soil, rock or groundwater samples shall be taken or soil
tests carried out in-situ while the pile is being bored. The samples shall be taken to an
approved laboratory for testing as specified.
(a)
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(a)
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(a)
4.3.4
Materials
Permanent Casings
(a)
Permanent casings shall be as specified.
Drilling Fluid Supply

(a)
A certificate shall be obtained by the Contractor from the manufacturer of the bentonite
powder showing the properties of each consignment delivered to the Site. This
certificate shall be made available to the Engineer on request. The properties to be
given by the manufacturer are the apparent viscosity range (in Pascal seconds) and
the gel strength range (in Pascal) for solids in water.
QCS 2014
Page 17
Drilling Fluid Mixing

(a)
Bentonite shall be mixed thoroughly with clean fresh water to make a suspension
which will maintain the stability of the pile bore for the period necessary to place
concrete and complete construction. The temperature of the water used in mixing the
bentonite suspension, and of the suspension when supplied to the borehole, shall be
not lower than 5 C.
(b)
Where saline or chemically contaminated groundwater occurs, special precautions

shall be taken to modify the bentonite suspension or prehydrate the bentonite in fresh
water so as to render it suitable in all respects for the construction of piles.
Drilling Fluid Tests

(a)
The frequency of testing drilling fluid and the method and procedure of sampling shall
be proposed by the Contractor for approval prior to the commencement of the work.
The frequency may subsequently be varied as required, depending on the consistency
of the results obtained, subject to approval.
(b)
Control tests shall be carried out on the bentonite suspension, using suitable
apparatus. The density of freshly mixed bentonite suspension shall be measured daily
as a check on the quality of the suspension being formed. The measuring device shall
be calibrated to read to within 0.005 g/ml. Tests to determine density, viscosity, shear
strength and pH value shall be applied to bentonite supplied to the pile bore. For
average soil conditions the results shall generally be within the ranges in Table 4.2.
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Part
Table 4.2.Tests on Bentonite
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Viscosity
Less than 1.10 g/ml
Mud density balance
30 - 90 s
or
less than 0.020 Pa s
Marsh cone method
1.4-10 Pa
Or
4-40 Pa
Shear meter
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9.5 - 12
Fann viscometer*
Fann viscometer
pH indicator paper strips
or electrical pH meter
Where the Fann viscometer is specified, the fluid sample should be screened by a
number 52 sieve (300 m) prior to testing.
Shear strength
(10 minute gel strength)
pH
Test method
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Density
Range of results at 20 C
as
Property to be measured
(c)
The tests shall be carried out until a consistent working pattern has been established
account being taken of the mixing process, any blending of freshly mixed bentonite
suspension and previously used bentonite suspension, and any process which may be
used to remove impurities from previously used bentonite suspension. When the
results show consistent behaviour, the tests for shear strength and pH value may be
discontinued, and tests to determine density and viscosity shall be carried out as
agreed with the Engineer. In the event of a change in the established working pattern,
tests for shear strength and pH value shall be reintroduced for a period if required.
4.3.5
Boring

(a)
Piles shall not be bored so close to other recently completed piles as to damage them.
QCS 2014
Page 18
Temporary Casings
(a)
Temporary casing of approved quality or an approved alternative method shall be used

to maintain the stability of a pile bore which might otherwise collapse.
(b)
cross-section throughout each continuous length. During concreting they shall be free
from internal projections and encrusted concrete which might adversely affect the
(c)
The use of a vibrator to insert and withdraw temporary casing may be permitted by the
Engineer subject to compliance with Noise and Disturbance and Damage to Adjacent
Structures of this section and to the method not causing disturbance of the ground
which would adversely affect the construction or the capacity of piles.
(d)
Where piles are bored under water or bentonite suspension in an unlined state, the
insertion of a full-length loosely fitting casing to the bottom of the bore prior to placing
concrete will not be permitted.
(e)
Where permanent casing is specified to ensure the integrity of a pile, the Contractor
shall submit for approval his proposals regarding the method of installation.
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Stability of Pile
Where boring takes place through unstable water-bearing strata, the process of
excavation and the depth of temporary casing employed shall be such that soil from
outside the area of the pile is not drawn into the pile section and cavities are not
created outside the temporary casing as it is advanced.
(b)
Where the use of drilling fluid is specified or approved for maintaining the stability of a
bore, an adequate temporary casing shall be used in conjunction with the method so
as to ensure stability of the strata near ground level until concrete has been placed.
During construction the level of drilling fluid in the pile excavation shall be maintained
within the cased or stable bore so that it is not less than 1.0 m above the level of
external standing groundwater at all times.
(c)
In the event of a rapid loss of drilling fluid from a pile excavation, the bore shall be
backfilled without delay and the instructions of the Engineer shall be obtained before
boring at that location is resumed.
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Part
Spillage and Disposal of Drilling Fluid

(a)
Pumping from Pile Bores

(a)
All reasonable steps shall be taken to prevent the spillage of bentonite suspension on
the Site in areas outside the immediate vicinity of boring. Discarded bentonite shall be
removed from the Site without undue delay. Any disposal of bentonite shall comply
with the regulations of the local controlling authority.
Pumping from pile bores shall not be permitted unless the bore has been sealed
against further water entry by casing or unless the soil is stable and will allow pumping
to take place without ground disturbance below or around the pile.
Continuity of Construction
(a)
For a pile constructed in a stable cohesive soil without the use of temporary casing or
other form of support, the pile shall be bored and the concrete shall be placed without
such delay as would lead to significant impairment of the soil strength.
QCS 2014

Part
Enlarged Pile Bases

(a)
A mechanically formed enlarged base shall be no smaller than the dimensions

specified and shall be concentric with the pile shaft to within a tolerance of 10 % of the
shaft diameter. The sloping surface of the frustum forming the enlargement shall make
an angle to the axis of the pile of not more than 35 .
4.3.6
(a)
sufficiently workable to ensure that the concrete is not lifted. During extraction the
motion of the casing shall be maintained in an axial direction relative to the pile.
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Concrete Level

maintained within it to ensure that pressure from external water, drilling fluid or soil is
exceeded and that the pile is neither reduced in section nor contaminated.
(b)
The concrete level within a temporary casing shall be topped up where necessary
during the course of casing extraction in such a way that the base of the casing is
always below the concrete surface until the casting of the pile has been completed.
(c)
Adequate precautions shall be taken in all cases where excess heads of water or
drilling fluid could occur as the casing is withdrawn because of the displacement of
water or fluid by the concrete as it flows into its final position against the walls of the
pile bore. Where two or more discontinuous lengths of casing (double casing) are
used in the construction the proposed method of working shall be approved.
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(a)
For piles cast in dry bores using temporary casing and without the use of a permanent
lining, pile heads shall be cast to a level above the specified cut-off so that, after
trimming, a sound concrete connection with the pile can be made. The casting level
above the original ground level. No pile shall be cast with its head below standing
water level unless approved measures are taken to prevent inflow of water causing
segregation of the concrete as temporary casing is extracted, and, where approved by
the Engineer, the groundwater level for each pile shall be treated as the cut-off level for
the purpose of calculating tolerance.
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Pile Head Casting Level Tolerances
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Page 19
(b)
For piles cast in dry bores within permanent lining tubes or permanent casings, or
where their cut-off levels are in stable ground below the base of any casing used, pile
heads shall be cast to a level above the specified cut-off so that, after trimming, a
sound concrete connection with the pile can be made. The casting level shall be within
the tolerance above the cut-off level shown in Table 4.4, but shall not be above the
original ground level.
QCS 2014

Part
Page 20
(c)
For piles cast under water or drilling fluid, the pile heads shall be cast to a level above
the specified cut-off so that, after trimming to remove all debris and contaminated
concrete, a sound concrete connection with the pile can be made. The casting level
above the commencing surface level. Cut-off levels may be specified below the
standing groundwater level, and where this condition applies the borehole fluid level
shall not be reduced below the standing groundwater level until the concrete has set.
(d)
Where the cut-off level of piles lies at depths greater than 10 m below the original
ground level, then the tolerances given in Tables 4.3, 4.4 and 4.5 will be varied after
discussion with the Contractor and before the commencement of the piling to take
account of the special conditions which apply.
Table 4.3
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H, m
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Casting Tolerance above Cut-off Level for Piles Cast In Dry Bores Using Temporary Casing
and Without the Use of a Permanent Lining
ta
0.3 + H/12 + C/8

below the commencing surface*
qa
0.15-10.00
*
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If H is greater than C, then this tolerance is no longer applicable and the tolerances in
Table 4.4 will apply.
Table 4.4
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Casting Tolerance above Cut-off Level for Piles Cast in Dry Bores within Permanent Lining
Tubes or Permanent Casings, or Where Their Cut-Off Levels is in Stable Ground below the
Base of Any Casing Used

H, m
0.3 + H/10
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0.15-10.00
Table 4.5
Casting Tolerance above Cut-off Level for Piles Cast Under Water or Drilling Fluid**
H, m
0.15-10.00
**
4
1.0 + H /12 + C/8

below the commencing surface
In cases where a pile is cast so that the cut-off is within a permanent lining tube, the appropriate
tolerance is given by deletion of the casing term C/8 in the table.
Water levels
(a)
During extraction of temporary casings, where circumstances are such that newly
placed unset concrete is brought into contact with external groundwater, precautions
shall be taken to ensure that the internal concrete pressure at all levels within the pile
exceeds the external groundwater pressure.
QCS 2014
After each pile has been cast, any empty bore remaining shall be protected and shall
be carefully backfilled as soon as possible with approved materials.
Disposal of excavated material

(a)
Page 21

(a)

Part
Disposal of excavated material shall be carried out by the Contractor as necessary to

facilitate the Works and to the satisfaction of the Engineer.

(a)
provide a full and sound section at the cut-off level
BORED PILES CONSTRUCTED USING CONTINUOUS FLIGHT AUGERS

AND CONCRETE OR GROUT INJECTION TROUGH HOLLOW AUGER
STEMS
4.4.1
Scope
This Part applies to bored piles which employ a continuous flight auger for both advancing
the bore and maintaining its stability. The spoil-laden auger is not removed from the ground
until concrete or grout is pumped into the pile bore from the base of the hollow-stemmed
auger to replace the excavated soil.
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4.4
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This Section
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Section 5, Concrete
Materials
Concrete Mix Design and Workability
4.4.2
(a)
Where not otherwise stated in this Part, the concrete shall comply with Section 5. The
design and workability of concrete to be used in the formation of a pile shall produce a
mix which is suitable for pumping. It shall have a minimum slump of 150 mm unless
3
otherwise approved and a minimum cement content of 340 kg/m . The mix shall be
designed so that segregation does not occur during the placing process, and bleeding
of the mix shall be minimised.
Grout Mix Design and Workability

(a)
Mix design of grout shall be subject to approval. Cement, water and aggregates for
grout shall be according to Section 5. Course aggregate to be used shall be of 6 mm
nominal size and shall be rounded and evenly graded.
QCS 2014
(b)

Part
The workability of grout mixes, where used, shall be measured by a suitable and
approved means. The procedure for monitoring the suitability of grout throughout the
Works shall be stated in writing to the Engineer before beginning of the Works and
shall be subject to approval.
(c)
Additives to the grout shall require prior approval of the Engineer.
Reinforcement
All reinforcement shall be placed with the minimum delay after the completion of the
concreting or grouting operation. It shall be designed and fabricated in cages to permit
it to be placed in the correct position and to the depth specified through the concrete or
grout of the pile. Suitable approved spacers shall be provided to maintain the specified
concrete or grout cover to steel.
(b)
The transverse reinforcement of any reinforcing cage shall be approved and may
consist of either spirals, hoops or links.
(c)
Longitudinal main steel reinforcement shall be continuous over the specified length.
Where splices are necessary, the number of laps shall be kept to a minimum and bars
shall be welded or joined together in an approved manner.
(d)
Reinforcement shall be supported and centred so that it will provide the required
projection above the cut-off level, and the proper concrete cover.
Boring
General
During uncased boring with continuous flight auger, the feed forward and speed
(revolutions per minute) are to be adjusted according to the soil conditions in a way
that the excavation of soil will be limited to a quantity that the lateral support of the
uncased borehole wall will be ensured.
Removal of Augers from the Ground
Piles shall not be bored so close to other piles which have recently been cast as to
damage them.
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(a)
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4.4.3
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(a)
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Page 22
(a)
Depth of Piles
(a)
Augers shall not be extracted from the ground during the boring or construction of a
pile in such a way that an open unsupported bore or inflow of water into the pile section
would result. While withdrawing the continuous flight auger, the auger shall be rotated
in the same direction as during drilling into the soil or shall be withdrawn without
rotation.
Any failure of a pile to reach the designated depth shall be reported to the Engineer
without delay and a full statement of the reasons given.
Suitability of Boring Equipment

(a)
The piles shall be bored using approved and suitable equipment capable of
penetrating the ground without drawing surrounding soils laterally into the pile bore.
QCS 2014

Part
4.4.4
Equipment for Supply of Concrete or Grout to Piles

(a)
Grout or concrete shall be supplied to the pile through suitable tubing and the hollow
auger stem. All pipe fitments and connections shall be so constructed that grout does
not leak during the injection process.
Commencement of Concrete or Grout Supply to Each Pile

(a)
The base of the auger stem shall be fitted with a suitable means of sealing it against
ingress of water and soil until concrete or grout placing begins.
(b)
At the beginning of concrete or grout placement this sealing device shall be removed
by the application of concrete or grout pressure. Care shall be taken to ensure that the
auger is lifted only sufficiently to initiate the flow of concrete or grout, and that water
inflow and soil movement at the base of the auger are minimised. The technique and
equipment used to initiate and maintain the concrete or grout flow shall be such that a
pile of the full specified cross-section is obtained from the maximum depth of boring to
the final pile cut-off level.
The concrete or grout shall be supplied to the pile at a sufficient rate during auger
withdrawal to ensure that a continuous monolithic shaft of the full specified crosssection is formed, free from debris or any segregated concrete or grout.
(b)
The rate of withdrawal of the auger, the injection pressures and the rate of supply of
concrete or grout shall be measured and recorded throughout the phase of auger
withdrawal for each pile.
(c)
The Contractor shall submit proposals for his method of monitoring construction for
approval before beginning the Works.
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Completion of Piles
If the concrete or grout placing in any pile cannot be completed in the normal manner,
then the pile shall be rebored before concrete has hardened and shall be completely
replaced.
(a)
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(a)
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Rate of Supply of Concrete or Grout
Casting Level of Pile Head

Concrete or grout shall be cast to the original ground level in all cases, and the
reinforcing cage set, as appropriate.
(a)
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Page 23
4.4.5
When cutting off and trimming piles to the specified cut-off level, the Contractor shall take
care to avoid shattering or otherwise damaging the rest of the pile. Any laitance, or
contaminated, cracked or defective concrete shall be cut away and the pile repaired in an
approved manner to provide a full and sound section up to the cut-off level.
4.5
DRIVEN CAST IN PLACES PILES
4.5.1
Scope
This Part applies to piles for which a permanent casing of steel or concrete is driven,
reinforcement placed within it if required, and the casing filled with concrete. It also applies to
piles in which a temporary casing is driven, reinforcement placed within it and the pile formed
in the ground by filling the temporary casing with concrete before and during its extraction.
QCS 2014

Part
Page 24

This Section
Section 5, Concrete
Submittals
Where the Contractor wishes to form a pile with an enlarged base, details of the proposed
method of forming the base and the materials to be used shall be submitted at the time of
tendering.
4.5.3
Quality Assurance
Before placing concrete in a pile casing, the Contractor shall check in an approved manner
that the casing is undamaged, and free from water or other foreign matter. In the event of
water or foreign matter having entered the pile casing, either the casing shall be withdrawn,
repaired if necessary and re-driven, or other action shall be taken as may be approved to
continue the construction of the pile.
4.5.4
Materials
Permanent Casings
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Permanent casings shall be as specified. Where a permanent casing is to be made

from a series of short sections it shall be designed and placed so as to produce a
continuous water-free shaft. The dimensions and quality of the casing shall be
adequate to withstand the stresses caused by handling and driving without damage or
distortion.
external cross-section throughout each continuous length. During concreting they
shall be free from internal projections and encrusted concrete which might prevent the
(a)
Temporary Casings
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4.5.2
Pile Shoes
(a)
Pile shoes shall be manufactured from durable material capable of withstanding the
stresses caused by driving without damage, and shall be designed to give a watertight
joint during construction.
Reinforcement
(a)
This type of pile shall normally be reinforced over its full length unless permanently
cased. The use of shorter reinforcement in piles which are not permanently cased
shall be subject to the approval of the Engineer.
(b)
The number of splices in longitudinal steel bars shall be kept to a minimum. The full
strength of each bar shall be effective across each splice, which shall be made so that
there is no detrimental displacement of the reinforcement during the construction of
the pile.
QCS 2014

Part
4.5.5
Driving piles
Piling Near Recently Cast Piles

(a)
Casings shall not be driven or piles formed so close to other piles which have recently
been cast as to damage them.

(a)
energy of the driving equipment
(b)
Drop hammers shall not be used from floating craft in such a manner as to cause
instability of the craft.
Length of Piles
Driving Procedure
(a)
Each pile casing shall be driven continuously until the specified or approved depth or
resistance (set), or both, has been reached. In the event of unavoidable interruption to
driving, the pile will be accepted provided on resumption the casing can be driven to
the specified depth or resistance (set), or both, without damage.
(b)
driving characteristics is encountered. A detailed record of the driving resistance over
the full length of the nearest available subsequent pile shall be taken if required.
(c)
over the full length of the first pile to be installed and over the last 3 m of the driving of
subsequent piles until consistency of behaviour is established. Where required,
detailed driving records shall also be made for 5 % of the piles driven, the positions of
such piles being specified by the Engineer.
(d)
The Contractor shall give adequate notice and provide all facilities to enable the
Engineer to check driving resistance. A set shall be taken only in the presence of the
Engineer unless otherwise approved.
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Final Set
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The length of pile to be driven in any location shall be approved.
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(a)
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Page 25
(a)
Where piles are driven to a set, the final set of each pile, pile shell or casing shall be
recorded either as the penetration in millimetres per ten blows or as the number of
blows required to produce a penetration of 25 mm.
(b)
(i)
The exposed part of the pile casing shall be in good condition, without damage
or distortion.
(ii)
The dolly, helmet and packing, if any, shall be in sound condition.
(iii)
(iv)
(v)
Temporary compression of the pile casing shall be recorded if required.
QCS 2014
If preboring is specified the pile casing shall be pitched after preboring to the
designated depth and diameter.
Jetting
(a)
Page 26
Preboring
(a)

Part
approved by the Engineer
Internal Drop Hammer

Where a casing for a pile without an enlarged base is to be driven by an internal drop
hammer, a plug consisting of concrete grade 20 with a water/cement ratio not
exceeding 0.25 shall be placed in the pile. This plug shall have a compacted height of
not less than 2.5 times the diameter of the pile. Fresh concrete shall be added to
ensure that this height of driving plug is maintained in the casing throughout the period
of driving, and in any event a plug of fresh concrete shall be added after 1.5 h of
normal driving or after 45 min of hard driving, or, should the driving of a pile be
interrupted for 30 min or longer, fresh concrete shall be added prior to driving being
resumed.
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(a)
Risen Piles
When required, levels and measurements shall be taken to determine the movement of the
ground or any pile resulting from the driving process.
When a pile has risen with detrimental effects as a result of adjacent piles being driven the
Contractor shall, if required, submit to the Engineer his proposals for correcting or
compensating for this and for avoidance or control of heave effects in subsequent work.
4.5.7
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4.5.6
(a)
sufficiently workable to ensure that the concrete is not lifted.
Concrete Level
(a)

maintained within it to ensure that pressure from external water or soil is exceeded and
that the pile is neither reduced in section nor contaminated.
(b)
Concrete shall be topped up as necessary while the casing is extracted until the
required head of concrete to complete the pile in a sound and proper manner has been
provided. No concrete is to be placed once the bottom of the casing has been lifted
above the top of the concrete.
Vibrating Extractors
(a)
The use of vibrating casing extractors will be permitted subject to Part 1 (Noise and
Disturbance) and (Damage to Adjacent Structures).
QCS 2014

Part
Page 27
Concrete Casting Tolerances

(a)
For piles constructed without the use of a rigid permanent lining, pile concrete shall be
cast to the original ground level.
(b)
Where piles are constructed inside rigid permanent lining tubes or permanent casings,
pile heads shall be cast to a level above the specified cut-off so that, after trimming, a
sound concrete connection with the pile can be made. In this case, the tolerance of
casting above the cut-off level shall be determined according to Table 4.6.
Table 4.6
Casting Tolerance above Cut-off Level for Piles Constructed Inside Rigid Permanent Lining
Tubes or Permanent Casings
Cut-off distance below original
ground, H, (m)
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Casting tolerance above cut-off level

(m)
2.2 + H/10
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Repair of damaged pile heads and making-up of piles to the correct level
When repairing or extending the head of a pile, the head shall be cut off square in
sound concrete, and all loose particles shall be removed by wire brushing, followed by
washing with water.
(b)
If the driving of a pile has been accepted but sound concrete of the pile is below the
cut-off level, the pile shall be made good to the cut-off level with concrete of a grade
not inferior to that of the concrete of the pile.
as
(a)
Lengthening of cast-in- place piles after driving

When it is required to extend a cast-in-place driven pile above ground, the materials to
be used and procedures to be adopted shall be subject to the approval of the
Engineer.
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0.15 to any depth
Lengthening of permanent pile casings during construction

The lengthening of permanent steel pile casings by adding an additional length of the
same steel casing during construction shall be carried out in accordance with the
relevant clauses of this Section or by other approved methods. The use of casing
extension materials and methods other than those specified shall be subject to
approval.
(a)

(a)
After each pile has been cast, any hole remaining shall be protected and shall be
carefully backfilled as soon as possible with approved materials.

(a)
provide a full and sound section to the cut-off level.
QCS 2014

Part
Page 28
4.6
STEEL PILES
4.6.1
Scope
This Part applies to driven steel piles designed to act as bearing piles.

This Section
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Section 5, Concrete
References
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4.6.2
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BS 4, ..........................Structural steel sections
BS 3100, ....................Steel casting for general engineering purposes.
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BS 5135, ....................Process of arc-welding of carbon and carbon manganese steels

BS 6265, ....................Resistance steam welding of uncoated and coated low carbon steel
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BS 7613, ....................Hot rolled quenched and tempered weldable structural steel plates
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API 5L,........................Interpretation of non-destructive testing.

Submittals
Where coatings are specified, the Contractor shall submit for approval full details of the
coating procedure and surface preparation according to relevant British or Swedish
Standards.
4.6.4
Quality Assurance
The Contractor shall provide the Engineer with Works test certificates, analyses, and mill
sheets, together with a tube manufacturer's certificate showing details of the pile number,
cast number of the steel and a record of all tests and inspections carried out. The Engineer
has the right to inspect any stage of the manufacturing processes and shall be given
adequate notice by the Contractor of such processes and production tests, provided that,
once he has been notified, any delay in his attendance does not cause delay to, or disrupt,
the manufacturing process. The Contractor shall provide the Engineer with samples for
independent testing when requested.
The Contractor shall submit for approval full details of the welding procedures and
electrodes, with drawings and schedules as may be necessary. Tests shall be undertaken as
may be required by the relevant British Standard or as may be required by the Engineer.
Only welders who are qualified in the approved welding procedure in accordance with the
tests laid down in the relevant British Standard, or who have a proven record over the
previous six months, or who have attained a similar standard, shall be employed on the
Works. Proof of welders' proficiency shall be made available to the Engineer on request.
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4.6.3
QCS 2014

Part
4.6.5
The Contractor shall

(a)
Order the piles to suit the construction programme.
(b)
Obtain the Engineer's approval before placing the order.
Page 29
When preliminary piles are specified, the approval for the piles for the main work will not
necessarily be given until the results of the driving and tests on preliminary piles have been
received and evaluated.
Each pile shall be clearly numbered and its length shown near the pile head using white
paint. In addition, before being driven, each pile shall be graduated at appropriate intervals
along its length and at intervals of 250 mm along the top 3 m.
All piles within a stack shall be in groups of the same length and on approved supports. All
operations such as handling, transporting and storing of piles shall be carried out in a manner
such that damage to piles and their coatings is minimised.
4.6.6
Materials
Pile Shoes
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Cast steel shoes shall be of steel to BS 3100, grade Al. Flat plate and welded
fabricated steel shoes shall be grade 43A or 50A, conforming to BS 7613 and related
standards.
Strengthening of Piles
The strengthening to the toe of a pile in lieu of a shoe or the strengthening of the head
of a pile shall be made using material of the same grade as the pile unless otherwise
approved.
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Manufacturing Tolerance
All piles shall be of the type and cross-sectional dimensions specified. For standard
rolled sections the dimensional tolerances and weight shall comply with the relevant
standard. The tolerance on length shall be -0 and +75 mm unless otherwise specified.
For proprietary sections the dimensional tolerances shall comply with the
manufacturer's standards. The rolling or manufacturing tolerances for proprietary
sections shall be such that the actual weight of section does not differ from the
theoretical weight by more than +4 % or -2 % unless otherwise agreed. The rolling
or manufacturing tolerances for steel tubular piles shall be such that the actual weight
of section does not differ from the theoretical weight by more than 5 %.
(a)
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Straightness of Piles
(a)
For standard rolled sections the deviation from straightness shall be within the
compliance provisions of BS 4, Part 1. When two or more rolled lengths are joined by
butt-jointing, the deviation from straightness shall not exceed 1/600 of the overall
length of the pile.
(b)
For proprietary sections made up from rolled sections, and for tubular piles, the
deviation from straightness on any longitudinal face shall not exceed 1/600 of the
length of the pile nor 5 mm in any 3 m length.
QCS 2014
Page 30
Fabrication of Piles
(a)
For tubular piles where the load will be carried by the wall of the pile, and if the pile will
be subject to loads that induce reversal of stress during or after construction, the
external diameter at any section as measured by using a steel tape on the
circumference shall not differ from the theoretical diameter by more than 1.
(b)
The ends of all tubular piles as manufactured shall be within a tolerance on ovality of
1 % as measured by a ring gauge for a distance of 100 mm at each end of the pile
length.
(c)
The root edges or root faces of lengths of piles that are to be shop butt-welded shall
not differ by more than 25 % of the thickness of pile walls not exceeding 12 mm thick
or by more than 3 mm for piles where the wall is thicker than 12 mm. When piles of
unequal wall thickness are to be butt-welded, the thickness of the thinner material shall
be the criterion.
Matching of Pile Lengths
Longitudinal seam welds and spiral seam welds of two lengths of tubular piles being
joined shall, whenever possible, be evenly staggered at the butt. However, if in order
to obtain a satisfactory match of the ends of piles or to meet specified straightness, the
seams cannot be staggered evenly, then they shall be staggered by at least 100 mm.
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Welding
Welding of H-piles and piles that will be subjected to stress reversal, during or after
construction, shall be in accordance with BS 5135.
(b)
For a tubular pile where the load will be compressive and non-reversible and will be
carried by the wall of the pile or by composite action with a concrete core, the welding
shall be to BS 5135 or BS 6265.
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(a)
Coating Piles for Protection against Corrosion

Where coatings are specified they shall be provided in accordance with the Particular
Specification. In general, coatings will not be called for where piles are fully in contact
with undisturbed natural soils or below the standing water table. Cathodic protection
may be called for when there is a possibility of stray electrical current from the
supported structure flowing to earth through the piles.
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Part
4.6.7
Acceptance Standards for Shop Welds

(a)
Longitudinal or spiral welds made in the manufacture of tubular piles are subject to the
acceptance standard for interpretation of non-destructive testing specified in latest
edition of API 5L. The maximum projecting height of weld reinforcement shall not
exceed 3 mm for wall thicknesses not exceeding 13 mm and 5 mm for wall
thicknesses greater than 13 mm.
(b)
Longitudinal welds joining the constituent parts of the box or proprietary section shall
be in accordance with the manufacturer's specification.
(c)
The maximum projecting height of weld reinforcement for circumferential welds in

tubular piles shall be the same as specified above for longitudinal welds in tubular
piles.
QCS 2014

Part
Page 31
Acceptance Standards for Site Butt Welds

(a)
Welds shall comply with the requirements of the Weld Quality Acceptance Standards
for Site Butt Welds in Steel Bearing Piles published by British Steel Corporation,
General Steels Group.
The finished coating shall be generally of smooth and uniform texture and free from sharp
protuberances or pin holes. Excessive sags, dimpling or curtaining will not be acceptable.
Any coat damaged by subsequent processes, or which has deteriorated to an extent such
that proper adhesion of the coating is in doubt, shall be removed and the surface shall be
cleaned to the original standard and recoated with the specified number and thicknesses of
coats.
The completed coating shall be checked for thickness by an approved magnetic thickness
gauge. Areas where the thickness is less than that specified shall receive approved
additional coating.
Average measured thickness should be equal to or greater than the specified thickness and
no single reading should be less than 85 % of the specified thickness. The completed
coating shall also be checked for adhesion by the cross-hatching method with lines spaced at
ten times the thickness of the coating. Adhesion tests should not be carried out prior to
seven days after coating.
The tests shall be made on 10 % of the piles. Areas where the adhesion is not approved
shall be sand blasted and recoated. The coating shall be approved before pitching and
driving of the piles.
4.6.9
Driving of piles
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At all stages during driving and until incorporation in the superstructure, the free length
of the pile shall be adequately supported and restrained by means of leaders, trestles,
temporary supports or other guide arrangements to maintain position and alignment
and to prevent buckling. In marine works, lengths which remain unsupported after
driving shall be adequately restrained until incorporated into the permanent Works.
These constraint arrangements shall be such that damage to piles and their coatings is
minimised.
(a)
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4.6.8

(a)
energy of the driving equipment. Where required in the Contract, dynamic evaluation
and analysis shall be provided.
(b)
such a manner as to cause instability of the craft.
QCS 2014
Length of Piles
(a)
The length of pile to be driven and any additional lengths of pile to be added during
driving shall be approved by the Engineer.

the pile will be accepted provided it can be driven to the specified depth or resistance
(set), or both, without damage.
(b)
A follower shall not be used unless approved, in which case the Engineer will require
the set where applicable to be revised in order to take into account reduction in the
effectiveness of the hammer blow.
(c)
The Contractor shall inform the Engineer as soon as an unexpected change in driving
characteristics is noted. A detailed record of the driving resistance over the full length
of the nearest subsequent pile shall be taken, if required by the Engineer.
(d)
At the start of the work in a new area or section a detailed record shall be made over
the full driving length of the first pile, and during the last 3 m of the driving of
subsequent piles, to establish the driving behaviour. Where required, detailed driving
records shall also be made for 5 % of the piles driven, the locations of such piles being
(e)
(f)
Redrive checks, if required, shall be carried out in accordance with an approved

procedure.
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(a)
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When a final set or resistance is being measured, the following requirements shall be
met:
(b)
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Final Set or Resistance
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Page 32
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Part
(i)
distortion.
(ii)
The dolly and packing, if any, shall be in sound condition.
(iii)
(iv)
The hammer shall be in good condition, delivering adequate energy per blow
(v)
The temporary compression of the pile shall be recorded, if required by the

Engineer.
Preboring
(a)
If preboring is specified the pile shall be pitched after preboring to the designated
depth and diameter.
QCS 2014

Part
Page 33
Jetting
(a)
approved.
Risen Piles
When required by the Engineer, levels and measurements shall be taken to determine the
movement of the ground or any pile resulting from the driving of adjacent piles.
When a pile has risen as a result of adjacent piles being driven, the Engineer may call for
redriving or other testing to demonstrate that the performance of the pile under load is
unimpaired. If required, the Contractor shall make proposals for correcting detrimentally
affected piles and for avoidance or control of heave in subsequent work.
4.6.11
If a steel superstructure is to be welded to piles, the pile cut-off shall be square and to within
5 mm of the elevations shown on the Drawings. If pile heads are to be encased in concrete
they shall be cut to that same tolerance and protective coatings shall be removed from the
surfaces of the pile heads down to a level 100 mm above the soffit of the concrete.
4.7
MICROPILES (TO BE ADDED LATER)
4.8
REDUCTION OF FRICTION ON PILES
4.8.1
Scope
This Part includes preapplied bituminous or other proprietary friction-reducing coating, preapplied low-friction sleeving, formed-in-place low-friction surround, and preinstalled lowfriction sleeving.
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4.6.10
This Section
4.8.2
Submittals
Where the particular method of reducing friction is not specified, the Contractor shall submit
full details of the method which he proposes.
4.8.3
General
(a)
Where a means of reducing friction on any specified length of pile is required by the
Contract, the Contractor shall provide a suitable interface between pile and soil by one
of the following, or other approved, methods
QCS 2014
Page 34
(i)
Preapplied bituminous or other proprietary friction-reducing coating.
(ii)
Preapplied low-friction sleeving.
(iii)
Formed-in-place low-friction surrounds.
(iv)
Preinstalled low-friction sleeving.
Preapplied Bituminous or other Friction-Reducing Coating Materials

(a)
Where a proprietary product is specified, the process of cleaning pile surfaces, and the
conditions and methods of application shall conform to the manufacturer's current
instructions. All materials shall conform to the manufacturer's specification, which
shall be given to the Engineer before any coating is applied.
(b)
Where a friction-reducing material has been applied to a preformed pile prior to

installation, it shall be protected from damage during handling and transportation. In
the event of inadvertent damage to the coating, it shall be repaired on site, prior to the
pile being driven, to the same specification as the original coating. Where bituminous
materials are involved, precautions shall be taken as necessary in hot weather to
prevent excessive flow or displacement of the coating. The coated piles shall be
adequately protected against direct sunlight and, if stacked, they shall be separated to
prevent their coatings sticking together.
(c)
In the case of applied coatings, the piles shall not be driven when the air temperature
is such that the coating will crack, flake or otherwise be damaged prior to entry into the
ground. Where bituminous materials are involved, driving shall be carried out while
the temperature is at or above 5 C unless otherwise approved or called for in the
Formed-In-Place Low-Friction Surround

Where a hole is bored in the ground and filled with low-friction material through which a
pile is subsequently driven or placed, the method and the properties of the low-friction
material both above and below standing groundwater level, together with the
dimensions of the prebored hole in relation to the pile, shall be approved by the
Engineer.
(a)
Piles may be driven with a preapplied low-friction sleeving subject to the approval of
the detailed design and method by the Engineer.
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Preapplied Low-Friction Sleeving
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Part
Preinstalled Low-Friction Sleeving

(a)
Where a system is employed involving placing a low-friction sleeve in the ground prior
to pile installation, the detailed materials and method of installation of the sleeving shall
be approved by the Engineer.
4.8.4
Inspection
The Engineer may call for piles to be partially exposed or extracted at the commencement of
a contract in order to demonstrate that the method of installation does not impair the
effectiveness of the system in the circumstances of use on the particular site. Where damage
is found to have occurred, or is likely to occur in the opinion of the Engineer, additional
measures or variation of the method may be called for. At the discretion of the Engineer,
further inspections shall be carried out to ascertain the effectiveness of the additional
measures.
QCS 2014

Part
Page 35
4.8.5
Driving resistance
Allowance shall be made in driving piles to a required resistance or set for any differences
between the short-term driving resistance and the long-term static resistance of the coating
or surrounding low-friction material which is in use.
4.9
PILE LOAD TESTING
4.9.1
Scope
This Part deals with the testing of a pile by the controlled application of an axial load. It
covers vertical and raking piles tested in compression (i.e. subjected to loads or forces
in a direction such as would cause the piles to penetrate further into the ground) and
vertical or raking piles tested in tension (i.e., subjected to forces in a direction such as
would cause the piles to be extracted from the ground).
References
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(a)
Allowable pile capacity: a load which is not less than the specified working load and
which takes into account the pile's ultimate bearing capacity, the materials from which
the pile is made, the required factor of safety, settlement, pile spacing, downdrag, the
overall bearing capacity of the ground beneath the piles and any other relevant factors.
The allowable pile capacity indicates the ability of a pile to meet the specified loading
requirements.
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Definitions
When required, the design and full details of the proposed load application system
shall be submitted to the Engineer prior to the commencement of testing. The load
application system shall be satisfactory for the required test.
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(a)
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Submittals
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BS 1881, ....................Methods of testing concrete.
(b)
Compression pile: a pile which is designed to resist compressive (downward) axial

load.
(c)
Constant rate of penetration (CRP) test: a test in which the pile is made to penetrate
the soil at a constant controlled speed, while the loads applied at the top of the pile in
order to maintain the constant rate of penetration are continuously measured. The
purpose of the test is to derive the ultimate bearing capacity of a pile and not its load
settlement characteristics.
(d)
Constant rate of uplift (CRU) test: the same in principle as the CRP test, but the pile is
subject to tension rather than compression. The purpose of the test is to determine
the 'pull-out' capacity of a pile.
(e)
Design verification load (DVL): a test load, in lieu of a specified working load, applied
to a single pile at the time of testing to determine that site conditions conform to design
assumptions. This load will be peculiar to each preliminary (test) pile and should equal
the maximum specified working load for a pile of the same dimensions and material,
plus allowances for soil-induced forces and any other particular conditions of the test.
QCS 2014
Page 36
Kentledge: ballast used in a loading test.
(g)
Maintained load test: a loading test in which each increment of load is held constant
either for a defined period of time or until the rate of settlement falls to a specified
value.
(h)
Preliminary pile: a test pile installed before the commencement of the main piling
works or a specific part of the Works for the purpose of establishing the suitability of
the chosen type of pile and for confirming its design, dimensions and bearing capacity.
(i)
Proof load: a load applied to a selected working pile to confirm that it is suitable for the
load at the settlement specified. A proof load should not normally exceed the design
verification load plus 50 % of the specified working load.
(j)
Raking pile: a batter pile, installed at an inclination to the vertical.
(k)
Reaction system: the arrangement of kentledge, piles, anchors or rafts that provides a
resistance against which the pile is tested.
(l)
Specified working load (SWL): the designated load on the head of a pile.
(m)
Tension pile: a pile which is designed to resist a tensile (upward) axial force.
(n)
Test pile: any pile, preliminary or part of the works, to which a test is applied.
(o)
Ultimate bearing capacity: the load at which the resistance of the soil becomes fully
mobilised through friction, end bearing or a combination thereof.
(p)
Working pile: one of the piles forming the foundation of a structure.
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(f)
Notice of Construction
(b)
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commencement of construction of any preliminary pile which is to be testloaded.
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(i)
Method of Construction
Each preliminary test pile shall be constructed in a manner similar to that to be
used for the construction of the working piles, and by the use of similar
equipment and materials. Any variation will be permitted only with prior approval.
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(i)
(a)
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Construction of a preliminary pile to be tested

Part
(c)
Boring or Driving Record

(i)
(d)
For each preliminary pile to be tested, a detailed record of the conditions

experienced during boring and of the progress during driving, shall be made and
submitted to the Engineer daily, not later than noon on the next working day.
Where the Engineer requires soil samples to be taken or in-situ tests to be
made, the Contractor shall include that in the daily report, as well as the test
results.
Concrete Test Cubes

(i)
In the case of concrete piles, four test cubes shall be made from the concrete
3
used in the manufacturer of each preliminary test pile and from each 50 m of
the concrete used in the manufacture of working piles. If a concrete pile is
extended or capped for the purpose of testing, an additional four cubes shall be
made from the corresponding batch of concrete. The cubes shall be made and
QCS 2014

Part
(ii)
(e)
If a test is required on a working pile the Contractor shall cut off or otherwise
prepare the pile for testing as required by the Engineer.
Cut-off Level
(i)
The cut-off level for a preliminary test pile shall be approved by the Engineer.
Supervision
The setting-up of pile testing equipment shall be carried out under competent
supervision and the equipment shall be checked to ensure that the set-up is
satisfactory before the commencement of load application.
(b)
All tests shall be carried out only under the direction of an experienced and competent
supervisor experienced with the test equipment and test procedure. All personnel
operating the test equipment shall have been trained in its use.
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(a)
Safety precautions
General
Design, erection and dismantling of the pile test reaction system and the
application of load shall be carried out according to the requirements of the
various applicable statutory regulations concerned with lifting and handling
heavy equipment and shall safeguard operators and others who may from time
to time be in the vicinity of a test from all avoidable hazards.
Kentledge
Where kentledge is used, the Contractor shall construct the foundations for the
kentledge and any cribwork, beams or other supporting structure in such a
manner that there will not be differential settlement, bending or deflexion of an
amount that constitutes a hazard to safety or impairs the efficiency of the
operation. The kentledge shall be adequately bonded, tied or otherwise held
together to prevent it becoming unstable because of deflexion of the supports or
for any other reason.
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(i)
(b)
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(i)
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(a)
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The pile test shall not be started until the strength of the cubes taken from the
pile exceeds twice the average direct stress in any pile section under the
maximum required test load, and the strength of the cubes taken from the cap
exceeds twice the average stress at any point in the cap under the same load.
Variation of procedure will be permitted only if approved by the Engineer.
Preparation of a Working Pile to be Tested

(i)
(f)
Page 37
(ii)
When kentledge constitutes the principal component of a reaction system, its

weight for each test shall be at least 25% greater than the maximum test load
for that test. The weight may be determined by scale or the density and volume
of the constituent materials. In adding kentledge, care shall be taken to properly
position the centre of gravity of the stack.
QCS 2014
(c)

Part
Tension Piles, Reaction Piles and Ground Anchorages
(i)
Where tension piles, reaction piles or ground anchorages constitute the principal
components of a reaction system, they shall be so designed that they will resist
the forces applied to them safely and without excessive deformation which could
cause a safety hazard during the work. Such piles (which, unless approved, will
not be working piles) or anchorages shall be driven in the specified locations,
and all bars, tendons or links shall be aligned to provide a stable reaction in the
direction required. Any welding employed to extend or to fix anchorages to a
reaction frame shall be carried out so that the full strength of the system is
adequate and unimpaired.
Testing Equipment
(i)
In all cases the Contractor shall ensure that when the hydraulic jack and loadmeasuring device are mounted on the pile head the whole system will be stable
up to the maximum load to be applied.
(ii)
If in the course of carrying out a test any unforeseen occurrence should take
place, further loading shall not be applied until a proper engineering assessment
of the condition has been made and steps have been taken to rectify any fault.
Reading of gauges should, however, be continued where possible and if it is
safe to do so.
(iii)
Where an inadequacy in any part of the system might constitute a hazard,

means shall be provided to enable the test to he controlled from a position
remote from of the kentledge stack or test frame.
(iv)
The hydraulic jack, pump, hoses, pipes, couplings and other apparatus to be
operated under hydraulic pressure shall be capable of withstanding a pressure
of 1.5 times the maximum pressure used in the test without leaking. The
maximum test load expressed as a reading on the gauge in use shall be
displayed and all operators shall be made aware of this limit.
Pile Head for Compression Test

For a pile that is tested in compression, the pile head or cap shall be formed to
give a plane surface which is normal to the axis of the pile, sufficiently large to
accommodate the loading and settlement measuring equipment and adequately
reinforced or protected to prevent damage from the concentrated load applied
by the loading equipment.
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(i)
(e)
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(d)
Page 38
(f)
(ii)
Any test pile cap shall be concentric with the test pile; the joint between the cap
and the pile shall have a strength equivalent to that of the pile.
(iii)
Sufficient clear space shall be made under any part of the cap projecting beyond
the section of the pile so that, at the maximum expected settlement, load is not
transmitted to the ground by the cap.
Pile Connection for Tension Test

(i)
For a pile that is tested in tension, means shall be provided for transmitting the
test load axially without inducing moment in the pile. The connection between
the pile and the loading equipment shall be constructed in such a manner as to
provide strength equal to 1.5 times the maximum load which is to be applied to
the pile during the test.
QCS 2014
Page 39
Reaction systems
(i)
The reaction for compression tests shall be provided by kentledge, tension piles
or specially constructed anchorages. Kentledge shall not be used for tests on
raking piles except where the test set-up has been specifically designed to
conform to Item 7(g). and has been approved by the Engineer.
(ii)
Where kentledge is to be used, it shall be supported on cribwork and positioned

so that the centre of gravity of the load is as close as possible to the axis of the
pile. The bearing pressure under supporting cribs shall be such as to ensure
stability of the kentledge stack.
Tension Tests
(i)
The reaction for tension tests shall be provided by compression piles, rafts or
grillages constructed on the ground. In all cases the resultant force of the
reaction system shall be coaxial with the test pile.
(ii)
Where inclined piles or reactions are proposed, full details shall be submitted for
approval prior to the commencement of testing.
ta
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Working piles shall not be used as reaction piles without approval from the
Engineer.
(ii)
Where working piles are used as reaction piles their movement shall be
measured and recorded to with an accuracy of 0.5 mm, and recorded.
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(i)
Spacing
Where kentledge is used for loading vertical piles in compression, the distance
from the edge of the test pile to the nearest part of the crib supporting the
kentledge stack in contact with the ground shall be not less than 1.3 m.
(ii)
The centre-to-centre spacing of vertical reaction piles from a test pile shall
conform to Paragraph 1 above, but shall be not less than three times the
diameter of the test pile or the reaction piles or 2 m, whichever is the greatest,
except in the case of piles of 300 mm diameter (or equivalent) or less, where the
distance may be reduced to 1.5 m. Where a pile to be tested has an enlarged
pile cap, the same criterion shall apply with regard to the pile shaft, with the
additional requirement that no surface of a reaction pile shall be closer to the
pile cap of the test pile than one half of the pile cap plan dimension.
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(i)
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(d)
Working Piles
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(c)
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(b)
Compression Tests
(a)

Part
(iii)
(e)
Where ground anchorages are used to provide a test reaction for loading in
compression, no section of fixed anchor length transferring load to the ground
shall be closer to the test pile than three times the diameter of the test pile.
Where the pile to be tested has an enlarged pile cap, the same criterion shall
apply with regard to the pile shaft, with the additional requirement that no section
of the fixed anchor transferring load to the ground shall be closer to the pile cap
than a distance equal to one half the pile cap plan dimension.
Adequate Reaction
(i)
The reaction frame support system shall be adequate to transmit the maximum
test load in a safe manner without excessive movement or influence on the test
pile. Calculations shall be provided to the Engineer when required to justify the
design of the reaction system.
QCS 2014
(f)

Part
Care of Piles
(i)
Page 40
The method employed in the installation of the reaction system shall be such as
to prevent damage to any test pile or working pile.
Equipment for applying load

The equipment used for applying load shall consist of a hydraulic ram or jack. The
jack shall be arranged in conjunction with the reaction system to deliver an axial load
to the test pile. Proposals to use more than one ram or jack will be subject to approval
by the Engineer of the detailed arrangement. The complete system shall be capable of
safely transferring the maximum load required for the test. The length of stroke of a
ram shall be sufficient to account for deflexion of the reaction system under load plus a
deflection of the pile head by up to 15 % of the pile shaft diameter unless otherwise
specified or agreed prior to commencement of test loading.
Measurement of load
A load measuring device shall be used and in addition a calibrated pressure gauge
included in the hydraulic system. Readings of both the load measuring device and the
pressure gauge shall be recorded. In interpreting the test data the values given by the
load measuring device shall normally be used; the pressure gauge readings are
required as a check for gross error.
(b)
The load measuring device may consist of a load measuring column, pressure cell or
other appropriate system. A spherical seating of appropriate size shall he used to
avoid eccentric loading. Care shall be taken to avoid any risk of buckling of the load
application and measuring system. Load measuring and application devices shall be
short in axial length in order to secure stability. The Contractor shall ensure that axial
loading is maintained.
(c)
The load measuring device shall be calibrated before and after each series of tests,
whenever adjustments are made to the device or at intervals appropriate to the type of
equipment. The pressure gauge and hydraulic jack shall be calibrated together.
Certificates of calibration shall be supplied to the Engineer.
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(a)
Control of loading
The loading equipment shall enable the load to be increased or decreased smoothly or
to be held constant at any required value.
(a)
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(a)
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Measuring pile head movement

(a)
Maintained Load Test

(i)
(b)
In a maintained load test, movement of the pile head shall he measured by one
of the methods in Items 11 (d), (e), (f), (g) in the case of vertical piles, or by one
of the methods in 11 (d), (f), (g) in the case of the raking piles, as required.
CRP and CRU Tests

(i)
In a CRP or a CRU test, the method in Item 11 (d) shall be used. Checklevelling of the reference frame or the pile head shall not be required. The dial
gauge shall be graduated in divisions of 0.02 mm or less.

Part
(c)
Page 41
Reference Beams and Dial Gauges

(i)
An independent reference beam or beams shall be set up to enable

measurement of the movement of the pile to be made to the required accuracy.
The supports for a beam shall be founded in such a manner and at such a
distance from the test pile and reaction system that movements of the ground
do not cause movement of the reference beam or beams which will affect the
accuracy of the test. The supports of the beam or beams shall be at least three
test pile diameters or 2 m from the centre of the test pile, whichever distance is
the greater.
(ii)
Check observations of any movements of the reference beam or beams shall be

made and a check shall be made of the movement of the pile head relative to a
remote reference datum at suitable intervals during the progress of the test.
(iii)
The measurement of pile movement shall be made by four dial gauges rigidly
mounted on the reference beam or beams, bearing on prepared flat surfaces
fixed to the pile cap or head and normal to the pile axis. Alternatively, the
gauges may be fixed to the pile and bear on prepared surfaces on the reference
beam or beams. The dial gauges shall be placed equidistant from the pile axis
and from each other. The dial gauges shall enable readings to be made to an
accuracy of at least 0.1 mm and have a stem travel of at least 25 mm.
Machined spacer blocks may be used to extend the range of reading. Equivalent
electrical displacement-measuring devices may be substituted.
Optical Levelling Method
An optical levelling method by reference to a remote datum may be used.
(ii)
Where a level and staff are used, the level and scale of the staff shall be chosen
to enable readings to be made to within an accuracy of 0.5 mm. A scale
attached to the pile or pile cap may be used instead of a levelling staff. At least
two reliable independent datum points shall be established. Each datum point
shall be so situated as to permit a single setting-up position of the level for all
readings.
(iii)
No datum point shall be located where it can be affected by the test loading or
other operations on the Site.
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Reference Wires and Scales
(e)
(f)
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QCS 2014
(i)
Two parallel reference wires, one on either side of the pile, shall be held under
constant tension at right angles to the test pile axis between supports formed as
in the method in Item 11 (d). The wires shall be positioned against scales fixed
to the test pile head in an axial direction and the movements of the scales
relative to the wires shall be determined.
(ii)
Check observations of any movements of the supports of the wires shall be

made and a check shall be made on the movement of the pile head at approved
time intervals. Readings shall be taken to within an accuracy of 0.5 mm.
Other Methods
(i)
The Contractor may submit for approval any other method of measuring the
movement of the test pile head.
QCS 2014
Protection of testing equipment

(a)
Protection from Weather

(i)
(b)
Throughout the test period all equipment for measuring load and
shall be protected from exposure to adverse effect of weather.
movement
Prevention of Disturbance
(i)
14
Page 42
Construction activity and persons who are not involved in the testing process
shall be kept at a sufficient distance from the test to avoid disturbance to the
measuring apparatus. Full records shall be kept of any intermittent unavoidable
activity that might affect the test set-up.
Notice of test
commencement of the test. No load shall be applied to the test pile before the
commencement of the specified test procedure.
Test procedure
ta
Proof Load Test Procedure (working compression piles)
The maximum load which shall be applied in a proof test shall normally be the
sum of the design verification load (DVL) plus 50 % of the specified working load
(SWL). The loading and unloading shall be carried out in stages as shown in
Table 4.7. Any particular requirements given in the particular contract
documentation shall be complied with.
(ii)
Following each application of an increment of load, the load shall be maintained

at the specified value for not less than the period shown in Table 4.7 and until
the rate of settlement is less than 0.25 mm/h and decreasing. The rate of
settlement shall be calculated from the slope of the line obtained by plotting
values of settlement versus time and drawing a smooth curve through the
points.
(iii)
Each decrement of unloading shall proceed after the expiry of the period shown
in Table 4.7.
(iv)
For any period when the load is constant, time and settlement shall be recorded
immediately on reaching the load, at not more than 5 min intervals up to 15 min;
at approximately 15 min intervals up to 1 h; at 30 min intervals between 1 h and
4 h; and 1 h intervals between 4 h and 12 h after the application of the increment
of load.
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(i)
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(a)
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(i)
13

Part
(v)
Where the methods of measuring pile head movement given in Item 11 is used,
the periods of time for which loads must be held constant to achieve the
specified rates of settlement shall be extended as necessary to take into
account the lower levels of accuracy available from these methods and to allow
correct assessment of the settlement rate.
QCS 2014

Part
Page 43
Table 4.7
Minimum time of holding load
25% DVL
50% DVL
75% DVL
100% DVL
75% DVL
50% DVL
25% DVL
0
100% DVL
100% DVL + 25% SWL
100% DVL + 50% SWL
100% DVL + 25% SWL
100% DVL
75% DVL
50% DVL
25% DVL
0
100% DVL
100% DVL + 50% SWL
100% DVL + 75% SWL
100% DVL + 100% SWL
100% DVL + 75% SWL
100% DVL + 50% SW
100% DVL + 25% SW
100% DVL
75% DVL
50% DVL
25% DVL
0
1h
1h
1h
1h
10 min
10 min
10 min
1h
6h
1h
6h
10 min
10 min
10 min
10 min
10 min
1h
6h
6h
1h
6h
10 min
10 min
10 min
10 min
10 min
10 min
10 min
1h
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Load *
(b)
SWL denotes specified working load; DVL denotes design verification load.
Test Procedure for Preliminary Compression Piles
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Applicable
to tests on
Preliminary
Pile only
(i)
The procedure to be adopted for carrying out load tests on preliminary

compression piles shall be either the extended proof load test procedure or the
constant rate of penetration testing procedure given below. A normal proof load
test will constitute the first stage of such a test unless otherwise specified.
(ii)
Extended proof load test procedure. Where test pile is to be loaded up to the
sum of design verification load (DVL) plus 100 % of the specified working load,
the loading procedure may be carried out as a continuation of the proof load
testing procedure given in Item 14 (a).
(iii)
Following the completion of the proof load test, the load shall be restored in two
stages (DVL, DVL +50 % SWL), and shall subsequently be increased by stages
of 25 % of the specified working load. Following each application of an
increment of load, the load shall be maintained at the specified value for the
period shown in Table 4.7 and until the rate of settlement is decreasing and is
less than 0.25 mm/h.

Part
Page 44
(iv)
Where verification of required minimum factor of safety is called for or the pile is
to be tested to failure, the loading procedure shall be continued after reaching
DVL +100 % SWL stage by increasing the load in increments of 25 % of the
specified working load or other specified amount until the maximum specified
load of the test is reached. Following each application of increment of load, the
load shall be maintained at the specified value for not less than 1 h and until the
rate of settlement is decreasing and is less than 0.25 mm/h, or other approved
rate appropriate to the stage of loading and its proximity to a failure condition.
Permissible settlement at the load corresponding to the required minimum factor
of safety called for in the design will not normally be specified.
(v)
The rate of settlement shall be calculated from the slope of the line obtained by
plotting values of settlement versus time and drawing a smooth curve through
the points. Reduction of load at the end of the test shall be gradual as required
by Item 14 (a).and the final rebound of the pile head shall be recorded.
(vi)
Constant rate of penetration (CRP) testing procedure. Where it is required to

determine the ultimate load of a preliminary compression pile, and particularly
where piles are largely embedded in and bearing on clay soils, the CRP testing
procedure will normally be specified.
(vii)
The rate of movement of the pile head shall be maintained constant in so far as
is practicable and shall be approximately 0.01 mm/s.
(viii)
Readings of loads, penetration and time shall be made simultaneously at regular

intervals; the interval chosen shall be such that a curve of load versus
penetration can be plotted without ambiguity.
(ix)
Loading shall be continued until one of the following results is obtained
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QCS 2014
The maximum required test load.
2.
A constant or reducing load has been recorded for an interval of

penetration of 10 mm.
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A total movement of the pile base equal to 10 % of the base diameter, or

any other greater value of movement specified, has been reached.
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3.
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1.
(x)
(c)
16
The load shall then be reduced in five approximately equal stages to zero load,
penetration and load being recorded at each stage.
Testing of Piles Designed to Carry Load in Tension

(i)
The testing of piles designed to carry load in tension shall follow the same
procedure as specified in 4.9.1
(ii)
In testing by the constant rate of uplift method, overall movements of the pile
head will normally be less than those expected in a constant rate of penetration
test. The rate of movement of the pile head shall be maintained at approximately
0.005 mm/s in so far as is practicable.
Completion of a test
(a)
Removal of Test Equipment
QCS 2014
(b)

Part
Page 45
(i)
On completion of a test and subject to the approval of the Engineer, all

measuring equipment and load application devices shall be dismantled and
checked. All other test equipment, including kentledge, beams and supporting
structures shall be removed from the test pile location. Measuring and other
demountable equipment shall be stored in a safe manner so that it is available
for further tests, or removed from the Site as approved by the Engineer.
(ii)
Temporary tension piles and ground anchorages shall be cut off below ground
level, and off-cut materials removed from the Site. The ground shall be restored
to the original contours.
Preliminary Test Pile Cap

Unless otherwise specified, the head of each preliminary test pile shall be cut off
below ground level, off-cut material shall be removed from the Site and the
ground restored to the original contours.
Proof Test Pile Cap
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On completion of a test on a proof pile, the test pile cap shall be prepared as
specified and left in a state ready for incorporation into the Permanent Works.
Any resulting off-cut materials shall be removed from the Site.
Results to be submitted
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4.9.2
ta
(i)
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(c)
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(i)
During the progress of a test, all records taken shall be available for inspection by the
Engineer.
(b)
Results shall be submitted as
Preliminary report of the test results to the Engineer, unless otherwise directed,
within 24 hours of the completion of the test, which shall show.
For a test by maintained load: for each stage of loading, the period for
which the load was held, the load and the maximum pile movement at the
end of the stage.
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1.
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(i)
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(a)
2.
(ii)
For a CRP or CRU test: the maximum load reached and a graph of load
against penetration or load against uplift.
The final report of recorded data as prescribed in Item 15 (b).within ten days of
the completion of the test.
Schedule of Recorded Data

(a)
The Contractor shall provide information about the test pile in accordance with the
following schedule where applicable.
(i)
General.
1.
site location contract identification
2.
proposed structure
3.
main contractor
4.
piling contractor
5.
engineer client/employer
6.
date and time of test
QCS 2014

Part
Pile details.
1.
all types of pile
2.
identification (number and location)
3.
specified working load (SWL)
4.
design verification load (DVL)
5.
original ground level at pile location
6.
head level at which test load was applied
7.
type of pile
8.
vertical or raking, compression or tension
9.
shape and size of cross-section of pile, and position of any change in

cross-section
10.
shoe or base details
11.
head details
12.
length in ground
13.
tip Elevation
14.
dimensions of any permanent casing
15.
concrete piles
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(ii)
Page 46
concrete mix/grade
aggregate type and source
cement type and cement replacement and type where used
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admixtures
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(iii)
16.
slump
cube test results for pile and cap
date of casting of precast pile
reinforcement
steel piles
steel quality
coating
filling or core materials type and quality, if applicable
Installation details.
1.
2.
all piles
dates and times of boring, driving and concreting of test pile
difficulties and delays encountered
date and time of casting concrete pile cap
bored piles
type of equipment used and method of boring
temporary casing - diameter, type and length

Part
Page 47
full log of pile borehole
Volume of concrete placed
driven preformed and driven cast-in-place piles
Method of support of hammer and pile driven length of pile or

temporary casing at final set
Hammer type, and size or weight
Dolly and packing, type and condition
Driving log (depth, hammer drop, blows per 250 mm,

interruptions or breaks in driving)
Final set in number of blows to produce penetration of 25 mm
Redrive check, time interval and set in number of blows to

produce penetration of 25 mm or other agreed amount at final
set and at redrive set, for a drop hammer or for a single acting
hammer the length of the drop or stroke, for a diesel hammer
the length of the stroke and the blows per minute, for a double
acting hammer the operating pressure and the number of blows
per minute
condition of pile head or temporary casing after driving
use of a follower
use of preboring
use of jetting
lengthening
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(iv)
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QCS 2014
Test procedure.
mass of kentledge
1.
tension pile, ground anchorage or compression pile details
3.
plan of test arrangement showing position and distances of kentledge

supports, rafts, tension or compression piles or ground anchorages, and
supports to pile movement reference system
4.
jack capacity
5.
method of load measurement
6.
method(s) of penetration or uplift measurement
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2.
(v)
Test results.
1.
in tabular form
2.
in graphical form: load plotted against pile head movement
3.
ambient temperature records during test.
4.9.3
Section 2
QCS 2014

Part
Page 48
This test shall be carried out in accordance with ASTM D4428, D6760 in a frequency as
mentioned in Section 2
4.9.5
Section 2
4.9.6
Section 2
4.9.7
Lateral Load Test
Section 2
4.9.8
Scope
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4.9.4
This Part outlines the alternative methods for testing piles. A significant advance in
identifying the existence of defects in construction of piles has been the development
and adoption of modern integrity testing systems which may be employed to check the
quality of construction when required by the Engineer.
(b)
Dynamic pile-testing is normally used to evaluate the pile capacity, soil resistance
distribution, and immediate settlement characteristics, hammer transfer energy
(efficiency), and pile stresses during driving. The results obtained relate directly to
dynamic loading conditions.
(c)
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(a)
This Section
Section 2
Quality Assurance
(a)
The testing shall be carried out by an approved firm.
(b)
The interpretation of tests shall be carried out by persons competent in the test
procedure, and the full test results and findings shall normally be given to the Engineer
within 10 d of the completion of each phase of testing. Full details of the ground
conditions, pile dimensions and construction method shall be made available to the
specialist firm when required in order to facilitate interpretation of the tests.
Integrity-testing of piles
(a)
General

Part
Page 49
(i)
Integrity-testing of piles is designed to give information about the physical

dimensions, continuity and consistency of materials used in piles, and not to
give direct information about the performance of piles under the conditions of
loading. The methods available are normally applied to preformed concrete piles
made in a single length, to steel piles and to cast-in-place concrete piles.
(ii)
This type of testing will not be regarded as a replacement for static load testing,
but as a source of supplementary information.
(iii)
There is normally a limit to the length: diameter ratio of pile which can be
successfully and fully investigated in this way, depending on the ground
conditions.
(iv)
In the event that any anomaly is found in the results of such testing, the
Engineer may call for further testing to be carried out in order to investigate the
cause, nature and extent of the anomaly and whether the pile is satisfactory for
its intended use.
Method of Testing
Where integrity-testing is called for but the method is not specified, the method
to be adopted shall be approved by the Engineer and shall be one of the
following
3.
The sonic logging method.
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The vibration method.
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Other methods may be adopted subject to the approval of the Engineer and
subject to satisfactory evidence of performance.
In the case of cast-in-place concrete piles, integrity tests shall not be carried out
until 7 d or more have elapsed after pile-casting, unless otherwise approved by
the Engineer.
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Preparation of Pile Heads
(i)
2.
Age of Piles at Time of Testing

(i)
(d)
The sonic method.
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(c)
1.
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(ii)
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(i)
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(b)
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QCS 2014
Where the method of testing requires the positioning of sensing equipment on

the pile head, the head shall be clean, free from water, laitance and loose
concrete and readily accessible for the purpose of testing.
Dynamic pile-testing
(a)
General
(i)
Dynamic pile-testing involves monitoring the response of a pile to a heavy

impact applied at the pile head. The impact is often provided by the pile-driving
hammer and response is normally measured in terms of force and acceleration
or displacement close to the pile head.
(ii)
The results directly obtained refer to dynamic loading conditions. Interpretation

in terms of static loading requires soil- and pile-dependent adjustments, and
corroboration from experience may be required to correlate dynamic testing with
normal static load tests as specified in clause 4.9.1 of this Section.
(iii)
Details of the equipment to be used and of the method of analysis of test results
shall be provided to the Engineer before the commencement of testing.
QCS 2014
(b)

Part
Measuring Instruments
(i)
(c)
All instruments affixed to the pile for the purpose of measuring stress and
movement, and all equipment for receiving and processing data shall be suitable
for the purpose. The equipment required to be attached to the pile shall be
appropriately positioned and fixed to the approval of the Engineer.
Hammer
(i)
(d)
Page 50
The hammer and all other equipment used shall be capable of delivering an
impact force sufficient to mobilise the equivalent specified test load without
damaging the pile.
Preparation of the Pile Head

The preparation of the pile head for the application of the dynamic test load shall
involve, where appropriate, trimming the head, cleaning and building up the pile
using materials which will at the time of testing safely withstand the impact
stresses. The impact surface shall be flat and normal to the axis of the pile.
(e)
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(i)
Time of Testing
Dynamic load tests shall be carried out at appropriate and approved times after
pile installation. The time between the completion of installation and testing for
a preformed pile shall normally be more than 12 h, and in the case of a cast-inplace concrete piles shall be after the concrete has reached 75 % of its specified
28 day strength so that the pile is not damaged under the impact stresses.
Set Measurements
(g)
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Where required and appropriate, the permanent penetration per blow and
temporary compression of the pile and soil system shall be measured
independently of the instruments being used to record the dynamic test data.
er
(i)
Results
Initial the results shall be provided to the Engineer within 24 hours of the
completion of a test. These shall include
(i)
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(f)
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(i)
The maximum force applied to the pile head.
2.
The maximum pile head velocity.
3.
The maximum energy imparted to the pile.
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1.
(ii)
Normally within 10 d of the completion of testing final report shall be given to the
Engineer which includes:
1.
Date of pile installation.
2.
Date of test.
3.
Pile identification number and location.
4.
Length of pile below ground surface.
5.
Total pile length, including projection above commencing surface at time

of test.
6.
Length of pile from instrumentation position to tip.
7.
Hammer type, drop and other relevant details.
8.
Blow selected for analysis.
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9.
Test load achieved (i.e. total mobilised deduced static load).
10.
Pile head movement at equivalent design verification load.
11.
Pile head movement at equivalent design verification load plus 50 % of

specified working load.
12.
Pile head movement at maximum applied test load.
13.
Permanent residual movement of pile head after each blow.
14.
Temporary compression.
DESIGN METHODS AND DESIGN CONSIDERATIONS
4.10.1
Design method
The design shall be based on one of the following approaches:
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4.10
The results of static load tests, which have been demonstrated, by means of
calculations or otherwise, to be consistent with other relevant experience;
(b)
Empirical or analytical calculation methods whose validity has been demonstrated by

static load tests in comparable situations;
(c)
The results of dynamic load tests whose validity has been demonstrated by static load
tests in comparable situations;
(d)
The observed performance of a comparable piles foundation, provided that this

approach is supported by the results of site investigation and ground testing.
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(a)
Design values for parameters used in the calculations should be in general accordance with
design parameters from geotechnical investigations report, but the results of load tests may
also be taken into account in selecting parameter values.
Static load tests may be carried out on trial piles, installed for test purposes only, before the
design is finalized, or on working piles, which form part of the foundation.
4.10.2
When considering a limit state of rupture or excessive deformation of a structural element or

section of the ground (Structural and Geotechnical), it shall be verified in accordance with
(Eurocode1997-1) or equivalent.
4.10.3
The behavior of individual piles and pile groups and the stiffness and strength of the structure
connecting the piles shall be considered.
In selecting calculation methods and parameter values and in using load test results, the
duration and variation in time of the loading shall be considered.
Planned future placement or removal of overburden or potential changes in the ground-water

regime shall be considered, both in calculations and in the interpretation of load test results.
The choice of type of pile, including the quality of the pile material and the method of
installation, shall take into account:
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the ground and ground-water conditions on the site, including the presence or
possibility of obstructions in the ground;
(b)
the stresses generated in the pile during installation;
(c)
the possibility of preserving and checking the integrity of the pile being installed;
(d)
the effect of the method and sequence of pile installation on piles, which have already
been installed and on adjacent structures or services;
(e)
the tolerances within, which the pile can be installed reliably;
(f)
the deleterious effects of chemicals in the ground;
(g)
the possibility of connecting different ground-water regimes;
(h)
the handling and transportation of piles;
(i)
the effects of pile construction on neighboring buildings.
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(a)
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In considering the aspects listed above, the following items should receive attention:
the spacing of the piles in pile groups;
(b)
displacement or vibration of adjacent structures due to pile installation;
(c)
the type of hammer or vibrator used;
(d)
the dynamic stresses in the pile during driving;
(e)
for those types of bored pile where a fluid is used inside the borehole, the need to
keep the pressure of the fluid at a level to ensure that the borehole will not collapse
and that hydraulic failure of the base will not occur;
(f)
cleaning of the base and sometimes the shaft of the borehole, especially under
bentonite, to remove remolded materials;
(g)
local instability of a shaft during concreting, which may cause a soil inclusion within
the pile;
(h)
ingress of soil or water into the section of a cast-in-situ pile and possible disturbance
of wet concrete by the flow of water through it;
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the effect of unsaturated sand layers around a pile extracting water from the
concrete;
(i)
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(a)
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Part
(j)
the retarding influence of chemicals in the soil;
(k)
soil compaction due to the driving of displacement piles;
(l)
soil disturbance due to the boring of a pile shaft.
4.11
AXIALLY LOADED PILES
4.11.1
Limit state design
The design shall demonstrate that exceeding the following limit states is sufficiently
improbable:
(a)
ultimate limit states of compressive or tensile resistance failure of a single pile;
(b)
ultimate limit states of compressive or tensile resistance failure of the pile foundation
as a whole;
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(c)
ultimate limit states of collapse or severe damage to a supported structure caused by

excessive displacement or differential displacements of the pile foundation;
(d)
serviceability limit states in the supported structure caused by displacement of the piles.
Normally the design should consider the margin of safety with respect to compressive or
tensile resistance failure, which is the state in which the pile foundation displaces significantly
downwards or upwards with negligible increase or decrease of resistance.
For piles in compression it is often difficult to define an ultimate limit state from a load
settlement plot showing a continuous curvature. In these cases, settlement of the pile top
equal to 10% of the pile base diameter should be adopted as the "failure" criterion.
For piles that undergo significant settlements, ultimate limit states may occur in supported
structures before the resistance of the piles is fully mobilized. In these cases a cautious
estimate of the possible range of the settlements shall be adopted in design.
4.11.2
To demonstrate that the pile foundation will support the design load with adequate safety
against compressive failure, the following inequality shall be satisfied for all ultimate limit
state load cases and load combinations:
qa
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as
Fc Rc
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Where
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Fc: design axial compression load on a pile or a group of piles
In principle Fc should include the weight of the pile itself and Rc should include the
overburden pressure of the soil at the foundation base. However these two items may be
disregarded if they cancel approximately. They need not cancel if:
(a)
downdrag is significant;
the soil is very light,
(b)
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Rc: design value
(c)
3
the pile extends above the surface of the ground.
For piles in groups, two failure mechanisms shall be taken into account:
(a)
compressive resistance failure of the piles individually;
(b)
compressive resistance failure of the piles and the soil contained between them acting
as a block.
NOTE: The design resistance shall be taken as the lower value caused by these two
mechanisms.
4
The compressive resistance of the pile group acting as a block may be calculated by
treating the block as a single pile of large diameter.
The stiffness and strength of the structure connecting the piles in the group shall be
considered when deriving the design resistance of the foundation.
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If the piles support a stiff structure, advantage may be taken of the ability of the structure
to redistribute load between the piles. A limit state will occur only if a significant numbe r of
piles fail together; therefore a failure mode involving only one pile need not be considered.
If the piles support a flexible structure, it should be assumed that the compressive
resistance of the weakest pile governs the occurrence of a limit state.
Special attention should be given to possible failure of edge piles caused by inclined or
eccentric loads from the supported structure.
If the layer in which the piles bear overlies a layer of weak soil, the effect of the weak layer
on the compressive resistance of the foundation shall be considered.
10
The strength of a zone of ground above and below the pile base shall be taken into
account when calculating the pile base resistance.
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NOTE: This zone may extend several diameters above and below the pile base. Any weak
ground in this zone has a relatively large influence on the base resistance.
Punching failure should be considered if weak ground is present at a depth of less than 4
times the base diameter below the base of the pile.
12
Where the pile base diameter exceeds the shaft diameter, the possible adverse effect
13
For open-ended driven tube or box-section piles with openings of more than 500 mm in
any direction, and without special devices inside the pile to induce plugging, the base
resistance should be limited to the smaller of:
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11
the shearing resistance between the soil plug and the inside face of the pile;
(b)
the base resistance derived using the cross-sectional area of the base.
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(a)
The manner in which load tests are carried out shall be in accordance with 4.11.2 and shall be
specified in the Geotechnical Design Report.
Trial piles to be tested in advance shall be installed in the same manner as the piles that will
form the foundation and shall be founded in the same stratum.
If the diameter of the trial pile differs from that of the working piles, the possible difference in
performance of piles of different diameters should be considered in assessing the
compressive resistance to be adopted.
In the case of a very large diameter pile, it is often impractical to carry out a load test on a full
size trial pile. Load tests on smaller diameter trial piles may be considered provided that:
4.11.3
(a)
the ratio of the trial pile diameter/working pile diameter is not less than 0,5;
(b)
the smaller diameter trial pile is fabricated and installed in the same way as the piles
used for the foundation;
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the trial pile is instrumented in such a manner that the base and shaft resistance can be
derived separately from the measurements.
NOTE: This approach should be used with caution for open-ended driven piles because of
the influence of the diameter on the mobilisation of the compressive resistance of a soil plug
in the pile.
In the case of a pile foundation subjected to downdrag, the pile resistance at failure, or at a
displacement that equals the criterion for the verification of the ultimate limit state determined
from the load test results, shall be corrected. The correction shall be achieved by subtracting
the measured, or the most unfavorable, positive shaft resistance in the compressible stratum
and in the strata above, where negative skin friction develops, from the loads measured at
the pile head.
During the load test of a pile subject to downdrag, positive shaft friction will develop along the
total length of the pile. The maximum test load applied to the working pile should be in excess
of the sum of the design external load plus twice the downdrag force.
When deriving the ultimate characteristic compressive resistance from values measured in
one or several pile load tests, an allowance shall be made for the variability of the ground and
the variability of the effect of pile installation.
The systematic and random components of the variations in the ground shall be recognized
in the interpretation of pile load tests.
The records of the installation of the test pile(s) shall be checked and any deviation from the
normal execution conditions shall be accounted for.
10
The characteristic compressive resistance of the ground may be derived from the
characteristic values of the base resistance and of the shaft resistance in accordance with
Eurocode1997-1.
4.11.4
Methods for assessing the compressive resistance of a pile foundation from ground test
results shall have been established from pile load tests and from comparable experience.
A model factor may be introduced as described as following to ensure that the predicted
compressive resistance is sufficiently safe :
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(a)
(b)
any systematic errors known to be associated with the method of analysis
In assessing the validity of a model based on ground test results, the following items should
be considered:
(a)
soil type, including grading, mineralogy, angularity, density, pre-consolidation,

compressibility and permeability;
(b)
method of installation of the pile, including method of boring or driving;
(c)
length, diameter, material and shape of the shaft and of the base of the pile (e.g.
enlarged base);
(d)
method of ground testing.
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4.11.5
Where a dynamic impact (hammer blow) pile test [measurement of strain and acceleration
versus time during the impact event is used to assess the resistance of individual
compression piles, the validity of the result shall have been demonstrated by previous
evidence of acceptable performance in static load tests on the same pile type of similar
length and cross-section and in similar ground conditions.
When using a dynamic impact load test, the driving resistance of the pile should be
measured directly on the site in question.
NOTE
A load test of this type can also include a process of signal matching to
measured stress wave figures. Signal matching enables an approximate evaluation of shaft
and base resistance of the pile as well as a simulation of its load-settlement behaviour.
The impact energy shall be high enough to allow for an appropriate interpretation of
the pile capacity at a correspondingly high enough strain level.
The design value of the compressive resistance of the pile could be calculated and
verified according to Eurocode1997-1.
4.11.6
Pile driving formulae shall only be used if the stratification of the ground has been
determined.
If pile driving formulae are used to assess the ultimate compressive resistance of individual
piles in a foundation, the validity of the formulae shall have been demonstrated by previous
experimental evidence of acceptable performance in static load tests on the same type of
pile, of similar length and cross-section, and in similar ground conditions.
For end-bearing piles driven into non-cohesive soil, the design value of the compressive
resistance shall be assessed by the same procedure as in 4.11.5.
When a pile driving formula is applied to verify the compression resistance of a pile, the pile
driving test should have been carried out on at least 5 piles distributed at sufficient spacing in
the piling area in order to check a suitable blow count for the final series of blows.
The penetration of the pile point for the final series of blows should be recorded for each pile.
4.11.7
Wave equation analysis shall only be used where stratification of the ground has been determined
by borings and field tests.
Where wave equation analysis is used to assess the resistance of individual compression piles,
the validity of the analysis shall have been demonstrated by previous evidence of acceptable
performance in static load tests on the same pile type, of similar length and cross- section, and in
similar ground conditions.
The design value of the compressive resistance derived from the results of wave equation analysis
of a number of representative piles, shall be assessed by the same procedure as in 4.11.3.
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NOTE Wave equation analysis is based on a mathematical model of soil, pile and driving
equipment without stress wave measurements on site. The method is usually applied to
study hammer performance, dynamic soil parameters and stresses in the pile during driving.
It is also, on the basis of the models, possible to determine the required driving resistance
(blow count) that is usually related to the expected compressive resistance of the pile.
The design of piles in tension shall be consistent with the design rules given in 4.11.2, where
applicable. Design rules that are specific for foundations involving piles in tension are presented
below.
To verify that the foundation will support the design load with adequate safety against a failure in
tension, the following inequality shall be satisfied for all ultimate limit state load cases and load
combinations in accordance with Eurocode1997-1.
For isolated tensile piles or a group of tensile piles, the failure mechanism may be governed by the
pull-out resistance of a cone of ground, especially for piles with an enlarged base or rock socket.
When considering the uplift of the block of ground containing the piles the shear resistance along
the sides of the block may be added to the resisting forces.
Normally the block effect will govern the design tensile resistance if the distance between the piles
is equal to or less than the square root of the product of the pile diameter and the pile penetration
into the main resisting stratum.
The group effect, which may reduce the effective vertical stresses in the soil and hence the shaft
resistances of individual piles in the group, shall be considered when assessing the tensile
resistance of a group of piles.
The severe adverse effect of cyclic loading and reversals of load on the tensile resistance shall be
considered.
Comparable experience based on pile load tests should be applied to appraise this effect.
4.11.9
Pile load tests to determine the ultimate tensile resistance of an isolated pile shall be carried out in
accordance with 4.9.1 and with regard to 4.11.3.
The design tensile resistance could be calculated and verified according to Eurocode1997-1.
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4.11.8
4.11.10 Ultimate tensile resistance from ground test results

1
Methods for assessing the tensile resistance of a pile foundation from ground test results shall
have been established from pile load tests and from comparable experience.
A model factor may be introduced as following to ensure that the predicted tensile resistance is
sufficiently safe.
(a)
(b)
any systematic errors known to be associated with the method of analys is
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The design value of tensile resistance of a pile could be calculated and verified according to
Eurocode1997-1.

1
Vertical displacements under serviceability limit state conditions shall be assessed and checked.
When calculating the vertical displacements of a pile foundation, the uncertainties involved in the
calculation model and in determining the relevant ground properties should be taken into account.
Hence it should not be overlooked that in most cases calculations will provide only an approximate
estimate of the displacements of the pile foundation.
.l.
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NOTE For piles bearing in medium-to-dense soils and for tension piles, the safety
requirements for the ultimate limit state design are normally sufficient to prevent a
serviceability limit state in the supported structure.
The occurrence of a serviceability limit state in the supported structure due to pile settlements shall
be checked, taking into account downdrag, where probable.
ta
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as
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NOTE When the pile toe is placed in a medium-dense or firm layer overlying rock or very
hard soil, the partial safety factors for ultimate limit state conditions are normally sufficient to
satisfy serviceability limit state conditions.
Assessment of settlements shall include both the settlement of individual piles and the settlement
due to group action.
The settlement analysis should include an estimate of the differential settlements that may occur.
When no load test results are available for an analysis of the interaction of the piled foundation with
the superstructure, the load-settlement performance of individual piles should be assessed on
empirically established safe assumptions.
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The assessment of upward displacements shall be done and Particular attention should be paid to
the elongation of the pile material.
When very severe criteria are set for the serviceability limit state, a separate check of the upward
displacements shall be carried out.
4.12
TRANSVERSELY LOADED PILES
4.12.1
Design method
The design of piles subjected to transverse loading shall be consistent with the design rules given
in 4.10, where applicable. Design rules specifically for foundations involving piles subjected to
transverse loading are presented below.
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To demonstrate that a pile will support the design transverse load with adequate safety against
failure, the following inequality shall be satisfied for all ultimate limit state load cases and load
combinations:
Ftr Rtr
Where;
Ftr: design value of the transverse load on a pile or a pile foundation
Rtr : design resistance of transversally loaded pile
One of the following failure mechanisms should be considered:
for short piles, rotation or translation as a rigid body;
(b)
for long slender piles, bending failure of the pile, accompanied by local yielding and
displacement of the soil near the top of the pile.
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(a)
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The group effect shall be considered when assessing the resistance of transversely loaded piles.
It should be considered that a transverse load applied to a group of piles may result in a
combination of compression, tension and transverse forces in the individual piles.
4.12.2
Transverse pile load tests shall be carried out in accordance with 4.9.6.
Contrary to the load test procedure described in 4.9 tests on transversely loaded piles need not
normally be continued to a state of failure. The magnitude and line of action of the test load should
simulate the design loading of the pile.
An allowance shall be made for the variability of the ground, particularly over the top few meters of
the pile, when choosing the number of piles for testing and when deriving the design transverse
resistance from load test results.
Records of the installation of the test pile(s) should be checked, and any deviation from the normal
construction conditions should be accounted for in the interpretation of the pile load test results.
For pile groups, the effects of interaction and head fixity should be accounted for when deriving the
transverse resistance from the results of load tests on individual test piles.
4.12.3
Transverse load resistance from ground test results and pile strength parameters
The transverse resistance of a pile or pile group shall be calculated using a compatible set of
structural effects of actions, ground reactions and displacements.
The analysis of a transversely loaded pile shall include the possibility of structural failure of the pile
in the ground.
The calculation of the transverse resistance of a long slender pile may be carried out using the
theory of a beam loaded at the top and supported by a deformable medium characterized by a
horizontal modulus of subgrade reaction.
The degree of freedom of rotation of the piles at the connection with the structure shall be taken
into account when assessing the foundations transverse resistance.
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4.12.4
The assessment of the transverse displacement of a pile foundation shall take into account:
the stiffness of the ground and its variation with strain level;
(b)
the flexural stiffness of the individual piles;
(c)
the moment fixity of the piles at the connection with the structure;
(d)
the group effect;
(e)
the effect of load reversals or of cyclic loading
.l.
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A general analysis of the displacement of a pile foundation should be based on expected degrees
of kinematic freedom of movement.
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END OF PART
(a)
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RETAINING STRUCTURES ---------------------------------------------------------------------------------- 2
5.1
GENERAL---------------------------------------------------------------------------------------------------------- 2
5.2
LIMIT STATES ---------------------------------------------------------------------------------------------------- 2
5.2.2
5.2.3
Ultimate Limit State ---------------------------------------------------------------------------------------------- 2

Serviceability Limit State ---------------------------------------------------------------------------------------- 3
5.3
ACTIONS AND GEOMETRICAL DATA -------------------------------------------------------------------- 3
5.3.1
5.3.2
5.3.3
Actions -------------------------------------------------------------------------------------------------------------- 3
Geometrical data ------------------------------------------------------------------------------------------------- 4
Design Situations ------------------------------------------------------------------------------------------------- 4
5.4
DESIGN AND CONSTRUCTION CONSIDERATIONS ------------------------------------------------- 5
5.5
DETERMINATION OF EARTH PRESSURES ------------------------------------------------------------ 6
5.5.1
5.5.2
5.5.3
5.5.4
5.5.5
General ------------------------------------------------------------------------------------------------------------- 6
At rest values of earth pressure------------------------------------------------------------------------------- 7
Limiting values of earth pressure ----------------------------------------------------------------------------- 7
Intermediate values of earth pressure ----------------------------------------------------------------------- 7
Compaction effects ---------------------------------------------------------------------------------------------- 7
5.6
WATER PRESSURES ------------------------------------------------------------------------------------------ 8
5.7
ULTIMATE LIMIT STATE DESIGN -------------------------------------------------------------------------- 8
5.7.1
5.7.2
5.7.3
5.7.4
5.7.5
5.7.6
5.7.7
General ------------------------------------------------------------------------------------------------------------- 8
Overall stability ---------------------------------------------------------------------------------------------------- 8
Foundation failure of gravity walls ---------------------------------------------------------------------------- 8
Rotational failure of embedded walls ------------------------------------------------------------------------ 8
Vertical failure of embedded walls --------------------------------------------------------------------------- 9
Structural design of retaining structures -------------------------------------------------------------------- 9
Failure by pull-out of anchorages ----------------------------------------------------------------------------- 9
5.8
SERVICEABILITY LIMIT STATE DESIGN ----------------------------------------------------------------- 9
5.8.1
5.8.2
General ------------------------------------------------------------------------------------------------------------- 9
Displacements ---------------------------------------------------------------------------------------------------- 9
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RETAINING STRUCTURES
5.1
GENERAL
The provisions of this Part 5 apply to retaining structures in general. These are structures
used to retain ground comprising soil, rock or backfill and water and this at an angle steeper
than the angle they would normally adopt without the presence of those structures. Common
retaining structures used within the state of Qatar taking into account the prevailing geologic
conditions are:
Sheet Piles
(b)
Bored and Cast in Place Concrete Piles
Secant Piles
(c)
Diaphragm Walls
(d)
Composite Shoring Systems
(e)
Concrete Retaining Walls
(ii)
Counter Fort Retaining Wall
(iii)
Gravity Retaining Wall
(iv)
Buttressed Retaining Wall
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as
Cantilever Retaining Wall
Reinforced Soil Retaining Structures

Geogrid and Geotextile Reinforced Earth Systems
(ii)
Galvanized Strips Reinforced Earth System
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(i)
Soil and Rock Nailing Systems
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(g)
(i)
(f)
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(ii)
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Contiguous Piles
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(i)
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(a)
This revision of Section 4 Part 5 is considered preliminary and shall be reviewed and
amended as needed in the next revision to elaborate on various subjects not covered herein.
This revision of Section 4 Part 5 is based generally on EN1997-1:2004+A1:2013

Eurocode 7.
Section 4 Part 5 will cover at this stage the general design aspects knowing that the
construction procedures shall be added in future revisions of this Section. Hence, at this
stage, the construction related subjects of the retaining structures will follow relevant Parts of
the QCS.
5.2
LIMIT STATES
During the design of retaining structures the following typical limit states should be
considered:
5.2.2
Ultimate Limit State
Loss of overall stability: it should be demonstrated that an overall stability failure is unlikely.
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Foundation failure of retaining structures with footings: it should be demonstrated that the
foundation pressures (lateral and vertical) do not exceed neither the ground allowable
bearing capacity nor the sliding resistance. Uplift pressures under the foundation due to
water seepage should also be included in the analysis.
Foundation failure of gravity walls, which is the loss of equilibrium of the wall considered as a
rigid body.
Failure of embedded walls by rotation or horizontal translation or by lack of vertical

equilibrium.
Failure of a structural element such as a wall, anchorage, wale or strut, including failure of
the connection between those elements.
Failure of a retaining structure by hydraulic heave, internal erosion or piping, unacceptable

leakage of water, or transport of soil particles through or under the wall caused by excessive
hydraulic gradients.
5.2.3
Serviceability Limit State
Unacceptable movement of the retaining structure, which may affect the appearance or
functionality of the structure itself, or other neighbouring structures or utilities influenced by
the movement.
Unacceptable change in the groundwater regime.
5.3
ACTIONS AND GEOMETRICAL DATA
5.3.1
Actions
Generally, the forces exerted on retaining structure with values assumed known at the
beginning of the calculation are considered as 'actions', while forces with initially unknown
values, to be determined by the interaction of the retaining structure with support elements
(ground springs, anchorages, struts, etc.), are considered as 'reactions'. The following
actions are to be taken into account:
Weight of backfill material
(a)
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(b)
Surcharges
(c)
Weight of water
(d)
Wave forces for marine projects
(e)
Seepage forces
(f)
Collision forces
(g)
Temperature effects
(h)
Forces from propping elements (i.e. post-tensioned anchors)
(i)
Siesmic related effects
The above actions should result in the determination of various earth pressures acting on the
retaining structure.
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Page 4
5.3.2
Geometrical data
This paragraph covers the uncertainties in the geometrical data namely excavation and water
levels. In general, small variations in geometrical data are considered to be covered by the
safety factors included in the calculations. However, since the design of retaining structures
is sensitive to ground and water levels, special requirements are included in this paragraph,
mainly for unforeseen over-dig in front of the wall and groundwater levels change on both
sides of the wall.
Unforeseen over-dig in front of the wall
Equal to 10% of the wall height above excavation level (up to a maximum of 0.5 m), for
cantilever walls;
(b)
Equal to 10% of the distance between the lowest support and the excavation level (up
to a maximum of 0.5 m), for supported walls.
Groundwater levels in front of and behind the wall
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(a)
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In Ultimate Limit State design calculations, where the wall stability depends on the earth
resistance in front of the wall, the level of the resisting soil should be lowered below the
nominally expected level by an amount which depends on the degree of control on the
excavation level. With a normal degree of control the expected difference in resisting soil
level should be:
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as
The selection of the levels of the phreatic surfaces in front of and behind the wall must
consider long-term variations of the groundwater regime and/or the ground permeability, the
presence of perched or artesian aquifers and the possibility that drainage behind the wall
may cease to function with time.
Design Situations
The following conditions shall be considered during the design of retaining structures:
Anticipated variations in soil properties
(b)
Variations in actions and the ways they are combined
(c)
Excavation, scour or erosion in front of the retaining structure

The effect of compaction of the backfill behind the retaining structure
(d)
(a)
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(e)
The effect of anticipated future structures and surcharge loads/unloads
(f)
Anticipated ground movements
(g)
Inclination of the wall to the vertical
(h)
Variations in groundwater table and the seepage forces in the ground
(i)
Horizontal as well as vertical equilibrium for the entire retaining structure
(j)
The shear strength and weight density of the ground
(k)
The rigidity of the wall and the supporting system
(l)
The wall roughness
(m)
Seismic effect on the various forces
QCS 2014

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Page 5
5.4
DESIGN AND CONSTRUCTION CONSIDERATIONS
The design of retaining structures requires consideration of all relevant Ultimate Service
States and Service Limit States.
For retaining structures without strict serviceability requirements, the geometry is usually
determined by Ultimate Limit State design calculations and checked by Service Limit State
calculations (if relevant). For the retaining structures with strict serviceability requirements,
the Service Limit State requirements often govern the design.
The design and construction considerations should cover the following:

Demonstrate that vertical equilibrium can be achieved for the assumed pressure
distributions and actions on the wall.
(b)
Verification of vertical equilibrium may be achieved by reducing the wall friction

parameters.
(c)
Retaining walls should be designed in such a way that there are visible signs of the
approach of an ultimate limit state. The design should prevent brittle failure of the
structure, e.g. sudden collapse without conspicuous preliminary deformations.
(d)
A critical limit state should be considered to occur if the wall has displaced enough to
cause damage to nearby structures or services. Although collapse of the wall may not
be imminent, the degree of damage may considerably exceed a serviceability limit
state in the supported structure.
(e)
The design methods and partial factor values recommended by EN19971:2004+A1:2013 are usually sufficient to prevent the occurrence of ultimate limit
states in nearby structures, provided that the soils involved are of at least medium
density or firm consistency and adequate construction methods and sequences are
adopted. Special care should be taken, however, with some highly over-consolidated
clay deposits in which large at rest horizontal stresses may induce substantial
movements in a wide area around excavations.
(f)
The complexity of the interaction between the ground and the retaining structure
sometimes makes it difficult to design a retaining structure in detail before the actual
execution starts. In this case, use of the observational method for the design should be
considered. The observational method consists of setting criteria enabling monitoring
during construction, allowing necessary corrective actions to be taken to rectify the
design. Hence, the following requirements shall be set before construction:
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(a)
(g)
(i)
Acceptable limits of behaviour
(ii)
The range of potential behaviour shall be analysed showing acceptable

probability that the actual behaviour will be within the acceptable limits
(iii)
A plan of monitoring shall be established (including necessary instruments and

procedures) enabling the comparison of the actual behaviour to the acceptable
limits. The monitoring shall allow early detection of nonconformities, allowing
enough time for corrective actions to be taken successfully.
(iv)
A list of contingency actions shall be established which could be used if the

actual observed behaviour is outside of the acceptable limits.
The effects of constructing the wall, including:

(i)
The provision of temporary support to the sides of excavations;
QCS 2014

Part
Page 6
(ii)
The changes of in situ stresses and resulting ground movements caused both
by the wall excavation and its construction;
(iii)
Disturbance of the ground due to driving or boring operations;
(iv)
Provision of access for construction;
The required degree of water tightness of the finished wall;
(i)
The practicability of constructing the wall to reach a stratum of low permeability, so

forming a water cut-off. The resulting equilibrium ground-water flow problem shall be
assessed;
(j)
The practicability of forming ground anchorages in adjacent ground;
(k)
The practicability of excavating between any propping of retaining walls;
(l)
The ability of the wall to carry vertical load;
(m)
The ductility of structural components;
(n)
Access for maintenance of the wall and any associated drainage measures;
(o)
The appearance and durability of the wall and any anchorages;
(p)
For sheet piling, the need for a section stiff enough to be driven to the design
penetration without loss of interlock;
(q)
The stability of borings or slurry trench panels while they are open;
(r)
For fill, the nature of materials available and the means used to compact them
adjacent to the wall.
(s)
Drainage systems
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If the safety and serviceability of the designed structure depend on the successful
performance of a drainage system, the consequences of its failure shall be
considered, taking into account both safety and cost of repair. One of the following
conditions (or a combination of them) shall apply:
A maintenance program for the drainage system shall be specified and the
design shall allow access for this purpose;
(ii)
It shall be demonstrated both by comparable experience and by assessment of

any water discharge that the drainage system will operate adequately without
maintenance.
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The quantities, pressures and eventual chemical content of any water discharge
should be taken into account.
5.5
DETERMINATION OF EARTH PRESSURES
5.5.1
General
The Determination of the earth pressures shall take into account the acceptable mode and
amount of any movement and strain, which may occur at the limit state under consideration.
In the following context the words "earth pressure" should also be used for the total earth
pressure from soft and weathered rocks and should include the pressure of ground-water.
QCS 2014

Part
Page 7
Calculations of the magnitudes of earth pressures and directions of forces resulting from
them shall take account of the issues highlighted under paragraph 5.3.3.
The amount of mobilized wall friction and adhesion should be considered as a function of:
The strength parameters of the ground
(b)
The friction properties of the wall-ground interface
(c)
The direction and amount of movement of the wall relative to the ground
(d)
The ability of the wall to support any vertical forces resulting from wall friction and
adhesion
A concrete wall or steel sheet pile wall supporting sand or gravel may be assumed to have a
design wall ground interface parameter d k. cv ;d . k should not exceed 2/3 for precast
(a)
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concrete or steel sheet piling. For concrete cast against soil, a value of k = 1.0 may be
assumed. For a steel sheet pile in clay under undrained conditions immediately after driving,
no adhesive or frictional resistance should be assumed. Increases in these values may take
place over a period of time.
In the case of structures retaining rock masses, calculations of the ground pressures shall
take into account the effects of discontinuities, with particular attention to their orientation,
spacing, aperture, roughness and the mechanical characteristics of any joint filling material.
Account shall be taken of any swelling potential of the ground when calculating the pressures
on the retaining structure.
5.5.2
At rest values of earth pressure
When no movement of the wall relative to the ground takes place, the earth pressure shall be
calculated from the at rest state of stress. The determination of the at-rest state shall take
into account the stress history of the ground.
5.5.3
Limiting values of earth pressure
Limiting values of earth pressures shall be determined taking into account the relative
movement of the soil and the wall at failure and the corresponding shape of the failure
surface.
5.5.4
Intermediate values of earth pressure
Intermediate values of earth pressure occur if the wall movements are insufficient to mobilize
the limiting values. The determination of the intermediate values of earth pressure shall take
into account the amount of wall movement and its direction relative to the ground.
The intermediate values of earth pressures may be calculated using, for example, various
empirical rules, spring constant methods or finite element methods.
5.5.5
Compaction effects
The determination of earth pressures acting behind the wall shall take into account the
additional pressures generated by any placing of backfill and the procedures adopted for its
compaction.
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WATER PRESSURES
Determination of characteristic and design water pressures shall take account of water levels
both above and in the ground.
When checking the ultimate and serviceability limit water pressures shall be accounted for in
the combinations of actions considering the possible risks of flooding or change in
groundwater levels from either sides of the retaining structure.
For structures retaining earth of medium or low permeability (silts and clays), water pressures
should normally be assumed to act behind the wall. Unless a reliable drainage system is
installed, or infiltration is prevented, the values of water pressures should normally
correspond to a water table at the surface of the retained material.
Where sudden changes in a free water level may occur, both the non-steady condition
occurring immediately after the change and the steady condition shall be examined.
Where no special drainage or flow prevention measures are taken, the possible effects of
water-filled tension or shrinkage cracks shall be considered.
5.7
ULTIMATE LIMIT STATE DESIGN
5.7.1
General
The design of retaining structures shall be checked at the ultimate limit state for the design
situations appropriate to that state, as specified in 5.3.3, using the design actions or action
effects and design resistances.
All relevant limit modes shall be considered. These will include, as a minimum, limit modes of
the types illustrated in Figures 5.1 to 5.6 for the most commonly used retaining structures.
Calculations for ultimate limit states shall establish that equilibrium can be achieved using the
design actions or effects of actions and the design strengths or resistances. Compatibility of
deformations shall be considered in assessing design strengths or resistances.
5.7.2
Overall stability
Principles and calculations should be used as appropriate to demonstrate that an overall

stability failure will not occur and that the corresponding deformations are sufficiently small
taking into account progressive failure and liquefaction into account as relevant.
5.7.3
Foundation failure of gravity walls
The principles of foundation design shall be used as appropriate to demonstrate that a

foundation failure is sufficiently remote and that deformations will be acceptable. Both
bearing resistance and sliding shall be considered. Failure modes shown in Figure 5.2 should
be verified as a minimum.
5.7.4
Rotational failure of embedded walls
It shall be demonstrated by equilibrium calculations that embedded walls have sufficient

penetration into the ground to prevent rotational failure. As a minimum, limit modes of the
types illustrated in Figure 5.3 should be considered.
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5.6
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Part
Page 9
The design magnitude and direction of shear stress between the soil and the wall shall be
consistent with the relative vertical displacement, which would occur in the design situation.
5.7.5
Vertical failure of embedded walls
It shall be demonstrated that vertical equilibrium can be achieved using the design soil
strengths or resistances and design vertical forces on the wall. As a minimum, the limit mode
of the type illustrated in Figure 5.4 should be considered.
Where downward movement of the wall is considered, upper design values shall be used in
the calculation of pre-stressing forces, such as those from ground anchorages, which have a
vertical downward component. The design magnitude and direction of shear stress between
the soil and the wall shall be consistent with the check for vertical and rotational equilibrium.
If the wall acts as the foundation for a structure, vertical equilibrium shall be checked using
the principles of Pile Foundations Design.
5.7.6
Structural design of retaining structures
Retaining structures, including their supporting structural elements such as anchorages and
props, shall be verified against structural failure in accordance with EN1997-1:2004+A1:2013
2.4 Geotechnical Design by Calculation and EN1992, EN1993, EN1995 and EN1996. As a
minimum, limit modes of the types illustrated in Figure 5.5 should be considered.
5.7.7
Failure by pull-out of anchorages
It shall be demonstrated that equilibrium can be achieved without pull-out failure of ground
anchorages. Anchors shall be designed in accordance with Anchorage Design procedures
with minimum the limit modes of the types illustrated in Figure 5.6 (a, b) should be
considered. For dead-man anchors, the failure mode illustrated in Figure 5.6 (c) should also
be considered.
5.8
SERVICEABILITY LIMIT STATE DESIGN
5.8.1
General
The design of retaining structures shall be checked at the serviceability limit state using the
appropriate design situations as specified in 5.3.3. The assessment of design values of earth
pressures should take account of the initial stress, stiffness and strength of the ground and
the stiffness of the structural elements.
The design values of earth pressures should be derived taking account of the allowable
deformation of the structure at its serviceability limit state. These pressures need not
necessarily be limiting values.
5.8.2
Displacements
Limiting values for the allowable displacements of walls and the ground adjacent to them
shall be established for a particular deformation is the value at which a serviceability limit
state, such as unacceptable cracking or displacement of adjacent structures or utilities, is
deemed to occur. This limiting value shall be agreed during the design, taking into account
the tolerance to displacements of supported structures and services.
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If the initial cautious estimate of displacement exceeds the limiting values, the design shall be
justified by a more detailed investigation including displacement calculations.
It shall be considered to what extent variable actions, such as vibrations caused by traffic
loads behind the retaining wall, contribute to the wall displacement.
Displacement calculations should also be considered in the following cases:

(a)
where the wall retains more than 6m of cohesive soil of low plasticity,
(b)
where the wall retains more than 3m of soils of high plasticity;
(c)
where the wall is supported by soft clay within its height or beneath its base.
Displacement calculations shall take into account the stiffness of the ground and structural
elements and the sequence of construction.
The effect of vibrations on displacements shall be considered with regard to the following:
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Foundations for structures subjected to vibrations or to vibrating loads shall be

designed to ensure that vibrations will not cause excessive settlements.
(b)
Precautions should be taken to ensure that resonance will not occur between the
frequency of the dynamic load and a critical frequency in the foundation-ground
system, and to ensure that liquefaction will not occur in the ground.
(c)
Vibrations caused by earthquakes shall be considered using the guidelines of the

designated section of the QCS.
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(a)
Figure 5.1 Examples of Limit Modes for Overall Stability of Retaining Structures
(EN 1997-1:2004+A1:2013)

Part
Page 11
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QCS 2014
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Figure 5.2 Examples of Limit Modes for Foundation Failures of Gravity Walls
(EN 1997-1:2004+A1:2013)
Figure 5.3 Examples of Limit Modes for Rotational Failures of Embedded Walls
(EN 1997-1:2004+A1:2013)

Part
Page 12
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Figure 5.4 Example of a Limit Mode for Vertical Failure of Embedded Walls
(EN 1997-1:2004+A1:2013)
Figure 5.5 Examples of Limit Modes for Structural Failure of Retaining Structures
(EN 1997-1:2004+A1:2013)

Part
Page 13
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Figure 5.6 Examples of Limit Modes for Failure by Pull-out of Anchoes

(EN 1997-1:2004+A1:2013)
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END OF PART
QCS 2014

Part
01: General
Page 1
GENERAL------------------------------------------------------------------------------------------------------------ 2
1.1
1.1.1
1.1.2
1.1.3
1.1.4
INTRODUCTION --------------------------------------------------------------------------------------------------- 2
Scope ----------------------------------------------------------------------------------------------------------------- 2
References----------------------------------------------------------------------------------------------------------- 2
Definitions ------------------------------------------------------------------------------------------------------------ 3
Approved Products ------------------------------------------------------------------------------------------------ 4
1.2
1.2.1
1.2.2
1.2.3
1.2.4
IMPLEMENTATION ----------------------------------------------------------------------------------------------- 4
Approved Installers ------------------------------------------------------------------------------------------------ 4
Field Quality Control ----------------------------------------------------------------------------------------------- 4
Rejected materials ------------------------------------------------------------------------------------------------- 5
Records --------------------------------------------------------------------------------------------------------------- 5
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QCS 2014

Part
01: General
Page 2
GENERAL
1.1
INTRODUCTION
1.1.1
Scope
This Section includes the requirements for concrete work for pipelines, roadworks, runways,
structures, water retaining structures, foundations and bases for structures and equipment.
This Part includes relevant standards, definitions, abbreviations, and requirements for testing
facilities, rejected materials, and record keeping.
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Aggregates
Water
Admixtures
Concrete Plants
Transportation and Placing of Concrete
Formwork
Curing
Reinforcement
Construction Joints
Inspection and Testing of Hardened Concrete
Protective Coatings to Concrete
Hot Weather Concrete
Miscellaneous
Precast Concrete
Water Retaining Structures
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This Section:
Part 2,
Part 3,
Part 4,
Part 5,
Part 6,
Part 7,
Part 8,
Part 9,
Part 10,
Part 11,
Part 12,
Part 13,
Part 14,
Part 15,
Part 16,
Part 17,
Part 18,
Part 19,
Section 1,
Section 2,
Section 4,
Section 6,
Section 8,
Section 9,
General
Roadworks
Drainage Works
1.1.2
References

ASTM C31 ..................Standard Practice for Making and Curing Concrete Test Specimens in
the Field
ASTM C39 ..................Standard Test Method for Compressive Strength of Cylindrical
Concrete Specimens
ASTM C143 ................Standard Test Method for Slump of Hydraulic-Cement C Concrete
ASTM C1064 ..............Standard Test Method for Temperature of Freshly Mixed HydraulicCement Concrete
QCS 2014

Part
01: General
Page 3
BS 6100, ....................Glossary of Building and civil engineering terms

BS EN 932-1 ..............Tests for general properties of aggregates. Methods for sampling
BS EN 932-2 ..............Tests for general properties of aggregates. Methods for reducing
laboratory samples
BS EN 12350-1 ..........Method of sampling fresh concrete in site
BS EN 12350-2 ..........Testing fresh concrete. Slump-test
BS EN 12390-1 ..........Shape, dimensions and other requirements for specimens and moulds
BS EN 12390-2 .......... Making and curing specimens for strength tests
GSO ISO 1920-2 ........Testing of concrete Part 2: Properties of fresh concrete
GSO ISO 1920-3 ........Testing of concrete Part 3: Making and curing test specimens
Definitions
Definitions used in this Section.
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1.1.3
The following are terms and abbreviations used:
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degree Celsius
calorie
centimetre
day
Characteristic compressive strength of concrete determined by testing cylinders
Compressive strength of concrete determined by testing cylinders
Characteristic compressive strength of concrete determined by testing cubes
Compressive strength of concrete determined by testing cubes
Mean compressive strength of concrete
Mean compressive strength of concrete at the age of (j) days
ground granulated blast furnace slag
guaranteed ultimate tensile strength
hour
kilogram
kilojoule
kilonewton
litre
metre
square metre
cubic metre
milligram
minute
millimetre
square millimetre
months
mega Pascal
kilo Pascal
moderate sulphate resisting Portland cement
ordinary Portland cement
pulverised fuel ash
polyvinylchloride
second
silica fume
sulphate resisting Portland cement
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C
cal
cm
d
fck,cyl
fc,cyl
fck,cube
fc,cube
fcm
fcm,j
GGBS
GUTS
h
kg
kJ
kN
l
m
2
m
3
m
mg
min
mm
2
mm
months
MPa
kPa
MSRPC
OPC
PFA
PVC
s
SF
SRPC
QCS 2014
ton
ppm
1000 kg
part per million
micron
10
10 meter
Page 4
-6
-6

accordance with the following abbreviations.
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American Society for Testing and Materials
British Standard
British Standard Code of Practice
British Standards Institution
Construction Industry Research and Information Association
Concrete Society
Deutsches Institut fur Normung e.V.
Euro Norm
GCC Standardization Organization
Qatar Construction Specifications
Qatar Standards
United Kingdom Department for Transport
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AASHTO
ACI
ASTM
AWS
BS
BSCP
BSI
C & CA
CIRIA
CRSI
CS
DIN
EN
FHWA
GSO
ICE
ISO
PCI
QCS
QS
UK DfT
Products
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Part
01: General
Approved Products
The contract specific documentation may identify approved products and approved or
prequalified manufacturers and suppliers of products used in concrete work.
1.2
IMPLEMENTATION
1.2.1
Approved Installers
The contract specific documentation may identify approved or prequalified providers of

concrete construction services.
1.2.2
Field Quality Control
The Contractor shall carry out the test procedures required by this Section and any other
tests and test procedures as directed by the Engineer from time to time. The test procedures
shall be carried out using the facilities of an approved independent testing laboratory.
Supply, storage, sampling and testing of all materials shall be the responsibility of the
Contractor, unless the Contract specifies otherwise.
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1.1.4
QCS 2014

Part
01: General
Page 5
The Engineer may also require the Contractor to take samples of materials and deliver them
to the Central Materials Laboratory for additional tests to be carried out by the Employer.
Sampling procedures shall be in accordance with BS EN 932 or relevant ASTM Standards,
and sample sizes shall conform to the requirements shown in Table 1.1.
The minimum equipment required for testing on Site is given in Table 1.2. This equipment
shall be maintained on Site at all times during concreting operations together with the
necessary scoops, buckets, sample containers, and other items required for sampling. The
cube curing tank shall be located in an air-conditioned area as stated in part 06.
1.2.3
Rejected materials
Any material rejected by the Engineer, in particular cement which has deteriorated or
aggregates which have segregated or become contaminated, shall be immediately removed
from the Site.
1.2.4
Records
The Contractor shall maintain on the Site full records of all work carried out accurately
related to the location of the work on site, which shall include:
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formwork props were fully removed

all cubes and other tests
(c)
daily maximum and minimum temperatures.
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One copy of all test results shall be sent to the Engineer immediately upon completion of the
tests
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Table 1.1
Sampling Procedure and
Minimum Sample Sizes for Central Materials Laboratory
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Cement
Material
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the time and date when all concrete was poured, formwork removed and when
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(a)
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Aggregate
Reinforcement
Water
Test
Min. Sample
Full range of tests
Composite sample of 7 kg
taken from at least 12 bags
Full range of tests
200 kg
Sieve analysis
Chemical analysis
Soundness test
Water absorption
Particle density
Flakiness index
Fines content
LA Abrasion value
50 kg
Tensile test
500 mm
Bend test
300 mm
Full range of tests
5 litres
QCS 2014

Part
01: General
Page 6
Table 1.2
Minimum Testing Equipment for Each Site*
Test
Equipment to be Provided
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ASTM C1064
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Cube curing
BS EN
12390-2
or
GSO ISO 1920-3
or ASTM C39
Hessian or sacking, impervious sheet

Maximum/minimum thermometer
Waterproof marking crayon/paint or
equivalent
Curing tank (in air conditioned room)
Supply of packing materials for sending
cubes to commercial laboratory
Concrete thermometer
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Cube making
BS EN 12390-1
and
BS EN 12350-1:2000
or
GSO ISO 1920-1
and
GSO ISO 1920-3
or ASTM C31 and C39
Slump cone with base plate

Compacting rod, circular cross-section
and round ends
Remixing container, 300 mm ruler,
moist cloth
Scoop and shovel
Timer
100 or 150 mm cubical or cylindrical
1
moulds
Compacting rod or bar Set of tools for
assembling and stripping moulds
Remixing container
Trowel, Scoop, Shovel and Mallet
Mould release agent in closed
container with brush
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Slump test BS EN
12350-2
or
GSO ISO 1920-2
or
ASTM C143
Minimum Number
Required
1
1
1
1
1
6
1
1
1
lot
1
1
1
Lot
1
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1 - The use of 100 mm cube and cylinder moulds are permitted when the nominal maximum aggregate
size is not greater than 20mm
END OF PART
QCS 2014

Part
10: Curing
Page 1
CURING .................................................................................................................. 2
10.1
10.1.1
10.1.2
10.1.3
10.1.4
10.1.5
GENERAL ............................................................................................................... 2
Scope
2
References
2
Submittals
2
Quality Assurance
2
Storage
2
10.2
10.2.1
10.2.2
10.2.3
10.2.4
10.2.5
10.2.6
10.2.7
10.2.8
10.2.9
10.2.10
10.2.11
10.2.12
CURING .................................................................................................................. 2
General
2
Water for Curing
3
3
4
4
Moisture Curing
4
4
5
Steam Curing
5
Pavements and other slab on ground
5
Buildings, bridges, and other structures
5
Mass concrete
6
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10
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Part
10: Curing
Page 2
10
CURING
10.1
GENERAL
10.1.1
Scope
This part covers the requirements for the curing of concrete.
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References
AASHTO M 148.74, ...Liquid Membrane Curing
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ACI 308 ..................... Guide to Concrete Curing
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10.1.2
This Section
Part 1, ............ General
Part 4, ............ Water
Part 6, ............ Property Requirements
Part 15, ........... Hot Weather Concreting
Part 16, ........... Miscellaneous.
ASTM C 309, .............. Specification for Liquid Membrane-forming Compounds for Curing
Concrete
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BS 7542,..................... Method of test for curing compounds for concrete.

Quality management systems -- Requirements
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ISO 9001: 2008

Submittals
The Contractor shall submit to the Engineer the proposed method of curing for approval.
10.1.4
Quality Assurance
The Contractor shall submit to the Engineer for approval the details of proposed curing
media, if any. Details shall include chemical tests for the product in accordance with
BS 7542 and details of quality assurance procedures, including ISO 9001 certificates if held.
10.1.5
Storage
Chemical curing compounds shall be stored in accordance with manufacturer's

recommendations.
10.2
CURING
10.2.1
General
The Contractor shall ensure that curing is provided for 24 hours per day including holidays
and that all related necessary plant and labour resources are also available.
Special attention shall be given to the curing of vertical and overhanging surfaces to ensure
satisfactory curing.
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10.1.3
QCS 2014

Part
10: Curing
Page 3
The Contractor shall adopt curing measures that preclude the possibility of thermal shock to
the concrete during curing. This may be achieved by ensuring that the temperature of the
water used for curing does not differ from that of the concrete by more than 15 C.
Curing shall continue for at least 7 days and until it attains an in-place compressive strength
of the concrete of at least 70% of the specified compressive or flexural strength, whichever
period is longer. Curing shall not stop unless otherwise approved by the Engineer.
When low W/cm is used, the concrete shall be preferably cured by water.
10.2.2
Water for Curing
Water used for any curing purposes shall conform to the requirements of Part 4 of this
Section.
10.2.3
Freshly placed concrete shall be protected from sun, wind, rain, exposure and excessive
drying out.
All concrete shall be cured for a period of time required to obtain the full specified strength,
but not less than seven consecutive days. The method of curing shall be by water for the first
seven days and by water or membrane until the concrete has reached the full specified
strength.
For mixtures with a low to zero bleeding rate, or in the case of aggressively evaporative
environments, or both, the curing shall start at early anytime between placement and final
finishing of the concrete. The curing shall be by reducing the moisture loss from surface
using fogging systems and the use of evaporation reducers such as monomolecular water
curing compound.
Exposed surfaces shall be protected from air blown contamination until 28 d after the
concrete is placed.
The method of curing shall ensure that sufficient moisture is present to complete the
hydration of the cement, and shall be to the approval of the Engineer. The method of curing
shall not:
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(a)
disfigure permanently exposed surfaces
(b)
affect bonding of subsequent coatings
(c)
increase the temperature of the concrete.
During the curing period, exposed concrete surface shall be protected from the direct rays of
the sun.
When liquid membrane is used to cure the concrete, it shall not be applied if bleeding water
is present on the surface of the concrete.
The applied film of the liquid membrane shall be continuous and protected from rain and any
damages for at least 14 days.
QCS 2014

Part
10: Curing
Page 4
Formed surfaces, including the underside of beams, girders, supported slabs and the like, by
moist curing with the forms in place for the full curing period, or until the forms are removed.
When the forms are stripped, curing shall continue by any approved method.
When liquid membrane curing is used, it shall be applied immediately after de-shuttering. In
such cases the concrete surface shall be prepared prior to the application of the membrane
as recommended by the manufacturer.
Water curing is not required when liquid membrane is used.
10.2.5
Unformed surfaces shall be protected as soon as possible after the concrete has been
placed by polythene sheeting. When sufficiently hard, hessian or other absorbent material
shall be placed on the concrete surface and shall be kept wet for the required period. The
hessian shall be overlaid with a sheet of 1000 gauge polythene to assist in the retention of
water. Alternatively a curing method approved by the Engineer may be used.
Once the concrete is sufficiently hard, the top exposed surface of walls, columns and beams
shall be water cured and covered with wet hessian for the required curing period.
10.2.6
Moisture Curing
Moisture curing shall be performed by :
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10.2.4
covering the surface of the concrete with water and keeping it continuously wet
(b)
continuous use of fine fog water sprays
(c)
covering the surface with a saturated absorptive cover and keeping it continuously
wet.
(d)
Burlap, cotton mats, and other absorbent materials can be used to hold water on
horizontal or vertical surfaces.
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Wet straw or hay can be used for wet-curing small areas, but there is the danger that
wind might displace it unless it is held down with screen wire, burlap, or other means
(e)
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(a)
Where method (a) is employed, the bunds used shall not be made from fill from excavations
or any other areas where there is the possibility of chloride contamination.
10.2.7
The concrete surface shall be covered with a suitable absorptive covering, such as wet
hessian.
The absorptive covering shall be overlaid with a 1000 gauge polythene sheet.
The cover shall be in the widest practical widths and shall have 100 mm side and end laps.
Any penetrations or tear in the covering shall be shall be repaired with the same material and
waterproof tape.
QCS 2014

Part
10: Curing
Page 5
Liquid membrane curing shall be in accordance with the requirements of BS 7542, ASTM
C 309 or C1315 when tested at the rate of coverage use on the job.
ASTM C 156 shall be used as a test method to evaluate water-retention capability of liquid
membrane forming compounds. ASTM C 1151 provides an alternative laboratory test for
determining the efficiency of liquid membrane-forming compounds.
Membrane forming curing compounds shall be applied in accordance with the manufacturer's
recommendations immediately after any water sheen which may develop after finishing has
disappeared from the surface and within 2 h of stripping formwork on formed surfaces.
Membrane forming curing compounds shall not be used on surfaces against which additional
concrete or other material is to be bonded unless:
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10.2.8
it is proven that the curing compound will not prevent bond, or
(b)
positive measures are taken to remove it completely from those areas which are to
receive bonded applications
(c)
on fair faced concrete surfaces.
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(a)
Steam Curing
An enclosure shall be formed around the concrete using tarpaulin or other suitable means.
Application of steam shall not be commenced until at least 2 h after final placement of
concrete.
Steam shall be applied at a temperature between 65 C and 80 C.
Excessive rates of heating and cooling shall be prevented during steam curing and
temperatures in the enclosure shall not be allowed to increase or decrease by more than
22 C per hour.
The maximum steam temperature shall be maintained in the enclosure until concrete has
reached its specified strength.
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10.2.9
10.2.10 Pavements and other slab on ground

1
Curing shall ensure that no plastic shrinkage crack will occur, this can be done by protective
measures such as sun shields, wind breaks, evaporation reducers, or fog spraying should be
initiated immediately to reduce evaporation.
Mats used for curing can either be left in place and kept saturated for completion of the
curing, or can be subsequently replaced by a liquid membrane-forming curing compound,
plastic sheeting, reinforced paper, straw, or water
10.2.11 Buildings, bridges, and other structures

1
Additional curing shall be provided after the removal of forms
QCS 2014

Part
10: Curing
Page 6
After the concrete has hardened and while the forms are still in place on vertical and other
formed surfaces, form ties may be loosened when damage to the concrete will not occur and
water applied to run down on the inside of the form to keep the concrete wet.
o
Immediately following form removal, the surfaces shall be kept continuously wet by a water
spray or water-saturated fabric or until the membrane-forming curing compound is applied.
Curing
10.2.12 Mass concrete

Mass concrete is often cured with water for the additional cooling benefit in warm weather;
however, this can be counterproductive when the temperature gradient between the warmer
interior and the cooler surface generates stress in the concrete.
Horizontal or sloping unformed surfaces of mass concrete can be maintained continuously

wet by water spraying, wet sand, or water saturated fabrics.
For vertical and other formed surfaces, after the concrete has hardened and the forms are
still in place, the form ties may be loosened and water supplied to run down the inside of the
form to keep the concrete wet
o
Curing shall start as soon as the concrete has hardened sufficiently to prevent surface
damage.
For unreinforced massive sections not containing ground granulated blast-furnace slag or
pozzolan, curing shall be continued for not less than 2 weeks. Where ground granulated
blast-furnace slag or pozzolan is included in the concrete, the minimum time for curing shall
be not less than 3 weeks.
For reinforced mass concrete, curing shall be continuous for a minimum of 7 days or until
70% of the specified compressive strength is obtained, if strength is the key concrete
performance criterion. For construction joints, curing shall be continued until resumption of
concrete placement or until the required curing period is completed.
Curing shall not stop until favourable differential temperature is attained and at the approval
of the Engineer.
For mass concrete, thermocouples shall be used to monitor the temperature differential of
the concrete.
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END OF PART
QCS 2014

Part
11: Reinforcement
Page 1
REINFORCEMENT ................................................................................................. 2
11.1
11.1.1
11.1.2
11.1.3
11.1.4
11.1.5
GENERAL ............................................................................................................... 2
Scope
2
References
2
Submittals
3
Quality Assurance
3
3
11.2
11.2.1
11.2.2
11.2.3
REINFORCING MATERIALS .................................................................................. 4

Reinforcing Bars
4
4
Tie Wire
5
11.3
11.3.2
11.3.3
INSPECTION, SAMPLING AND TESTING.............................................................. 5

Sampling
5
Testing
6
11.4
CUTTING AND BENDING OF REINFORCEMENT ................................................. 6
11.5
11.5.1
11.5.2
11.5.3
11.5.4
11.5.5
11.5.6
11.5.7
11.5.8
11.5.9
11.5.10
11.5.11
FIXING OF REINFORCEMENT ............................................................................... 6

General
6
Welding
7
Mechanical Splices
8
8
Examination
8
Electrolytic Action
8
Cover
8
Reinforcement
8
Forms and Linings
9
Tanking
9
Adjustment and Cleaning
9
11.6
11.6.2
11.6.3
11.6.4
PROTECTIVE COATINGS TO REINFORCEMENT ................................................ 9

9
11
11
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11
QCS 2014

Part
11: Reinforcement
Page 2
11
REINFORCEMENT
11.1
GENERAL
11.1.1
Scope
This Part includes tension, compression, and temperature reinforcing steel, including welded
wire fabric, and epoxy coated reinforcing. The work includes furnishing, fabrication, and
placement of reinforcement for cast-in-place concrete, including bars, welded wire fabric,
ties, and supports.

This Section
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References
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ASTM A416/A416M....Standard Specification for Steel Strand, Uncoated Seven-Wire for

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ASTM 615/615M ........Standard Specification for Deformed and Plain Carbon-Steel Bars for
Concrete Reinforcement
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ASTM A706, ...............Specification for Low-allow Steel Deformed Bars for Concrete
Reinforcement
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ASTM A881/A881M ...Standard Specification for Steel Wire, Deformed, Stress-Relieved or

Filled
Epoxy-Coated
Seven-Wire
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ASTM A882/A882M- ..Standard Specification for

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ASTM A955/A955M-14 Standard Specification for Deformed and Plain Stainless-Steel Bars
for Concrete Reinforcement
ASTM A1022/A1022M-14a Standard Specification for Deformed and Plain Stainless Steel
Wire and Welded Wire for Concrete Reinforcement
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ASTM A1035/ A1035M Deformed and Plain, Low-carbon, -Chromium, -Steel Bars for
Concrete Reinforcement:
11.1.2

Part 17 ............. Structural Precast Concrete
BS 4449 : 2005...........Specification for Carbon steel bars for the reinforcement of concrete
BS 4482: 2005,...........Specification for Cold reduced steel wire for the reinforcement of
concrete
BS 4483: 2005............Steel fabric for the reinforcement of concrete
of concrete.
EN 1011, ....................Welding. Recommendation for welding of metallic materials
EN 1992-1-1 Eurocode 2: Design of concrete structures. General rules and rules for buildings
ISO 14654, .................Epoxy- coated steel for the reinforcement of concrete
ISO 14656, .................Epoxy powder and sealing material for the coating of steel for the
reinforcement of concrete
QCS 2014

Part
11: Reinforcement
Page 3
ISO 3766 ...................Construction drawings -- Simplified representation of concrete

reinforcement
QS ISO 6935-1:2007, .Steel for the reinforcement of concrete -Part 1: Plain bars
QS ISO 6935-2:2007 ..Steel for the reinforcement of concrete Part 2: Ribbed bars
QS ISO 6935-3:2007 ..Steel for the reinforcement of concrete Part 3: Welded fabric
Submittals
Product data including the manufacturers specification and installation instructions for
proprietary materials and reinforcement accessories shall be provided.
The Contractor shall submit the manufacturers records of chemical and physical properties
of each batch of billet steel bars and a certificate that the respective material furnished meets
the requirements for the steel reinforcement specified. The manufacturers records shall
include certificates of mill as well as analysis, tensile and bend tests of the reinforcement.
Three copies of the steel test report shall be furnished with each consignment of steel
reinforcement. The steel shall be tagged and cross-referenced with mill certificates.
11.1.4
Quality Assurance
The Contractor shall submit to the Engineer for source approval details of the proposed
source of supply of the reinforcement. Details shall include chemical and physical tests for
the past six months production and any independent test results for this period. Details of
quality assurance procedures, including ISO 9000 certificate if held, shall also be given.
The Contractor shall furnish the Engineer with a certificate of compliance for each shipment
of epoxy coated bars. The certificate of compliance shall state that representative samples of
the epoxy coated bars have been tested and that the test results comply with the
requirements herein specified. Test results shall be retained by the Contractor for seven
years. A complete set of test results shall also be handed to the client at the completion of
reinforcement works, and shall be made available to the Engineer upon request.
11.1.5
On delivery, bars in each lot shall be legibly tagged by the manufacturer. The tag shall show
the manufacturers test number and lot number and other applicable data that will identify the
material with the certificate issued for that lot of steel. The fabricator shall furnish three
copies of a certification which shows the batch number or numbers from which each size of
bar in the shipment was fabricated.
Storage of reinforcement shall be on suitable structures a minimum of 450 mm above the

ground surface to prevent damage and accumulation of dirt, rust and other deleterious
matter. Storage facilities shall be such as to permit easy access for inspection and
identification. Reinforcement bundles shall be clearly tagged with bar schedule and bar mark
reference.
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11.1.3
QCS 2014

Part
11: Reinforcement
Page 4
The reinforcement shall not be roughly handled, dropped from a height, or subjected to shock
loading or mechanical damage. Steel reinforcing bars shall be kept clean and shall be free
from pitting, loose rust, mill scale, oil, grease, earth, paint, or any other material which may
impair the bond between the concrete and the reinforcement. The reinforcement shall be
covered to ensure protection from wind blown dust, condensation and other deleterious
materials.
11.2
REINFORCING MATERIALS
11.2.1
Reinforcing Bars
Reinforcement shall be from an acceptable source. All steel reinforcement bars shall comply
with the requirements of:
QS ISO 6935 with minimum grade of B500 MPa or
(ii)
BS 4449 with minimum grades of B500 MPa ; or..
(iii)
ASTM A615 / A615M with minimum grade of 75 [520MPa]; or
(iv)
Deformed and Plain, Low-carbon-Chromium-Steel

Reinforcement: ASTM A1035/ A1035M
(v)
ASTM A1022/A1022M-14a Standard Specification for Deformed and Plain

Stainless Steel Wire and Welded Wire for Concrete Reinforcement
(vi)
ASTM A955/A955M-14 Standard Specification for Deformed and Plain

Stainless-Steel Bars for Concrete Reinforcement
(vii)
Other types of reinforcement, as approved by Qatar Standards
Bars
for
Concrete
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(i)
As per project design, other steel grades of less than B500MPa may be used only for stirrups
and secondary reinforcement of diameter of 10mm or less.
If the steel has excessive surface rust, dust or other deleterious material then the steel shall
be sand blasted. Sand for blasting shall not contain materials deleterious to the durability of
the reinforcement or concrete. Dune sand shall not be used for the sandblasting of
reinforcement.
For extreme exposure class X5; protection measures such as epoxy coated bars; Lowcarbon-chromium-steel bars; or Stainless Steel may be considered.
11.2.2
Steel fabric reinforcement shall comply with the requirements of QS ISO 6935-3 or BS 4483
and shall be delivered to Site in flat mats.
Welded intersections shall not be spaced more than:
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(a)
300 mm for plain round bars
(b)
400 mm apart for deformed high yield bars in direction of calculated stress except
when used as stirrups.
QCS 2014

Part
11: Reinforcement
Page 5
Tie Wire
Tie wire shall conform to the requirements of BS 4482.
1.6 mm black annealed mild steel shall be used for tie wire.
No wires smaller than size D-4 shall be used.
11.3
INSPECTION, SAMPLING AND TESTING
Inspection of reinforcing steel and the installation thereof will be conducted by the Engineer.
The Contractor shall give 24 hour notice to the Engineer before closing forms or placing
concrete.
The Engineer may instruct the Contractor to break out and remove completely all sections of
the work already constructed under any of the following circumstances:
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11.2.3
reinforcing steel sample under test fails to meet the specification requirements at any
time
(b)
the Engineer considers that samples which were presented to him for test were not
truly representative
(c)
a previously rejected reinforcing steel has been used in the Works.
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(a)
Sampling
Representative samples of all reinforcing steel proposed for use in the Works must be
submitted by the Contractor, before work is commenced, to the Engineer for his written
approval.
Manufacturer's certificates stating clearly for each sample:

(a)
place of manufacture
expected date and size of deliveries to site
(b)
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11.3.2
(c)
all relevant details of composition, manufacture, strengths and other quality of the
steel.
The Engineer reserves the right to sample and inspect reinforcement steel upon its arrival at
the work site.
Frequency of sampling and the method of quality control shall be in accordance with steel
bars manufactured standard QS ISO 6935 or BS 4449 .
Where epoxy coated steel is used, a sample of the coating material shall be supplied with
each batch in an airtight container and identified by the batch number.
Allow 14 days for Engineers review of samples.
QCS 2014

Part
11: Reinforcement
Page 6
Testing
Tests shall be carried out when directed by the Engineer.
Tests shall be carried out in accordance with QS ISO 6935 or BS 4449.
The following information shall be provided with each delivery of reinforcement:

elastic limit
(b)
ultimate strength
(c)
stress/strain curve
(d)
cross-sectional area
(e)
deformation/bond characteristics of deformed bars.
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(a)
11.3.3
The Contractor shall allow for dimensions and weight measurements, tensile, bend and/ or
rebend tests at own cost, for each size of bar to be used in the concrete construction.
Test results for each bar size shall be submitted to the Engineer three weeks before concrete
work commences on Site.
Full testing shall be required if the source of supply of reinforcement changes, in which case
the cost of such extra testing will be borne by the Contractor.
When any test results do not conform to the relevant standard the reinforcement steel shall
be removed from the Site and all costs resulting therefrom shall be borne by the Contractor.
11.4
CUTTING AND BENDING OF REINFORCEMENT
Cutting and bending of reinforcement shall be in accordance with ISO 3766 or BS 8666 and
shall be done without the application of heat. Bends shall have a substantially constant
curvature. For epoxy coated steel the provisions of Clause 11.6.1 of this Part shall apply
Steel bars manufactured according to the approved ASTM standards shall be bent according
to the same standard.
Reinforcement shall not be straightened or rebent without the approval of the Engineer. If
permission is given to bend projecting reinforcement care shall be taken not to damage the
concrete and to ensure that the radius is not less than the minimum specified in ISO 3766 or
BS 8666.
11.5
FIXING OF REINFORCEMENT
11.5.1
General
All reinforcement shall be securely and accurately fixed in positions shown on the Drawings
to ensure that the reinforcement steel framework as a whole shall retain its shape. The
framework shall be supported to retain its correct position in the forms during the process of
placing and consolidating the concrete.
The ends of all tying wires shall be turned into the main body of the concrete and not allowed
to project towards the surface.
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QCS 2014

Part
11: Reinforcement
Page 7
No part of the reinforcement shall be used to support access ways, working platform or for
the conducting of an electric current.
The Contractors specific attention is drawn to the following general requirements:

(a)
lapped joints shall be as indicated on the Drawings and/or in accordance with the
requirements of EN 1992-1-1 or BS 8666
(b)
hooks shall be semicircular with a straight length of at least:

(i)
four bar diameters for mild steel
(ii)
six bar diameters for high yield steel.
Welding
Welding shall not be used unless authorised by the Engineer and recommended by the
reinforcement manufacturer.
Where welding is approved it shall be executed under controlled conditions in a factory or

workshop.
Welding shall not take place on site without the approval of the Engineer and unless suitable
safeguards and techniques are employed and the types of steel employed have the required
welding properties.
Welding if approved, may be used for:
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11.5.2
fixing crossing or lapping reinforcement in position
(b)
fixing bars to other steel members
(c)
structural welds involving transfer of loads between reinforcement or between bars

and other steel members.
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(a)
The length of run deposited in a single pass shall not exceed five times the bar diameter. If a
longer welded length is required, the weld shall be divided into sections with the space
between runs made not less than five times the bar diameter.
Butt welds shall be formed by flash butt welding or metal-arc welding. Other methods may be
approved, subject to their satisfactory performance in trial joints.
Metal-arc welding or electrical resistance welding may be used for fixing suitable steels or for
lapped joints.
Flash butt welding shall be executed with the correct combination of flashing, heating,
upsetting and annealing, using only machines which automatically control this cycle of
operations.
Metal-arc welding shall comply with EN 1011 and the recommendations of the reinforcement
manufacturer.
10
Welded joints shall not be made at bends in the reinforcement. Joints in parallel bars of
principle reinforcement shall be staggered, unless otherwise approved. The distance
between staggered joints shall be not less than the end anchorage length joints.
11
Weldable reinforcement where shown on the Drawings shall conform to ASTM A706.
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QCS 2014

Part
11: Reinforcement
Page 8
Mechanical Splices
Mechanical splices shall comply with EN 1992-1-1 or BS 8666, and shall be used as and
where indicated on the Drawings.
Details of mechanical splices shall be submitted to the Engineer for approval.
11.5.4
Bundling and splicing of bundled bars shall be in accordance with EN 1992-1-1 or BS 8666.
Splicing, except where indicated on the Drawings or approved shop drawings, will not be
permitted without the approval of the Engineer.
11.5.5
Examination
The Contractor shall notify the Engineer at least 24 hours before commencing the fixing of
reinforcement in order to facilitate the inspection of formwork.
The Contractor shall ensure that areas to receive reinforcement are cleaned before fixing.
11.5.6
Electrolytic Action
Reinforcement shall not be fixed or placed in contact with non-ferrous metals.
11.5.7
Cover
Correct concrete cover to reinforcement shall be maintained with the aid of approved spacer
pieces.
The cover shall not be less than given in Section 5 Part 6.
Spacers, chairs and other supports shall be provided as necessary to maintain the
reinforcement in its correct position.
In a member where the nominal cover is dimensioned to the links, spacers between the links
and formwork shall be the same dimension as the nominal cover.
Spacer bars shall be of the same diameter as longitudinal bars, but not less than 25 mm in
diameter, and shall be fixed between two layers at 1.5 m centres except where bundled bars
are detailed.
Spacers, chairs and other supports shall be made of concrete, plastic or other material to the
approval of the Engineer. Where supports are made of concrete they shall have at least the
same cube strength as the concrete in the host member.
11.5.8
Reinforcement
Placing of all reinforcement steel bars will be checked by the Engineer and in no case is
concrete to be placed around any reinforcement steel that has not been approved by the
Engineer. Insertion of bars into or the removal of bars from concrete already placed will not
be permitted.
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11.5.3
QCS 2014

Part
11: Reinforcement
Page 9
Reinforcement steel temporarily left projecting from the concrete at the joints shall not be
bent without the prior approval of the Engineer.
11.5.9
Forms and Linings
Damage to forms and linings shall be avoided.
11.5.10 Tanking
1
Reinforcement shall not be fixed until completion of placing tanking (membrane) protection.
11.5.11 Adjustment and Cleaning
Check position of reinforcement before and during placing concrete:

pay particular attention to the position of top reinforcement in cantilever sections
(b)
ensure that reinforcement is clean and free from corrosive pitting, loose rust, loose mill
scale, oil and other substances which may adversely affect reinforcement, concrete, or
the bond between the two.
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(a)
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Protect projecting reinforcement from the weather where rust staining of exposed concrete
surfaces may occur.
At the time of concreting, all reinforcement steel shall have been thoroughly cleaned and
freed from all mud, oil or any other coatings that might destroy or reduce the bond:
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clean all set or partially set concrete which may have been deposited thereon during
the placing of a previous lift of concrete
(b)
all uncoated rust bars shall be again sand blasted and pressure washed.
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(a)
Immediately before concrete placing the reinforcing steel shall be washed thoroughly with
high pressure potable water jets to remove any deposited salts.
11.6
PROTECTIVE COATINGS TO REINFORCEMENT
All the forgoing clauses of this part apply equally to epoxy coated reinforcing bars.
11.6.2
Reinforcing steel which are to be coated shall be free of slivers, scabs, excessive pitting,
rust, grease, oil and other surface defects detrimental to proper coating.
The surface shall be prepared in accordance with ISO 14654.
Coating shall be applied to the cleaned surface as soon as possible after cleaning and before
any visible oxidation to the surface occurs.
Reinforcing steel shall not have surface defects that would be detrimental to coating.
Coating material shall be epoxy resin powders as specified in ISO 14654 and ISO 14656 for
coating of reinforcing bars and as follows:
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(a)
epoxy resin powders which do not meet the above requirements must be tested by an
approved independent testing laboratory and accepted by the Engineer before use
QCS 2014

Part
11: Reinforcement
Page 10
(b)
only fusion bonded epoxy-coated reinforcing steel will be accepted
(c)
no other means of epoxy coating will be approved.
Patching material shall be:

(a)
furnished by the epoxy coating manufacturer
(b)
compatible with the coating
(c)
inert in concrete
(d)
suitable for repairs to the coated reinforcing bars to be made by the coating applicator
and the Contractor at the project site.
Fabrication shall be performed before coating except as hereinafter specified for bent bars
and straight bars less than 7.6 m long.
Bent reinforcing steel bars shall be coated after bending, unless the fabricator can show that
satisfactory results can be obtained by coating before bending.
Any visible cracks in the coating on the outside of the bend or damage to coating resulting in
debonding of the coating after bending shall be rejected.
10
Bars less than 7.6 m long may be sheared or sawn to length after coating, provided:
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end damage to coating does not extend more than 12 mm back
(b)
cut end is patched before any visible oxidation appears.
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(a)
Flame cutting will not be permitted.
12
Epoxy coating shall be checked visually after cure for continuity of coating and shall be free
from holes, contamination, cracks and damaged areas.
13
There shall not be more than two holidays (pinholes not visually discernible) in any 300 mm
of the epoxy coated bar.
14
A holiday detector shall be used in accordance with the manufacturer's instruction to check
the epoxy coating for holidays. A 67.5 V detector such as the Tinker and Rasor Model M-1 or
its approved equivalent shall be used.
15
Patching of holidays is not required if there are less than three holidays per 300 mm length.
Bars having three or more holidays per 300 mm shall be cleaned and recoated or replaced
16
Epoxy coating film shall be cured and/or post cured to a fully cured condition. A
representative proportion of each production lot shall be checked by the epoxy coating
applicator, using the method most effective for measuring cure to ensure that the entire
production lot of epoxy coating is supplied in the fully cured condition.
17
Contractor shall repair all coating damaged by fixtures used to handle or support the bars in
the coating process as follows:
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11
(a)
patching shall be done as soon as possible and before visible oxidation occurs
(b)
excessive patching from other causes will not be permitted
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(c)

Part
11: Reinforcement
Page 11
satisfactory correction shall consist of proper adjustment of process, and rerunning

the bars through the plant.
The Engineer reserves the right for access to the epoxy coating applicators plant to witness
epoxy coating processes for project work and to obtain specimens from test bars for any
testing desired.
19
All chairs, tie wires and other devices used in connecting, supporting, securing or fastening
epoxy coated reinforcement steel shall be made of or coated with a dielectric material.
20
Before the reinforcement is lowered into place and before placement of the concrete, the
coated bars shall be inspected by the Engineer for damage to the epoxy coating.
21
Sheared ends of bars and other areas requiring limited repair due to scars and minor defects
shall be repaired, using the specified patching or repair materials.
11.6.3
Reinforcement steel bars shall be handled and stored in a manner to prevent damage to bars
or, where used, the epoxy coating.
Bars, or where used epoxy coating, damaged in handling or other operations shall be
satisfactorily repaired at no additional cost to the Employer.
Where epoxy coated bars are used all handling systems shall have plastic mandrel and
padded contact areas wherever possible.
Where epoxy coated bars are used all bundling bands shall be padded.
All bundles shall be lifted with a strongback, multiple supports or a platform bridge so as to
prevent bar to bar abrasion from sags in the bar bundle.
Bars or bundles shall not be dropped or dragged.
During vibration care shall be taken to ensure that the epoxy-coated reinforcement is not
damaged by the pokers.
11.6.4
Adhesion and flexibility of the epoxy coating shall be evaluated on test bars coated with each
production lot.
At least 1 % of the length or 6 m, whichever is less, of each size of bar to be coated shall be
furnished as test bars.
Test bars may be in one length or multiple lengths as required to have one test bar of each
size with each production lot.
The production epoxy coated test bars shall be evaluated by bending 120 (after rebound)
around a mandrel of a diameter corresponding to size of bar indicated in Table 11.1.
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18
QCS 2014

Part
11: Reinforcement
Page 12
Table 11.1
Mandrel Diameter for Bar Diameter for
Evaluation Test of Epoxy Coated Test Bars
Diameter of Mandrel
(mm)
10
12
13
14
16
18
20
22
24
25
26
28
30
32
34
36
79
95
103
111
127
143
159
175
191
198
206
222
238
254
270
286
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Bar Diameter
(mm)
Bend shall be made at a uniform rate and may take up to one minute to complete.
Bend test shall be conducted at a room temperature of between 20 C and 30 C after the
specimen has been exposed to room temperature for a sufficient time to ensure that it has
reached thermal equilibrium.
No cracking of the epoxy coating shall be visible to the naked eye on the outside radius of the
bent bar.
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END OF PART
QCS 2014

Part
12: Joints
Page 1
JOINTS.................................................................................................................... 2
12.1
12.1.1
12.1.2
12.1.3
12.1.4
12.1.5
GENERAL ............................................................................................................... 2
Scope
2
References
2
Submittals
2
Quality Assurance
3
Definitions
3
12.2
12.2.1
12.2.2
CONSTRUCTION JOINTS ...................................................................................... 4

General
4
4
12.3
12.3.1
12.3.2
12.3.3
MOVEMENT JOINTS .............................................................................................. 5

General
5
Joint Filler
6
Joint Sealants
6
12.4
12.4.1
SLIP BEARINGS ..................................................................................................... 7

General
7
12.5
12.5.1
12.5.2
12.5.3
12.5.4
WATERSTOPS ....................................................................................................... 7
General
7
Waterstops
7
8
8
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12
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Part
12: Joints
Page 2
12
JOINTS
12.1
GENERAL
12.1.1
Scope
This part deals with movement and construction joints, slip bearings, waterstops and
associated sealants and filler materials.
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12.1.2
This Section
Part 1 ............... General
Part 10, ............ Curing
References
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ASTM D1751 ..............Standard Specification for Preformed Expansion Joint Filler for
Concrete Paving and Structural Construction (Non-extruding and
Resilient Bituminous Types)
ASTM D2240 ..............Standard Test Method for Rubber PropertyDurometer Hardness
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ASTM D3575 ..............Standard Test Methods for Flexible Cellular Materials Made From
Olefin Polymers
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BS 903........................Physical testing of rubber

BS 2571......................General purpose flexible PVC compounds for moulding and extrusion
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BS 6093,.....................Design of joints and joining in building construction
BS 7164,.....................Chemical tests for raw and vulcanized rubber
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BS EN 1992-3 ............Eurocode 2. Design of concrete structures. Liquid retaining and

BS EN ISO 7214 ........Cellular plastics. Polyethylene. Methods of test

CRD-C572 ..................Corps of Engineers Specifications for Polyvinylchloride Waterstop
ISO 9001 ....................Quality management systems. Requirements
12.1.3
Submittals
The Contractor shall submit for approval by the Engineer as soon as practicable after
acceptance of his Tender and not less than three weeks before commencement of
concreting, drawings showing his proposals for the position of construction joints having due
regard to any that may be shown on the Contract Drawings.
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Part
12: Joints
Page 3
For slide bearings the Contractor shall provide at least three samples of the proposed
material, together with the manufacturer's technical specifications and recommendations in
respect of application and performance.
For slip joints the Contractor shall provide at least three samples of materials proposed,
together with manufacturer's technical specifications and recommendations in respect of
application and performance.
For waterstops the Contractor shall provide at least three samples of proposed types,
including prefabricated joints and junctions, if applicable. If joints are to be made up on site,
provide worked samples, including samples for each make of waterstop, where samples
from different manufacturers are provided.
The Contractor must supply a certificate of compliance for the joint sealant, stating that it
meets the requirements of the specification. The Contractor shall also supply the
Manufacturers technical and installation data for the proposed material. The Contractor shall
provide details of previous installations of the product, with the client name, structure name,
type of joint and value of contract.
The Contractor shall prepare shop drawings that show the layout of the waterstops, specials
and joints.
12.1.4
Quality Assurance
The joint sealant, including primers and debonding materials shall be compatible with each
other and shall be supplied from a manufacturer operating the ISO 9001 or 9002 Quality
Assurance Scheme.
12.1.5
Definitions
Construction Joint: The surface where two successive placements of concrete meet, across
which it is desirable to develop and maintain bond between the two concrete placements, and
through which any reinforcement which may be present is not interrupted.
Contraction Joint: Formed, sawed, or tooled groove in a concrete structure to create a

weakened plane and regulate the location of cracking resulting from the dimensional change
of different parts of the structure. (See also Isolation Joint.)
Expansion Joint: A separation between adjoining parts of a concrete structure which is

provided to allow small relative movements such as those caused by thermal changes to
occur independently.
Isolation Joint: A separation between adjoining parts of a concrete structure provided to

isolate and element and thus allow independent movement.
Joints Fillers: Materials that are used to fill space within movement joints during construction.
They may provide support to a sealant applied subsequently.
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QCS 2014

Part
12: Joints
Page 4
CONSTRUCTION JOINTS
12.2.1
General
Where construction joints are required in slabs or beams (designed by Direct Design Method
DDM) they shall be located within the middle third of their spans, and at one-third to onequarter of span in slabs and beams subject to a maximum spacing of approximately 9
metres. Where slabs are supported by beams then the beams and slabs shall be constructed
in one operation.
In all cases vertical stop boards of a form to be approved by the Engineer shall be provided
by at the end of each section of work which is to be concreted in one operation and the
concrete shall be thoroughly compacted against these stop boards.
Where slabs, beams and walls incorporate construction joints, panels shall generally be
constructed consecutively. Where this is not possible a gap not exceeding one metre shall be
formed between adjacent panels. This gap shall not be concreted until a minimum interval of
7 d has expired since the casting of the most recent panel.
The size of bays for reinforced floors, walls and roofs shall be as shown on the drawings but
in no event shall they exceed 7.5 m in either direction and 6 m when unreinforced or with
nominal reinforcement.
Horizontal construction joints in walls will only be permitted when the wall is continuous with
the floor slab. Walls shall be keyed on cast kickers 150 mm high or on the tops of walls
meeting the soffits of suspended members.
Construction joints in monolithic structures shall be aligned with each other whenever
practicable.
Before placing new concrete against concrete which has already set the latter shall be
treated to expose the aggregate over the full section and leave a sound irregular surface.
This shall be done while the concrete is still fresh by means of water spray and light brushing
or other means approved by the Engineer.
Immediately before the new concrete is placed all foreign matter shall be cleaned away and
the surface moistened.
If during the course of the Contract it should become apparent that the Contractors methods
of forming construction joints are not proving effective the Engineer may order the Contractor
to execute at the Contractors expense such preventative measures as the Engineer may
consider necessary to ensure the watertightness of the construction joints in further work.
12.2.2
The floor may be designed as fully restrained against shrinkage and thermal contraction and
should be cast directly onto the blinding concrete.
In large structures, the floor shall be designed as a series of continuous strips with transverse
induced contraction joints provided to ensure that cracking occurs in predetermined
positions. Longitudinal joints between the strips should form contraction joints.
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12.2
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Part
12: Joints
Page 5
Waterstops shall be incorporated into construction joints, crack induced joints, contraction
joints and expansion joints in water retaining structures. The Contractor shall ensure that all
such joints are watertight and any joints which may leak or weep shall be rectified by the
Contractor to the Engineers satisfaction.
joints in water retaining structures shall be shown on the design drawings.
Where the positions or type of joints are not indicated on the drawings, the spacing of
construction joints or crack induced joints in water retaining structures shall not exceed 5 m.
slab, construction joints, crack induced joints, contraction joints and expansion joints shall be
incorporated into the works as appropriate. for slabs on grade, construction joints or crack
induced joints should be provided at areas where differences in subgrade and slab support
may cause cracks. The slab shall be cast in strips not more than 15 metres wide across the
width of the building. Within each strip for both directions, crack induced joints shall be
provided at areas where cracks are expected and not more than 5.0 metre spacing, and
construction or contraction joints shall be provided at not more than 15.0m spacing.
Construction or contraction joints shall be provided between adjacent strips.
Waterstops of a type acceptable to the Engineer shall be embedded in the concrete. The
waterstop should be made of a high quality material, which must retain its resilience through
the service life of the structure for the double function of movement and sealing. The surface
of waterstops should be carefully rounded to ensure tightness of the joint even under heavy
water pressure. To ensure a good tightness with or without movement of the joints, the
waterstop should be provided with anchor parts. The cross-section of the waterstops should
be determined in accordance with the presumed maximum water pressure and joint
movements. The complete works of fixed and welded connections must be carried out
12.3
MOVEMENT JOINTS
12.3.1
General
Movement joints for expansion and contraction shall be constructed in accordance with the
details and to the dimension shown on the Drawings or where otherwise ordered by the
Engineer and shall be formed of the elements specified.
Movement Joints in Water Retaining Structures shall be in accordance with the details and to
the dimension shown on the Drawings and EN 1992-3.
The Contractor shall pay particular attention to the effects of climatic extremes on any
material which he may desire to use on any movement joint and shall submit for approval by
the Engineer his proposals for the proper storage, handling and use of the said materials
having due regard for any recommendations made by the manufacturer in this connection.
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Part
12: Joints
Page 6
Joint Filler
Joint fillers shall conform to the requirements of BS 6093 or ASTM D1751 or equivalent if
they are bituminous type or to the requirements of ASTM D3575 or BS EN ISO 7214 or
equivalent if they are polymer foam type.
The joint filler shall be fixed to the required dimensions of the joint cross-section and shall
provide a firm base for the joint sealer.
When required between two concrete surfaces as a resilient movement joint, the filler shall
be an approved granulated cork bound with insoluble synthetic resin.
When required between blockwork and concrete as a low density movement joint filler or for
building details it shall be an approved bitumen impregnated fibreboard or preformed closed
cell polyethylene.
12.3.3
Joint Sealants
All joints to be sealed shall be formed and the groove grit blasted to remove all traces of
deleterious materials such as form oil or curing compounds and also to remove any surface
laitance from the sides of the joint. The joint shall be dry prior the application of priming.
Where the use of grit blasting is not possible the Contractor may propose alternative
methods subject to the approval of the Engineer.
The back of the joint shall receive a debonding tape or polyethylene foam backer cord in
order to provide the correct depth to width ratio and prevent three sided adhesion.
The areas adjacent to the joint shall be protected using masking tape.
The sides of the joint shall be primed with the relevant primer as recommended by the
sealant manufacturer and the sealant material applied in accordance with the manufacturers
instructions.
The sealant material shall be a non-biodegradable multicomponent pitch polyurethane

elastomeric joint sealant, carefully selected as appropriate for the specific climatic and
environmental exposure conditions expected. Alternative types of sealant will be considered,
including epoxy-polyurethane, rubber bitumen and acrylic, subject to the requirements of the
specification and the approval of the Engineer.
Where the joint sealant is to be in contact with a protective coating the Contractor shall
satisfy the Engineer that the sealant and protective coating are compatible
Sealants shall exhibit the following properties:
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12.3.2
(a)
Movement accommodation factor
25 %
(b)
Shore A hardness
(c)
Solids content
(d)
Service temperature range
(e)
Chemical resistance to Sewage, Sabkha, Mineral acids and Alkalis
(f)
Width to depth ratio
20 - 25
100 %
2:1
0 C to 90 C
QCS 2014

Part
12: Joints
Page 7
Where shown on the Drawings sealants shall also be suitable for use with potable water.
All surface preparation, priming, mixing and application shall be carried out in strict
accordance with the manufacturers instructions.
10
The sealant shall have a proven track record of no less than ten years under similar local
conditions.
12.4
SLIP BEARINGS
12.4.1
General
Slip bearings shall be preformed low friction bearing strips to form a thin sliding joint.
They shall be extruded from specially formulated polyethylene to form a durable lamina
resistant to sewage, mineral acids and alkalis, solvents and weathering.
Slip bearings shall be applied in two layers with the bottom layer bonded to the substrate with
a high quality solvent borne adhesive based on polychloroprene rubber. The substrate shall
be clean and free from deleterious materials such as form oil or curing compounds and
surface laitance. The surface shall be level and even along the full length of the joint
The applied loads for slip bearings shall not exceed 0.7 MPa.
Operating temperatures shall be up to 80 C
The coefficient of friction shall not exceed 0.15
12.5
WATERSTOPS
12.5.1
General
Waterstops and associated materials shall be by a manufacturer with a minimum of ten years
experience in the field of engineering waterproof products.
PVC waterstops shall be suitable for storage, handling, installation and service within a range
of 15 C to 65 C.
12.5.2
Waterstops
The waterstop shall be a high performance system forming a continuous network as shown
on the Drawings.
Site jointing is to be limited to butt joints and shall be performed strictly in accordance with
Centrally placed waterstops shall employ centre bulbs/shutter stop with ribs on the web
sections.
Externally placed waterstops shall have ribs on either side of the centre of the waterstop. The
water bar used at the location of expansion joints shall have a bulb in the centre to
accommodate the movements.
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Part
12: Joints
Page 8
Waterstops shall have a minimum thickness of 3 mm.
The minimum test performance data for PVC waterstops shall be as follows:
Tensile strength
Elongation at break
Hardness
>12 MPa
300 %
Shore A 80 to 90
The materials shall be tested in accordance with BS 2571 or BS 2782 or CRDC572 or

ASTM D2240.
12.5.3
Butyl rubber waterstops shall have the properties stated in Table 12.1 when tested in
Property
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Table 12.1
Properties Requirements of Butyl Rubber Waterstops
Requirements
3
Density
Part A26
Handness
Part A2
Tensile Strength
Part A2
Elongation at break point
Not less than 450 %
Part A/6
Water Absosption (48 hours immersion)
Not exceeding 5 %
1100 kg/m ( 5 %)
60-70 IRHD
Not less than 17.5 N/mm
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Part A1
Butyl rubber waterstops shall be suitable for storage, handling, installation and service within
a temperature of 0 C to 40 C
12.5.4
Where active sealing is required for critical areas, waterstops shall be hydrophilic polymer
modified chloroprene rubber strips. The rubber strips shall conform to the following properties
as applicable:
Water pressure resistance
(a)
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(b)
Expansion in contact with water :
(c)
Reversible
- 30 to + 70 C
(d)
5 Bar (50 m)
Application Temperatures
2 x original SRE
The selected rubber strips shall be available for three exposures:

(a)
Fresh Water
(b)
Seawater
(c)
Chemicals (if the condition demands or upon the Engineers request)
The supplier shall furnish references upon request of the Engineer.

END OF PART
QCS 2014

Part
Page 1
INSPECTION AND TESTING OF HARDENED CONCRETE .................................. 2
13.1
13.1.1
13.1.2
13.1.3
13.1.4
13.1.5
13.1.6
GENERAL ............................................................................................................... 2
Scope
2
References
2
Submittals
2
Quality Assurance
3
3
4
13.2
13.2.1
13.2.2
13.2.3
13.2.4
CONCRETE CORES ............................................................................................... 4

General
4
Drilling Cores
5
6
7
13.3
REINFORCEMENT COVER MEASUREMENTS ..................................................... 7
13.4
13.4.1
13.4.2
13.4.3
13.4.4
ULTRASONIC PULSE MEASUREMENTS .............................................................. 8

General
8
8
Execution of Tests
8
9
13.5
RADIOGRAPHY OF CONCRETE ........................................................................... 9
13.6
13.6.1
13.6.2
13.6.3
13.6.4
SURFACE HARDNESS ........................................................................................... 9

General
9
Method of Test
9
Equipment
10
Reporting
10
13.7
13.7.1
13.7.2
CHEMICAL CONTENT .......................................................................................... 10

Sampling
10
Laboratory Testing
11
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13
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Part
Page 2
13
INSPECTION AND TESTING OF HARDENED CONCRETE
13.1
GENERAL
13.1.1
Scope
This Part of the specification covers the inspection, sampling and testing of hardened
concrete.
This Section
References
The following standards are referred to in this part of the specification:
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13.1.2
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ACI 214.4R .................Guide for Obtaining Cores and Interpreting Compressive Strength
Results
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ACI 318 ERTA ............Building Code Requirements for Structural Concrete (ACI 318-08) and
Commentary
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ASTM C42 ..................Standard Test Method for Obtaining and Testing Drilled Cores and
Sawed Beams of Concrete
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ASTM C823 ................Standard Practice for Examination and Sampling of Hardened

Concrete in Constructions
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BS 1881-124 ..............Testing concrete. Methods for analysis of hardened concrete
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BS 1881-204, .............Testing concrete. Recommendations on the use of electromagnetic

covermeters
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BS EN 12504-1 ..........Testing concrete in structures cored specimens taking, examining and

testing in compression
BS EN 12504-2 ..........Non-destructive testing. Determination of rebound number
BS EN 12504-3:2005 Testing concrete in structures. Determination of pull-out force

BS EN 12504-4 ..........Determination of ultrasonic pulse velocity
BS EN 13791..............Assessment of in-situ compressive strength in structures and precast
concrete components
GSO ISO 1920-6 ........ Testing of concrete part 6: sampling, preparing and testing of
concrete core .
13.1.3
Submittals
The Contractor shall submit to the Engineer his quality assurance procedures for the
particular parts of the testing work that will be carried out.
The Contractor shall submit for the Engineers approval the curriculum vitae (CV) of the
supervisor proposed for the work.
QCS 2014

Part
Page 3
The Contractor shall through testing agency prepare a factual report that identifies the test
methods used and the test results. The report shall also identify any unusual results or
pertinent information relating to the testing. The report shall be presented in hard and
electronic copies.
For each of the test results the Contractor shall identify the precision or repeatability of the
particular sampling and testing method. This shall be as given from experience of the
particular test by the laboratory or as expected from information in the particular test
standard.
In-place tests will be valid only if the tests have been conducted using properly calibrated
equipment in accordance with recognized standard procedures and acceptable correlation
between test results and concrete compressive strength has been established and is
submitted.
Non-destructive tests shall not be used as the sole basis for accepting or rejecting concrete,
but they may be used to evaluate concrete when the standard-cured strengths fail to meet
the specified strength criteria
13.1.4
Quality Assurance
All field and laboratory testing of concrete shall be carried out by an independent laboratory
The evaluation of concrete in structure is needed when an existing structure is to be modified

or redesigned; to assess structural adequacy when doubt arises about the compressive
strength in the structure due to defective workmanship, deterioration of concrete due to fire or
other causes;when an assessment of the in-situ concrete strength is needed during
construction; to assess structural adequacy in the case of non-conformity of the compressive
strength obtained from standard test specimens; assessment of conformity of the in-situ
concrete compressive strength when specified in a specification or product standard.
13.1.5
If the 28 d works test cubes as defined in clause 6.6 of this Section fail to meet the minimum
criteria, the Engineer shall direct the Contractor to carry out in-place methods to estimate the
concrete strength by non-destructive testing, in-situ drilling of concrete cores or load testing.
The parts or elements of the structure made from the defective batch or batches of concrete
as represented by the works test cubes shall be identified by the Engineer and based on this
information the Engineer shall instruct the Contractor on the required number and position of
concrete cores.
The Engineer shall review the concrete core test results in conjunction with BS EN 13791 or
ACI 318 whichever is applicable to the structural design.
Based on this assessment the Engineer shall decide the acceptability of the concrete in the
structural element and may either:
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(a)
accept the concrete
(b)
instruct that certain remedial works are carried out
(c)
instruct that the element is replaced.
QCS 2014

Part
Page 4
The Contractor shall make all arrangements to provide safe stable access to testing
locations.
When gaining access to testing locations and whilst testing the Contractor shall take care not
to damage the structure or leave it in an untidy or unclean state.
The Contractor shall take precautions to ensure that cooling water from concrete coring/other
operations is discharged such as not to cause a mess or damage the interior or exterior parts
of the structure.
The Contractor shall be responsible for arranging the water supply required for testing.
The Contractor shall arrange for a suitable power supplies. Where testing is being carried out
on an occupied structure a power supply from the building services may not available and the
Contractor shall make arrangements for power supply and extension leads of adequate
length.
The Contractor shall appoint a qualified field supervisor to co-ordinate and manage the field
work. The supervisor shall have not less than five years experience of such work.
Before starting the work, the Engineer with the Contractors supervisor will mark the positions
where field testing is to be carried out. A unique referencing system to identify each sample
or testing location will be adopted, and this will either be referenced on sketch plans or
drawings or by a detailed description used throughout the report to identify test locations.
If testing is being carried out on an occupied structure the Contractor shall co-ordinate with
the owner or operator of the structure to arrange the detailed programme for the works and
gain access to the various parts of the structure.
As soon as laboratory test results are available these shall be submitted by hand or faxed to
the Engineer in draft form. The testing laboratory, or technical bureau assigned by the testing
agency, assigned by the contractor shall provide a technical report providing visual
information and analysing the tests conducted.
10
All core holes, dust sample holes and exploratory investigation areas shall be reinstated with
a proprietary non shrink cementitious repair mortar. The preparation of the hole or area
before reinstatement shall be carried out as per the recommendation of the repair mortar
supplier.
11
Before filling any core holes, dust sample holes or exploratory investigation areas, the
Contractor shall allow the Engineer time to inspect these areas and obtain written
confirmation from the Engineer before filling.
13.2
CONCRETE CORES
13.2.1
General
The drilling and testing of cores shall be carried out in accordance with BS EN 13791 & BS
EN 12504-1, or GSO ISO 1920-6 or ASTM C42 and ACI 214.4 whichever is applicable to the
structural design.
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13.1.6
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Part
Page 5
All of the supplementary information listed by the relevant standards shall be included in the
test report with photographs of the cores.
An assessment of in-situ compressive strength for a particular test region shall be based on
at least 3 cores. Consideration shall be given to any structural implications resulting from
taking cores. The diameter of concrete core shall be at least 100 mm for strength evaluation
unless clear spacing of reinforcement is less than 100 mm and approved by Engineer.
The preferred minimum core diameter is three times the nominal maximum size of the
coarse aggregate, but it shall be at least two times the nominal maximum size of the coarse
aggregate
The Engineer will advise the required number and locations of cores. If the results of the
initial coring are inconclusive, the Engineer may instruct that further cores be taken at certain
locations.
Unless otherwise directed by the Engineer, the Contractor shall ensure that coring does not
cut through any reinforcing steel. The required diameter and depth of concrete cores shall be
as stated in table 13.1
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Table 13.1
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Minimum Depth of Sampling of Concrete for Testing Purposes (ASTM C823)

Thickness of
Section, m
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Types of Construction
0.3 or less
0.3 or greater
entire depth
0.3
0.15 or less
entire depth
0.15 0.6
one half the thickness or

0.15 whichever is greater
0.6 or greater
0.6
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Slabs, pavements, walls, linings, foundations,

structural elements accessible from one side
only
2
Suspended slabs , walls, conduits,
foundations, structural elements exposed to
the atmosphere at two or more sides;
concrete products
Massive sections
Minimum Depth to Be
Sampled, m
1 The requirements of table 13.2.1 may not provide the quantities or dimensions of samples
that are required for all tests, in that case, the necessary additional quantity of concrete in
pieces of appropriate minimum size should be taken at each sampling location.
2 When suspended slabs are cored, it is desirable to leave the lower 25 mm uncored, so as
not to lose the core by its falling from the barrel and to make it easier to patch the core hole.
13.2.2
Drilling Cores
Before beginning coring operations the Contractor shall use a proprietary cover meter to
identify the position of steel reinforcing bars at the testing location.
QCS 2014

Part
Page 6
The Engineer may instruct that the core is taken through the concrete without hitting any
reinforcement or the Engineer may instruct that the core is taken in a position where it is
expected reinforcement will be cut in order to provide a sample of the reinforcement to check
its condition. The locations of all drilling points shall be chosen so that the core contains no
steel parallel to its length.
Before capping, the core shall have a length of at least 95 % of its diameter. Once prepared
for test the core shall have a length at least equal to the diameter and not more than 1.2
times its diameter.
Cores of both 100 mm and 150 mm nominal diameters may be tested provided that the
aggregate size does not exceed 20 mm and 40 mm respectively. Where possible 150 mm
cores should be taken to reduce the variability due to drilling and increase the reliability of the
testing, unless reinforcement is congested and the use of 100 mm cores will reduce the
possibility that the core will contain steel or it is necessary to restrict the sampling to a length
of less than 150 mm.
Where the size of the section precludes the use of 100 mm or 150 mm cores, smaller cores
may be used with the permission of the Engineer.
During drilling operations, a log of observations that may affect the interpretation of core
samples shall be prepared.
If instructed by the Engineer, immediately after the core has been cut and removed and the
structure a carbonation test will be carried out by using a 1 or 2 % solution of phenolphthalein
poured over the cut surface. A photograph shall be taken of the cut core with the
phenolphthalein solution applied to provide a record of the test.
If during the drilling of the core, the core collapses due to weak honeycombed or defective
concrete, the Contractor shall stop the drilling operation and carry out testing at an adjacent
location as advised by the Engineer. If when testing at the second location, the core again
breaks due to honeycombed or defective concrete the freshly cut core shall be retained for
reference and a note made of the condition.
13.2.3
The compressive strength of field concrete cores shall be assessed in accordance with BS
EN 13791.
The details of the concrete core in accordance with BS EN 13791 shall be recorded and two
photographs on either side of the core taken.
Where there is reinforcement in the core, the size and the type of bar shall be noted along
with its cover to the concrete surface, the condition of reinforcing bars shall be noted with a
detailed description of any corrosion of the reinforcement.
Before carrying out the compressive strength testing of the cores, the Contractor shall inform
the Engineer to allow him to witness the testing if required.
Crushed core samples shall be retained by the laboratory and only disposed of after written
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The estimated in-situ strength of the concrete shall be calculated from the core result using
BS EN 13791, ACI 214.4 or ACI 318 whichever is applicable by the structural design.
13.3
REINFORCEMENT COVER MEASUREMENTS
The measurement of cover to reinforcing steel and other metallic items in concrete shall be
carried out in accordance with BS 1881 Part 204 using an electromagnetic device that
estimates the position depth and size of the reinforcement.
The locations for checking cover and the spacing between measurements shall be advised
by the Engineer based on the objective of the investigation. The Contractor shall carry out
calibrations of the electric magnetic device for a particular bar size to allow the bar diameter
to be measured.
While testing, the orientation of steel bars shall be checked.
The electromagnetic device shall incorporate scale or digital display range and shall be
calibrated in accordance with BS 1881 Part 204. When calibrated in this manner the
indicated cover to steel reinforcement shall be accurate to within 5 % or 2 mm which ever
is the greater over the working range given by the manufacturer.
The cover meter shall be used in accordance with the manufacturers instructions and checks
on the zero carried out as specified.
The search head shall be traversed systematically across the concrete, and, where
reinforcement is located, rotated until the maximum disturbance with electromagnetic field is
indicated by the meter.
The cover to the reinforcement shall be noted along with the axis of the reinforcement. The
cover shall also be recorded on the concrete surface with chalk or a suitable non-permanent
marking pen.
Care should be taken to avoid interference from other metallic sources or magnetic material.
The cover meter checks shall be carried out by an operator with five years experience.
10
The test report on cover shall include the following information:
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13.2.4
(a)
date
(b)
time and place of test
(c)
description of the structure or component under investigation
(d)
location of test areas
(e)
make and type of cover meter used
(f)
date of last laboratory calibration of cover meter
(g)
details of site calibration of cover meter, indicated values of cover
(h)
estimated accuracy of quantitative measurements
(i)
configuration of steel reinforcement
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ULTRASONIC PULSE MEASUREMENTS
13.4.1
General
The ultrasonic velocity test equipment shall be capable of measuring the transit time of a
pulse vibration through concrete. The length of the pulse part between the transducer
equipment shall be measured, and the pulse velocity calculated.
Ultrasonic pulse velocity testing shall be carried out in accordance with the provisions of BS
EN 12504-4.
Velocities shall be measured at a number of locations around a structure and a velocity

contour of the structure established. A minimum of 40 velocities shall be measured for each
structural element.
13.4.2
Wherever possible direct transmission arrangements shall be used. The transducers shall be
mounted on a specially formed moulded surface.
The minimum path length shall be 100 mm for concrete in which the nominal maximum size
of aggregate is 20 mm or less and 150 mm for concrete in which the nominal maximum size
of aggregate is between 20 mm and 40 mm. but the path length shall not be longer than
required to detect small regions of bad concrete.
Where concrete contains steel the pulse velocity shall be adjusted in accordance with the
requirement of BS EN 12504-4.
Locations that contain reinforcement directly along or close to the pulse paths shall be
avoided.
Where repositioning is not possible the semi-direct transmission measurement, where

transducers are placed on adjacent faces of the concrete, may be used.
13.4.3
Execution of Tests
Positions chosen for the test locations shall be clearly and accurately marked on the surface
of the concrete.
The surface of the concrete shall be shall be cleaned and free from grit and dust. Path
lengths shall be determined to an accuracy of 1 % and a suitable couplant (such as grease)
applied to each of the test points.
Pulse transit times shall be measured by a skilled operator, with a minimum of five years
experience in the use of the equipment.
Pulse velocity measurement equipment shall be in accordance with the requirements of BS

EN 12504-4.
Test results shall be examined and any unusual readings repeated carefully for verification or
amendment.
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13.4
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A correlation shall be established between the cube crushing strength of the particular mix
used in the structure and the pulse velocity.
Where it is not possible to obtain cubes with the same mix design as the original structure a
combination of coring and ultrasonic pulse velocity testing may be carried out at the direction
of the Engineer, where the cores are used to provide the correlation information required for
the interpretation of the ultrasonic pulse velocity tests.
13.5
RADIOGRAPHY OF CONCRETE
Gamma rays and high energy X-rays, which illustrate by radiographs the concrete defects:
The testing shall be carried out in accordance with the requirements of BS 1881-205 or
equivalent.
13.6
SURFACE HARDNESS
13.6.1
General
Testing of concrete surfaces for hardness using rebound hammers shall be carried out in
accordance with BS EN 12504-2.
The rebound hammer shall only be used for estimation of concrete strength where a specific
correlation is carried out of the concrete from the structure being tested; this shall be from
works test cubes or cores taken from the structure.
The correlation between concrete strength and the rebound number shall be carried out in
accordance with BS EN 12504-2. The precision of the correlation curve between the mean
rebound number and strength shall be stated and this shall be used when reporting any
strength interpretations from surface hardness readings. The use of general manufacturers
correlation or calibration curve for strength shall not be used.
It should be noted that the rebound hammer number only provides information on a surface
layer of approximately 30 mm in depth of the concrete and that this should be quoted in the
test report.
The rebound hammer maybe used to establish the uniformity of the finish products or similar
elements in a structure at a constant age, temperature, maturity and moisture condition.
13.6.2
Method of Test
A minimum of 12 readings shall be taken to establish a single surface hardness at a

particular location.
The reading shall be on a regular grid between 20 mm to 50 mm spacing over an area not
exceeding 300 mm by 300 mm.
The mean of each set of readings shall be calculated including abnormally high and
abnormally low results unless there is good reason to doubt the validity of a particular
reading.
The coefficient of variation and the standard deviation of the readings shall be reported.
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13.4.4
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Equipment
The rebound hammer shall be a proprietary type that has been used successfully and
serviced for a minimum of five years.
The hammer shall comprise of a mass propelled by a spring that strikes a plunger in contact
with the surface.
The manufacturers literature shall identify the impact energy and contact area of the plunger
for the hammer.
13.6.4
Reporting
The test report shall affirm that the hardness was determined in accordance with BS EN
12504-2 and shall provide the following information:
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13.6.3
date time and place of test
(b)
description of structure and location of test
(c)
details of concrete
(d)
type of cement
(e)
cement content
(f)
type of aggregate
(g)
type of curing
(h)
age of concrete
(i)
type of compaction of concrete
(j)
forming of surface
(k)
moisture condition of the surface
(l)
carbonation state of surface
(m)
any suspected movement of the concrete under test
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direction of test
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(a)
(o)
any other factors that are considered significant in influencing the hardness readings.
The details of the rebound hammer correlation with strength including the mean, range,
standard deviation and coefficient and variation of each reading shall also be included.
13.7
CHEMICAL CONTENT
13.7.1
Sampling
The Engineer shall instruct the depth increments over which the dust samples are to be
taken, the types of chemical testing to be carried out and the quantity of sample required.
The depth of sample shall not be less than the concrete cover to the reinforcement and at
least 50 mm from the surface of concrete. In presence of reinforcement, the chemical
content shall be tested at least at two levels before and after the depth of reinforcement from
the surface of concrete.
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To provide uniform samples of cement matrix and aggregate, three separate holes shall be
drilled at one location. The diameter of the holes shall be between 12 and 20 mm.
Care shall be taken to discard the material from any render or finish unless this is specifically
required under the investigation.
Care shall be taken to ensure that dust increments are accurately measured by marking the
drill bit.
The dust samples increments shall be carefully transferred to plastic bags and sealed to
avoid contamination. Each sealed bag shall be uniquely identified by the sample identification
and depth increment.
13.7.2
Laboratory Testing
Residual split samples of dust from the field investigation shall be retained until the Engineer
has reviewed the chloride test results. The Engineer may instruct that repeat tests are carried
out on certain samples.
Chloride testing of concrete dust samples shall be by an acid soluble method in accordance
with BS 1881 Part 124. The results shall be reported to two decimal places.
Sulphate testing of concrete dust samples shall be in accordance with BS 1881 Part 124,
using an acid soluble method.
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END OF PART
QCS 2014

Part
Page 1
PROTECTIVE TREATMENTS FOR CONCRETE ................................................... 2
14.1
14.1.1
14.1.2
14.1.3
14.1.4
14.1.5
14.1.6
14.1.7
14.1.8
14.1.9
GENERAL ............................................................................................................... 2
Scope
2
References
2
Submittals
2
Quality Assurance
3
4
4
Protection
4
5
Final Inspection
5
14.2
14.2.1
14.2.2
14.2.3
14.2.4
EPOXY COATING ................................................................................................... 5

General
5
Surface Preparation
5
Materials
6
Application
6
14.3
14.3.1
14.3.2
14.3.3
14.3.4
WATERPROOF MEMBRANE ................................................................................. 6

General
6
Materials
7
Waterproof Membrane
7
Application
7
14.4
14.4.1
14.4.2
14.4.3
14.4.4
PENETRATIVE PRIMER ......................................................................................... 8

General
8
Material
8
Surface Preparation
8
Application
8
14.5
14.5.1
14.5.2
14.5.3
14.5.4
PROTECTIVE COATING ........................................................................................ 9

General
9
Surface Preparation
9
Material
10
Application
10
14.6
14.6.1
14.6.2
14.6.3
14.6.4
14.6.5
14.6.6
14.6.7
14.6.8
14.6.9
14.6.10
14.6.11
PLASTIC SHEET LINER FOR CONCRETE STRUCTURES ................................. 11

General
11
11
11
12
12
Liner Details
12
Installation
13
13
14
Joints in Lining for In-Situ Concrete Structures
15
Testing and repairing damaged surfaces
15
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14
PROTECTIVE TREATMENTS FOR CONCRETE
14.1
GENERAL
14.1.1
Scope
This Part covers the materials and application requirements for coatings for concrete
surfaces including epoxy coatings, waterproof membranes, penetrative primers, protective
coatings, and coatings and treatments for specialist applications where there is a harsh
environment.
References
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14.1.2
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This Section
Part 1, ............. General
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ASTM D412 ................Test Methods for Vulcanized Rubbers and Thermoplastic Elastomers
Tension
ASTM D543 ................Test Method for Resistance of Plastics to Chemical Reagents
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ASTM D638 ................Test Method for Tensile Properties of Plastics (Metric)
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ASTM D746 ................Test Method for Brittleness Temperature of Plastics and Elastomers
by Impact
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ASTM D882 ................Test Methods for Tensile Properties of Thin Plastic Sheeting
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ASTM D1000 ..............Test Method for Pressure Sensitive Adhesive Coated Tapes Used for
Electrical and Electronic Applications
ASTM D1004 ..............Test Method for Initial Tear Resistance of Plastic Film and Sheeting
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ASTM D4541 ..............Test Method for Pull Off Strength of Coatings Using Portable Adhesion
Testers
ASTM E 96 .................Test Methods for Water Vapor Transmission of Materials
ASTM E154 ................Test Methods for Water Vapor Retarders Used in Contact with Earth
Under Concrete Slabs, on Walls, or as Ground Cover
BS 1881......................Testing Concrete
CIRIA Technical Note 130, Protection of Reinforced Concrete by Surface Treatments.
ISO 9000 ....................Quality management and quality assurance standards
ISO 9001 ....................Quality systems - Model for quality assurance in design, development,
production, installation and servicing
14.1.3
Submittals
Contract Documents.
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Part
Page 3
The Contractor shall submit samples of all materials to be used in the works before delivery
of material to Site. Samples of membrane waterproofing shall be 300 mm square. Samples
of liquid components shall be a minimum of one litre.
The Contractor shall submit comprehensive test results for the protective coating system as
per the tests in the specification which shall clearly indicate whether the values are mean
values measured in current production or minimum values which the property does not fall
below.
The Contractor shall clearly state the chemical composition of the material and the process
by which protection is given to the concrete.
In addition to the test methods identified in this clause of this specification, the Engineer may
require the Contractor to carry out further tests to different standards.
If the Contractor wishes to propose a material which has been tested to alternative
standards, the Contractor shall submit correlation tests showing the comparable values of the
two test methods. These test results shall be comprehensive giving full details of the sample
conditioning, preparation, method of test, criteria for assessment etc.
The Contractor shall submit comprehensive information of previous applications of the

material in similar conditions and environments. This information shall include: project name,
type/grade of material used, quantity of material used, name of client, name of consultant,
name of Contractor. If requested by the Engineer, the Contractor shall supply the contact
details of the client, consultant or Contractor where the material was previously installed.
The Contractor shall submit a guaranty for the protective coating system and the
workmanship. The guaranty shall be worded to reflect the required performance of the
material and shall be approved by the Engineer. The guaranty shall be worded to include the
phrase the Contractor shall, at the convenience of the Employer, effect all repairs and
replacements necessary to remedy defects all to the complete satisfaction of the Engineer.
Unless stated otherwise in the contract specific documentation, the performance guaranty
shall be for a period of ten years except for the penetrative primer which shall be for a period
of five years.
The use of alternatives may be considered by the Engineer. If the Contractor wishes to
propose such systems, a technical submission shall be made which shall include a
comprehensive justification giving an explanation of why the proposed system is equivalent
or superior to the one designated.
14.1.4
Quality Assurance
The protective coating system shall be supplied by a manufacturer who is certified to the
ISO 9000 series of quality standards. The Contractor shall submit to the Engineer a copy of
the ISO 9000 series certificate that clearly states the scope of the certification.
The protective coating system shall be supplied by a manufacturer who provides technical
assistance on the suitability for the application and installation for the material. For the initial
use of the material on Site, the Contractor shall arrange for the technical representative of
the manufacturer to be present to demonstrate the correct use of the material.
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The protective coating system shall be applied by a contractor or subcontractor who is

certified to the ISO 9000 series of quality standards. The Contractor shall submit to the
Engineer a copy of the ISO 9000 certificate that clearly states the scope of the certification.
the Engineer may permit the use of an applicator who is not certified to ISO 9000 if the
applicator works to a quality system that is approved by the Engineer.
The works shall be executed by an approved specialist subcontractor having a minimum of 5

years successful experience in the installation of the specified material. Only tradesmen
experienced with the installation of the materials specified shall be used.
14.1.5
After approval of all materials and before installation, a prework conference with the Engineer
shall be held at the Site. The meeting shall be attended by representatives of the Engineer,
Contractor, subcontractor, and manufacturer.
The parties shall:
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review drawings, specifications and approved materials
(b)
correct conflicts, if any, between approvals and specification requirements
(c)
examine Site conditions, including inspection of substrate, material labels and

methods of storing materials
(d)
review installation procedures and scheduling
(e)
review protection methods for finished work from other trades.
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(a)
Before applying the coating system to the permanent works the Contractor shall carry out a
small trial of the coating system for the review and approval of the Engineer.
14.1.6
Materials shall be delivered in their original, tightly sealed containers or unopened packages,
all clearly labelled with the manufacturer's name, brand name, and number and batch
number of the material where appropriate. Materials and equipment shall be stored as
directed in a neat and safe manner.
Storage areas shall comply with the manufacturers requirements with regard to shade,
ventilation and temperature limits and shall be located away from all sources of excess heat,
sparks or open flame. Containers of liquid material shall not be left open at any time in the
storage area.
Materials not conforming to these requirements will be rejected by the Engineer and shall be
removed from the Site and replaced with approved materials.
The Contractor shall deliver materials to Site in ample time to avoid delay in job progress and
at such times as to permit proper co-ordination of the various parts.
14.1.7
Protection
The Contractor shall protect the protection system installation from damage during the
construction period so that it will be without any indication of abuse, defects or damage at the
time of completion.
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The Contractor shall protect the building/structure from damage resulting from spillage,
dripping and dropping of materials.
The Contractor shall prevent any materials from running into and clogging drains.
Materials and plant shall not be stored on any newly constructed floor without the permission
of the Engineer.
Impervious membranes shall be laid as protection to all concrete surfaces in contact with the
soil and shall consist of tanking or similar accepted material, based on soil investigation
report.
All foundations shall be provided with protection such as epoxy coatings or similar other
accepted equivalents so that concrete is not exposed to harmful effects of soil, chlorides etc.
14.1.8
Protective treatments shall be applied where designated in the contract specific

documentation.
All protective coating systems to be used shall be applied strictly in accordance with the
The Contractor shall take all necessary precautions against fire and other hazards during
delivery, storage and installation of flammable materials specified herein and comply any
regulations imposed by the Civil Defence Department of the Ministry of the Interior in respect
of the storage and use of hazardous materials required under this section.
The Engineer shall specify the required final colour of the coating and the Contractor shall
submit samples showing the colour before ordering the materials.
14.1.9
Final Inspection
Upon completion of the installation, an inspection shall be made by a representative of the

material manufacturer in order to ascertain that the system has been properly installed.
14.2
EPOXY COATING
14.2.1
General
The coating shall be a decorative flexible high solids, epoxy polyurethane coating applied in
two coats to a dry film thickness of 200 m minimum.
14.2.2
Surface Preparation
The surface of the concrete shall be free from oil, grease, loose particles, decayed matter,
moss or algae growth and general curing compounds. All surface contamination and surface
laitance shall be removed by high pressure water jetting or sweep blasting.
Blow holes and areas of substantial pitting shall then be filled with a solvent free thixotropic
epoxy resin fairing coat. The mixing and application of this coat shall be in accordance with
the product manufacturers recommendations.
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Part
Page 6
Where surface cracking is apparent these cracks shall be chased, by an approved

mechanical means, to the depth of the crack. A thixotropic epoxy resin shall be applied using
a trowel, scraper or filling knife ensuring that full compaction is achieved into the chased
section and providing a flush finish with the concrete surface. A minimum period of 24 h shall
be allowed before applying any subsequent protective coating systems.
14.2.3
Materials
External above ground coating materials shall provide protection against chlorides and
carbonation, and be UV and abrasion resistant.
The above ground coating shall be applied over the below ground coating and shall continue
for a minimum of 150 mm above the ground level.
The epoxy coating shall be UV stable.
The finished coating shall be pinhole free and have a total minimum dry film thickness of
200 m.
The materials used in the coating system shall comply with the following requirements:
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> 85 %
-20 C to 70 C
4 MPa
6 MPa
greater than 3.5 MPa
90 MPa (neat resin)
6-8 % (neat resin)
Nil
50 mg
97 MPa @ 7 days
-6
46.8 x 10 mm/mm/degree C
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Solids content
Service temperature
Tensile strength (DIN 53504)
Resistance against crack (DIN 53515)
Adhesion to concrete (ASTM D-4541)
Compressive strength (ASTM D-695)
Tensile elongation (ASTM D-638)
Water absorption (MIL D-24613)
Abrasion resistance (ASTM C-501)
Compressive strength (ASTM C-579)
Thermal coefficient of expansion (ASTM C-531)
Application
treated using the selected materials.
shall be treated with the material.
Engineer.
In all operations of storage, mixing and application, the Contractor is to comply with the
14.3
WATERPROOF MEMBRANE
14.3.1
General
This Subpart covers the use of waterproof membrane for general protection to buried
concrete.
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14.2.4
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Part
Page 7
Where indicated on the Drawings or directed by the Engineer, concrete in contact with the
ground shall be protected by a preformed flexible self-adhesive bituminous type membrane.
The laying, lapping and sealing of the membrane shall be in accordance with the
14.3.2
Materials
The material shall be an externally applied waterproof membrane shall be an impervious,

cold applied flexible laminated sheet, consisting of multilayer high density cross-laminated
polyethylene film with a backing of self-adhesive rubber bitumen compound, protected with
silicone coated release paper.
Primer for Sheet Membrane: As recommended by the manufacture of the sheet membrane.
Protection Board: Provide a minimum 6 mm thick asphalt protection board manufactured

from selected aggregates, bound in modified bitumen encased between two layers of
strengthened asphalt paper. The bituminous material shall be a minimum of 1.0 mm thick
and the membrane shall be capable of bridging crack widths in the substrate up to 0.6 mm
wide.
14.3.3
Waterproof Membrane
The material shall be suitable for use in the Gulf region the compound shall be specially
formulated for hot climates and shall have proven experience in the Middle East.
The waterproofing material shall conform to the standards detailed in Table 14.1
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Table 14.1
Waterproof Membrane Property Requirements
Property
Standard
ASTM D638
Tear resistance
ASTM D1004
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Elongation Film
Value
Longituduial 210 %
Transverse 160 %
Longitudinal 340 MPa
Transverse 310 MPa
Adhesion to primed concrete
ASTM D1000
1.8 MPa
Elongation compound
ASTM D1000
1.8 MPa
Puncture resistance
ASTM E154
220 N over 65 mm
Water resistance
ASTM D570
After 24 h. 0.14 %
After 35 d 0.95 %
Environmental resistance
Moisture vapour transmission rate
ASTM D543
ASTM E96
Minimum thickness
0.3g/M 24 h
1.0 mm.
14.3.4
Application
Waterproofing membranes placed on vertical concrete faces shall be protected by preformed

asphalt board.
QCS 2014

Part
Page 8
Boards shall be bonded onto position with high quality solvent borne contact adhesive based
on polychloroprene rubber.
The Contractor shall co-ordinate the installation of waterproofing membrane with floor drains,
equipment bases and other adjacent work and mask adjacent work to prevent soil marks.
Areas where waterproofing is applied shall be protected from all traffic and where necessary
backfilling. All damage to finished portions of the waterproofing membrane shall be either
repaired or replaced, or both, in a manner acceptable to the Engineer.
14.4
PENETRATIVE PRIMER
14.4.1
General
The system shall be a penetrating hydrophobic treatment that protects concrete from both
water and chloride intrusion, while permitting water vapour transmission.
The treatment shall significantly reduce the absorption of water and water borne salts but
allow the transmission of water vapour from the substrate.
The treatment shall not produce any discoloration of the substrate and shall have excellent
resistance to weathering.
14.4.2
Material
The material shall be a low viscosity silane-siloxane system which penetrates deeply into a
The material shall be resistant to petrol, oil, and atmospheric contaminants such as car
exhaust fumes and industrial exhausts.
14.4.3
Surface Preparation
The surface shall be dry, free from oil and grease, loose particles, decayed matter, algae
growth and curing compounds.
If the concrete surface is newly cast and has a very smooth finish, the surface shall be
roughened by sand or grit blasting, water blasting or some mechanical means. The Engineer
shall decide if this means of preparation is required.
Moss or algae growth on the surface shall be removed using a proprietary fungicidal wash in
Concrete finishing required shall be completed before the application of the treatment.
Cracks of width greater than 0.2 mm shall be filled in accordance with the manufacturers
recommendations.
14.4.4
Application
Unless directed otherwise by the Engineer the treatment shall be applied a minimum period
of 24 h after the wet curing period, and shall be surface dry.
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The Contractor shall carry out tests to verify the depth of penetration of the material. These
tests shall be carried out on specimens of the actual mix design and shall use coloured dyes
to trace the penetration of the material.
Where fine cracking has occurred in the concrete (at a width not greater than 0.3 mm for
reinforced concrete and 0.2 mm for water retaining structures) an additional four 'stripe coats'
of the treatment shall be applied before the main treatment.
The application of the material on surfaces shall be by a low pressure spray direct from the
can. Under no circumstances should thinning of the material be carried out.
The rate of application shall ensure that the surface is completely saturated. The
impregnated coating shall be applied to two or more flood coats each flood coat shall be a
2
minimum of 0.4 l/m .
The material shall be applied strictly in accordance with the manufacturers instructions and
as follows:
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the material shall be applied by a fine nozzle spray
(b)
application will not be permitted when the ambient air temperature is above 35 C or
in windy conditions
(c)
the surface shall be cleaned by a stiff brush or compressed air to remove all loose
deposits
(d)
concrete to be treated shall be surface dry for a minimum period of 24 h before

impregnation
(e)
membranes, joint sealers and cast in concrete ancillaries shall be masked off before
treatment
(f)
application shall be made by saturation flooding
(g)
the interval between application shall be at least 6 h
(h)
treated areas shall be protected from sea water and rain for 6 h after treatment.
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(a)
PROTECTIVE COATING
14.5.1
General
The coating system shall be used for the protection of new or existing reinforced concrete
structures against carbonation or chloride induced corrosion.
The system shall comprise of a penetrating, reactive primer and an acrylic polymer top coat
system to minimise ingress of acidic gases, chlorides and water.
14.5.2
Surface Preparation
Before application, all surfaces must be dry and free from oil, grease, loose particles,
decayed matter, moss or algae growth and general curing compounds.
All such contamination and laitence must be removed by the use of grit blasting, high
pressure water jetting or equivalent mechanical means.
14.5
QCS 2014

Part
Page 10
Before proceeding to apply the protective coatings, all surfaces which are not to be coated
but which may be affected by the application of the coating shall be fully masked and, in
particular, flora and fauna shall be protected.
Blow holes and areas of pitting shall be made good with a one part modified cementitious
material and allowed to cure in accordance with the manufacturer's recommendations. In
particular, the application shall be in accordance with the manufacturer's recommendations,
with respect to the maximum application thickness.
14.5.3
Material
The materials are required to provide in-depth protection against carbonation and chloride
penetration whilst permitting water vapour transmission from the concrete.
The primer shall be a low viscosity silane-siloxane system which penetrates deeply into a
The material employed for the coating shall comply with the following requirements:
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400 m
200 m
R Value at 325 microns > 161 metres.
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Wet film thickness

Dry film thickness
Carbon Dioxide diffusion resistance
Water vapour transmission
Reduction in chloride ion penetration
(BS 1881 : Part 124)
Tear Resistance (ASTM D624)
Crack bridging (BRE Method)
Chloride Ion Diffusion
(Taywood Engineering Labororatories)
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Shall be more than 13 g/m .d

94 % minimum at 28 d
7.3 kN/mm
5.1 mm
-10
3.63 x 10
cm /sec.
Where test methods are not specified, the procedure for establishing compliance with the
above criteria shall be agreed with the Engineer.
The Contractor is required to adhere strictly to the manufacturer's recommendations

regarding the use, storage, application and safety rules in respect of the approved materials.
14.5.4
Application
treated using the selected materials. These trial areas shall be noted on the Drawings and
shall be carried out using the type of materials, mixing procedures and applications that will
be used on the contract and shall be approved by the Engineer before the Contractor
commences with the general work.
shall be conditioned by the application of a penetrating hydrophobic treatment. The primer
shall be allowed to dry in accordance with the manufacturer's requirements.
The Contractor shall then apply two coats of pigmented topcoat in accordance with the
manufacturer's instructions. The finished coating shall be pinhole free and have a total
minimum dry film thickness of 150 m. The colour and finish is to be as agreed with the
Engineer.
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QCS 2014

Part
Page 11
Engineer.
In all operations of storage, mixing and application the Contractor shall comply with the health
and safety recommendations of the manufacturer and governing authorities.
14.6
PLASTIC SHEET LINER FOR CONCRETE STRUCTURES
14.6.1
General
This Subpart covers the supply and installation of sheet liners in reinforced concrete
structures.
The liner must be continuous and free of pinholes both across the joints and in the liner itself.
All work for and in connection with the installation of the lining in concrete pipe and structure,
and the field sealing and welding of joints, will be done in strict conformity with all applicable
specifications, instructions, and recommendations of the lining manufacturer.
14.6.2
The Contractor shall submit to the Engineer for approval the following:
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liner schedule
(b)
material certifications
(c)
test results
(d)
material samples
(e)
the manufacturer of the lining will submit an affidavit attesting to the successful use
of its material as a lining for sewer pipes and structures for a minimum period of
five years in service conditions recognised as corrosive or otherwise detrimental to
concrete.
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(a)
The sheet liner shall be manufactured from, high molecular weight PVC or PE resin and
other components necessary to make a material of permanent flexibility suitable for a liner in
concrete pipes and structures in sewerage service. The weld strips and the joint strips shall
be made from like material. For PVC and PE sheet liners, the actual resin used in
manufacture must constitute not less than 99 % of the resin used in the formulation.
Copolymer resins will not be permitted.
All plastic sheets including locking extensions, all joints and welding strips shall be free of
cracks, asperities and other defects that may affect the protective properties of the material.
The properties of PVC and PE sheet are shown in Table 14.2
14.6.3
QCS 2014

Part
Page 12
Table 14.2
Properties of PVC and PE Sheet Liners
Property
Test Method
PVC
Elongation at break
Tensile Strength
PE
Elongation at break
Tensile Strength
Requirement
ASTM D638/882
ASTM D638/412
ASTM D746
300 %
15 MPa
0C
ASTM D638/882
ASTM D638/412
ASTM D746
Exceeds 600 %
10-20 MPa
-75 C
Except at shop welds, all plastic sheet liners and strips shall have the properties shown in
Table 14.3 when tested at 25 C.
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14.6.4
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Table 14.3
Properties of Plastic Sheet Liner Strips
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Property
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Shore Durometer
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Weight change
15 MPa
200 %
1 s 50 - 60 5 (with respect to 10 s
35 - 50 5)
1.5 %
as
Tensile strength
Elongation at break
Requirement
The minimum thickness of the material shall be as shown in Table 14.4
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14.6.5
Table 14.4
Plastic Sheet Liner Minimum Dimensions
Material Thickness
Sheet with locking extensions

Sheet, plain
Joint strip
Weld strip
Structures
4.0 mm
2.3 mm
1.9 mm
2.4 mm
14.6.6
Liner Details
Locking extensions (T-shaped) shall be of the same materials as that of the liner and shall be
integrally extruded with the sheet.
Locking extensions shall be approximately 65 mm apart and shall be at least 10 mm high.
Sheets not used for shop fabrication into larger sheets shall be shop tested for pinholes using
an electrical spark tester set at 9000 V per 1.0 mm thickness of lining minimum. Holes shall
be repaired and retested.
QCS 2014

Part
Page 13
14.6.7
Installation
Installation of the lining, including preheating of sheets in cold weather and the welding of all
joints, shall be performed in accordance with the recommendations of the manufacturer.
The lining to be held snugly in place against inner forms by means of steel banding straps or
other means recommended by the manufacturer.
Concrete that is to be poured against the lining shall be vibrated, spaded, or compacted in a
careful manner to protect the lining and produce a dense, homogenous concrete, securely
anchoring the locking extensions into the concrete.
In removing forms care shall be taken to protect the lining from damage. In particular:
(b)
when forms are removed, any nails that remain in the lining to be pulled, without
tearing the lining, and the resulting holes clearly marked.
(c)
form tie holes to be marked before ties are broken off and all areas of serious
abrasion or damage shall be marked.
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sharp instruments not to be used to pry forms from lined surfaces.
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All nail and tie holes and all cut, torn, and seriously abraded areas in the lining shall be
patched as follows:
patches made entirely with welding strip to be fused to the liner over the entire patch
area
(b)
larger patches may consist of smooth liner sheet applied over the damaged area with
adhesive
(c)
all edges must be covered with welding strip fused to the patch and the sound lining
adjoining the damaged area.
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(a)
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(a)
Hot joint compounds, such as coal tar, shall not be poured or applied to the lining.
The Contractor shall take all necessary measures to prevent damage to the installed lining
from equipment and materials used in or taken through the work.
14.6.8
Samples taken from sheets, joints or weld strips shall be tested to determine material
properties. Determination of tensile strength and elongation shall be in accordance with
ASTM D 412 using Die B. Determination of indentation hardness shall be in accordance with
ASTM D 2240 using a Type D Durometer, except that a single thickness of material and
indentation hardness shall be made on 25 mm by 75 mm specimens. Thickness of
specimens shall be the thickness of the sheet or strip.
The measurement of initial physical properties for tensile strength, weight, elongation and
indentation hardness shall be determined before chemical resistance tests.
Chemical resistance tests shall be carried out to determine the physical properties of the
specimens after exposure to chemical solutions. Test specimens shall be conditioned to
constant weight at 43 C before and after submersion in the solutions detailed in Table 14.5
for a period of 112 d at 25 3 C.
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QCS 2014

Part
Page 14
Volumetric percentages of concentrated reagents of CP grade: At 28 day intervals,

specimens shall be removed from each chemical solution and tested. If any specimen fails to
meet the 112 day exposure, the material will be subject to rejection.
Pull test for locking extensions: Liner locking extensions embedded in concrete shall
withstand a test pull of at least 18 kN/m, applied perpendicularly to the concrete surface for a
period of 1 min, without rupture of the locking extensions or withdrawal from embedment.
This test shall be made at a temperature between 21 C to 27 C inclusive.
Shop-welded joints: Shop-welded joints, used to fuse individual sections of liner together,
shall be a least equal to the minimum requirements of the liner for thickness, corrosion
resistance and impermeability. Welds shall show no cracks or separations and shall be
tested for tensile strength. Tensile strength measured across the welded joint in accordance
with ASTM D 412 using Die B shall be at least 15 MPa. Test temperature shall be 25 3 C
and the measured minimum width and thickness of the reduced section shall be used.
Spark test: All liner shall be shop tested for holes with a spark tester set to provide from
15 000 to 20 000 V. Sheets having holes shall be satisfactorily repaired in the shop before
shipment from the manufacturers plant.
The Contractor shall provide the Engineer with certified copies of test reports before the
shipment of the product to the Site.
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Table 14.5
Chemical Resistance Tests
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Chemical Solutions
Sodium Hydroxide
Nitric Acid
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Soap
5%
1%
1%
Ferric Chloride
5%
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Ammonium Hydroxide
20 %
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Sulphuric Acid
Concentration
0.1 %
Detergent (Linear alkyl benzyl sulphonate or LAS)
0.1 %
BOD not less than 700 mg/l
Bacteriological
Phosphoric Acid
14.6.9
Liner sheets to be closely fitted and properly secured to the inner forms.
50 %
(a)
sheets that are to be cut to fit curved and warped surfaces shall use a minimum
number of separate pieces
(b)
a 50 mm wide water resistant tape or welding strip shall be welded on the back of butt
joints to prevent wet concrete from flowing around the edges.
Unless otherwise shown on the Drawings, the lining will be returned at least 75 mm at the
surfaces of contact between the concrete structure and items not of concrete and
(a)
the same procedure will be followed at joints where the type of protective lining is
changed or the new work is built to join existing unlined concrete
QCS 2014

Part
Page 15
(b)
at each return, the returned liner will be sealed to the item in contact with the plastic
lined concrete with an adhesive system
(c)
if the liner cannot be sealed with this adhesive because of the joint at the return being
too wide or rough or because of safety regulations, the joint space shall be densely
caulked with lead wool or other approved caulking material to a depth of 50 mm and
finish with a minimum of 25 mm of an approved corrosion resistant material.
14.6.10 Joints in Lining for In-Situ Concrete Structures

Field joints and Lining at joints shall be free of all mortar and other foreign material and shall
be clean and dry before joints are made.
All welding is to be in strict conformance with the specifications of the lining manufacturer.
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all welds shall be physically tested by a non-destructive probing method
(b)
all patches over holes, or repairs to the liner wherever damage has occurred.
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(a)
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Each transverse welding strip which extends to a lower edge of the liner will be tested by an
approved testing agency at the cost of the Contractor.
the welding strips will extend 50 mm below the liner to provide a tab.
(b)
a 5 kg pull will be applied to each tab. The force will be applied normal to the face of
the structure by means of a spring balance
(c)
liner adjoining the welding strip will be held against the concrete during application of
the force
(d)
the 5 kg pull will be maintained if a weld failure develops until no further separation
occurs.
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(a)
(e)
(f)
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All surfaces covered with lining, including welds, will be tested with an approved electrical
holiday detector with the instrument set at 9000 V per 1.0 mm of lining minimum:
defective welds will be retested after repairs have been made

tabs shall be trimmed away neatly by the installer of the liner after the welding strip has
passed inspection.
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14.6.11 Testing and repairing damaged surfaces
(g)
inspection will be made within two days after joints has been completed in order to
prevent tearing the projecting weld strip and consequent damage to the liner from
equipment and materials used in or taken through the work.
END OF PART
QCS 2014

Part
Page 1
HOT WEATHER CONCRETING ............................................................................. 2
15.1
15.1.1
15.1.2
15.1.3
15.1.4
15.1.5
GENERAL ............................................................................................................... 2
Scope
2
References
2
2
System Description
3
Submittals
3
15.2
PLACING TEMPERATURE ..................................................................................... 3
15.3
PLANNING CONCRETING ..................................................................................... 4
15.4
MIX DESIGN ........................................................................................................... 4
15.5
15.5.1
15.5.2
15.5.3
15.5.4
15.5.5
15.5.6
TEMPERATURE CONTROL ................................................................................... 4

General
4
Aggregates
4
Water
5
Cement
5
Addition of Ice
5
Liquid Nitrogen
6
15.6
BATCHING AND MIXING ........................................................................................ 6
15.7
TRANSPORTATION ............................................................................................... 6
15.8
PLACING AND FINISHING ..................................................................................... 6
15.9
CURING AND PROTECTION.................................................................................. 7
15.10
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15
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HOT WEATHER CONCRETING
15.1
GENERAL
15.1.1
Scope
This Part covers the precautions to be taken for hot weather concreting for all structural
concrete except blinding concrete, where a minimum compressive strength is specified.
15.1.2
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This Section
Part 8 .............. Transportation and Placing of Concrete
Part 10 ............. Curing
15
References
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ACI 305R-91...............American Concrete Institute , Hot Weather Concreting
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ASTM C1064 ..............Measuring the Temperature of Concrete
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BS EN 1992-1-1 .........Eurocode 2, Design of concrete structures. General rules and rules for
buildings
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BS EN 480..................Admixtures for concrete, mortar and grout. Test methods
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BS EN 934..................Admixtures for concrete, mortar and grout

The requirements of the following clauses of the specification are applicable during the hot
weather period in Qatar.
The hot weather period shall be defined as starting when the maximum ambient air shade
temperature on the Site exceeds 35 C for three consecutive days. The end of the hot
weather period shall be defined as the period when the maximum air shade temperature is
below 35 C on three consecutive days.
The Contractor shall establish a thermometer on Site that records the ambient air shade
temperature. The thermometer shall be established at a position to provide representative air
temperature for the Site conditions. If requested by the Engineer the Contractor shall arrange
for the calibration of the Site thermometer.
rate of cement hydration, or otherwise causing detrimental results such as:
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15.1.3
(a)
High ambient temperature (when the shade temperature is above 40 deg C on a rising
thermometer, 43 deg C on a falling thermometer),
(b)
High concrete temperature,
(c)
Low relative humidity,
(d)
High wind speed
QCS 2014

Part
(e)
the rate of evaporation exceeds 0.75 kg/m /h
Page 3
15.1.4
System Description
The Contractor shall undertake hot weather concreting procedures that are effective in
controlling the following potential problems associated with concreting in hot weather:
increased water demand of the mix
(b)
increased rate of slump loss
(c)
increased rate of setting
(d)
increased tendency for plastic shrinkage cracking
(e)
decreased long-term strength
(f)
increase tendency for drying shrinkage and cracking
(g)
increased tendency for differential thermal effects with consequent cracking
(h)
decreased durability from cracking where there is increased permeability.
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(a)
Submittals
The Contractor shall prepare weekly in advance his proposed concreting programme
showing the quantities to be placed and the anticipated placing hours.
At least one month before the start of the hot weather period the Contractor shall submit his
specific proposals for the control of the concrete temperature for the constituent materials;
cement, water aggregates.
Where required the Contractor shall submit to the Engineer his proposals for the use of liquid
nitrogen for cooling which shall include details of previous project application and the
intended methods to be used and quantities of liquid nitrogen.
15.2
PLACING TEMPERATURE
This Subpart of the specification applies at all times of the year and at all times of the day.
Maximum fresh concrete temperature (at placement) shall not exceed 32C unless
construction testing to verify a proposed concrete mixture will function satisfactorily at a
concrete temperature greater than 32C. No concrete shall be placed if the concrete
Concrete shall not be placed if the shade temperature exceeds 40C.
The temperature of each truck of concrete shall be measured using either a glass, dial type
or electronic thermometer, just before the placing of the concrete and the temperature
recorded on the delivery ticket. The maximum temperature at placing shall apply to the entire
load of concrete in the truck or conveyer.
The Contractor shall allow for the increase in concrete temperature in the period from
dispatch from the plant while in transportation or whilst awaiting placement on Site and take
adequate measures to ensure the maximum temperature is not exceeded.
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15.1.5
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Part
Page 4
PLANNING CONCRETING
During the hot weather period as defined in Clause 15.1.3 of this Part, the Contractor shall
plan concreting operations such that no concreting takes place between the hours of
10:00 hours and 17:00 hours.
The Contractor shall arrange concrete pours such that the programme of works can be
achieved without concreting during the period from 10:00 hours to 17:00 hours.
The Contractor shall nominate one member of his staff to be the co-ordinator for the supply
of concrete. The co-ordinators responsibilities shall include ensuring the batched rate
matches that of delivery and placement and the preparations needed before commencing a
concrete pour.
15.4
MIX DESIGN
In the hot weather period, the Contractor shall review all concrete mix designs to ensure that
the design slump or workability specified is achieved without increase in the mix water
content. The Contractor shall make modifications to the mix design to allow for increased
slump loss during transportation in hot weather.
This shall be achieved by adjusting the proportion of admixture, plasticiser or super

plasticiser. The permitted range of admixture shall be clearly stated on the concrete mix
design with nominal values for cold weather and hot weather use.
Under no circumstances will the addition of extra water that increases the water cement ratio
be permitted during hotter weather.
All concrete materials and proportions used in periods of hot weather shall be those that have
a satisfactory record of use in such conditions.
15.5
TEMPERATURE CONTROL
15.5.1
General
The Contractors specific proposals for the control of the concrete temperature shall include
extent and type of shading of aggregates, method of chilling mix water and procedures for
batching and mixing, transportation, placing and finishing, curing and protection.
These shall include calculations in accordance with ACI 305R, clause 3.1 estimating
concrete temperature. The Contractor shall calculate the temperature of freshly produced
concrete based on the input temperatures of the constituent materials and the weights from
particular mix designs. The calculations shall make allowance for the rise in temperature
between mixing and placing due to the transportation and waiting period. The calculations
shall successfully demonstrate that the temperature can be maintained below 32 C at the
point of placing.
15.5.2
Aggregates
All practical means shall be employed to keep the aggregates as cool as possible.
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15.3
QCS 2014

Part
Page 5
Stockpiles of aggregates shall be shaded from direct sunlight. Shades shall extend beyond
the edge of aggregate storage areas and stockpile layouts shall be such that direct sunlight is
not incident on the aggregates. Shades shall be constructed to allow access for mechanical
shovels or means of conveyance. Shades and stockpiles shall be constructed so as to permit
the free flow of air over the aggregates. Embedded cooling pipes may also be used to cool
the aggregate.
Sprinkling of coarse aggregates to reduce temperature by evaporation or direct cooling shall

not be permitted.
15.5.3
Water
Mix Water shall be cooled by storing in underground tanks or insulated tanks above ground.
The water shall be chilled by the use of proprietary chillers or the addition of ice to the water
tank. Measures shall be taken to ensure that ice pieces are not inadvertently deposited
directly into the mixer.
Water shall not be chilled below a temperature of 5 C.
Tanks, pipes or trucks used for the storage or transportation of water shall be insulated and
painted white.
The mechanical refrigeration equipment and insulated water storage shall be adequate for
the anticipated hourly and daily production rates of concrete during the hot weather period.
Mixing water may also be chilled by injection of liquid nitrogen into an insulated holding tank,
such procedures shall be to the approval of the Engineer.
Ice shall be completely melted in mixing water prior to adding water to the mixer.
15.5.4
Cement
The use of freshly ground cement at very high temperatures is not permitted.
The cement shall be kept below the temperature which there is a tendency of false set.
Under no conditions shall the temperature of the cement exceed 75 C when it enters the
mixture.
The Contractor shall make arrangements for storage on Site to allow cooling of freshly
ground and delivered cement.
15.5.5
Addition of Ice
Crushed shaved or chipped ice can be used as part of the mixing water for reducing the
concrete temperature.
The maximum nominal size of ice particles shall be 10 mm and all the ice must be melted
before the completion of mixing of the concrete in the pan.
To ensure proper concrete mixing the maximum proportion by substitution shall be 75 % of

the batch water requirement.
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QCS 2014

Part
Page 6
Crushed ice shall be stored at a temperature that will prevent lumps from forming by
refreezing of particles.
The batching plant shall incorporate a mechanical system for correctly proportioning and
weighing the ice to be added to the mixture.
The quantity of ice shall be deducted from the total batch water.
The Contractor shall ensure there are adequate quantities of ice in suitable refrigerated
storage on the Site at the plant to meet the anticipated daily and hourly production rates of
concrete during the hot weather period.
15.5.6
Liquid Nitrogen
Freshly mixed concrete maybe cooled by the injection of liquid nitrogen.
Care shall be taken to ensure that the concrete directly adjacent the injection nozzle is not
frozen.
The use of liquid nitrogen for cooling concrete shall include a nitrogen supply vessel and
injection facility for the batching plant or one or more injection stations for truck mixers.
The system may be set up at the Site for injection just before placing.
Proper safety precautions as advised by the supplier of the liquid nitrogen shall be used.
15.6
BATCHING AND MIXING
The drums of concrete mixer trucks shall be painted white to minimise solar heat gain.
Where a truck mixer has been left standing in the sun, the empty drum shall be sprayed with
water and the drum flushed out with cold water before batching. Care shall be taken to
ensure all water is removed from the drum before batching.
The temperature of the concrete shall be checked after discharge from the mixer and written
on the delivery ticket. Temperature check shall be carried out at the plant on the concrete
3
floor for every 50 m produced or every hour which ever is the minimum.
A water-reducing, set-retarding chemical admixture conforming to the requirements of BS EN

480 Parts 1, 2 and 4 may be used in varying proportions under different air temperature
conditions.
15.7
TRANSPORTATION
The transportation, placing, compaction and finishing of concrete shall be at the fastest
possible rate. Delivery of concrete to the Site shall be properly scheduled to match the rate of
placement and compaction.
15.8
PLACING AND FINISHING
If the temperature of the first truck of concrete of a particular pour is above the specification
maximum temperature limit then placing shall not commence.
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QCS 2014

Part
Page 7
If a pour is in progress and the temperature of a particular truck exceeds the maximum
permitted temperature the placing may be allowed to continue at the discretion of the
Engineer in order to avoid the possible development of a cold joint.
However, no further concreting pours shall take place until the Contractor has submitted
revised calculations, in accordance with ACI 305R clause 3.1 to demonstrate that the
maximum temperature will not be exceeded in the future. Before beginning new pours the
temperature of the concrete constituent materials shall be monitored to verify that they meet
the assumptions of the calculations.
15.9
CURING AND PROTECTION
Curing and protection shall conform to the requirements of Part 10 of this Section.
Evaporation shall be minimised, particularly during the first few hours subsequent to placing
concrete, by suitable means such as applying moisture by fog spraying or any other means
acceptable to the Engineer.
15.10
All thermometers used for the measurement of concrete temperature shall be calibrated
weekly against a glass mercury thermometer. Calibration shall be carried out over the
temperature range of 10 C to 100 C using a water bath with ice or heating.
The method used to determine acceptance of temperature controlled concrete should be in

accordance with ASTM C1064.
All concrete test specimens for strength or other purposes shall be carefully protected and
cured.
Specimens shall be protected from accidental damage by plant personnel or equipment on

Site.
Specimens shall be kept moist by the addition of water or covering by suitable curing
materials.
The exact time of preparation of the specimen on Site shall be noted and the time when it is
transferred to the laboratory. These times shall be written on the test report.
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END OF PART
QCS 2014

Part
16: Miscellaneous
Page 1
MISCELLANEOUS .................................................................................................. 2
16.1
16.1.1
16.1.2
GENERAL ............................................................................................................... 2
Scope
2
References
2
16.2
16.2.1
16.2.2
16.2.3
16.2.4
16.2.5
16.2.6
16.2.7
16.2.8
PAVEMENT QUALITY CONCRETE ........................................................................ 3

Scope
3
Mix Designs
3
Cement
4
Water
4
Aggregates
5
Admixtures
5
Air content
5
Density
5
16.3
16.3.1
16.3.2
16.3.3
CEMENTITIOUS GROUT ........................................................................................ 6

General
6
Material
6
Workmanship
6
16.4
16.4.1
16.4.2
SCREEDS ............................................................................................................... 7
Scope
7
General
7
16.5
CELLULAR CONCRETE ......................................................................................... 9
16.6
16.6.1
16.6.2
16.6.3
REPAIR OF CONCRETE ........................................................................................ 9

General
9
9
Crack injection
11
16.7
POLYESTER RESIN CONCRETE (PRC) - PIPING SYSTEMS FOR NONPRESSURE DRAINAGE AND SEWERAGE ......................................................... 13
General
13
Resin
13
Minimum strength
14
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16.7.1
16.7.2
16.7.3
16
QCS 2014

Part
16: Miscellaneous
Page 2
16
MISCELLANEOUS
16.1
GENERAL
16.1.1
Scope
This Part deals with miscellaneous items related to concrete works including pavement
quality concrete, no fines concrete, lightweight concrete, cementitious grout, screeds, repair
of concrete and guniting.
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Part 2, .............. Aggregate

Part 3, .............. Cementitious Material
Part 4, .............. Water
Part 5, .............. Admixture
Part 9, .............. Formwork
Part 10, ............ Curing
Part 15, ............ Hot Weather Concreting.
This Section
References
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16.1.2
ACI 506, .....................Guide to Shotcrete
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ASTM C989 10, ........Standard Specification for Slag Cement for Use in Concrete and
Mortars
BS 146,.......................Portland-blast furnace cement
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BS 812,.......................Testing aggregates
BS 1881,.....................Testing concrete

BS 3892,.....................Pulverised fuel ash
BS 4551,.....................Methods of testing mortars, screeds and plasters
BS 5075,.....................Concrete admixtures
BS 6319,.....................Testing of resin and polymer / cement compositions for use in
construction
BS 6610,.....................Specification for pozzolanic pulverised-fuel ash cement.
BS 8203,.....................Code of practice for installation of resilient floor coverings.
BS 8500,.....................Concrete
BS EN 197-1, .............Cement. Composition, specifications and conformity criteria for
common cements
BS EN 480,.................Admixtures for concrete, mortar and grout. Test methods (parts: 1, 2,
4, 5, 6, 8, 10, 11, and 12)
BS EN 934,.................Admixtures for concrete, mortar and grout (parts: 2, 6)
BS EN 998,.................Specification for mortar for masonry
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BS EN 1744-1, ...........Tests for chemical properties of aggregates. Chemical analysis

BS EN 12390-5, .........Flexural strength of test specimens
BS EN 12620,............. Aggregates for concrete
EN 197-4:2004 ...........Cement. Composition, specifications and conformity criteria for low
EN 197-4, ...................Cement. Composition, specifications and conformity criteria for low
EN 12350, ..................Testing fresh concrete
EN 1744-1, .................Tests for chemical properties of aggregates. Chemical analysis
GSO EN 206-1, ..........Concrete Specification, performance, production and conformity
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SHW 1000 ..................Specification for Highway Works UK ROAD PAVEMENTS

CONCRETE MATERIALS
PAVEMENT QUALITY CONCRETE
16.2.1
Scope
This Subpart covers the mix design for concrete used for aircraft aprons and roadworks as
surface slabs, continuously reinforced concrete roadbase, and wet lean mix except cement
bound granular material used as a roadbase or sub-base or as a backfill material for
excavations.
16.2.2
Mix Designs
Concrete in rigid or composite pavements shall be one of the grades given in Table 16.1
below, in accordance, with the pavement design shown on the Drawings or as directed by the
Engineer.
All concrete for use in pavements shall be designed mixes or equivalent standard mixes in
accordance with the relevant clauses of BS 8500 and GSO EN 206-1, except where
otherwise specified.
Prescribed mixes may be used for rapid construction with the approval of the Engineer.
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16.2
Table 16.1
Pavement Grades
Pavement Layer
BS 8500 and
GSO EN 2061Designed
Mix
Surface Slabs
Unreinforced Concrete
C40
Jointed Reinforced Concrete ( JRC )
C40
Continuously Reinforced Concrete Pavement ( CRCP )
C40
Continuously Reinforced Concrete Roadbase ( CRCR )
C40
Ground Anchorage Beam
C40
BS 8500 and
GSO EN 206-1
Standard Mix
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Part
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Page 4
BS 8500 and
GSO EN 2061Designed
Mix
BS 8500 and
GSO EN 206-1
Standard Mix
C20
ST4
C15
ST3
C10
ST2
C7.5
ST1
Pavement Layer
Cement
The general term 'cement' in this Part means the materials shown below.
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16.2.3
Complying with
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Cement
EN 197-1
Specification for pozzolanic pulverised-fuel ash cement (grades

C20 or below)
BS 6610
BS 146 or EN 197-4
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Cement. Composition, specifications and conformity criteria for

common cements
Portland blast furnace cement
The use of a combination of Portland cement and ground granulated blast furnace slag is
permitted subject to the approval of the Engineer. In such cases, the Engineer will stipulate
the minimum combined cementitious material content required for the mix.
The use of a combination of Portland cement and pulverised fuel ash (PFA) is permitted
subject to the approval of the Engineer. In such cases, the Engineer will stipulate the
minimum combined cementitious material content required for the mix. PFA shall be in
The use of microsilica in the mix designs will be permitted if approved by the Engineer.
The Engineer will stipulate the minimum combined cementitious material content required for
the mix where PFA or GGBFS are used.
The maximum proportion of ground granulated blastfurnace slag with Portland cement shall
In combination with Portland cement, the proportion of PFA by mass to the total cement shall
The limit of chloride content of the concrete shall be as stated in Table 6.5 of Part 5.6.
The minimum cement content for concrete pavements shall be preapproved by Qatar
Standards.
16.2.4
Water
Water for use in the making and curing of concrete shall conform to the requirements of Part
4 of this Section.
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The water content shall be the minimum required to provide the agreed workability for full
compaction of the concrete to the required density, as determined by trial mixes or other
means approved by the Engineer..
16.2.5
Aggregates
The requirements of Part 2 of this specification will govern, except as modified below.
Aggregates for all pavement concrete shall be complying with BS EN 12620
Alternatively coarse aggregate of recycled and secondary aggregate materials may be used
to replace up to 50% by mass of coarse aggregate
The nominal size of coarse aggregate shall not exceed 40 mm. When the spacing between
longitudinal reinforcement is less than 90 mm, the nominal size of coarse aggregate shall not
exceed 20 mm.
If requested by the Engineer, the Contractor shall carry out tests on the proposed aggregate
combination to check for the possibility of alkali silica reaction. Such tests shall be carried out
in accordance with the procedure laid down in Part 2 of this Section.
16.2.6
Admixtures
Plasticisers or water reducing admixtures shall comply with BS 5075, BS EN 480 and BS EN
934. Admixtures containing calcium chloride shall not be used.
Other chloride-free admixtures may be used with the approval of the Engineer.
16.2.7
Air content
The total quantity of air in air-entrained concrete as a percentage of the volume of the mix
shall be 5 1.5 % for mixes of nominal aggregate size 20 and be 4 1.5 % for mixes of
nominal aggregate size 40.
The air content shall be determined at the point of delivery by a pressure type air meter in
accordance with BS EN 12350-7, at the rate of one determination per 300 m2 of slab or at
least six times per day whichever is the greater, in conjunction with tests for workability and
strength. For areas less than 300 m2, the rate shall be at least one determination to each 20
m length of slab or less constructed at one time or at least three times per day. If the air
content is outside the specified limits, a further determination shall be made immediately on
the next available load of concrete before discharging. If the air content is still outside the
limit, the Contractor shall immediately adjust the air content of the concrete to improve its
uniformity, before further concrete is used in the Works.
The air-entraining agent shall be added at the mixer, by an apparatus capable of dispensing
the correct dose within the tolerance for admixtures given in EN 206-1, and so as to ensure
uniform distribution of the agent throughout the batch during mixing.
16.2.8
Density
The density of concrete Grades greater than C30 shall be such that without air-entrainment
the total air voids are not more than 3 %. With air entrainment, the total air voids shall be not
more than 8 %, for 20 mm aggregate or 7 % for 40 mm aggregate.
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Part
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Page 6
The density of concrete Grades B15 and B20, mix ST4 or below shall be at least 95 %, of the
theoretical maximum dry density.
16.3
CEMENTITIOUS GROUT
16.3.1
General
This Subpart covers a general purpose non-shrink cementitious grout. The grout shall be
used to where it is necessary to eliminate shrinkage when filling the void between a base
plate and a substrate such as in the grouting of stanchion bases, anchorage fixings, including
masts, anchor bolts and fence posts.
The grout shall be supplied by a reputable construction chemical company as a single pack
prepackaged cement based product which is chloride free.
For a particular application, the Contractor shall submit a method statement detailing how the
formwork will be placed and the points where the grout will be poured.
Before beginning work on large repetitive works, the Contractor shall arrange for a site trial of
the materials and methods with the suppliers representative being present to train the
Contractors personnel in the correct use of the material.
16.3.2
Material
The grout shall be suitable for filling gaps of thickness up to 100 mm and shall be free flowing
and non shrink.
Positive volumetric expansion shall take place while the grout is plastic by means of gaseous
expansion to avoid shrinkage and cracking.
The compressive strength of the grout when tested in accordance with BS EN 12390-3 shall
be a minimum of 25 MPa at 24 h, 40 MPa at 7 d and 50 MPa at 28 d.
The grout shall exhibit a high early strength gain yet not be subject to cracking or other
detrimental effects.
At ambient temperatures above 35 C, cool water shall be used for mixing the grout before
placing.
16.3.3
Workmanship
The storage handling and pouring of the grout shall be in strict accordance with the
The substrate surface shall be free from oil grease or loose or partially bonded material.
If the concrete surface is defective or has laitance it shall be cut back to a sound base.
Bolt holes and fixing pockets shall be blown clean of dirt or debris.
The substrate shall be soaked with fresh potable water before grouting, although immediately
before grouting, free water shall be removed and blown out of bolt holes or pockets.
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Part
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Grout shall not be placed in a gap of less than 25 mm for base plates larger than 1 m wide.
For larger base plates or flow areas the manufacturers instructions shall be followed.
Base plates and metallic items shall be clean and free from oil, grease, or scale.
Vent holes shall be provided to allow the release of air from isolated spots.
Formwork shall be made leak proof by the use of form rubber strip or mastic sealant between
the constructive formwork and joints. Formwork shall extend above the required pour height
and if necessary shall be extended to allow a hydrostatic head to aid placement.
10
The grout shall be mixed mechanically with a slow speed drill fitted with a high-shear mixer.
11
The quantity of water to be added to the preweighed bags shall be enough to give the
desirable consistency as trowelable or flowable.
12
Mixing shall take place for a minimum of 5 min.
13
The grout shall be placed within the time limit specified by the manufacturer depending on
the actual application temperature.
14
Grout shall be poured from one side and it shall be verified that the grout has flowed under all
of the base plate with no voids. Pouring from several sides shall not be permitted.
15
Exposed areas of grout shall be thoroughly cured in accordance with Part 10 of this Section.
16.4
SCREEDS
16.4.1
Scope
This Subpart covers screeds that provide by means of a layer of mortar a level surface in
flooring applications and to provide falls on flat concrete roofs.
16.4.2
General
Screeds shall be suitable for application onto a concrete substrate.
The screeds shall be suitable for receiving surface finishes which may arrange from thin
flexible sheeting to ceramic tiling. The screed is not intended to be the final wearing surface.
Screed mortars shall generally comprise sand and cement modified by additives or
substituted by other materials such as polymers in order to provide specific performance
requirements.
For screeds of thickness greater than 40 mm it is permissible to incorporate a proportion of

10 mm aggregate.
Aggregates used for screeds shall not contain deleterious materials such as coal or iron
particles which may affect the finish the surface of the screed.
Admixtures for mortar screeds shall assist workability or alter rates of setting and hardening
and shall comply with the appropriate part of BS EN 480 and BS EN 934.
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Polymer based additives may be used to improve adhesion and strength of thin or featured
screeds, these shall be based on polyvinyl acetate (PVA) styrene bituene rubber (SPR) or
acrylic polymers.
Ready to use sand cement screeds shall comply with the material requirements BS EN 998.
Screeds with a rapid drying time to enable earlier floor finishes to be applied shall be used
10
The interface of the screed in the concrete substrate shall be specified as one of the
following options by the Engineer:
Monolithic with the concrete base: The screed shall be applied within 3 hours of
placing the concrete base.
(b)
Bonded to the concrete base: Screed shall be laid onto a concrete base which is
hardened and is subsequently been prepared to receive the screed, the minimum
thickness of the screed shall be 25 mm and the maximum thickness 40 mm.
(c)
As an unbonded screed: The screed shall be laid on a separating layer.
(d)
As a floating screed: The screed shall be laid on an insulating material.
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(a)
The cement and sand screed mix shall have the minimum amount of water added to give
sufficient workability and allow the material to be thoroughly compacted.
12
Pan type mixes shall be used to ensure efficient mixing of materials, the cement to aggregate
ratio shall be between 1 to 3 and 1 to 4.5 by weight. The mixing of the sand cement, water
and admixtures shall ensure a thorough homogeneous mixture with no balling up of the
cement.
13
Screeds shall be laid either between carefully levelled and trued batons or between strips of
screed laid and compacted to a finished level.
14
For bonded screed where a high degree of bond is required the surface laitance of the
concrete base shall be mechanically removed to expose the coarse aggregate. A thin layer
of neat cement grout shall be applied to the prewetted or dampened concrete and the screed
applied and compacted while the grout is wet.
15
Screeds shall be fully compacted by heavy hand or mechanical tamping. The screed at joints
around the perimeter shall be particularly well compacted to avoid breaking out and curling.
16
Screeds thicker than 50 mm shall be laid in two approximately equal layers; screed shall be
kept protected by waterproof sheeting for at least 7 days after laying.
17
Sheet and non ceramic tiling finishes shall only be applied after the screed has cured and
necessary strength achieved.
18
If requested by the Engineer the Contractor shall carry out a soundness and impact test in
19
Screeds shall be laid in bays of a size to minimise thermal moisture contraction. Contraction
or movement joints shall be provided as appropriate, where shown on the drawings or as
directed by the Engineer. Bays shall be laid alternatively.
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Part
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Page 9
Bay sizes shall be approximately 15 m2 for 100 mm thick screed and 12 m2 for 75 mm thick
screed.
16.5
CELLULAR CONCRETE
Cellular Concrete (CC) is conventional concrete, where natural aggregate (gravel) is

exchanged for an insulation medium, namely air, embedded in an organic and biodegradable foam. It behaves, like conventional concrete, in particular concerning curing,
hardening and most important "ageing ". CC infinitely increases its strength by hydration as
long as exposed to humidity in the atmosphere.
CC offer more thermal insulation and a substantially higher fire-rating than conventional
concrete.
Minimum compressive strengths shall be 4.0 MPa.
The required density and strength of the CC shall be specified on the drawings and approved
by the Engineer.
The method of production of Cellular Concrete shall be shown on the drawings or directed by
the Engineer. The Contractor shall submit full technical details of the materials and method of
production for the CC along with a list of previous projects where the particular system has
been used.
After source approval of the material and system the Contractor shall submit a mix design for
the CLC for the approval of the Engineer. After the review and approval of the mix theoretical
mix design the Contractor shall carry out a trial mix to check the workability of the fresh
concrete and to allow samples to be made for compressive strength and density.
The Engineer may also instruct that tests are carried out for abrasion resistance and thermal
insulation properties.
Cellular Concrete shall not be used for structural reinforced members.
16.6
REPAIR OF CONCRETE
16.6.1
General
The extent and nature of the defects in concrete shall be established in accordance with Part
15 of this Section. Based on these results the Engineer shall confirm the acceptability of the
work and whether remedial works are required.
If remedial works are required the Contractor shall submit a detailed method statement
identifying the specific materials to be used and the sequence of activities for the repair.
Only proprietary proven materials that form part of a standard repair system shall be used.
16.6.2
Where there is honeycombed concrete or concrete damaged by physical forces such as

impact that has caused spalling, the concrete shall be replaced using a high strength free
flowing cementitious micro-concrete.
The areas of repair shall be marked out and agreed with the Engineer.
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All honeycombed, loose, cracked or friable concrete in these areas shall be removed until
sound concrete is reached. Due account shall be taken of propping or other instructions
given by the Engineer regarding sequences of removal and repair.
The equipment and methods used to break out the concrete shall be such that no reinforcing
steel or other embedded items such as conduits, lifting sockets, or other inserts are loosened
or damaged unless so directed by the Engineer.
Where the removal of concrete by mechanical means is difficult due to reinforcement

congestion, then the use of high pressure water jetting shall be considered and necessary
provisions for protecting the rest of the structure shall be made.
The prepared void shall be profiled so that entrapment of air is avoided during the repair
process using fluid micro-concrete.
The minimum depth of repair shall be 40 mm throughout. The perimeter of the area to be
repaired shall first be cut to a depth of 10 mm using a suitable tool. Feather edges will not be
accepted.
The prepared concrete surface shall be sound and clean and free of loose particles, dust and
debris.
Where exposed reinforcement is sound, it shall be mechanically cleaned of rust and loose
millscale.
10
Reinforcement damaged during the removal of concrete or the preparation process shall, if
required by the Engineer, be repaired or replaced.
11
Adequate formwork shall be provided in accordance with of Part 9 of this Section. This shall
be securely fixed to withstand the hydraulic pressures of the fluid micro-concrete repair
material without distortion or movement during placement.
12
The formwork shall be watertight at all joints between panels and between the formwork and
the existing concrete surface so as to prevent grout leakage.
13
The formwork shall be constructed from appropriate materials as agreed with the Engineer to
achieve the required finish.
14
Formwork surfaces that are to be in contact with the repair micro-concrete shall be treated
with a suitable mould release agent. This shall be used in accordance with the
manufacturer's recommendations.
15
The entry point of the feed pipe into the form shall be at the lowest point of the void. Sufficient
hydrostatic head or pumping pressure shall be maintained to ensure that the void is filled
completely and no air remains entrapped.
16
Where necessary, provision shall be made for controllable bleed points to prevent air
entrapment and enable the extent of flow of the repair material to be assessed.
17
The formwork shall be inspected by the Engineer and, if approved, filled with clean water
which demonstrates that the formwork is grout-tight and saturates the prepared concrete
surfaces. The formwork shall be then be completely drained and resealed
18
In situations where the completed repair will be subjected to constant immersion an epoxy
bonding agent shall be applied in accordance with the manufacturers instructions.
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19
Both the Compressive strength and Flexural strength shall be at a water:powder ratio of 0.18
and tested at 20 oC
20
The thermal conductivity and the elastic modulus of the repair material shall be compatible
with the host concrete.
21
If requested by the Engineer, recent test results of the material for the following properties
shall be submitted:
(a)
thermal conductivity
(b)
elastic modulus, BS 1881
(c)
expansion characteristics, ASTM C 827, CRD 621-82A
(d)
flow characteristic, UK DOT BD 27/86 paragraph 4.6 B.
The micro-concrete shall be mixed and placed in accordance with the manufacturer's
recommendations, particularly with regard to water content, mixing equipment and placing
time.
23
As far as possible the placing of the micro-concrete shall be continuous. The mixing
operation shall be timed so that there is minimal interruption in the material flow. If, however,
placing is interrupted, the operation shall recommence as soon as possible while the repair
material retains its flow characteristics.
24
The formwork shall not be removed until the repair micro-concrete has achieved a
compressive strength of at least 10 MPa or as directed by the Engineer.
25
Immediately after removal of the formwork the repair area shall be cured in accordance with
26
The repair material shall:
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22
be shrinkage compensated in both liquid and cured states
(b)
contain no metallic expansion system
(c)
be prepacked and factory quality controlled
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be a free-flowing cementitious material that has a coefficient of thermal expansion fully

compatible with the host concrete and which complies with the requirements of Table
16.3.
(d)
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(a)
Table 16.3
Property requirements of micro concrete
Property
Test Method
Minimum Value
BS EN 12390-3 @ 28 d
50 MPa
Flexural strength
BS 4551 @ 28 d
10 MPa
Anchorage bond
BS 8110
Passes
16.6.3
Crack injection
This clause of the specification covers non-active cracks within concrete elements caused by
shrinkage or other structural movement. Non-active cracks shall be injected with a lowviscosity epoxy resin to fill and seal the crack and restore the structural integrity.
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Part
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Before to starting the injection operation it shall be established by testing and investigation
work that cracks manifest within concrete elements due to either or both shrinkage or
structural movement are non-active.
The extent of the cracks to be filled will be as directed by the Engineer. The cracks to be
filled shall be marked out in detail on the concrete elements by the Contractor and agreed
with the Engineer before proceeding.
The extent of the work may be adjusted by the Engineer as the project proceeds, according
to the conditions found.
Grease, oil or other contaminants shall be removed. Algae and other biological growth shall
also be removed by scrubbing with bactericide or detergent and clean water. If necessary,
wire brushes shall be used.
Loose or spalling areas of concrete, laitance, traces of paint or other coating materials within
the marked out scope of the work shall be removed.
All cracks shall be thoroughly cleaned out using clean, oil-free compressed air. Both the
concrete surface and the cracks shall be allowed to dry thoroughly before continuing.
The injection nipples shall be fixed at intervals along the length of each crack. The distance
between each nipple will depend on the width and depth of the crack.
Spacing shall be close enough to ensure that the resin will penetrate along the crack to the
next point of injection. This will normally be between 200 mm and 100 mm.
10
Each nipple shall be firmly bonded to the concrete surface by using a sealant. The sealant
shall be supplied in two pans (liquid base and hardener system). The two components shall
be thoroughly mixed together for 3 to 4 min until a putty-like consistency is achieved.
11
The mixed sealant shall be applied to the metal base of each surface-fixed nipple. They shall
be pressed firmly into place and held for several seconds until secure. The mixed sealant
shall be applied around each embedded nipple, ensuring a complete seal is made. In this
way, all the nipples shall be fixed along the length of the crack.
12
In the case of a wall or slab which is cracked all the way through, nipples shall be located on
both sides with those at the back placed at midway points between those it the front.
13
The surface of the cracks between the nipples shall be sealed with a band of sealant 30 to
40 mm wide and 2 to 3 mm thick. Both sides if cracks which go all the way through a wall or
slab shall be sealed in this way.
14
The prepared cracks shall be allowed to cure for 12 to 24 h. At low ambient temperatures
(5 C to 12 C) the curing time will be extended and the Contractor shall ensure that the
surface sealant has adequately cured before continuing.
15
One end of the injection hose shall be attached to the lowest nipple on vertical cracks or to
either end of horizontal cracks.
16
Each crack shall be treated in a single, continuous operation. Sufficient material shall
therefore be made ready before the commencement of the work.
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The Contractor shall to ensure that sufficient cracks are prepared to provide effective use of
the mixed material.
18
The preparation, mixing and application of the materials shall be undertaken in strict
accordance with the manufacturer's recommendations. The Contractor is to ensure that all
necessary tools and equipment are on Site.
19
Both the compressive strength and flexural strength shall be tested at 7 d.
20
The material shall exhibit excellent bond to concrete and when tested for tensile adhesion the
failure shall be in the concrete and not at the interface.
21
The injection resin shall be of a prepackaged or preweighed type and only the use of full units
will be allowed. No part packs or on-Site batching will be allowed under any circumstances.
22
In all operations of storage, mixing and application, the Contractor shall comply with the
23
The injected system shall be allowed to cure for 24 h and shall be left undisturbed for this
time.
24
The nipples and bands of surface sealant shall then be removed and damaged areas made
good to the satisfaction of the Engineer.
25
The injection material shall be compatible with the host concrete and shall have the
properties shown in Table 16.4 when tested in accordance with the relevant standards.
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Property
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Table 16.4
Property Requirement for Epoxy Crack Injection Material
Method
BS 4551, BS 2782 BS 6319
Flexural strength
BS EN 12390-5
70 MPa
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Minimum Value
POLYESTER RESIN CONCRETE (PRC) - PIPING SYSTEMS FOR NONPRESSURE DRAINAGE AND SEWERAGE
16.7.1
General
16.7.2
Resin
16.7
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Page 14
D648. The resin content shall not be less than 7 % of the weight of the sample as determined
by Test Method D2584.
16.7.3
Minimum strength
The minimum strength classes for different pipe shapes are given below.
Table 16.4

Strength class
Sc
Nominal size
N/mm
DN
PRC-TC
150 DN 500
180
180
600 DN 1000
145
1200 DN 3000
120
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PRC-OC
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145
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Table 16.5
Strength class
Sc
N/mm
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WN/HN
PRC-TE
300/450 WN/HN 600/900
180
180
700/1050 WN/HN 1000/1500
145
160
120
145
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PRC-OE
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1200/1800 WN/HN 1400/2100
Table 16.6
Strength class
Sc
N/mm
Nominal size
DN
PRC-OK
PRC-TK
800 DN 1000
145
160
1200 DN 1800
120
145
END OF PART
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Part
17: Structural Precast Concrete
Page 1
STRUCTURAL PRECAST CONCRETE .................................................................. 2
17.1
17.1.1
17.1.2
17.1.3
17.1.4
17.1.5
17.1.6
17.1.7
17.1.8
17.1.9
GENERAL ............................................................................................................... 2
Scope
2
References
2
Submittals
3
Qualifications
4
Quality Assurance
4
Quality Control
5
Testing
6
7
Design Loadings, Actions and Structural Members Selection
7
17.2
17.2.1
17.2.2
17.2.3
17.2.4
MATERIALS ............................................................................................................ 8
General
8
Reinforcing Bars
8
Bearing Pads
8
Embedded Steel
8
17.3
17.3.1
17.3.2
FORMING ............................................................................................................... 8
General
8
Tolerances
9
17.4
17.4.1
17.4.2
17.4.3
17.4.4
17.4.5
17.4.6
17.4.7
17.4.8
INSTALLATION ....................................................................................................... 9
General
9
Survey
9
Guying, Bracing and Shoring
9
Adjustment and Correction
9
Erection Tolerances
10
Welding
10
Grouting
10
Field Cutting
10
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STRUCTURAL PRECAST CONCRETE
17.1
GENERAL
17.1.1
Scope
The work included in this Section comprises furnishing all plant, labour, equipment,
appliances and materials and performing all operations in connection with Structural Precast
Concrete Work.
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This Section
Part 2 ............... Aggregates
Part 3 ............... Cementitious materials
Part 5 ............... Admixtures
Part 6 ............... Property requirements
Part 7 ............... Concrete Plants
Part 8 ............... Transportation and placing of concrete
Part 9 ............... Formwork
Part 10 ............. Curing
Part 11 ............. Reinforcement
Part 15 ............. Hot weather concreting
17
References
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17.1.2
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AASHTO ....................Standard Specification for Highway Bridges, Section 25

ACI 523.2R .................Guide for Precast Cellular Concrete Floor, Roof, and Wall Units
ACI 533R ....................Guide for Precast Concrete Wall Panels
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ACI 533.1R .................Design Responsibility for Architectural Precast-Concrete Projects

ACI 543R ....................Design, Manufacture, and Installation of Concrete Piles
ACI 550.1R-09............Guide to Emulating Cast-in-Place Detailing for Seismic Design of

Precast Concrete Structures
ASCE/SEI 7-05...........Minimum Design Loads for Buildings and other Structures
ACI 318-11 .................Building Code Requirements for Structural Concrete
BS 8110......................The structural use of concrete.
BS EN 1991-1-4 .........Eurocode 1. Actions on structures. General actions. Wind actions
BS EN 1992-1-1 .........Eurocode 2. Design of concrete structures. General rules and rules for
buildings
Prestressed Concrete Institute (PCI) , Manual 116
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Part
17.1.3
Submittals
Manufacturer's Literature:
(a)
the Contractor shall provide copies of manufacturer's specifications and installation

instructions for each item of proprietary material to be used, showing compliance with
this specification. Information on equipment, embedded items and other accessories
shall also be provided.
Design Mixes:
(a)
copies of mix designs with support material
(b)
the requirements of the mix design shall be in accordance with Parts 6 and 7 of this
Section.
Product Design Criteria:
initial handling and erection stresses
(ii)
all dead and live loads as specified on the contract drawings or as required
(iii)
all other loads specified for the member where they are applicable.
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Product Design Calculations:

(a)
the design calculations shall be performed by a Structural Engineer experienced in

precast concrete design. They shall cover all stages of handling, transportation and
erection. The design shall be carried out in accordance with the requirements of BS
EN 1992-1-1 or relevant ACI codes, and shall be accepted by the Engineer.
(b)
calculations for the design of precast members shall be supported by a statement

explaining the principle of design and type of analysis adopted
(c)
the influence of individual members in achieving the overall stability of the structure
should be considered
(d)
computer programmes used in the designs shall be fully described and details of input
and printout shall be presented in a manner which can be readily understood and the
following requirements shall be met:
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loadings for design:
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(a)
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programme manuals and instructions to programme users shall be made

available to the Engineer upon request
(ii)
where such programme cannot be demonstrated by the Contractor to have been

fully checked or where the Engineer considers it necessary, the Contractor shall
run such test examples as the Engineer may choose, in order to verify the
completeness and accuracy of the programme
(i)
(e)
members that are exposed to the weather shall be designed to provide for the
movement of components without damage, failure of joint seals, undue stress on
fasteners or other detrimental effects when subject to seasonal or cyclic day/night
temperature ranges
(f)
precast systems shall be designed to accommodate construction tolerances, deflection

of other building structural members and the clearance of intended openings
(g)
calculate structural properties of framing members in accordance with BS 8110 or BS

EN 1992-1-1, or relevant ACI codes.
Shop Drawings. The Contractor shall provide the following information for the approval of the
Engineer:
(a)
layout plans and detailed fabrication and placement drawings for each structural
precast element
QCS 2014
(b)
size, grade, profile and dimensions of all materials used
(ii)
connection and anchorage details
(iii)
lifting devices, locations and handling limitations
(iv)
steel reinforcement details
(v)
all openings, sleeves, inserts and other provisions in full co-ordination with all
trades in the Contract
(vi)
identification marks.
detailed outline of sequence and methods of erection including but not limited to types,
capacities and numbers of cranage, methods of support and transportation.
(ii)
date of pour
(iii)
concrete test results
(iv)
shop drawing reference number
(v)
type and duration of curing
(vi)
date of delivery to Site
(vii)
date of fixing in position.
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copies of all testing and inspection reports.
the Contractor shall produce trial panels in accordance with the requirements of
trial panels shall be retained for reference purposes for the acceptance of the
production work.
(b)
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type and number
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(i)
Trial Panels:
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A record shall be kept for every piece of precast element produced showing the
following:
Test Reports:
(a)
(i)
Fabrication Records:
(a)
shop drawings are to include the following information:
Erection Procedures:
(a)
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Part
17.1.4
Qualifications
Structural precast work shall be executed by an approved specialist Subcontractor for casting
and also for transportation, handling and erection.
The Contractor may execute this work himself if he can satisfy the Engineer that he has
sufficient experience and expertise in this field. As a minimum the Contractor shall:
(a)
provide satisfactory evidence that his tradesmen and their supervisory personnel
engaged in such work have successful experience with work comparable to that
shown and specified
(b)
provide details of organised quality control and testing procedures.
17.1.5
Quality Assurance
The precast concrete supplier shall have a quality assurance scheme that meets ISO 9000 or
equivalent.
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All work shall be performed to secure for the project homogeneous concrete having the
required strength, surface finish, materials, durability, and weathering resistance, without
planes of weakness or other structural defects, and free of honeycombs, air pockets, voids,
projections, offset of plane and other defacements of concrete.
No alterations or substitutions of the structural systems shown on the Drawings are permitted
unless otherwise specified.
The Contractor shall supervise and co-ordinate all phases of the structural precast concrete
construction process and be responsible for the complete manufacturing process.
All methods of manufacture and practices of handling raw materials and manufactured
concrete shall be reviewed by the Engineer before execution of the structural precast
concrete work, at least 14 days before the beginning of precasting work.
Only materials of known quality shall be incorporated in the work.
All materials shall be properly selected, reviewed and approved by the Engineer before use,
and maintained during shipment, storage and use.
Construction systems and techniques shall be properly selected, reviewed and approved by
the Engineer before use, and maintained throughout the complete structural precast concrete
construction phase.
Adequate spare equipment, parts, additional components and repair facilities shall be
available for all tools and equipment.
10
Regardless of approvals by the Engineer, the Contractor shall be responsible for all materials
and methods of structural precast concrete work.
11
If work does not meet the specified requirements, the Contractor shall at no additional cost to
the Employer:
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implement removal, replacement or remedial work
(b)
revise procedures or materials to prevent recurrence of unacceptable work.
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(a)
Quality Control
The Contractor shall prepare and provide his quality control programme for structural precast
concrete work with particular attention to details, pre-checking processes, procedures and
close supervision, and in particular the Contractor shall:
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17.1.6
(a)
in order to assure that proper work is performed to prevent later corrective actions,
assign at least one experienced supervisor full time to provide quality control for
structural precast concrete work
(b)
the assignment will not relieve the Contractor's other quality control personnel of their
duties relative to the quality control of the structural requirements and surface finish of
the structural precast concrete work.
The Contractor shall arrange for the training of his quality control personnel who will perform
quality control of structural precast concrete work and whose training shall include but not be
limited to:
(a)
materials evaluation
(b)
special mix design techniques
(c)
mix placement
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Part
(d)
vibrator selection and use
(e)
formwork details formwork protection
(f)
release agent use
(g)
reinforcing steel
(h)
detailing and installation
(i)
finishing equipment and techniques
(j)
corrective procedures and protection of completed work.
Page 6
The Contractor's quality control personnel shall be responsible for verifying all details
necessary to produce the final structural design objectives.
The Contractor's quality control personnel shall also verify the quality of the structural precast
concrete work and guide the production of results which will be within acceptable physical
tolerances
17.1.7
Testing
Concrete shall be tested as specified in Part 6 of this Section.
The Contractor shall:
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furnish labour required to facilitate testing
(b)
inform the Engineer with at least one day's advance notice when concrete is to be
placed
(c)
provide storage facilities for concrete test cubes
(d)
provide material samples and access to materials as required for testing.
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(a)
Should the batching plant be located more than 500 meters away from the site offices, the
Contractor shall provide suitable transport acceptable to the Engineer, for the sole use of the
Engineer's staff.
The Contractor shall station a qualified technician at the casting site to continuously test,
inspect and report on the following:
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(a)
that concrete testing is being carried out in accordance with the requirements of Part 6
of this Section
(b)
check the following and verify conformance with specified requirements and approved
shop drawings:
(c)
(i)
all reinforcing bars
(ii)
all embedded items
(iii)
all formwork
check all openings and provisions for co-ordination with all trades in the Contract as
shown on approved shop drawings.
The Contractor shall provide facilities and equipment for the conducting of all tests specified
herein except for the strength test which should be carried out by an approved independent
testing agency.
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The structural precast elements shall be removed from the form without damaging or over
stressing and stored or placed for transportation on a stable bed that will not allow distortion
of the member.
Separate stacked members with suitable battens and bracing.
Mark each member with an identifying reference or piece mark, and the date of casting.
All piece marks are to be correlated with test reports and plan layouts or erection drawings.
The structural precast element shall be transported with sufficient battens, bracing, and
supports so as to prevent over-stress by vibration or impact loadings. The Contractor shall
submit his proposed method of transportation to the Engineer for approval.
Structural precast units shall be stored, handled and transported in a manner that will avoid
undue strains, hair cracks, staining, or other damage.
The Contractor shall deliver the units from the casting site to the project Site in accordance
with schedule and proper setting sequence.
Structural precast units shall be stored free of the ground and protected from wind or rain
splashes.
The units shall be covered and protected from dust, dirt or other staining materials.
10
During fabrication, construction and after erection, the Contractor shall protect the castings to
avoid the possibility of damage.
17.1.9
Design Loadings, Actions and Structural Members Selection
The provisions of this Clause shall apply if the Contractor is responsible for the design of the
structural precast units.
The precast elements shall be designed to withstand all loading conditions against which
strength and serviceability must be measured.
Vertical loads shall include the self-weight of precast elements, floor coverings and live loads
as indicated on the contract drawings.
The wind loads shall be calculated based on the wind speed provided in Section 1 part 1
clause 1.5.2.
Account shall be taken of the loads and deformation caused by temperature and time
dependent deformations. For such purpose 55 C temperature variation and 90 % relative
humidity should be considered for all members, except exterior elements and facade
o
elements shall consider 85 C.
Precast elements shall be designed in accordance with BS EN 1992-1-1 or relevant ACI

code. Design tensile stresses should not exceed the design flexure tensile stress of concrete,
at the particular age of the concrete.
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17.1.8
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Nominal cover to steel including links must meet the durability requirement of severe
condition of exposure and to meet requirement for 2 h period of fire resistance, as provided
for in BS EN 1992-1-1 or relevant ACI code.
Total deflection of precast elements should be limited to 1/350 of the span of this element.
Plan and design for openings for building services, where required or necessary.
17.2
MATERIALS
17.2.1
General
The Contractor shall obtain cement, aggregates and water from a single source, sufficient to
complete the entire structural precast concrete work to assure regularity of appearance and
uniformity of colour.
The Contractor shall provide all materials in accordance with and meet all applicable
requirements of this section.
17.2.2
Reinforcing Bars
Reinforcing bars shall conform to the requirements of Part 11 of this Section
17.2.3
Bearing Pads
These shall be Elastomeric neoprene, conforming to AASHTO Standard Specifications for

Highway Bridges (Section 25) with the following stipulations:
use unfactored loads for design
(b)
maximum compressive stress, 0.70 MPa
(c)
maximum shear stress, 0.07 MPa
(d)
maximum shear deformation, 1/2 thickness
(e)
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maximum compressive strain, 15 %
17.2.4
Embedded Steel
All embedded items shall be of stainless steel Grade 316L.
17.3
FORMING
17.3.1
General
Forms and casting beds are to be firmly seated so as not to deflect or be displaced under
concreting or tensioning loads.
Correct for thermally induced strains or forces.
For member penetrations larger than 150 mm, coring or field cutting is not permitted unless
Clean and coat forms with release agent before installation or reinforcing or embedments.
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Part
Page 9
17.3.2
Tolerances
Permissible deviations of formed surfaces are not to exceed tolerances outlined in PCI
Manual 116, with items as summarised or modified in Table 17.1
Table 17.1
Tolerances for Structural Precast Concrete
Description
Tolerance
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5 mm
3 mm
Stem 3 mm; Flange 2.0 mm.
0.2 %
3 mm. for 300 cm
3 mm
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Dimensions
Length:
Width:
Thickness:
Embedment or penetration location:
Straightness:
End squareness:
INSTALLATION
17.4.1
General
The Contractors erection responsibilities include the safe and proper placing, aligning, and
levelling of the structural precast elements on the accepted bearing surfaces and affecting
their proper fastening.
17.4.2
Survey
Before placement of the structural precast elements the Contractor shall survey and maintain
all temporary supports shown or required to control alignment, and deflection.
Temporary supports shall be retained until framing elements braced thereby have attained
integral stability in accordance with the design.
17.4.3
Guying, Bracing and Shoring
The Contractor shall install in proper sequence and maintain all temporary supports shown or
required to control alignment, deflection and stress levels.
Temporary supports shall be retained until framing elements braced thereby have attained
integral stability in accordance with the design.
17.4.4
Adjustment and Correction
The Contractor shall compensate and correct for the misaligning affect of temperature, draw
from welding, bolting or erection sequence or grouting.
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17.4
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Part
Page 10
17.4.5
Erection Tolerances
The following erection tolerances shall apply unless otherwise specified in the Contract:
(a)
Variations from plumb
6 mm in 6 m run;
12 mm total in a12 m or longer run
(b)
Variation from level or elevation
6 mm in runs;
12 mm in 12 m run; maximum 12 mm at
single locations
12 mm maximum.
(c)
Variation from position in plan
(d)
Offsets in alignment of adjacent

1.5 mm in 3 m run, 6 mm maximum.
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members at joints
Welding
Where permission for welding is given by the Engineer, the following shall apply:
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17.4.6
welding shall not take place until all adjacent elements to be connected have been
aligned, firmly seated and braced
(b)
control of heat build-up by limiting voltage, electrode size, and rate
(c)
spalled or heat damaged concrete around weldments shall not be acceptable.
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(a)
Grouting
Joints, gaps and connections shall be filled with grout as shown on the Drawings and as
17.4.8
Field Cutting
Field cutting of holes may be done only with the Engineer's concurrence, and only with power
saws or core drills. Steel reinforcement or prestressing strand shall be avoided, where the
reinforcement or strand is damaged the unit shall be repaired to the satisfaction of the
Engineer, or rejected.
The maximum hole size shall be 150 mm diameter or as limited by member size or strand
location
Any cracks, spalls and sharp corners created by field cutting are to be ground, eased, and
patched with epoxy type bonding and patching compounds.
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17.4.7
END OF PART
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Part
18: Prestressed Concrete
Page 1
PRESTRESSED CONCRETE ................................................................................. 2
18.1
18.1.1
18.1.2
18.1.3
18.1.4
GENERAL ............................................................................................................... 2
Scope
2
References
2
Submittals
3
Storage and Handling
3
18.2
18.2.1
18.2.2
18.2.3
18.2.4
18.2.5
18.2.6
18.2.7
18.2.8
18.2.9
PRESTRESSING .................................................................................................... 3
General
3
Wires and Strands
4
Sheaths, Cores and Ducts
5
Anchorages
5
Jacking Equipment
5
Tensioning
6
Grouting
7
Grout Mixer
7
Grout Trials
8
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18
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18
PRESTRESSED CONCRETE
18.1
GENERAL
18.1.1
Scope
This section describes the requirements for prestressed post-tensioned concrete, including
materials and procedures for installation, stressing and grouting.
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References
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ACI 325.7R ------------- Recommendations for Designing Prestressed Concrete Pavements

ACI 343R ---------------- Analysis and Design of Reinforced Concrete Bridge Structures
ACI 350.3R ------------- Seismic Design of Liquid-Containing Concrete Structures
ACI 358.1R ------------- Analysis and Design of Reinforced and Prestressed-Concrete
Guideway Structures
ACI 372R ---------------- Design and Construction of Circular Wire- and Strand-Wrapped
Prestressed-Concrete Structures
ACI 373R ---------------- Design and Construction of Circular Prestressed Concrete Structures
with Circumferential Tendons
ACI 423.3R ------------- Recommendations for Concrete Members Prestressed with Unbonded
Tendons
18.1.2
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Part 3 ............... Cementitious Material
Part 4, ........... Water
Part 5, ........... Admixtures
Part 6, ............ Property requirements
Part 7, ........... Concrete Plants
Part 8, ............ Transportation and placing of concrete
Part 9, ........... Formwork
Part 10, ........... Curing
Part 11, ........... Reinforcement
Part 15, ........... Hot weather concreting
Part 16, ........... Miscellaneous
This Section
ASTM A881/A881M -- Standard Specification for Steel Wire, Deformed, Stress-Relieved or

ASTM A882/A882M--- Standard Specification for Filled Epoxy-Coated Seven-Wire
ASTM A641/A641M Standard Specification for Zinc-Coated (Galvanized) Carbon Steel
Wire
ASTM A416/A416M-10 Standard Specification for Steel Strand, Uncoated Seven-Wire for
AWWA D110-------------Wire- and Strand-Wound, Circular, Prestressed Concrete Water
Tanks
BS 1881......................Testing Concrete.
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Part
Page 3
BS EN 12390,.............Testing hardened concrete

of concrete.
BS EN 1992
Eurocode 2: Design of concrete structures
GSO ISO 1920, .......... Testing of concrete

18.1.3
Submittals
Samples
Technical details of the proposed materials and equipment shall be submitted. Details of the
jack type and size shall be submitted to allow for clearances to be checked. A calibrated
stress-recording device shall be used. Design Data. The Contractor shall submit:
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(c)
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(b)
a 1 m length sample of strand shall be taken from every 1000 m of strand to be

installed in the works with a minimum of one sample of strand per reel, on Site in the
presence of the Engineer for strength test at an independent laboratory approved by
the Engineer. A reel shall only be accepted if both the breaking load and the 0.1 %
proof load of the sample exceed the characteristic load given in BS 5896 Table 6
a minimum of three samples of strand shall be taken at random from each reel of
prestressing steel on Site in the presence of the Engineer. The reels on Site shall only
be accepted if the relaxation values determined by the tests are equal to or lower than
the specified relaxation class of BS 5896.
Sample requirements and frequency for prestressing wire shall meet the requirements
of AWWA D110 and ACI 372R.
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(a)
(b)
tendon extension calculations
(c)
vent pipe spacing and location details.
(d)
detailed execution and shop drawings
(e)
calculation notes
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details of the proposed grout mix design
Other Submittals. The Contractor shall also submit:
Safety procedures, including warning signs, barricades and communication between

different stressing locations
(b)
Curriculum vitae and experience record of the supervisor proposed, who shall have a
minimum of five years experience in such a position
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(a)
(c)
The name of the proposed the prestressing company, giving details of previous
projects.
18.1.4
Storage and Handling
Prestressing steel shall be stored on palettes at least 300 mm above the ground, and be
protected from contamination by wind blown sand or rain.
Prestressing strand shall be in coils of sufficiently large diameter to ensure that the strand
pays off straight.
18.2
PRESTRESSING
18.2.1
General
Prestressing operation shall be carried out only under the direction of an experienced and
competent supervisor and all personnel operating the stressing equipment shall have been
properly trained in its use.
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Part
Page 4
In addition to the normal precautions against accident, which should be taken at all times for
the whole of the Works, special care shall be taken when working with or near tendons which
have been tensioned or are in the process of being tensioned.
The system of prestressing used shall be a system approved by the Engineer. Such system
shall be used strictly in accordance with the recommendations of the system manufacturer.
Under no circumstances shall equipment or fittings designed for use with one system of
prestressing be used in conjunction with equipment and fittings designed for use with another
system.
Prestressing components shall be stored in clean dry conditions. They shall be clean and
free form loose rust and lose mill scale at the time of fixing in position and subsequent
concreting. Slight rusting of the steel, which can be removed by moderate rubbing, is
acceptable, but the surface shall not show signs of pitting.
18.2.2
Wires and Strands
All prestressing strands shall be seven-wire super stabilised low relaxation strands with a
Guaranteed Ultimate Tensile Strength (GUTS) of not less than 1770 MPa, complying with BS
5896 or relevant ASTM standards.
All prestressing wire shall be cold-drawn, high-carbon wire meeting the requirements of
ASTM A821/A821M, Type B having a minimum ultimate tensile strength of 1,448 MPa
(210,000 psi) prior to galvanizing. Zinc coating for galvanizing shall meet the requirements of
ASTM A641/A641M, with a minimum weight per unit area of uncoated wire surface of 259
g/m2 (0.85 oz/ft2). The minimum ultimate strength of the wire after galvanizing shall be no
less than 1,241 MPa (180,000 psi).
All wires or strands to be stressed at the same time shall be taken from the same parcel. The
coil numbers of the steel used for each tendon shall be recorded.
Welding of tendons shall not be permitted.
All cutting of strands shall be carried out using a high-speed abrasive cutting wheel or friction
saw at not less than one diameter from the anchor. Cutting shall take place only after the
Contractor has submitted the stressing records and the Engineer has approved them in
writing. Flame cutting will not be permitted.
Tendons shall be built into the Works strictly in accordance with the system which is being
employed.
Sufficient strand shall project from the anchorage to allow jacking to take place at the
stressing end of the tendon.
The cable (tendons) or individual strands comprising the cable shall not be kinked or bent.
No strand that has become unravelled shall be used.
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Part
Page 5
Sheaths, Cores and Ducts
Sheaths shall be accurately located both vertically and horizontally as described in the
Specific Project Specification. Unless otherwise described in the Specific Project
Specification the tolerance in the location of the centre line of the sheath shall be within
5 mm.
All sheaths and cores shall be maintained in their correct positions during the placing of the
concrete. Unless otherwise agreed with the Engineer, sheaths shall be rigidly supported at
points not less than 50 mm and not more than 500 mm apart. The method of support shall be
to the approval of the Engineer.
Where sheaths are used, the number of joints shall be kept to a minimum and sleeve
connectors shall be used for jointing. Each joint shall be adequately sealed against the
ingress of material. Joints in adjacent sheaths shall be staggered by at least 300 mm
Sheaths shall be kept free of matter detrimental to the bond between the grout and the
sheath and, except for material sealing a sheath joint, between the sheath and concrete.
Within 24 hours of the concrete being placed the Contractor shall satisfy the Engineer that
the tendons are free to move if they are in ducts or that the ducts are free from obstruction.
The number and position of grout vents for entry and outlet points and for checking that the
entire length of duct has been adequately grouted, shall be agreed with the Engineer before
the ducts are formed.
Vents shall be provided at low points in the tendon profile to allow the disposal of water that
may have collected as a result of rain or curing, for example. The vents shall be sealed
before grouting operations beginning.
18.2.4
Anchorages
Anchorages, end blocks and plates shall be positioned and maintained in position during
concreting so that the centre line of the duct passes axially through the anchorage assembly.
All bearing surfaces shall be clean before concreting and tensioning.
Anchoring of prestressing wires shall meet the requirements of AWWA D110 and ACI 372R.
18.2.5
Jacking Equipment
All jacking equipment used for stressing operations shall be of the type applicable to the
system adopted.
Jack and pumps shall be calibrated at an independent facility, in the presence of the
Engineer, before beginning stressing operations. Calibration of the equipment shall take
place at six-month intervals for equipment permanently present on Site. Whenever new
equipment is brought to the Site, or equipment is removed and returned, or serviced,
recalibration of the equipment as described will be required.
All gauges, load cells, dynamometers and other devices used for measurement shall have a
reading accuracy of within 2 %.
Stressing equipment for prestressing wires shall meet the requirements of AWWA D110 and
ACI 372R.
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18.2.3
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Part
Page 6
Tensioning
The Contractor shall submit details of the proposed stressing loads and stressing sequence
to the Engineer for approval.
Tensioning shall be carried out only in the presence of the Engineer or his representative
unless permission has been granted to the contrary.
The Contractor shall ensure that personnel carrying out the stressing are provided with
particulars of the required tendon loads, order of stressing and extensions.
Immediately before tensioning, the Contractor shall prove that all tendons are free to move
between jacking points.
Unless otherwise permitted in the Contract, concrete shall not be stressed until it has
reached at least the age at which two test cubes taken from it attain the specified transfer
strength. The cubes shall be made and tested as described in BS 1881 , BS EN 12350, BS
EN 12390 or GSO ISO 1920. They shall be cured in similar conditions to the concrete to
which they relate to, and in a manner approved by the Engineer.
The friction factors assumed for the calculation of tendon extension shall be verified by on
Site measurement of the force-extension relationship of a typical sample of installed tendons.
The Contractor shall establish the datum point for measuring extension and jack pressure to
The tendons shall be stressed at a gradual and steady rate until they attain the force
required.
The maximum force exerted on the shall not exceed 75 % of the GUTS of the strand. For the
purposes of cable detensioning, where the installed strand is to be discarded the jacking
force may be increased to 80 % GUTS.
10
The force in the tendons shall be obtained from the readings on a load cell or pressure gauge
and the extension of the tendons measured. The two readings shall conform to the limits set
by the Engineer but in all cases the force in the tendon as computed from the extension
measurement shall be within +5 % to -2 % of the force indicated by the gauging system.
11
When stressing from one end only the pull in at the dead end shall be accurately measured
and the appropriate allowance made in the measured extension at the live end.
12
If the calculated and measured extensions vary from each other by more than 6 % then
corrective action shall be taken. This may involve detensioning and retensioning of the
tendons if required by the Engineer.
13
When the required force, including overloads of short duration, has been applied to the
satisfaction of the Engineer, the tendons shall be anchored. The jack pressure shall then be
relieved in such a way as to avoid shock to the anchorage or tendons.
14
If the pull-in of tendons at the completion of anchoring is greater than that acceptable to the
Engineer, the tendons shall be detensioned and the tendon tensioned again.
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18.2.6
QCS 2014

Part
Page 7
The Engineer may direct that the force in any tendon be tested by rejacking. This will only be
instructed if there is doubt that the calibration of tensioning equipment is accurate. Care shall
be exercised by the Contractor during the retensioning to ensure that the jacking load does
not exceed more than 80 % of the GUTS of the strand.
16
If it is necessary to crop the tendons to enable the ducts to be grouted, this shall be delayed
as long as is practicable up to the time of grouting. In all other cases, unless otherwise
agreed with the Engineer, the tendons shall not be cropped less than three days after
grouting.
17
The Contractor shall keep full records of all tensioning operations, including the measured
extensions, pressure gauge or load cell readings and the amount of pull-in at each
anchorage. Copies of these records, on suitable forms, shall be supplied to the Engineer
within 24 hours of each tensioning operation.
18
Tensioning prestressing wires shall meet the requirements of AWWA D110 and ACI 372R
18.2.7
Grouting
Grouting shall take place only with the written approval of the Engineer.
All ducts shall be thoroughly cleaned by means of compressed air and all anchorages shall
be sealed before grouting.
Ducts shall be grouted as soon as practicable after the tendons in them have been stressed
and the Engineers written permission to commence has been obtained. Grout shall be
injected in one continuous operation and allowed to flow from the vents until the consistency
is equivalent to that being injected. The maximum time between mixing and injection shall not
exceed 30 min.
The ducts shall be completely filled with grout.
Vents shall be sealed consecutively in the direction of flow and the injection tube sealed
under pressure until the grout has set. The filled ducts shall be protected to the satisfaction of
the Engineer to ensure that they are not subject to shock or vibration for one day.
Two days after grouting, the level of grout in the injection and vent tubes shall be inspected
and made good if necessary.
The Contractor shall keep full records of grouting including the date each duct was grouted,
the proportions of the grout and admixtures used, the pressure, details of interruptions and
topping up required. Copies of these records shall be supplied to the Engineer within three
days of grouting.
Prestressing wires shall be protected against corrosion and other damage by a shotcrete
cover coat meeting the requirements of AWWA D110 and ACI 372R
18.2.8
Grout Mixer
The grout mixer shall produce a grout of colloidal consistency. The grout injector shall be
capable of continuous operation with a sensibly constant pressure up to 0.7 MPa and shall
include a system of circulating or agitating the grout whilst the actual grouting is not in
progress. All baffles to the pump shall be fitted with sieve strainers size BS 14.
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The equipment shall be capable of maintaining pressure on completely grouted ducts and
shall be fitted with a nozzle which can be locked off without loss of pressure in the duct.
The pressure gauges shall be calibrated before they are first used in the Works and
thereafter as required by the Engineer. All equipment shall be thoroughly washed with clean
water at least once every three hours during grouting operations and at the end of use for
each day.
The Contractor shall ensure that standby grouting equipment is available in the event of a
breakdown.
18.2.9
Grout Trials
The Contractor shall carry out grouting trails to the satisfaction of the Engineer before actual
grouting taking place.
Unless otherwise directed or agreed as a result of grouting trials, the grout shall:
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consist only of ordinary Portland cement, water and an approved expansion agent
(b)
have a water: cement ratio as low as possible consistent with the necessary
workability. Under no circumstances shall the water: cement ratio exceed 0.4
(c)
not be subject to bleeding in excess of 2 % after 3 h or 4 % maximum when measured

o
at 18 C in a covered glass cylinder approximately 100 mm diameter with a height of
approximately 100 mm and the water shall be reabsorbed after 24 h.
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(a)
Admixtures containing chloride or nitrates shall not be used. Other admixtures shall be used
only with the written permission of the Engineer and shall be used strictly in accordance with
The grout shall be mixed for a minimum of 2 minutes and until a uniform consistency is
obtained.
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END OF PART
QCS 2014

Part
19: Testing of Water Retaining Structures
Page 1
TESTING OF WATER RETAINING STRUCTURES................................................ 2
19.1
19.1.1
19.1.2
19.1.3
19.1.4
GENERAL ............................................................................................................... 2
Scope
2
References
2
Submittals
2
General
2
19.2
19.2.1
19.2.2
TESTING ................................................................................................................. 2
General
2
Cleaning
3
19.3
19.3.1
19.3.2
19.3.3
TESTING PROCEDURE ......................................................................................... 4

Walls
4
Roofs
5
Disposal of Water Used for Testing
5
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19
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Page 2
TESTING OF WATER RETAINING STRUCTURES
19.1
GENERAL
19.1.1
Scope
This Part of the specification applies to the testing of structures that are designed with the
intention of retaining water.
References
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19.1.2
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This Section
Part 1 ............... General
Part 13 ............. Inspection and Testing of Hardened Concrete
Part 14 ............. Protective Treatments for Concrete
19
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BS 8007......................Code of Practice for Design of concrete structures for the retaining of

aqueous liquids
Submittals
The Contractor shall record and submit to the Engineer within 24 hours the results of the
watertightness tests carried out.
19.1.4
General
Water retaining structures shall be watertight when subjected to external groundwater

pressures or to tests as specified in this Part.
19.2
TESTING
19.2.1
General
The Contractor shall test watertightness of water retaining structures including storage
reservoirs and other miscellaneous structures that require to be watertight.
All water used for testing shall be potable or irrigation water and the Contractor shall make
arrangements for the supply and disposal of this water.
Water retaining structures shall be tested for watertightness after completion, in accordance
with the following method or as directed by the Engineer:
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19.1.3
(a)
the structure shall be filled with potable or irrigation water in stages not exceeding 1 m
in 24 h held at each water level for such time as the Engineer may require. Should
dampness or leakage occur, the water shall be drawn off and the defects remedied to
the satisfaction of the Engineer
(b)
in the case of structures which are subdivided into individual tanks, each individual
tank shall be tested separately. In the case of underground or partially underground
structures, the testing shall take place before application of water proofing membrane,
liner material or perimeter drain, filter material or backfilling is placed against the walls
QCS 2014

Part
Page 3
in the case of hopper bottomed tanks, this shall be taken to mean that no material is
placed against the vertical external walls of the tank, the sloping walls of the hopper
bottoms of the tanks being assumed built directly against the excavation apart from the
blinding concrete
(d)
no placing of material against the walls shall take place until the Engineer has given
his written approval and acceptance of the water retaining structures as watertight
(e)
filling shall not take place earlier than 28 d after the casting of the final sections of the
structure which will be stressed by the filling of the structure.
(f)
testing shall not be undertaken until the structure to be tested has been; completed
structurally including roof, if any, and has been passed by the Engineer in writing as
satisfactory in all respects other than watertightness, especially in regard to the final
finish of the work
(g)
not withstanding the satisfactory completion of the seven day test, leakage, cracks,
and damp patches and sweating visible on the outside faces of the structure shall be
rectified from the water face by an injection system to the approval of the Engineer
(h)
repair making the outer face only watertight wall not be accepted, this applies to bobbin
holes also
(i)
the structure shall be retested until the watertightness is approved by the Engineer.
(j)
should the structure fail a test in the above respects, the Contractor shall immediately
take such steps as may be necessary to:
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(c)
ascertain the nature and positions of defects or leakage's
(ii)
empty the structure
(iii)
remedy the defects in a manner approved by the Engineer, employing workers

who are specialists in this class of work
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(i)
when the remedial work has been completed in the manner approved by the Engineer,
the testing and if necessary rectification shall be repeated until a satisfactory test is
achieved.
(l)
if necessary, in extreme cases of lack of watertightness, the Engineer may reject the
structure or portions thereof.
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(k)
Cleaning
All water retaining structures shall, on completion, be carefully cleaned of all debris, to the
complete satisfaction of the Engineer as follows:
19.2.2
(a)
shall be brushed down on all internal faces with a stiff broom while still dry
(b)
all resulting debris removed
(c)
all associated reservoir pipe work shall be cleaned in accordance with the specified
requirements
(d)
the structure shall then be flooded with approximately 75 mm of clean water
(e)
whole of internal faces shall be carefully brushed down with stiff brooms using the
water continuously until all faces are clean
(f)
water shall then be drained off
(g)
walls and floors hosed and flushed with clean water until perfectly clean.
QCS 2014

Part
Page 4
TESTING PROCEDURE
19.3.1
Walls
After completion and cleaning of the structure and all associated pipe work, if any, the
Contractor shall fill the structure up to the top water level and leave for a stabilising period of
21 d in order to allow for absorption and autogenous healing to take place.
Water shall be added over this period to maintain the top water level.
The Contractor shall ensure that all pipes and specials are available in ample time ahead of
testing.
Two sets of evaporation trays shall be provided along with two sets of rain gauges.
Levels in the trays and structure shall be made and recorded by a hook gauge with vernier
attachments.
Before and during testing, flows in the structure under drainage, if any, shall be monitored,
measured and recorded.
Each under drain shall be numbered and observations reported by under drain number to
facilitate analysis of the data.
All leaks shall be repaired within one month of their detection.
On the twenty-second day, two shallow watertight evaporation trays of area 0.4 m2 shall be
filled with 75 mm of water and placed to float in the structure.
10
The water level in the structure shall be recorded and the test commenced and carried out
over the next 7 d.
11
Readings of water levels in the structure and trays shall be made and recorded every 24 h
over this period.
12
If the water level in the tank falls by more than indicated by the evaporation trays, or other
sign of leakage occurs by the end of the test period then the Contractor shall search and
mark all areas of defect.
13
The structure shall then be emptied and the defects made good as specified herein.
14
After completion of remedial measures the structure shall be refilled and the test repeated.
15
This process shall be repeated until the structure is watertight to the satisfaction of the
Engineer.
16
The fall of water level in the structure over the test period of 7 d, minus the fall accounted for
by evaporation and rainfall shall not exceed 1/500 of the average water depth of the full
structure or 10 mm whichever is less.
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19.3
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Part
Page 5
Roofs
The roofs of structures shall be tested for watertightness before laying of roof membrane.
Roof and fittings shall be hosed down vigorously and this shall be repeated in such a way as
to keep the roof wet for three successive days.
Roof and fittings shall be deemed satisfactory for watertightness if no discernible leaks or
damp patches show in the soffit.
Roof covering shall be completed as soon as possible after testing.
19.3.3
Disposal of Water Used for Testing
The Contractor shall provide suitable means for disposal of water used for testing, such that
no damage results to facilities, structures or property.
These means shall be subject to the approval of the Engineer and local authorities.
Details shall be submitted to Engineer on request.
The Contractor shall be responsible for damage caused by his filling, testing, flushing and
wastewater disposal operations.
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19.3.2
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END OF PART
QCS 2014

Part
02: Aggregates
Page 1
AGGREGATES ....................................................................................................... 2
2.1
2.1.1
2.1.2
2.1.3
2.1.4
2.1.5
GENERAL ............................................................................................................... 2
Scope
2
References
2
Definitions
3
Source Approval
4
Sampling
4
2.2
QUALITY AND TESTING ........................................................................................ 5
2.3
STORAGE AT CONTRACTOR PLANT ................................................................... 5
2.4
FINE AGGREGATE FOR CONCRETE AND MORTAR ........................................... 7
2.5
COARSE AGGREGATE FOR CONCRETE............................................................. 8
2.6
COMBINED AGGREGATE FOR CONCRETE......................................................... 8
2.7
WASHING AND PROCESSING .............................................................................. 9
2.8
LIGHTWEIGHT AGGREGATES.............................................................................. 9
2.9
COARSE RECYCLED AGGREGATES ................................................................... 9
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QCS 2014

Part
02: Aggregates
Page 2
AGGREGATES
2.1
GENERAL
2.1.1
Scope
This part covers the requirements of aggregates for use in structural concrete.
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References
ASTM C33 ..................Standard Specification for Concrete Aggregates
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ASTM C40 ..................Test Method for Organic Impurities in Fine Aggregates for Concrete
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ASTM C88 ..................Test Method for Soundness of Aggregates by Use of Sodium Sulphate
or Magnesium Sulphate
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ASTM C123 ................Test Method for Lightweight Pieces in Aggregate

ASTM C127 ................Test Method for Specific Gravity and Absorption of Coarse Aggregate
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ASTM C128 ................Test Method for Specific Gravity and Absorption of Fine Aggregate
ASTM C131 ................Test Method for Resistance to Degradation of Small-Size Coarse

Aggregate by Abrasion and Impact in the Los Angeles Machine
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ASTM C136 ................Standard Test Method for Sieve Analysis of Fine and Coarse
Aggregate
ASTM C142 ................Test Method for Clay Lumps and Friable Particles in Aggregates.
2.1.2
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This Section.....
Part 3, .............. Cementitious Materials
Part 4, .............. Water
Part 8, .............. Transportation and Planning of Concrete
Part 15, ............ Hot weather Concreting
Part 17, ............ Structural Precast Concrete
Part 18, ............ Prestressed Concrete
ASTM C535 ................Test Method for Resistance to Degradation of Large-Size Coarse

Aggregate by Abrasion and Impact in the Los Angeles Machine
ASTM C702 ................Standard Practice for Reducing Samples of Aggregate to Testing Size
ASTM D75 ..................Standard Practice for Sampling Aggregates
BRE Digest 330-2.......Alkali-Silica Reaction in Concrete Detailed Guidance for New
Construction.
BS 933-3 ....................Tests for geometrical properties of aggregates Determination of
particle shape. Flakiness index
BS 933-7 ....................Tests for geometrical properties of aggregates Determination of shell
content. Percentage of shells in coarse aggregates
BS 933-9 ....................Tests for geometrical properties of aggregates Assessment of fines.
Methylene blue test
QCS 2014

Part
02: Aggregates
Page 3
BS 933-11 ..................Tests for geometrical properties of aggregates Classification test for

the constituents of coarse recycled aggregate
BS 1097-6 ..................Tests for mechanical and physical properties of
Determination of particle density and water absorption
aggregates
BS 8500 part 2 ...........Concrete. Complementary British Standard to BS EN 206-1.

Specification for constituent materials and concrete
BS EN 12620 ..............Aggregates for concrete
BS EN 1744-1 ............Tests for chemical properties of aggregates, Chemical analysis
BS EN 1744-5 ............Tests for chemical properties of aggregates. Determination of acid
soluble chloride salts
aggregates.
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drying
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BS EN 1367-2 ............Tests for thermal and weathering properties of

Magnesium sulphate test. BS EN 1367-4 Determination
shrinkage
BS EN 933 ..................Tests for geometrical properties of aggregates
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BS EN 1097-2 ............Tests for mechanical and physical properties of aggregates. Methods

for the determination of resistance to fragmentation
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BS EN 1097-6 ............Tests for mechanical and physical properties of aggregates.

Determination of particle density and water absorption
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BS EN13055-1 ...........Lightweight aggregates. Lightweight aggregates for concrete, mortar

and grout.
BS PD 6682-1 ............Aggregates for concrete. Guidance on the use of BS EN 12620
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BS PD 6682-4 ............Aggregates Lightweight aggregates for concrete, mortar and grout.

Guidance on the use of BS EN 13055-1
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EN 13139 ..................Aggregates for mortar

EN 998-1 ...................Specification for mortar for masonry Rendering and plastering mortar
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EN 998-2 ...................Specification for mortar for Masonry mortar

ISO 9001:2008 ...........Quality management systems -- Requirements
ISO 17025 ..................General requirements for the competence of testing and calibration
laboratories
RILEM AAR1 ..............RILEM Recommended Test Method AAR-1 Detection of potential
alkali-reactivity aggregates, Petrographic method
RILEM AAR3 ..............RILEM Recommended Test Method AAR-3 Detection of potential
alkali-reactivity - 38C test method for aggregate combinations using
concrete prisms
2.1.3
Definitions
Aggregate: granular material used in construction and may be natural, manufactured or

recycled.
Natural aggregate: aggregate from mineral sources which has been subjected to nothing
more than mechanical processing.
QCS 2014

Part
02: Aggregates
Page 4
Manufactured aggregate: aggregate of mineral origin resulting from an industrial process

involving thermal or other modification.
Recycled aggregate: aggregate resulting from the processing of inorganic material previously
used in construction.
Lightweight aggregate: aggregate of mineral origin having a particle density not exceeding
2,000 kg/m3 or a loose bulk density not exceeding 1,200 kg/m3.
2.1.4
Source Approval
The Contractor shall use only those imported materials sourced from an Accredited Quarry
Producer or Accredited Supplier and which have been approved by Qatar Standards or their
representatives.
The accredited aggregate suppliers shall provide the source name(s) for every shipment of
aggregates delivered to the concrete supplier.
The source of material supply may be changed by the Contractor during the project, provided
that the replacement materials shall be sourced from an Accredited Quarry Producer and the
replacement materials are not significantly different in terms of physical and chemical
properties, thus ensuring that the resultant concrete continues to comply fully with the
specified requirements.
When considering whether an aggregates supplier and aggregates producer are suitable to
be Accredited, preference will be given to organisations with a proper quality management
system, such as ISO 9001 or another quality management system approved by Qatar
Standards.
When requested by the engineer, the aggregate supplier shall provide a geotechnical
analysis on the rock samples before blasting and grinding to ensure the proper quality of
materials.
The aggregates shall be properly stocked and labelled without intermingling at any storage
area.
When requested by the engineer, the aggregates supplier shall provide data for the past 6
months that shows the consistency of materials and conformity with this specification.
The supplier shall verify the compliance of aggregates as per QCS by an independent
qualified testing agency accredited to ISO 17025, and approved by Qatar Standards.
2.1.5
Sampling
The Contractor shall provide samples of both fine and course aggregate to the Engineer, in
accordance with the requirements of relevant standards in QCS for sampling, sample
reducing and testing of Aggregates, for testing at least two weeks before beginning deliveries
to the Site.
All samples shall be taken in the presence of the Engineer or an approved testing agency
assigned by the Engineer.
Aggregate sampling and testing shall be conducted by qualified staff.
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Part
02: Aggregates
Page 5
QUALITY AND TESTING
Aggregates shall consist of tough, hard, durable and uncoated particles containing no
harmful material in quantities sufficient to adversely affect the concrete or reinforcing steel,
and shall contain no materials likely to cause staining or otherwise disfigure the concrete
surface.
Aggregates shall be obtained from a source approved by the Engineer.
Aggregate shall meet the requirements given in Table 2.1. Additional tests detailed in BS EN
12620 with BS PD 6682, EN 13139, EN 998-1, EN 998-2, or relevant ACI and ASTM
standards and codes of practice may be required by the Engineer to satisfy certain
requirements.
Contractor shall provide all data as specified in QCS.
Sampling of the aggregates shall be carried out in accordance with the requirements of BS
EN 12620, BS EN 933, or ASTM D75 and ASTM C702.
Fine aggregates shall be natural sand or manufactured crushed rock sand. Crushed rock
sand shall be the direct product of a manufacturing process, not the by-product of coarse
aggregate production.
Beach sand shall not be permitted for use in concrete mixes.
The use of clean Dune Sand, blended with coarser sand, may be permitted providing it can
be shown that the sand is free from contaminants. The use of local Dune sand shall be
preapproved by the Ministry of Environment.
Samples of aggregates shall be taken in accordance with the requirements of Table 1.1- Part
1.
10
Frequency of routine testing shall meet the requirements as listed in Section 2. Frequency of
testing may be increased by the engineers request if testing results show inconsistency, and
frequency may be reduced if approved by the engineer if materials are highly consistent.
11
Mineralogical tests are to be carried out as instructed by the Engineer.
12
No aggregate deliveries shall be made to the Site until the Engineer has approved the
samples as complying with this specification.
2.3
STORAGE AT CONTRACTOR PLANT
Aggregate shall be stored as follows:
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2.2
(a)
each nominal size of coarse aggregate and fine aggregate shall be kept separated and
clearly labelled at all times.
(b)
The height of stockpiles shall be controlled to prevent harmful segregation and

breakage of the aggregate.
(c)
stockpiles shall be on hard and clean surfaces with not more than 5 % slope
QCS 2014

Part
02: Aggregates
Page 6
(d)
contamination of the aggregates by the ground or other foreign matter shall be

effectively prevented at all times
(e)
each heap of aggregate shall be capable of draining freely
(f)
stockpiles shall be protected from direct sunlight
(g)
unloading of aggregate shall be controlled to prevent harmful segregation and

breakage.
The Contractor shall maintain the stockpiles of coarse aggregate in separate gradings.
At the construction site, the preparation, location and size of any stockpile shall be approved
by the Engineer.
Test Methods
Requirement
BS / EN
Permissible Limits
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No.
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Table 2.1
Limits for Physical, Chemical and Mechanical Properties of Aggregates for Normal Concrete
ASTM
Fines
Coarse
933-1
2. Natural: materials finer than 0.063 mm.
933-1
Crushed rock: materials finer than

0.063mm.
3. Fines quality
a) Structural concrete
Sand Equivalent (%)
933-8
60% min
933-9
2% max
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b)
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1. Grading
Non-structural concrete
Methylene blue adsorption
3
value (0/2mm)
Standard
Standard
3% max
7% max
2% max
2% max
C142
5. Lightweight pieces
C123
0.5% max
0.5% max
C40
NA
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4. Clay lumps and friable particles
1.0 (g/kg)
max
2% max
7. Water absorption (saturated surface
1097-6
Colour
standard not
darker than
4
plate No. 3
2.3% max
8. Particle density for normal weight
1097-6
2.0 min
2.0 min
9. Shell Content:
933-7
3% max
3% max
10. Flakiness index
933-3
11. Acid-soluble chlorides:
1744-5
dry)
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6. Organic impurities for fine aggregates
2.0% max
concrete
35% max
a) Reinforced and mass concrete
0.06% max
0.03% max
b) Prestressed concrete and steam

5
cured structural concrete
0.01%
0.01%
QCS 2014

Part
02: Aggregates
Page 7
Test Methods
No.
Permissible Limits
Requirement
BS / EN
ASTM
Fines
Coarse
12. Acid-soluble sulphate
1744-1
0.4% max
0.3% max
13. Soundness by magnesium sulphate (5
1367-2
15% max
15% max
cycles)
Resistance to fragmentation: Los
1097-2
30% max
15. Drying shrinkage
1367-4
0.075% max
14. Angeles abrasion
16. Potential reactivity:
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See Note 6 below
Notes:
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3.
4.
Use of BS EN or relevant GSO standards.

If the Sand Equivalent value is less than 60% and greater than or equal to 50%, the sand shall be
considered non-harmful and is accepted provided that the Methylene Blue value is less than or equal to
1.0 (g/kg).
Not required when the fines content in the fine aggregate, or in the all-in aggregate, is 3% or less.
Organic impurities: use of a fine aggregate failing in the test is not prohibited, provided that:
a. The discoloration is due principally to the presence of small quantities of coal, lignite, or similar
discrete particles.
b. When tested for the effect of organic impurities on strength of mortar, the relative strength at 7
days, calculated in accordance with ASTM C87, is not less than 95 %.
If the chloride content is higher than 0.01% the following steps may be taken:
a- The aggregates may be washed by suitable water (Sec 5 Part 4) before mixing to lower the chloride
content to the specified value (0.01%).
b- If the washing process does not reduce the chloride content to the required value, then the Acid
Soluble Chloride content in the concrete ingredients (the sum of the contributions from the
constituent materials) shall be tested as mentioned in BS 8500-2. The allowable Acid Soluble
chloride content limit shall not exceed the values given in Section 5, Part 6, Para 6.5.3.
The alkali-aggregate reactivity shall be assessed at source in accordance with BS 206-1 and BS 85002. Certification shall be obtained from the aggregate source indicating absence of deleterious
expansion of concrete due to alkali aggregate reactivity.
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1.
2.
2.4
FINE AGGREGATE FOR CONCRETE AND MORTAR
Fine aggregate consist of natural clean sand, stone screenings or a combination and can be
produced from natural disintegration of rock or gravel and/or by the crushing of rock or gravel
or processing of manufactured aggregate or artificial, conforming to the requirements of
physical and chemical properties complying with Table 2.1 and subject to the Engineer's
acceptance.
Crushed fine aggregates may be blended with local washed sand provided that the final
aggregate complies with the requirements in Table 2.1.
The gradation of fine aggregate for concrete and mortar shall be in accordance with the
gradation designations in BS EN 12620 with BS PD 6682, EN 13139 , EN 998-1 , EN 998-2,
or relevant ACI and ASTM standards and codes of practice and subject to the Engineers
acceptance.
QCS 2014

Part
02: Aggregates
Page 8
Each batch of aggregate delivered to the Site shall be kept separate from previous batches,
and shall be stored to allow for inspection and tests to be carried out.
Local natural sand shall be mechanically washed to remove salts and other impurities in
order to meet the specified requirements.
The storage area for the clean washed sand shall be shaded from the direct rays of the sun
and shall be screened for protection from dust. The area in the neighbourhood of
stockpile/mixing plant shall be watered as necessary, to reduce the rising of dust.
The usage of Dune sand shall be accepted as governed by the regulations of Qatar Ministry
of Environment and shall be:
Not used for any reinforced concrete
(b)
Used only for blocks, block mortar, plasters, soil cement, shotcrete and insulation
concrete.
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(a)
COARSE AGGREGATE FOR CONCRETE
The coarse aggregate is granular material and may be natural, manufactured, recycled or a
combination. It shall be free from deleterious matter and conforming to the requirements of
physical and chemical properties in Table 2.1 as a minimum requirements and subject to the
Engineer's acceptance within BS EN 12620, BS PD 6682 or ASTM C33
For imported aggregate, Qatar Standards may publish more requirements and stringent limits
than specified in Table 2.1.
For other types of concrete mixes and subject to Engineer's acceptance, coarse aggregate
shall comply with the relevant BS EN or relevant ACI and ASTM standards and codes. The
nominal maximum size of coarse aggregate shall be not larger than: (a) 1/5 the narrowest
dimension between sides of forms, nor (b) 1/3 the depth of slab, nor (c) 3/4 the minimum
clear spacing between individual reinforcing bars or wires, bundles of bars, individual
tendons, bundled tendons, or ducts.
These limitations shall not apply if, in the judgment of the licensed design professional,
workability and methods of consolidation are such that concrete can be placed without
honeycombs or voids.
As requested by the Engineer, the Contractor shall mechanically wash the aggregates to
remove salts and other impurities in order to meet the requirements specified.
2.6
COMBINED AGGREGATE FOR CONCRETE
The material passing the 0.063mm sieve shall not exceed 3.0 % of the combined aggregate
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2.5
(by weight). The combined aggregate gradation used in the work shall be as specified,
except when otherwise approved or directed by the Engineer.
2
Changes in the approved gradation shall not be made during the progress of the works
unless approved or directed by the Engineer.
QCS 2014

Part
02: Aggregates
Page 9
WASHING AND PROCESSING
Where aggregates have been washed shortly before delivery to the Site, or if stockpiles have
been sprayed to cool them, samples of the aggregate shall be taken frequently to determine
the correct amount of water to add to the mix.
2.8
LIGHTWEIGHT AGGREGATES
Lightweight aggregates are those having particle densities not exceeding 2,000 kg/m3 or
3
loose bulk densities not exceeding 1200 kg/m .
Lightweight aggregates include natural aggregate, aggregate manufactured from natural

materials and/or a by product of industrial processes, and some recycled aggregate.
Lightweight aggregates shall be in accordance with BS EN13055-1 and BS PD 6682-4, or

equivalent ASTM standards.
2.9
COARSE RECYCLED AGGREGATES
Excavation Waste (EW), coarse recycled aggregates (RA), and coarse recycled concrete
aggregates (RCA) shall meet with the requirements of Table 2.1, with the exception that
water absorption shall not exceed;
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2.7
3% for structural concrete
(b)
4% for non-structural concrete.
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(a)
For structural concrete EW and/or RCA may be used in designated concrete of maximum
C30. Its proportion shall be not more than a mass fraction of 20% of coarse aggregate (BS
8500-2 sec 6.2.2), except where approved by Qatar Standards to use a higher proportion.
For non-structural concrete, such as crash barriers and soakaways, EW and/or RCA may be
used in designated concrete of maximum C40. Its proportion shall be not more than a mass
fraction of 50% of coarse aggregate (BS 8500-2 sec 6.2.2), except where approved by Qatar
Standards to use a higher proportion.
For non-structural concrete RA may be used in designated concrete of maximum C25. Its
proportion shall be not more than a mass fraction of 20% of coarse aggregate (BS 8500-2
sec 6.2.2), except where approved by Qatar Standards to use a higher proportion.
When the composition of coarse RCA and coarse RA is tested in accordance with BS EN
933-11, the test result obtained for each type of particle shall not exceed the maximum value
specified in Table 2.2.
EW aggregate shall meet the same requirements for RCA, as given in Table 2.2.
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QCS 2014

Part
02: Aggregates
Page 10
Table 2.2
Requirements for coarse RCA and coarse RA, (mass fraction, %)
RCA
1, 3
5.0
5.0
0.5
5.0
1.0
1.0
100
1.0
10.0
-4
Maximum
acid soluble
sulphate
(SO3)
1.0
Where the material to be used is obtained by crushing hardened concrete of known

composition that has not been in use, e.g. surplus precast units or returned fresh concrete,
and not contaminated during storage and processing, the only requirements are those for
grading and maximum fines.
Material with a density less than 1,000 kg/m3
The provisions for coarse RCA may be applied to mixtures of natural coarse aggregates
blended with the listed constituents.
The appropriate limit and test method needs to be determined on a case-by-case basis (see
Note 6 to 4.3 of BS 8500-2).
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4.
Maximum
Asphalt
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2.
3.
Maximum
lightweight
2
material
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1.
Maximum
fines
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RA
Maximum
masonry
content
Maximum
foreign
material
e.g. glass,
plastic,
metals
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Type of
Aggregate
Requirement
The floating material (FL) content, as per BS EN 933-11, shall not exceed 5.0 cm /kg.
RCA should be treated as highly reactive aggregate. The alkali contribution from RCA shall
be determined as given in BS 8500-2.
For manufacturing of masonry concrete blocks, the usage of recycled aggregates is

permitted up to 100% as given in Sec. 13 in accordance with ACI 555.
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END OF PART
QCS 2014

Part
20: Personnel Qualifications and Certification
Page 1
PERSONNEL QUALIFICATIONS AND CERTIFICATIONS ..................................... 2
20.1
GENERAL ............................................................................................................... 2
20.2
AUDITORS .............................................................................................................. 2
20.3
20.3.1
20.3.2
READY MIXED CONCRETE COMPANIES ............................................................. 2

Technical Department
2
Production and Operation Department
4
20.4
20.4.1
TESTING LABORATORIES .................................................................................... 5

Concrete Laboratory Department
5
20.5
20.5.1
CONTRACTORS ..................................................................................................... 6
Concrete Construction Department
6
20.6
20.6.1
20.6.2
CONSULTANTS ...................................................................................................... 7
Site Supervision Department
7
Site Supervision / Design Office Department
7
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20
QCS 2014

Part
Page 2
PERSONNEL QUALIFICATIONS AND CERTIFICATIONS
20.1
GENERAL
The qualification requirements given in this part are optional unless otherwise mentioned
below. The purpose of the qualifications is to prepare the industry to cope with the required
quality of construction. The requirements will become compulsory as and when stated by
Qatar Standards.
Qualifications shall be approved by Qatar Standards or their representatives.
20.2
AUDITORS
Qatar Standards auditors and their approved representatives shall be qualified for inspecting
concrete ready mix plants and testing laboratories.
20.3
READY MIXED CONCRETE COMPANIES
20.3.1
Technical Department
Position:
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20
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Technical Manager / QC Manager
Qualifications:
Concrete specification review and concrete mixture proportioning
(b)
Concrete constituent materials, their characteristics, and effects on concrete properties
(c)
Fresh and hardened concrete properties
(d)
Durability of concrete
(e)
Production and delivery of Ready Mixed Concrete
(f)
Handling, placing and curing of concrete
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Specifying and evaluation of concrete strength

Testing of concrete and its constituents
(h)
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(g)
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(a)
(i)
Quality control procedures and statistical analysis
(j)
Hot weather concreting
(k)
Troubleshooting concrete problems
Position:
Site Supervisor
Qualifications:
(a)
The supervisor shall be capable of satisfactorily reading, understanding and

performing the below fresh concrete tests:
BS EN 12350-1 ..........Testing fresh concrete - Sampling

ASTM C1064/C1064M Temperature of freshly mixed hydraulic-cement concrete
QCS 2014

Part
Page 3
BS EN 12350-2 ..........Testing fresh concrete Slump test

BS EN 12350-6 .........Testing fresh concrete Density
BS EN 12390-2 .........Testing hardened concrete Making and curing specimens for
strength tests
ASTM C1611/C1611M Standard test method for slump flow of self consolidating concrete
3
Position:
Lab Supervisor
Qualifications:
BS EN 12350-1 .........Testing fresh concrete - Sampling

performing the below fresh and hardened concrete tests:
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(a)

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BS EN 12350-2 .........Testing fresh concrete Slump test
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BS EN 12350-7 .........Testing fresh concrete Air content (Pressure Method)
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strength tests
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BS EN 12390-3 ..........Testing hardened concrete - Compressive strength of test specimens
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BS EN 932-1 .............Aggregates - Methods of sampling

BS EN 932-2 .............Aggregates Methods of reducing laboratory samples
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BS EN 933-1 .............Aggregates Determination of particle size distribution (and dust

content)
BS EN 1097-6 ...........Aggregates Determination of particle density and water absorption
BS EN 1097-3 ...........Aggregates Determination of loose bulk density and voids
Position:
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ASTM C566 ............Method of determination of moisture content
Site Technician (compulsory if requested by the Engineer)
Qualifications:
(a)
The technician shall be capable of satisfactorily performing the below fresh concrete
tests:

strength tests
QCS 2014

Part
Position:
Page 4
Lab Technician (compulsory if requested by the Engineer)
Qualifications:
(a)
The technician shall be capable of satisfactorily performing the below fresh and
hardened concrete tests:

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strength tests
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BS EN 12390-3 .........Testing hardened concrete - Compressive strength of test specimens

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content)
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Production and Operation Department
Position:
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20.3.2
Plant/Production/Operation Manager and/or Supervisor
Materials management
(b)
Properties of concrete and its constituents
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(a)
Qualifications:
(c)
Plant design, function and maintenance
(d)
Batching operations, procedures and dispatching
(e)
Materials management and inventory
(f)
Safety regulations and procedures
Position:
Plant Operator
Qualifications:
(a)
Basic concrete properties and characteristics of its constituents
(b)
Scales, meters and batching sequence and control system
(c)
Central mixing and discharging
(d)
Tolerances, overweight/underweight controls
QCS 2014

Part
(e)
Troubleshooting scales, gates and other plant components
(f)
Safety procedures
20.4
TESTING LABORATORIES
20.4.1
Concrete Laboratory Department
Position:
Page 5
Laboratory Manager / QC Manager
Qualifications:
(b)
(c)
(d)
(e)
(f)
(g)
Evaluation of concrete strength
(h)
(i)
(j)
(k)
Position:
Supervisor

performing the below fresh and hardened concrete tests:
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(a)
Qualifications:
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(a)

strength tests
content)
QCS 2014

Part
Page 6

Position:
Technician (compulsory if requested by the Engineer)
Qualifications:
(a)
The technician shall be capable of satisfactorily performing the below fresh and
hardened concrete tests:
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strength tests
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content)
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CONTRACTORS
20.5.1
Concrete Construction Department
Position:
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20.5
Site Engineer
Qualifications:
(a)
The site engineer shall be capable of satisfactorily reading, understanding and


strength tests
QCS 2014

Part
Position:
Page 7
QC Manager/ QC Engineer/ Material Engineer
Qualifications:
(b)
(c)
(d)
(e)
(f)
(g)
Specifying and evaluating of concrete strength
(h)
(i)
(j)
(k)
20.6
CONSULTANTS
20.6.1
Site Supervision Department
Position:
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Site Inspector/ Material Inspector
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Qualifications:
The site engineer shall be capable of satisfactorily reading, understanding and

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(a)
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(a)
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strength tests
20.6.2
Site Supervision / Design Office Department
Position:
Material Engineer
Qualifications:
(a)
(b)
(c)
(d)
QCS 2014

Part
(e)
(f)
(g)
Specifying and evaluating of concrete strength
(h)
(i)
(j)
(k)
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END OF PART
Page 8
QCS 2014

Part
03: Cementitious Materials
Page 1
CEMENTITIOUS MATERIALS................................................................................. 2
3.1
3.1.1
3.1.2
3.1.3
GENERAL ............................................................................................................... 2
Scope
2
References
2
Terms and Definitions:
3
3.2
SOURCE APPROVAL ............................................................................................. 3
3.3
SAMPLING .............................................................................................................. 3
3.4
QUALITY AND TESTING ........................................................................................ 3
3.5
DELIVERY, STORAGE AND HANDLING ................................................................ 4
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QCS 2014

Part
Page 2
CEMENTITIOUS MATERIALS
3.1
GENERAL
3.1.1
Scope
This Part covers the requirements for the testing and use of cement in structural concrete.
3.1.2
References
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Part 6
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ASTM C10 ..................Standard specification for natural cement

ASTM C91 ..................Specification for Masonry cement
ASTM C114 ................Test methods for chemical analysis of Hydraulic Cement
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ASTM C115, ...............Test method for fineness of Portland cement by the Turbidimeter
qa
ASTM C150 ................Standard specification for Portland cement
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ASTM C183 ................Standard Practice for sampling and the amount of testing of Hydraulic
cement
ASTM C188 ................Test method for density of Hydraulic cement
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ASTM C186 ................Test method for heat of hydration of Hydraulic cement

ASTM C204 ................Test method for fineness of Hydraulic cement by air permeability
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ASTM C348 ................Test method for flexural strength of Hydraulic cement mortar
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ASTM C349 ................Test method for compressive strength of Hydraulic cement mortar
using portion of prism broken in flexure
ASTM C430 ................Test method for fineness of Hydraulic cement by the 45mm (No.325)
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ASTM C595 ................Standard specification for blended Hydraulic cement
ASTM C618 ................Standard Specification for Coal Fly Ash and Raw or Calcined Natural
Pozzolan for Use in Concrete
ASTM C845 ................Specification for Expansive Hydraulic cement
ASTM C989 ..............Standard Specification for Slag Cement for Use in Concrete and
Mortars
ASTM C1157 ..............Standard performance specification for Hydraulic cement
ASTM C1240 .............Standard Specification for Silica Fume Used in Cementitious Mixtures
ASTM C1328 ..............Specification for plastic cement (Stucco)
ASTM C1329 ..............Specification for Mortar cement
BS 146 ........................Portland blast furnace cement
BS 1370 ......................Low heat Portland cement
BS 4027 ......................Sulphate-resisting Portland cement
BS EN 196, .................Methods for testing cement
QCS 2014

Part
Page 3
BS EN 197-1, .............Cement, Composition, specifications and conformity criteria for

common cements.
BS EN 197-4 .............Cement. Composition, specifications and conformity criteria for low
Terms and Definitions:
Cementitious Materials: Portland cement in combination with one or more of the following:
blended hydraulic cement, fly ash and other pozzolans, ground granulated blast-furnace slag,
silica fume and Metakaolin; subject to compliance with requirements of this specification.
PC: shall mean Portland cement or CEM I.
FA or PFA: shall mean fly ash or pulverised fuel ash.
GGBS: shall mean ground granulated blast furnace slag.
3.2
SOURCE APPROVAL
The Contractor shall submit to the Engineer for approval full details of the proposed source of
cement. These sources of cement supply shall be regularly and thoroughly investigated to
ensure that the quality of the material supply is satisfactory and that it does not deteriorate
during the performance of the project.
The cement source shall not be changed without the Engineer's acceptance.
The Contractor shall supply the Engineer with the manufacturers test certificates certifying
that the cement is in compliance with the relevant standards.
For imported cement the manufacturers test certificates shall be provided with each
consignment. The Contractor shall submit to the Engineer the date of manufacture and proof
that the specifications have been complied with, certified by an independent agency in the
country of origin.
Cement manufacturers shall label their packaging and delivery documents and shall provide,
where applicable, information on the packing/dispatch date, storage conditions and the
storage period appropriate to maintaining the activity of any reducing agent and to keeping
the content of soluble chromium (VI) below the 2 ppm limit. The Engineer has the right to test
the cement for presence of chromium at the contractors expense.
3.3
SAMPLING
The methods of obtaining samples of cement for testing shall be carried out as described in
EN 196 or ASTM C183
3.4
QUALITY AND TESTING
The cementitious material shall fully comply with the relevant standard(s) from the following
list:
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3.1.3
ASTM C150 ................Standard specification for Portland cement

ASTM C595 ................Standard specification for blended Hydraulic cement
QCS 2014

Part
Page 4
ASTM C618 ...............Standard specification for coal fly ash and raw natural pozzolan for use
in concrete
ASTM C989 ...............Standard specification for ground granulated blastfurnace slag for use
in concrete and mortars
ASTM C1157 ..............Standard performance specification for Hydraulic cement
ASTM C1240 ..............Standard specification for silica fume used in cementitious mixtures
BS 146 ........................Portland-blast furnace cement
BS 1370 ......................Low heat Portland cement
BS 4027 ......................Sulphate-resisting Portland cement
BS EN 197-1, ............minimum grade 42.5
BS EN 450 .................Fly ash for concrete.
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BS EN 15167 .............Ground granulated blastfurnace slag for use in concrete, mortar and
grouts.
EN 12363 ..................Silica fume for concrete.
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Relevant GSO
The water-soluble chromium (VI) content shall not exceed 2ppm (0,0002%) by total dry
weight of cementitious materials.
3.5
DELIVERY, STORAGE AND HANDLING
Cement shall be delivered to the Site in sealed and branded bags, or in the manufacturers
containers, bearing the manufacturers name, cement type and date of manufacture, in
batches not exceeding 100 tons.
Cement shall be stored at the site in such a manner, as to prevent its deterioration, intrusion
of moisture and foreign matter. It must be kept dry at all times. Immediately upon arrival at
the Site the Contractor shall store the cement in
dry, weather tight and properly ventilated structures with floors raised a minimum of
450 mm above the ground with adequate provision to prevent absorption of moisture.
(b)
bins or silos designed for the purpose. It shall be tight and provide for free movement
to discharge opening, or
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All storage facilities shall be subject to the approval of the Engineer, and shall be such as to
permit easy access for inspection and identification. Prolonged storage of cement at site is to
be avoided.
For bagged cement, each consignment of cement shall be kept separately, and the
Contractor shall use the consignments in the order in which they are received.
The Contractor shall keep records of the various consignments of cement in store, giving
quantities received and used, and the sections of the work in which the cement has been
used, on a daily basis and make a weekly return to the Engineer accordingly. Cement used in
the Works shall be free flowing and free from lumps.
In no case shall bagged cement be stored in stacks more than eight bags high.
QCS 2014

Part
Page 5
A free passage of at least 1 m shall be left between the cement and the side walls of the
structure.
Different types of cement shall be kept in clearly marked separate storage facilities.
Cement delivered to Site in drums or bags by the supplier or manufacturer shall be stored in
the drums or bags until used in the Works.
10
Any cement in drums or bags which have been opened shall be used immediately.
11
Cement that has partially or fully caked in storage will not be permitted in work and shall be
immediately removed from the storage area. Any bag or package or sample of cement which
has been damaged, or rebagged or in any way has deteriorated shall be rejected either as an
individual bag or package or as the whole consignment in which such bag, package or
sample is contained, as advised by the Engineer.
12
Where Site limitations preclude the storage of cement on Site, cement shall be stored at a
central location and shall be delivered daily as required to specific job sites.
13
The Contractor shall provide weighing machines which shall be kept permanently in each
shed for checking the weight of the bags or barrels of cement. The weighing machines shall
be calibrated by an independent agency. The Engineer shall have access at all times to the
cement storage sheds.
14
During transport and storage the cement shall be fully protected from all weather elements.
15
Any consignment of cement not used within two months from the date of manufacture and
cement which in the opinion of the Engineer is of doubtful quality shall not be used in the
Works until it has been retested and test result sheets showing that it complies in all respects
with the specification and relevant standards have been delivered to the Engineer.
16
Cement stored for longer than 28 days shall be tested for loss on ignition" prior to use to
check for deterioration, and any cement which fails the test shall not be used in the works.
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END OF PART
QCS 2014

Part
04: Water
Page 1
WATER ................................................................................................................... 2
4.1
4.1.1
4.1.2
GENERAL ............................................................................................................... 2
Scope
2
References
2
4.2
4.2.1
4.2.2
4.2.3
4.2.4
QUALITY OF WATER ............................................................................................. 3

General
3
pH of Water
3
Permissible Temperatures
3
Supply and Storage
3
4.3
4.3.2
TESTING AND SAMPLING ..................................................................................... 3

Health and Safety
5
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QCS 2014

Part
04: Water
Page 2
WATER
4.1
GENERAL
4.1.1
Scope
This Part includes water used for concrete mixtures, washing of aggregates and equipment,
wetting of surfaces or ponding during curing or for wetting formwork and washing
reinforcement.
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This Section
Part 2, .............. Aggregates
Part 9, .............. Formwork
Part 10, ............ Curing
Part 11, ............ Reinforcement
References
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4.1.2
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ASTM C109 ................test Method for Compressive Strength of Hydraulic Cement Mortars
(using 2-in or 50 mm Cube Specimens)
BS 1377 ......................Methods of test for soils for civil engineering purposes.
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BS 2690 ......................Methods of testing water used in industry
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BS 6068 ......................Water quality
BS EN ISO 9963-1 .....Determination of total and composite alkalinity
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BS EN ISO 9963-2 .....Determination of carbonate alkalinity
EN 196-1 ....................Determination of strength

EN 196-2 ....................Methods of testing cement - Part 2: Chemical analysis of cement
EN 196-3 ....................Determination of setting time and soundness
EN 1008 .....................Mixing water for concrete, Specification for sampling, testing and
assessing the suitability of water, including water recovered from
processes in the concrete industry, as mixing water for concrete
SM 5220 B ................. Chemical Oxygen Demand (COD)
SM 4500 ....................Standard Methods for the Examination of Water and Wastewater
ISO 7890
...............Water quality -- Determination of nitrate -- Part 1: 2,6-Dimethylphenol

spectrometric method
SM 3125B (ICP/MS) ...Metals by Inductively Coupled Plasma/Mass Spectrometry
QCS 2014

Part
04: Water
Page 3
QUALITY OF WATER
4.2.1
General
Potable water is suitable for use in concrete, while water of other origin such as underground
water, natural surface water, recovered water, as well as municipal treated water or mixed
water shall be tested to prove that its quality shall conform to water quality requirements as
given below in 4.3.
On site, where a permit is issued for Municipal Treated Effluent use for concrete, the effluent
shall be treated by tertiary treatment stage: Reverse Osmosis (R.O.), and disinfection
(Ultraviolet Radiation, or ozonation).
The water shall be examined in accordance with the test procedures stated in Table 1, EN
1008. Water not conforming to one or more of the requirements in Table 1, EN 1008 may be
used only, if it can be shown to be suitable for use in concrete, in accordance with the
physical tests of Table 1 below.
The site health and safety services and Treated Effluent Quality shall fulfil the requirements
of 5
4.2.2
pH of Water
The pH of water used in concrete works shall be as shown in Table 4.2.
4.2.3
Permissible Temperatures
Temperature of water for concrete shall not be less than 5 C and not more than 40 C
Water may be cooled to not less than 5 C by the gradual addition of chilled water or ice as
(b)
alternatively, flaked ice may be used

ice to be used shall be crushed and shall be a product of frozen water which
complies with the acceptance criteria of Tables 4.1 and 4.2 and 4.3.
(c)
no ice particles shall be present in the mix
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(a)
follows:
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4.2
Every effort should be made to protect water pipes and tanks from the sun; e.g., burying,
shading, insulation or painting white.
4.2.4
Supply and Storage
The Contractor shall make his own arrangements and obtain the approval of the Engineer for
the supply of water.
Storage of water should be such that contamination is prevented from occurring. Any
measures taken to avoid contamination of the water shall be to the approval of the Engineer.
4.3
TESTING AND SAMPLING
Whenever required to do so by the Engineer, the Contractor shall take samples of the water
being used, or which it is proposed to use, for mixing concrete and test them for quality.
QCS 2014

Part
04: Water
Page 4
Samples of water of not less than 5 l shall be taken, sealed and sent for testing at an
approved independent laboratory, prior to the approval of any water source, and whenever
the sources of water is changed periodically during the continuance of its use.
Water of questionable quality should comply with the physical tests of Table 4.1 and chemical
limitations listed in Table 4.2 & Table 4.3.
No source of water shall be used until the required tests have demonstrated its suitability for
concreting.
The use of water from a municipal or government supply does not preclude the requirement
for testing.
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Test Method
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Table 4.1
Acceptance Criteria and Physical Tests for Mixing Water
EN 196-1
Setting time, max. deviation from control, (h:min)
EN 196-3
90 %
from 1:00 early to 1:30 later
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Compressive strength at 7 d, min % of control
Limits
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BS 6068-1.37 (ISO
9297)
(a-1) for Prestressed concrete.
500
(a-2) for reinforced concrete.
1000
(a-3) for concrete without reinforcement.
4500
(b)
(c)
Alkali
2-
Sulphates (as SO4 )
(c-1) Alkali carbonates and bicarbonates
(c-2) Alkali equivalent sodium oxides

(d)
Total dissolved ions, including

a, b and c above
EN 196-2
pH
2000
BS 6068-2.51
BS EN ISO 9963-1
BS EN ISO 9963-2
500
EN 196-2
1500
BS 1377 : Part 3
1000
2000
5000
(d-1) for prestressed concrete

(d-2) reinforced concrete.
(d-3) for concrete without reinforcement.
(e)
Maximum Limit,
mg/l
Chloride (as CI)
Test Method
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(a)
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Parameter
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Table 4.2
Chemical Limitations for Mixing Water
BS 6068-2.50
6.5 - 9.0
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Part
04: Water
Page 5
Table 4.3
Maximum limit of Harmful Contaminants
Parameter
Test Method
Maximum Limit, mg/l
SM 5220 B
50
Phosphate; expressed as PO4 - P
SM 4500 P B, C, SM 4500
PD by subtraction
30
ISO 7890-1
100
Lead; expressed as Pb
SM 3125B (ICP/MS)
2+
100
SM 3125B (ICP/MS)
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Zinc; expressed as Zn
2+
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Nitrate; expressed as NO3 -N
COD
100
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SM: Standards Methods for the Examination of Water and Wastewater.
Health and Safety
On site, where a permit is issued for Municipal Treated Water use in construction works, the
effluent should be treated by tertiary treatment stage including filtration and disinfectant
(Chlorine alone, or Ultraviolet Radiation, or ozonation). Furthermore, the following site health
and safety services and the Treated Effluent Quality shall be fulfilled:
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4.3.2
Residual chlorine level shall be within the range of 0.5 1.0 mg/l. For water to be used
for concrete, the disinfectant shall be Ultraviolet Radiation, or ozonation.
(b)
Coliform level shall fulfil one of the following:
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(a)
Fecal Coliform < 200 CFU/100 ml, in case there is no direct exposure on site
labour.
(ii)
Total Coliform < 23 CFU/100 ml, in case there is direct exposure on site labour.
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(i)
(c)
The site shall be facilitated by health and safety guidelines signs, where it is indicated
by Arabic, English, and any other languages where there are 5 workers or more on the
site, that Water not for Human Consumption
(d)
The site shall be facilitated by health and safety equipment, as well as, personal health
and safety protection equipment.
(e)
Labour shall follow health and safety guidelines and instructions and use their health
and safety personal protection equibment.
END OF PART
QCS 2014

Part
05: Admixtures
Page 1
ADMIXTURES ......................................................................................................... 2
5.1
5.1.1
5.1.2
5.1.3
5.1.4
GENERAL ............................................................................................................... 2
Scope
2
References
2
Definitions
2
Submittals
2
5.2
5.2.1
5.2.2
USE OF ADMIXTURES ........................................................................................... 3

General
3
Trials
3
5.3
5.3.1
5.3.2
5.3.3
5.3.4
5.3.5
5.3.6
5.3.7
WATER PROOFING ADMIXTURES ....................................................................... 3

General
3
Water resisting admixtures
4
Permeability reducing admixture
4
Submittals
4
General
4
Organic Corrosion Inhibitors
4
Inorganic Corrosion Inhibitors
5
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Part
05: Admixtures
Page 2
ADMIXTURES
5.1
GENERAL
5.1.1
Scope
This Part includes materials added to the concrete materials during mixing.
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This Section
Part 1 ............... General
Part 7 ............... Concrete Plants
References
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5.1.2
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ACI 212.3R-10............Report on Chemical Admixtures for Concrete

ACI 302 ......................Guide for Concrete Floor and Slab Construction
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ACI 305 ......................Hot Weather Concreting
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ACI 308 ......................Standard Practice for Curing Concrete

ASTM C494, ...............Standard Specification for Chemical Admixtures for Concrete
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ASTM C1582, .............Standard Specification for Admixtures to Inhibit Chloride-Induced

Corrosion of Reinforcing Steel in Concrete
BS EN 934 ..................Admixtures for concrete, mortar and grout (Parts: 2, 6)
BS EN 196, ................Methods of testing cement
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BS EN 14889 .............Fibres for concrete Polymer fibres. Definitions, specifications and

conformity
NSF ............................ Standard 61
5.1.3
Definitions
Admixtures are materials added during the mixing process of concrete to modify the
properties of the concrete mix in the fresh and/or hardened state.
5.1.4
Submittals
In addition to the specified general requirements for approval of materials, approval of

admixtures shall be subject to extensive trials to demonstrate the suitability, adequacy of
dosing arrangements and performance.
QCS 2014

Part
05: Admixtures
Page 3
5.2
USE OF ADMIXTURES
5.2.1
General
Admixtures are materials added to the concrete materials during the mixing process to
modify its properties in the fresh and/or hardened state.
Where approved and or directed by the Engineer, admixtures shall be used as a means of:
enhancing concrete durability
(b)
increasing workability of the concrete without increasing the water:cement ratio
(c)
controlling retardation and setting time.
(a)
water reducing/plasicizing admixture
(b)
high range water reducing/plasticizer admixture
(c)
set retarding admixtures
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Admixtures shall comply with the following BS EN 934 2 requirements or the equivalent
ASTM C494:
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(a)
The methods and the quantities of admixture used shall be in accordance with the
manufacturers instruction and subject to the Engineers approval after evaluation in trial
mixes and shall in no way limit the Contractors obligations under the Contract to produce
concrete with the specified strength, workability and durability.
The effects of accidental overdose of the admixture and measure to be taken if an overdose
occurs shall be provided by the Contractor to the Engineer.
No admixtures containing chlorides shall be used. In particular, the use of acceleration

admixtures containing calcium chloride shall not be used.
The use of the admixtures shall be controlled; i.e., strict quality control to ensure correct
dosages as prescribed by the manufacturer and justified by trial mixes to be used. A
calibrated dispenser or flowmeter shall be used for the addition of the admixture.
5.2.2
Trials
In addition to the standard requirements for the approval of materials, approval of admixtures
shall be subject to extensive trials to demonstrate the suitability, adequacy of dosing
arrangements and performance, when a proven history of performance cannot be provided to
5.3
WATER PROOFING ADMIXTURES
5.3.1
General
The admixture shall be suitable for use in the Gulf condition, and specially formulated for
higher ambient temperature.
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Part
05: Admixtures
Page 4
The admixture shall be added as per manufacturers datasheet. Approved third party
laboratory verification shall be conducted prior to use of material for the works. The
manufacturers technical representative shall be present to ensure proper dosage of
admixture during the trial mix.
5.3.2
Water resisting admixtures
Water resisting admixtures may be used with the permission of the Engineer and shall
comply with the requirements of BS EN 934-2.
The admixture is to be added as per the Manufacturers supplier data sheet at the time of
mixing. An approved lab verification shall be made prior to use,
5.3.3
Permeability reducing admixture
The admixture shall be a permeability reducing admixture for Non-Hydrostatic Conditions

(PRAN) and for hydrostatic conditions (PRAH) as indicated by ACI 212.3R-10, or crystalline
waterproofing admixture.
For PRAH, independent testing shall be performed according to NSF Standard 61 and
approval for use of waterproofing material on structures holding potable water shall be
evidenced by NSF certification.
5.3.4
Submittals
Contract Documents.
The Contractor shall submit comprehensive test results for the water proofing admixture as
per the tests in the specification, and evidence of their ability to meet all the requirements
specified.
The Contractor shall submit a guarantee for the water proofing admixture. The guarantee
shall be worded to reflect the required performance of the material and shall be approved by
the Engineer.
CORROSION INHIBITING ADMIXTURES
5.3.5
General
Where reinforced concrete structures are exposed to aggressive environment such as

underground and marine structures, the use of a corrosion inhibiting admixture shall be used.
Corrosion Inhibiting Admixtures shall comply with ASTM C1582 Standard Specification for
Admixtures to Inhibit Chloride-Induced Corrosion of Reinforcing Steel in Concrete.
5.3.6
Organic Corrosion Inhibitors
The admixture shall be based on either aqueous emulsion of amines and esters or amine
carboxylates and shall be capable of forming a protective corrosion resistant film around the
steel reinforcement.
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QCS 2014

Part
05: Admixtures
Page 5
The corrosion inhibitor shall be capable of effecting protection to the steel where concrete
has cracked and allows access to the elements responsible for corrosion.
Organic corrosion inhibitors have a fixed dosage rate independent of chloride levels and shall
be incorporated at the dosage rate recommended and tested by the Manufacturer.
5.3.7
Inorganic Corrosion Inhibitors
Inorganic corrosion inhibitors shall be based on calcium nitrites capable of oxidizing steel to a
more stable form increasing its passivity in the presence of chlorides.
Dosage of inorganic corrosion inhibitors ranges from 10 to 30L/m3 depending on the

expected chloride levels as defined by ACI 212 Table 13.1.
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END OF PART
QCS 2014

Part
06: Property Requirements
Page 1
PROPERTY REQUIREMENTS ............................................................................... 2
6.1
6.1.1
6.1.2
6.1.3
6.1.4
GENERAL ............................................................................................................... 2
Scope
2
References
2
Definitions:
6
Submittals
7
6.2
6.2.1
6.2.2
EXPOSURE CLASSES ......................................................................................... 10

General
10
Reinforcement corrosion and sulphate classes
10
6.3
6.3.1
FRESH CONCRETE ............................................................................................. 12

General
12
6.4
GRADES OF CONCRETE..................................................................................... 13
6.5
6.5.1
6.5.2
6.5.3
6.5.4
6.5.5
6.5.6
6.5.7
DURABILITY REQUIREMENTS ............................................................................ 13

General
13
Maximum acid soluble chloride content
14
Type of cementitious material
14
Resistance to alkali-silica reaction
15
Recommendations to resist reinforcement corrosion
15
Recommendations to resist sulphate attack
16
Durability-Related Properties
16
6.6
6.6.1
DESIGN OF CONCRETE MIXES .......................................................................... 17

Concrete
18
6.7
TRIAL MIXES ........................................................................................................ 25
6.8
6.8.1
6.8.2
6.8.3
6.8.4
QUALITY AND TESTING ...................................................................................... 27

General
27
Tests for Concrete
27
Hardened Tests for Fiber-Reinforced Concrete
29
Quality Control charts
29
6.9
WORKS TEST CUBES ......................................................................................... 30
6.10
6.10.1
6.10.2
REJECTION OF CONCRETE MIXES ................................................................... 30

Rejection of Concrete Mixes:
30
Unsatisfactory Concrete Works
31
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QCS 2014

Part
Page 2
PROPERTY REQUIREMENTS
6.1
GENERAL
6.1.1
Scope
This Part includes Grades 15 MPa and above of concrete to be used in the civil works, with
the requirements for workability, permeability, and drying shrinkage.
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This Section
Part 2, ........... Aggregates
Part 3, ........... Cementitious Materials
Part 4, ............ Water
Part 5, ........... Admixtures
Part 7, ............ Concrete Plants
Part 8, ........... Transportation and Placing of Concrete
Part 9, .............. Formwork
Part 13, ............ Inspection and Testing of Hardened Concrete
References
The following standards are referred to in this Part. The designer along with contractor are
responsible to use the latest update standard as published by the organization:
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6.1.2
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ACI 207.1R .................Guide to Mass Concrete
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ACI 207.2R .................Report on Thermal and Volume Change Effects on Cracking of Mass
Concrete
ACI 207.5R .................Roller - Compacted mass concrete
ACI 213, .....................Guide for Structural Lightweight-Aggregate Concrete
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ACI 214, .....................Evaluation of Strength Test Results of Concrete
ACI 221, .....................Guide for Use of Normal Weight and Heavyweight Aggregates in
Concrete
ACI 237R 07 ..............Self Consolidating Concrete
ACI 301, .....................Specifications for Structural Concrete
ACI 304, .....................Guide for Measuring, Mixing, Transporting, and Placing Concrete
ACI 304.2, ..................Placing Concrete by Pumping Methods
ACI 318, .....................Metric Building Code Requirements for Structural Concrete &
Commentary
ACI 506, ....................Guide to Shotcrete
ACI 506.1, ..................Guide to Fiber-Reinforced Shotcrete
ACI 506.2, ..................Specification for Shotcrete
ACI 555, .....................Removal and Reuse of Hardened Concrete
ASTM A 820, ..............Specification for Steel Fibers for Fiber-Reinforced Concrete
ASTM C 31, ................Practice for making and curing concrete test specimens in the field
ASTM C 33, ...............Specification for Concrete Aggregates
QCS 2014

Part
Page 3
ASTM C 39, ................Test Method for Compressive Strength of Cylindrical Concrete

Specimens
ASTM C 42, ................Test Method for Obtaining and Testing Drilled Cores and Sawed
Beams of Concrete
ASTM C 94, ................Specification for Ready-Mixed Concrete
ASTM C192, ...............Practice for Making and Curing Concrete Test Specimens in the
Laboratory
ASTM E 119, ..............Test Methods for Fire Tests of Building Construction and Materials
ASTM C 138, ..............Test Method for Density (Unit Weight), Yield, and Air Content
(Gravimetric) of Concrete
ASTM C 150, .............Specification for Portland Cement
ASTM C 172, ..............Practice for Sampling Freshly Mixed Concrete
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ASTM C 173, ..............Test Method for Air Content of Freshly Mixed Concrete by the
Volumetric Method
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ASTM C 231 ...............Test Method for Air Content of Freshly Mixed Concrete by the
Pressure Method
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ASTM C 232, .............Test Methods for Bleeding of Concrete
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ASTM C 311, .............Test Methods for Sampling and Testing Fly Ash or Natural Pozzolans
for Use in Portland-Cement Concrete
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ASTM C 387, ..............Specification for Packaged, Dry, Combined Materials for Mortar and
Concrete
ASTM C 597, ..............Test Method for Pulse Velocity through Concrete
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ASTM C 617, .............Practice for Capping Cylindrical Concrete Specimens
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ASTM C 618, .............Specification for Coal Fly Ash and Raw or Calcined Natural Pozzolan
for Use in Concrete
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ASTM C 637, ..............Specification for Aggregates for Radiation-Shielding Concrete

Constituents
of
Aggregates
for
ASTM C 638, .............Descriptive Nonmenclature of

Radiation-Shielding Concrete
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ASTM C 803, .............Test Method for Penetration Resistance of Hardened Concrete

ASTM C 805, .............Test Method for Rebound Number of Hardened Concrete
ASTM C 856, .............Practice for Petrographic Examination of Hardened Concrete

ASTM C 900, .............Test Method for Pullout Strength of Hardened Concrete
ASTM C 989, ..............Standard Specification for Slag Cement for Use in Concrete and
Mortars
ASTM C 1018, ............Test Method for Flexural Toughness and First-Crack Strength of FiberReinforced Concrete
ASTM C 1116, ...........Specification for Fiber-Reinforced Concrete
ASTM C 1140, ............Practice for Preparing and Testing Specimens from Shotcrete Test
Panels
ASTM C 1152 .............Standard Test Method for Acid-Soluble Chloride in Morter and
Concrete.
ASTM C 1218 .............Standard Test Method for Water-Soluble Chloride in Morter and
Concrete.
ASTM C 1231, ............Practice for Use of Unbonded Caps in Determination of Compressive
Strength of Hardened Concrete Cylinders
QCS 2014

Part
Page 4
ASTM C 1240, ............Specification for Silica Fume Used in Cementitious Mixtures

ASTM C 1385, ............Practice for Sampling Materials for Shotcrete
ASTM C 1399, ............Test Method for Obtaining Average Residual-Strength of FiberReinforced Concrete
ASTM C 1480, ............Specification for Packaged, Pre-Blended, Dry, Combined Materials for
Use in Wet or Dry Shotcrete Application
ASTM C 1550, ............Test Method for Flexural Toughness of Fiber Reinforced Concrete
(Using Centrally Loaded Round Panel)
ASTM C 1604, ............Test Method for Obtaining and Testing Drilled Cores of Shotcrete
ASTM C 1609, ............Test Method for Flexural Performance of Fiber-Reinforced Concrete
(Using Beam With Third-Point Loading)
ASTM C 1611, ............Test Method for Slump Flow of Self-Compacting Concrete
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ASTM C 1666, ............Specification for Alkali Resistant (AR) Glass Fiber for GFRC and
Fiber-Reinforced Concrete and Cement
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ASTM D 5759, ............Guide for Characterization of Coal Fly Ash and Clean Coal
Combustion Fly Ash for Potential Uses
BRE digest 433, .........Recycled Aggregates
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ASTM D 6942, ............Test Method for Stability of Cellulose Fibers in Alkaline Environments
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BS 4027, ....................Specification for Sulphate-Resisting Portland Cement
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BS 6073-2:2008, ........Precast concrete masonry units. Guide for specifying precast concrete
masonry units
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BS 8500, ....................Concrete, Complementary British Standard to BS EN 206-1.
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BS EN 206-1, ............Concrete. Specification, Performance, Production And Conformity
BS EN 450,.................Fly Ash for Concrete. Definition, Specifications And Conformity Criteria
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BS EN 771-3, .............Specification for masonry units. Aggregate concrete masonry units

(dense and light-weight aggregates
BS EN 772-2, ............. Methods of test for masonry units. Determination of percentage area
of voids in masonry units (by paper indentation)
BS EN 12350,.............Testing Fresh Concrete
BS EN 12350-1, .........Testing fresh concrete - Part 1: Sampling
BS EN 12350-2, .........Testing fresh concrete - Part 2: Slump test
BS EN 12350-3, .........Testing fresh concrete - Part 3: Vebe test
BS EN 12350-4, .........Testing fresh concrete - Part 4: Degree of compactability
BS EN 12350-5, .........Testing fresh concrete - Part 5: Flow table test
BS EN 12350-6, .........Testing fresh concrete - Part 6: Density
BS EN 12350-7, .........Testing fresh concrete - Part 7: Air content - Pressure methods
BS EN 12390,.............Testing Hardened Concrete
BS EN 12390-1, .........Testing hardened concrete - Part 1: Shape, dimensions and other
requirements for specimens and moulds
BS EN 12390-2, .........Testing hardened concrete - Part 2: Making and curing specimens for
strength tests
QCS 2014

Part
Page 5
BS EN 12390-3, .........Testing hardened concrete - Part 3: Compressive strength of test

specimens
BS EN 12390-4, .........Testing hardened concrete - Part 4: Compressive strength Specification for testing machines
BS EN 12390-5, .........Testing hardened concrete - Part 5: Flexural strength of test
specimens
BS EN 12390-6, .........Testing hardened concrete - Part 6: Tensile splitting strength of test
specimens
BS EN 12390-7, .........Testing hardened concrete - Part 7: Density of hardened concrete
BS EN 12390-8, .........Testing hardened concrete - Part 8: Depth of penetration of water
under pressure
BS EN 12620,.............Aggregate For Concrete
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BS EN 15167 .............Ground Granulated Blast Furnace Slag For Use In Concrete, Mortar
And Grout. Conformity Evaluation
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BS EN 1744, ..............Tests For Chemical Properties Of Aggregates
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BS EN 1992-3:2006 ...Eurocode 2. Design of concrete structures. Liquid retaining and

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BS EN 1992-3:2006 ...UK National Annex to Eurocode 2. Design of concrete structures.

Liquid retaining and containment structures
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BS PD 6682-1, ...........Aggregates for Concrete. Guidance on the Use of BS EN 12620
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Concrete Society Report No. 31, Permeability testing of site concrete

EN 1011, .................... Welding. Recommendation for welding of metallic materials
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EN 1992-1-1, ..............Eurocode 2: Design of concrete structures. General rules and rules for
buildings
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GSO ISO 1920-2 ........Testing of concrete part 2: properties of fresh concrete
GSO ISO 1920-3 ........Testing of concrete part 3: Making and curing test specimens.
GSO ISO 1920-4 .......Testing of concrete part 4: strength of hardened concrete.
GSO ISO 1920-5 .......Testing of concrete part 5: properties hardened concrete other than
strength.
GSO ISO 1920-6 ........Testing of concrete part 6: sampling, preparing and testing of
concrete core .
GSO ISO 1920-7 .......Testing of concrete part 7: Non destructive test on hardened
concrete.
ISO 1920-8 .................Testing of concrete -- Part 8: Determination of drying shrinkage of
concrete for samples prepared in the field or in the laboratory
ISO 1920-9 .................Testing of concrete -- Part 9: Determination of creep of concrete
cylinders in compression
ISO 1920-10 ...............Testing of concrete -- Part 10: Determination of static modulus of
elasticity in compression
QCS 2014

Part
Page 6
CSTR11......................Concrete core testing The concrete Society

RILEM CPC 11.3 .......Absorption of water by immersion under vacuum
The Concrete Society CS163. Guide to the design of concrete structures in the Arabian
Peninsula.
The European Guidelines for Self-Compacting Concrete Specification, Production and Use
6.1.3
Definitions:
Exposure conditions will apply as follows:

Class X0: No risk of corrosion or attack. Non saline conditions. Blinding concrete, nonreinforced concrete or slab on ground.
(b)
Class X1: Mild exposure Non saline conditions (dry or wet, rarely dry) External
concrete at least 3m above ground level, internal concrete in dry conditions, concrete
permanently submerged in non-saline water or non-aggressive groundwater.
(c)
Class X2: Moderate exposure Non saline conditions (Cyclic wet and dry). External
reinforced concrete less than 3m above ground level, water-retaining structures
exposed to fluctuating water levels.
(d)
Class X3: Aggressive exposure Permanently submerged or wet (rarely dry) Concrete
in contact with groundwater including capillary rise zone, concrete containing or
permanently exposed to saline water.
(e)
Class X4: Severe exposure Moderate humidity External concrete within 1km from
the sea or in contact with high saline water table or sabkhas. Concrete not affected by
condensation, irrigation or leakage, which are more than 3m above ground level.
(f)
Class X5: Extreme exposure Cyclic wet and dry, external concrete within 1km from
the sea or in contact with high saline groundwater or sabkhas. Concrete affected by
condensation, irrigation or leakage, which are less than 3m above ground level or
within capillary zone. Concrete surfaces exposed to sea water splash or in sea water
tidal zone.
(g)
Sulphate exposure classes S1 to S4: the exposure classes are related to sulphate
attack in relation to sulphate and pH of the ground water.
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(a)
Concrete is a mixture (mix) of cementitious materials, coarse and fine aggregate, and water,
with or without admixtures, which develops its properties by cement hydration.
"Cementitious Materials": Portland cement in combination with one or more of the following:
blended hydraulic cement, fly ash and other pozzolans, ground granulated blast-furnace slag
and silica fume; subject to compliance with requirements of this specification.
Water/Cementitious Ratio shall mean the ratio between the total weight of water in the
concrete (less the water absorbed by the aggregate) and the weight of cementitious
materials, expressed as a decimal fraction.
Admixtures shall mean a material other than water, aggregate, cementitious materials or
fiber reinforcement, used as an ingredient of concrete or mortar. Admixtures are added
during the mixing process of concrete to modify the properties of the concrete mix in the
fresh and/or hardened state.
rate of cement hydration, or otherwise causing detrimental results such as: a. High ambient
temperature (when the shade temperature is above 40 deg C on a rising thermometer, 43
deg C on a falling thermometer), b. High concrete temperature, c. Low relative humidity, d.
2
High wind speed and e. whenever the rate of evaporation exceeds 0.75 kg/m /h
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QCS 2014

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Page 7
Mass concrete is defined as any volume of concrete with dimensions large enough to
require that measures be taken to cope with generation of heat form hydration of the cement
and attendant volume change to minimize cracking. Reinforced Massive concrete structures
include pile caps, transfer plates, and structural members where the least dimension
exceeds 1.5 meters.
Coarse Aggregate shall be considered as that size passing a 20mm sieve (or larger sieve
size) and predominately retained on a 4mm sieve.
Fine Aggregate shall be considered as that size predominately passing a 4mm sieve and
predominately retained on a 0.063mm size.
10
PC shall mean Portland cement or CEM I.
11
FA shall mean pulverised fuel ash or fly ash.
12
GGBS shall mean ground granulated blastfurnace slag.
13
SF shall mean silica fume. Other names are condensed silica fume and microsilica
14
Gap-graded aggregate shall mean graded aggregate without one or more of the
intermediate sizes.
15
Single-size aggregate shall mean aggregates containing a major proportion of particles of

one sieve size.
16
Target Mean Strength shall mean the specified characteristic strength plus the margin.
17
Margin shall mean the difference between the specified characteristic strength and the
target mean strength.
18
Acceptable or Accepted shall mean acceptable or accepted by the Engineer.
19
Approval or Approved shall mean approval from the Engineer.
20
All-in aggregate shall mean the materials composed of a mixture of coarse and fine
aggregates.
21
Self-Compacting Concrete (SCC): concrete that is able to flow and consolidate under its own
weight, completely fill the formwork even in the presence of dense reinforcement, whilst
maintaining homogeneity and without the need for any additional compaction.
6.1.4
Submittals
The Contractor shall submit details of mix designs to the Engineer for approval.
Material Safety Data Sheet MSDS or equivalent for all products. test results and other
information as required to prove compliance with the specification shall be submitted to the
Engineer for approval according to the relevant sections of QCS on at least the following
products
Cement:
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(a)
Recent independent test results acceptable to the Engineer confirming compliance

with the specified requirements and referenced standards.
(b)
Manufacturer's certificates shall also be supplied for each batch of production of

cement or on a weekly basis, whichever is more frequent, certifying compliance with
the BS EN 197 or other equivalent standard.
QCS 2014
(c)
Page 8
The early compressive strength of each consignment of cement shall conform to the
requirements of QCS part 3 at the independent site laboratory. Deviation of more than
10% from either the previous consignment value or the rolling average shall be
immediately reported to the Engineer. Testing at an independent laboratory shall be as
instructed by the Engineer.
GGBS:
(a)

(b)
Manufacturer's certificates with all information necessary to verify compliance shall

also be supplied for each consignment of GGBS or on weekly basis, whichever is
more frequent.
(c)
The early compressive strength of each consignment of GGBS shall be determined in

accordance with BS EN 197 and BS EN 15167 or ASTM C989 at the independent site
laboratory based on a blend of 50/50 % GGBS and CEM 1. Deviation of more than 5%
in strength from either the previous consignment value or the rolling average shall be
immediately reported to the Engineer. Testing at an independent laboratory shall be in
accordance with per BS EN 197 and BS EN 15167 standards, and approved by the
Engineer.
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FA:

with specified requirements of BS EN 450 or ASTM C618.
(b)
Manufacturer's certificates with all information necessary to verify compliance with

internationally recognized standards shall also be supplied with each consignment of
FA.
(c)
The materials shall comply with QCS part 3. Deviation of the strength factor by more
than 5% from either the previous consignment value or the rolling average shall be
immediately reported to the Engineer and the Technical Manager of the premix
company.
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(a)
Silica fume:
Manufacturer's certificates with all information necessary to verify compliance with

internationally recognized standards shall also be supplied with each consignment of
silica fume.
(b)

with specified requirements and referenced standards.
(a)
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Part
(c)
7 day pozzolanic activity test in accordance with BS EN 13263-1 or ASTM C 1240 on

each consignment of silica fume at the Independent site laboratory. Deviation of the
activity index by more than 5% from either the previous consignment value or the
rolling average shall be immediately reported to the Engineer and the Technical
Manager of the premix company.
Aggregates:
(a)

(b)
Full details of the proposed sources of aggregates.
Water: Recent independent test results acceptable to the Engineer confirming compliance
QCS 2014

Part
Page 9
Admixtures: Manufacturers technical specifications and recommendations. Recent trial

results acceptable to the Engineer illustrating the efficiency of the product for its particular
application. Tests on specific gravity and solids content shall be conducted at the
Independent site laboratory on each consignment.
10
Mix Designs: Submit concrete mix designs for each type and strength of concrete required at
least thirty (30) days before placing concrete.
11
New mix designs, with historic data less than 6 months, shall be verified by an approved
independent testing laboratory in accordance with requirements of QCS Part 05 and shall be
coordinated with design requirements and Contract Documents.
12
Submit complete mix design data for each separate mix to be used on the Project in a single
submittal with at least the following information:
Type of cement*.
(b)
Portland cement content*.
(c)
Cementitious content* (GGBS, FA, natural pozzolan, rice husk ash and/or silica fume).
(d)
Max. aggregate size*.
(e)
Combined grading curve for coarse aggregate
(f)
Quantities of all individual materials*
(g)
Type of admixture(s)*
(h)
Target slump/slump flow (at discharge)* as per BS EN 12350-2
(i)
Initial and final concrete setting time for each mix design as per ASTM C403 or
equivalent BS EN standards, if specified
(j)
Fresh density of concrete as per BS EN 12350-6
(k)
Air content as per BS EN 12350-7
(l)
Target temperature*
(m)
Bleeding, if specified
(n)
Chloride and sulphate (SO3) contents
(o)
Details of calculated water/cementitious material (w/c) ratio*
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Compressive strength grade*

Hardened density
(q)
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(p)
(a)
(r)
Water absorption (%) and water penetration (mm), if specified
(s)
Rapid chloride permeability - Coulomb value, if specified
(t)
Chloride migration coefficient (m /sec), if specified
*Include on delivery ticket as a minimum

13
Data shall be from the same production facility that will be used for the Project.
14
Mix Design data shall include but not be limited to the following:
(a)
Locations on the Project where each mix design is to be used corresponding to

Structural General Notes on the Drawings.
(b)
Proportions: Concrete constituent materials shall be proportioned to yield 1 m
(c)
Submit strength test records, mix design materials, conditions, and proportions for
concrete used for record of tests, standard deviation calculation, and determination of
required average compressive strength, if required by the Engineer.
QCS 2014
Page 10
(d)
If early concrete strength is required, contractor shall submit trial mixture results as
required.
(e)
Test records to support proposed mixtures shall be no more than 12 months old and
use current cement and aggregate sources. Test records to establish standard
deviation may be older if necessary to have the required number of samples.
(f)
Manufacturer's product data for each type of admixture.
(g)
Manufacturers certifications that all admixtures used are compatible with each other.
(h)
All information indicating compliance with Contract Documents including method of

placement and method of curing.
Mass Concrete:
(a)
Submit mix design for mass concrete elements in conformance with requirements of
ACI 301 Section 8. The concrete mix design shall not be designed with a high early
strength unless otherwise demonstrated by the Contractor for capability of maintaining
proper temperature and approved by the Engineer.
(b)
Submit proposed methods of temperature control, including cementitious material

content control in mix design to reduce heat-generating potential of concrete,
precooling of ingredients to lower concrete temperature as placed, and methods to
protect mass concrete elements from excessive temperature differentials.
(c)
Submit analysis of anticipated thermal development within mass concrete elements

with the proposed mix design for these elements. Results of the analysis, using
methods in ACI 207.1R and ACI 207.2R such as the Schmidt model and site specific
data, shall address the maximum differential temperature and the maximum
temperature during curing
(d)
Submit proposed number and locations of temperature monitoring devices to record

temperature development between the interior and the exterior of mass concrete
elements.
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15

Part
EXPOSURE CLASSES
6.2.1
General
The exposure classes are related to the environmental conditions surrounding the concrete
in service.
The concrete may be subject to more than one of the classes described below, and the
environmental conditions to which it is subjected need to be expressed as a combination of
exposure classes.
Where two or more aggressive characteristics lead to the same class, the exposure shall be
classified into the next higher class; unless a special study for this specific case proves that it
is not necessary.
For a given structure, different concrete elements may be subject to different environmental
classes.
6.2.2
Reinforcement corrosion and sulphate classes
The classification system described below is based on the approach in BS EN 206-1, BS

8500-1, and the Concrete Society CS 163.
The exposure classes related to reinforcement corrosion are associated with carbonation and
chlorides as per Table 6.1.
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6.2
QCS 2014

Part
Page 11
The exposure classes related to sulphate attack are given in Table 6.2 in relation to sulphate
and pH of the ground water.
The sulphate content as S04 mg/l shall be determined as per BS EN 196-2.
The pH shall be determined as per ISO 4316.

Table 6.1.
Exposure classes for reinforcement corrosion
Exposure Class
Class description
No risk of corrosion or attack. Non saline conditions. Blinding concrete,
non-reinforced concrete or slab on ground
X1
Mild exposure Non saline conditions (dry or wet, rarely dry). External
concrete at least 3m above ground level, internal concrete in dry
conditions, concrete permanently submerged in non-saline water or nonaggressive groundwater (Class S1).
X2
Moderate exposure Non saline conditions (cyclic wet and dry). External
reinforced concrete less than 3m above ground level, water-retaining
structures exposed to fluctuating water levels.
X3
Aggressive exposure Permanently submerged or wet (rarely dry).

Concrete in contact with groundwater including capillary rise zone,
concrete containing or permanently exposed to saline water.
X4
Severe exposure Moderate humidity. External concrete within 1km from

the sea or in contact with high saline water table or sabkhas. Concrete not
affected by condensation, irrigation or leakage, which are more than 3m
above ground level.
X5
Extreme exposure Cyclic wet and dry. External concrete within 1km from
the sea or in contact with high saline groundwater or sabkhas. Concrete
affected by condensation, irrigation or leakage, which are less than 3m
above ground level or within capillary zone. Concrete surfaces exposed to
sea water splash or in sea water tidal zone.
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X0
Table 6.2.
Sulphate exposure classes
Sulphate and magnesium
Exposure
class
2:1 water/soil or groundwater

SO4 (mg/l)
Mg (mg/l)
Natural soil
Static
water pH
Mobile
2
water pH
Brownfield
Static
water
pH
Mobile
2
water pH
S1
< 1500
> 3.5
Not mobile
> 5.5
Not mobile
S2
1500-3000
> 3.5
Not mobile
> 5.5
Not mobile
S3
3001-6000
1000
> 3.5
Not mobile
> 5.5
Not mobile
S4
> 6000
1000
> 3.5
> 5.5
> 5.5
> 6.5
S5
> 6000
> 1000
> 3.5
> 5.5
> 5.5
> 6.5
Notes
1.
2.
Brownfield sites are those previously occupied and contain chemical residues into the ground
or groundwater
The mobility of water shall be determined as described in the Concrete Society CS 163.
QCS 2014

Part
Page 12
6.3
FRESH CONCRETE
6.3.1
General
Where adequate workability is difficult to obtain at the maximum water/cementitious ratio

allowed, the use of plasticisers or water reducing admixtures may be considered.
Alternatively an increase in cementitious content may be considered where this will not
adversely affect the durability of the concrete.
Cementitious contents in excess of 400 kg/m shall not be used unless special consideration
has been given to the effect for heat of hydration and reduce thermal stress in the concrete,
and approval has been obtained from the Engineer. The maximum cementitious content shall
not exceed 500kg/m
The proportioning, mixing and placing of the mixture shall be in accordance with Parts 7 and
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Temperature (at placement):
Maximum fresh concrete temperature shall not exceed 32C unless construction
testing to verify a proposed concrete mixture will function satisfactorily at a concrete
temperature greater than 32C. No concrete shall be placed if the concrete
(b)
For mass concrete, the concrete producer shall demonstrate that temperature of
concrete due to hydration shall comply with the maximum fresh concrete temperature
specified. The supplier may use in his demonstration testing heat sensors and
simulation technologies which measure the concrete heat of hydration and its rate
versus concrete curing age.
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(a)
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8 of this Section
The Contractor is responsible for ensuring that the concrete is able to be fully compacted
within the concrete element regardless of reinforcing density or other limitations. This may
involve reducing the maximum aggregate size, increase the level of concrete workability or
use self-compacting concrete.
Where the consistence of concrete is to be determined, it shall be measured either by means

of:
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(a)
Slump test conforming to BS EN 12350-2
(b)
Flow table test conforming to BS EN 12350-5
The consistence of concrete shall be determined at the time of use of the concrete or in the
case of ready-mix concrete, at the time of delivery.
The tolerances for the different consistence tests and target values are given in Table 6.3.
Table 6.3.
Tolerances for target values of consistence
Slump*
Flow diameter*
Target value (mm)
40
50 to 90
100
Tolerance (mm)
-30, +40
-40, +50
-50, +60
Target value (mm)
All values
Tolerance (mm)
-60, +70
* For spot samples taken from initial discharge.
QCS 2014

Part
Page 13
6.4
GRADES OF CONCRETE
Where strength is classified with respect to compressive strength, Table 6.4 gives the
concrete grade with the requirements for w/c ratio and cementitious content.
The characteristic compressive strength at 28 days of 150mm cubes (f ck, cube) or 150mm
diameter by 300mm cylinders (fck, cyl) may be used for the classification.
Exception will be made for concrete mixtures containing fly ash, silica fume or GGBS, where
testing shall be requested at 56 days, or 90 days as approved by the Engineer.
(N/mm )
B 15
15
12
B 20
20
16
C 25
25
20
C 30
30
C 35
35
C 40
40
C45
45
C 50
50
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(kg/m )
Maximum
Water : Cementitious
Ratio
(w/c)
260
0.60
300
0.58
28
320
0.55
32
335
0.50
35
355
0.47
40
370
0.45
60
50
380
0.40
75
60
390
0.35
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C 75
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C 60
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(N/mm )
Minimum cementitious
content
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Concrete Grade
Minimum
characteristic
cylinder strength
(fck, cyl)
Minimum
characteristic cube
strength (fck, cube)
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Table 6.4:
Concrete grades and composition requirements
6.5
DURABILITY REQUIREMENTS
6.5.1
General
Constituent materials shall not contain harmful ingredients in such quantities as may be
detrimental to the durability of concrete or cause corrosion of the reinforcement.
For reinforced concrete in the ground, the need for protection from chlorides must be
balanced against the need for protection from sulphates.
Protective measures include the use of surface treatment, alternative reinforcement and
increasing the concrete cover. In every case, the need for good quality concrete with low
permeability is paramount.
QCS 2014

Part
Page 14
6.5.2
Maximum acid soluble chloride content
The chloride content of the concrete, expressed as the percentage of chloride ions by mass
of cementitious materials, shall not exceed the values given in Table 6.5.
Calcium chloride and chloride based admixtures shall not be used in concrete containing
steel reinforcement or other embedded metal.
The determination of the chloride content in the concrete shall be conducted by the sum of
the contributions from the constituent materials as described in BS EN 206-1 and BS 8500-2.
Table 6.5.
Maximum chloride content of concrete (by weight of cementitious materials)
Concrete made with sulphate
resisting Portland cement
Concrete made with other cementitious

materials than SRPC
Reinforced concrete
0.15 %
0.3 %
Pre-stressed concrete
0.08 %
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Concrete type
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0.10 %
Type of cementitious material
Different types of cementitious materials offer different resistance to sulphate attack and
penetration of chlorides
The minimum cementitious content for different concrete grades is given in Table 6.4.
Table 6.6 gives the different types of cementitious materials and their combinations.
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Table 6.6.
Cementitious materials and combinations
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Cementitious material
Percentage of components
100% PC
Sulphate-resistance Portland
cement
100% SRPC
Portland cement
PC/fly ash
PC/ground granulated
blastfurnace slag
Triple blend
PC/FA/SF
65-79% PC
35-21% FA
35-65% PC
65-35% GGBS
55-70% PC
35-25% FA
10-5% SF
30-45% PC
Triple blend PC/GGBS/SF
60-50% GGBS
10-5% SF
BS EN 197-1
designation
ASTM
standard
CEM I
Type 1
Type 5
CEM II/B-V
CEM III/A
QCS 2014

Part
Page 15
Resistance to alkali-silica reaction
Alkali-silica reaction is the most common form of alkali-aggregate reaction.
Dry concrete is not prone to cracking by alkali-silica reaction, as it needs an external source
of water to develop sufficiently to cause cracking.
Where aggregate contain varieties of silica susceptible to attack by alkalis from cement and
other sources and the concrete is exposed to humid conditions, actions shall be taken to
prevent deleterious alkali-silica reaction using recommendations and procedures given in BS
EN 206-1 and BS 8500-2.
6.5.5
Recommendations to resist reinforcement corrosion
Durability design should start at the concept design stage, continuing through the design,
detailing, specification and execution phases.
This section covers the concrete grade, cementitious type, and minimum concrete cover for
various exposure classes as given in Table 6.1.
Table 6.7 provided recommended values of concrete grade and cover thickness to resist
reinforcement corrosion at different exposure classes.
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6.5.4
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Table 6.7.
Recommended durability requirement to resist reinforcement corrosion
Mild
X2
Moderate
X3
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X1
25
No risk of
corrosion
All
40
35
30
50
45
40
35
Aggressive
70
65
60
55
PC/FA
PC/GGBS
Triple blend
X4
Severe*
75
70
65
60
PC/FA
PC/GGBS
Triple blend
X5
Extreme*
80
75
70
65
Triple blend
C30
C40
C50
C60
C75
45
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X0
Cementitious type
(Table 6.6)
Minimum concrete cover (mm)
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Exposure Class
Minimum concrete
grade
All
All
*High level of cement replacement is required for severe and extreme exposure conditions.
Other protection measures such as coated reinforcement or surface treatment may be
considered.
QCS 2014

Part
Page 16
Recommendations to resist sulphate attack
The exposure classification shall be identified based on the sulphate and magnesium
contents in the ground and groundwater, pH and mobility of groundwater as given in Table
6.2.
The recommended concrete specification requirements in terms of concrete grade and

cementitious type are given in Table 6.8.
Unless stated otherwise by the Engineer or project designs, all concrete below ground shall
have surface protection to prevent the movement of moisture from the ground, through the
foundations into the superstructure. The method of protection shall be in accordance with
Section 15 of the QCS or as approved by Qatar Standards.
6.5.6
Minimum concrete grade
S1
C35
C50
Triple blend
SRPC, PC/FA, PC/GGBS
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SRPC, PC/FA, PC/GGBS
C60
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C75
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Triple blend
C50
C60
S4
All
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S3
S5
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C40
S2
Cementitious type
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Exposure class
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Table 6.8
Recommended durability requirement to resist sulphate attack
See Note
Triple blend
See Note
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Note:
1
S5 requires special treatment when the sulphate content exceeds 6000 mg/l and the magnesium
content exceeds 1000 mg/l.
Durability-Related Properties
The durability of concrete is greatly influenced by the ability of the concrete cover to resist the
movement of liquid and gas through concrete.
The commonly used test for assessing the transport properties of concrete are listed in Table
6.9 together with typical values. Lower value indicates more durable concrete.
No values are currently specified for various exposure classes, but may be requested by the
Engineer. Table 6.9 gives the recommended durability-related properties and typical values
for the development of mix design and comparative performance as given in the Concrete
Society CS163.
For Severe and Extreme exposures, it is recommended to use high durable concrete (Table
6.9)
6.5.7
QCS 2014

Part
Page 17
Table 6.9
Recommended properties and typical values for concrete
Concrete property
Age range between 28 and 90 days
Test method
Water absorption
Water penetration,
Rapid chloride permeability (RCP),
Chloride migration
High durability
Minimum durability
BS 1881: Part 122
2%
4%
BS EN 12390-8
5 mm
30 mm
ASTM C 1202
500 coulombs
NT Build 492
2.0 x10
-12
(m /s)
4000 coulombs
9.0 x10
-12
(m /s)
1. Concrete shall be tested for any of the transport properties when requested by the Engineer and shall
be tested at 28 days.
2. Exception will be made for concrete mixtures containing fly ash, silica fume or GGBS, where testing
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shall be requested at 56 days, or 90 days.
DESIGN OF CONCRETE MIXES
At the start of the construction period, the Contractor shall design a mix for each grade of
concrete as stated hereafter.
Each mix design shall be such that:
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6.6
the aggregate shall comprise fine aggregate and coarse aggregate with size specified
in Section 5, Part 2.
(b)
the combined aggregate grading shall be continuous
(c)
the aggregate quantity shall be calculated by weight.
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(a)
Where a concrete production facility has strength test records not more than 12 months old,
a sample standard deviation, Ss, shall be established. Test records from which Ss is
calculated shall consist of at least 30 consecutive tests or two groups of consecutive tests
totalling at least 30 tests
Where a concrete production facility does not have strength test records meeting
requirements of 6.6 (3) above, but does have test records not more than 12 months old
based on 15 to 29 consecutive tests, a sample standard deviation Ss shall be established as
the product of the calculated sample standard deviation and modification factor of Table 6.10
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Table 6.10
Modification Factor for Sample Standard Deviation When Less Than 30 Tests Are Available
No. of tests
Modification factor for sample standard

deviation
Less than 15
Use para 7. Below
15
1.16
20
1.08
25
1.03
30
1.00
1- Interpolate for intermediate number of tests

2- Modified sample standard deviation, Ss, to be used to determined required
average strength fcr
QCS 2014

Part
Page 18
To determine the correction factor between cube strength and cylinder strength, the
contractor shall establish at least 30 consecutive strength tests from each proposed mix
design. This correction will remain valid thru the project providing that no change in the
properties of the materials and no change in source occurred.
Required average compressive strength (Target Mean Strength) fcr used as the basis for
selection of concrete proportions shall be determined from Table 6.11 using the sample
standard deviation, Ss
Required average compressive strength, Target

2
Mean Strength, N/mm or MPa
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strength,
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Specified compressive
N/mm2 or MPa
Table 6.11:
Required Target Mean Strength when data are available
to establish a sample Standard Deviation
Fcr = fc + 1.34Ss ------------------ Eq. 1
ta
Fc < 35 MPa --- see footnote
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Fcr = fc + 2.33Ss 3.5 ---------- Eq. 2

Fc > 35 MPa --- see footnote
Fcr = fc + 1.34Ss ------------------ Eq. 1
as
Fcr = 0.90fc + 2.33Ss ------------ Eq. 3
When a concrete production facility does not have field strength test records for calculation of
Ss, Required average strength (Target Mean Strength) fcr shall be determined as follow:
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Note: Use the larger value computed from any equation
Fcr = fc + 8.5 MPa when 20 < fc < 35 MPa
(b)
Fcr = 1.10fc + 5 MPa when fc > 35 MPa
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(a)
Concrete
Portland cement concrete shall consist of a mixture of cementitious materials, fine aggregate,
coarse aggregate, water, and additives (when required). It shall be classified as in Table 6.4
unless otherwise stated hereafter and requested by the Engineer.
Blinding concrete
6.6.1
(a)
Blinding concrete shall be of minimum Grade C15 and above.
(b)
The thickness of the blinding concrete shall be as shown on the Drawings, but shall in
no instance be less than 75 mm.
(c)
The surface finish to blinding concrete shall be Class U4 as specified in Clause 9.3.1
of Part 9 of this Section or as directed by the Engineer.
QCS 2014
Page 19
Mass Concrete
(a)
The fresh concrete temperature at placing shall not exceed 21C to minimise thermal
cracking. A higher temperature of up to 27C may be accepted with a demonstration of
the satisfactory performance of concrete including mock up and thermal calculations.
The maximum allowable differential temperature between the interior and the exterior
of the mass concrete element shall not exceed 20 C. The maximum temperature in
any location within the mass concrete structure during curing shall not exceed 70 C.
The drop in concrete surface temperature during, and at the conclusion of the
specified curing period, shall not exceed 11 C in any 24 hour period.
Self-Compacting Concrete
(a)
General: Self-Compacting Concrete (SCC) is a special concrete that requires

minimum or no vibration for placing and compaction. It is able to flow under its own
weight, completely filling formwork and achieving full compaction, even in the presence
of congested reinforcement. The hardened concrete is dense, homogeneous and has
the same engineering properties and durability as traditional vibrated, fully compacted
concrete.
(b)
Self-Compacting Concrete Supplier: SCC shall be supplied by a competent concrete

producer with a record of successfully producing this type of concrete at considerable
volume and with high consistency.
(c)
Constituent Materials, General: The constituent materials for SCC are the same as
those used in traditional concrete conforming to EN 206-1, as specified in part 2 of this
section.
(d)
To achieve these requirements the control of the constituent materials needs to be

increased and the tolerable variations restricted, so that daily production of SCC is
within the conformity criteria without the need to test and/or adjust every batch.
(e)
Recommended Test Requirements for SCC:
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Part
Field Tests
600 750 mm
550 750 mm
6 25 sec
N.A
L-Box (3 bars)
> 0.80
N.A
J-Ring
< 10mm
N.A
Laboratory tests
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Slump-flow
V-Funnel
(f)
Concrete specimens shall be moulded in single layer without rodding and tapping
(g)
Slump flow and VSI testing shall be performed as outlined in the European Guidelines
for SCC, BS EN 12350-8 and BS EN 12350-9 or ACI 237R 07 and ASTM C 1611/C
1611M
Pile Concrete
3
(a)
The cementitious content shall not be less than 380 kg/m , as specified in Section 4.
(b)
The water-cementitious ratio shall not exceed 0.45
QCS 2014
Page 20
(c)
The concrete mixture shall be designed of high slump not less than 150 mm allowing
proper free fall with excellent homogeneity. When concrete mixture requires slump of
greater than 230 mm, it shall be designed as Self-Compacting Concrete or as
instructed by the Engineer.
(d)
The concrete slump shall have adequate workability retention using approved type of
retarder and shall be submitted in the design mix.
(e)
The increase in workability shall not permit any decrease in the specified design
strength
(f)
The concrete in a pile shall, if at all possible, be placed in one continuous operation.
Underwater Concrete
Shall comply with ACI 304 Chapter 8
(b)
The Cementitious content shall not be less than 390 kg/m
(c)
The water-cementitious ratio must not exceed 0.40
(d)
Fine aggregate contents of 45 to 55% by volume of total aggregate and air contents of
up to approximately 5% are generally specified.
(e)
Concrete shall be more cohesive and less prone to washout of cement or fines from
the concrete during placement. Antiwashout admixtures or alternative concrete mix
shall be used for underwater concrete.
(f)
Trial placements shall be conducted to verify that the concrete proportioned with the
antiwashout admixture can maintain adequate slump life and can flow for the required
distance.
(g)
The concrete mixture shall be designed of high slump not less than 150 mm allowing
proper free fall with excellent homogeneity. The use of air-entraining admixture shall
be evaluated as it increases the workability. When concrete mixture requires slump of
greater than 230 mm, it shall be designed as Self Compacted Concrete. The increase
in slump shall be made using proper admixtures.
(h)
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(a)
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The increase in workability shall not permit any decrease in the specified design
strength
(i)
The concrete slump shall have adequate retention using approved type of retarder and
shall be submitted in the design mix.
(j)
The concrete shall be placed in one continuous operation
(k)
The final selection of a concrete mixture shall be based on test placements made
under water in a placement box or in a pit that can be dewatered after the placement.
Test placements shall be examined for concrete surface flatness, amount of laitance
present, quality of concrete at the extreme flow distance of the test, and flow around
embedded items, if appropriate.
Shotcrete
(a)
The classification of shotcreting shall be in accordance to the process used (wet-mix

or dry-mix) and the size of aggregates used.
(b)
All materials shall be as per QCS except for aggregate where gradation shall be as per
ACI 506R and 506.2R
QCS 2014

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(c)
Steel and synthetic fibers will be used to reduce propagation of cracks. Fibers shall be
as per Manufacturer supplier data sheet and shall conform to ASTM A 820 for steel
fibers and ASTM C1116 for synthetic fibers.
(d)
The nozzle operator should be certified (refer to ACI CP-60) and have completed at
least one similar application as a nozzle operator on a similar project. The nozzle
operator should also be able to demonstrate, by test, an ability to satisfactorily perform
the required duties and to apply shotcrete as required by specifications
(e)
Before shotcreting the surface shall be prepared and maintained before and during
shotcrete application. Surface preparation shall conform to ACI 506 R chap. 5
(f)
The cementitious content shall not be less than 360 kg/m where wet-mix is applied
the slump shall be in the range of 40 to 80 mm
(g)
Normal testing ages for compressive strength are 7 and 28 days; however, shorter
periods may be required for particular applications or conditions as directed by the
3
Engineer. Testing shall be on daily production or every 30 m whichever is greater.
(h)
Sampling and testing, however, should be varied according to the size and complexity
of the project. Sampling should be done in accordance with ASTM C 1385. Making
extra cylinders or panels shall be at the request of Engineer if testing results vary.
(i)
Testing for water absorption and drying shrinkage shall be at the request of the
Engineer.
(j)
Fiber-reinforced shotcrete requires fiber washout tests or flexural toughness testing

according to ASTM C 1018.
(k)
Acceptance of shotcrete should be based on results obtained from drilled cores or

sawed cubes (ASTM C 42). The use of data from nondestructive testing devices, such
as impact hammers or probes (ASTM C 805, ASTM C 803), ultrasonic equipment
(ASTM C 597), and pull-out devices (ASTM C 900) may be useful in determining the
uniformity and quality of the in-place shotcrete. These tests, however, may not provide
reliable values for compressive strength.
(l)
Core grading is a method used to evaluate encasement of reinforcement. Core

grading shall be used for nozzle operator evaluation. Core grading should not be used
to evaluate structures.
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No-Fines Concrete and Pervious concrete
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(a)
No-fines concrete shall be made using a coarse aggregate conforming QCS section 5
part 3
(b)
Proportion of aggregate, cement and water shall be determined by trial mixes by the
Contractor and to be accepted by the Engineer.
(c)
All the aggregate particles are to be coated with a film of cement grout.
(d)
No-fines concrete when placed shall contain no layers of laitance.
(e)
No-fines concrete shall not be mixed by hand.
(f)
Mechanical vibration shall not be used to compact no-fines concrete.
(g)
Three test cubes of no-fines concrete shall be made of each preliminary mix.
(h)
Minimum crushing strength of the chosen mix shall be 5 MPa at 28 days.
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The porosity of no-fines concrete shall be such that water will pass through a slab
2
300 mm thick at the rate of not less than 7 l/m s of slab with a constant 100 mm
depth of water on the slab.
Where a slab incorporating vertical weep holes or drain holes is casted above a layer
of no-fines concrete; any polyethylene sheeting shall be pierced below the pipes
forming such drain holes and the edges of the sheeting sealed to the lower end of the
pipe to prevent the ingress of grout and fine particles from the slab concrete into the
no-fines concrete.
(k)
The limit for the maximum height of drop while placing is not applicable for no fines
concrete.
(l)
Formwork shall remain in place until the no fines concrete has gained adequate
strength to support itself as per the requirements of Part 10 of this Section.
(m)
Curing shall be carried out in accordance with the provisions of Part 11 of this Section
(n)
The fresh density of Pervious concrete shall be tested as per ASTM C1688 and the
infiltration rate shall be tested as per ASTM C1701 and to follow ACI 522.1R for testing
and quality control scheme.
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Concrete with recycled aggregates shall be generally approved once the source of recycled
aggregates is identified based on type and approved by the Engineer.
The recycled aggregates shall meet with BS EN 12620 and QCS requirements.
(b)
The concrete made with recycled aggregates shall be limited to design strength of C40
MPa cube strength; unless otherwise accepted by the Engineer. BS EN 206-1 shall be
the code of practice and guide for the usage of recycled concrete aggregates in
concrete or ACI 555 and BRE digest 433.
(c)
The Water-cementitious ratio shall not exceed 0.50
(d)
To determine a target mean strength on the basis of a required strength, a higher

standard deviation (increased by 40%) shall be used when designing a concrete with
recycled aggregates of variable quality than when recycled aggregate of uniform
quality or virgin aggregates are used
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(a)
Specific gravity, unit weight, and absorption of aggregates should be determined

before mixture proportion studies
(e)
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(j)
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(f)
The mixture proportion should be based on the measured density of the recycled
aggregates intended in the job concrete
(g)
Trial mixes shall be made to verify the requirements with project specification and
QCS.
Heavyweight and radiation shielding concrete

(a)
The quality of the aggregates should comply with the requirements of QCS for normal
weight aggregates, ASTM C 637 for heavyweight aggregates and ASTM C638 for
aggregates to be used in radiation-shielding concrete.
(b)
When ferrophosphorous aggregates are used, tests shall be made to determine if

gases (nontoxic) might be released during construction.
(c)
Aggregates shall be checked for every delivery to ensure that they conform completely
with purchase specifications
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Aggregates shall be frequently evaluated for the effects of deleterious substances or

aggregate coatings on concrete strength or the promotion of corrosion in metallic
aggregates or embedments
(e)
The chemical properties of all high-density aggregates must be provided to the

Engineer for evaluation before use with due consideration given to chemical reactivity,
particularly in highly alkaline environment as found in cement paste.
(f)
Tests for alkali-aggregate reactivity shall be determined from each source and supplier
and shall be made every 3 months.
(g)
The fresh density of high-density concrete shall be made from each truck
(h)
Lead shot concrete shall not be use for structural concrete.
(i)
Thermal conductivity, elastic behaviour and shrinkage, hardened density, strength as

well as other hardened concrete properties shall be tested and verified before the use
of concrete.
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Classification of fiber-reinforced concrete shall be made based on the material type of

the fiber incorporated:
Type I Steel Fiber-Reinforced ConcreteContains stainless steel, alloy steel, or
carbon steel fibers conforming to Specification of BS EN 14889-1 or ASTM
A820 /A820M .
(ii)
Type II Glass Fiber-Reinforced ConcreteContains alkali-resistant (AR) glass

fibers conforming to Specification C 1666/C 1666M.
(iii)
Type III Synthetic Fiber-Reinforced Concrete Contains synthetic fibers for

which documentary evidence can be produced confirming their long-term
resistance to deterioration when in contact with the moisture and alkalis present
in cement paste and the substances present in admixtures and shall conform to
BS EN 14889-2
(iv)
Type IV Natural Fiber-Reinforced Concrete Contains natural fibers for which

documentary evidence can be produced confirming their long-term resistance to
deterioration when in contact with the moisture and alkalis present in cement
paste and the substances present in admixtures. Test Method ASTM D 6942
shall be used to determine the susceptibility of these fibers to deterioration as a
result of exposure to alkalis in concrete
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Fiber-Reinforced Concrete
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(d)
(v)
(b)
When the purchaser chooses to permit the use of fibers other than those
complying with the above classifications, the manufacturer or supplier shall
show evidence satisfactory to the purchaser that the type of fiber proposed for
use shows long-term resistance to deterioration when in contact with the
moisture and alkalis present in cement paste and the substances present in
admixtures
The contractor shall submit:

(i)
Type of fiber-reinforced concrete required
(ii)
Designated size, or sizes, of coarse aggregates
QCS 2014

Part
Page 24
Slump or time of flow required at the point of delivery, or when appropriate the point of
placement, subject to the tolerances hereinafter specified Slump shall be specified
when it is anticipated to be 50 mm or more. Except as otherwise specifically permitted
by the Engineer, cement, supplementary cementitious materials, fine and coarse
aggregates, mixing water, and admixtures shall be measured in accordance with the
applicable requirements of QCS
(d)
Fibers shall be measured by mass. When the fibers are to be measured by mass,
bags, boxes, or like containers are acceptable provided that such like containers are
sealed by the fiber manufacturer and have the mass contained therein clearly marked.
No fraction of a container delivered unsealed, or left over from previous work, shall be
used unless weighed.
(e)
Prepackaged, dry, combined materials, including fibers, shall comply with the
packaging and marking requirements of Specification ASTM C 387 or C 1480 and
shall be accepted for use provided that after addition of water, the resulting fiber
reinforced concrete meets the performance requirements of this specification
(f)
Batching plant used for the preparation of continuously mixed fiber-reinforced concrete
shall comply with the applicable requirements of NRMCA. Fiber-reinforced concrete
shall be added directly to the concrete at the time of batching in amounts in accord
with approved submittals for each type of concrete required. Mix concrete in strict
accord with fiber-reinforced concrete manufacturer, instructions and recommendations
(g)
Fiber-reinforced concrete shall be free of fiber balls when delivered
(h)
The manufacturer of the fiber-reinforced concrete shall furnish to the purchaser a

delivery ticket or statement of particulars on which is printed, stamped, or written,
information with details of the type, brand, and amount of fibers used.
(i)
The contractor shall afford the inspector all reasonable access, without charge, for the
procurement of samples of freshly mixed fiber-reinforced concrete at the time of
placement to determine compliance with the requirements of this specification.
(j)
Samples of batch-mixed fiber-reinforced concrete shall be obtained in accordance with

Practice ASTM C 172 or C 1385/C 1385M for shotcrete as appropriate, except that
wet-sieving shall not be permitted. Sampling for uniformity tests shall be in accordance
with specification ASTM C 94/C 94M
If the measured slumps, time of flow, or air content fall outside the limits permitted by
this specification, make a check test immediately on another portion of the same
sample. If the results again fall outside the permitted limits, the material represented by
the sample fails to meet the requirements of this specification
(k)
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(c)
(l)
The following shall apply to all forms of fiber-reinforced concrete except dry-mix
shotcrete. When applicable, the slump shall be in tolerance with this section para
6.4.2.5 (a) and (b).
(m)
The time of flow shall be in the tolerances as follow:

(i)
When the project specifications for time of flow are written as a minimum or
not less than requirement
Plus Tolerance
Minus Tolerance
Specified time of flow

If 15sec or less
If more than 15 sec
5s
10s
0s
0s
QCS 2014

Part
(ii)
When the project specifications for time of flow are not written as a minimum
or not less than requirement:
For specified time of flow
8 to 15 s
More than 15 s
Tolerances for time of flow

Tolerance
+ 3s
+ 5s
Finishability - Pre-project trials shall be utilized to determine acceptable surface

finishability by the Engineer. The manufacturer shall provide the services of a qualified
technician to instruct the concrete supplier in proper batching and mixing of materials
to be provided.
(o)
Provide fibers for concrete reinforcing capable of achieving a two hour fire resistance
rating when tested under ASTM E 119. Fire tests must be certified.
(n)
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Lightweight concrete
This clause of the specification refers to lightweight concrete with improved insulation
properties where the practical range of densities is between about 300 and 1850
kg/m3.
(b)
The required density and strength of the lightweight concrete will be specified on the
drawings or directed by the Engineer.
(c)
The method of production of lightweight concrete will be shown on the drawings or

directed by the Engineer. The Contractor shall submit full technical details of the
materials and method of production for the lightweight concrete along with a list of
previous projects where the particular system has been used.
(d)
After source approval of the material and system the Contractor shall submit a mix
design for the lightweight concrete for the approval of the Engineer. After the review
and approval of the mix theoretical mix design the Contractor shall carry out a trial mix
to check the workability of the fresh concrete and to allow samples to be made for
compressive strength and density.
(e)
The Engineer may also instruct that tests are carried out for abrasion resistance and
thermal insulation properties.
(f)
Iightweight concrete shall be made with lightweight aggregates as approved in part 2 of

section 05 in QCS for its use in concrete
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The performance of lightweight concrete shall follow ACI 213R
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6.7
TRIAL MIXES
As soon as the Engineer has approved the concrete mix design for each grade of concrete
and during or following the carrying out of the preliminary tests, the Contractor shall prepare a
trial mix of each grade in the presence of the Engineer at least 35 days before
commencement of concreting. Trial mix shall be mixed and handled by means of the same
plant which the Contractor proposes to use in the Works. The trial mix shall comprise not
3
less than 50% from the central mixing drum capacity but not less than 3.0 m of concrete.
The trial mix can be exempted if concrete supplier provides through an independent
approved testing agency adequate history on strength:
(a)
Not less than 30 strength test results as in para 6.6 of this specification
(b)
The results shall valid by no more than 6 months from the date of approval
Batch the field concrete trial mixture within -5C of the proposed maximum allowable fresh
3
concrete temperature in a truck-mixer with a minimum batch size of 3 m .
QCS 2014

Part
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The concrete mixture shall be held in the mixer for 120 minutes, unless otherwise specified
by the Engineer. During the entire 120-minute period, agitate the mixer at 1 to 6 rpm. At the
end of 120 minutes, mix the concrete mixture at full mixing speed designated by the
manufacturer (6 to 18 rpm) for 2 minutes.
For each trial mix, a plant production trial shall be carried out and the slump of the concrete
checked immediately after discharge from the mixer and thereafter at 30 min intervals up to
the maximum time period envisaged for delivery and standing on site. Based on this trial the
mix design shall identify any adjustments to the range of plasticiser for acceptable workability
for different times after batching. Where ready mix concrete is being used, the above
requirement may be waived at the discretion of the Engineer if the Contractor has
documented previous experience of a particular mix design with test results available.
The proportions of cement, aggregate and water shall be carefully determined by weight in
accordance with the Contractor's approved mix design (or modified mix design after
preliminary tests).
Each sample shall consist of at least 9 specimens for strength analysis where 3 specimens
for each age will be tested to determine the concrete strength at the required age.
If either or both the average value of the strength of the three cubes tested at 28 d is less
than the required strength (target strength) or the difference between the greatest and the
least strengths is more than 15 % of the average strengths, as per BS EN 206-1, the
Contractor shall take measures as deemed necessary such as:
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Propose new mix design
(b)
Provide new materials and prepare and test further trial mixes until specified
requirements are achieved.
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(a)
Additionally, the Contractor shall measure the temperature, workability of concrete in each
batch.
When requested by engineer, a mock-up of 2x2x2 m shall be made at jobsite and full scale
tests of the workability of each trial mix shall be made by the Contractor in the presence of
the Engineer. The following tests shall be made on the Site by filling trial moulds to confirm
the suitability of:
(a)
mix for the works

type of plant used for mixing
(b)
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(c)
face intended for use in the works
(d)
type of form oil
(e)
type of protective coatings.
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Redesign of the concrete mixes and trial mixes of concrete shall be repeated for each grade
of concrete until the concrete meets the requirements in this specification and it is verified by
full scale mockup test as described above.
11
Approval of the job-mix proportions by the Engineer or his assistance to the Contractor in
establishing those proportions, in no way relieves the Contractor of the responsibility of
producing concrete which meets the requirements of this Specification.
12
All costs connected with the preparations of trial mixes and the design of the job mixes shall
be borne by the Contractor.
13
The Contractor shall declare any change in the source of the material and any changes in the
cement content consumption greater than 20.0kg/m from that used in the trial mixes.
QCS 2014

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QUALITY AND TESTING
6.8.1
General
In order to ensure that the quality of materials and mix proportions are maintained throughout
concreting operations, sampling and testing shall be carried out using the relevant standard
procedures and all other relevant codes quoted in this specification in accordance with a
routine testing program that shall be agreed with the Engineer before the start of concrete
work.
The Contractor, through a third party approved testing agency, shall supply all necessary
tools for tests, shall cast all concrete specimens, strip and store them in water as stated in
BS EN 12390-2. The Contractor shall also arrange for the transport of samples to the place
of testing and shall supply the Engineer with duplicate copies of all test certificates.
6.8.2
Tests for Concrete
Unless the Engineer directs otherwise, the program shall include at least the tests specified
below.
Tests on aggregates shall be as described in Part 2 of this Section.
Concrete shall be tested in accordance with the requirements of this specification by qualified
field testing technicians or engineer. Concrete testing laboratory personnel shall be certified
from a recognised Institution. Field personnels in charge of sampling concrete; testing for
slump, and temperature; and making and curing test specimens shall be certified from a
recognised Institution too.
Slump tests (and VSI testing when applicable) shall be carried out at the rate of one test per
3
load of concrete delivered to the Site, or one test per 10 m whichever is the lesser for the
3
3
first 50 m of concrete then at a rate of 1 slump test for every 50 m if concrete was
consistent during production. In the event of inconsistent slump values, the Engineer may
instruct the Contractor to check the slump test on each truck of concrete at the plant. The
Contractor shall carry out an investigation to establish the cause of the high variation in slump
and shall take any necessary corrective measures. The slump requirements for the fresh
concrete are to be approved by the Engineer.
The adjustment for the slump of concrete to fit the job requirement can be conducted only
one time using a proper additive at jobsite provided that such addition does not increase the
water-cement ratio and setting time above the maximum permitted by the specifications. This
addition will only be made at the approval of Engineer.
Concrete shall be available within the permissible range of slump for a period of 30 min
starting either on arrival at the job site or after the initial slump adjustment as permitted
3
above, whichever is later. The first and last quarter m discharged are exempt from this
requirement. If the user is unprepared for discharge of the concrete from the vehicle, the
producer shall not be responsible for the limitation of minimum slump after 30 min have
elapsed starting either on arrival of the vehicle at the prescribed destination or at the
requested delivery time, whichever is later.
When air-entrained concrete is desired the purchaser shall specify the total air content of the
concrete. The air content of air-entrained concrete when sampled from the transportation unit
at the point of discharge shall be within a tolerance of +1.5% of the specified value.
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6.8
QCS 2014
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Concrete strength test:

(a)
Each concrete strength sample shall consist of at least seven specimens, two to be
tested at 7 days, three at 28 days and two to be tested at the discretion of the
Engineer. Additional samples may be prepared as directed by the Engineer to be
tested at the discretion of the Engineer for strength and/or durability.
(b)
When concrete cylinders have been specified, the concrete specimens shall not be
capped using sulphur for environmental effect. The Contractor shall follow one of the
following procedures and as approved by the Engineer:
(i)
Cap the specimens in accordance with ASTM C617 using neat cement paste
and/or High-strength gypsum cement paste
(ii)
Saw cut and Grind the surface of the concrete to the desired planeness and
perpendicular
(iii)
Test the concrete cylinders using Unbonded Caps in accordance with ASTM
C1231
(iv)
For field specimens, the contractor has the right to either use the conversion
listed in EN 206 or determine the conversion factor for each specified concrete
mix design by testing at least 36 comparative specimens (i.e. 18 cubes versus
18 cylinders sampled from 3 consecutive batch trial mix).
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A minimum of one sample shall be taken of each mix every day the mix is used
(d)
Samples shall be taken at the average rate of the followings:
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(c)
One sample every 30 m3, if the pour is less than or equal to 90 m
(ii)
One sample every 100 m3, if the pour is greater than 90m and equal to or less
than 2000 m3,
(iii)
One sample every 200 m3, if the pour exceeds 2000 m .
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(i)
Test specimens for compressive strength testing shall be prepared and cured in
accordance with BS EN 12390-2. The compressive strength of the specimens shall be
determined in accordance with BS EN 12390-3.
(f)
A test shall be the average of the strength of the specimens tested at the age
specified. If a specimen shows definite evidence other than low strength, of improper
sampling, moulding, handling, curing, or testing, it shall be discarded and the strength
of the remaining cubes shall then be considered the test result.
Identity criteria of concrete strength shall be assessed for each individual test result
and the average of non-overlapping results as per BS EN 206-1 and explained below:
(g)
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(e)
(i)
The average strength tests (average of two specimens or more) shall be equal
to or greater than the characteristic (fck) + 2 MPa, and
(ii)
Any individual test result shall be equal to or greater than fck 4 MPa. The test
result shall be that obtained from the average of the results of two or more
specimens made from one sample for testing at the same age.
If works test specimens fail at 28 days the Contractor shall suspend concreting operations
and shall not proceed further without approval. The Contractor shall carry out in-situ testing
of the suspect concrete in accordance with Part 13 of this Section, in the presence of the
Engineer. All defective work shall be replaced and retested to the satisfaction of the
Engineer.
QCS 2014
Page 29
Hardened Tests for Fiber-Reinforced Concrete

(a)
When post-crack flexural performance is used as the basis for acceptance of fiberreinforced concrete, make, condition, and test sets of test specimens in accordance
with Test Method ASTM C1399, C1550 or C1609/C1609M as specified.
(b)
When flexural strength is used as the basis for acceptance, make and test sets of at
least three test specimens in accordance with the requirements for sampling and
conditioning given in Test Method ASTM C1609/C1609M. Test specimens
representing thin sections, as defined in C1609/C1609M, or specimens representing
fiber-reinforced shotcrete of any thickness, shall be tested as cast or placed without
being turned on their sides before placement on the support system. Acceptance shall
not be based on flexural strength alone when post-crack performance is important.
Test Method C1609/C1609M provides for the determination of first peak flexural
strength when required by the purchaser. For many type-amount fiber combinations,
the first peak flexural strength is not significantly greater than the peak strength in
flexure.
(c)
When compressive strength is used as part of the basis for acceptance of fiberreinforced concrete, make sets of at least two test specimens in accordance with the
applicable requirements of Practices ASTM C31/C31M and C192/C192M and as
specified in this section, or Test Methods C42/C42M or C1604/C1604M and condition
and test in accordance with Test Methods BS EN 12390, C39/C39M, C42/ C42M, or
C1604/C1604M. Acceptance shall not be based on compressive strength alone.
(d)
The frequency of tests on hardened fiber-reinforced concrete shall be in accordance

with the following requirements:
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6.8.3

Part
Batch-Mixing: Tests shall be made with same frequency as in conventional

concrete. Each test shall be made from a separate batch. On each day fiberreinforced concrete is mixed, at least one test shall be made for each class of
material.
(ii)
When fibers are added, subject for approval of the Engineer, at the truck mixer
3
the tests shall be made for each 20 m or fraction thereof, or whenever
significant changes have been made in the proportioning controls. On each day
fiber-reinforced concrete is mixed, at least one test shall be made for each class
of material.
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(i)
(iii)
For Shotcrete: Tests shall be made for each 38 m placed using specimens
sawed or cored from the structure or from corresponding test panels prepared in
accordance with Practice ASTM C1604 and C 1140. On each day fiberreinforced shotcrete is prepared; at least one test shall be made for each class
of material.
6.8.4
Quality Control charts
The Contractor shall submit a continuous statistical analysis, on a monthly basis, for strength
showing the potential strength of the concrete, variations in measured strength by
determining the standard deviation (margin), batch-to-batch variations of the proportions and
characteristics of the constituent materials in the concrete, the production, delivery, and
handling process, and climatic conditions; and variations in the sampling, specimen
preparation, curing, and testing procedures (within-test).
QCS 2014

Part
Page 30
The Contractor shall provide in his analysis the mean strength, calculated standard deviation,
the normal distribution of concrete strength and the frequency histogram. The Contractor
shall draw the upper and lower lines for warning line (Target mean strength + 2 x standard
deviation) and control line (Target mean strength + 3 x standard deviation)
The contractor shall use the methods, of computing standard deviation along with coefficient
of variation and factors for computing within-test standard deviation from range, addressed in
ACI 214
This recalculated margin, if adopted by the Engineer, becomes the current margin for the
judgement of compliance with the specified characteristic strength of concrete
6.9
WORKS TEST CUBES
Test cubes shall be taken as specified from fresh mixed concrete which is being used in the
Works and which has been prepared in the normal way.
Cubes shall be numbered sequentially and marked:

Time, date and name of individual
(b)
Section of work from which samples are taken
(c)
Mix reference and delivery note number
(d)
Name of technician
(e)
and any other relevant information.
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Tests for slump, as per BS EN 12350-2, and temperature shall be made and recorded
whenever samples are taken.
The cube manufacture shall be in accordance with BS EN 12390-2.
When Self Compacting Concrete is used, the concrete specimens shall not be consolidated
in moulds and it shall be placed in a single lift then levelled with minimum manipulation.
All samples shall be moulded at jobsite on a levelled surface area to within 20 mm per meter
Immediately after moulding and finishing, the specimens shall be stored for a period up to 48
h in a temperature range from 20 to 26 C and in an environment preventing moisture loss

from the specimens
Specimens shall not be transported or handled until at least 14 h after casting
Transportation time from site to laboratory for final curing and strength testing shall not
exceed 4 hours. Specimens shall be protected from direct sun or rapid evaporation and
placed on cushion layer to reduce vibration
6.10
REJECTION OF CONCRETE MIXES
6.10.1
Rejection of Concrete Mixes:
Concrete mixes shall be rejected if they fail to meet one or more requirements, which cannot
be brought into compliance as related to any of the following:
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QCS 2014

Part
(a)
Improper class or grade of concrete
(b)
Slump or temperature not within specified limits
(c)
Oversized aggregate
(d)
Maximum water-cementitious ratio is exceeded
Page 31
Concrete shall not be rejected unless it has been visually inspected by the Engineer or
representatives.
6.10.2
Unsatisfactory Concrete Works
A test shall be the average of the strengths of the specimens tested at the age specified. If a
specimen shows definite evidence other than low strength, of improper sampling, moulding,
handling, curing, or testing, it shall be discarded and the strength of the remaining specimens
shall then be considered the test result and where the range of the test values is more than
15 % of the mean, the results shall be disregarded unless an investigation reveals an
acceptable reason to justify disregarding an individual test value. To conform to the
requirements of this specification, strength tests representing each class of concrete must
meet the following requirements:
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The average of any three consecutive strength tests shall be equal to, or greater than,
the specified strength, f c, and
(b)
When the specified strength is 35 MPa or less, no individual strength test (average of
at least two specimen tests) shall be more than 3.5 MPa below the specified strength, f
c
(c)
When the specified strength is greater than 35 MPa, no individual strength test
(average of two specimen tests) shall be less than 0.90 f c.
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(a)
Should any of the test results be unsatisfactory, the Engineer may order the work to be
stopped pending his further instructions. Executed work for which test results are
unsatisfactory shall be liable to rejection and if so advised the work shall be rebuilt at the
Contractor's expense.
In the case of the 7-day works cube tests proving unsatisfactory, the work may be stopped
liable to rejection pending the result of the 28-day test. If the test results fail to comply with
the requirements, the work represented shall be immediately liable to rejection.
The cost of all such cuttings, preparation of specimens, transportation and testing, and of
making good the portions of the structure affected shall be borne by the Contractor.
Regardless of satisfactory test cube results, any concrete work which, in the Engineer's
opinion, is excessively honeycombed or in any other way is defective, shall be liable to
rejection. Minor defects apparent on stripping the formwork must be made good at the
Contractor's expense. No such repair work shall be carried out until after inspection by the
Engineer and his acceptance of the proposed treatment has been given. Work which has
not been previously inspected but which shows signs of such treatment shall be liable to
rejection as defective work.
The cost of all delays on site due to faulty concrete work shall be met by the Contractor.
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END OF PART
QCS 2014

Part
07: Concrete Plants
Page 1
CONCRETE PLANTS.............................................................................................. 2
7.1
7.1.1
7.1.2
GENERAL ............................................................................................................... 2
Scope
2
References
2
7.2
7.2.1
7.2.2
7.2.3
7.2.4
7.2.5
7.2.6
BATCHING .............................................................................................................. 3
General
3
Plant Type
5
Bins and Weight Batchers
5
Tolerances of Measuring Equipment
5
Batching Tolerances
6
Charging the Mixer
7
7.3
7.3.1
7.3.2
7.3.3
7.3.4
MIXING.................................................................................................................... 7
Charging Concrete Materials
7
Mixing Time for Stationary Mixers
7
Mixing
8
Limitation of Water : Cement Ratio
8
7.4
7.4.1
READY-MIXED CONCRETE ................................................................................... 9

General
9
7.5
APPENDIX A: CONCRETE PLANT INSPECTION CHECKLIST ........................ 11
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Part
07: Concrete Plants
Page 2
CONCRETE PLANTS
7.1
GENERAL
7.1.1
Scope
This Part covers batching and mixing of concrete together with inspection of concrete plants.
References
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ACI 304 ......................Guides for Measuring, Mixing, Transporting, and Placing Concrete
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ASTM C94 ..................Specification for ready-mixed concrete
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BS 1881......................Testing concrete
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BS 8500......................Concrete Specification complementary to EN 206

BS EN 12390..............Testing of hardened concrete
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BS EN 12390-1:2000 .Testing hardened concrete Part 1: Shape, dimensions and other

requirements for specimens and moulds
BS EN 12390-2:2000 .Testing hardened concrete Part 2: Making and curing specimens
for strength tests
7.1.2
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Part 1 ............... General

Part 3 ............... Cementitious materials
Part 4 ............... Water
Part 5 ............... Admixtures
Part 8 ............... Transporting and Placing of Concrete
Part 15 ............. Hot Weather Concreting
This Section
BS EN 12390-3:2000 .Testing hardened concrete Part 3: Compressive strength of test

specimens
BS EN 12390-4:2000 .Testing hardened concrete Part 4: Compressive strength Specification for testing machines
BS EN 12390-5:2000 .Testing hardened concrete Part 5: Flexural strength of test
specimens
BS EN 12390-6:2000 .Testing hardened concrete Part 6: Tensile splitting strength of test
specimens
BS EN 12390-7:2000 .Testing hardened concrete Part 7: Density of hardened concrete
BS EN 12390-8:2000 .Testing hardened concrete Part 8: Depth of penetration of water
under pressure
BS EN 12350-1:2000 .Testing fresh concrete - Part 1: Sampling
QCS 2014

Part
07: Concrete Plants
Page 3
BS EN 12350-2:2000 .Testing fresh concrete - Part 2: Slump test

BS EN 12350-3:2000 .Testing fresh concrete - Part 3: Vebe test
BS EN 12350-4:2000 Testing fresh concrete - Part 4: Degree of compatibility
BS EN 12350-5:2000 Testing fresh concrete - Part 5: Flow table test
BS EN 12350-6:2000 Testing fresh concrete - Part 6: Density
BS EN 12350-7:2000 Testing fresh concrete - Part 7: Air content - Pressure methods
GSO EN 206-1, ..........Concrete. Specification, performance, production and conformity
GSO ISO 1920-2 ........Testing of concrete part 2: properties of fresh concrete
GSO ISO 1920-3 ........Testing of concrete part 3: Making and curing test specimens.
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GSO ISO 1920-4 ........Testing of concrete part 4: strength of hardened concrete.
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GSO ISO 1920-5 ........Testing of concrete part 5: properties hardened concrete other than
strength.
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GSO ISO 1920-6 ........Testing of concrete part 6: sampling, preparing and testing of
concrete core.
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GSO ISO 1920-7 ........Testing of concrete part 7: Nondestructive test on hardened

concrete.
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ISO 1920-8 .................Testing of concrete -- Part 8: Determination of drying shrinkage of

concrete for samples prepared in the field or in the laboratory
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ISO 1920-9 .................Testing of concrete -- Part 9: Determination of creep of concrete

cylinders in compression
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ISO 1920-10 ...............Testing of concrete -- Part 10: Determination of static modulus of

elasticity in compression
BATCHING
7.2.1
General
During measurement operations, aggregates shall be handled in a manner to maintain their

desired grading, and all materials shall be weighed to the tolerances required for the desired
reproducibility of the selected concrete mix.
The coarse aggregate shall be controlled to minimize segregation and undersized material.
Fine aggregate shall be controlled to minimize variations in gradation, giving special attention
to keeping finer fractions uniform and exercising care to avoid excessive removal of fines
during processing
Avoid blending two sizes of fine aggregate by placing alternate amounts in bins or stockpiles
or when loading cars or trucks. Satisfactory results are achieved when different size fractions
are blended as they flow into a stream from regulating gates or feeders. A more reliable
method of control for a wide range of plant and job conditions, however, is to separate
storage, handling, and batching of the coarse and fine fractions
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7.2
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Part
07: Concrete Plants
Page 4
Stockpiling of coarse aggregate shall be kept to a minimum because fines tend to settle and
accumulate. When stockpiling is necessary use of correct methods minimizes problems with
fines, segregation, aggregate breakage, excessive variation in gradation, and contamination.
Stockpiles shall be built up in horizontal or gently sloping layers, not by end-dumping. Trucks,
loaders, and dozers, or other equipment shall not be operated on the stockpiles because, in
addition to breaking the aggregate, they frequently track dirt onto the piles
Stockpiles located to prevent contamination; arranged to assure that each aggregate as

removed from its stockpile is distinct and not intermingled with others. The concrete supplier
is asked to separate storage bins or compartments for each size and type of aggregate
properly constructed and charged to prevent mixing of different sizes or types
Sequencing and blending of the ingredients during charging of the mixers shall be carried out
in such a way as to obtain uniformity and homogeneity in the concrete produced as indicated
by such physical properties as unit weight, slump, air content, strength and air-free mortar
content in successive batches of the same mix proportions and as stated in ASTM C94
Annex A.
The mix recipe for the mixes to be produced shall be readily available to the mixer operator.
Only authorised personnel shall be allowed to make changes to the mix design.
All cement bags shall be stored in weathertight, properly ventilated structures to prevent
absorption of moisture.
Storage facilities for bulk cement shall include separate compartments for each type of
cement used. The interior of a cement silo shall be smooth, with a minimum bottom slope of
50 degrees from the horizontal for a circular silo and 55 to 60 degrees for a rectangular silo.
Silos shall be equipped with non-clogging air-diffuser flow pads through which small
quantities of dry, oil-free, low-pressure air can be introduced intermittently at approximately 3
to 5 psi (20 to 35 kPa) to loosen cement that has settled tightly in the silos. Storage silos shall
be drawn down frequently, preferably once per month, to prevent cement caking.
10
Each bin compartment from which cement is batched shall include a separate gate, screw
conveyor, air slide, rotary feeder, or other conveyance that effectively allows both constant
flow and precise cutoff to obtain accurate batching of cement
11
Fly ash, ground slag, or other pozzolans shall be handled, conveyed, and stored in the same
manner as cement. The bins, however, shall be completely separate from cement bins
without common walls that could allow the material to leak into the cement bin.
12
All bins and silos shall be properly tagged at silos, bins and near charging hose.
13
Bags of cement should be stacked on pallets or similar platforms to permit proper circulation
of air. For a storage period of less than 60 days, stack the bags no higher than 14 layers, and
for longer periods, no higher than seven layers.
14
The water batcher and the water pipes should be leak-free. If ice is used, the ice facilities,
including the equipment for batching and transporting to the mixer, should be properly
insulated to prevent the ice from melting before it is in the mixer.
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Part
07: Concrete Plants
Page 5
Plant Type
Manual control batching. Manual plants are acceptable for small jobs having low batching
3
3
rate requirements, generally for jobs up to a total concrete quantity of 1000 m and 10 m /h.
Semi-automatic control batching. In this system, aggregate bin gates for charging batchers
are opened by manually operated push buttons or switches. Gates are closed automatically
when the designated weight of material has been delivered.
Automatic control batching. Automatic batching of all materials is electrically activated by a

single starter switch. However, interlocks shall interrupt the batching cycle when the scale
has not returned to 0.3 % of zero balance or when weighing tolerances detailed in
Clause 7.2.5 of this Part are exceeded.
7.2.3
Bins and Weight Batchers
Batch plant bins shall be of sufficient size to effectively accommodate the production capacity
of the plant. Compartments in bins separate the various concrete materials, and the shape
and arrangement of aggregate bins shall prevent aggregate segregation and leakage.
Weight batchers shall be charged with easy-operating clam shells or undercut radial-type bin
gates.
Gates used to charge semi-automatic and fully automatic batchers shall be power operated
and equipped with a suitable in flight correction to obtain the desired weighing accuracy. They
shall be calibrated by the plant supplier for the types of aggregate used at the standard range
of moisture contents.
Weigh batchers shall be accessible for obtaining representative samples, and they shall be
arranged to obtain the proper sequencing and blending of aggregates during charging of the
mixer.
The amount of concrete mixed in any one batch shall not exceed the rated capacity of the
mixer.
All mixing and batching plants shall be maintained free of set concrete or cement and shall
be clean before commencing mixing.
For each different type of cement at use at the plant a separate silo shall be provided.
7.2.4
Tolerances of Measuring Equipment
Scales for weighing concrete ingredients shall be accurate when in use within 3 % and
1.5 % for additives. Standard test weights shall be available to permit the checking of scale
accuracy.
Testing of the weighers shall be at three-month intervals. If water is dispensed by flow meter
the frequency of testing shall be at three-month intervals. Such testing shall be undertaken by
a calibration company approved by the Central Materials Laboratory, and calibrated to
recognized international standards.
Test certificates shall be displayed in the plant in prominent positions.
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7.2.2
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Part
07: Concrete Plants
Page 6
Batching Tolerances
Operation of batching equipment shall be such that the concrete ingredients are consistently
measured within the following tolerances. The plant shall have the ability to flag values that
are outside these limits. The operator shall make manual adjustments to the batching and
the final weights shall be within the given limits stated in table 7.1. Any adjustments shall be
displayed on the batch weight printouts.
Cementitious materials shall be measured by mass. When supplementary cementitious

materials are used in the concrete mixtures, the cumulative mass is permitted to be
measured with hydraulic cement, but in a batch hopper and on a scale which is separate and
distinct from those used for other materials.
Aggregate shall be measured by mass. Batch mass measurements shall be based on dry
materials and shall be the required masses of dry materials plus the total mass of moisture
(both absorbed and surface) contained in the aggregate
Mixing water shall consist of water added to the batch, ice added to the batch, water
occurring as surface moisture on the aggregates, and water introduced in the form of
admixtures. The added water shall be measured by weight or volume.
Added ice shall be measured by weight. In the case of truck mixers, any wash water retained
in the drum for use in the next batch of concrete shall be accurately measured; if this proves
impractical or impossible the wash water shall be discharged prior to loading the next batch
of concrete
Chemical admixtures in powdered form shall be measured by mass. Liquid chemical

admixtures shall be batched by mass or volume
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7.2.5
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Table 7.1
Typical batching tolerances Ingredient
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Typical batching
tolerances
Ingredient
Cement and other

cementitious
Materials
Water (by volume or

weight), %
Batch weights greater than

30% of scale capacity
Individual
Cumulative
batching
batching
1% of required mass or
0.3% of scale capacity,
whichever is greater
1
Not
recommended
Batch weights less than

30% of scale capacity
Individual
batching
Cumulative
batching
Not less than required weight or 4%

more than required weight
Not recommended
Aggregates, %
0.3% of scale
capacity or
3% of required
cumulative
Weight, whichever is
less
Admixtures (by
volume or weight), %
Not
recommended
Not recommended
QCS 2014

Part
07: Concrete Plants
Page 7
Cement supplied in bags shall be placed directly from the bag into the intake of the mixing
plant and each batch must contain one or more complete bags of cement. No mixer having
a rated capacity of less than a one-bag batch shall be used and the mixer shall not be
charged in excess of its rated capacity.
7.2.6
Charging the Mixer
Each batch shall be so charged into the mixer that some of the water will enter in advance of
the cement and aggregates. Controls shall be provided to prevent batched ingredients from
entering the mixer before the previous batch has been completely discharged.
The first batch of concrete through the mixer shall contain an excess of cement to allow for
coating of the inside of the mixing drum without reducing the required mortar content of the
mix.
Mixing plant that has been out of action for more than 30 minutes shall be thoroughly cleaned
before any fresh concrete is mixed in it.
When a change of mix is made to one using a different type of cement, the mixing plant shall
be thoroughly cleaned of all traces of the previously used cement, whatever is the time
interval between successive mixes.
7.3
MIXING
7.3.1
Charging Concrete Materials
Water shall enter the mixer first with continuous flow while other ingredients are entering the
mixer. Water charging pipes must be of the proper design and of sufficient size so that water
enters at a point well inside the mixer and charging is completed within the first 25% of the
prescribed mixing time and where concrete uniformity shall be verified by approved inspector.
Admixtures shall be charged to the mixer in accordance with the instructions of the
manufacturer. Automatic dispensers shall be used.
7.3.2
Mixing Time for Stationary Mixers
The mixing time required shall be based upon the ability of the mixer to produce uniform,
homogeneous, consistent mixture throughout the batch and from batch to batch.
Final mixing times shall be based on the results of mixer performance tests made at the start
of the project and the time fixed unless a change is authorised by the Engineer. The time
shall however not be less than 60 Sec unless otherwise verified as stated hereafter. Where
no mixer performance tests are made, the acceptable mixing time for mixers having
3
capacities of 0.75 m or less shall be not less than 1 min. For mixers of greater capacity, this
minimum shall be increased 15 s for each cubic meter or fraction thereof of additional
capacity.
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Part
07: Concrete Plants
Page 8
Where mixer performance tests have been made on given concrete mixtures in accordance
with the testing program ASTM C94 Annex A and NRMCA certification, and the mixers have
been charged to their rated capacity, the acceptable mixing time is permitted to be reduced
for those particular circumstances to a point at which satisfactory mixing defined in ASTM
C94 and NRMCA certification for central mixing plants shall have been accomplished. When
the mixing time is so reduced the maximum time of mixing shall not exceed this reduced time
by more than 60 s for air-entrained concrete. The mixing time shall be measured from the
time all ingredients are in the mixer.
Batch mixers with audible indicators used in combination with interlocks which prevent mixer
discharge prior to completion of a preset mixing time shall be provided on automatic plants
and are also desirable on manual plants.
The mixer shall be designed for starting and stopping under full load.
7.3.3
Mixing
All structural concrete to be placed in-situ shall be manufactured in a computer controlled

batching plant of the types described in Clause 7.2.2 of this Part.
The plant shall be complete with suitable water chilling or ice making facilities, or both, to
ensure concrete temperatures are maintained as specified in Parts 6 and 15 of this Section.
Concrete shall be mixed in batches in plant capable of combining the aggregates, cement
and water (including admixtures, if any) into a mixture of uniform colour and consistency and
of discharging the mixture without segregation.
Automatic moisture content probes, set in the hoppers shall be used to continuously
determine the moisture content of the aggregates.
Contractor shall make due allowance for the water contained in the aggregates when
determining the quantity of water to be added to each mix.
The amount of water added to each mix shall be adjusted to maintain the constant approved
water : cement ratio of the mixed concrete.
7.3.4
Limitation of Water : Cement Ratio
No concrete shall exceed the water : cement ratio as given in Part 6 of this Section.
The quantity of water used in mixing shall be the least amount that will produce a workable
homogeneous plastic mixture which can be worked into the forms and around the
reinforcement.
Excess water over the maximum allowed by the mix design shall not be permitted and any
batch containing such excess will be rejected.
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Part
07: Concrete Plants
Page 9
7.4
READY-MIXED CONCRETE
7.4.1
General
The manufacture of readymix concrete for use in government projects may only be carried
out in batching plants that have an approval certificate issued by the Central Materials
Laboratory. When this certificate is under renewal process by the readymix concrete
manufacturer, other certificate such as NRMCA shall be considered by the Engineer as
approval on the uniformity and consistency of the facility. The engineer may request to revalidate the uniformity tests under his supervision. In addition, the use of readymix concrete
in any part of the work shall require the Engineers written approval.
The Contractor shall satisfy the Engineer on the following:

materials used in ready-mixed concrete comply with the specification in all respects
(b)
manufacturing and delivery resources of the proposed supplier are adequate to ensure
proper and timely completion.
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(a)
The specified requirements as to the sampling, trial mixing, testing and quality of concrete, of
various grades as described in Part 6 of this Section, shall apply equally to ready-mixed
concrete.
Every additional facility, including but not limited to testing equipment, labour, laboratory
facilities and transport, which the Engineer or persons authorised by him may require for the
supervision and inspection of the batching, mixing, testing and transporting to Site of readymixed concrete shall be provided by the Contractor at no extra cost.
Copies of all delivery notes shall be submitted to the Engineer in duplicate, on computer
generated forms and shall include at least the following information.
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name of supplier, serial number of ticket and date
(b)
truck number
(c)
name of Contractor
name of Contract and location of office
grade of concrete
(e)
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(d)
(a)
(f)
specified workability
(g)
type and source of cement
(h)
source of aggregate
(i)
nominal maximum size of aggregate
(j)
quantity of each concrete ingredient
(k)
type of admixture and quantity
(l)
water content
(m)
time of loading and departure from ready-mix plant
(n)
arrival and departure times of truck
(o)
time of completion of discharge
QCS 2014
(p)

Part
07: Concrete Plants
Page 10
notations to indicate equipment was checked and found to be free of contaminants

prior to batching.
A copy of the delivery note shall be given to the Engineer's site representative for each load.
Unless approved otherwise in advance of batching all concrete of single design mix for any
one day's pour shall be from a single batch plant of a single supplier.
Ready-mix concrete shall conform to BS 8500 in addition to GSO EN 206-1, except

materials, testing and mix design shall be as specified in this Section.
Transit mixers equipped with automatic devices for recording the number of revolutions of
the drum shall be used.
10
Excess water over the maximum allowed by the mix design shall not be added.
11
Each mixer truck shall arrive at the job site with its water container full.
12
In the event that a container is not full or concrete tests give a greater slump than acceptable,
the load shall be rejected.
13
Shade temperature and concrete temperature shall be recorded at the point of discharge of
the mixer and at placement for each load of concrete delivered to site.
14
Maximum and minimum temperatures and wet bulb temperatures shall be recorded daily.
15
Slump tests shall be performed in accordance with BS EN 12350 or relevant GSO standard
at the point of placement as stated in Part 6.
16
No water shall be added at the Site.
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END OF PART
QCS 2014
Page 11
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APPENDIX A: CONCRETE PLANT INSPECTION CHECKLIST
7.5

Part
07: Concrete Plants
Qatar General Organization for Standards and Standardization
CONCRETE PLANT INSPECTION CHECK LIST
New Approval
Renewal
Regular Inspection
1.0 GENERAL INFORMATION OF PLANT
1.3
Plant Location
1.4
Plant No/s
1.5
Plant Manufacturer
1.6
Plant ID No.
1.7
Approval Certificate No :
1.8
Contact a Plant
AM / PM
Inspection Date
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Company Name
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1.1
2.0 FACTORY CONDITION
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Yes No
Concrete Floor Under Mixer and silos
2.2
Concrete floor with Slope under materials
2.3
Hard and stable surface for Access and ramps
2.4
Floors Clean
2.5
Cleaning plan implements
Yes No
2.6
Drainage System
Yes No
2.7
Separated Place of Waste materials
2.8
Separated Place of wash tank
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2.1
Yes No
Yes No
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Yes No
Yes No
Yes No
3.0 MATERIAL STORAGE AND HANDLING

3.1
Cement and Cementations materials (including blended cements, fly ash, GGBS, silica fume..)
3.1.1 The Silos of Cement

No
A.
Outside Cleaning for Cement silo
Yes
B.
Cement scale calibration
Current Expired
C.
Reflective color for cement silo
Yes
No
D.
Board clarify the cement type
Yes
No
3.1.2 The silos of cementations materials

A.
Outside Cleaning for Cementations silo
Yes
No
Page 12 of 15
Cementations scale calibration
Current Expired
C.
Reflective Color for Cementations Silo
Yes
No
D.
Board Clarify the Cementations Type
Yes
No
E.
All Cementations Materials Excess of use

protected under shad
Yes
No
3.2
Aggregates:
A.
Aggregate Shading
Yes
No
B.
Aggregate Separation under shad
Yes
No
C.
Aggregate Separation in bins
Yes
No
D.
Aggregate scale calibration
Current Expired
E.
Cover for Conveyer Belts
Yes
No
F.
Board Clarify the Aggregate Type
Yes
No
G.
Effective method for checking the level of

material inside the bins
Yes
No
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Yes
No
Yes
No
Yes
No
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Water supply
Water pipe insulated
B.
Chiller using
C.
Ice plant or Nitrogen cooling
D.
Water gauge calibration
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A.
Current Expired
Admixture supply
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4.0 Water & Admixture Supply

4.1
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B.
Additive storage silos
B.
Additive Gage calibration
C.
Board Clarify the Admixture Type
Yes
No
D.
All admixture excess of use protected under

shad
Yes
No
E.
Agitation system for all storage tanks or silos

more than 5000 liter
Yes
No
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Yes
No
A.
Current Expired
5.0 Requirements of the Concrete batching plant

5.1
Certificate validity
Yes
No
5.2
Computer controlled
Yes
No
5.3
Plant type
Wet mix
5.4
Computer printout
Yes
5.5
Calibration validity
Current
5.6
Cleaning of plant blades
Yes
Dry mix
No
Expired
No
Page 13 of 15
6.0 Laboratory
Records for raw materials and cube tests
Frequency
of Tests
Was Test
Performed?
Yes No
6.1.3 Fines quality
Yes No
6.1.4 Clay lumps and friable

particles
Yes No
6.1.5 Lightweight pieces
Yes No
6.1.6 Organic impurities
Yes No
6.1.7 Water Absorption
Yes No
6.1.8 Particle density
Yes No
6.1.9 Shell Content
Yes No
6.1.10 Flakiness Index (%)
Yes No
6.1.11 Chloride content (%)
Yes No
6.1.12 Sulphate content (%)
Yes No
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6.1.13 Soundness (%)
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6.1.2 Fines content (%)
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6.1.1 Grading
Comments of Inspection
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Required Tests to QCS 2014
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6.1
Yes No
6.1.15 Moisture Content (%)
Yes No
6.1.16 Compressive Strength
Yes No
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6.1.14 Los Angeles abrasion
6.1.17 Other test*
*Such as recycled aggregate
6.2
Specimens testing at inspection time

ITEMS
CASE
6.2.1 Method of slump test
Yes
No
6.2.2 Curing of samples
Yes
No
6.2.3 Water Temperature Of Curing Tank Yes
No
6.2.4 Concrete Temperature at plant
Yes
No
6.2.5 Concrete Slump at plant
Yes
No
COMMENTS
Page 14 of 15
6.3
Laboratory equipment calibration

EQUIPMENT
CASE
COMMENTS
6.3.1 Compression Testing Machine
Yes
No
6.3.2 Sieves
Yes
No
6.3.3 Balance
Yes
No
6.3.4 Thermometers
Yes
No
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8.0 Plant representative information
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Name of representative
Contract number
:
:
Signature
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9.0 Inspector team
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Signature
Inspected by
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7.0 Recommendations
Page 15 of 15
QCS 2014

Part
08: Transportation and Placing of Concrete
Page 1
TRANSPORTATION AND PLACING OF CONCRETE ............................................ 2
8.1
8.1.1
8.1.2
8.1.3
GENERAL ............................................................................................................... 2
Scope of Work
2
References
2
Submittals
2
8.2
8.2.1
8.2.2
8.2.3
TRANSPORTATION ............................................................................................... 3
General
3
Pumped Concrete
3
Records
4
8.3
8.3.1
8.3.2
8.3.3
8.3.4
8.3.5

General
4
Preparation
4
Placing
5
Compaction
7
Continuity of Concrete Work
8
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QCS 2014

Part
TRANSPORTATION AND PLACING OF CONCRETE
8.1
GENERAL
8.1.1
Scope of Work
This part deals with the transportation, placing and compaction of concrete.
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8.1.2
This Section
Part 1 ............... General
Part 9, .............. Formwork
Page 2
References
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ACI 304, ............. Guide for Measuring, Mixing, Transporting, and Placing Concrete
ASTM C94, ......... Specification for ready-mixed concrete
BS 8500,............. Concrete, Complementary British Standard to BS EN 206-1.
BS EN 206-1, ..... Concrete. Specification, performance, production and conformity
EN 1992-1-1 ....... Eurocode 2: Design of concrete structures. General rules and rules for
buildings
Submittals
Should the Contractor propose to use concrete pumps for the transportation and placing of
concrete, he shall submit details of the equipment and operating techniques he proposes to
use for the approval of the Engineer.
A method statement shall be submitted for approval for major concrete placements, which
shall address
(b)
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8.1.3
(c)
number of trucks
(d)
number and positioning of pumps
(e)
pour sequence
(f)
quality control measures
(g)
spare equipment
(h)
any other factors that might affect the placing of concrete.
the planned rate of placing

number of batching plants
(a)
The method statement should be submitted at least three days in advance of the planned
pour. If required by the Engineer or any other concerned party a prepour planning meeting
may be arranged with representatives from the ready-mix supplier, Contractor and Engineer.
The Contractor shall submit to the Engineer for approval details of his proposed operations
and standby equipment.
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Part
Page 3
TRANSPORTATION
8.2.1
General
Transportation delivery and handling shall be in accordance with the requirements of BS

8500 and BS EN 206-1.
Concrete shall be conveyed from the mixer to its place in the Works as rapidly as possible by
methods which will prevent segregation or drying out and ensure that the concrete is of the
required workability at the point and time of placing.
Should segregation occur in the concrete then the materials shall be remixed to the
satisfaction of the Engineer or discarded. Furthermore the cause of the segregation shall be
determined and further occurrences prevented.
The Contractor shall ensure that the time between placing of different lifts or layers of
concrete is short enough to prevent the formation of cold joints. The Contractor shall ensure
that there is a back up plant that can be used in the event of a breakdown, and that adequate
provision has been made for the number of delivery trucks.
The concrete shall be transported to the site in an approved type of truck mixer or agitator
truck which apart from the cab and chassis shall be painted white and kept clean at all times.
The discharge chute and other dirty areas shall be washed down after delivery to prevent
spillage on the roads.
If a truck mixer or a truck body with an agitator is used for central-mixed concrete, limit the
volume of concrete charged into the truck to 80% of the drum or truck volume as per ASTM
C94 and NRMCA requirements. if shrink mixing is approved by the engineer limit the volume
of concrete charged into the truck to 63% of the drum volume.
All trucks shall be rotated 30 revolutions at mixing speed before discharging concrete to
assure uniformity.
The insides of concrete mix trucks shall be inspected periodically, and any build up of
concrete removed that may impair the efficiency of the mixing action. All trucks shall be
NRMCA certified or any equivalent certification
Discharge of the concrete shall be completed within 90 min, or before the drum has revolved
300 revolutions, whichever comes first, after the introduction of the mixing water to the
cement and aggregates or the introduction of the cement to the aggregates. These limitations
are permitted to be waived by the purchaser if the concrete is of such slump or slump flow
after the 90 min time or 300-revolution limit has been reached that it can be placed, without
the addition of water, to the batch. In hot weather, or under conditions contributing to quick
stiffening of the concrete, a time less than 90 min is permitted to be specified by the Engineer
8.2.2
Pumped Concrete
Access for the pump shall be checked prior to the pour. If access cannot be assured, the
Contractor shall not continue with concreting operations.
If approval is obtained for pumped concrete, the Contractor shall ensure that shock is not
transferred from the pipeline to the formwork and previously laid concrete.
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8.2
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Part
Page 4
During placing concrete by pumping the end hose must never reach into the concrete. All
measures shall be taken to avoid blockage of the delivery hose system. The Compaction of
concrete shall be carried out as per standard practice procedures.
Grout shall be pumped through the concrete pump to provide initial lubrication. The initial
discharge of any pumped concrete shall not be incorporated in the permanent works.
Where concrete is conveyed by chuting or pumping the plant shall be of a size and design to
ensure continuous flow in the chute or pipe. The slope of the chute or the pressure of the
pump shall allow the concrete to flow without the use of any water additional to that approved
by the Engineer to produce the required consistency and without segregation of the
ingredients. The delivery end of the chute or pipe shall be thoroughly flushed with water
before and after each working period and kept clean. The water used for this purpose shall
be discharged outside and away from any permanent works.
8.2.3
Records
Within 24 h of delivery, the Contractor shall provide the Engineer with delivery notes giving
the information required under Paragraph 7.4.1.5 of this Section.
8.3
PLACING CONCRETE
8.3.1
General
The Contractor shall obtain the approval of the Engineer to his proposed arrangements
before beginning concreting.
All placing and compacting of concrete shall be carried out under the direct supervision of a
competent member of the Contractors staff with a minimum of five years of experience in
concreting works, and in a manner to produce a watertight concrete of maximum density and
strength.
For night concreting operations, the Contractor shall arrange adequate suitable lighting.
The Contractor shall provide safe secure access for all personnel on concreting operations.
Where the thickness of the concrete section exceeds 600 mm the Contractor shall adopt
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special precautions, to be approved by the Engineer, to avoid thermal cracking due to

external and core temperature differentials.
6
Concrete shall not be placed in adverse weather conditions such as dust storms or heavy
rain.
8.3.2
Preparation
No concrete shall be placed until the Engineer has inspected and approved in writing the
surfaces upon which the concrete is to be placed, the formwork, and reinforcing steel. The
Contractor shall give the Engineer at least 24 hours notice to enable this inspection to be
carried out. If concrete is not placed within 24 hours of approval being given, approval shall
be obtained again before concreting. An inspection shall be made immediately prior to
concreting to check the cleanliness of the forms.
QCS 2014

Part
Page 5
Wood forms, unless lined, shall be oiled or wetted with water in advance of placing concrete
so that joints will tighten and prevent seepage of cement grout from the mix.
The reinforcement shall be sprayed with a small amount of water prior to starting the pour.
Reinforcement shall be secured in position, inspected, and accepted by the Engineer before
placing the concrete.
All inserts, anchor bolts, sleeves and other embedded items shall be accurately located,
using templates where appropriate, and held securely to prevent displacement during the
placing of the concrete. Aluminium items shall be completely covered and protected when
embedded in the concrete.
Except where shown on the drawings, no fixtures shall be attached to the concrete by shot
fixing or drilling without acceptance by the Engineer. Notwithstanding any such authorisation,
the Contractor shall be responsible for all damage so caused to the concrete and make good
at his own expense.
Water shall be removed from excavations before concrete is deposited. Any flow of water
shall be diverted through proper side drains and shall be removed without washing over
freshly deposited concrete. All dewatering works shall be continued as long as required.
Hardened concrete, debris, and foreign materials shall be removed from interior of forms and
from inner surfaces of mixing and conveying equipment.
Runways or other means accepted by the Engineer shall be provided for wheeled equipment
to convey the concrete to the points of deposit. Equipment used to deposit concrete shall not
be wheeled over reinforcement nor shall runways be supported on reinforcement.
Before depositing new concrete on or against concrete that has set, existing surfaces shall
be thoroughly roughened and cleaned of laitance, foreign matter and loose particles. Forms
shall be re-tightened and existing surfaces slushed with a grout coat of mortar consisting of
cement and fine aggregate in the same proportion in the mix, but not leaner than one (1) part
cement to two (2) parts fine aggregate, after the existing surface has been moistened. New
concrete shall be placed before the grout has attained initial set. Horizontal construction
joints shall be given a brush coat of grout consisting of cement and fine aggregate in the
same proportion as concrete to be placed, followed by approximately 75mm of concrete of
regular mix, except that the proportion of coarse aggregate shall be reduced 50%.
High strength grout for precision support of machine base and soleplates, including
equipment subject to thermal movement, tanks, column baseplates, bridge seats, anchor
bolts and dowels, etc., shall be a non-shrink, ready-to-use, fluid precision grout material,
proportioned, premixed and packaged at the factory, delivered to the job site to be placed
with only the addition of water, formwork, and curing shall be as specified.
8.3.3
Placing
Concrete shall be placed in its final position before initial set has commenced and shall not
be subsequently disturbed. All concrete shall be placed within 15 min of mixing unless carried
in purpose made agitators.
Concrete shall be carefully placed in horizontal layers which shall be kept at an even height
throughout the work. The depth of layers and time between placement of layers shall be such
that each layer can be properly merged into the preceding layer before initial set takes place,
the depth of layer shall be determined from the type of plant the Contractor proposes to use.
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Page 6
Concrete shall be allowed to slide or flow down sloping surfaces directly into its final position
from skips, down pipes or other placing machines or devices or, if this is not practical, it
should be shovelled into position, care being taken to avoid separation of the constituent
materials.
Concrete placed in horizontal slabs from barrows or other tipping vehicles shall be tipped into
the face of the previously placed concrete.
Concrete dropped into place shall be dropped vertically. It shall not strike the formwork
between the point of its discharge and its final place in the Work, and except by approval of
the Engineer it shall not be dropped freely through a height greater than 1.5 m. Chutes and
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conveyor belts shall be also designed so that there is no segregation or loss of mortar and
shall be provided with a vertical tapered down pipe, or other device, to ensure that concrete is
discharged vertically into place.
Concrete shall not be placed in standing water in the formwork.
Concrete that has attained its initial set or has contained its water content for more than 1.5
hours or 300 drum revolutions, whichever comes first, shall not be deposited in the work.
Cold weather concreting shall be in accordance with EN 1992-1-1 or CIRIA Report 67 and
ACI 306.
Hot weather concreting shall be in accordance with Part 15 of this section.
10
Special care shall be taken to protect new concrete from the harmful effects of drying winds.
11
During wet weather, the concrete shall be adequately protected as soon as it is in position.
12
No concreting shall be carried out during periods of continuous heavy rain unless it is
completely covered during mixing, transporting and placing.
13
No concrete shall be carried out during dust storms.
14
Underwater placing of concrete is allowed only for unreinforced components, the placing
being effected exclusively with stationary tremies or with a bottom-opening watertight boxes
and shall be in accordance with the requirements of design or equivalent as accepted.
15
Underwater concrete is to be placed continuously without interruption. For water depths up to

1 m the concrete may be placed without tremie. In the case of water depths exceeding 1 m
the concrete is to be placed in such a way that it does not fall freely through the water. The
tremies must at all times dip sufficiently far into the freshly placed concrete to ensure that the
concrete emerging from the tremie does not come into contact with the water.
16
All work connected with the placing of concrete under water shall be designed, directed and
inspected with due regard to local circumstances and purposes. Work shall not proceed until
all phases and methods to be used in the placing operations have been accepted by the
Engineer.
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QCS 2014

Part
Page 7
Stops in concrete, at the end of a period of work, shall be made only at construction joint
locations shown on the drawings and/or positions accepted. Where the positions of
construction joints are not indicated on the drawings, these may be assumed, for estimating
purposes, to occur at 5 metre intervals in foundations and retaining walls and at one-third to
one-quarter of span in slabs and beams subject to a maximum spacing of approximately 9
metres.
18
At construction joint location the surface of the completed concrete shall be prepared by
spraying, wire brushing or chipping so that it is free from all laitance, scum and loose material
and shows a slightly roughened texture and tips of the coarse aggregate exposed. Before
continuing concreting the exposed concrete face shall be thoroughly wetted.
19
In the ground floor slab (where ground bearing), construction joints, crack inducer joints,
contraction joints and expansion joints shall be incorporated into the work as appropriate.
joints in water retaining structures shall be shown on the design drawings
20
slab, the slab shall be cast in strips not more than 4.0 metres wide, in alternating sequence,
across the width of the building. A minimum of 3 days shall elapse between the casting of
adjacent strips. Within each strip, crack induced joints shall be provided at not more than 5.0
metre spacing, and contraction joints shall be provided at not more than 15.0m spacing.
Across the width of the building, construction joint shall be provided between adjacent strips
th
with contraction joint at every 4 construction joint.
21
Wherever necessary and as required by the Engineer, waterstops of a type acceptable to the
Engineer shall be embedded in the concrete. The waterstop should be made of a high
quality material, which must retain its resilience through the service life of the structure for the
double function of movement and sealing. The surface of waterstops should be carefully
rounded to ensure tightness of the joint even under heavy water pressure. To ensure a good
tightness with or without movement of the joints, the waterstop should be provided with
anchor parts. The cross-section of the waterstops should be determined in accordance with
the presumed maximum water pressure and joint movements. The complete works of fixed
and welded connections must be carried out strictly in accordance with the manufacturers
instructions.
22
23
Waterstops shall be carefully maintained in position prior to concreting on accurately profiled

stop boards to create rigid conditions.
24
The type of waterbar to be used shall suit the joint and purpose according to water bar
manufacturers recommendations
8.3.4
Compaction
Concrete shall be thoroughly compacted by vibration during the operation of placing and
thoroughly worked around the reinforcement, around embedded fixtures and into corners or
the formwork to form a solid mass free from voids.
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17
QCS 2014

Part
Page 8
When vibrators are used to compact the concrete, vibration shall be applied continuously
during the placing of each batch of concrete until the expulsion of air has practically ceased
and in a manner that does not promote segregation of the constituents of the concrete.
Immersion type vibrators shall be capable of producing not less than 10000 cycles per
minute, and external vibrators not less than 3000 cycles per minute.
A sufficient number of vibrators in serviceable condition shall be on site to ensure that spare
equipment is always available in the event of breakdown.
Immersion type vibrators shall be inserted into the uncompacted concrete vertically and at
regular intervals. Where the uncompacted concrete is in a layer above freshly compacted
concrete the vibrator shall penetrate vertically for about 100 mm into the previous layer.
Vibrators shall not come into contact with the reinforcement or the formwork. They shall be
drawn back slowly from the mass concrete so as to leave no voids. Internal type vibrators
shall not be placed in the concrete in a random or haphazard manner nor shall concrete be
moved from one part of the work to another by means of the vibrators.
Operators shall be trained in the use of vibrators. Foremen shall have a minimum of five
years of experience in the supervision of placing concrete
Vibration of the concrete shall not be applied by way of the reinforcement.
Compaction shall commence as soon as there is sufficient concrete to immerse the vibrator
and continue during the placing operations so that at no time shall there be a large volume of
uncompacted concrete in the formwork.
The duration of vibration shall be limited to that required to produce satisfactory compaction
without causing segregation. Vibration shall on no account be continued after water or
excess grout has appeared on the surface.
10
During the placing of all reinforced concrete, a competent steel fixer and a competent
carpenter shall be in attendance on each concreting gang. They shall ensure the
reinforcement embedded fittings and forms are kept in position as work proceeds.
8.3.5
Continuity of Concrete Work
Whenever instructed by the Engineer, the Contractor shall carry out the work in such a
manner that the placing of the concrete in any particular section of the structure shall be
executed without any interruption whatsoever from the beginning to the end of the operation.
Casting of concrete shall not begin until a sufficient quantity of approved material is at hand
to ensure continuity of operation, nor shall work begin until there is sufficient equipment in
reserve in case of breakdown.
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END OF PART
QCS 2014
Page 1
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FORMWORK ........................................................................................................... 2
GENERAL ............................................................................................................... 2
Scope
2
References
2
Submittals
2
Quality Assurance
3
FORMWORK MATERIALS ...................................................................................... 5
General
5
CLASS OF FINISH AND MATERIALS: .................................................................... 5
Unformed surfaces
5
Surface Finish Classifications
7
Formwork Materials
7
Exposed Concrete Surface Finishes
7
Form Ties
8
Coating and Accessories
8
FORMWORK EXECUTION ..................................................................................... 9
General
9
Trial Panels
9
Formwork Face in Contact with Concrete
9
Sloping Surfaces
10
Temporary Openings
10
Form Windows
10
Co-ordination
10
Conduits
10
Ties and Bolts
11
Chamfers
11
Cambers
11
Exterior Angles
11
Surface Retarders
11
Detection of Movement During Concrete Placement
11
Building in Pipes
12
Working Platform
12
Safe Access
12
Kickers
12
Cover Spacers
12
Water Bars
12
REMOVAL OF FORMWORK................................................................................. 13
General
13
Stripping of Formwork
13
Holes to be Filled
14
Repair to Damaged Concrete Surfaces
14
DELIVERY AND STORAGE .................................................................................. 14
Delivery
14
Storage
14
TOLERANCES ...................................................................................................... 15
EARLY LOADING .................................................................................................. 15
9
9.1
9.1.1
9.1.2
9.1.3
9.1.4
9.2
9.2.1
9.3
9.3.1
9.3.2
9.3.3
9.3.4
9.3.5
9.3.6
9.4
9.4.1
9.4.2
9.4.3
9.4.4
9.4.5
9.4.6
9.4.7
9.4.8
9.4.9
9.4.10
9.4.11
9.4.12
9.4.13
9.4.14
9.4.15
9.4.16
9.4.17
9.4.18
9.4.19
9.4.20
9.5
9.5.1
9.5.2
9.5.3
9.5.4
9.6
9.6.1
9.6.2
9.7
9.8

Part
09: Formwork
QCS 2014

Part
09: Formwork
Page 2
FORMWORK
9.1
GENERAL
9.1.1
Scope
This Part includes permanent forms, temporary formwork, and falsework for structural and
architectural cast-in-place concrete including form liners, coatings, and accessories.
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management/administration
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prevention
system
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Section 11: Health and Safety

Part 1, ............. Regulatory document
Part 2, ............. Safety and accident
(SAMAS)
This Section
Part 10, ............ Curing
Part 17, ............ Structural Precast Concrete.
References
The following standards and other document are referred to in this Part:
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ACI Committee 117 ....Standard Tolerances for Concrete Construction and Materials (ACI
117-90), American Concrete Institute, Detroit, 22 pp.
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ACI Manual of Concrete Practice, Parts 2 and 5.

BS 8500......................Concrete
BS 5975......................Code of practice for false work
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BS EN 12812..............Falsework. Performance requirements and general design CP3

chapter V-2: 1972
EN 1992-1-1 ...............Eurocode 2: Design of concrete structures. General rules and rules for
buildings
GSO EN 206-1 ...........Concrete. Specification, performance, production and conformity
Concrete Society Technical Report No. 13
9.1.3
Submittals
Shop drawings shall include plans and sections, giving the following minimum information for
each level:
(a)
details of individual panels
(b)
position, size and spacing of adjustable steel shores
(c)
position, size and spacing of joists, soldiers, ties
(d)
details of formwork for columns, beams, parapets, slab and kickers
QCS 2014
Page 3
details of construction joints and movement joints
(f)
details of retaining walls and deep beams showing the position and size of ties, joints,
soldiers and sheeting, together with detailed information on erection and casting
sequences and construction joints
(g)
general assembly details
(h)
full calculation sheets
(i)
proposals at all penetrations through the concrete
(j)
proposed sequence of shoring and reshoring beams and slabs for different spans and
floor heights and number of floors shored, and the stripping time for supported and
suspended structural elements, clearly identifying the supported element and
suspended element.
(e)
details: 1:1, 1:5, 1:10, 1:20
(b)
construction: 1:50, 1:100
(c)
layout and Site Plan: 1:100 or 1:200
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(a)
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Scales of shop drawings shall be as follows:
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Part
09: Formwork
The Contractor shall submit samples of all proposed formwork materials and samples of ties
proposed for use in general situations above the water table and for fair faced concrete.
The Contractor shall allow 14 days for Engineers review of submittals or samples.
Supply and delivery of built-in pipework should be clearly shown on the detailed construction
program to be submitted by the Contractor.
Method Statements for erection and removal of formwork shall be submitted by the
Contractor before the start of the works for the Engineers review and approval. The Method
Statement shall include the Risk Assessments related to the activity.
When the formwork is to be carried out by a sub-contractor, then the pre-qualification

documents shall be submitted for the Engineers review and approval.
9.1.4
Quality Assurance
Formwork shall comply with the requirements of BS 5975 and EN 1992-1-1
The erection of formwork and associated falsework shall be executed and supervised by fully
qualified personnel having a minimum of five years experience.
The Contractor shall obtain approval to load any particular section of the works from the
Engineer.
Formwork design shall be carried out in accordance with the Concrete Society Technical
Report No. 13.
The erected formwork shall be watertight from the ingress of external liquids and the egress
of internal liquids. Adjustable steel supports and shores shall allow formboards and
framework to be accurately adjusted to line and level. The Contractor shall ensure that
adequate ground support for falsework is available, and if not shall take measures to make
them suitable.
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Part
09: Formwork
Page 4
Formwork shall be designed to be sufficiently rigid to maintain the correct position, shape and
profile so that the final concrete structure is within the dimensional tolerances specified
Subpart 9.7 of this Part.
Formwork shall be designed to be demountable without causing shock, disturbance or

damage to the concrete.
Soffit formwork, properly supported on shores only, shall be capable of being retained in
position during the concrete maturing period.
The design shall allow free movement and accessibility under the formwork.
10
Shores for abnormal ceiling heights shall be specially designed.
11
The forms shall be designed to incorporate 20 mm chamfers on exposed corners of

columns, walls and beams.
12
The design of formwork shall take into account the following:
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height and rate of pour
(b)
thickness of the member
(c)
concrete slump and density
(d)
placing temperature
(e)
texture of finish
(f)
construction joints
(g)
wind load
(h)
on soffit forms (in addition to concrete weight)
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(ii)
if a motorised cart is used, an additional live load of 3.75 kPa
minimum design load for combined dead and live load
(i)
(ii)
(j)
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an additional live load of 2.5 kPa, or
(i)
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(a)
6.50 kPa
if a motorised cart is used, 7.75 kPa
the worst combination of:

(i)
self-weight
(ii)
formwork forces
(iii)
reinforcement weight
(iv)
wet concrete weight
(v)
construction loads
(vi)
wind loads,
(vii)
incidental dynamic effects caused by placing, vibrating and compacting

concrete
(viii)
the use of externally applied vibrators
QCS 2014
13

Part
09: Formwork
Page 5
(k)
method of concrete discharge
(l)
access for concrete placement and vibration.
Before beginning related formwork operations the Contractor shall erect a job mock-up, to a
reasonable size including all items such as sheeting, stiffeners, soldiers, ties etc. (and
including release agents, where used) for the following types of formwork, and shall obtain
the approval the Engineer before proceeding:
(a)
columns
(b)
slabs and beams
(c)
staircases
(d)
fair-faced concrete (show method used to conceal tie holes) cove ties not required.
Upon prior consultation, agreement of location and approval, the job mock-ups may remain
as part of the finished work.
9.2
FORMWORK MATERIALS
9.2.1
General
Forms shall be of wood; metal or other material acceptable to the Engineer.
The design of formwork shall be the responsibility of the Contractor.
Formwork shall conform to the requirements of EN 1992-1-1
Form oil and form sealer shall be of quality as acceptable to the Engineer.
9.3
CLASS OF FINISH AND MATERIALS:
9.3.1
Unformed surfaces
Unformed surfaces shall be classified as either:

U4, timber trowel finish
(a)
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14
(b)
U3, steel trowel finish
(c)
U2, brush finished
(d)
U1 other finish designated by the Engineer, such as:

(i)
Screeded Finish - Where the floor slab is to receive a screeded finish, the slab
shall be laid to the slopes and levels shown on the drawings and the top surface
shall be tamped whilst unset, to produce a suitable keyed surface for the receipt
of the appropriate finishing materials.
(ii)
Floated Finish - Where a floated finish is required to the floor slabs the top
surface shall be leveled and floated whilst unset to an uniform finish to the
slopes and levels shown on the drawings. The floating shall be done in such a
manner as not to bring an excess of mortar to the surface.

Part
09: Formwork
Page 6
Dustproof Finish - Where concrete surfaces are required to provide a dustproof

finish these shall be treated with two coats of accepted material. Each coat
shall be applied with a soft brush on a clean and dry surface in accordance with
the manufacturer's printed instructions.
(iv)
Non-slip Finish - Concrete surfaces described on the drawings as having a nonslip finish shall be treated with carborundum dust, evenly sprinkled on whilst the
concrete is still green, at a rate of 1 kg/m and lightly trowelled in before final
finishing. Alternatively, the carborundum dust may be incorporated into the finish
by means of a mechanical power float.
(v)
Hardened Finish - Where a hardened finish is required to the floor slabs these
shall be treated with three coats of accepted material. Each coat shall be
applied with a soft brush on a clean and dry surface in accordance with the
manufacturer's printed instructions.
(vi)
Finishing Unformed Surfaces - Finishing unformed surfaces shall be tamped,

floated, trowelled or brushed as defined below and shown on the drawings.
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(iii)
1.
Type T - Tamped surfaces shall be formed by levelling and tamping the

concrete to produce a uniform plain or ridged surface, surplus concrete
being struck off by a straight edge immediately after compaction. It is
also the first stage of the following finish.
2.
Type F - Floated surfaces shall be uniform surface which has been

worked no more than is necessary to remove screed marks by hand with
a wood float or by power float of a type acceptable to the Engineer. The
surface shall not be floated until the concrete has hardened sufficiently.
3.
Type ST - Steel trowelled shall be a hard, smooth finish, free from trowel
marks and formed with a steel trowel under firm pressure. Trowelling shall
not commence until the moisture film has disappeared and the concrete
has hardened sufficiently to prevent excess laitance from being worked to
the surface. If laitance is brought to the surface it shall be removed.
Type BR - Brushed shall be formed before the concrete has hardened by
drawing a wire broom over the concrete surface at right angles to the
traffic flow to give an average texture depth of 1mm.
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QCS 2014
5.
For ground slab concrete shall be treated with sodium silicate or a similar
dust preventive coating. This must be applied in accordance with the
The type of finish will be specified on the drawings or as directed by the Engineer. Before
beginning any concrete pour with unformed surfaces, the Contractor shall obtain confirmation
of the type of finish required from the Engineer.
Initial finishing of unformed surfaces shall commence immediately after the placing and
compaction have taken place.
Suitable access boards or platforms shall be provided to allow access to all parts of
unformed surfaces to be finished.
Where a protective treatment or topping layer is to be applied to the concrete the

manufacturers and suppliers recommendations shall be followed concerning the required
finish.
QCS 2014

Part
09: Formwork
Page 7
Brush to finish shall be obtained by carrying out a steel trial finish and then using a suitable
stiff nylon brush dragged lightly across the surface.
The addition of small quantities of water to the finishing trowel will be permitted to aid
finishing.
9.3.2
Surface Finish Classifications
Finishes to formed surfaces of concrete shall be classified as F1, F2 and F3, or such other
special finish as may be designated.
Where the class of finish is not designated:

all internal concrete shall be finished to Class F3
(b)
external concrete below ground shall be finished to Class F1
(c)
where surfaces are to be tanked by covering with paint or sheeting, the formwork
shall be capable of achieving a finish suitable for the proposed tanking as directed by
the Engineer.
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(a)
Formwork Materials
Formwork for Class F3 finish shall be lined with as large panels as possible of non-staining
material with a smooth unblemished surface such as sanded plywood or hard compressed
fibre board, arranged in a uniform approved pattern and fixed to back formwork by oval nails.
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9.3.3
the same type of lining shall be used throughout any one structure
(b)
unfaced wrought boarding or standard steel panels shall not be permitted.
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(a)
Formwork for Class F2 finish shall be faced with wrought tongued and grooved boards or
plywood arranged in a uniform approved pattern free from defects likely to detract from the
appearance of the surface.
Formwork for Class F1 finish shall be constructed of timber, or of any suitable materials
which will prevent loss of grout when the concrete is vibrated.
9.3.4
Exposed Concrete Surface Finishes
Exposed concrete surfaces shall have a Class F3 finish.
Care shall be taken to ensure that the finish to the exposed concrete on the external and
internal surfaces are of the highest quality to produce a smooth concrete surface of uniform
texture and appearance without visible imprint of grains, steppings or ridges.
The resulting concreting shall be free from honeycombing, stains, fins, lipping, nail and screw
marks, raised grain marks or any other imperfections and shall be of a uniform surface
texture and colour. Only very minor surface blemishes caused by entrapped air or water will
be accepted provided that they do not exceed 0.5% by area of each square metre considered
separately and in addition they shall not be concentrated in a manner such that they are
noticeable.
Formwork to the wetted surfaces of water retaining structures shall be Class F3
All exposed concrete corners and edges shall have 20 mm by 20 mm chamfers.
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QCS 2014

Part
09: Formwork
Page 8
Grooves in exposed concrete shall be formed by attaching tapered planed timber battens
accurately aligned to the face of formwork.
9.3.5
Form Ties
Form ties shall conform to the following requirements:

factory-fabricated
(b)
adjustable in length
(c)
use removable or snap-off metal form ties
(d)
designed to prevent formwork deflection and to prevent spalling concrete surfaces on

removal
(e)
no metal shall be left closer than the applicable level of cover to the surface of the
concrete
(f)
holes larger than 10 mm diameter in the concrete surface, when using snap ties shall
not be permitted
(g)
form ties shall have a factor of safety not less than 1.5.
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(a)
Coating and Accessories
Form coatings shall be commercial formulation form-coating compounds that will not bond
with, stain, nor adversely affect concrete surfaces requiring bond or adhesion, nor impede the
wetting of surfaces to be cured, shall be used. The use of form coatings shall be strictly in
accordance with the manufacturer instructions.
Formwork in contact with the concrete shall be treated with a suitable non-staining mould oil
to prevent adherence of the concrete.
Forms for exposed surfaces shall be coated with oil before reinforcement is placed. Forms
for unexposed surfaces may be thoroughly wetted with water in lieu of oiling, immediately
before placing of concrete except during freezing weather.
Excessive oiling of the forms shall not be permitted in order to prevent discoloration of the
cement plaster. Where concrete surface is to be painted, the form-oil must not affect the
bond between concrete and paint.
Care shall be taken to prevent the oil from coming in contact with reinforcement or with
concrete at construction joints. Any oil on reinforcing steel shall be removed.
Release agents shall not be used where concrete surfaces receive special finishes or applied
coatings which may be affected by the agent, unless approved by the Engineer.
Fillet and chamfer strips shall be PVC or timber to the approval of the Engineer.
Tapes to be used to seal joints of formwork panels for smooth finish concrete shall be plastic
faced adhesive tape to the approval of the Engineer.
Precast concrete moulds shall be rigid steel, wood or fibreglass moulds.
10
Flashing reglets shall be galvanised steel of the longest possible length.
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9.3.6
QCS 2014

Part
09: Formwork
Page 9
FORMWORK EXECUTION
9.4.1
General
Where formwork to external faces will be permanently exposed, all horizontal and vertical
formwork joints shall be so arranged that joint lines will form a uniform pattern on the face of
the concrete.
Where the Contractor proposes to make up the formwork from standard sized manufactured
formwork panels, the size of such panels shall be approved by the Engineer before they are
used in the construction of the Works.
The finished appearance of the entire elevation of the structure and adjoining structures shall
be considered when planning the pattern of joint lines caused by the formwork and by the
construction joints to ensure continuity of horizontal and vertical lines.
Masonry nails or similar items shall not be used to fix formwork of the like to permanent
concrete works.
9.4.2
Trial Panels
The trial panels shall comprise surfaces that have unformed surfaces and formed surfaces
F1, F2 and F3.
The concrete cast from the job mock-up shall be used to assess the acceptability of the
Contractors workmanship for finishing.
If the finishing is deemed unacceptable by the Engineer, the Contractor shall prepare a
further mock-up with a particular class of finish.
The job mock-ups shall be retained during the course of the works to allow comparative
inspection, with production concreting and finishing and for the purpose of colour comparison
to ensure colour consistency.
9.4.3
Formwork Face in Contact with Concrete
Faces of formwork in contact with concrete shall be free from adhering foreign matter,
projecting nails and the like, splits or other defects, and all formwork shall be clean and free
from standing water, dirt, shavings, chippings or other deleterious matter.
Joints between forms and tie holes shall be watertight to prevent the escape of mortar or the
formation of fins or other blemishes on the face of the concrete.
The Contractor shall verify lines, levels and measurement before proceeding with formwork
erection.
The formwork surface shall be made clean and free from any foreign and deleterious matter,
prior to start the concrete pour.
In hot weather, the surface of the formwork shall be sprayed with water in order to lower the
temperature, prior to start the pour.
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9.4
QCS 2014

Part
09: Formwork
Page 10
Sloping Surfaces
Formwork shall be provided for the top surfaces of sloping work where the slope exceeds
15 from the horizontal (except where any such top surface is specified as a spaded finish).
The formwork shall be anchored to enable the concrete to be properly compacted and to
prevent flotation.
Care shall be taken to prevent air being trapped under the sloping formwork.
9.4.5
Temporary Openings
The Contractor shall provide temporary openings for inspection of the inside of the formwork
and for the removal of water used for washing down. The openings shall be formed as to be
easily closed before placing concrete.
Temporary opening shall be avoided in the case of fair faced concrete.
9.4.6
Form Windows
The Contractor shall provide windows in forms wherever directed by the Engineer or
necessary for access for concrete placement and vibration.
The windows shall be of a size adequate for tremies and vibrators spaced at maximum 1.8 m
centres horizontally.
Any windows shall be tightly closed and sealed before proceeding to place concrete at a
higher level.
9.4.7
Co-ordination
The Contractor shall ensure that the work of other trades in forming and setting openings,
slots recesses, chases, sleeves, bolts, anchors and other inserts is fully co-ordinated.
9.4.8
Conduits
Conduits or pipes shall be located so as not to reduce the strength of the construction.
In no case shall pipes other than conduits be placed in a slab 125 mm or less in thickness.
Conduits embedded in a concrete slab shall not have an outside diameter greater than
one-third the thickness of the slab nor be placed below the bottom reinforcing steel or over
the top reinforcing steel.
Conduits may be embedded in walls provided they are not larger in outside diameter than
one-third the thickness of the wall, are not spaced closer than three diameters on centre, and
do not impair the strength of the structure.
Embedded pipes and conduits shall be supported independently from reinforcing steel in a
manner to prevent metallic contact and thereby prevent electrolytic deterioration.
Pipes and conduits where embedded shall be placed as nearly as possible to the centre line
of the concrete section.
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9.4.4
QCS 2014

Part
09: Formwork
Page 11
Conduits, piping, and other wall penetrations or reinforcements shall be subject to the
Engineers review and approval.
Conduits shall be fixed properly to avoid any displacement during concreting and prevent
coming in contact with the forms.
9.4.9
Ties and Bolts
The position of ties passing through concrete shall be subject to the approval of the Engineer.
Ties, bolts or other devices shall not be built into the concrete for the purpose of supporting
formwork without the prior approval of the Engineer. The whole or part of any such supports
shall be capable of removal so that no part remaining embedded in the concrete shall be
nearer to the surface than the cover required for reinforcement.
9.4.10
Chamfers
Chamfer moulding strips shall be positioned on the exposed corners of columns and beams.
9.4.11
Cambers
If required, cambers shall be as shown on the Drawings.
The depth of beams at all points in the span, where cambers are used, shall be as shown on
the Drawings.
Allowance shall be made for compression and settlement of the formwork on line and level.
9.4.12
Exterior Angles
All exterior angles to concrete exposed to view in the completed structure shall be cast to the
true angles evenly throughout the length.
Care shall be taken to ensure that no waviness occurs along the angle and that no spalling
occurs to the concrete on removal of the formwork.
9.4.13
Surface Retarders
Surface retarders shall not be used on any formwork surface in contact with concrete unless
expressly authorised by the Engineer.
9.4.14
Detection of Movement During Concrete Placement
Devices of telltale type shall be installed on supported forms and elsewhere as required to
detect formwork movements and deflection during concrete placement.
Where required slab and beam cambers shall be checked and correctly maintained as
concrete loads are applied on forms.
Workmen shall be assigned to check forms during concrete placement and to promptly seal
all mortar leaks.
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QCS 2014

Part
09: Formwork
Page 12
The forms shall be checked during concreting in order to identify any displacement and
provide corrective actions immediately.
9.4.15
Building in Pipes
Pipes and pipe specials through concrete walls and floors shall as far as possible be
positioned and built in during construction. They shall be located exactly in the positions
shown on the Drawings and shall be true to line and level.
The Contractor shall take particular care to ensure that fully compacted concrete is in contact
with the pipe at all points.
Where it is not practicable to cast pipes and specials in the concrete, boxholes shall be
formed in the shuttering.
The box shall have six or eight sides, depending on the pipe diameter, and shall be no larger
in size than will give adequate clearance for the subsequent positioning and grouting in of the
pipe. The sides of the boxhole shall be provided with a tapered central annular recess to
provide a positive key. The boxhole shall be provided with a grout hole and, at the top of the
central annular recess, a vent hole. The boxhole shall be stripped with the main shuttering
and the concrete surface thoroughly cleaned and roughened.
When the pipe is later fixed, the remaining hole shall be reshuttered and filled with non-shrink
epoxy grout or non-shrink concrete. In the case of water retaining structures, the Contractor
shall ensure that the measures adopted shall provide a finished joint which is resistant
against and free from leakage.
9.4.16
Working Platform
Safe working platform shall be provided according to Section 11 (Health and Safety).
9.4.17
Safe Access
Safe access shall be provided for the workers, inspectors, and other users according to
Section 11 (Health and Safety).
9.4.18
Kickers
Kickers shall be provided for walls and columns
The kickers shall be water tight in order to prevent any grout loss.
9.4.19
Cover Spacers
Cover spacers shall be used in order to maintain the required cover between the formwork
and reinforcement.
9.4.20
Water Bars
In the case of watertight constructions water bars or equivalent, as approved by the Engineer,
shall be used at joints.
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QCS 2014

Part
09: Formwork
Page 13
REMOVAL OF FORMWORK
9.5.1
General
The Engineer shall be notified in writing before the removal of any formwork.
The Contractor, under no circumstances, shall strike the formwork until the concrete has
attained adequate strength to resist damage, in particular to arises and features.
Concrete shall be thoroughly wetted as soon as the forms are first loosened and shall be kept
wet during the removal operations and until the curing media is applied.
A potable water supply with hoses having fine fog spray attachments shall be ready at each
removal location before operations are commenced.
The forms after removal shall be cleaned and prepared for subsequent use.
9.5.2
Stripping of Formwork
The period of time elapsing between the placing of the concrete and the striking of the
formwork shall be approved by the Engineer after consideration of the loads likely to be
imposed on the concrete and shall in any case be not less than the periods shown in
Table 9.1
Stripping of the formwork within the time limits listed above does not relieve the Contractor
from successfully crushing test cubes and achieving the specified compressive strength
results.
Notwithstanding the foregoing the Contractor shall be held responsible for any damage
arising from removal of formwork before the structure is capable of carrying its own weight
and any incidental loading.
Where finished surfaces have re-entrant angles, the formwork shall be removed as early as
possible, within the time limits set above, to avoid shrinkage cracks.
The formwork shall be carefully stripped to avoid sudden shocks from the removal of
wedges, or vibration which might cause damage to the concrete.
Reshoring to beams and slabs shall be placed immediately after stripping formwork.
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9.5
Table 9.1
Stripping Times of Formworks
Type Of Formwork
Minimum Period Before

Stripping (Times Are From
Concrete Placement)
Beam sides, walls and column

Soffits of slabs (props left under)
Soffits of beams, joists and girders (props left under)
Props to slabs
Props to beams
1d
4d
10 d
11 d
15 d
QCS 2014

Part
09: Formwork
Page 14
Holes to be Filled
Holes formed in concrete surfaces by formwork supports or the like shall be filled neatly with
non-shrink grout.
The Contractor shall clean and scarify any hole that is to be filled with non-shrink grout.
9.5.4
Repair to Damaged Concrete Surfaces
Where the concrete surface has been damaged, the Contractor shall break out any loose,
broken or cracked concrete or aggregate.
The concrete surrounding the hole shall be then be thoroughly soaked after which the
surface shall be dried so as to leave a small amount of free water on the surface. The
surface shall then be dusted with ordinary Portland cement by means of a small dry brush
until the whole surface that will come into contact with the dry-pack mortar has been covered
and darkened by absorption of the free water by the cement. Any dry cement in the hole shall
be removed
Dry-pack material shall then be placed and packed in layers having a compacted thickness in
accordance with the manufacturers instructions. Compaction shall be carried out by the use
of a hardwood stick and a hammer and shall extend over the full area of the layer, particular
care being taken to compact the dry-pack against the side of the hole. After compaction the
surface of each layer shall be scratched before further loose material is added
The hole shall not be over-filled and the surface shall be finished by layering a hardwood
block against the dry-pack fill and striking the block several times. Steel finishing tools shall
not be used and water shall not be added to facilitate finishing.
The surface of the concrete shall be rubbed down smooth with carborundum and water in an
approved manner within three days of removing the formwork. Holes left after removal of
such supports shall be neatly filled with non-shrink grout of a suitable consistency and
matching colour.
9.6
DELIVERY AND STORAGE
9.6.1
Delivery
The delivery of formwork materials shall be done in such a manner that damage can be
prevented.
9.6.2
Storage
Formwork should be stored, after cleaning and preparing for reuse if used before, in such a
manner that access to all different materials is available.
Materials which can be affected by weathering shall be stored in appropriate buildings or

under cover.
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9.5.3
QCS 2014

Part
09: Formwork
Page 15
9.7
TOLERANCES
The concrete work shall be constructed to an accuracy which shall permit the proper
assembly of components and installations and shall be compatible with the finish. The
accuracy of the work shall be within the tolerances shown on the Drawings or specified
elsewhere and, in the absence of any other requirements, shall comply with the following:
5 mm
5 mm
All laying out dimensions

Sections of concrete members
10 mm
Top surfaces of foundations, bases and piers
20 mm
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5 mm
10 mm
5 mm
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Surface level of floor slabs (5m straight edge)

Surface level of floor slabs to datum
Plumb of columns and walls in storey height
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Surface of foundations against ground
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Plumb of columns and walls in full building height (for each

storey) above the top of foundation:
20m building height
150m building height 20 m
building height 150 m
5 mm
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Inside faces of elevator shafts in storey height
20 mm
(1/1000) of height
150 mm
10 mm
(0.5/1000) of height
75 mm
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Inside faces of elevator shafts in full building height (for each

storey) above the top of foundation:
20m building height
150m building height 20 m
building height 150 m
EARLY LOADING
The Contractor should note that the loading from the falsework and wet concrete, during the
construction of a floor, will not exceed the permissible loading on the floor immediately below.
Consequently two of the floors immediately below the one being constructed will need to be
used, to share the loading.
While propping through two floors, the Contractor shall ensure, that the props beneath the
floor last constructed are released over its full extent as soon as the concrete has achieved
sufficient strength to support itself plus any superimposed loading, but not sooner than the
periods given in Table 9.1. The props shall then be re-tightened so that these may be used
to share the construction loading from the floor above.
Not withstanding the requirements of this Section for the removal times for formwork, the
following provisions shall apply to early loading of concrete.
9.8
QCS 2014

Part
09: Formwork
Page 16
Concrete shall at no time be subject to loading including its own weight which will induce a
compressive stress in excess of 0.33 of the actual compressive strength of the concrete at
the time of loading or 0.33 of the specified 28 d characteristic strength whichever is the lower.
For the purpose of this clause the assessment of the strength of the concrete and the stress
produced by the loads shall be subject to the agreement of the Engineer.
If, due to his method of construction, the Contractor wishes to place an imposed load on the
structure, he shall arrange for additional cubes to be cast at the point of the structure to be
loaded and these cubes will be crushed to monitor the compressive strength in accordance
with BS EN 12390-3 Compressive strength of test specimens. The Contractor shall submit
calculations showing the stresses induced by any proposed temporary loads to be placed on
the structure.
No superstructure load shall be placed upon finished piers or abutments until the Engineer
has given his approval in writing and in no case shall any load be placed until the curing
period is complete.
Deck slabs of bridges shall only be opened to traffic or construction equipment and plant
when authorised by the Engineer and in no case until the curing period is complete.
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END OF PART
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QCS 2014
Section 06: Road Works

Part
01: General
Page 1
GENERAL ............................................................................................................... 2
1.1
1.2
RELATED DOCUMENTS & REGULATIONS ................................................ 2

BENCH MARKS AND MONUMENTS............................................................ 2
1.2.1
1.2.2
1.2.3
General
Permanent Monuments
Setting Out
1.3
1.4
1.5
1.6
1.7
1.8
1.9
1.10
1.11
EXISTING GROUND LEVELS....................................................................... 3

MATERIALS TESTING .................................................................................. 4
NUCLEAR DENSITY TESTING DEVICES .................................................... 5
TEMPORARY FENCING ............................................................................... 5
ROAD OPENING ........................................................................................... 5
CONCRETE WORKS .................................................................................... 5
STANDARDS AND CODES OF PRACTICE ................................................. 6
TRAFFIC MANAGEMENT ............................................................................. 6
ARMED FORCES .......................................................................................... 6
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2
2
3
QCS 2014

Part
01: General
Page 2
GENERAL
1.1
RELATED DOCUMENTS & REGULATIONS
The information given in this Part is supplemental to QCS Section 1 - General. Reference
should be made to Section 1 General prior to referring to the clauses in this part of the
specification which cover specific requirements for roadworks and are additional to Section 1
- General.
The Government specifications, regulations, notices and circulars mentioned in QCS Section
1 General are amended and complemented by this Specification as detailed hereafter. In
the case of any ambiguity or discrepancy the provisions of this Specification shall prevail over
the provisions of the aforementioned Government published specifications.
1.2
BENCH MARKS AND MONUMENTS
1.2.1
General
The Contractor shall consult the Survey Section of the Ministry of Municipal Affairs and
Agriculture prior to any earthworks or site clearance to determine if the work is likely to
disturb survey marks.
If the survey section require a survey mark to be moved the Contractor will be responsible for
recreating the survey mark to an approved design and specification, and for re surveying the
point using survey companies approved by the Survey Section.
On the Practical Completion of the Works the Survey Section will issue a certificate stating
that all survey marks, whether disturbed or otherwise, by the Contractor have been reinstated
or protected to the satisfaction of the Survey Section.
In the event of failure to comply with the requirements of this Clause the Government, without
prejudice to any other method of recovery, may deduct the costs of any remedial work after
the Practical Completion date, carried out by Survey Section from any monies in its hands
due to or which may become due to the Contractor.
All pertinent levels, lines and locations must be checked and verified by the Contractor before
commencing the Works.
1.2.2
Permanent Monuments
At the time of substantial completion of the whole of the works, a schedule and plan drawings
of all remaining Project related and supplementary bench marks and monuments shall be
prepared and transmitted to the Engineer. All project related bench marks and monuments
made permanent as above will be shown on the as-built plans, including the co-ordinates and
level information for each.
Certain bench marks and monuments determined by the Engineer shall be made into
permanent bench marks and monuments.
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Part
01: General
Page 3
Fabrication and installation of bench marks and monuments shall be as shown on the
drawings or in the specifications and shall include attaching warning reflectors and painting if
required. Each bench mark and monument shall be set accurately at the required location
and elevation and in such manner as to ensure its being held firmly in place.
The Contractor may request the Engineer's approval for concrete monuments, markers and
posts supplied by an established commercial manufacturer, whose capability of producing
survey monuments has been well established by both testing and performance. Written
approval shall be obtained prior to installation of the units on the project.
1.2.3
Setting Out
The level datum for the works shall be the Qatar Datum as defined by the PWA.
The works shall be set out to the Qatar national grid as defined by the PWA. The Contractor
will be supplied with the details and grid reference of setting out monuments.
The works shall be set out in accordance with the standard specification of the PWA.
Before commencing the works the Contractor shall obtain from the Engineer all information
pertaining to project related bench marks and monuments bearing local grid co-ordinates.
After the Contractor takes possession of the Contract Drawings and has noted all the existing
bench marks, he shall carry out at his own expense the setting out of the works, definition of
levels, centre lines and slopes, all in accordance with the Drawings.
The Contractor shall be responsible for the true and proper setting out of the work in relation
to original points, lines and levels of references given in the Drawings and for the accuracy of
the positions, levels, dimensions and alignment of all parts of the work, and for any delay or
loss resulting from errors made in completing the setting out of the work.
The Contractor shall protect, preserve and be responsible for all existing bench narks, pegs
and boundary marks and shall keep these in place or replace them when necessary either in
their positions or in other approved positions.
Setting out shall be approved by the Engineer before commencing the Works, but such
approval shall in no way relieve the Contractor of his responsibility for the correct execution of
the works.
1.3
EXISTING GROUND LEVELS
The Contractor will survey cross-sections of the site prior to the commencement of works in
any section.
The Contractor shall include in his critical path programme the date by which survey work
should be completed in each section of the site. No works may commence in any section
prior to the programme date without the written approval of the Engineer.
Sections will be prepared at such intervals as are necessary to give a representative record
of existing conditions and in no case will the intervals exceed 50 metres.
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Part
01: General
Page 4
The Engineer may choose to carry out his own survey of the site and in such cases will give
the Contractor 48 hours notice of his intention to carry out survey work in any particular
section of the Site.
The Contractor may nominate a representative to be present to observe the survey. If, having
been given such notice, the Contractor fails to appoint a representative or if the
representative should fail to be present during the survey work, the Engineer shall proceed
with the survey which shall be deemed to have been prepared in the presence of the
Contractor.
The Contractor shall prepare drawings showing the various cross-sections obtained from the
above survey.
The original of the drawings shall be signed by the Engineer and the Contractor as an agreed
record of the existing ground levels.
A copy transparency of each original drawing will then be given to the Engineer. These
drawings shall be deemed to be the Contract Drawings replacing the original.
1.4
MATERIALS TESTING
Reference should be made to the requirements for the provision of facilities and equipment
for the testing of materials given in Section 1.
In addition to these requirements the Contractor shall provide a fully equipped site laboratory
or shall arrange for materials and samples to be transported to the Ministry of Environment
(MOE) for testing or otherwise specified by the Engineer or the Project Documentation.
In addition the Contractor shall provide suitable facilities at the asphalt batching plants to
enable the Engineer to carry out all necessary tests on the raw materials and mixes. Such
facilities will be subject to the Engineer's approval and the preparation of asphalt mixes shall
not be allowed until the facilities have been approved by the Engineer.
Approved equipment shall be maintained on site at all times to:

Determine the laying and rolling temperature of bituminous materials.
(a)
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(b)
Check surface tolerance by using a straightedge and wedges or rolling straightedge.
(c)
Carryout soil grading shape, classification, moisture content and compaction tests, as
required.
(d)
Carryout in situ dry density tests.
(e)
Carryout bitumen extraction.
Equipment shall also be made available when required by the Engineer to take 150 mm
diameter cores from the carriageway.
The Engineer may require samples of materials to be delivered to the MOE for additional
tests.
QCS 2014

Part
01: General
Page 5
1.5
NUCLEAR DENSITY TESTING DEVICES
No person or company will be permitted to determine in-situ density by mean of a nuclear

density measuring device without complying with the following regulations:
(a)
Each device shall have a valid Calibration Certificate issued by the MOE.
(b)
Persons operating the device shall hold a valid authorised user certificate issued by the
MOE.
(c)
During the operation of the device the person operating it and any assistants shall
wear a suitable film badge or a personal radiation warning alarm. Copies of radiation
exposure report of the film badges should be submitted on monthly basis to the MOE.
TEMPORARY FENCING
Temporary fencing shall be appropriate to the usage of the adjoining land and unless
otherwise described on the drawings may be of a type selected by the Contractor taking into
account the usage of the adjoining land subject to the approval of the Engineer.
As soon as the Contractor is placed in possession of any part of the site he shall immediately
erect fencing on the boundaries of the land as shown on the Drawings. In places where
permanent fencing cannot be erected immediately or where none is required, the Contractor
shall erect, and when and where required re-erect and maintain, temporary fencing and
subsequently take down and remove as necessary.
The Contractor shall not use barbed wire in areas accessible to the general public. Access
shall be made in temporary fencing as necessary for the use of the occupiers of adjacent
lands.
If temporary fencing is removed temporarily for the execution of any part of the Works it shall
be reinstated as soon as possible and in the meantime, subject and without prejudice to the
Conditions of Contract, the gap in the fencing shall be patrolled so that no unauthorised entry
onto adjoining land takes place.
Temporary fencing shall remain in position either until it is replaced by permanent fencing or
until its removal on completion of the Works, unless otherwise described in the contract or
directed by Engineer.
1.7
ROAD OPENING
Road openings shall be carried out in accordance with the procedures laid down in The Code
of Practice and Specification for Road Openings in the Highway, prepared by the Ministry of
Industry and Public Works, January 1992.
Newly compacted bituminous courses shall not be opened to traffic until they have cooled to
ambient temperature. Longer periods may be applied during the summer months for heavily
trafficked roads at the discretion of the supervising engineer
1.8
CONCRETE WORKS
All concrete works shall be carried out in accordance with the requirements of Section 5.
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1.6
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Part
01: General
Page 6
Concrete works shall include; mass concrete, reinforced concrete, in-situ concrete, precast
concrete and prestressed concrete.
Concrete works shall be deemed to include reinforcement, formwork and all the other
materials procedures and requirements covered by Section 5 - Concrete.
1.9
STANDARDS AND CODES OF PRACTICE
The standards, codes of practice and other reference documents referred to in the roadworks
section of the specification are listed in the first clause of each of the parts of the
specification.
Unless otherwise agreed with the Engineer a full set of these documents shall be provided by
the Contractor within 30 days of the commencement of the contract. These documents shall
be kept at the site and shall be available at all times for the use of the Engineer and his staff.
1.10
TRAFFIC MANAGEMENT
The Contractor shall comply with all instructions given by the Qatar Traffic Police in relation to
traffic management and road safety.
1.11
ARMED FORCES
The Contractor shall comply with all reasonable instructions given by the Qatar Armed
Forces to allow them access to the Works and with the PWA.
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END OF PART
QCS 2014

Part
10: Vehicle Crash Barriers
Page 1
10
VEHICLE CRASH BARRIERS ....................................................................... 2
10.1
GENERAL REQUIREMENTS ........................................................................ 2
10.1.1
10.1.2
10.1.3
10.1.4
10.1.5
10.1.6
Scope
References
Performance Requirements
Submittals
Quality Assurance
Maintenance
10.2
STEEL WIRE ROPE BARRIERS .................................................................. 5
10.2.1
10.2.2
10.2.3
10.2.4
10.2.5
10.2.6
10.2.7
10.2.8
General
Component Ropes
Tail Rope
Safety Check Rope
Posts
Anchorage Frames
Other Components
Installation
10.3
TENSIONED CORRUGATED BEAM SAFETY FENCE ................................ 9
10.4
UNTENSIONED CORRUGATED SAFETY FENCE .................................... 10
10.5
OPEN-BOX BEAM SAFETY FENCE ........................................................... 11
10.6
TENSIONED RECTANGULAR HOLLOW SECTION SAFETY

FENCE ......................................................................................................... 12
10.7
MARKERS FOR BARRIERS ....................................................................... 12
10.8
CRASH CUSHIONS AND TERMINALS ...................................................... 12
10.9
VEHICLE BARRIER UNITS (VBU) .............................................................. 13
10.10
TEMPORARY CONCRETE BARRIERS ...................................................... 13
10.11
ALUMINIUM BRIDGE PARAPET ................................................................ 14
5
5
6
6
6
7
7
8
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2
3
3
4
5
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Part
Page 2
10
VEHICLE CRASH BARRIERS
10.1
GENERAL REQUIREMENTS
10.1.1
Scope
This section of the specification covers the supply, installation and foundation requirements
of the following representative types of vehicle crash barriers. The definition of each type of
barrier is given in the relevant section of the specification.
steel wire rope barriers.
(b)
tensioned corrugated beam safety fence
(c)
untensioned corrugated beam safety fence
(d)
open box beam safety fence
(e)
tensioned rectangular hollow section safety fence
(f)
permanent concrete barriers
(g)
temporary concrete barriers
(h)
aluminium bridge parapet.
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(a)
This section of the specification does not cover the design criteria for deciding on the type of
barrier to be applied in a particular situation.
Related Sections and Parts
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Section 5
Concrete
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This Section
Part 12
References
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10.1.2
BS 4............................Structural steel sections

BS 302........................ Wire ropes for cranes, excavators and general engineering purposes
BS EN 13411-1 ..........Specification for Thimbles for wire ropes
BS EN ISO 1461 ........Hot dip galvanised coatings on iron and steel articles
BS 970........................Wrought steels for mechanical and allied engineering purposes
BS 1449: Part 2 ..........Stainless and heat resistant steel plate sheet and strip
BS 1474......................Wrought aluminium and aluminium alloys for engineering purposes
BS 1490......................Aluminium and aluminium ingots for engineering purposes
BS EN ISO 2081 & BS EN ISO 2082, Electroplated coatings of cadmium and zinc on iron
and steel
BS EN 10264..............Round carbon steel wire for wire ropes
BS 3416......................Bitumen based coatings for cold application
BS EN 1011................MIG Welding of aluminium and aluminium alloys
BS 4320......................Metal washers for general engineering purpose
BS 4464......................Spring washers for general engineering and automobile purposes
BS EN ISO 3506 ........Corrosion-resistant stainless steel fasteners
BS 6579......................Safety fences and barriers for highways
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Part
Page 3
BS EN 1317................"Highway parapets for bridges and other structures. Part 1.

Specification for vehicle containment parapets of metal construction
BS EN 10025..............Hot rolled products of non-alloy structural steels - Technical delivery
conditions.
DTP, Manual of contract documents for highway works - volume 1 specification series 400
DTP, Manual of contract documents for highway works - volume 3 standard details
ASTM D 1248 .............Specification for Polyethylene Plastics Moulding and Extrusion
Materials US, Department of Transportation Research Report NCHRP,
No. 230.
ISO 9002 ....................Quality assurance system for production and installation
The vehicle crash barriers shall present a continuous smooth face to an impacting vehicle so
that the vehicle is redirected without turning on its side or rolling over to a course that is
nearly parallel to the barrier face and with a lateral deceleration which is tolerable to the
vehicle occupant. The vehicle shall be redirected without rotation about either its horizontal
axis (spinning out) or vertical axis (overturning) and the rate of lateral deceleration shall be
such as to cause minimum risk of injury to the passengers.
The vehicle shall be directed so that no part of the vehicle crosses the line parallel with and
4 m from the original alignment of the traffic face of the fence or barrier within a distance of
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10.1.3
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10 m from the last point of initial impact in the direction of the adjacent traffic flow.
On impact the safety fence or barrier shall contain and redirect a vehicle of a certain mass
travelling at a certain velocity at an angle of incidence of 20 degrees to the fence or barrier.
The level of vehicle containment shall be lower, normal or higher as designated, with the
following value for vehicle mass and vehicle speed.
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Vehicle Mass, kg
1500
1500
5000
Vehicle Speed, km/h

113
80
80
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Containment
Normal
Lower
Higher
The centre of gravity of the test vehicle prior to impact shall be 500 mm above the ground.
5
All the components of a vehicle crash barrier shall be designed to achieve a serviceable life
of not less than 20 years except for the use of temporary concrete barriers where the nominal
service life shall not be less than 10 years.
10.1.4
Submittals
The Contractor shall submit details of previous installations of the vehicle crash barrier over a
10-year period, indicating the system, its location and the type of highway.
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Part
Page 4
For the particular crash barrier system proposed, the Contractor shall submit a detailed
report giving the results of vehicle impact tests, and may include photographs and video
recordings. The report shall be from an internationally recognised laboratory approved by the
Engineer. The report shall describe in detail the arrangements for the test including vehicle
weight, speed, impact area, full details of the test vehicle guidance and measuring systems
and speed measurements. The report shall include photographs showing the results of the
test. The report shall give full details of the actual vehicle speed, approach angle, vehicle
interaction and fence movement of vehicle and roll, yawl and pitch of the vehicle movement
after exit from safety fence. The report shall include details of the safety fence damage and
the vehicle damage.
Crash cushions and terminals. The Contractor shall make a detailed technical submission
that will include drawings indicating the layout for the system at different locations. The
Contractor shall also submit design calculations for the system for head on impact and side
impact. These calculations shall indicate the reduction in G force or all vehicles of specified
weight and speed. The submission shall contain the precise specification of the individual
elements of the system, installation procedures, fixing details and fully dimensioned scale
layout drawings. The Contractor shall submit reports from the highway authority where the
particular barrier system has been used showing details of vehicle collisions and the results
of such collisions.
The Contractor shall submit calculations to show that post foundations can withstand an
overturning moment of 6.0 kNm.
The Contractor shall submit full technical details of the safety fence system proposed
including post to beam connection details of beam joints and post to beam connection details
of posts, and details of tensioning assembly.
The Contractor shall submit calculations showing the required size and details of the lifting
eyes for permanent and temporary concrete barriers for the designated barrier details.
10.1.5
Quality Assurance
Vehicle crash barriers shall have been tested by an approved Testing establishment such as
the UK Transport and Research Laboratory. The Engineer shall decide what is an approved
Testing establishment.
The manufacturer shall operate an approved quality assurance system complying with ISO
9002 for the fabrication and supply of components used in the vehicle safety barriers. Only
components complying with the manufacturers specifications may be used.
The supplier shall submit certification showing that tensioned rectangular hollow section
safety fence systems have been tested in accordance with the requirements of the UK
Transport and Research Laboratory.
Crash cushion and terminal systems shall have been satisfactory tested following the
procedures set down in the US Department of Transportation Research Report NCHRP, No.
230. The installation of the system shall be supervised by a representative of the
manufacturer with a minimum of five years of experience in the use of the system.
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Page 5
10.1.6
Maintenance
For vehicle crash barriers, crash cushion and terminal systems the Contractor shall supply:
(a)
four copies of the installation and maintenance manual
(b)
a relevant spare parts list for the system showing the recommended set of spare parts
needed to restore one system to its original condition after a head on impact
(c)
if specified elsewhere in the Contract the Contractor shall supply spare parts for the
system
(d)
current prices of spare parts
(e)
profile of a local agent
STEEL WIRE ROPE BARRIERS
10.2.1
General
Steel wire rope safety fence barriers shall be supplied and installed in accordance with the
designated dimensions and details shown on the contract drawings. The post details,
spacing, anchorage, size shapes and general layout shall be as per the details shown on the
contract drawings.
Wire rope barriers shall consist of either two or four, tensioned, galvanised, steel-wire ropes.
The type of system to be specified shall be as shown on the contract drawings.
Four wire rope barriers shall consist of two upper ropes located in a slot at the top of the steel
posts and two lower ropes interwoven along the fence between each pair of ropes. The
ropes shall be joined and tensioned by means of screws at the designated intervals.
The ends of the ropes shall be attached to anchor blocks and embedded in the ground.
Steel posts may be located in the ground either as driven posts or in concrete footings. In the
case of any obstruction, the Contractor shall propose an alternative steel post, surface
mounted to the equivalent of strain. Steel posts shall be removable and replaceable.
The supply and installation of steel wire safety fence barriers is to be carried out in
accordance with BS 6579, except as modified herein.
10.2.2
Component Ropes
Component ropes shall consist of steel wire ropes fitted with end terminals.
The rope shall be 19 mm diameter, 3 x 7 (fill) galvanised wire rope generally to BS 302: Part
1 with a minimum breaking force of 173.6 kN. All wire used in the rope shall be to BS EN
10264 galvanised normal duty. Various galvanised wire finishes may be used by agreement
with the Engineer.
The rope shall be prestressed by applying a cyclic loading until all initial extension has been
removed. After prestressing the rope will exhibit a minimum modulus of elasticity of 8300
kg/mm2 based on an area of 283 mm2.
The complete component rope shall have terminals, one end right-hand thread and the other
left-hand thread.
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10.2
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Part
Page 6
The fittings shall be attached to the rope whose length measured over the extreme ends of
the threaded portion of the fittings shall be 153.35 m, -0/+25 mm. Other special lengths of
rope with identical construction may be detailed as necessary for specific applications.
All threaded terminals shall be made from steel to BS 970: Part I Grade 65SM13 and either
cadmium plated to BS EN ISO 2081 & BS EN ISO 2082 class B or alternatively galvanised to
BS EN ISO 1461.
A test will be carried out to destruction on a threaded terminal test piece consisting of a
terminal and a length of rope such that the minimum test length is 600 mm. This assembly
shall have a minimum breaking force of 164.6 kN.
10.2.3
Tail Rope
Tail ropes shall be short lengths of rope fitted with threaded terminals at both ends that are
used to connect component ropes to anchors. Tail ropes shall be supplied to the site
prefabricated.
Tail ropes are of identical construction and specification to the component ropes but of
different overall length. These ropes must also be prestressed.
The length of the fitted rope measured over the extremities of the threaded portions of the
screwed terminals shall be 6 m 10 mm.
Tail ropes shall be terminated in one of two ways using identical terminals to those specified
for component ropes: with right-hand terminations on both ends, or with a right-hand at one
end and a left-hand termination at the other.
10.2.4
Safety Check Rope
Safety Check Ropes are steel wire ropes fitted with end terminations. The rope itself shall be
8 mm diameter 6 x 19 (9/9/1) IWRC galvanised wire rope to BS 302 with a minimum breaking
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The rope shall have a galvanised heart-shaped thimble to BS EN 13411-1 capable of

accepting a 38 mm diameter pin fitted by using a pressed ferrule on one end and a forked
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force of 40.3 kN. All wires used in the rope shall be to BS EN 10264 grade normal duty,
galvanised to class 'A' finish.
terminal on the other end.

3
The length of the rope between the centre of the 38 mm pin hole and the 9 mm pin hole shall
be 1.8 m 0/+20 mm.
10.2.5
Posts
There are three types of posts with variations for embedded style or surface mounting: line,
deflection and surface.
All posts shall be manufactured from 6 mm section cold rolled mild steel plate to BS EN
10025 grade Fe 50A, having a minimum yield strength of 355 N/mm2. All posts shall be
galvanised to BS EN ISO 1461. Dimensions and tolerances of the types of posts shall be as
designated.
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Part
Page 7
Post foundations and anchor blocks shall be as per the dimensions and details designated by
the supplier.
10.2.6
Anchorage Frames
A range of anchorage frames must be available for various locations and applications. These
are: on the median, verge and for end/intermediate and embedded/surface mounted fixings.
The anchorage frames shall comply with the requirements of clause 4.3 of BS 6579.
End anchorage frames shall be constructed from weldable structural steel as defined in BS
EN 10025 Grade Fe 430A with steel plate to section 4, and steel bar to section 6. Rolled steel
channel to BS 4. All materials shall be galvanised to BS EN ISO 1461.
Intermediate anchorage frames are double sided frames. All materials and finishes shall be
as defined above.
The intermediate anchor frames may be surface mounted.
10.2.7
Other Components
Sockets for post foundation shall be constructed from 3 mm steel to BS EN 10025 Grade Fe
430A. Galvanised to BS EN ISO 1461.
Excluders shall be produced from high-density polyethylene type iii class C Cat 4, ASTM D
1248
Rigging screws shall be used to connect component ropes together and component to tail
ropes. The rigging screws shall be the body of a rigging screw manufactured to BS 4429.
Except for the threads which are to be right and left hand M24 x 3-7H. Each rigging screw
shall be hot dipped galvanised to BS EN ISO 1461.
Steel pins used in the fork terminal on the safety check rope shall be made from BS 970
Grade 045M10.
Split cotter pins shall be in stainless steel 2.5 mm x 16 mm to BS 4320 and shall have a
retaining pin.
Nuts used to secure the threaded rope terminal to an anchor frame shall be M24 thread in
zinc electroplated condition. Steel washers shall be M 24 to BS 4320 and fitted over the
threaded terminal and between the nut and anchor frame.
Locating hooks shall be made in stainless steel to BS 970 Part I. Nuts (for hooks) shall be M6
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to BS 3692 Grade A2.

8
Caps for posts shall be high-density polyethylene Type III class c cat 4, ASTM D 1248
Ordinary thimbles shall be size 9, fitted to safety check rope made to BS EN 13411-1.
10
The fork terminal shall be fitted to the safety check rope shall be made to BS 970 Grade
45 M10.
QCS 2014

Part
Page 8
11
All ropes, terminals, rigging screws, posts and anchor frames are to be clearly marked with
the manufacturers identification and the date of manufacture and the standard of
construction.
10.2.8
Installation
Steel wire ropes safety fences shall not be used where

the length of fence at full height would be less than 37.5 m
(b)
on horizontal kerb at radius less than 600 m
(c)
on vertical sag curves of radius less than 300 m
(d)
on medians having a width of less than 3.14 m
(e)
where the height of any kerb at the edge of the adjacent surface exceeds 100 mm
(f)
where high mast lighting columns are situated within 10m of the edge of the paved
surface
(g)
where the fence has to be connected to any other fence or building
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(a)
All components shall be suitably protected and supplied in packaging that prevents any
permanent damage particularly to threaded components. Damage to metallic coating shall
be prevented by appropriate means. Any damage found on inspection prior to installation
shall be made good to the satisfaction of the Engineer.
Component ropes and tail ropes shall be supplied on reels with a bar of diameter not less
than 450 mm.
Ropes shall not be twisted or kinked.
Driven line posts shall be installed to the alignment and level shown on the drawing without
damage to the slot on the top of the post.
The top of the post shall be capped with a black polypropylene excluder.
The length of the line rope between any two adjacent anchors shall be not greater than
627m.
Tensioning between any two limits shall not proceed until the Engineer is satisfied that each
limit is anchored sufficiently securely to resist the load effects due to tensioning.
The tension shall be measured using a device approved by the Engineer.
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QCS 2014
Page 9
The ambient air temperature shall be noted at the time of tensioning and adjusted as follows;
AMBIENT TEMPERATURE C
14.00
16.75
19.50
22.25
25.00
27.75
30.50
33.25
36.00
45
40
35
30
25
20
15
10
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ROPE TENSION kN
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Part
TENSIONED CORRUGATED BEAM SAFETY FENCE
Except as modified herein, tension corrugated beam safety fences shall comply with the DTP
Manual of Contract Documents for Highway Works Specification - Volume 1, specification
series 400.
Tensioned corrugated beam safety fences are for use on high speed roads at the road edge
or on the central median in one of the following forms:
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10.3
Single sided for road edges.
(b)
Double sided for medians.
(c)
Dual single sides for medians .
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(a)
In the event of an accident, the support post shall give away while the safety fence remains in
tension absorbing the impact energy while protecting the traffic on the opposite carriageway.
The angle of deflection shall be reduced and as the vehicle decelerates it shall be redirected
towards the carriageway.
The barrier shall consist of a strong corrugated steel beam section mounted and tensioned
on steel universal posts. End posts shall be set in concrete and intermediate posts can be
driven or set in concrete.
Surface mounted posts may be used where there are obstructions. In all cases the end posts
which are attached to barriers must be set in concrete.
The layout and the positioning of the barrier shall be as shown on the contract drawings. The
details and sizes and spacing of the various components shall be as shown on the contract
drawings.
The height of the centreline of the barrier shall be 610 mm above the edge of the carriageway
unless shown otherwise on the contract drawings.
There is no maximum length for installation. Where the line of the barrier is interrupted for an
obstacle or gap, additional end anchorages shall be provided.
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Where a barrier protects an individual short obstacle the barrier should extend from at least
30 m in front of the obstacle to at least 7.5 m or more beyond it. A minimum clearance of
1.2 m behind the barrier shall be allowed for deflection.
10
Circular installations shall be at a radius of not less than 120 m. Tighter radii than this shall
not be used without the written approval of the Engineer.
Tensioners shall consist of two longitudinal bulbs installed in brackets and shall be positioned
in intervals along the barrier and bolted to the corrugated beam.
12
Beams shall be connected by lap joints using screws nuts and washers. Beams shall be
spliced by lapping with the edge facing away from the direction of traffic. Longitudinal
clearance between screws and slotted holes in the beams shall be removed by prising apart
the beams. The nuts shall be tightened to a torque approved by the supplier.
13
Tensioning between any two limits shall not proceed until the Engineer is satisfied that each
limit is anchored sufficiently securely to resist the load effects due to tensioning. Tensioning
shall be carried out strictly in accordance with the system manufacturers recommendations.
Adjustments to the tensioning shall be made for the ambient temperature at the time of
tensioning strictly in accordance with the system manufacturers recommendations.
14
The beam shall be completely formed, punched with holes for mounting and splicing and
ready for assembly when delivered. It shall be uniform corrugated section straight or curved
sections, galvanising shall be carried out after fabrication and each element and end sections
shall be marked at the point of fabrication with the manufacturers name or trade mark,
gauge and heat ( steel batch ) number and with the coating lot referenced.
15
The barrier system shall be supplied with all required terminals and approach flares for the
particular installation situation.
16
Safety barriers shall be erected to present a flowing alignment, with the alignment in plan not
more than 30 mm from the prescribed alignment and no deviations in a 10 m length by
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more than 15 mm from the prescribed alignment. The height of the beam shall not depart
from the prescribed height by more than 30 mm nor deviate in any 10 m length from the
prescribed height by more than 10 mm.
10.4
UNTENSIONED CORRUGATED SAFETY FENCE
Untensioned corrugated safety fences shall meet the requirements of the tensioned
corrugated safety fence except as modified herein and the fence shall not be tensioned.
Untensioned corrugated safety fences can be used in low-speed situations to prevent

vehicles crossing median and for protection at the verge.
Beams shall be shaped so that there are no sharp edges protruding into traffic. Beams shall
be connected by lap joints made in the direction of the traffic flow. The beams shall be
formed from a 3 mm steel strip to give a corrugated cross-section. On curves less than 45 m
radius, the beam shall be provided in preformed curves, internal or external, without any
reduction in strength.
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At terminations, the end rails shall be sloped down at a slope of approximately 1 in 6 to

terminate just above ground level. Anchorage shall be provided by an end post set in
concrete. Unless otherwise designated the centreline of the beam shall be 610 mm above
the edge of the carriageway or hard shoulder.
10.5
OPEN-BOX BEAM SAFETY FENCE
Open box beam safety fences shall meet the requirements of the DTP - Manual of contract
documents for highway works - volume 1 specification series 400 except as modified herein.
The open-box beam barrier shall be used on high-speed roads where a stiffer barrier than
the tensioned corrugated beam is required. The open-box barrier can be used for a double
sided installation in a median.
The layout, positioning, post spacing and all dimensions of the system shall be as
designated.
The systems shall comprise a main traffic section rail element with a traffic face 150 mm
wide. This shall be ground mounted on relatively weak Z-section posts or with hexagonal
energy absorbing brackets bolted to a reinforced concrete wall or bridge pier. The traffic face
shall be set to a height of 610 mm at the centreline of the rail.
There is no limit to the length of the installation, but end rails shall be taken down to ground
level and bolted to end posts to form anchors which are set in concrete.
Where the installed barrier exceeds 100 m in length, expansion joints are to be inserted in
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The standard section length shall be 4.8 m unless otherwise designated, and this value shall
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the main rail.
be used on curves of radii down to 335 m.

For radii between 335 m and 107 m special fish plates shall be used.
For radii between 107 m and 50 m, 2.4 m rail lengths shall be used with special fish plates.
10
Z-section intermediate posts shall be connected to the main rail by shear bolts and clamp
plates into the back of the rail section.
11
Rail sections shall be butt jointed together connected by fish plates and bolted in connection.
12
Where a non-standard situation arises in the use of the crash barrier, the supplier shall obtain
recommendations from the UK Transport Research Laboratory.
13
In particularly hazardous locations where vehicles with a high centre of gravity are in use, the
open box barrier may be installed to a double height with two protective rails. The horizontal
centreline of the second rail shall be positioned 1 m above the adjacent carriageway. The
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two box section rails shall be connected together with vertical straps or a single shear bolt in
the centre of each connection of the rails to longer intermediate posts.
QCS 2014

Part
Page 12
10.6
TENSIONED RECTANGULAR HOLLOW SECTION SAFETY FENCE
Tensioned rectangular hollow section safety fences shall be installed as designated. The
position, layout dimensions and details shall be as designated.
The barriers shall be used where protection is required for bridge piers lighting columns and
other obstructions.
The size of the rectangular hollow section shall be 100 mm wide x 100 mm high or
100 mm wide x 200 mm high.
The minimum recommended curve for the barrier shall be 120 m radius. Tensioners shall be
fitted at a maximum spacing of 70.5 m and the first tensioner shall be within 50 m of the
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anchorage.
When supplied the system shall include a detailed packing list with each component
referenced and clearly marked to the standard of manufacture and the manufacturers name
and date of manufacture.
10.7
MARKERS FOR BARRIERS
To ensure that the vehicle crash barriers are clearly delineated, reflectorized markers shall be
fixed to the barriers. The work shall consist of the fabrication supplied and fixing of
reflectorized markers to vehicle crash barriers and other road side obstructions.
Reflectorized markers shall consist of two retro-reflective faces of minimum area 4000 mm2
on a weather proof durable backing capable of being fixed to the barrier. All metal fixings and
fittings shall be galvanised or stainless steel and approved by the Engineer.
Reflectorized faces shall consist of a minimum of 210 glass beads set in a 3 mm thick tough
durable plastic backing. The two faces of the marker shall be of the colour specified in the
Qatar Traffic Manual unless shown otherwise in the drawing or instructed otherwise by the
Engineer.
Reflectors shall be fixed to safety barriers and other structures where designated. Stainless
steel fixings complying with BS EN ISO 3506 grade A4 shall be used to attach markers to
concrete. Plastic isolation washers shall be used if the marker is galvanised.
10.8
CRASH CUSHIONS AND TERMINALS
Where designated, permanent or portable energy absorbing terminal systems shall be

provided for protection of traffic as shown on the drawings.
Proposed systems shall have a proven record of satisfactory performance of at least five
years in a number of locations.
The system shall be able to withstand head on and side impacts within the specified design
criteria. The system shall have the performance characteristics of a conventional metal
beam guard rail for strength durability and redirectional properties.
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QCS 2014

Part
Page 13
All of the components and materials of the system shall be suitable for use in the climatic
conditions of Qatar and shall not be liable to damage or deterioration in high temperatures or
by prolonged exposure to direct sunlight.
The system shall be such that most major components can be reused after a typical impact.
All metal work used in the system shall be galvanised or stainless steel.
All concrete used in the system shall meet the requirements of Section 5.
No work or fabrication of the system or ordering of the materials shall be carried out until the
Engineer has given formal approval in writing to the Contractors detailed submission.
10.9
VEHICLE BARRIER UNITS (VBU)
Vehicle barrier units and their foundations shall be as per the details and dimensions shown
on the drawings.
Vehicle barrier units shall be mass concrete of grade C25
The barriers shall be cast in-situ in nominal 6 m length units unless designated otherwise.
All the concrete materials and procedures including any steel reinforcement for the barriers
shall comply with Section 5.
Forms shall be smooth and tight-fitting which can be held rigidly to the line and grade during
the placing of concrete.
At the option of the Contractor, the barriers may be precast in sections not exceeding 6 m in
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length. In such cases the barrier shall be reinforced to ensure that information technology can
be safely handled and have 2 no. lifting eyes of galvanised steel cast in at the top. The
method of casting, handling and placing of barrier sections shall be proposed by the
Contractor for approval by the Engineer.
The joints between the barriers shall be as per the details shown on the drawings.
Vehicle barrier units shall be cast onto blinding concrete laid onto compacted subgrade
10.10
TEMPORARY CONCRETE BARRIERS
Temporary concrete barriers shall be used for traffic management at road diversions or
detours where there is slow moving traffic.
Temporary concrete barriers shall be as per the designated detailed dimensions. The
barriers shall be either double or single sided.
The barriers shall be cast in nominal 6 m length units unless otherwise designated.
Each barrier shall have cast in at the top two lifting eyes of galvanised steel.
QCS 2014

Part
Page 14
Where adjacent barriers are put together two galvanised steel wire eyes shall be cast in to
the ends to allow a steel pin to be placed through the eyes and into the road surface to
secure the barrier laterally.
The Contractor shall propose the reinforcement in the precast barriers which shall be
adequate to resist the forces and moments induced during lifting and handling.
All the concrete work including any steel reinforcement for the barriers shall comply with
Section 5 of this specification.
The method of casting, handling and placing of barrier sections shall be proposed by the
Contractor for approval by the Engineer.
10.11
ALUMINIUM BRIDGE PARAPET
The aluminium alloy parapets for installation on the bridges and retaining walls shall be
designed to the requirements of BS EN 1317 "Highway parapets for bridges and other
structures. Part 1. Specification for vehicle containment parapets of metal construction".
The parapet shall be designed for normal level of containment as defined by the standard i.e.
that required to resist penetration from the following vehicles impact characteristics:
as
Saloon Car
1500 kg
600 mm
2 degrees
113 km/h
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Vehicle
Mass
Height of centre of gravity
Angle of impact
Speed
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The parapet proposed for use shall be a three rail system of an established design the
prototypes of which have been subjected to full scale dynamic testing. The parapet design
which shall therefore be considered exempt from further dynamic testing shall be taken from
the list in Appendix G of BS EN 1317.
The parapets supplied to the project shall be certified by the supplier as a normal
containment system complying with one of the following.
That it complies in all respects with the design of parapet that successfully met the
requirements of Clause 26.1 or 26.5 (concerning dynamic testing) of BS EN 1317 as
appropriate.
That any modifications that have been made to the tested design comply with Clause 26.6 or
26.7 of BS EN 1317 as appropriate.
The parapet construction materials shall be as follows:
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Extruded sections
Castings
Aluminium alloy 6082-T6 to BS 1474

Aluminium alloy LM6M to BS 1490
The finish of the parapets shall be high quality defect free mill finish and as cast finish for
extrusions and castings respectively.
All aluminium welds shall confirm to BS EN 1011 and the requirements of BS EN 1317.
QCS 2014

Part
Page 15
All setscrews and nuts are to be stainless steel to BS EN ISO 3506 material grade A4.
Setscrews are to be strength class 80. Washer material is to be stainless steel to BS 1449:
Part 2 conforming to grade A4 or A2 as defined in BS EN ISO 3506.
11
Rail attachment and rail joint screws are to be M12 x 30 long hexagon head each complete
with one spring washer to BS 4464 type B, and one plain washer to BS 4320 form A.
12
Holding down bolts are to be M20 hexagon head bolts of sufficient length to give the
engagement required in BS EN 1317.
13
Bottom mesh fixing screws if required, are to be to the M8 long hexagon head set screws
each complete with one spring washer, two plain washers and one M8 nut where appropriate.
14
The holding down arrangement shall be in accordance with the requirements of BS EN 1317.
15
Loctite grade 270 (or similar approved) to be applied on erection to all rail joint and rail
attachment setscrews. At the holding down bolts, contact between the stainless steel and
aluminium baseplate shall be avoided by the use of a suitable "top-hat" insert manufactured
from an inert material.
16
Underside of baseplates are to be given at least two coats of an alkali resistant bitumastic
paint or pitch complying with BS 3416.
17
Mesh, if required, shall be 10 gauge welded steel wire in accordance with BS EN 1317,
where appropriate. It may be galvanised, or any other finish as directed by the Engineer.
18
Rivets shall consist of Avdel drive rivets, code 5141 or 06 37 or similar approved. Where
there is no substantial backing Avdel chrobert rivets, code 1125 06 13 with sealing pins code
1182 06 07 or similar approved, shall be used.
19
Full details of the proposed supplier with his technical specification in English covering
materials, main dimensions and sizes shall be submitted to the Engineer for approval before
the Contractor places an order.
20
Two copies of detailed shop drawings shall be submitted and the Engineer's approval
obtained before manufacture is commenced.
21
During erection, parapets shall be securely held in their correct position until all connections
and fastenings are complete and the post fixings have attained adequate strength to the
Engineer's approval.
22
The finished parapets shall be true to line and level throughout their length.
23
Panels and members shall be free from twist, and posts shall be truly vertical.
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END OF PART
QCS 2014

Part
11: Kerbs, Footways and Paved Areas
Page 1
KERBS, FOOTWAYS AND PAVED AREAS............................................................ 2
11.1
11.1.1
11.1.2
11.1.3
11.1.4
GENERAL ............................................................................................................... 2
Scope
2
References
2
Submittals
2
Quality Assurance
2
11.2
11.2.1
11.2.2
11.2.3
KERBS .................................................................................................................... 3
General
3
Materials and Manufacture
3
Laying
5
11.3
PRECAST CONCRETE PAVING BLOCKS ............................................................. 6
11.4
LAYING PRECAST CONCRETE PAVING BLOCKS ............................................... 7
11.5
PRECAST CONCRETE PAVING SLABS ................................................................ 8
11.6
CAST-IN-PLACE CONCRETE PAVED AREAS....................................................... 9
11.7
BITUMINOUS PAVED AREAS ................................................................................ 9
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11
QCS 2014

Part
Page 2
11
KERBS, FOOTWAYS AND PAVED AREAS
11.1
GENERAL
11.1.1
Scope
Highway kerbs, edging kerbs for footways and other paved areas. Precast concrete paving
slabs and precast interlocking concrete block areas.
Related Sections and Parts:
Earthworks
Asphalt Works
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This Section
Part 3
Part 4
Part 5
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Section 5, Concrete
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Section 13, Masonry

References
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11.1.2
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BS 812........................Testing Aggregates
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BS 1377......................Methods of test for soil for civil engineering purposes

BS 7533......................Code of practice for laying precast concrete units
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BS 7533-3 ..................Laying precast concrete paving blocks

and conformity criteria for
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BS EN 197-1 ..............Cement composition specifications

comments cements
BS EN 1338................Precast concrete paving blocks
BS EN 1339................Concrete paving flags
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BS EN 1340................Concrete kerbs unit

BS EN 12620..............Aggregates for concrete
BS EN 12878..............Pigments for the colouring of building materials
11.1.3
Submittals
The Contractor shall submit samples of the various types of concrete kerbs and other
pavement materials for approval by the Engineer before beginning the work.
11.1.4
Quality Assurance
Tests shall be carried out on the concrete mix before beginning manufacture of precast kerbs
and other items to ascertain the strength and surface finish requirements can be met. If the
required strength and surface finish are not obtained, the Engineer may order revisions to be
made in order to achieve the designated requirements.
QCS 2014

Part
Page 3
The Engineer shall, at all reasonable times, have access to the place where paving blocks
and other items and their constituent materials are manufactured and stored, for the purpose
of examining and sampling the materials and finished blocks, inspecting the process of
manufacture and marking the blocks.
The laying of paving blocks shall comply with the requirements of the Code of Practice for
Laying Precast Concrete Block Pavements and BS EN 1338 except where otherwise
designated.
KERBS
11.2.1
General
The following are the types of precast kerbs to be constructed where designated together
with associated channels, edgings and quadrants:
Non-mountable.
(b)
Dropped.
(c)
Flush.
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11.2
The dimensions and shapes of the different kerb types shall be as per the details in BS EN
1340 unless otherwise shown on the drawings or designated in the contract.
The bedding and support for such units shall be as shown on the drawings.
Except as modified in this Part, all precast concrete kerbs, channels, edgings and quadrants
shall be hydraulically pressed complying with BS EN 1340.
Kerbs shall be laid and bedded in accordance with BS 7533 on the concrete pavement slab,
a mortar bed, the road base, or on a concrete foundation while it is still plastic or after it has
set. All precast units shall be backed with concrete as per the designated details.
The use of cast-in-situ concrete for kerbs will not be permitted except with the express written
approval of the Engineer.
11.2.2
Constituent concrete materials for kerbs shall conform to the requirements designated in
Section 5. Kerbs shall be prepared with a concrete mixture containing not less than 400
kg/m3 of sulphate resisting Portland cement.
Testing of concrete kerbs shall be carried out in accordance with the requirements of BS EN
1340.
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QCS 2014

Part
Page 4
The aggregate shall meet the designated requirements and conform to the following
gradation.
Table 11.1
Aggregate Gradation for Kerb Concrete
% Passing by Weight
19
100
13.2
76-100
9.50
60-80
4.75
40-60
2.36
22-42
1.18
12-32
0.6
7-23
0.3
4-15
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0.15
2-10
0-2
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0.075
The 28-day compressive strength of the concrete shall be not less than 30 N/mm2
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Sieve mm
determined on 150 mm cube specimens, and not less than 75 % of this figure after seven
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days.
Non-mountable kerb, dropped kerb, flush kerb and heel kerb elements shall only be precast
from concrete produced in a fully automatic batching plant.
Before approval of elements of commercial manufacture, cores shall be taken from a random
sample to ascertain that the concrete strength is not less than 25 N/mm2 at 7 days.
Elements shall be manufactured to the designated dimensions as standard 900 mm lengths

unless specified otherwise in the contract documents.
Non-mountable and dropped precast kerbs shall be formed by elements 500 mm long where
required to be laid in straight lines but may be reduced to 250 mm long where required to be
laid to curves, depending on the radii of the curves.
The finished product shall be of solid appearance with clean planar faces, be free of
segregation, honeycombing, pits, broken corners or other defects and there shall be no
evidence of external rendering.
10
Bull-nosed and curved faces shall be of constant radius with a smooth change from radius to
straight.
11
Tolerances of manufacture shall be 3 mm in any one dimension and end faces shall be truly
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perpendicular to the base.
QCS 2014
12

Part
Page 5
Transverse strength requirements shall be assessed in accordance with BS EN 1338

appendix B. The loads at failure shall not be less than the appropriate value given in Table
11.1A.
Table 11.1A
Transverse strength of kerbs, channels and edgings
Width as tested
(mm)
Load at failure
(kN)
150
305
22.2
125
150
8.0
125
255
13.3
50
255
50
205
50
150
Dropper kerbs
125
255 to 150
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4.5
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Water absorption requirements shall be assessed in accordance with BS EN 1338 appendix

C. The water absorption shall not exceed the appropriate value given in Table 11.1B.
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Depth as tested
(mm)
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Table 11.1B
Water absorption of kerbs, channels and edgings
Water absorption in % by mass

Edgings
3.0
3.6
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Kerbs, channels and quadrants
11.2.3
Laying
Elements shall be set on to the designated lines and grades. Under no circumstances shall it
be permitted for levels to be set by direct measurement from pavement layers.
Unless otherwise indicated, elements shall be laid either directly onto a wet-concrete base or
onto a sand/cement (3:1) mortar bedding, 25 mm thick, on a previously laid concrete base or
approved subbase. The dimensions of the base and concrete class shall be as designated.
After kerb units have been laid, a contiguous backing of concrete shall be poured for the
elements using steel forms, unless otherwise designated. Lateral resistance shall be
provided to the kerbs by placing dowel bars in the backing concrete in not more than 500mm
intervals.
QCS 2014

Part
Page 6
No pavement layers shall be laid against kerbing until such time as the backing is completed,
backfilled and approved by the Engineer.
Joints between kerbs, shall have a width of 4 mm. These joints shall be filled completely with
fluid sand cement mortar approved by the Engineer and the joints shall be formed again.
Immediately after any concrete is in place, and for seven days thereafter, the kerbs, base,
and backing shall be fully cured and protected from drying out and against the harmful effects
of weather, including rain and rapid temperature changes. The method of protection shall be
subject to the Engineer's approval. The use of coloured curing membranes will not be
permitted. Concrete not properly cured and protected will be rejected and shall be removed
from the site.
At every 10 m interval movement joint 20 mm thick shall be formed through the concrete bed
and backing. The joint filler shall be bitumen impregnated cork board. The filler shall extend
through the kerb, bed, backing and channel, and shall be trimmed to the finished shape of
the kerb and channel.
At access points, the kerbs, including the bed backing shall be dropped to show a face of
25 mm or as otherwise designated.
At the termination of any kerb run, the end kerb section shall be sloped down to ground level,
if applicable, and angled away from the road at 30 degrees in accordance with BS 7533.
10
All kerbs shall be thoroughly cleaned of all extraneous materials.
11
Kerbs shall be laid within a tolerance of 3 mm, at each end of an element, to the designated
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lines and grades.
PRECAST CONCRETE PAVING BLOCKS
Standard rectangular precast concrete paving blocks shall have a work size length of 200
mm and a work size width of 100 mm. Paving blocks of any other shape may be made
provided they fit within a 295 mm square co-ordinating space. The preferred work size
thicknesses are 60 mm, 80 mm and 100 mm for all types of paving blocks.
The actual sizes of the paving blocks as determined in accordance with BS EN 1338 shall not
deviate from the work size dimensions by more than the following tolerances:
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11.3
Length
2 mm
Width
2 mm
Thickness
3 mm
The binder used in making the paving blocks shall be Ordinary Portland Cement, Sulphate
Resisting Portland Cement or Moderate Sulphate Resisting Portland Cement which complies
with BS 4027 or ASTM C150; respectively.
The aggregates used in making the paving blocks shall be Gabbro, and they shall comply
with section 5 of QCS.
QCS 2014

Part
Page 7
The water used in the manufacturing of the blocks shall be of drinking quality or shall be in
conformance with section 5 of the QCS.
The pigments, which are used to give colour to the paving blocks, shall comply with BS EN
12878.
The average tensile splitting strength of 16 paving blocks tested in accordance with BS EN
1338 shall not be less than 3.6MPa and the strength of any individual block shall not be less
than 2.9MPa and the failing load not lower than 250N/mm.
The average water absorption of three tested samples shall not exceed 5% and no individual
block shall have a water absorption greater than 6%.
11.4
LAYING PRECAST CONCRETE PAVING BLOCKS
The paving blocks shall be laid generally in accordance with BS 7533-3 and to a pattern
A laying course consisting of fine aggregates (sand), which complies with the corresponding
grading requirement given in Table 11.2, shall be constructed. The fine aggregates shall be
placed in a moist but not a saturated condition and shall be compacted so that a laying
course thickness of 50 mm approximately is formed. This sand layer shall be placed on a
compacted aggregate subbase or base as indicated in the project specifications/drawings.
The paving blocks shall be laid on the laying course and compacted using a plate compactor
with a plate area of not less than 0.25 m2, transmitting an effective pressure of not less than
75 kN/m2 of plate at a frequency of vibration in the range of 75 Hz to 100 Hz.
A maximum deviation for the block paving from design levels of 6 mm shall be maintained.
The joints between the paving blocks shall be filled with dry jointing sand by spreading it over
the surface and brushing it into the joints. The dry sand shall be natural and shall comply with
the corresponding grading requirement given in Table 11.2. The block paving shall be
vibrated to ensure that the joints have been completely filled.
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Table 11.2
Grading for laying course & jointing sand
% Passing
Sieve Size
Laying Course Sand
Jointing Sand
10 mm
100
5 mm
90-100
100
2.36 mm
75-100
95-100
1.18 mm
55-90
90-100
600 m
35-70
55-100
300 m
8-35
15-50
150 m
0-10
0-15
75 m
0-3
0-3
QCS 2014
11.5

Part
Page 8
PRECAST CONCRETE PAVING SLABS
Precast concrete paving slabs shall be hydraulically pressed, complying with BS EN 1339.
The dimensions of precast concrete paving slabs shall be as per Table 3 of BS EN 1339
unless shown otherwise on the contract drawings.
Where permitted by the Engineer as an alternative, slabs 450 mm x 450 mm and smaller
may be bedded on a layer of clean sharp sand complying with BS EN 12620 Grading C or M,
25 mm 10 mm thick.
On circular work where the radius is 12 m or less, all slabs shall be radially cut on both edges
to the required line.
Transverse strength and water absorption requirements shall be assessed in accordance

with BS EN 1339 - appendix B and appendix C; respectively. The loads at failure shall not be
less than the appropriate value given in Table 11.3 and the water absorption shall not exceed
the limit given in the aforementioned Table.
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Table 11.3
Transverse strength and water absorption of flags
Minimum load at failure for thickness
(kN)
as
65 mm
70 mm
12.7
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Flag type
16.9
18.8
9.1
15.4
9.6
13.8
60 mm
8.3
B,C,D
11.1
9.6
F
G
63 mm
4.0
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50 mm
Maximum water
absorption in %
by mass
The mortar bed shall be spread only after the base has been approved by the Engineer. The
subbase shall be tested for density and the minimum density shall be greater than 95% of the
maximum dry density.
Slabs shall be laid in accordance with BS 7533 to the designated cross-section and with
joints at right angles to the kerb.
Slabs shall be bedded on a sand/cement (3:1) mortar bedding not less than 10 mm and not
more than 40 mm thick.
Unless designated elsewhere paving slabs shall be laid with close joints of between 2 to 4
mm. After laying the joints shall be filled with sand complying with clause 8.3.3.
10
Where designated paving slabs shall be laid with open joints of between 5 to 10mm laid in
QCS 2014
11.6

Part
Page 9
CAST-IN-PLACE CONCRETE PAVED AREAS

Cast-in-place concrete for footways and paved areas shall only be permitted for small areas
where it is awkward or impractical to use one of the alternative paving materials specified in
this part of the specification.
The use of steel reinforcement bars or mesh in cast-in-place concrete slabs is not permitted.
Paving shall be cast in sizes to avoid the formation of shrinkage cracks. The actual maximum
size of area to be cast at one time will be advised by the Engineer based on the mix design
and layer thickness shown on the drawings. The Contractor may be permitted to cast larger
areas at one time if non-metallic fibres are added to the concrete mix to eliminate cracking. In
such cases the maximum pour size shall be proposed by the Contractor and approved by the
Engineer.
Cast-in-place concrete for footways and paved areas shall be mixed, laid and cured as
described in Section 5.
The grade of concrete, layout, thickness, position of joints and surface finish shall be as
designated.
Cast-in-place concrete shall be laid on a designated sub-base in accordance with Part 4.
BITUMINOUS PAVED AREAS
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11.7
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Flexible surfacing for footways and paved areas shall be made and laid in compliance with
Part 5.
The type of mix and the surface treatment/finish to the paving will be as designated..
Surfacing shall be laid to true levels and crossfalls and be of the designated thickness.
Surfacing shall be laid on a designated sub-base in accordance with Part 4.
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END OF PART
QCS 2014

Part
12: Fencing
Page 1
12
FENCING ....................................................................................................... 2
12.1
GENERAL ...................................................................................................... 2
12.1.1 Scope
12.1.2 References
12.1.3 Submittals
2
2
3
FENCING GENERALLY ................................................................................ 3
12.3
CHAIN LINK FENCING.................................................................................. 4
12.3.1
12.3.2
12.3.3
12.3.4
12.3.5
General
Materials
Gates
Finish to Components
Construction
12.4
STRAINED WIRE FENCING ......................................................................... 7
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12.4.1 General
12.4.2 Materials
12.4.3 Installation
4
4
5
6
6
7
8
10
PEDESTRIAN GUARD-RAIL ....................................................................... 11
12.5.1
12.5.2
12.5.3
12.5.4
Aluminium Guard Rails

Galvanised Steel Rails
Materials and Fabrication
Installation
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12.5
11
12
12
13
QCS 2014

Part
12: Fencing
Page 2
FENCING
12.1
GENERAL
12.1.1
Scope
This part of the specification covers the materials and installation requirements for the
following permanent fence types. The definition of each type is given in the relevant section
of the specification.
(b)
strained wire fencing.
(c)
pedestrian guard-rail.
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chainlink fencing.
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References
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BS 970........................Wrought steels for mechanical and allied engineering purposes

BS 1449: Part 2 ..........Stainless and heat resistant steel plate sheet and strip
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BS 1474......................Wrought aluminium and aluminium alloys for engineering purposes
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BS 1490......................Aluminium and aluminium ingots for engineering purposes

BS 1722-2 ..................Strained wire fences
BS 1722, Part 1 ..........Chain link fences
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BS 1722, Part 2 ..........Rectangular wire mesh and hexagonal wire netting fences
BS 4102......................Specifications for steel wire and wire products for fences
BS 4320......................Metal washers for general engineering purpose
12.1.2
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This Section
Part 1
General
Part 10 Vehicle Crash Barriers
Section 5, Concrete
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(a)
12
BS 4464......................Spring washers for general engineering and automobile purposes

BS 4652......................Specifications for zinc rich priming paint
BS EN 1011................Welding
BS EN ISO 1461 ........Hot dip galvanised coatings on iron and steel articles
BS EN ISO 3506 ........Corrosion-resistant stainless steel fasteners
BS EN 10210-2 ..........Hot finished structural hollow sections of non alloy and fine grain steels
BS EN 10244-2 ..........Steel wire and wire products
ASTM A53 ..................Specification for Pipe, Steel, Black and Hot-Dipped, Zinc-Coated
Welded and Seamless
ASTM A193 ................Specification for Alloy-Steel and Stainless Steel Bolting Materials for
High-Temperature
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ASTM A240 ................Specification for Heat-Resisting Chromium and Chromium-Nickel

Stainless Steel Plate, Sheet, and Strip for Pressure Vessels
ASTM B108 ................Specification for Aluminium-Alloy Permanent Mould Castings
ASTM B221 ................Specification for Aluminium-Alloy Extruded Bars, Rods, Wire, Shapes,
and Tubes
ASTM D4364 ..............Practice for Performing Accelerated Outdoor Weathering of Plastics
Using Concentrated Natural Sunlight
ASTM Dl499 ...............Standard practice for filtered open-frame carbon-arc exposure of
plastic
ASTM G152................Standard practice for operating open flame carbon-arc light apparatus
for exposure of non-metallic materials
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ASTM G153................Standard practice for operating endorsed arc light apparatus for
exposure of non-metallic materials.
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ASTM G23..................Practice for Operating Light-Exposure Apparatus (Carbon-Arc Type)

With and Without Water for Exposure of Non-metallic Materials
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AASHTO M181...........Chain link fence
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USA Federal Salt Spray Test (Test Standard 141 Method 6061)
Submittals
For all fencing systems, the Contractor shall submit the following for the Engineers approval,
before an order is placed with the manufacturer:
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12.1.3
Name and address of the factories at which the required materials will be
manufactured.
(b)
Technical submittals accompanied by a completed specification in the English

language, catalogues and a tabulation showing the overall dimensions of each type
and size of the required materials.
(c)
Programme of delivery certified by the manufacturer and supplier.
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Detailed drawings.
(d)
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(a)
(e)
Material composition certificates.
(f)
Technical information for the materials and system.
The submittals shall clearly show the standard to which the material complies. All materials
shall meet the requirements of the relevant BS. The Engineer may accept materials that
comply to a comparable international standard if the contractor demonstrates that the
standard is equivalent.
12.2
FENCING GENERALLY
All permanent fencing, unless otherwise designated shall be erected to present a flowing
alignment both in plan and elevation following approximately the level of the finished ground
along the line of the fence. The Contractor shall trim or fill the ground along the line of the
fence when required. The fencing shall be neatly and effectively joined to existing fences and
to other structures and parapets.
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Where designated, existing fences, gates and stiles, with posts shall be carefully taken down,
laid aside, removed or later re-erected. Fences, gates, stiles and posts which are to be reerected shall be handled carefully to avoid any damage.
12.3
CHAIN LINK FENCING
12.3.1
General
This work consists of the supply and installation of all plastic coated chain link fencing
complete with all necessary hardware and appurtenances as designated and in conformity
with the lines and grades directed by the Engineer.
All materials to be furnished and installed shall conform to all requirements of BS1722: Part 2
except as otherwise designated.
12.3.2
Materials
The base metal for the manufacture of posts and braces shall conform to the requirements of
BS1722: Part 1, except that the carbon content of steel posts shall not be more than 0.4 % if
welding is required. Posts and braces shall be galvanised in accordance with BS EN ISO
1461.
Fence posts and braces and gate frames shall be pipe conforming to the requirements of
Table 12.1 unless otherwise designated:
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Table 12.1
Fence posts and braces and gate frames requirements
End, Corner, Pull Posts
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Line Posts
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Location
Minimum Weight, kg/m
60.3
5.43
48.3
4.05
42.2
3.38
Posts for each side of gates shall be pipe conforming to the requirements of Table 12.2:
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Braces
Minimum O.D., mm
Table 12.2
Post dimensions for chain link fences
Gate Opening, m
Minimum O.D., mm
Minimum Weight, kg/m
1.5
60.3
5.43
4.0
73.0
8.62
All fence and gate posts (including all end and corner posts) shall be fitted with plastic or vinyl
coated aluminium tops designed to fit securely over the posts and crowned to shed water.
Changes in line where the angle of deflection is 15 or more shall be considered as corners
and corner posts shall be installed.
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Extension arms, stretcher bars, and other required fittings and hardware shall be steel,
malleable iron or wrought iron and shall be hot dipped galvanised. All required fittings and
hardware shall be fastened to the posts in the proper manner.
Chain link fence fabric shall be galvanised steel fabric conforming to the BS1722: Part 1. The
base metal for the fabric shall be medium high carbon hot-dip galvanised steel wire. All chain
link fence fabric shall be woven into approximately 50 mm mesh such that in a vertical
dimension of 600 mm along the diagonals of the openings there shall be at least 7 meshes.
Between posts, chain link fabric shall be fastened to a top and bottom tension cable. The
tension cable shall be 10 gauge galvanised steel.
Tie wires and post clips shall be at least 9 gauge galvanised steel.
10
Turnbuckles and truss tighteners shall be fabricated of steel, malleable iron, or wrought iron
and shall be hot dipped galvanised. The truss tighteners shall have a strap thickness of not
less than 6 mm.
11
The class of concrete for post footings shall be as designated.
12.3.3
Gates
Gate frames shall be constructed of not less than 42.2 mm galvanised pipe weighing
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3.38 kg/m and conforming to ASTM A53. Gate frames shall be cross trussed with 9 mm
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adjustable truss rods. The corners of gate frames shall be fastened together and reinforced
with a malleable iron fitting designed for the purpose or by welding. All welds shall be ground
smooth.
Chain link fence fabric designated for the fence shall be attached to the gate frame by the
use of stretcher bars and the tie wires as designated for fence construction, and suitable
tension connectors shall be spaced at approximately 300 mm intervals.
The gates shall be hung by at least two steel or malleable iron hinges not less than 80 mm in
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width, so designed as to securely clamp to the gate post and permit the gate to be swung
back against the fence. The bottom hinge shall have a socket to take the bail end of the gate
frame.
4
Gates shall be provided with a combination steel or malleable iron catch and locking
attachment of approved design. Stops to hold gates open and a centre rest with catch shall
be provided where required.
All gates shall be provided with standard hardware and heavy duty padlocks with four keys
each, the type and details of which shall be to the approval of the Engineer.
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12.3.4
Finish to Components
All posts, gate frames, rails and similar materials shall have a coating thickness of 254 to 356
micron of a polyvinyl chloride (PVC) which has been chemically bonded to the metal surface
with an appropriately cured primer. Final finish colour shall be as designated.
Chain link fence fabric shall have a vinyl coating of minimum wall thickness of 0.559 mm over
the galvanised substrate. The vinyl coating shall be continuously extruded (not sprayed or
dipped) over the galvanised steel wire by the thermal extrusion process under pressures to
352 kg/cm2 to ensure a dense and impervious covering free of voids, having a smooth and
lustrous surface appearance.
The wire shall be vinyl-clad before weaving and shall be free and flexible at all joints.
Colours shall be stabilised and have a light fastness that shall withstand a minimum
WEATHER-O-METER exposure time of 4000 h without any deterioration in accordance with
ASTM Dl499 and G23, Type E. Alternatively a sample of fencing may be subject to an
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exposure time of 2000 h at 85 C humidity in a humidity oven. The sample shall exhibit no
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colour loss, cracking, peeling, blistering or other deterioration.

The vinyl-clad wire shall withstand an accelerated ageing test of 2000 hours at 62 C without
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cracking or peeling.
The vinyl covering shall, in addition, resist attack from prolonged exposure to dilute solutions
of most common mineral acids, sea water and dilute solutions of most salts and alkali.
The pipe resin formulation shall meet the standard ASTM D4364, minimum 5000 h
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WEATHER-O-METER requirement without cracking, blistering, or loss of adhesion. The

protective resin coating shall withstand an impact resistance test (Gardner Test Method) of a
minimum of 1850 mm/kg. Certified abrasion resistance shall be in excess of a ten minute
blast of 5.6 kg/cm2 at 305 mm at 25 C with S230 shot at an impingement angle of 90
without exposing the steel substratum.
It shall not support combustion and shall be self-extinguishing; and shall withstand a salt
spray test (Federal Test Standard 141, Method 6061 of greater than 10,000 h with no
perceptive deterioration to coating or evidence of metal corrosion for unscored samples. For
scored samples after exposure of 1000 h, under-cutting shall not exceed 5 mm. The
protective resin coating shall exhibit a chemical resistance after prolonged exposure at 24 C
to fumes.
12.3.5
Construction
Line posts shall be spaced at not more than 3.0 m intervals, measured from centre to centre
of posts, in general, in determining the post spacing, measurement will be made parallel to
the slope of the natural ground, and all posts shall be placed in a vertical position, except in
unusual locations where the posts shall be set perpendicular to the ground surface if so
directed by the Engineer.
All posts shall be set in concrete footings conforming to the designated details.
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Part
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End, corner, pull and gate posts shall be braced to the nearest line post with galvanised
diagonal or horizontal braces used as compression members and galvanised 9 mm steel
truss rods with turnbuckles or truss tighteners used as tension members.
Pull posts shall be placed at locations agreed by the Engineer. They shall be placed at 200 m
intervals between posts to which the ends of the fabric are clamped or midway between such
posts when the distance is greater than 40 m but less than 200 m.
Chain link fabric shall be fastened on the side of the posts designated by the Engineer.
The fabric shall be stretched and securely fastened to the posts, and between posts the top
and bottom edges of the fabric shall be fastened to the tension wires. Tension wires shall be
stretched tight, the bottom tension wire shall be installed on a straight grade between posts
by excavating at the high points of ground and in no case will filling of depressions be
permitted.
The fabric shall be fastened to end, corner and gate posts tall with minimum 10 mm diameter
steel stretcher bars and not less our than 3 mm by 18 mm stretcher bar bands spaced at
maximum or 300 mm intervals. The fabric shall be fastened to line posts ends and tension
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wires with tie wires or post clips. The fasteners shall be spaced at maximum intervals of 500
mm.
STRAINED WIRE FENCING
12.4.1
General
Strained wire general and dropper fences shall be as designated and they shall comply with
BS 1722-2 with the following amendments.
This part of the specification covers the requirements for materials and workmanship for
strained wire fences of the general pattern and of the dropper pattern. Droppers are defined
as intermediate and vertical stiffeners between some or all of the wires that are used to
maintain the spacing of the wires. The droppers are not connected to the ground.
Strained wire fences comprise of tensioned horizontal steel wires fixed between vertical
straining posts with support angle struts and connected to intermediate posts. Posts shall be
constructed of either steel or precast reinforced concrete and anchored in concrete
foundations.
Wire dropper fencing shall be provided at locations where it is necessary to restrict the
access of vehicles, and camels and wandering animals.
Strained wire general and dropper fences shall be of one of the types shown in Table 12.3
The strained wire fences shall be coded according to the type dependant on the number of
line wires, whether droppers are used, material used for the posts, these type references are
given in Table 12.3. The first letter indicates that it is either a general pattern or a dropper
pattern strained wire fence, the second letter indicates the type of posts that are used, the
numbers give an indication of the height of the fence e.g. DC90 indicates a 0.9m high fence
with concrete posts and droppers.
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12.4
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Part
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For the sake of uniformity quoted heights of those to the top wire and exclude any variation in
ground clearance to the base, the third letter where present indicates the number of line
wires.
Table 12.3
General Characteristics of Strained Fences - Fence Types
With Concrete
Posts
Dropper
Pattern
General
Pattern
Dropper
Pattern
General
pattern
Dropper
Pattern
SC105A
DC 90
DC105A
SS90
SS105A
DS90
DS105A
SW90
SW105A
DW90
DW105A
m
0.90
1.05
No.
3
5
SC105B
SS105B
SS105B
DS105B
SW105B
DW105B
1.05
SC120
DC120
SS120
DS120
SW120
DW120
1.20
SC135A
DC135A
SS135A
DS135A
SW135A
DW135A
1.35
SC135B
DC135B
SS135B
DS135B
SW135B
DW135B
1.35
SC135C
DC135C
SS135C
DS135C
SW135C
DW135
C
1.35
DW180
1.80
11
DW210
2.10
16
DC210
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Spacing between
horizontal wires,
from the top wires
mm
330,330
250,250,230,150
250,250,230,150,
100
250,250,230,150,
150
250,250,230,150,
150,150
250,250,230,150,
150,150,100
250,225,225,150,
125,125,100,75
225,225,200,175,
175,175,150,150,
125,100
100,100,100,100,
100
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DS210
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DS180
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DC180
With Wooden Posts
General
Pattern
Height of
Top Wire &
Number of
Wires
With Steel Posts
Materials
The sizes stated for components are the minimum requirements and it is permissible to use
larger sizes except where this would adversely affect the fit of the components or where
replacement parts need to match those already present.
Line wire shall comply with BS 4102 and shall be one of the following:
Zinc coated low carbon steel with a nominal wire diameter of either 4.5 or 5mm
Zinc coated high tensile wire with a nominal wire diameter of 3.15mm
Plastic coated high tensile wire having a tensile strength of 1050 N/mm2 with a Zinc coated
core of 3.15mm nominal core diameter and a 4 .0mm overall diameter.
Stirrup wire shall comply with BS4102 and shall be of zinc coated low carbon steel with grade
A plastic coated low carbon steel and should have a nominal wire core diameter of 2.5 mm.
Barbed wire shall comply with BS 4102, shall be zinc coated and made from either low
carbon steel or high tensile steel wire.
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12.4.2
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The materials, protective treatment, tolerances on size and general construction details of
steel posts and struts, for strained wire fences shall comply with the requirements for chain
link fences, except that components shall not be plastic coated unless specifically required
under the contract documentation.
The materials and tolerances on precasting of all concrete components shall comply with the
relevant parts of section 5.
10
The minimum concrete grade for posts shall be C25 and the minimum cement content
should be 350 kg.
11
The mixing, placing and compaction of the concrete shall be as per Section 5.
12
All inserts and holes cast into precast concrete components with posts shall be adequate for
the bolts or appurtenances to be fitted.
13
All holes shall be free from obstructions and accurately positioned.
14
The minimum grade of concrete to be used for posts shall be C25 and the minimum cover to
embedded steel in posts shall be 50mm.
15
The dimensions of concrete fence posts and struts shall be as given in Table 12.4.
16
Posts shall be reinforced with 4 steel reinforcing bars of the size given in Table 12.4.
17
Straining posts and struts shall not be tapered.
18
The dimensions and details of the foundations shall be as shown in the contract drawings.
Concrete for foundations for the bases of posts and struts shall comply with the requirement
of section 5 of the specification and shall be grade C15.
19
Straining posts shall be provided with a firm bearing struts at a point within the top of the
length of the string posts, measured above the ground level.
20
Straining posts shall be provided with holes for the attachment of straining fittings.
21
Where line wires are to be passed through them, struts shall be provided with either holes or
slots.
22
Intermediate posts shall be tapered to 75mm x 75mm at the top and shall be holed to allow
the attachment of line wires.
23
High bolt strain shall consist of bolts of 250mm overall length, not less than 9.5mm diameter
with an eye at one end. They should be threaded and fitted with nuts and washers.
24
2 way eye bolt strainers shall be fitted with ring nuts. They shall be hopped and galvanised to
BS EN ISO 1461. Widening brackets intended for attachment to the post shall be
manufactured from mild steel flat not less than 25mm x 3mm and shall be fitted with a
widening bolt 12mm minimum diameter with a friction type ferrule or ratchet winder.
25
Hair pin staples shall be of not less than 3mm diameter round wire or sectional wire of the
same cross sectional area and shall have a zinc coating complying with BS EN 10244-2.
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26

Part
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Page 10
Droppers shall be at least 65 mm longer than the distance between the top and bottom wires
covered by them and shall be made of steel of the section not less than 0.0066 kg/m or steel
wire or galvanised in accordance with BS EN ISO 1461.
Table 12.4
Concrete Fence Posts and Struts
Strain Posts
Reinf.
Dia.
Length
mm x
mm
mm
0.90
1.57
100 x 100
1.57
1.05
1.72
100 x 100
1.87
1.20
1.35a
and b
1.35c
1.80
2.10
1.87
125 x 125
2.02
mm x
mm
100 x 100
or
125 x 125
100 x 100
or
125 x 125
125 x 125
2.02
125 x 125
2.17
125 x 125
2.17
2.62
2.92
125 x 125
125 x 125
125 x 125
2.32
2.77
3.07
150 x 150
200 x 200
200 x 200
Reinf.
Dia.
Length
mm
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Section
Reinf.
Dia.
1.98
mm x
mm
75 x 75
or
100 x 75
75 x 75
or
100 x 75
100 x 75
2.13
100 x 75
10
12
12
2.13
2.73
3.03
100 x 75
100 x 100
100 x 100
6
8
8
5
or
8
5
or
8
8
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Section
1.50
mm
Section
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Length
Struts
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Intermediate Posts
Height
6
6
Installation
Droppers shall be securely fixed to all the line wires covered by them and be of sufficient
strength to maintain the spacing of the line wires and spread the load between them in use.
The post shall be adequately braced in both directions after insertion into the wet concrete
and support shall be maintained till the concrete is fully hardened.
Excavation for foundations for post and struts shall be of the minimum stipulated dimensions
at the base of the hole.
When erecting fence posts the concrete shall be placed in position before the
commencement of the initial set.
The entire foundation hole shall be filled with concrete, the use of partly backfilled holes shall
not be permitted. Straining posts shall be provided at the ends and corners of changes of
direction or acute variations in level and at intervals not exceeding 150m for mild steel line
wire or 300m for high tensile line wire in straight lengths of fence.
Struts shall be provided at each straining post.
Where there is a change in plan direction of the fence two struts shall be provided.
Intermediate posts shall be provided at intervals measured centre to centre of posts not
exceeding 3.5m.
The number of line wires shall be as given in Table 12.3.
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12.4.3
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Part
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The top wire shall be secured with approximately 75mm below the top of the posts, each line
wire shall be strained tightly and secured to each straining posts by either widening brackets
attached to the post with fixing bolts or high bolt strainers passing through a hole in the post
and secure with a nut and washer.
11
If barbed wire is specified it shall be attached to the straining posts and intermediate posts by
the same method as the line wire.
12
Attachment to intermediate posts with the exception of the high tensile line wire for which
stirrups are not permitted each line wire shall be secured to each intermediate posts by one
of the following means;
13
A wire stirrup pass through a hole in the posts secured to the
14
a hairpin stapled post through a hole in the post and the ends twice bent over
15
A line wire pass through a hole in the post
16
Small areas of hot dipped galvanised coating damaged by welding cutting or by excessively
rough treatment during the transit and erection shall be renovated either by the use of melting
point zinc alloy repair rods or powders made specifically for this purpose or by the use of at
least 3 coats of good quality zinc paint as per BS 4652. Sufficient material shall be applied to
provide a zinc coating at least equal in thickness.
17
Droppers shall be attached after all wires have been strained and secured in position.
18
The interval between dropper and the posts or between adjacent droppers shall not exceed
the following:
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10
For full length droppers 2m.
(b)
For sectional droppers, bottom wires 2m.
(c)
Top wires 2.5m.
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(a)
Where sectional droppers are used the ends of all droppers or adjacent levels of wire shall
be fixed to at least one wire common to both levels.
20
When measured within 14 days of erection the settled tension in the line wire between
straining posts at 100 m apart shall be at least 1.6 kN
21
The method of approximately measuring the tension shall be as described in appendix F to

BS 1722-2.
12.5
PEDESTRIAN GUARD-RAIL
12.5.1
Aluminium Guard Rails
This Sub-section covers the requirements for the supply and installation of aluminium
pedestrian guard-rails and accessories.
Guard-rails shall be constructed to the designated line and grade and shall not reflect any
unevenness in the founding construction. Unless otherwise designated, railing posts shall be
vertical. For bridges, railing shall not be placed on a span until centring or falsework has been
removed, rendering the span self-supporting.
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The foundation details for the fence shall be as per the designated details and dimensions.
12.5.2
Galvanised Steel Rails
Galvanised steel pedestrian guard rails shall comply with the strength requirements of BS
3049 Clause A and shall be fabricated to the dimensions shown on the drawings from hot
rolled steel section and bars to BS EN 10210-2 and BS 4360, Grade 43C.
The following Minimum steel section thickness shall be used:

:
:
2.5 mm
4.0 mm
Posts - Sealed hollow sections

Other sections
:
:
3.0 mm
5.0 mm
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Rails - Sealed hollow section

Other sections
Joints shall be welded by metal arc welding to BS EN 1011 except where shown otherwise on
the drawings.
The guard rails and components shall be fabricated such that no burrs or sharp edges occur,
that the finished work is free from distortion and cracks and that welded joints are fully
bonded, form accurate fit and are finished smooth and flush with adjacent surfaces.
The guard rail components shall be fixed to the posts at the lower joints by 12 mm diameter,
80 mm long galvanised steel bolts with one galvanised steel washer through 40 x 40 x 6 mm
cleats. End units shall be purpose made to project over the posts with a rounded end.
Posts shall be closed at the top with a 6 mm plate having two 12.5 mm, 25 mm long dowels
welded thereto. The holding down plate at the bottom of the post shall be a minimum of 20 x
100 x 6 mm thick.
All steel posts shall be hot dip galvanized both inside and outside to BS EN ISO 1461. -end
of specification addition.
12.5.3
Materials and Fabrication
Material for cast aluminium guard-rail posts shall conform to the requirements of AASHTO
M193 and ASTM B108, alloy S7A - T4 (A444 - T4).
Aluminium alloy extruded rail shall conform to the requirements of ASTM B221 alloy, 6061-T6
or 6351-T5 with a minimum yield strength of 2466 kg/cm2, a minimum tensile strength of
2677 kg/cm2 and an elongation of 10 % in 50 mm.
Stainless steel hardware for aluminium railings shall be machine bolts or cap screws
conforming to ASTM A193, grade B8, Class 2.
Stainless steel flat washers and lock washers shall conform to the requirements of ASTM
A240, Type 302.
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Material 12.7 mm thick or less may be cut by shearing, sawing or milling. Material over 12.7
mm thick shall be sawed or milled. Cut edges shall be true and smooth and free from
excessive burrs or ragged breaks. Re-entrant cuts shall be filleted by drilling before cutting.
Flame cutting will not be permitted. Material may be heated to a temperature not exceeding
240 C for a period not exceeding 30 minutes to facilitate bending unless cold bending is
required to retain the original mechanical properties of the material furnished.
Rivet and bolt holes shall be drilled to finished size or stub punched smaller than the nominal
diameter of the fastener and reamed to size. The amount by which the diameter of a stub
punched hole is smaller than that of the finished hole shall be at least one-quarter the
thickness of the piece. The finished diameter of circular holes shall be not more than 7 %
greater than the nominal diameter of the fastener. Slotted bolt holes to take care of
expansion shall be provided as designated. Anchor-bolt holes may be up to 25 % greater
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than the nominal bolt diameter with a maximum of 12.7 mm greater than the nominal bolt
diameter.
Installation
The Contractor shall co-ordinate and space the rail posts to miss any items which may be
furnished and installed under this Contract. The Contractor shall also co-ordinate and space
the rail posts to miss lighting poles and any other existing obstructions.
Where aluminium alloys come in contact with other metals, except stainless steel, the
contacting surfaces shall be thoroughly coated with an aluminium-impregnated caulking
compound, or a synthetic rubber gasket may be placed between the two surfaces. Aluminium
alloys shall not be placed between the two surfaces. Aluminium alloys shall not be placed in
contact with copper, copper base alloys, lead or nickel.
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12.5.4
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END OF PART
QCS 2014

Part
13: Traffic Signs, Markings and Studs
Page 1
13
TRAFFIC SIGNS, MARKINGS AND STUDS ................................................. 2
13.1
GENERAL ...................................................................................................... 2
13.1.1
13.1.2
13.1.3
13.1.4
Scope
References
Definitions for Reflective Traffic Studs
Submittals
13.2
TRAFFIC SIGNS ........................................................................................... 3
13.2.1
13.2.2
13.2.3
13.2.4
13.2.5
Scope of Work
Sign Foundations
Traffic Sign Materials
Installation Requirements for Traffic Signs
Advance and far Advance Directional Signs
13.3
PAVEMENT MARKINGS ............................................................................. 10
13.3.1
13.3.2
13.3.3
13.3.4
13.3.5
Scope of Work
Materials for Pavement Markings
Application of Thermoplastic
Performance Requirements and Testing
Protection of Pavement Markings
13.4
TEMPORARY ROAD MARKING ................................................................. 14
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13.4.1 ROAD MARKING PAINT

13.4.2 ADHESIVE ROAD MARKING STRIP
13.4.3 REMOVAL OF ROAD MARKINGS
2
2
2
3
3
4
5
7
8
10
10
12
13
14
14
15
15
REFLECTIVE STUDS ................................................................................. 15
13.5.1
13.5.2
13.5.3
13.5.4
General
Reflectors
Reflectivity
Installation of Reflective Studs
13.6
NON-REFLECTIVE STUDS ........................................................................ 19
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13.5
13.6.1 General
13.6.2 Materials and Manufacture
13.6.3 Installation
15
16
17
18
19
20
21
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13
TRAFFIC SIGNS, MARKINGS AND STUDS
13.1
GENERAL
13.1.1
Scope
This Part covers the supply and installation of traffic signs (complete with posts and
foundations), thermoplastic road marking, road marking paint for temporary roads and
diversions, reflectorised studs and non-reflective studs.

Traffic Signals
Section 5,
Concrete
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This Section
Part 16,
References
The following manuals and standards are referred to in this Part:
ta
13.1.2
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Qatar Traffic Control Manual
BS 381C .....................Colours for identification purposes
as
BS 873........................Road traffic signs
se
BS 1470......................Wrought aluminium for general engineering purposes; plate sheet and

strip
er
BS 1474......................Wrought aluminium for general engineering purposes; bar, extruded

round tubes and sections
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BS 1490......................Aluminium and aluminium alloy ingots for general casting purposes

BS 2000, Part 58 ........Determination of softening point of bitumen (ring and ball)
BS 3262,(Part 1) l989 .Hot applied thermoplastic road marking materials
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BS 6088 1981.............Solid glass beads for Road Marking

BS EN ISO 591-1 .......Titanium dioxide pigments
BS EN ISO 1461 ........Hot dipped galvanising

ASTM A307 ................Steel anchor bolts
ASTM C373 ................Standard test methods for water absorption
ASTM C424 ................Test methods for crazing resistance
CML 14-97..................Standard Method of test for determination of appearance, shape,
dimensions
and compressive strength of ceramic non-reflecting road studs.
TRL Road Note 27 .....Skid resistance portable tester.
13.1.3
Definitions for Reflective Traffic Studs
Entrance Angle: The angle in the horizontal plane between the direction of incident light and
the normal (perpendicular) to the leading edge of the stud.
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Observation Angle: The angle at the reflector between observer's line of sight and the
direction of the light incident on the reflector.
Specific Intensity (S.I.): The candle-power of the returned light at the chosen observation and
entrance angles for each foot candle of illumination at the reflector on a plan perpendicular to
the incident light.
13.1.4
Submittals
Within three weeks of acceptance of the manufacturer's tender, the Contractor shall submit
for approval working drawings for signs posts and base plates. Fabrication shall not begin
until approval has been given.
The Contractor shall submit detailed drawings of the foundations proposed for traffic signs.
The Contractor shall submit samples of the proposed materials for approval on request by
the Engineer before delivery to Site, at his own cost.
The Contractor shall submit to the Engineer for approval three copies of his working drawings
for all traffic sign faces both in Arabic and English. Size and style of lettering shall be as
designated. No order shall be placed without written agreement of the Engineer and the
Concerned Authorities.
Before proceeding with drilling holes for sign foundations, the Contractor shall submit to the
Engineer for approval; the type of plant proposed for drilling holes, details of any temporary
metal casings, proposed method of concreting and the proposed method of conduit
installation.
13.2
TRAFFIC SIGNS
13.2.1
Scope of Work
This work shall consist of furnishing and installing road signs and posts assemblies as
designated. All sign faces and lettering shall be in accordance with the Qatar Traffic Control
Manual. The required post sizes for different sign sizes shall be as tabulated in the Qatar
Traffic Control Manual. Where in this section of the specification the term designated is
used, this refers to the contract drawings and the Qatar Traffic Control Manual.
The minimum depths and sizes for sign foundations shall be as per the requirements of the
Qatar Traffic Control Manual. For each of the signs the Contractor shall submit design
calculations for the proposed foundations.
The following documents should be specifically referred to for this work;
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(a)
BS 873
(b)
Permanent traffic signs shall be reflectorised or non reflectorised illuminated and shall, in
respect of quality, comply with the requirements of the latest editions of;
(a)
BS 873
(b)
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In the case of conflict with these specifications and the above documents, the matter shall be
referred to the Engineer.
All foundations, framing and fixings for information signs shall be suitable for local conditions.
The design calculations shall be submitted to the Engineer for approval. The wind loads shall
be calculated based on the wind speed provided in Section 1 part 1 clause 1.5.2.
A positive system of identification of signs, posts and all fittings shall be adopted. The
reference number of the sign together with the date of manufacture shall be indicated by selfadhesive numbers on the reverse side of the sign in the bottom left hand corner and in a
consistent and readily visible position on all posts and fittings. The manufacturer's name of
trademark will not be permitted on the face of the sign. It may be affixed on the back of the
sign, provided approval to the size and colour of the mark has been obtained from the
Engineer. Any previously marked reference number should be transferred to new signs on
replacement.
All road signs shall be guaranteed by the Contractor against any defect in material and
workmanship for a period of five years from the date of completion of the Works under the
Contract. If any defect should arise due to poor material or workmanship, it shall be rectified
by the Contractor.
13.2.2
Sign Foundations
Sign foundations shall either be reinforced concrete columns in drilled holes or shallow
reinforced concrete spread footings. The dimensions and details of the foundations shall be
as designated.
The number of anchor bolts and bolt locations and anchor bolt dimensions shall be as
designated. All anchor bolts nuts and washers shall be hot dipped galvanised to BS EN ISO
1461. Any protruding parts to the bolt thread or nut shall be further protected by the
application of a wax or grease impregnated tape. Any conduit cast into the foundation for
cable access shall be mild steel, hot dipped galvanised after fabrication to BS EN ISO 1461.
The minimum bend of conduit shall be 600 mm radius.
All concrete and reinforcing steel used in the sign foundations shall be of the designated
grade and type and shall comply with the requirements of Section 5. Anchor bolts shall
2
comply with the requirements of ASTM A307 with a minimum tensile strength of 414 N/mm .
Each bolt shall be supplied with two hexagonal nuts for levelling purposes complete with
washers.
If an obstruction is encountered whilst drilling the foundation hole the Contractor shall inform
the Engineer. The Contractor may elect to bore or drill through the obstruction depending on
its nature or may propose to reallocate the signs slightly to avoid the obstruction subject to
the approval of the Engineer. In either case the work is deemed to be included in the scope
covered by this Part.
The sides of excavation shall be vertical and any additional excavations carried out beyond
that designated, for the particular post and sign being erected, shall be filled with concrete or
granular material as directed by the Engineer.
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The reinforcement cage shall be securely fixed centrally about the axis of the foundation, any
electrical conduit shall be securely fixed in position as designated before replacement of
concrete.
The top of the concrete foundation shall be finished with a steel trowel to a smooth finish.
The top of the concrete foundation shall not extend more than 100 mm nor less than 50 mm
above the finish grade level unless otherwise designated.
All backfilling and compaction shall be completed before the erection of any sign on the
structure.
11
All excavations shall be approved by the Engineer before the sign is erected and before
backfilling with fill or concrete as designated.
13.2.3
Traffic Sign Materials
Sign plates shall be manufactured either from sheet aluminium to BS 1470, SIC - 1/2H, NS33/4N, NS-1/2H or HS 30-WP with a minimum thickness of 3 mm (11 swg) or from extruded
aluminium plank sections to BS 1470, HE 9-WP, HE 9P or HE 30-WP or extruded aluminium
alloy plank sections to BS 1474, HE 9 TE and HE 30 TF. However information signs shall be
constructed in extruded aluminium planks, which will either be self-locking or rear fixing, and
the aluminium shall be BS 1470, BS 1474 or BS 1490 or other approved equivalent
International standard.
All sign plates shall have clean, smooth edges cut to the required shape of the sign, and shall
be etched and degreased to the sign sheeting manufacturer's specifications before
application of the sheeting.
Illuminated signs shall be covered with "Super Engineering Grade" reflective sheeting.
Reflective signs shall be covered over the whole front face with "High Intensity" reflective
sheeting. The sheeting shall be of the designated colour and shall have a manufacturer's
guarantee of not less than five years. The rear faces shall be non-reflective grey and should
give a similar life span to the sign face.
The reflective sheeting shall be fixed to the sign plate either with a heat activated adhesive
using vacuum applicator or with a pressure sensitive adhesive using a pressure roller in
accordance with the sheeting manufacturer's instructions.
Sign faces shall be formed from a single piece of reflective sheeting, but if for any reason the
sign face must be fabricated from more than one piece of material all joints in the material
shall be overlapped by not less than 6 mm and where sheeting is applied to extruded
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sections it shall extend over the top and bottom edges of the sections by not less than 3 mm.
No butt joints shall be permitted and in horizontal joints the overlap shall be from the top.
7
The corners of all direction signs shall be rounded to a radius of 75 mm.
Signs constructed of aluminium sheet shall, when recommended by the Traffic Signs Manual,
be framed on all edges using hot dipped galvanised steel angle or angle-channel of
equivalent section.
QCS 2014

Part
Page 6
Signs constructed from extruded aluminium plank sections are to present the same flanged
appearance on all edges of the sign by fitting an aluminium end capping to the exposed ends
of the plank section on both sides of the sign.
10
Where the designated sign width requires the use of more than one length of plank section,
support beams shall be provided and positioned as approved by the Engineer.
11
For plank type signs supported on two posts the plank rails and support beams shall be
manufactured from one length of extruded aluminium section. One tie bar shall be fitted
between the bottom two plank rails (or the plank rail and support beam) at the centre of the
span between the mounting posts.
12
Where plank type signs are supported on more than two posts, and the designated sign
width is wider than the plank rail and support beams, the plank rail and support beam may
comprise two or three lengths provided butt joints occur at an inner post. One tie bar shall be
fitted between the bottom plank rail and support beam at the centre of the span between the
mounting posts.
13
All stiffening and framing shall be continuous and shall prevent the sign from twisting.
14
All rivets or other devices fixing sign plates to their framework shall be of non-staining steel or
other material approved by the Engineer and shall have a sufficient cross-sectional area to
prevent failure from thermal stresses or wind pressure or such other stresses as may be
designated.
15
All rivet and bolt holes shall be edge-sealed with clear lacquer after the application of the
plastics sheeting.
16
Rivets shall be spaced at not more than l50 mm apart, around the outside edge of the sign
plate and on cross braces the spacing shall be not more than 300 mm.
17
Any rivet brought through the sign face shall be coloured to match the sign face. Any rivet or
other device fixing sign plates to their frame work shall have a protective washer of nylon or
other approved insulating material inserted where they would be in contact.
18
All brackets, clips, screws, bolts, nuts and washers used for mounting sign plates to support
posts shall be manufactured from stainless steel. For plank type signs, brackets and clips
shall be extruded aluminium alloy section.
19
Saddles shall be aluminium alloy or other material approved by the Engineer and shall be
provided with a nylon strip or other approved insulating material.
20
There shall be full adhesion of all sheeting material including letters, symbols and borders
and there shall be no air bubbles, creases or other blemishes.
21
All panels, cut-out letters, numbers, borders, symbols and back grounds on reflective
sheeting shall be carefully matched for colour at the time of sign fabrication to provide
uniform appearance both by day and night. The sheeting manufacturer's recommendations
on colour matching methods shall be observed. Non-uniform shading or undesirable contrast
between reflective sheeting on any one sign will not be accepted.
22
The edges of all applied sheeting materials including edges of all plates which make up a
sign, letters, symbols and borders shall be sealed as designated by the manufacturer.
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QCS 2014

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Where required by the sheeting manufacturer the face of the sign plate shall have a coat of
clear lacquer of a type designated by him.
24
The top of sign support posts shall be capped with a plastic cap.
13.2.4
Installation Requirements for Traffic Signs
All sign faces shall be of the designated type, colour and size.
Signs delivered for use in the project shall be in new and unused condition, except where
otherwise designated; and shall be stored off the ground and under cover in a manner
approved by the Engineer. Any sign damaged, discoloured or defaced during transportation,
storage or erection shall be rejected.
The position and mounting height of each sign shall be as designated.
Designated post lengths are approximate only. When progress of the work is at the
appropriate stage the Engineer will authorise the location of each sign, with the chainage and
offset distance from the edge of the road pavement. The Contractor shall be responsible for
determination of the exact post lengths to provide the designated vertical clearance. Field
cutting of posts shall be performed by sawing. Welded posts will not be permitted.
All posts shall be erected vertically and where two or more posts are provided for any sign
the faces of these posts shall be lined up and their deflection angle checked for compliance
with this Part before concreting in.
For a period of 14 days after concreting in position, all posts shall be suitably braced to
prevent movement. Sign faces should not be fixed to posts until after the bracing has been
removed and the Engineer has inspected and approved the post stability and foundations.
All posts shall be of the designated type and shall be protected against corrosion by hot dip
galvanising to BS EN ISO 1461.
Unless otherwise designated, all signs shall be erected so that the edge and face of the sign
are truly vertical and the face is at an angle of 95 to the centreline; that is, facing slightly
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23
away from the centreline of the lane which the sign serves. Where lanes divide or are on
sharp curves, the Contractor shall refer the orientation of the sign face to the Engineer for his
instruction.
9
All sign supports shall be plumbed vertical.
10
The distance between the lower edge of the signs and the road surface shall be as
designated.
11
Signs shall be fastened to sign supports in accordance with the designated requirements and
the recommendations of the sign manufacturer to the satisfaction of the Engineer.
12
The Contractor shall at his own expense, immediately after erection and approval by the
Engineer cover the sign in order to prevent misleading information being displayed. The
covering shall be close weave hessian securely fixed over the face of the sign using a lacing
of nylon cord so as not to damage the sign. The Contractor shall maintain such coverings in
good order until receipt of the Engineer's instruction for their removal.
QCS 2014

Part
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13
Signs shall be thoroughly cleaned immediately before being handed over. The type of
detergent used shall be approved by the Engineer.
13.2.5
Advance and far Advance Directional Signs
The face of the sign shall be completely covered with 3M Diamond Grade or similar approved
reflective material complying with the following Table 13.1A for retro-reflectivity.
Table 13.1A
Minimum Coefficients of Retro-Reflection
2
(b)
30 Entrance Angle
0.33
0.5
1.0
430
350
110
45
20
300
250
75
33
15
250
200
60
25
10
80
65
20
10
4.0
0.33
0.5
1.0
150
130
30
18
7
170
140
40
19
7
50
40
13
5
2.5
0.5
35
30
10
3.5
1.5
1.0
20
17
6
2.0
0.7
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Observation Angle
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0.2
235
190
60
24
11
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White
Yellow
Red
Green
Blue
0.2
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White
Yellow
Red
Green
Blue
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Observation Angle
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4 Entrance Angle
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(a)
(c)
90 Orientation, 40 Entrance Angle
Observation Angle
White
Yellow
Red
Green
Blue
1
0.2
150
125
40
15
6
0.33
85
75
25
8
4
Observation (Divergence) Angle the angle between the illumination axis and the
observation axis
2
Entrance (Incidence) Angle The angle from the illumination axis to the retroreflector axis
the retroreflector axis is perpendicular to the retroreflective surface.
QCS 2014

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Values for screened red colour on white sheeting may be significantly lower.
The material also shall satisfy the requirements of the following Tables 13.1B & 13.1C with
regard to colourimetric and photometric performance.
Table 13.1B
Chromacity factors
1
Limit Y (%)
Min
Max
White
.035
.305
.355
.355
.335
.375
.285
.325
40
Yellow
.487
.423
.545
.454
.465
.534
.427
.483
24
45
Red
.690
.310
.595
.315
.569
.341
.655
.345
15
Green
.030
.398
.166
.364
.286
.446
.201
.794
Blue
.078
.171
.150
.220
.210
.160
.137
.038
10
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Colour
Table 13.1C
Minimum Luminance Factors
Factor
0.03
0.24
0.01
0.40
0.01
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Red
Yellow
Blue
White
Green
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Colour
All plastic sheeting shall be fixed in accordance with the sheeting manufacturers instructions.
Unless otherwise agreed by the Engineer, sign faces shall be formed from a single piece of
plastic sheeting.
Where, with the agreement of the Engineer, more than one sheet is used the number of
sheets shall be kept to a minimum.
Only vertical and horizontal joints shall be permitted and all joints in plastics sheeting shall be
overlapped by not less than 6 mm. The overlap on the horizontal joints shall be from the top;
but joints in plastics sheeting shall not be permitted. The number of joints shall be kept to
minimum.
Where sheeting is applied to extruded sections by pressure roller, it shall extend over the top
and bottom edges of these sections by not less than 3mm.
All materials comprising the sign face, including the background, border and legends shall be
carefully matched for colour at the time of sign fabrication to provide uniform appearance
both by day and night. The sheeting manufacturers recommendations on colour matching
methods shall be observed.
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Page 10
Letter, numerals, symbols and borders shall be of material compatible with the sheeting to
which they are applied.
They shall be applied in accordance with the sheeting
10
Sheeting materials including letters, numerals, symbols and borders shall be fully adhered
with a pre-coated heat activated adhesive using a vacuum applicator equipped with a
temperature controller and there shall be no air bubbles, creases, cracks or other blemishes.
Application of the material shall be made using equipment specifically designed and
manufactured for the purpose by the sheeting manufacturer and maintained according to his
instructions. Where the sheeting manufacturer requires the assembly materials to be
provided with a coat of clear lacquer, it shall be uniform and continuous. All lacquer shall be
applied at the time of fabrication of the sign face and shall be of a type specified or supplied
by the sheeting manufacturer.
11
Details of the graphic designs, Arabic and English legends to be used on directional and
certain informatory signs are given on the Contract Drawings. The Contractor shall submit
design drawings detailing the proposed layout of all such signs for the approval of the
Engineer prior to their manufacturer. Otherwise, the signs shall be in accordance with the
specified regulatory, warning and informatory signs detailed in the Qatar Traffic Manual,
Volume 1.
13.3
PAVEMENT MARKINGS
13.3.1
Scope of Work
This Work shall consist of the supply and application of thermoplastic road marking paint for
marking of the pavement as outlined herein. It shall include the marking of the centreline, the
shoulder strip or edge, the barrier lines, the cross walks and any other markings required on
the pavement for the control and direction of the traffic.
Where designated, thermoplastic road marking paint shall be used in the construction of
rumble strips and jiggle bars. In such cases the requirements of this Part will apply except
that the thickness and profile of the thermoplastic will be as per the designated details.
The pavement markings shall be painted on the road to the dimensions and in the locations
designated on the drawings as per Qatar Traffic Control Manual.
The Contractor shall set out the markings and obtain the Engineer's approval before
beginning the work.
13.3.2
Materials for Pavement Markings
The material used shall conform to the superimposed type British Standard Specification for
Road Marking Materials BS 3262: Part 1. Where the materials do not conform to the BS
the deviations shall be clearly given in reference to the relevant tables and paragraphs of BS
3262: Part 1.
Ballotini shall comply with the requirements of BS 6088.
The material shall consist of light coloured aggregate, pigment and extender, bound together
with hard wearing resins, plasticised with oil as necessary in approximately the proportions by
weight as Table 13.1.
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Table 13.1
Composition of Thermoplastic
Material
Composition
Aggregate
40 %
Ballotini
10 - 20 %
Pigment and Extender
20%
Binder
20 %
The Contractor shall be responsible for blending the material to ensure that the performance
requirements of this part of the specification are met. This approximate composition of the
material as indicated above shall include the sprayed on ballotini.
The grading of various ingredients shall be such that the final product, when in a molten
state, can be sprayed on the surface at a nominal 1.5 mm thickness.
The aggregate shall consist of white silica sand, crushed calcite, calcined flint or quartz, or
other approved aggregate, and the colour shall comply, with the requirements laid down in
paragraph 4b of BS 3262: Part 1.
Ballotini incorporated in the mixture shall be reasonably spherical, and free from flaws and
not less than 80 % shall be transparent glass. The grading of the ballotini shall be as stated in
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BS 6088.
The pigment shall be titanium dioxide in accordance with paragraph 6a (I) of BS 3262: Part 1
and shall be not less than l0 % by weight of the mix.
The extender shall be whiting in accordance with paragraph 6b of Part 1 of BS 3262.
10
For yellow material sufficient suitable yellow pigment in accordance with BS 3262 shall be
substituted for all or part of the titanium dioxide to comply with the performance requirements
of this specification.
11
The binder shall not contain more than 5 % of resin or other acidic material. It shall consist
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mainly of hydrocarbon resins plasticised with mineral oil.

12
The resins used shall be of a colour at least as pale as Grade WG resin. It shall have an acid
value not greater than 2, and must pass the heat stability test described below.
13
The oil used as plasticiser shall be a mineral oil with colour and viscosity as defined in
paragraph 7a (ii) of BS 3262: Part 1; i.e., at least as pale as grade 4 on the P-R-S- Shellac
and Varnish "A" Disc, and 1/2 to 3 1/2 poises at 25 C viscosity. In addition, when heated for
16 hours at 150 C it shall not darken excessively.
14
The softening point of the binder shall be used only as a guide to quality control, and the
behaviour of the thermoplastic shall be judged from the performance tests described below.
15
The viscosity of the melted binder at the spraying temperature must be such as to produce a
thermoplastic mix of the required spraying properties.
QCS 2014
16

Part
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The temperature limits imposed by BS 3262: Part 1 for materials based on resin shall not
apply. Temperatures up to 220 C may be used; at these temperatures the material shall not
discolour in the time required for its use.
Containers shall be made of a material which does not contaminate the contents and will
protect the contents from contamination.
18
The capacity of each container shall be not less than 25 kg or more than 100 kg.
19
Each container shall be clearly marked with the manufacturer's name, batch number and
date of manufacture.
20
Testing for the composition of the material and the grading of the aggregate shall be carried
out in accordance with the methods in BS 3262 except as modified by this part of the
specification. The composition of the laid material as found on analysis shall comply with
Table 13.2 & Table 13.3;
Table 13.2
Proportion of Constituents
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Percent by Weight
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Constituent
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Binder
Maximum
18
22
78
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Aggregate, pigment and extender and ballotini
Minimum
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Table 13.3
Grading of Combined Aggregate Pigment and Extender
Sieve (mm)
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BS
Percent by Weight
Minimum
Maximum
0.850
100
0.600
75
95
0.300
35
65
0.075
25
35
13.3.3
Application of Thermoplastic
Application shall be by mobile sprayer, either hand-propelled or self-propelled.
The road surface shall be dry, and free of loose, detritus mud, or other extraneous matter.
All existing markings of more than 1 mm thick shall be removed completely before new
markings are applied.
A tack coat should not be necessary when the thermoplastic is applied to carriageways.
Where it is considered necessary to use a tack coat, this shall be rubberised type
recommended by the manufacturers of the thermoplastic material.
QCS 2014

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In addition to the ballotini included in the mix, an additional quantity of glass beads shall be
sprayed on to the hot thermoplastic line at the time of application. The rate of application
2
shall be at the rate of about 0.5 kg/m .
The thermoplastic material shall be applied in intermittent or continuous lines of thickness

1.5 mm 0.3 mm.
For special lettering, arrows or symbols the material shall be applied by hand methods.
The finished lines shall be free from raggedness at all edges and be true in place with the
road surface.
The upper surface shall be level, uniform and free from streaks, blisters, lumps and other
defects.
13.3.4
Performance Requirements and Testing
The thermoplastic material shall meet the requirements of Table 13.4:
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Property
3
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Table 13.4
Properties of Thermoplastic Material
Maximum
2.0 approx.
230
95
65
45
No Slump
45
105
25
0.3
-
Testing of thermoplastic material shall be as described below. All specimens shall be

prepared by carefully heating a representative sample to a temperature of (softening point +
50 C) whilst stirring thoroughly to avoid segregation. The molten material shall be used
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Density, g/cm
Open flashpoint C
Softening point (ring and ball BS 2000 Part 58), C
Luminance
Luminance (Yellow)
Flow resistance
Flow resistance after 48 h at 40 C
Abrasive wear 9/100 revs
Skid resistance
Minimum
without delay.
3
Heat Stability Luminance Test: The material shall be cast on to a suitable flat, glossy surface
coated with a colourless release agent to give a slab 100 mm square by 3 mm thick. The
luminance of the cast face, with reference to that of a block of magnesium oxide (luminance
factor l00) shall be measured with the sample illuminated by a tungsten light source at an
angle of 45 viewed at right angles by a selenium barrier layer photoelectric cell.
Flow Resistance Test: The material shall be cast into a conical mould having an apex angle
of 60 and a vertical height of 100 mm. After cooling and setting for 24 h the cone shall be
removed from the mould, placed on a flat level surface and maintained at a temperature of
23 C 2 C for 48 h.
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Impact Test: A 3 mm thick coating of material shall be prepared as a screed on a Monel alloy
panel 1.25 mm thick, previously coated with rubberised bitumen emulsion. The impact
instrument, a 4.7 kg weight, shall be dropped vertically through 250 mm on to the surface of
the panel, striking the surface with a hemispherical indentor of radius of 6 mm. The panel
shall be retained by a metal block drilled to allow the indentor to strike the panel, with the
depth of indentation limited to 2 mm. Five panels shall be tested and no fracture shall result
from impact. A crack not longer than 2 mm will be accepted provided there is a smooth
indentation in the material.
Abrasive Test: A 3 mm thick coating of material shall be screeded on to a Monel alloy panel
and subject to wet (water lubricated) abrasion at 23 C on a Taber Model 503 standard
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abrasion tester using H-22 Calibrade wheels, refaced between tests. The loss in weight after
two successive tests of 100 revolutions shall be recorded and the average taken as the
abrasive wear. The abrasive wear shall be less than the figure in Table 13.4.
Skid Resistance: A 100 mm wide line of material 1.5 mm thick shall be screeded on to a flat,
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level base for a minimum length of 800 mm. After cooling to ambient temperature the skid
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resistance shall be measured using the TRRL Portable Tester as described in Road Note 27.
Measurements shall be made on different parts of the specimen, corrected for temperature
effects, and the average recorded.
Protection of Pavement Markings
The Contractor shall control the traffic in such a manner as to protect the freshly marked
surface from damage. The traffic control shall be so arranged as to give minimum
interference to the travelling public. Signs, barricades, flagmen and control devices shall be
supplied by the Contractor and a system of spaced warning flags or blocks shall be used to
protect the fresh marking until it has dried as required. Any lines, stripes or markings which
become blurred or smeared by the traffic shall be corrected by the Contractor.
13.4
TEMPORARY ROAD MARKING
13.4.1
ROAD MARKING PAINT
The use of road marking paint shall be restricted to traffic diversions or for other uses as
Road marking paint shall be by an approved manufacturer. It shall be suitable for applying by
brush or mechanical means to cement, concrete or bituminous pavement to give a
chemically stable film of uniform thickness and shall be chlorinated rubber, one pack epoxy
or alkyd based.
White paint shall contain not less than 6 % by mass of titanium dioxide as a pigment,
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13.3.5
conforming to type A (anatase) or type R (rutile) specified in BS EN ISO 591-1

4
Yellow paint shall be standard colour BS 381C No. 355, except where an alternative shade
has been designated, and contain not less than 6 % by mass of a suitable yellow pigment.
QCS 2014

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Page 15
The paint shall be supplied fresh and ready for use in sealed containers and stored in
accordance with the manufacturer's instructions. The paint shall be applied without the use of
thinners or other additives.
Paint shall be applied at a covering rate recommended by the manufacturer and approved by
the Engineer.
Where markings are to be reflectorised with ballotini it shall be sprayed uniformly on to the
2
wet paint film at the rate of 400-500 g/m . Ballotini shall be graded to comply with the
Road marking materials shall only be applied to surfaces which are clean and dry. Markings
shall not be ragged at their edges and shall be uniform and free from streaks. Carriageway
lane and edge lines shall be laid by approved mechanical means to a regular alignment.
13.4.2
ADHESIVE ROAD MARKING STRIP
For temporary diversions the use of self adhesive proprietary marking strips will be permitted.
Self adhesive proprietary road marking strips shall be of the details and dimensions shown
on the drawings.
The strips shall have a metallic backing that peels of and shall have reflective properties by
the incorporation of ballotini.
13.4.3
REMOVAL OF ROAD MARKINGS
Where it is necessary to remove existing thermoplastic road markings the material shall be
completely removed by sand blasting or other abrasive methods.
Care shall be taken to avoid damaging the wearing course surface during this operation.
Any damage caused to the wearing course shall be made good to the satisfaction of the
engineer.
The painting over of old road markings with black paint shall not be permitted.
13.5
REFLECTIVE STUDS
13.5.1
General
Reflective road markers shall be smooth, pressure moulded aluminium alloy, complying with
BS 1490 with lenses to meet the performance requirements of this specification. They shall
be capable of withstanding the climatic conditions of Qatar and be maintained free. A
performance guarantee of five years is required.
The Road stud shall measure 130 mm x 115 mm x 25 mm when seated on the road surface.
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Exact size of the road stud shall be as designated.

3
The shaft shall be "Anti-Twist/Hot-Tite", 76 mm long.
The slope of the reflecting face shall be 20.
QCS 2014

Part
Page 16
The enveloping profile of the head of road studs shall be smooth and the studs shall not
present any sharp edges to traffic.
The body of the stud shall be constructed in one integral part.
The anchorage part of the stud shall consist of a circumferential ribbed shank with parallel
flats, the flats on the alternative ribs being at 90 to each other to prevent rotation of the stud
when located in the road surface.
The studs shall be constructed in aluminium alloy to BS 1490 to provide a robust and durable
location for the lenses. The alloy shall have the characteristics listed in Table 13.5.
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0.1
13.0
0.6
0.5
0.1
0.1
0.1
0.1
0.5
Remainder
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Maximum (%)
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Copper
Silicon
Iron
Manganese
Nickel
Zinc
Lead
Tin
Titanium
Aluminium
Minimum (%)
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Composition
Table 13.5
Composition of Alloy for Road Studs
Reflective studs mechanical and physical properties shall comply with the Table 13.6
requirements:
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The Contractor shall submit mill certificates for the material showing the actual composition.
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Table 13.6
Mechanical and Physical Properties of Reflective Studs
Mechanical Properties
0.2 proof stress test, N/m

2
Tensile Strength, N/mm .
Elongation, mm
Physical Properties
Specific gravity
Minimum
120
280
2-5
Minimum
2.65
Method of Casting
Injection
Corrosion rating
Excellent
Brinell hardness number
55 - 60
13.5.2
Reflectors
The reflectors shall be rectangular in shape. The rectangular reflective unit shall be firmly
located into a recess within the body of the stud such that the reflective face is established at
the correct orientation. A sample of the proposed reflective studs shall be submitted for the
Engineers approval.
QCS 2014

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Page 17
The Optical Performance (specific intensity) of each crystal reflecting surface shall not be
less than the values listed in Table 13.7.
Table 13.7
Optical Performance of Reflectors
Observation Angle,
0.3
0.5
1.0
2.0
Entrance Angle,
10
10
15
Specific Intensity
160
100
27
Specific Intensity
120
72
20
For yellow reflectors the specific intensity shall be 50% of the value for crystal. For red and
green reflectors the specific intensity shall be 20% of the value for crystal.
The colour limits of the reflector(s) when illuminated by CIE standard illumination A, with an
entrance angle V= 0 , H= 5 L or R, and an observation angle of 0.3 shall comply with the
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requirements given in the following paragraphs.
White (uncoloured) reflectors shall not produce a selective reflection; that is to say, the
trichromatic co-ordinates X and Y of the standard illuminant A used to illuminate the reflector
shall undergo a change of more than 0.91 after reflection by the reflector.
Red reflectors shall have chromaticity co-ordinates which lie within the area formed by the
straight lines defined by the following pairs of points, 1 and 2, 2 and 3, the spectrum locus,
and the line joint the ends of the spectrum locus:
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Point 2
0.657
0.335
Point 3
0.730
0.262
Amber reflector shall have chromaticity co-ordinates which lie within the area formed by the
straight lines defined by the following pairs of points, 1 and 2, 2 and 3, 3 and 4, and the
spectrum locus:-
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Point 1
0.665
0.335
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Co-ordinate
X
Y
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Co-ordinates
X
Y
Point 1
0.330
0.385
Point 2
0.228
0.351
Point 3
0.321
0.493
Point 4
0.302
0.692
Compliance with the colorimetric requirements shall normally be verified by means of a visual
comparison test. If any doubt remains after this test, compliance shall be verified by the
determination of the trichromatic co-ordinates as defined in the proceedings of the 1951
meeting of the International Commission (CIE).
13.5.3
Reflectivity
A sample of the road stud shall be submitted by the Contractor and relevant technical
information, catalogues supplied by the manufacturers shall accompany the sample.
The reflectivity of the stud when new shall well exceed minimum standard as laid down in BS
873 and meet typical values as shown below:
QCS 2014

Part
Page 18
Table 13.8
White Reflectors Tested to BS 873
Orientation
CIL Value
(mod/1x)
CIL Value
(mod/1x)
Typical
Minimum
5-7.5
26.5-30
59-93
100-190
2
10
15
20
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Table 13.9
Amber Reflectors Tested to BS 873
Observation angle 2 Entrance Angle 15 L and 15 R.

Observation Angle 2 Entrance Angle 10 L and 10 R
Observation Angle 0.5 Entrance Angle 10 L and 10 R
Orientation
CIL Value
(mod/1x)
Typical
Minimum
3-4
10-20
20-50
30-90
1.0
5.0
7.0
10.0
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Observation angle 2 Entrance Angle 15 L and 15 R.

Observation Angle 1 Entrance Angle 10 L and 10 R.
Observation Angle 0.5 Entrance Angle 10 L and 10 R.
CIL Value
(mod/1x)
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Table 13.10
Red Reflectors Tested to BS 873
Orientation
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Observation angle 2 Entrance Angle 15 L and 15 R

Observation Angle 1 Entrance Angle 10 L and 10 R
CIL Value
(mod/1x)
CIL Value
(mod/1x)
Typical
Minimum
1.5-2.0
4.5-7
10-20
16-35
2.0
10.0
15.0
20.0
13.5.4
Installation of Reflective Studs
Reflective studs shall be installed and anchored to the pavement as follows:

(a)
Drill a hole into the asphalt pavement to the dimensions recommended by the
manufacturer. Ensure that the hole is free of dust and also the pavement surface
within a radius of 200 mm of the hole is free from debris and dust.
(b)
Fill the hole to overflow with the two part epoxy adhesive of the type specified in clause
10.6.2.
QCS 2014

Part
Page 19
(c)
Immediately after pouring the grout, the road stud shall be inserted into the hole and
the reflective face aligned to the oncoming traffic. The road stud shall be firmly
embedded into the ground ensuring a good bed of grouting compound under the road
stud and solid fixing. Protect the installed marker until the epoxy adhesive has
completely set.
(d)
Clean off any surplus grouting and protect the road stud from traffic for approximately
60 minutes.
NON-REFLECTIVE STUDS
13.6.1
General
Non-reflective road studs shall be ceramic and of approximately 100 mm diameter at the
base, the studs shall consist of a heat-fired, vitreous ceramic base and a heat fired opaque
smooth matte surface.
The colour of the studs shall be white unless otherwise designated. The base of the stud
shall have a rough surface to ensure a good bond to the road.
The adhesive used for the installation of non-reflective ceramic studs shall be a two part
epoxy or other material recommended by the manufacturers and tested under the climatic
and traffic conditions prevalent in Qatar.
The non-reflective ceramic studs shall conform to the dimensions and shapes shown on the
drawings and shall be installed at the location indicated on the drawings or where designated
by the Engineer.
The studs shall be ceramic manufactured and shall consist of a heat-fired, opaque, glazed
surface. The glazed surface shall not be present on the bottom of the studs which will be
cemented to the road surface. The outer surface of the studs shall be smooth except for
purpose of identification, and all edges exposed to traffic must be convex and the radius
nearest the edge may be less. Any change in curvature shall be gradual. The bottom
surface of the marker shall be of a roughness comparable to at least that of a fine grade of
sandpaper, and shall be substantially free form gloss or substance that may reduce its bond
to the adhesive.
The body of the marker shall be white.
Brightness will be measured with equipment conforming ASTM E97 using a Brightness
Standard of 75%. The minimum weight of the marker shall be 125 grams.
A random sample of 5 buttons shall be subjected to the compressive load test. The average
compressive strength of the 5 buttons shall not be less than 680 kg and no individual button
shall have a compressive strength less than 544 kg. The button shall be centered base
down, over the open end of a vertically positioned hollow metal cylinder. The cylinder shall
be 25.4 mm high, with an internal diameter of 76.2 mm and a wall thickness of 6.4mm. A
load necessary to break the button shall be at speed of 2.5 mm per minute to the top of the
button. In the event that the bottom of the marker is dimpled, a 2 mm layer of wood shall
insert between the base of the maker and the hollow cylinder. Should any of the samples
tested for strength fail to comply with this specification, 10 additional samples will be tested.
The failure of any one of the additional samples shall be cause for rejection of the entire lot or
shipment represented by the samples.
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13.6
QCS 2014

Part
Page 20
The studs shall be produced from a combination of intimately mixed clays, shales, flints,
feldspars or other inorganic material which will ensure the required properties are met. All
studs shall be thoroughly and evenly matured and free from defects which affect appearance
or serviceability.
The studs shall be of uniform composition and free from surface irregularities cracks,
chipping, peeling spoiling, crazing and any other physical damage. The studs shall be precast
in the form of a single based spheroidal segment terminating in a rounded or squared
shoulder.
The height of the studs above road level shall be between 18 mm and 20 mm.
Compliance of the studs with respect to appearance, shape, dimensions and compressive
strength shall be determined in accordance with CML Method 14-97. In particular, they shall
exhibit an average compressive load at failure for each sample of 5 studs of not less than
680 kg and no individual value shall be less than 544 kg. Furthermore, the water absorption
shall not exceed 1.0% when tested in accordance with ASTM C373. And the glazed surface
of the stud shall not craze, spell, or peel when subjected to one cycle of the Autoclave test at
250 psi when tested in accordance with ASTM C424.
The adhesive for reflective studs and non-reflective studs shall be a two component epoxy.
Each component shall be supplied in separate clearly marked containers and the time of use
the contents of the two parts shall be thoroughly redispersed by mixing. Only complete
containers of each part shall be used and these shall be mixed thoroughly until a uniform
colour is achieved with no streaks of individual colours. The blend of the two components of
epoxy thoroughly mixed together shall meet Table 13.11.
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13.6.2
Property
Value
Gel time
5 to 30 minutes
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Table 13.11
Specification for Epoxy Adhesive
Minimum Tensile strength of 1.6 mm film between steel blocks cured

24 h at 21 C tested at 21 C
7 N/mm
Shore hardness on 24 h sample at 21C
70 to 80
Shore hardness on 24 h sample at 49 C
30 minimum
Deformation temperature, C
49 minimum
The Contractor shall submit recent test results that confirm the above properties of the
supplied adhesive are met.
The epoxy shall be used strictly in accordance with the manufacturers recommendation for
storage preparation, mixing and application. Any differences from the manufacturers
recommendations and this specification shall be referred to the Engineer.
QCS 2014

Part
Page 21
The final colour of the epoxy adhesive shall be uniform grey unless designated otherwise.
13.6.3
Installation
All sand, dirt and extraneous material shall be removed from the mark location and the
surface cleaned and abraded. Cleaning shall be by compressed air. In the case of adhering
material the application of heat or sand blasting will be required.
The surface shall be completely dry for the application of the adhesive.
The base of the supplied stud shall be free of any wax or grease from the manufacturing
process. Any such wax or grease shall be sanded off the bottom of the marker.
The adhesive components shall be stored at the temperature recommended by the

manufacturer both before use and during application. The two components of the adhesive
shall be added to each other just before use, any unused mixed adhesive shall be discarded
when catallic actions cause stiffening and reduction of workability or balls of gelled resin
formed in the container.
The mixed adhesive shall be applied to the prepared pavement area to be covered by the
marker and the stud pressed onto the adhesive so as to squeeze out a small bead of
adhesive around the periphery of the stud.
The Contractor shall carry out a trial outside of the permanent works to establish the
approximate amount of adhesive required per marker and application on the works shall be
carried out to this quantity.
The studs shall not be fixed to the pavement where asphalt has been laid within the last 14
days unless otherwise directed by the Engineer. The studs shall be spaced and aligned as
designated or as per the Qatar Traffic Control Manual. The tolerance for placing shall be not
more than 10 mm.
Where studs are to be applied to pavement where the road is to be opened to public traffic
shortly after placing, the preheating of the roadway surface to permit a rapid set is permitted.
In such cases, the procedure followed shall be as recommended by the supplier of the epoxy
adhesive and as approved by the Engineer.
On roadway sections that are not opened to public traffic no preheating of the studs or road
2
surface is required as long as the required bond strength of 12 kg/cm can be achieved in
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less than 3 h.
END OF PART
QCS 2014

Part
14: Works in Relation to Services
Page 1
14
WORKS IN RELATION TO SERVICES ........................................................ 2
14.1
GENERAL ...................................................................................................... 2
14.1.1
14.1.2
14.1.3
14.1.4
Scope
References
Submittals
Notification to Service Authorities & Statutory Bodies
14.2
SERVICES GENERALLY .............................................................................. 3
14.2.1
14.2.2
14.2.3
14.2.4
14.2.5
14.2.6
14.2.7
14.2.8
14.2.9
General
Safety
Marking Services
Location of Existing Services
Protection of Services
Relocation of Services
Services Ducts
Excavation for Ducts
Bedding and Laying of Ducts
14.3
PARTICULAR REQUIREMENTS .................................................................. 8
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2
2
3
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14.3.1 Qatar General Electricity and Water Corporation, Electricity Networks

Affairs, QGEWC (ENA)
14.3.2 Qatar General Electricity and Water Corporation, Water Networks
Affairs, QGEWC (WNA)
14.3.3 Telecom Provider
14.3.4 Qatar Petroleum (QP) and Qatar Gas
14.3.5 PWA, Storm water and Groundwater
3
4
4
5
5
6
7
7
8
8
10
10
12
13
QCS 2014

Part
Page 2
WORKS IN RELATION TO SERVICES
14.1
GENERAL
14.1.1
Scope
This Part includes the provision of new services and the seeking, protection, diversion and
relocation of the existing services for the following service authorities:
General
Earthworks
Road Drainage
Section 1
Section 5
Section 20
General
Concrete
Drainage Works For Buildings
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Part 3
Part 17
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This Section
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Qatar General Electricity & Water Corporation (QGEWC)

Telecom Provider
Qatar Petroleum (QP) and Qatar Gas
Public Works Authority (PWA)
Urban Planning and Development Authority (UPDA)
Local Municipality
14
References
The following standards and reference documents are referred to in this Part:
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14.1.2
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BS 2484......................Straight concrete clayware cable covers
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BS 2782......................Methods of testing plastics.
Submittals
The Contractor shall prepare and submit records and sketches showing position, levels and
types of each existing service including manholes, joint boxes, inspection chambers and
connections. These records shall be maintained in the form of a daily diary.
The Contractor shall prepare and submit shop drawings for utility protection work and obtain
the approval of the appropriate Authority before beginning construction.
Samples of proposed ducts shall be submitted to the Engineer for his approval beforehand.
The Contractor shall prepare and maintain up-to-date drawings for each service authority
giving details of each duct laid including precise location, level, number and type, and these
drawings are to be submitted to the Engineer.
The Contractor shall keep accurate records of the arrangement, positions and details of all
works constructed by him as Record Drawings. The details, format, extent and procedures
for the preparation and submission of the record drawings shall be in accordance with
Section 1.
14.1.3
QCS 2014

Part
Page 3
Notification to Service Authorities & Statutory Bodies
All works in relation to services shall be carried out by a contractor or subcontractor

prequalified and approved by the concerned service authority. Proof of such approval shall be
required in writing before the start of Works on the Site. The name of any subcontractor to be
used shall be as designated.
No work concerning services will be started without having first informed and obtained
approval of the concerned service authorities. Before opening the ground for any purpose,
the Contractor must notify all concerned parties by issue of formal "Notice of Intent" and must
obtain information by formal notice regarding the location of all services. The complete
responsibility for obtaining this information rests with the Contractor. "Notices of Intent" shall
be circulated to all concerned parties including those listed in Clause 11.1.1:
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Qatar General Electricity & Water Corporation (QGEWC)

Telecom Provider
Public Works Authority (PWA)
Urban Planning and Development Authority (UPDA)
Local Municipality
14.1.4
Prior to commencing any work on excavation in a roadway the Contractor shall obtain the
approval of the Traffic Police. All excavations in a roadway shall be carried out in accordance
with PWA road opening procedures.
Drawings and notices shall be sent in duplicate one of which shall be retained by the
addressee and the other returned to the sender duly marked to show underground services.
"Notice of Intent" will be given 14 days in advance of starting the proposed Works. In the
event that the work is not started within eight weeks of the date of the "Notice of Intent", it will
be deemed to have lapsed. A further Notice of Intent will then be submitted. The Contractor
shall furnish copies of the above Notices of Intent to the Engineer.
The Contractor's attention is particularly drawn to the procedures to be followed concerning

existing services and service diversions laid down in all current administrative orders of the
service authorities.
14.2
SERVICES GENERALLY
14.2.1
General
The Contractor shall acquaint himself with the position of all existing services and shall obtain
clearance from the concerned service authority before commencing any work in a particular
area. Written evidence of such clearance shall be provided to the Engineer by the Contractor.
The position, types of ducts, pipes, cables, manholes and related structures are designated,
but the final location will be determined on site by the Contractor and submitted to the
Engineer for approval after having consulted with the concerned service authorities.
All concrete works shall conform to the requirements of Section 5.
The Contractor will be fully responsible for ensuring observance of the requirements of this
clause by his subcontractors.
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QCS 2014

Part
Page 4
Where any utility or service works are to be constructed under a separate contract by the
Engineer within the Site and concurrent with the execution of the Works, the Contractor shall
co-operate with the other contractor and shall co-ordinate his construction operations to avoid
interference with the other contractor's operations.
Any public or private service for water, electricity, drainage, or other utility, affected by the
Works shall not be interrupted without the written permission of the Engineer. Such
permission will be withheld until suitable approved permanent or temporary alternative
services have been provided by the Contractor or by the owner of the utility or his agents.
For temporary traffic diversions as may be required for the construction of road crossings, full
liaison with the Municipality and Police shall be required as well as compliance with the
requirements of the PWA road opening procedures.
The Contractor shall be responsible for following each service authorities inspection and
testing procedures.
The Contractor shall be responsible for liaison with each service authority to obtain their
approval for the completion of the works.
14.2.2
Safety
The Contractor shall be responsible for public safety during execution of work. He shall take
all measures, including, where necessary, the provision of ropes, picket fences, and other
temporary barriers on the sides of trenches and excavations with warning lights.
The Contractor shall arrange for night watchman and any other measures required to ensure
the safety of the public.
The Contractor will be held responsible for any damage to property or injury to persons due
to his negligence. Any instruction from the Engineer concerning the safety aspects of the
work must be carried out immediately, but the Contractor shall remain responsible for the
adequacy of the safety measures.
The Contractor shall take into account the current laws regarding the safety of service lines,
together with any amendment or additions thereto. The Contractor shall be responsible for
locating or verifying the location of existing services, liaison with the various service
authorities and complying with the above.
14.2.3
Marking Services
All services shall be provided with continuous warning tapes with the requirements of the
following paragraphs.
The Contractor shall install approved warning tapes during backfilling work over buried pipes,
cables, conduits and ducts, as required. Warning tapes shall be coloured and inscribed for
identification according to the requirements of the concerned service authority.
Warning tape shall be approved high quality, acid and alkali-resistant polyethylene film
250 mm wide, and with a minimum thickness of 150 microns. Tape shall have a minimum
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tensile strength of 125 kg/cm2 longitudinally and 105 kg/cm2 laterally with an elongation
factor of 350 %.
QCS 2014

Part
Page 5
Tape shall be printed with 50 mm high black lettering, alternatively in Arabic and English. The
complete wordings shall be repeated every 2 m along the tape. The colours shall be vivid,
glossy and permanent with a life expectancy of 40 years.
Warning tapes shall be placed with the inscriptions facing upwards. The level of the tape
relating to the top of service shall be in accordance with the requirements of the concerned
service authority.
Warning tapes over non-metallic services shall be backed with aluminium foil to facilitate
detection.
14.2.4
Location of Existing Services
The positions of all designated public and privately owned services have been based on the
records of various service authorities and must be regarded as approximate.
The positions designated for existing services are for informational purposes only and do not
necessarily show exact locations, depths, spacings, or the presence and location of smaller
services such as house connections which are not normally designated.
The Contractor shall verify this information and satisfy himself as to the exact nature and
position of all such apparatus. The Engineer does not guarantee the accuracy of the
designated information, and no warranty is given or implied.
The Contractor shall verify the position of services by digging trial trenches and pits. If ducts,
pipes, cables and manholes which are not designated are found, the Engineer and the
concerned service authority shall be informed as soon as possible. The concerned service
authority will then instruct on the action to be taken, if any.
The Contractor shall excavate by hand, take trial pits at regular distances and also at all road
intersections to locate existing services, their number, depth and route direction. As these
services are located the Contractor shall prepare record drawings indicating the
aforementioned information which shall be submitted to the Engineer.
14.2.5
Protection of Services
The Contractor shall take any and all measures reasonably required by any public or
concerned service authority for the support and full protection of all mains, pipes, cables and
other apparatus during the progress of the Works, and shall construct and provide to the
satisfaction of the concerned service authority, all works necessary for the prevention of
damage or interruption of services.
The protection of the existing services shall be carried out before the earth work starts in the
vicinity of the services to be protected.
If some services have already been protected by the various Departments, no protection will
be carried out under this Contract, but such protection can be extended or upgraded as
instructed by the Engineer on Site after having consulted with the concerned service
authority.
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QCS 2014

Part
Page 6
If in the execution of the Works, by reason of any subsidence caused by, or any act of
neglect or default of the Contractor, any damage to any apparatus or any interruption of, or
delay to, the provision of any service is caused, the Contractor shall report it to the Engineer
immediately and bear and pay the cost reasonably incurred by the service authority
concerned in making good such damage and shall make full compensation to the authority
for any loss, sustained by reason of such interruption or delay.
All protected services, existing ducts found or newly laid ducts shall be marked with markers
of approved of size and type as designated. The location of markers shall be as designated.
No asphalt course will be laid unless the ends of the ducts or protected services have been
exposed and marked with markers.
The Contractor shall, at all times during the progress of the works, afford facilities to properly
accredited agents of any concerned service authority for access to all or any of their
apparatus situated in or under the site, as may be necessary for inspecting, reporting,
maintaining, removing, renewing or altering such apparatus in connection with the
construction of the Works or any other purpose whatsoever.
14.2.6
Relocation of Services
The Contractor shall relocate certain utilities to service reservation areas as designated. This
work may only include constructing necessary protective housing such as box culverts, slabs,
and concrete encased sleeves in the service reservation areas for utility lines to be relocated.
Or this work may include necessary protective housing as described above and, in addition,
the relocation of specific utility lines to the service reservation areas.
In both cases the Contractor shall complete the necessary survey to establish the lines and
levels, prepare shop drawings and submit them to the Engineer for his review. The
Contractor shall obtain approval from the concerned service authority before commencing
this work.
After existing services, according to the Engineer's instruction, have been exposed and if
according to the opinion of the Engineer and after approval of the concerned service
authorities it is found necessary to proceed with the lowering or diversion thereof, the
Contractor shall proceed with the relevant excavation in co-ordination with the said
authorities.
The Contractor shall maintain records of such excavation in a form acceptable to the
Engineer. Two copies of such records shall be submitted to the Engineer on a weekly basis
or as agreed with by the Engineer.
All materials removed shall be disposed of by the Contractor as designated.
When directed by the Engineer, all such excavations shall be backfilled with suitable material,
placed and compacted as designated.
The Contractor shall place fill material and compact with care to avoid damage to the existing
services. The Contractor shall be responsible for any and all damages caused by his
construction operations.
The works relevant to the lowering of existing services will be started as soon as, according
to the Engineer, all the necessary precautions have been taken to prevent any injury to
person or damage to property or services.
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QCS 2014

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The excavation for lowering existing services shall be performed by hand down to the
elevation indicated by the Engineer and the concerned service authority.
10
At all times the Contractor shall provide and maintain access to the adjoining properties to
14.2.7
Services Ducts
Service ducts shall be provided as designated so that future services can pass through them
without disturbing road construction.
The Contractor shall supply, unless otherwise designated, and install all the necessary
service ducts required for the project. The duct material shall be as designated.
Road crossing ducts shall extend beyond the road or shoulder line at each side of the road
as designated.
To prevent earth blocking the ducts, the openings at both ends are to be protected with
appropriate blanking caps.
In general, all duct laying work is subject to the approval of the Engineer and any particular
requirements of the concerned service authority.
The Contractor shall after completing each duct, make the necessary arrangements with the
service authority for testing and acceptance of the work. As a minimum this shall involve the
verification of the duct by rodding or pulling through a mandrel.
14.2.8
Excavation for Ducts
The trench shall be excavated to the designated width and depth.
When appropriate, the excavation for the road crossing and laying of ducts, concreting and
related work shall only be carried out on half the width of the road at one time, the other half
being left available for traffic. In this case the necessary traffic warning signs on selfsupporting tripods or cones shall be provided well ahead of the duct crossing work and all
care and attention exercised to avoid risk of traffic accidents during preparation and
execution of the work.
All trenches and other excavation shall be maintained in a dry condition and the Contractor
shall arrange a suitable dewatering system for any dewatering involved, in agreement with
the Engineer, to keep the working place clean and dry.
The sides of pits and trenches shall be vertical and adequately supported at all times.
Excavations may if considered necessary be battered with a safe slope, but only with the
Engineer's written permission.
Where ducts are laid under any area of the road construction, the bottom of the excavation
shall be completed to a density of 95 % of the maximum dry density, as determined by BS
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1377 Test 13 or as otherwise approved by the Engineer.

6
Excavated material shall, if found unsuitable as defined in Part 3 of this Section, be disposed
of to an approved tip and replaced with suitable material. All surplus suitable excavated
material shall be used in road construction or disposed of in an approved manner.
QCS 2014

Part
Page 8
Where split ducts are required for existing services crossing the Works, hand excavation
shall be carefully undertaken until the position of the service to be protected is fully exposed.
14.2.9
Bedding and Laying of Ducts
As soon as possible after trench excavation, ducts of the required diameter shall be laid and
jointed as designated and in accordance with the manufacturer's instructions.
Ducts shall be laid to the designated lines and levels with the required depth of cover. Where
the designated minimum cover cannot be achieved, or as otherwise directed by the Engineer,
they shall be bedded and surrounded with 150 mm of grade 20 concrete.
Unless surrounded in concrete, ducts shall be bedded on a 150 mm thick layer of well graded
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sand of maximum particle size 5mm and fully surrounded with sand to a depth of 150 mm
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above the duct barrel, well packed and tamped. Filling with suitable material above this level
shall be free from large stones. For multiple ducts, the spaces between ducts are to be filled
with compacted sand and the ducts surrounded to a depth of l50 mm above the uppermost
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layer. Trench backfill shall be compacted to the designated requirements.

Ducts shall be cut by the Contractor as necessary only at right angles to their length using a
saw in a simple cutting guide. The inside cut edges Shall be thoroughly rounded off or
dressed before installation to prevent damage to cables drawn through the ducts.
In kerbed areas of new roadway duct markers shall be used. Duct marker shall be of
concrete construction, in-situ or precast depending on the location, as per the designated
details complete with approved abbreviation cast thereon. The finished product shall be solid
in appearance, free of segregation, honeycombing broken edges and other defects.
14.3
PARTICULAR REQUIREMENTS
14.3.1
Qatar General Electricity and Water Corporation, Electricity Networks Affairs, QGEWC
(ENA)
All of the works associated with electricity supply shall be carried out in accordance with the
latest specifications for materials, excavation and backfill, cable laying and jointing, as issued
by the QGEWC (ENA). Contractors are deemed to be in possession of the latest QGEWC
(ENA) specifications.
All QGEWC (ENA) MV, HV and EHV works shall be carried out by a Contractor or
subcontractor prequalified and approved by the QGEWC (ENA). Proof of such approval shall
be required in writing before the start of Works on the Site, and the name of any
subcontractor to be used shall be as designated. All cable jointers to be used on the Contract
shall be required to undertake and pass a trade test conducted by QGEWC (ENA).
The Contractor shall comply with all requirements of the Police Department for marking,
lighting and protecting excavation. It is the responsibility of the Contractor to ascertain the
requirements of the Police Department and to comply fully with these requirements.
Where carriageway works and road crossings are performed the Contractor shall provide
steel plates of sufficient size and quality to permit the safe passage of traffic and the plates
shall be so placed (and if necessary fixed) to permit reasonable traffic flow.
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All doorways, gates and entrances shall be kept clear with full access. Where excavations
impede pedestrian access crossing boards shall be provided. Crossing boards shall be 1250
mm wide with a handrail on both sides 1 m in height and guard-rails on both sides at
vehicular and pedestrian access to premises. Ducts will not be installed at entrances to
premises except on the express instruction of the Engineer.
Materials excavated shall be placed so as to prevent nuisance or damage. Where this is not
possible, the material shall be removed from site and returned for backfilling on completion of
cable laying. In cases where the excavated material is not to be used for backfilling trenches
it must be removed from site on the same day as it is excavated.
QGEWC (ENA) will require to carry out inspections at the following stages:
Completion of excavations.
(b)
Completion of bedding of trench before cable installation.
(c)
Cable installation.
(d)
Completion of surround over cables and installation of cable tiles.
(e)
Upon completion of reinstatement.
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(a)
The Contractor must not progress from one stage to the next of the above without the
approval of QGEWC (ENA) and the Engineer. The Contractor shall be responsible for
arranging inspections by QGEWC (ENA) to suit his programme of works.
Where materials are to be supplied by the Contractor, the requirements described in the
following paragraphs shall apply.
10
Materials shall be ordered in accordance with the specifications issued by QGEWC (ENA).
11
For works involving the use of high voltage overhead cables Contractors shall comply with
the requirements of QGEWC circular no 6.
12
Specifications and the details of the proposed supplier shall be submitted to QGEWC (ENA)
for approval before a firm order being placed.
13
On delivery of materials to Qatar, QGEWC (ENA) inspectors shall be given the opportunity to
inspect the materials before their use.
14
The Contractor shall supply all cables and jointing materials for the works unless expressed
stated to the contrary in the contract documentation. Cleaning materials, protection tiles,
warning tape, and other materials shall be supplied by the Contractor.
15
The Contractor is responsible for all liaison with QGEWC (ENA) in respect of programming
the installation and commissioning of the complete electrical system. He shall ensure that
QGEWC (ENA) are at all times kept informed of the current progress of the civil works on the
Site and that his approved electricity supply subcontractor programs the cable laying works in
the designated sequence in accordance with the approved programme.
16
The Contractor shall provide and install concrete cable tiles over all 66 kV cables. The cable
tiles shall be of the designated size and form. Samples must be provided for approval by
QGEWC (ENA) and the Engineer, and satisfy a test of impact strength in accordance with BS
2484.
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QCS 2014

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17
For cables of 132KV and above the measures for protection of the cable shall be as per the
requirements of QGEWC.
18
Cable tiles shall be installed over all 11,000 volt cables. Cable tiles shall be manufactured
from recycled polyethylene or similar with a minimum thickness of 12 mm, length 1 m, width
(minimum) 24 mm, tensile strength 8.40 N/mm2 as per BS 2782, Method 320 C.
The tiles shall be marked as designated. The cable tiles must be supplied complete with any
pins, pegs or other devices for jointing tiles together. Samples must be supplied to QGEWC
(ENA) and the Engineer for approval before use.
20
The Contractor shall liaise directly with QGEWC (ENA) regarding the removal of existing
cables and shall not, under any circumstance, commence removal of cables until QGEWC
(ENA) have verified such apparatus as being redundant.
21
Removal of cable shall only be carried out in the presence of a QGEWC (ENA) engineer.
22
The Contractor shall arrange uplift of empty cable drums from QGEWC (ENA) Stores and
shall return all recovered cables neatly coiled on the drums provided.
23
Ducts are to be supplied by the Contractor. They shall be of high impact resistant PVC of
internal diameter 150 mm or 100 mm as designated, minimum wall thickness 3.6 mm (for
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19
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150 mm) or 2.4 mm (for 100 mm). Samples must be provided for approval by the Engineer
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before use.
Qatar General Electricity and Water Corporation, Water Networks Affairs, QGEWC
(WNA)
All of the works associated with water supply shall be carried out in accordance with the
latest General Specifications for Main Laying Contracts and Main Laying Materials, as issued
by the QGEWC (WNA) except as modified in this Part. Contractors are deemed to be in
possession of the latest specifications.
All QGEWC (WNA) Works shall be carried out by a Contractor or subcontractor prequalified
and approved by the QGEWC (WNA). Proof of such approval shall be required in writing
before the start of Works on the Site and the name of any subcontractor to be used shall be
as designated.
The supply of the materials required to carry out the Works shall be as designated in the
contract documents. The Contractor will be responsible for the conveyance of all materials to
the site of the works.
14.3.3
Telecom Provider
All Telecom Provider works shall be carried out strictly in accordance with the Telecom
Provider Standard Specifications Telecom Provider WRK 4001 Underground Duct Laying
And Associated Works. Contractors are deemed to be in possession of the latest version of
the specifications.
All Telecom Provider works shall be carried out by a Contractor or subcontractor approved by
Telecom Provider. Proof of such approval shall be required in writing before the start of
Works on the Site and the name of any subcontractor to be used shall be as designated.
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14.3.2
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Page 11
Telecom Provider will supply as 'free issue" all ducts for Road Crossings projects only. Other
projects will be charged for the ducts. All other materials required for any type of project shall
be supplied by the Contractor.
Trenches for Telecom Provider ducts through rock fill shall be lined with geotextile, complying
with the requirements of Part 16, Geosynthetics.
The Telecom Provider specification S. 006 shall be modified as described in the following
paragraphs.
The Supervising Officer shall mean the Civil/Cable Engineer from Telecom Provider, for the
purpose of superintending the work, or, where the context permits, the representative of such
officers.
The concrete quality classes specified in Clause 202 of the Telecom Provider specifications
shall be of the comparable classes in Section 5 as designated by the Engineer.
Clause 105 of Telecom Provider Standard Specifications Telecom Provider WRK 4001
Underground Duct Laying And Associated Works should be read as:
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Backfill materials means earth free from stone or loose earth, compacted in
two equal layers above the protection dune sand, and shall not leave voids to
form a water course.
105 (b)
Sand bed and surround means dune sand, 75 mm below, above and around
the duct.
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105 (a)
The Contractor shall consult Telecom Provider not less than one month before it is proposed
to commence work to ascertain whether any underground installations will be affected by the
proposed works, in which event the Contractor shall make all necessary arrangements with
Telecom Provider to safeguard the installations.
10
The Contractor shall give at least one week's notice in writing to Telecom Provider of the
dates upon which it is intended to operate plant or equipment or carry out any work for which
permission has been given in writing by Telecom Provider. Such operations of work shall only
be carried out in the presence at Telecom Provider unless notice shall be obtained in writing
from Telecom Provider that they do not require to be present.
11
Telecom Provider may require work to be executed on their installations during the period of
the Contract. The Contractor shall allow access to Telecom Providers Contractor or
workmen until their diversion work is complete. The Contractor shall co-ordinate the work of
Telecom Provider and his own activities and when necessary shall amend his programme of
working to suit all requirements of Telecom Provider in connection with their diversion work
and shall keep the Engineer informed in writing of all arrangements made.
12
The Contractor shall locate and mark with suitable posts all Telecom Provider underground
installations that are within the area of the Works and shall ensure that such markers are
maintained in their correct positions at all times. The Contractor shall advise Telecom
Providers agent of any installation not found where designated, or found but not shown or
found damaged or subsequently damaged.
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All of the works associated with Qatar Petroleum and Qatar Gas shall be carried out in
accordance with their latest specifications except as modified in this Part. Contractors are
deemed to be in possession of the latest specifications. Before beginning any work the
Contractor shall approach Qatar Petroleum and Qatar Gas and obtain a copy of their latest
specification relating to the Works.
All Qatar Petroleum and Qatar Gas Works shall be carried out by a Contractor or
subcontractor prequalified and approved by Qatar Petroleum and Qatar Gas. Proof of such
approval shall be required in writing before the start of Works on the Site and the name of
any subcontractor to be used shall be as designated.
When working near existing QP Gas/Oil facilities the following conditions shall be adhered to.
All notices to be given to the Contractor shall be in writing and delivered by hand.
A permit to work must be obtained for all work within fifteen (15) meters distance from all
boundaries of existing facilities. These permits can be obtained from QP and twenty four (24)
hours notice should be given to prevent delays.
Mechanical or hydraulic rock breakers shall not be used adjacent to gas, oil or NGL pipelines.
Should jackhammers be required within two (2) meters of any buried pipelines and between
any pipelines running in the same easement all round pipe protection must be provided
before commencement
Pilot holes to locate existing lines shall be dug by hand tools only, before allowing mechanical
equipment to operate within five (5) meters of a QP live gas, oil or NGL pipelines.
Prior to exposure of any live pipeline the Contractor shall erect a suitable and substantial
barrier to prevent any damage to QP pipelines. This is particularly important where there are
heavy vehicles in the vicinity and the possibility that removal of the bond for trenching
operations opens up an illegal vehicle crossing.
When backfilling an exposed section of pipeline, naturally occurring soft dune sand shall be
used and the pipeline shall be covered and re-bedded all round with 150 mm minimum of
sand. The remaining height of the bund will be made up of selected desert fill with particle
size not exceeding 150mm from organic material. QP engineer shall witness the backfill
work, particularly the soft sand bedding operations.
10
When trenching between pipelines in the same easement, vehicle access between the
pipelines must be maintained.
11
The maximum length of exposed unsupported pipeline must not exceed seven (7) meters.
When it exceeds five (5) meters, a central substantial wooden support shall be installed
within a minimum 10 mm thick rubber shoe contacting the pipe.
12
When the bund is removed from any existing line its buried route shall be clearly indicated by
pegs and warnings.
13
Any damage to the pipe external protecting wrapping caused by the Contractor will be
repaired in strict accordance with QP procedures at the Contractors cost.
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14.3.4
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Page 13
Provision of a permit-to-work by QP does not release the Contractor from obligation of

obtaining relevant permits to expose or work near utilities/facilities not under QP area of
responsibility. Examples QGEWC, Telecom Provider etc.
14.3.5
PWA, Storm water and Groundwater
This subclause of the specification covers; stormwater and groundwater drainage, foul water
drainage and treated sewage effluent systems.
All of the material submission, inspection & testing, preparation of record sheets, preparation
of record drawings for works associated with PWA shall be carried out in accordance with the
requirements of this part of the specification.
Where it is necessary to make a connection to an existing water service this shall be in

accordance with Part 14 of this Section.
Works shall be in accordance with the latest PWA standard details except as modified in this
Part. Contractors are deemed to be in possession of the latest standard details. Before
beginning any work, the Contractor shall approach PWA and obtain a copy of their latest
specification & standard details relating to the Works.
All work shall be carried out by a contractor or subcontractor prequalified and approved by
PWA. Proof of such approval shall be required in writing before the start of Works on the
Site and the name of any subcontractor to be used shall be as designated.
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14
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END OF PART
QCS 2014
Section 06: Roadworks

Part
15: Road Lighting
Page 1
ROAD LIGHTING .................................................................................................... 4
15.1
15.1.1
15.1.2
15.1.3
15.1.4
15.1.5
15.1.6
GENERAL ............................................................................................................... 4
Scope of Works
4
References
5
Approved Contractors
6
Supply of Materials
6
Programme of Work
7
Technical Requirements
7
15.2
15.2.1
APPROVAL OF EQUIPMENT ................................................................................. 7

General
7
15.3
STORAGE OF PLANT AND EQUIPMENT .............................................................. 9
15.4
SPECIAL REQUIREMENTS .................................................................................... 9
15.5
15.5.1
15.5.2
15.5.3
15.5.4
15.5.5
15.5.6
15.5.7
15.5.8
15.5.9
15.5.10
15.5.11
15.5.12
15.5.13
15.5.14
15.5.15
15.5.16
15.5.17
15.5.18
HIGH MAST LIGHTING ......................................................................................... 10

General
10
High Mast Column
10
High Mast Head Frame
11
High Mast Luminaire Ring
11
Multi Core Mast Rising Cable
12
Raising and Lowering Equipment
12
Raising and Lowering Winch System
13
Finish
14
High Mast Luminaires
14
High Mast Distribution Equipment
15
Aircraft Obstruction Light
15
Earthing and Lightning Protection
16
High Mast Foundations Construction Requirements
16
High Mast General Requirements
16
High Mast Approval
17
Maintenance Requirements
17
High Mast Portable Cage for Maintenance
17
High Mast Lighting Performance
18
15.6
15.6.1
15.6.2
15.6.3
15.6.4
15.6.5
15.6.6
15.6.7
15.6.8
15.6.9
LIGHTING COLUMNS ........................................................................................... 18

General
18
Design Criteria for Columns
18
Details of Column
18
Details of Bracket
19
Doors and Base Compartments for Columns
20
Details of Base Flange Plate
20
Details of Column Foundation
21
Passively Safe Lighting Columns
21
Decorative Lighting Columns
23
15.7
15.7.1
LIGHTING UNITS .................................................................................................. 24

General
24
15.8
15.8.1
CONTROL GEAR .................................................................................................. 25

General
25
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15
QCS 2014

Part
15: Road Lighting
Page 2
LAMPS .................................................................................................................. 25
General
25
15.10
15.10.1
15.10.2
15.10.3
15.10.4
15.10.5
15.10.6
15.10.7
15.10.8
LIGHTING SYSTEM FOR UNDERPASSES .......................................................... 26

General
26
Vehicular Underpass
26
Pedestrian Underpass
26
Animal Underpass
26
Lantern Construction for use in Vehicular, Pedestrian and Animal Underpasses 27
Underbridge or Undercrossing Lantern and Installation
28
Underpass, Underbridge and Undercrossing Lantern Control Gear and Lamps 29
Underpass, Underbridge or Undercrossing Isolating Box
30
15.11
15.11.1
15.11.2
15.11.3
15.11.4
15.11.5
15.11.6
15.11.7
15.11.8
15.11.9
LED LIGHTING UNITS .......................................................................................... 30

Lighting Units
30
Lighting Performance
31
Thermal Management
32
Testing
33
In Situ Temperature Measurement Test (ISTMT)
34
Control Gear
34
LED Lamps
36
Quality Criteria for LED Lighting
37
LED manufacturers data
38
15.12
15.12.1
15.12.2
15.12.3
15.12.4
OVERHEAD SIGN GANTRY LANTERN AND INSTALLATION ............................. 38

General
38
Sign Gantry Lantern
39
Sign Gantry Lantern Control Gear and Lamps
40
Sign Gantry Isolating (Safety) Switch, Conduit and Associated Cables
41
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15.9
15.9.1
15.13 PHOTO ELECTRIC CONTROL CELL ................................................................... 41

15.13.1 General
41
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15.14 ROAD LIGHTING COLUMN CUTOUT / ISOLATORS ........................................... 42

15.14.1 General
42
FEEDER PILLAR ................................................................................................... 43
General
43
Cabinet
43
Components of Feeder Pillars
44
15.16
15.16.1
15.16.2
15.16.3
ROAD LIGHTING CABLES ................................................................................... 45

Underground Cables
45
Packing of Cables
45
Insulated PVC Sheathed Circular High Temperature (85C)
46
15.15
15.15.1
15.15.2
15.15.3
15.17 MARKER TAPE FOR UNDERGROUND POWER CABLES .................................. 46

15.17.1 General
46
15.17.2 Material & Quality
46
15.18 MARKER POSTS .................................................................................................. 46
15.18.1 General
46
QCS 2014

Part
15: Road Lighting
Page 3
15.19 EARTHING ............................................................................................................ 46

15.19.1 General
46
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TESTING AND COMMISSIONING ON SITE ......................................................... 53

General
53
Electrical Tests
53
Photometric Performance Testing
54
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15.21
15.21.1
15.21.2
15.21.3
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15.20 INSTALLATION ..................................................................................................... 47

47
15.20.2 Temporary Lighting
48
15.20.3 Removal of Existing Columns
48
15.20.4 Detailed Drawing for RCC foundation
49
15.20.5 Road lighting Column/Lantern Installation
49
15.20.6 Road lighting Feeder Pillar Installation
50
15.20.7 Road lighting Cable Installation
50
15.20.8 Road Crossing Ducts
51
15.20.9 Backfilling and Re-instatement
52
15.20.10
Road lighting Cable Terminations and Testing
52
15.20.11
Electrical Power Supply
53
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15.22 RECORD DRAWINGS .......................................................................................... 55

15.22.1 General
55
QCS 2014

Part
15: Road Lighting
Page 4
15
ROAD LIGHTING
15.1
GENERAL
15.1.1
Scope of Works
Work related to the road lighting installation provided for in this specification shall include the
supply, installation, testing, commissioning and putting into satisfactory operation any or all of
the following systems as required by the project drawings.
Road lighting (L.V) cables and terminations.
(b)
Road lighting Feeder Pillar and internal associated control equipment including
photocell control.
(c)
Road lighting column/lantern assemblies.
(d)
High mast lighting mast/lantern assemblies.
(e)
Roadway Lighting System control, adaptive, smart or remotely managed
(f)
Lighting network earthing, including electrical grounding.
(g)
Installation testing including lighting performance verification.
(h)
Provision of equipment technical and maintenance data.
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(a)
The Contractor shall provide the shop drawings and supporting calculations required by the
specification, as well as the provision of all required supporting technical literature and
samples in connection with the approval of proposed equipment.
The equipment supplied shall include all necessary items for a complete installation
according to the specification requirements in order to provide for satisfactory operation, not
withstanding errors and omission. The equipment listed in the Contract documents are,
therefore, indicative and not limitative.
On satisfactory completion and commissioning of the lighting installation the Contractor shall
be responsible for the maintenance of the whole system for a period of 400 days. This will
include for the free replacement of any component or lamp that fails during that period of
time. In addition, the Contractor shall be responsible for the rectification of any fault that
occurs within the cabling network. As part of this rectification work no cable joints will be
permitted.
All of the works associated with the road lighting installation shall be carried out in
accordance with the "Regulations for the Lighting of Roads for Motorised Traffic" and the
latest specifications issued by the PWA including The Qatar General Electricity & Water
Corporation KAHRAMAA Regulations for the Installation of Electrical Wiring, Electrical
Equipment.
The Contractor is deemed to be in possession of these regulations and the latest

specifications.
The luminaire shall be suitable for connection to the low voltage single phase supply of the
main network grid in The State of Qatar.
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QCS 2014

Part
15: Road Lighting
Page 5
15.1.2
References
ANSI/IESNA RP-008 ..Roadway Lighting
BS HD 60269-2 ..........Low Voltage Fuses. Supplementary requirements for fuses by
authorized persons (fuses mainly for for industrial application)
BS 302........................Specification for higher breaking load ropes
BS 791........................Solid-stem calorimeter thermometers
BS 1011......................Process of arc welding of carbon and carbon manganese steels
BS 2484......................Straight concrete clayware cable covers
BS 4343......................Plugs, socket-outlets and couplers for industrial purposes
BS 4360......................Weldable structural steels
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BS 4533......................Luminaires
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BS 4800...................Colour chart
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BS 5467......................Cables with thermosetting insulation for electricity supply for rated

voltages of up to and including 600/1000 V and up to and including
1900/3300 V
BS 5489......................Road lighting
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BS 5649......................Lighting columns
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BS 5486......................Low voltage switch gear and control gear assemblies
BS 5972......................Photoelectric Control Units for Road Lighting
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BS 6121......................Mechanical Cable Glands for Elastomer and Plastic Insulated Cables

BS 6141......................PVC insulated PVC sheathed circular flexible cables
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BS 6346......................PVC-insulated Cables for electricity Supply
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BS 6360......................High conductivity stranded copper shaped conductor with XLPE

insulation
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BS 6622......................Cables with extruded cross-linked polyethylene or ethylene propylene

rubber insulation for rated voltages from 3800 / 6600 V up to 19 000 /
33 000 V
BS 6746......................Extruded black PVC over sheath
BS 6977......................Specification for insulated flexible cables for lifts and other flexible
connections
BS 7430......................Code of practice for earthing
BS 7671......................Requirements for electrical installations
BS EN 40.................Lighting Columns
BS EN 295..................Vitrified clay pipes, fittings and pipe joints for drains and sewers
BS EN 1011................Welding
BS EN ISO 1461 ........Hot dip galvanized coatings on iron and steel articles
BS EN1559-1 ............Founding. Technical conditions of delivery. General.
BS EN1559-4 ............Founding. Technical conditions of delivery. Additional requirements for
aluminium alloy castings.
BS EN1676.................Aluminium and aluminium alloys. Alloyed ingots for remelting
BS EN 10137..............Plates and wide flats made of high yield strength structural steels
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BS EN 10210..............Hot-finished hollow sections

BS EN 12767...........Passive Safety of Support Structures
BS EN 60529..............Degrees of protection provided by enclosures
BS EN 60898..............Miniature and moulded case circuit breakers
BS EN 60947-3 ..........Air-break switches, air-break disconnectors, air-break switch
disconnectors and fuse combination units for voltages up to and
including 1000 V ac and 1200 V dc.
BS EN 62305..............Protection against the lighting
IEC 60598 ..................Luminaires for roadway lighting
CIE 126-1997 ............Guidelines for minimizing sky glow.
EN62262:2002 ..........(IEC62262:2002) Degrees of protection provided by enclosures for

electrical equipment against external mechanical impacts.
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The Qatar General Electricity & Water Corporation KAHRAMAA Regulations for the
Installation of Electrical Wiring, Electrical Equipment and Air Conditioning Equipment.
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The Qatar Highway Design Manual (QHDM). Current edition.
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WEEE Directive (2002/96/EC).

RoHS Directive (2002/95/EC).
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Institution of Lighting Engineers (ILE), Code of Practice for Electrical Safety
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Institution of Lighting Engineers (ILE), Technical Report No 7 High Masts for Lighting and
CCTV
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ISO 9001, Quality Management Systems
Institution of Electrical Engineers (IEE), Wiring Regulations
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State of Qatar, Qatar Wiring Regulations
American Association of State Highway and Transportation Officials (AASHTO) Roadside

Design Guide
15.1.3
Approved Contractors
All road lighting works shall be carried out by a contractor or sub-contractor approved by the
PWA. Proof of such approval shall be required in writing prior to the works commencing on
site and the name of any sub-contractor to be engaged shall be entered in appropriate forms
during tender submittal.
15.1.4
Supply of Materials
The Contractor shall supply all the materials required to carry out the Works as specified in
the Contract Documents and Drawings. No materials will be supplied by the Owner or the
PWA.
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Programme of Work
The Contractor is responsible, with the agreement of the Engineer, for all liaisons with the
respective department within PWA, in respect of programming the installation and
commissioning of the complete road lighting system. In addition to the Engineer, he shall also
ensure that relevant departments within the PWA are at all times kept informed of the current
progress of the road lighting works on site and that his approved sub-contractor programme
works are in the specified sequence in accordance with the overall approved Works
programme.
15.1.6
Technical Requirements
All works carried out on the installation shall be in accordance with the requirements of these
specifications so that their true meaning and intent are fulfilled. Minor deviations from the
drawings may be made to accomplish this but no change shall be made without written
approval of the Engineer and in consultation with the relevant departments within the PWA.
In addition to all the regulations, codes of practice and standards referred to within this
specification, all the lighting and associated electrical works shall comply with the current
Qatar wiring regulations and the requirements of PWA.
Where applicable, any associated work involving other authorities in the State of Qatar their
relevant standards and specifications, as issued by them, shall be complied with.
All equipment and materials supplied for the project shall be manufactured in strict
compliance with the latest standard of BS, IEC, EN their equivalent AASHTO or other
standards and regulations specifically referred to in this specification. Here in after they are
referred to as the Standards.
Acceptance tests shall conform to those referred to in the above mentioned Standards.
15.2
APPROVAL OF EQUIPMENT
15.2.1
General
All materials shall be approved by the Engineer. The Contractor shall be responsible to
ensure that, where applicable, for nominated items of equipment only the type and
manufacturer approved by the PWA, as detailed in their List of Approved Manufacturers are
submitted for incorporation into the works. In addition, written approval must be obtained
from the PWA, prior to ordering. Contractors shall note that only products with a proven
record of performance, efficiency and long life will be considered for approval.
The Contractor shall not order any equipment for the incorporation into the Works before
receipt of formal approval in writing. The approval procedure shall be as follows:
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15.1.5
(a)
The Contractor shall submit four copies of his equipment proposals to the Engineer.
This submission shall be comprehensive and clearly state any manufacturers
deviations from the specification. Manufacturers literature associated with the
submission shall be originals and not photocopies. Specific reference to the
compliance of certain specification requirements shall be identified.
(b)
The Engineer shall review this submission. The Engineers approval shall be as
follows.
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(i)
With the Engineers comments and recommendations attached, a copy of the

submission shall be forwarded to the departments concerned within the PWA, to
obtain their approval.
(ii)
Where minor deviations exist from the specifications but do not affect the
performance of the equipment or installation the Engineers recommendations to
accept such deviations, his approval together with a copy of the submission
shall be forwarded to the departments concerned within the PWA, to obtain their
approval.
(iii)
Approval shall be transmitted to the Contractor in writing once the approval of

the relevant departments within the PWA, has been given.
All submissions shall give clear, unambiguous details and performance data of the
equipment proposed, together with all supporting calculations where necessary. Clear
catalogue identification references shall be provided. Documents shall be in English.
The Engineer reserves the right to direct the Contractor to provide equipment of a make and
type that is essential to achieve the Contract design criteria.
Approval of samples by the Engineer in consultation with the relevant departments within the
PWA, does not in any way relieve the Contractor of his contractual obligation in respect of the
suitability of the equipment or their final performance once installed, and the co-ordination
with all the elements of the lighting works into a fully operational installation.
After receipt of equipment the Contractor shall arrange for them to be examined and
approved by the Engineers Representative in consultation with the relevant department
within the PWA, prior to installation.
Column and Mast Fabrication Requirements
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Specific Requirements for Columns
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In paved or walkways areas Enclosure plate is required. The Enclosure plate shall be cast
Aluminium or Galvanized steel, comprising two removal halves per base with size matching
the base plate. It shall be painted to match pole finish. Provided with backup plate to one
halve of Enclosure Plate and with tapped holes to accept stainless steel screws countersunk
into other half of Enclosure Plate.
The gap between base plate and top of foundation shall be grouted. Means of discharging
any accumulated moisture shall be provided at the pole base and provision shall be made for
adequate drainage.
9
Testing and Factory Visits

The contractor shall facilitate authorised Engineer representatives, and/or their appointed
representative, to examine the test and manufacturing facilities and witness
manufacturing processes and sample testing related to the luminaire and associated
components submitted for evaluation, at no cost to Ashghal or their appointed
representative.
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Saving Energy Lamps Luminaire specification data sheet arrangement or each model of
luminaire the manufacturer shall produce a data sheet providing a detailed and
comprehensive description of the luminaires characteristics and component parts. The data
sheet will contain adequate information for the reader to select and specify a particular model
from the luminaire range. This will include;
(a)
luminaire diagram external dimensions, weight and windage
(b)
optical arrangement (lens and reflectors types and settings)
(c)
driver type (drive current, system power consumption)
(d)
luminaire output (lm)
(e)
luminaire efficiency (lm/W)
(f)
glare rating
(g)
control and switching options (photocell, programmed stand alone, CMS, etc.)
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Part
15: Road Lighting
STORAGE OF PLANT AND EQUIPMENT
All plant and equipment shall be stored off the ground under weatherproof cover ready for
incorporation in the works. All electrical apparatus shall be examined and cleaned before
installation. All open conduit ends shall be fitted with plastic caps or suitable protective
covering to prevent the ingress of foreign matter. All drums with cables shall be protected
from direct sunlight.
15.4
SPECIAL REQUIREMENTS
All notices from the Contractor shall be in writing and delivered by hand.
The Contractor shall consult the Engineer not less than one month before it is proposed to
commence work to ascertain whether any underground installations will be affected by the
proposed work, in which event the Contractor shall make all necessary arrangements with
the Engineer to safeguard the installation. It will be the Contractors responsibility to liaise with
the utility authorities and to arrange for all road opening notices
The Contractor shall give at least one week's notice in writing to the utility authoritys
Engineer of the dates upon which it is intended to operate plant or equipment or carry out any
work for which permission has been given in writing by the utility authoritys Engineer. Such
operations of work shall only be carried out in the presence of the utility authoritys Engineer
unless notice shall have been in writing from the utility authoritys Engineer that they do not
require to be present.
The utility authorities may require work to be executed on their installation during the period
of the Contract. The Contractor shall afford all facilities to the utility authoritys contractors or
workmen until their diversion work is complete. The Contractor shall co-ordinate the work of
the utility authorities and his own activities and when necessary shall amend his programme
of working to suit all requirements of the utility authorities in connection with their diversion
work and shall keep the Engineer informed in writing of all arrangements made.
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15.3
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The Contractor shall locate and mark with suitable posts all the utility authoritys underground
installations that are within the area of the Works and shall ensure that such markers are
maintained in their correct positions at all times. The Contractor shall advise the utility
authoritys agent of any installation not found where shown on the Drawings, or found but not
shown or found damaged or subsequently damaged.
15.5
HIGH MAST LIGHTING
15.5.1
General
This work shall consist of the supply, installation upon prepared foundations, connections,
commissioning and putting into satisfactory service the high masts complete with the
operating mechanisms, luminaire support ring or bracket, luminaries, control gear, wiring and
distribution equipment.
The mast luminaire support ring shall be designed to provide for the appropriate distribution
of lighting either in one direction or in many directions thus making it possible to concentrate
the required number of luminaires on any zone and fix them rigidly in any direction desired.
Prepared foundations are specified in other sections of this specification.
15.5.2
High Mast Column
The high mast column shall be of the height specified on the Drawings, hot dipped
galvanized to BS EN ISO 1461 or BS 791 of multi-sided cross-section with a continuous
taper made of formed sheet steel in accordance with BS 4360 grade 43C and electrically
welded. They shall be delivered to the site in manageable sections of not greater than 12
metres and be joined by means of pressure over-lapping or slip-joints, which shall have a
minimum length of 1.5 times diameter of the joint. Site welding will not be allowed.
The walls of the masts shall have a minimum thickness of 6mm for the base section, 5mm
for the central section and 4mm for the top section. The steel used shall have tensile strength
between 490 and 630 MN/sqm and minimum yield strength of 355 MN/sqm.
The mast cross-sections shall be so designed that once installed and fully equipped, it shall
have safety factors in accordance with Technical Report No. 7 of the Institute of Lighting
Engineers London and shall be capable of withstanding wind load resulted from the wind
speed provided in Section 1 Part 1 Clause 1.5.2, and blowing in the most unfavourable
direction at a height of ten meters above ground level. Appropriate reinforcement shall be
provided where necessary to increase the strength. Its behaviour under wind induced
oscillation shall be such that it shall not fail due to fatigue and the design should ensure that
these oscillations be damped to a minimum of zero.
The maximum deflection at the top of the mast shall not exceed 2.5% of the mast height at
the minimum wind speed provided in Section 1 Part 1 Clause 1.5.2.
A steel flange plate of adequate thickness and free from laminations shall be welded above
and below the base of the mast developing fully the strength of the section. In addition
supplementary gussets shall be provided between bolt holes if deemed necessary.
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An access door shall be provided in the base of the mast of adequate dimensions to permit
clear access to the back plate installed for the mounting of the circuit breaker assembly and
junction box, winch, etc. The backboard shall be made of steel or other non-hydroscopic
material. The door shall be completely weatherproof fitted with a hidden hinge and a heavy
duty lock. The door area shall have appropriate reinforcement.
A stainless steel earthing 12mm diameter bolt shall be welded inside the mast near the
access door and shall be complete with stainless steel washers and nuts.
15.5.3
High Mast Head Frame
The head frame shall be hot-dipped galvanized steel attached to the mast by means of a
steel slip-fitter and secured by at least four stainless steel set screws. It shall be composed of
spun aluminium or other approved weatherproof cover, housing the required number of steel
cable sheaves and associated accessories for the operation and powering of the luminaire
ring.
15.5.4
High Mast Luminaire Ring
The high mast luminaire support ring or carriage shall be constructed of hot dipped
galvanized steel channel fitted with the appropriate number of luminaires, lamp gear
mounting brackets, wiring chamber and mounting plate. It shall be in two halves joined by
bolted flanges to permit removal from the erected mast. The luminaire shall be mounted on
the luminaire rings by means of either a specially designed bracket allowing it to be swiveled
in any desired direction or rigid bracket arm assembly. It shall be possible to lock each
luminaire firmly in position, thus preventing any rotation or falling while moving the luminaire
ring.
The carriage assembly shall be arranged to locate firmly against stops when in the secure
position and these shall be of adequate strength to ensure that they cannot be damaged by
over winding of the winch.
A shaped protective aesthetic canopy, designed to give a coordinated appearance of head

frame with the luminaire ring, shall cover the head frame.
For masts fitted with a mobile luminaire ring, rollers with a centering mechanism shall be
provided to ensure a perfect alignment of the luminaire ring both axially and in azimuth, while
ascending or descending the mast. Rollers shall be made of water resistant non-marking
composition material with oil-impregnated bronze brushings. All shafts and washers shall be
stainless steel.
A weatherproof wiring chamber or terminal box shall be provided constructed from a

corrosion resistant material or aluminium alloy and installed on the luminaire ring. It shall be
equipped with the high temperature shrouded terminal blocks and neutral bar or block and
shall include facilities on the luminaire ring to allow testing of luminaires while in the lowered
position. The wiring chamber shall be fitted with an earthing stud accessible from inside and
out for earthing connections. The housing shall be completely weatherproof.
The cables installed in the luminaire ring connecting each luminaire to the wiring chamber
shall be factory pre-wired avoiding the need for field wiring, and shall have single core copper
conductors with neoprene or cross-linked polythene or approved equivalent insulation and
2
sheath. Cables shall be either single core or 3 core 2.5mm with copper conductors and
colour coding of the different phases being in conformity with the relevant cabling standards.
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Cables from the terminal box shall run in PVC duct or metal duct fixed to or within the
luminaire carriage to each luminaire from the wiring chamber.
15.5.5
Multi Core Mast Rising Cable
The cable connecting the MCCB assembly at the base of the mast to the wiring chamber on
the luminaire ring, shall be a flexible multicore copper cable with conductors and neoprene or
approved equivalent high temperature resistant insulation and sheath in accordance with BS
6977.
The colour coding of the different phases of the cable shall conform to the relevant cable
standards. Each luminaire shall have its own neutral conductor connected to the neutral bar
or block.
The mast cable shall consist of a circular multi core cable to BS 6977 600/1000V grade.
Each conductor core shall be insulated with ethylene propylene rubber (EPR) and the
complete core is sheathed with heavy duty polychloroprene (PCP).
A multicore electrical power cable shall be provided terminating in the base compartment with
a special multi-pin plug and socket coupler fitted with a guard, and at mast head connected
to the wiring chamber fixed to the luminaire ring. It shall be suitable for the bending, flexible
and load carrying stresses involved.
The cable shall be fitted with a correctly rated multi pin weatherproof plug and socket within
the base compartment of the mast which will enable the cable to be disconnected before
lowering the luminaire carriage. The socket must be connected to the supply side of the
circuit and may either be free cable coming from the fuse box or be fixed to the fuse box in
the base compartment.
The wiring shall be such that the plug and socket can be isolated before disconnecting.
The cable shall be suitably restrained to prevent its own weight from causing the terminal box
to energise the lanterns.
15.5.6
Raising and Lowering Equipment
The pulleys located within the headframe shall be of non- corrosive cast aluminium alloy
material grooved to exactly suit the steel rope and cable diameters, and fitted with stainless
steel shafts. The pulleys shall be housed in a chassis integral with a sleeve, which slopes
over the top of the mast and is secured axially and in azimuth. The complete chassis
assembly shall be hot dipped galvanized. A guard is to be provided for the separation of the
wire rope and power cable before entering in the pulley and the locating of the steel wire rope
and power cables in their groves when operating either loaded or slack. An arrangement
shall be provided to ensure that the electric and steel cables are separated before passing
over their respective pulleys, and close fitting guides shall ensure that the cables cannot
disengage the pulley during operations.
The luminaire carriage shall have the provision made on it for supporting and gripping the
weight of the supply cable without damage of the cable sheath.
The luminaire ring shall be supported by 3 steel ropes coupled to 2 steel ropes and
suspended from the double drum winch by means of a manufactured steel coupling unit. A
divider bar shall ensure the separation of the steel ropes during raising and lowering.
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An MCCB providing overload protection shall be incorporated to stop the ring when the effort
required by the winch becomes superior to the nominal load.
The winch shall be fitted with suitable equipment to allow the winch to stop in a safe manner,
without damage to the mast finish, in the event of a supply failure to the power tool. The
winding mechanism should then be capable of being operated by hand.
10
Each winch supplied shall be uniquely identified. In addition it shall have its own individual
test certificate recording the safe working load. Lubrication details shall also be permanently
recorded on its housing for future maintenance purposes.
15.5.8
Finish
All welds shall be smooth with the splatter removed and the interior and exterior surface of
the mast and ring shall be cleaned by pickling or blasting and shall be free of any grease.
All components shall be hot dipped galvanized by total immersion in a bath of molten zinc
after completion of the fabrication. No further levelling up, finishing or modifications shall be
carried out after completion of the galvanizing process. The minimum thickness of zinc
coating shall be 450 gm/sqm on the inside and outside surfaces of the mast and ring. The
galvanizing shall conform to BS EN ISO 1461.
Any damage to the galvanizing shall be rectified during erection by wire brushing the affected
area and treating with an approved zinc restorative. Sufficient materials shall be applied to
provide a zinc coating at least equal in thickness to the galvanized layer.
If required by the Engineer the underside of the flange plate and internal surface of the mast
to a height of 0.5m shall be given a coat of heavy duty bitumen paint prior to erection.
15.5.9
High Mast Luminaires
The high mast luminaire shall have a cut off distribution. It shall be of the side entry
mounting type, with toughen a flat glass protector and integral control gear suitable for the
operation of either a 400W with lumens per watt rating of no less than 48,000, or 600W with
lumens per watt rating of no less than 88,000, 220-240V, 50Hz. High Pressure Sodium
tubular lamp of E-40 base, as defined for the contract.
The luminaires to be adopted shall be high performance street lighting lanterns currently
used for conventional roadway lighting routes to BS 5489 or equivalent suitable for use at a
mounting height of 25 or 30 metre. It shall comply with IEC 60598 or other approved
equivalent norms. The body shall be made of die-cast aluminium and shall be divided into
two separate compartments.
The first compartment of the luminaire shall house the optical system with polished and
anodized pressure aluminium reflector. The second compartment shall contain the electrical
accessories (control gear) cable feed terminals and side entry mounting socket. This
separation shall protect the electrical accessories from the direct radiant heat emitted by the
lamp. The optical compartment shall be protected by a toughened flat glass protector and
shall be dust and watertight to a protection rating of IP65.
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The access to the optical compartment shall be by tilting the protector frame around the
hinge without tools. A heat resistant gasket fitted on the frame shall ensure the tightness of
the optical compartment. The accessories such as ballast, ignitor, and capacitor shall be rewired and pre-assembled by a metallic plate that is mounted and fixed into the rear
compartment. Special care shall be taken to allow easy maintenance and quick replacement
of the accessories and to minimise the risk of falling.
The cable feed terminal and the earth-screw shall be fixed to the metallic compartment, a
cable holder shall be mounted near the terminals. The side entry mounting sockets should
accept a 125 mm. long spigot and 50 mm diameter OR adjustable from 42 to 60 mm dia.
Exterior side of both compartments should be with grey colour in finish.
15.5.10 High Mast Distribution Equipment

The high mast base compartment shall be fitted with a power control and distribution
assembly installed in a pre-wired weatherproof box opposite the access door inside the base
of the mast.
The assembly shall consist of a surface mounted sheet steel weatherproof box with a cover
enclosing:
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One 3-pole main 60Amp MCCB together with a neutral link for luminaire circuits. The
ratings of the MCCB shall be in accordance with the QGEWC regulations and suitable
to the connected load and cable.
(b)
One single pole 20 Amp MCB with neutral link for each luminaire circuit of a suitable
current rating.
(c)
One-pole MCCB with neutral link connected to the incoming supply and serving a 16A250 V DIN socket outlet complete with 3-pin plug to suit the raising and lowering
mechanism.
(d)
A multi-pin plug and socket outlet with guard fitted with cable outlet for connection to
the multi-core electric power cable provided from the MCCB to the luminaire ring wiring
chamber.
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(a)
The MCCBs shall be de-rated and calibrated to provide over-current and short circuit
protection when used in an ambient temperature of 50oC and shall have the required
breaking capacity. The incoming side of the triple pole MCCB with the neutral links shall be
fitted with a 4-way, line-tap type terminal block, with each terminal capable of accepting 2 x
2
35mm copper conductors.
The multi-pin coupler for supply to the portable raising and lowering power tool shall be
connected to the MCCB via a flexible connection to ensure accessibility.
Where an high mast assembly supplies a ground sign lighting unit or equivalent it shall be
equipped with an additional 15 Amps circuit breaker to supply the sign lighting installation.
The circuit breaker shall be installed inside the mast distribution box.
15.5.11 Aircraft Obstruction Light

1
Where required by Civil Aviation Authorities, two red luminaires within cast aluminium bodies
shall be fitted at the top of each high mast attached to the movable luminaire ring with a
purpose made bracket and arranged to project through the canopy.
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The luminaires shall be provided with a change over relay such that, in the event of lamp
failure, the second lamp is automatically connected. Lamps shall be GLS Rough Service 100
watt suitable for an E.S. (E27) lampholder.
The obstruction lights shall be wired on a separate circuit protected by a separate SP & N
circuit breaker with terminals to accept separate incoming cables.
15.5.12 Earthing and Lightning Protection

All masts shall be provided with a separate system for earthing as a protection against
lightning. This shall comply with BS EN 62305.
High masts shall be equipped with an air terminal of the correct height to provide the required
zone of protection for the mast head frames and fixtures. The air terminal shall be bonded to
the mast to ensure the discharge is dissipated via the earth ground terminal without damage
to the steel winch ropes or electrical cables.
Separate earthing shall be provided for each item of control equipment within the mast
assembly and connected to a central earthing point.
A 12mm diameter stainless steel or brass stud with nuts and washers in the base
compartment connected to the main body of the mast structure shall be provided.
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15.5.13 High Mast Foundations Construction Requirements

High masts shall be installed on concrete bases as detailed on the Drawings. The foundation
design and construction shall be as based on the high mast manufacturers recommendations
according to the ground and climatic conditions that exist at the site location. The erection of
high masts and the assembly of the luminaire, head frame with raising and lowering gear
shall be carried out strictly in accordance with the manufacturers instructions. The Contractor
shall before commencement of the construction work confirm by means of structural
calculations that the foundations proposed are suitable for use with the high mast installation
he proposes to install. Holding down bolts and plumb adjustment nuts, washers, locknuts or
nyloc nuts shall be galvanized steel or cadmium plated.
The holding down bolt/nuts complete with the anchor plate for casting into the foundation
shall be provided by the high mast manufacturer together with a mild steel anchor bolt
template with tube holes to ensure correct vertical and precision made horizontal bolt
alignment.
The anchor bolts shall be of guaranteed performance high tensile steel.
All buried external surface of the high mast foundation shall be protected by brush painted
tanking membrane and hard board protection.
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15.5.14 High Mast General Requirements

1
Final setting and adjustment of the luminaires shall only be carried out after all the masts
along a route, junction or interchange are complete and operational.
Each high mast metal work shall be bonded to a separate earth rod as indicated on the
Drawings and also to the separate earthing cable connected to the distribution system earth
bar.
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The high mast shall be of specified height carrying luminaires as indicated on the Drawings.
Each luminaire shall be fitted with the specific lamp or lamps arranged to be separately
oriented to give the correct illumination at designated locations along the road surfaces.
15.5.15 High Mast Approval

For the approval of the Engineer before manufacturing commences the Contractor shall
submit detailed calculations and supporting data to show that the mast meets the design
criteria detailed and shall include the following information:
The deflection at the top of the mast at the designed wind speed.
(b)
The neutral frequency of the mast.
(c)
The critical wind speed for resonance.
(d)
The damping characteristics of the mast.
(e)
The steel stressed under resonant conditions.
(f)
The acceleration at the top of the mast under resonant conditions.
(g)
Welding procedure.
(h)
Procedure to ensuring that the flange plate is not laminated.
(i)
Details of the joints between the mast sections and between the bottom section and
the flange.
(j)
Details of the base compartment with the method of reinforcement at the door area
and means adopted for making the door weather and tamperproof.
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15.5.16 Maintenance Requirements
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The following items must be provided for the Engineer at the time of the commissioning of
any high mast assembly:
Power tools 1 No.
(b)
L hooks 6 No.
(c)
Operating handles 2 No.

Foundation Bolt/Nut and Head frame Nut/Bolt Spanners 2 No. Sets.
(d)
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15.5.17 High Mast Portable Cage for Maintenance

1
The high mast system shall incorporate a mobile luminaire ring such that it is suitable for
utilising a purpose made portable cage for maintenance purposes.
The cage shall be obtained from the high mast supplier and shall be capable of carrying two
persons plus servicing equipment.
A safety system shall be provided for use with the cage according to the manufacturers
recommendations. One safety cage per project shall be allowed within the pricing structure
offered by the Contractor for the future use of the Engineer.
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15.5.18 High Mast Lighting Performance

1
The Contractor must provide guaranteed lighting performance data as part of his technical
submission to confirm the minimum light values that will be maintained at each location and
where specifically identified by the Engineer or representatives from the relevant departments
within the PWA.
The minimum light levels that must be obtained shall be:

Horizontal illumination
Diversity Factor (Ave/Min)
30 LUX
4:1
LIGHTING COLUMNS
15.6.1
General
All columns and brackets shall be produced by ISO 9001 certificated lighting column
manufacturers registered and certified for the manufacture, supply and certification of lighting
columns under their quality assessment schedule.
All columns of the same mounting height and with the same arrangement shall be identical in
construction.
Road lighting columns shall be hot dip galvanized steel, octagonal, multisided, tubular and
stepped shape, of height as detailed in the Contract specification and drawings, complete
with bracket of outreach, number of arms and of shape all again as detailed in the Contract
specification or on the drawings.
15.6.2
Design Criteria for Columns
For all columns and masts the stress and deflection calculations shall be based on the
maximum bracket and luminaire projection, on the bracket arm, with projected area, length
and weight as designated.
In still air conditions, loaded with the designated luminaire positioned in any of the variable
locations, there shall be no appreciable deflection of the column.
The maximum permissible deflection in the column or mast shall be 1 in any 1m length with
Columns must be designed to withstand the wind force.
The "K" factor for columns over 8 m in height shall be 2.2.
Columns shall be designed to support lanterns with the data given by the Engineer.
15.6.3
Details of Column
The column shall be made from hollow sections to BS EN 10210 in steel to BS 7613 grade
43C or any approved equivalent norms. The hollow sections shall have a minimum tensile
strength of 430 N/mm and minimum yield strength of 255N/mm.
Columns shall be in one piece tubular (round), stepped shape or multi-sided sheet steel and
be of the flanged (bolted) type.
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15.6
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Columns should be designed in accordance with BS 5649 in steel and finished with hot dip
galvanized internally and externally with no other treatment in accordance with BS EN ISO
1461 or equivalent.
The jointing of the column shall be carried out by reducing the diameter of the base section to
form an interface fit with the bore of the upper section. The upper section shall be heated and
pushed over the lower section. The thermal shrinkage shall ensure a complete bond over the
full area of the joint and develop the full strength of column at the transition. The final
operation is to weld the lower section to the upper section and dress the weld to a smooth
profile. Welding shall be carried out in accordance with BS 1011.
Strengthening shall be provided at the door opening. Care shall be taken to ensure that
rounded edges are provided at the corners of the door opening to avoid stress
concentrations.
The top of the column should be designed and provided as suitable to fix the bracket arm
collar with the top of the column as shown in the Contract drawings.
All dimensions for the column shall be in accordance with the latest requirements of the
PWA, and, if applicable, as detailed on the drawings. Modifications to suit the particular
foundation/support details proposed by the manufacturer shall be submitted to the Engineer
for approval prior to incorporation.
15.6.4
Details of Bracket
Brackets shall be formed of hollow sections to BS EN 10210 in steel to BS EN 10137 Grade

43C or equivalent.
The column bracket arms and spigots shall be so designed that when assembled with the
shaft the design altitude of the arm and projection shall be as detailed in the contract
requirements.
Welding on bracket arm shall be carried out in accordance with BS EN 1011.
Brackets shall be hot dip galvanized to BS EN ISO 1461 or equivalent. The bracket arm shall
be so designed that when assembled on the column shaft the altitude of the arm and spigot
shall be 5 above the horizontal unless otherwise stated in the Contract documents.
Length of the luminaire fixing spigot unless otherwise designated to suit the luminaire shall be
150mm, outside diameter of spigot shall be 42mm, thickness shall, be 4mm.
The securing arrangement of the bracket arm to the column shall be positive so as to ensure
that the arm does not rotate and shall be such that the bracket can be fixed in any of four 90
degree positions in relation to the column door opening. 8 No. socket set screws of size M10
x 16mm or approved equivalent arrangement shall fix the bracket onto the columns using
stainless steel screws.
The luminaire shall be securely fixed to the mounting post or bracket by means of a
clamping system that will prevent movement in high winds. All component parts shall be
manufactured from non-corrosive materials.
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Doors and Base Compartments for Columns
Each column and mast shaft shall have a base compartment large enough to offer easy
access to the equipment therein.
The weatherproof door provided for each opening which shall be interchangeable between
columns of the same mounting height. To avoid accidental spillage of water from irrigation of
flooding the bottom of the door shall be at least 0.5m above the top of the foundation.
A stainless steel durable non-corroding tamper-proof lock device shall be provided of the
triangular headed screw type, unless designated otherwise. Where applicable, door lock
recess shall incorporate adequate drainage such that they are unlikely to become blocked
and so form a water trap.
Door openings are to be kept to the minimum size consistent with the cable termination units
and any control gear.
When installing lighting columns on a single carriageway the column doors shall be located at
90 to the kerb line and in such a location that the maintenance operative faces the oncoming
traffic and to ensure that the door can be opened at all times without encroaching onto the
highway. In the case of installing lighting columns within the central median the column door
shall be located perpendicular to the road such that the maintenance operative will be facing
across the line of the carriageway. The door openings shall be free from any irregularities
and burrs.
Keys are to be provided with the first consignment of columns at the rate of 10 % of the total
number of columns.
A baseboard of non-hygroscopic hardwood, minimum thickness 15 mm, shall be securely

fixed in each compartment and shall be of sufficient size to accommodate the cable
termination unit.
Single purpose earth terminals shall be provided in a readily accessible position, preferably
on the left hand side of the opening and on the column door.
The baseboard shall be fixed using brass or stainless steel nut and bolt arrangement.
10
All door lock hinges and catches shall be greased before handover.
15.6.6
Details of Base Flange Plate
The base flange plate shall be manufactured from steel plate that is free from laminations.
The main shaft of the pole shall penetrate the full depth of the base plate and is to be welded
above and below using a semi automatic MIG shielded arc process. Additional strength shall
be provided by gusset plates located between hole positions.
4 No. slots allowing for adjustment shall be provided in the flange plate of suitable size so as
to accommodate the foundation bolt specified to fix the column on the RCC foundation.
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15.6.5
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Details of Column Foundation
The manufacturer of the road lighting column shall submit the dimensions and specification
of his proposed foundation including the steel reinforcement details to the Engineer for
approval.
The foundation shall accommodate 4 No. holding down bolts of size 25mm x 800mm for
columns up to 10 metres high and 33mm x 900mm for 12 and 16 metres high columns,
supplied with two nuts and two washers to each bolt.
Foundations shall be constructed such that they avoid being a hazard to pedestrians
and bicyclists on footways and shared use paths. The top surface of concrete column
foundations on pathways shall not be higher than ground level, and shall not be higher than
50 mm above ground level on all other surfaces.
15.6.8
Passively Safe Lighting Columns
Design Criteria
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15.6.7
All Passively Safe lighting Columns shall comply with BS EN 12767 Passive safety of
support structures for road equipment requirements, classification and test methods,
2007 or all road lighting columns within the clear zone (as AASHTO Roadside Design
Guide Table 3.1 or Chapter 10 Roadside Safety Urban or Restricted Environments)
shall be protected by an approved barrier system.
(b)
Each Passively Safe Lighting Column shall be anodized aluminium or galvanized steel
as specified in the Contract Documents.
Design of aluminium columns shall
comply with BS EN 40, Part 6 and its incorporated references. Design of steel
columns shall comply with BS EN 40, Part 5 and its incorporated references.
(c)
In addition to section 15.6.2-1 the passively safe columns in still air conditions, loaded
with the designated luminaire positioned in any of the variable locations, there shall be
no appreciable deflection of the column. The maximum permissible deflection for
passively safe poles shall not exceed 4% of the total length of the pole when furnished
with bracket arm, and 2% of the total length of pole with no bracket arm. Columns
must be designed to withstand a base wind speed of 30 metres/second. Columns
shall be designed to support lanterns with the data given by the Engineer.
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(a)
(d)
Per BS EN 12767, Annex F, passively safe tubular hollow section steel or

aluminium posts provided shall have a nominal diameter less than or equal to 89
mm, and a nominal wall thickness of 3.2 mm. Where steel poles are specified in the
Contract Documents, steel grade S355J2H shall be provided.
(e)
Aluminium columns shall be finish coated with an anodized aluminium finish

providing resistance to fading, peeling, cracking or corrosion. The guarantee provided
by the manufacturer shall be a minimum of 10 years against fading, peeling, cracking
or corrosion of the finish.
(f)
The maximum mass of combined luminaire support and fixtures attached to

breakaway supports shall be limited to 450 kg and the maximum column height shall
not exceed 18.0 metres.
(g)
Where slopes are greater than 6:1, no passively safe support shall be used without the
Passively safe supports shall not be used on any
columns mounted on median barriers, concrete or otherwise. No slip base
mechanisms may be used on Qatar roadways.
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Columns shall be certified by the manufacturer to comply with BS EN 12767 and shall
achieve the Passive Safety Performance Classes as indicated in Table 15.1.
Table 15.1 Passive Safety Performance Classes
Pole Support Requirement

Roadway Posted
Speed
CBD
Other
100:HE:1-3
100:NE:1-3
CBD Central Business District
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Term Descriptions
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Where columns may fall

on other carriageways
below (i.e. flyovers).
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All
(a) 70:HE:1-3
(b) 100:HE:1-3
(c) 70:LE:1-3
(d) 100:LE:1-3
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40 kph
40 kph
Impact Speed Class*/ Energy

Absorbing Type / Occupant
Safety Level**
Location
100:HE:1-3
HE High Energy Absorbing

LE Low Energy Absorbing
NE Non-Energy Absorbing
Certification of breakaway support shall be collected from the manufacturer and

submitted for Engineer approval prior to procurement. Certification documentation
shall confirm the Impact Speed Class, Energy Absorbing Type and Occupant Safety
Level of the supplied luminaires.
The column shall be rated to support Cloth Banners up to the length, width and height
as required in the Contract Documents. Each column shall be provided with a
240V earthed outlet rated for outdoor conditions in compliance with Section 21 Part
10.2.2 herein.
(a)
Related Equipment
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* Poles shall be procured in order of class per availability from the manufacturer.
** The Occupant Safety Level (OSL) provides for increasing levels of safety by reducing impact
severity. The preferred level of safety is OSL 3 and shall be procured as first choice when
available from the manufacturer.
(b)
When required by the provisions of the Contract Documents, all poles, whether
aluminium or steel in type, shall be supplied with a frangible element or
breakaway base tested and certified to provide passive safety elements as to
be in compliance with BS EN 12767, with special attention to National Annex
(informative) to BS EN 12767:2007.
Lighting System Requirements

(a)
Work related to the Passively Safe Lighting Column installation provided for in
this specification shall include the supply, installation, testing, commissioning and
putting into satisfactory operation all systems as required by the Contract Documents
and the Specification.
(b)
Electrical connections for lighting columns shall be quick disconnect type at ground
level, such that they provide for electrical isolation within 0.4 seconds upon impact of
the lighting pole, and be furnished as required by BS EN 12767:2007 NA.8.
QCS 2014
Page 23
(c)
Prior to procurement, the Contractor shall provide shop drawings and supporting
calculations required by the Specification, as well as the provision of all required
supporting technical literature and samples in connection with the acceptance of
proposed equipment approved by Ashghals authorized representative.
(d)
Due to the long lead times of such equipment, the Contractor shall order the poles
within 1 week of shop drawing approval. The equipment supplied shall include all
necessary items for a complete installation in accordance with the Specification and
other Contract Documents in order to provide for specified luminaire operation.
(e)
Contractor shall provide all necessary accessories, wiring and equipment from lamp to
base, feeder pillar to last luminaire, to complete a functional lighting system
regardless of their inclusion in the Contract Documents.
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Lighting Columns
(i)
The Passively Safe Lighting Columns shall be procured from an Ashghalapproved manufacturer. The manufacturer shall submit no less than three
references for contact on past performance, supplying previous installed
contracts contact person, title, agency or company name, phone number and
e-mail address to Ashghal Designs and Ashghal Operation and
Maintenances authorized representatives as part of the approval process.
(ii)
Columns shall be constructed with their anchor bolts at no more than 100 mm
above ground level. Anchor bolts furnished with the column support shall be
galvanized steel or stainless steel in type.
Luminaire
(c)
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Each luminaire fitted on the Passively Safe Lighting Columns shall meet all
illumination requirements set forth by Ashghal and the photometric specifics as
outlined in the Contract Drawings.
Foundations
Contractor shall submit the dimensions and specification of proposed

foundations for support of the Passively Safe Lighting Columns. Drawings
and specifications shall be prepared and sealed by a licensed structural
engineer. The structural engineer shall provide certification that the proposed
foundation design supports the performance of the breakaway mechanism, and
is designed properly to prevent movement or rotation in the surrounding soil.
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Part
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15.6.9
Decorative Lighting Columns
Decorative lighting systems are non-standard, themed luminaire and pole styles.
The
luminaires range from ornate globes known as acorns to four-sided glass fixtures having a
distinct character. The luminaires are mounted on the decorative lighting columns in a postmounted arrangement or with a bracket arm.
The Contractor shall coordinate final
decorative lighting column and foundation placement with the Engineer to avoid problems
related to the placement of trees, other street furniture and underground utilities.
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Each Decorative Lighting Column shall be anodized aluminium or galvanized steel as

specified in the Contract Documents. Design of aluminium columns shall comply with
BS EN 40, Part 6 and its incorporated references. Design of steel columns shall
comply with BS EN 40, Part 5 and its incorporated references. Galvanized steel
columns shall be supplied with aluminium cladding sufficient to provide the decorative
features when detailed as such in the Contract Documents.
Galvanized steel columns shall be supplied with aluminium cladding sufficient to

provide decorative features when detailed as such in the Contract Documents.
15.7
LIGHTING UNITS
15.7.1
General
Road lighting luminaires (light fitting) shall be semi cut-off or cut off and side entry mounting
type complete with bowl and integral control gear of rating 100W, 150W, 250W, or 400W,
220-240V, 50Hz as specified in 15.9.
All types of lamps shall be energy saving lamps (LED (light emitting diode), Induction lamps)
manufactured according to International Electrotechnical Commission IEC or International
Standards, and accepted or approved by Qatar Standards.
The luminaires for roadway lighting shall be to IEC 60598 and shall be capable of achieving
the lighting performance specification requirements set out in the Contract specification in
accordance with BS 5489 , EN 13201 and ANSI/IESNA RP-008 at the mounting heights
identified within the Contract.
Luminaires shall be side entry mounting and semi cut-off or cut off type with integral control
gear for use with either 1x 100W, 1x 150W or 1 x 250W, 220- 240V, 50Hz, high pressure
sodium tubular lamp of E-40 base. The E-40 lamp shall have a porcelain skin. The lamp
supports shall ensure that the lamp position in respect of the optical system remains fixed
throughout its operation. The body shall be made of die cast aluminium and shall be divided
into two compartments.
The first compartment shall house the optical system with a pressed high purity one
piece aluminium reflector that is anodized and polished. The positioning of the reflector
shall be such that should it nsslished. Tt lector
(a)
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The accessories such as ballasts, starters, capacitors etc., shall be pre-wired and preassembled in the rear compartment on a detachable metallic gear tray fixed securely to the
main body of the luminaire in such a way as to ensure effective earth continuity.
Special care shall be taken to allow easy maintenance and quick replacement of the
accessories and to minimise the risk of falling.
The incoming cable feed terminal block and the earth-screw shall be fixed to either the gear
tray or metallic compartment. A cable restraining device shall be mounted near the incoming
terminal block. All metal parts shall be effectively earthed to the luminaire earth-screw that
shall be readily visible and accessible once access is obtained to the rear compartment. The
spigot entry socket of the luminaire shall be compatible with the column bracket and able to
accept a 125mm long by 50mm diameter or adjustable from 42mm to 60mm diameter spigot.
15.8
CONTROL GEAR
15.8.1
General
All items of control gear shall be fitted with shrouds over all terminals to prevent accidental
contact during lamp replacement or routine equipment maintenance. All control gear shall
have a clearly marked circuit diagram to show its terminal connections in relation to all other
components. Control gear (choke, capacitor, ignitor etc.) shall be suitable to withstand
temperatures up to 86C and shall have a purpose made earth terminal. Internal connections
shall be with heat resistant non-hydroscopic insulated stranded copper conductors, cleated
and with porcelain connectors.
Ballast (choke) shall be closed type polyester filled can. It shall be suitable for single phase
voltage operation and silent in operation. All tappings shall be brought to suitably marked
standard terminals to which the lamp and supply connections shall be made.
The capacitor shall give a minimum power factor of 0.85 lagging. They shall have a tolerance
of + or 10% of its marked value. Where non-metallic capacitors are offered these shall be
supplied with a fixing band that shall not damage the capacitor when fitted. Where the
capacitor has an aluminium body it shall be provided with a separate earth terminal.
Ignitors shall be mounted within the control gear compartment of the luminaire. Each ignitor
shall be fitted with a device that will detect the presence of a faulty lamp and automatically
limit the generation of HV pulses. The ignitors shall be suitable for use with the lamp, ballast
and power factor correction capacitor included within the control gear circuit.
15.9
LAMPS
15.9.1
General
Lamps shall be energy saving lamps with clear tubular hard glass envelope with E-40 base
suitable for use on 220 - 240 V, 50Hz, AC. Lamps shall be manufactured according to
International Electrotechnical Commission IEC or International Standards, and accepted or
approved by Qatar Standards.
Energy saving lamps ( that have a minimum of 50% energy saving than the standard high
pressure sodium vapour gas lamps)shall be:
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High Intensity Discharge (HID) ,
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(b)
Induction lamp types;
(c)
Light Emitting Diodes (LED)
(d)
and any other types of energy saving lamps accepted and approved by Qatar
Standards .
These lamps shall either have a built in or an external ignitor. Initial Lumen output for High
Intensity Discharge (HID) lamps shall be no less than 4,500 lumens/watt for the 50 watt
lamps, no less than 6,500 lumens/watt for the 70 watt lamps, no less than 12,500
lumens/watt for the 100 watt lamps, no less than 17,500 lumens/watt for the 150 watt lamps,
no less than 33,150 lumens/watt for the 250 watt lamps or no less than 48,000 lumens/watt
for the 400 watt lamps,
15.10
LIGHTING SYSTEM FOR UNDERPASSES
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The basis for the lanterns for use within both the lighting of the vehicular, pedestrian and
animal underpasses pertains to lanterns designed for cornice surface mounting within each
underpasses, complete with lamp, fuse and associated control gear. The lighting
arrangement within each type of underpass shall be based on the use of a common lantern
designed such that it can incorporate either a multi lamp or single lamp luminaire
arrangement of a variable wattage.
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15.10.1 General
The lanterns for vehicular underpasses shall consist of either 1x 150 Watt SON/T (no less
than 17,500 lumens/watt) and 1 x 250 watt SON/T (no less than 33,150 lumens/watt) high
pressure sodium vapour luminaires, LED lamps or energy saving lamps with Lumen/Watt
equivalent to the above wattages, complete with all materials as specified herein and in the
Contract Documents and as required to provide a complete lighting installation.
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15.10.2 Vehicular Underpass
The lanterns for pedestrian underpasses shall consist of either 1x 70 Watt (no less than
6,500 lumens/watt) or 100 Watt SON/T (no less than 12,500 lumens/watt) high pressure
sodium vapour luminaires, or Lumen/Watt-equivalent LED lamps or energy saving lamps,
complete with all materials as specified herein and in the Contract Documents and as
required to provide a complete lighting installation.
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15.10.3 Pedestrian Underpass
15.10.4 Animal Underpass

1
The lanterns for animal underpasses shall consist of either 1x 70 Watt (no less than 6,500
lumens/watt) or 100 Watt SON/T (no less than 12,500 lumens/watt) high pressure sodium
vapour luminaires, or Lumen/Watt-equivalent LED lamps, or energy saving lamps complete
with all materials as specified herein and in the Contract Documents and as required to
provide a complete lighting installation.
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15.10.5 Lantern Construction for use in Vehicular, Pedestrian and Animal Underpasses
An underpass lantern shall consist of housing, front cover, reflector, socket, lamp, fuse,
control gear, wiring, latches, screws, washers, pins and other parts composing a complete
unit. The lantern shall provide illumination, be mechanically strong and easy to maintain. Its
optical housing shall have protection against the ingress of moisture and dust to degree IP55
of IEC529 under all operating conditions.
The optical seal which shall include the reflector mounting shall be adequate to maintain this
degree of protection. With the exception of the reflector, lamp holder mounting and
associated cable all other equipment shall be housed at the rear of the optical system and
shall be readily accessible by access through the lantern front plate. These components shall
include the lantern control equipment, associated cable and isolating fuse. The cable
connections to the lampholder within the lantern shall be of the heat resistant type with
silicon, glass fibre or other approved insulation.
The housing and front cover shall be made of stainless steel.
The reflector shall be made of aluminium sheet of such grade and quality that :
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The reflecting surface shall have a specular finish.
(b)
The reflecting surface shall have a dense protective coating of oxide not less than 1.2
2
mg/cm , applied by the anodic oxidisation process.
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(a)
The reflector shall be of such material and construction as to provide low brightness and
minimize glare. The latches, nuts, screws, washers, pins and other parts shall be made of
non-corrosive metals or of metals with non-corrosive finishes as approved by the Engineer.
The seal of the optical system shall be accomplished with a gasket material that will not
deteriorate with age. This gasketing shall be continuous and shall ensure a heat and
weatherproof seal. Suitably located knockouts to suit the cable conduit shall be provided in
the housing. The lamp socket shall be provided with grips or other suitable means to hold the
lamp against vibration.
The fascia plate of the lantern shall be manufactured from toughened glass protected, if
necessary due to a high incidence of vandalism by means of the manufacturers purpose
made wire mesh guard.
Between adjacent luminaries a stainless steel in fill plate shall be provided such that the
whole assembly gives the appearance of a continuous cornice arrangement. The main sub
circuit cables interconnecting each underbridge luminaire from the underpass isolating
control box shall be routed between fittings within the luminaire or in fill plate by means of a
purpose made cable tray arrangement. Within the structure the cabling shall be routed via
galvanized steel conduit cast within the underpass walls and soffit of size suitable to
accommodate the number of single core or multicore cables required whilst maintaining the
stipulated space factor according to the relevant regulations. The cabling shall be either
single core or multi core 6mm copper conductors within high temperature grade double
insulated or flexible cable.
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15.10.6 Underbridge or Undercrossing Lantern and Installation

The lantern for use within both the underbridge and undercrossing lighting shall be designed
for directly mounting immediately above the kerb edge of the carriageway and shall be
complete with lamp, fuse and associated control gear. The lighting arrangement shall be
such that it can incorporate either a single lamp of a variable wattage.
The underbridge or undercrossing lantern shall consist of housing, cover, reflector, socket,
lamp, fuse, control gear, wiring, latches, screws, washers, pins and other parts composing a
complete unit. The lantern shall provide illumination, be mechanically strong and easy to
maintain. Its optical housing shall have protection against the ingress of moisture and dust to
degree IP55 of IEC529 under all operating conditions.
The optical seal which shall include the reflector mounting shall be adequate to maintain this
degree of protection. With the exception of the reflector, lamp holder mounting and
associated cable all other equipment shall be housed at the rear of the optical system and
shall be readily accessible by access through the lantern front plate. These components shall
include the lantern control equipment, associated cable and isolating fuse. The cable
connections to the lampholder within the lantern shall be of the heat resistant type with
silicon, glass fibre or other approved insulation.
The housing and front cover shall be made of stainless steel.
The reflector shall be made of aluminium sheet of such grade and quality that :
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The reflecting surface shall have a specular finish.
(b)
The reflecting surface shall have a dense protective coating of oxide not less than 1.2
2
mg/cm , applied by the anodic oxidisation process.
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(a)
The reflector shall be of such material and construction as to provide low brightness and
minimize glare. The latches, nuts, screws, washers, pins and other parts shall be made of
non-corrosive metals or of metals with non-corrosive finishes as approved by the Engineer.
The seal of the optical system shall be accomplished with a gasket material that will not
deteriorate with age. This gasketing shall be continuous and shall assure a heat and
weatherproof seal. Suitably located knockouts to suit the conduit shall be provided in the
housing. The lamp socket shall be provided with grips or other suitable means to hold the
lamp against vibration.
The fascia plate of the lantern shall be manufactured from toughened glass protected, if
necessary due to a high incidence of vandalism by means of the manufacturers purpose
made wire mesh guard.
The main sub circuit cables interconnecting each underbridge or undercrossing luminaire
from the underbridge or uncrossing isolating control box Within the structure the cabling shall
be routed via galvanized steel conduit cast within the underbridge or structure walls and soffit
of size suitable to accommodate the number of single core or multicore cables required whilst
maintaining the stipulated space factor according to the relevant regulations. The cabling
shall be either single core or multi core 10mm copper conductors within high temperature
grade double insulated or flexible cable.
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15.10.7 Underpass, Underbridge and Undercrossing Lantern Control Gear and Lamps
The control gear shall be designed to operate the lamp of the power rating and type indicated
and it shall be able to start the lamp and control it continuously for ambient temperatures up
to +55C. The choke shall be tropicalised and have terminals to accept 240 V supply voltage.
Each terminal shall be brought out to a separate shrouded termination. Multi-lamp gear
operating more than one lamp shall not be employed.
of +/ 10% of its marked value. Where non-metallic capacitors are offered these shall be
supplied with a fixing band that shall not damage the capacitor when fitted and, if metallic,
shall be provided with a separate earth terminal. The permitted operating temperature of the
capacitor shall be marked on its case.
Each lamp shall operate using only one choke and one capacitor. Any combination of two or
more capacitors having the equivalent value of capacitance will not be accepted.
Chokes and capacitors shall comply with the relevant British Standard Specification or an
acceptable International equivalent and shall be fully compatible with the complete
associated operation lamp circuit.
The ignitor for energy saving lamp shall be of the electronic solid state type and shall be
arranged so that the ignitor circuit stops working after the lamp has started. It shall be totally
enclosed. The circuit shall include a shunt capacitor to isolate the mains from high frequency
start pulses; this capacitor may also be used for power factor correction. The length of wiring
between the ignitor and the lamp shall not exceed that recommended by the Manufacturer for
satisfactory lamp ignition and re-ignition of an extinguished lamp.
The control gear shall meet the following specifications:
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It shall be suitable for 50 Hz, 240 V AC + 10% operation.
(b)
It shall regulate the output power to 12% for the input voltage noted above.
(c)
It shall have an overall power factor of at least 0.85 when operated under rated lamp
load.
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It shall operate the lamp without affecting adversely the lamp life and performance as
specified herein.
(d)
(a)
(e)
It shall withstand a 2500 V dielectric test between core and windings.
(f)
The choke shall be encapsulated in an approved resin compound and totally enclosed.
The lamps for vehicular underpasses shall consist of either 1x 150 Watt SON/T (no less than
17,500 lumens/watt) and 1 x 250 watt SON/T (no less than 33,150 lumens/watt) high
pressure sodium vapour luminaires, LED lamps or energy saving lamps with Lumen/Watt
equivalent to the above wattages, complete with all materials as specified herein and in the
Contract Documents and as required to provide a complete lighting installation.
The lamps for pedestrian or animal underpasses shall consist of either 1x 70 Watt (no less
than 6,500 lumens/watt) or 100 Watt SON/T (no less than 12,500 lumens/watt) high pressure
sodium vapour luminaires, LED or energy saving lamps with Lumen/Watt-equivalent,
complete with all materials as specified herein and in the Contract Documents and as
required to provide a complete lighting installation.
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15.10.8 Underpass, Underbridge or Undercrossing Isolating Box

1
At each underpass, underbridge or undercrossing location an isolating box assembly shall be

provided to control and isolate the respective lighting. This assembly shall be constructed
from either galvanized steel or stainless steel with a hinged vandal resistant lockable front
cover complete with sealing gasket protection against the ingress of moisture and dust to
degree IP54 of IEC529 under all operating conditions providing. A three phase mcb isolator
shall be located within this housing to control the power supplies to each lighting sub circuit.
The galvanized steel conduit providing the cabling routing within the structure shall be
secured at the isolating box assembly by means of a locknut arrangement.
15.11
LED LIGHTING UNITS
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15.11.1 Lighting Units

The degree of Ingress Protection provided by the luminaire, including the facility for a
switching device, shall be rated at least IP66 in accordance with EN60529 (IEC529).
Specification for degrees of protection provided by enclosures (IP code). This shall be
certified by an independent IP testing and examination laboratory accredited by UKAS or
equivalent accreditation body.
The degree of Impact Protection provided by the luminaire against external mechanical
impact shall be rated at least IK10 (metals and plastics) and IK08 (glass) in accordance with
EN62262:2002 (IEC62262:2002) Degrees of protection provided by enclosures for electrical
equipment against external mechanical impacts (IK code). This shall be certified by an
independent IK testing and examination laboratory accredited by UKAS or equivalent
accreditation body.
The luminaire assembly shall be tested and approved by an independent ENEC

(European Norms Electrical Certification) national Certification Body and awarded the
ENEC mark or equivalent international standards. Contractor shall provide verifiable
certificate featuring contact information of Certification Body.
The luminaire shall be designed and suitably rated to ensure correct operation and
continuous trouble free service under the prevailing climatic conditions. The luminaire
shall be designed to withstand the effects of direct sun exposure during the day and dusty
weather conditions including the occasional sandstorm. The luminaire manufacturer shall
guarantee the performance and life time claims of lumen maintenance and luminaire
life of the luminaire under the stated climatic conditions.
The luminaire housing shall be constructed from corrosion resistant marine grade
aluminium alloy conforming to BS EN 1676, 1559-1, 1559-4 and 1706 and powder
coated by an Akzo Nobel approved applicator, or equivalent, conforming to EN12206-1:2004
Paints and varnishes. Coating of aluminium and aluminium alloys for architectural
purposes. Coatings prepared from coating powder.
The manufacturer shall supply a RAL colour chart depicting the range of powder coat colours
available for the external finish of the luminaire. Luminaire colour shall be specified at the
time of ordering.
The optical assembly and control gear components shall be integral to the luminaire
body.
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For maintenance the luminaire shall allow tool-less access and incorporate quick
disconnect features and universal fittings. All component parts shall be easily accessible and
securely mounted to prevent accidental falling and manufactured from corrosion
resistant materials or treated to prevent corrosion. The luminaire cover shall include an
optional security feature to enable locking by means of a tool. The cover shall also
incorporate a safety switch to disconnect power on opening and any upward rising
hinged canopy shall be secured in an open position by means of a brace to prevent
accidental closing.
The luminaire shall be procured from a prominent luminaire manufacturer that publishes
product specifications measured in compliance with the IEC/PAS performance
requirements or equivalent.
10
The complete luminaire shall be at least 98% recyclable.
11
The luminaire shall be vandal resistant. The ingress of insects through any system vent or
aperture shall be prevented by means of a filter.
12
The luminaire shall be compliant with the Waste Electrical and Electronic Equipment
(WEEE) Directive (2002/96/EC) and the Restriction of the use of certain Hazardous
Substances in electrical and electronic equipment (RoHS) Directive (2002/95/EC).
13
Each luminaire shall have a barcode securely attached internally within the gear
compartment identifying the luminaires reference/catalogue number, total wattage and
LED current setting and other attributes as required by Ashghal and as required of the
Enterprise Asset Management System (EAMS). The barcode type shall be compatible with
the handheld device authorized for use by Ashghal.
14
All internal and external wiring of the luminaire shall comply with EN60598-1:2008
Luminaires, General requirements and tests and shall be flexible and suitably rated and
insulated to withstand the voltages and temperatures encountered in service.
15
Any luminaire wiring passing through metal shall have suitable grommets or otherwise be
protected to avoid abrasion of the insulation.
16
All luminaire terminals and supply connections shall comply with EN60598-1:2008. The
conducting material of any terminal block shall be made of brass and shall have screw down
plates bearing on the wires. Terminals where screws bear down directly on wires will not be
acceptable.
17
Luminaires shall be earthed in accordance with EN60598-1:2008. An earth terminal forming

part of the luminaire body shall be provided. All parts of an earth terminal shall be made of
brass.
18
Luminaires shall be future proofed by allowing the LED modules to be upgraded easily in
situ, as LED efficiency improves. Upgrading of luminaires, or replacement of faulty
components, with manufacturer approved components shall not have any detrimental
impact whatsoever on the luminaires manufacturer warranty. Prototypes shall not be
accepted.
15.11.2
Lighting Performance
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Highway luminaires shall be suitable to achieve the lighting class standards as detailed in the
Qatar Design Management Manual, as referenced in ANSI/IESNA RP-008, and as applicable
to Primary, Secondary and Tertiary roads in The State of Qatar, under the control of Ashghal
and other areas as required.
The luminaire shall be compliant with EN60598-1:2008 Luminaires. General

requirements and tests, and EN60598-2-3:2003 Luminaires. Particular requirements.
Luminaires for road and street lighting.
The luminaire shall be able to restrict glare and control obtrusive light in accordance with the
full cut-off and semi cut-off concepts and associated luminous intensity classes defined in
ANSI/IESNA RP-008 or an equivalent, Ashghal-authorized standard. Individual project
contract drawings and design specifications shall detail the luminous intensity class
requirement.
The luminaire shall control light output to limit light pollution and minimise sky glow in
accordance with Commission Internationale de l'clairage (CIE) 126-1997 Guidelines for
minimizing sky glow and meet the requirements therein for maximum permissible
upward light output ratio (ULOR) expressed as the percentage of luminous flux
acceptable in each of four different Environmental Zones.
The efficacy of the luminaire is given by the total lumen output divided by the power into the
system and shall be equal to or greater than 100 lm/w (lumens per watt) operating within the
climate conditions as stated herein. The contractor shall obtain a statement from the
luminaire manufacturer declaring that quoted performance figures correspond to the stated
ambient air temperature and ensure that the specifics of operating in the Qatar environment
are written into any applicable section of the manufacturers warranty agreement.
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15.11.3 Thermal Management
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The luminaire shall be capable of withstanding severe climate conditions, as stated in

Section 21, Part 1. General Provisions for Electrical Installation, clause 1.1.14.
As a minimum, manufacturers shall use 50 C as the night time ambient temperature

with 95% humidity.
The luminaire shall be designed to provide satisfactory heat dissipation for any powered
component parts and maintain safe operating temperatures at all times under the stated
climatic conditions. Heat dissipation shall be by passive thermal management, active or
mechanical cooling is not acceptable.
All materials used in the luminaire shall be resistant to high temperature UV (ultra violet)
exposure and be 90% UV-stable.
The luminaire shall incorporate a passive thermal management system, active cooling such
as fan assisted systems will not be accepted. The manufacturer shall demonstrate that the
luminaire is suitable for continuous operation in the Qatar environment. Within the stated
climate conditions the LED junction temperatures shall be shown to remain within the range
required to limit the risk of accelerated degradation of the LEDs based on the stated life
expectancy of the luminaire.
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Junction temperature cannot be measured directly and must be derived using calculation
formulae and temperature measurements read from a thermocouple device attached to a
series of defined reference points (thermal pads) on the outer casing (package) of the LED.
Thermal verification testing is carried out as a laboratory based operation with ambient
conditions simulated.
The luminaire manufacturer shall submit a statement declaring that quoted LED
performance figures correspond to the stated ambient air temperature and ensure that the
specifics of operating in the Qatar environment are written into any applicable section
of the warranty agreement.
The maximum allowable ambient temperature for the LED lighting shall be stated, in
which the LED lighting can operate without adversely affecting any components life,
luminaire light output or colour stability. This shall take into consideration the maximum case
temperature of the driver and the design LED junction temperature.
Manufacturers shall state the predefined critical temperature level at which the dim down and
switch off protection events occur and relate to junction temperature and ambient
temperature. The luminaire shall be constructed in such a way that this protection
method shall not occur during climate conditions stated within this specification.
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15.11.4 Testing
LED Luminaire lighting performance shall be measured using an independent

photometric testing laboratory accredited by UKAS or equivalent accreditation body. The test
procedure and measurements shall be carried out in accordance and compliance with
IES_LM-79-08 Approved Method: Photometric Measurements of Solid State Lighting
Products. The photometric test report shall list all significant data for each SSL product
tested together with performance data and also pertinent data concerning conditions of
testing, type of equipment, and reference standards. The photometric test procedure shall
also be used to calculate correction factors in allowance of the stated climate conditions.
Photometric data for each luminaire optical setting shall be available in electronic file
format in accordance and compliance with IES_LM-63-02 Standard File Format for
Electronic Transfer of Photometric Data and Related Information and EN130321:2004+A1:2012 Light and lighting. Measurement and presentation of photometric data of
lamps and luminaires. Measurement and file format. The photometry files shall be
compatible for use with industry recognised road lighting design software packages or as
requested by Ashghal and include applied correction factors specific to the declared
ambient conditions.
Lighting performance of the LED luminaire in terms of design spacings relative to a

specified road lighting class should be comparable to a modern HID lamp based
luminaire with similar lumen output.
The luminaire manufacturer shall submit a statement declaring that quoted photometric
performance figures correspond to the stated ambient air temperature (not LED junction
temperature) and ensure that the specifics of operating in the Qatar environment are
written into any applicable section of the warranty agreement.
The luminaire shall be tested in accordance and compliance with EN62471:2008

(IEC62471:2006) Photobiological safety of lamps and lamp systems or an equivalent
standard. Any assumptions made during testing shall be clearly stated.
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The luminaire LED light source shall be tested in accordance and compliance with
IES_LM-80-08 Approved Method: Measuring Lumen Maintenance of LED Light Sources. The
LM-80-08 test report produced for the LED light source shall meet the eligibility
criteria necessary for submission to the U.S Department of Energy (DOE) Energy Star
Program Requirements for Solid State Lighting Luminaires.
15.11.5 In Situ Temperature Measurement Test (ISTMT)

In order to relate the LM-80 test to the luminaire and stated climatic conditions, testing shall
be completed that simulate this application. This shall be achieved by In Situ
Temperature Measurement Test (ISTMT) which follows ANSI/UL 1598-2004 Luminaires.
The luminaire manufacturer shall provide a written undertaking to the satisfaction of

Ashghal\s authorized Engineer to warranty the materials and performance as follows:
LED arrays shall have a written warranty for a minimum of 50,000 hours at the ambient
temperature specified herein and shall be replaced on a one for one basis upon failure.
An LED array will be deemed to have failed when:
(b)
equal to or greater than 10% of the individual LED chips in an array has failed or an
array does not provide the required lumen maintenance (L70).
(c)
Drivers shall have a written warranty for a minimum 50,000 hours and shall be
replaced on a one for one basis.
(d)
Luminaire housing and all external components such as; lenses, gaskets & fastenings
and the fixture finish shall have a written warranty for a minimum twenty (20) years
against the deterioration of, but not limited to, mechanical failure, UV degradation,
corrosion, yellowing, blistering, chalking, cracking, peeling or fading.
(e)
The Warranty shall be transferable without limitations in its entirety to Ashghal, Public
Works Authority, Qatar.
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(a)
Equivalent or more onerous standards can be proposed, by the manufacturer, as an

alternative to the detailed standards, with the exception of Qatar documents. Evidence shall
be submitted detailing the equivalent or more onerous sections that deviates from the
intended standard.
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15.11.6 Control Gear

1
The luminaire control gear (driver) shall be produced by a prominent manufacturer of

semiconductor components and comply with IEC 62384 DC or AC supplied electronic
control gear for LED modules - Performance requirements. The manufacturer shall
confirm that the packaged driver assembly is fabricated from high quality integrated
circuit components including long-life electrolytic capacitors and provide data relating to the
reliability of the device, in the climatic conditions stated in this specification.
The drivers shall be encapsulated / potted and Class II double insulated (IEC61140) and
have a minimum energy efficiency of 85% and power factor 0.9 (full load). The control gear
shall feature Surge Protection Device (SPD) for lightning strikes (IEC62305), short-circuit
protection and transient overvoltage protection (IEC61643-1 / IEC61000-4-5).
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The LED drivers shall be housed on a removable gear tray accessible with the luminaire
cover open and be compatible with the Qatar power supply. The supply cable shall pass
through the mounting post, or bracket, directly into the luminaire through an M20 cable gland
located at the base of the luminaire mounting socket.
For protection in the event of temperatures reaching predefined critical levels, both
LEDs and drivers shall have thermal protection, which will initially dim down and
eventually switch off the light. Manufacturers shall state the predefined critical
temperature level at which the dim down and switch off protection events occur and
relate to junction temperature and ambient temperature. The luminaire shall be
constructed in such a way that this protection method shall not occur during climate
conditions stated within this specification.
The driver system shall be compatible with Lighting Control Systems / Lighting
Management Systems (LMS), using both analogue (1-10V) and Digital Addressable
Lighting Interface (DALI) protocols including WiMAC or other similar Ashghal-approved
driver system. The driver system shall also be capable of being configured for
single, and multi-stage, stand-alone dimming configurations when not connected to a
CMS.
The drivers shall be programmable and permanently configured to operate under the
principle of constant flux output or maintenance factor harvesting or similar, Ashghalapproved configuration method. During this process light output is initially dimmed to an
equivalent end of life level value and then the operating current is gradually increased
throughout service life to compensate for lumen depreciation and maintain a constant
lighting level. The advantage of this system is to give energy savings and improve LED
life and reliability. The manufacturer shall provide details of how this facility is maintained
following replacement of a faulty driver or LED array.
The driver shall be capable of operating within the climate conditions previously
described and shall have documentation and certification supporting the claimed
minimum life expectancy of 50,000 hours in the stated conditions within this
specification.
The driver manufacturers device data sheet will provide specification details and the
maximum permissible ambient temperature range in which the driver can operate (free air
convection) at the defined driver current. The luminaire manufacturer shall
demonstrate that the LED driver is suitable for continuous operation in the Qatar
environment. Within the stated climate conditions the driver compartment enclosure shall be
shown to remain within the range required to limit the risk of driver failure during
operation based on the stated life expectancy of the luminaire.
The luminaire manufacturer shall submit a statement declaring that quoted driver
performance figures correspond to the stated ambient air temperature and ensure that the
specifics of operating in the Qatar environment are written into any applicable section
of the warranty agreement.
10
The luminaire shall conform to CE marking directives including the European

Electromagnetic Compatibility (EMC) Directive EN 61000-3-2:2009 (IEC 61000-32:2009) Electromagnetic compatibility (EMC) - Part 3-2: Limits - Limits for harmonic
current emissions (equipment input current 16 A per phase)
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15.11.7 LED Lamps

The LEDs shall be produced by a Ashghal Approved manufacturer of solid state lighting
(SSL) components and comply with the related standards and guidelines set by the
Illuminating Engineering Society of North America (IESNA) and the JEDEC Solid State
Technology Association and approved by Qatar Standards.
The light source is required to control light output with the aim of optimising luminaire
performance and efficiency in relation to the specific lighting application. The luminaire, or
luminaire series, shall provide the facility for varying luminous flux output ranging from 5klm
up to at least 40klm using an appropriate number of LEDs and a suitable control method for
each different lumen package.
The luminaire LED module shall comply with International Electrical Commission
Publicly Available Specification IEC/PAS62717 LED modules for general lighting
Performance requirements.
The LED arrays shall be capable of operating within the climate conditions previously
described and shall have documentation and certification supporting the claimed minimum
life expectancy of 50,000 hours at L70 in the stated conditions as within this specification.
Technical details shall be provided of the light source optical system and range of optics or
optical settings available for each model of luminaire including performance
characteristics. The optical system is required to control light output with the aim of
optimising luminaire performance and efficiency in relation to the specific lighting
application. The system should meet the lighting requirements of most rights of way
types and configurations and maximise the light output ratio (LOR) of the luminaire.
The inadvertent failure of any LEDs during the life of the luminaire shall not bring about any
reduction in uniformity of light output. Therefore, the multi-layer method of light distribution
shall take precedence over multiple spot methods.
Diffuser systems may be required for some lighting applications to eliminate the effect of
multiple-source shadows.
Chromaticity tolerance and associated colour consistency of luminaire LED modules

shall be measured in terms of the CIE 1931 chromaticity diagram and the CCT
quadrangles defined by the American National Standards Institute (ANSI) C78.3772008 Specifications for the Chromaticity of Solid State Lighting Products for Electric Lamps.
The ANSI quadrangle is made up by smaller quadrangles, commonly referred to as bins. The
x y chromaticity components of each LED module shall be enclosed by one bin and the bin
size shall not exceed a 4-step MacAdam ellipse. The binning process shall be in compliance
with National Electrical Manufacturers Association (NEMA) SSL 3:2010 High-Power
White LED Binning for General Illumination.
The chromaticity shift shall be measured and reported in accordance with IES_LM-80-08
Approved Method: Measuring Lumen Maintenance of LED Light Sources.
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For highway lighting the Correlated Colour Temperature (CCT) of the light emitted from the
luminaire shall be in the range 4000K with a Colour Rendering Index (CRI) of 60. The
manufacturer shall state the CCT ranges available with a 275K warranted window. The CCT
and CRI shall include the effects of colour shift over the life of the luminaire. Other CCT
ranges may be applicable to individual projects and manufacturers shall be notified as
required.
11
Lumen maintenance (L) is the luminous flux emitted by the light source at any specified time
during its operational life and is expressed as a percentage of the luminous flux
emitted at the start of life (L%). The rated lumen maintenance life of the LED light source
shall not exceed L70, or 30% lumen depreciation at the specified temperature conditions.
12
The luminaire manufacturer shall define the estimated service life of the light source in terms
of operating hours and rated lumen maintenance. The minimum standard expected shall be
50,000 operating hours at L70 at the temperature conditions specified herein.
13
The method of deriving rated lumen maintenance life beyond the limits of lumen
maintenance determined from actual measurements shall be demonstrated. The method for
projecting the lumen maintenance of LED light sources from the data obtained by the
procedures found in IES document LM-80-08 shall be in accordance and compliance
with IES_TM-21-11 Projecting Long Term Lumen Maintenance of LED Light Sources.
14
In combination with rated life predications the reliability of the LED modules shall also be
expressed in terms of the percentage (fraction) of failures in accordance with IEC/PAS
62722-2-1:2011 Luminaire performance - Part 2-1: Particular requirements for LED
luminaires. The failure fraction (Fy) corresponds to the percentage of LEDs that fail
before end of rated life. This failure fraction expresses the combined effect of all
components of a module including mechanical, as far as the light output is concerned. The
effect of the LED could either be less light than claimed or no light at all.
15
The failure fraction shall also be expressed in terms of its component parts, gradual failure
fraction (By) and abrupt failure fraction (Cy). The reliability curve relative to operating hours is
calculated using statistical formulae and data gathered under test conditions during luminaire
monitoring periods.
16
Luminaire maintenance factors (LMF) to follow model used in BS5489-1:2003+A2:2008

Annex D Table D1 with figures extrapolated to extend cleaning cycle interval up to 6
years and also adjusted to take account of environmental conditions specified herein.
17
Lamp flux maintenance factor (LFMF) shall be calculated by the manufacturer in accordance
with calculated lumen depreciation relative to a predefined cleaning cycle interval. Currently
the perceived cleaning interval is biannually due to the intense dust laden atmosphere.
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15.11.8 Quality Criteria for LED Lighting

1
Manufacturers shall submit data in accordance with IEC/PAS 62717 Performance

requirements LED modules for general lighting and IEC/PAS 62722 Performance
requirements LED luminaires for general lighting.
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15.11.9 LED manufacturers data

Manufacturer shall provide a standardised set of quality criteria, measured in
compliance with the appropriate standard. The performance claims shall be matched against
traceable data. The performance data required is summarised below and shall be headed
Quality Criteria:
(a)
Rated input power (in W)
(b)
Rated luminous flux of the luminaire (in lm)
(c)
luminaire efficacy (in lm/W)
(d)
Luminous intensity distribution
(e)
Photometric code
Rated Colour Rendering Index (CRI)
(ii)
Correlated Colour Temperature (CCT in K)
(iii)
Rated chromaticity co-ordinate values (initial and maintained)
(iv)
Maintained luminous flux
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(i)
Rated life (in h) of the module and the associated rated lumen
(g)
maintenance (Lx)
(h)
Failure fraction (Fy), corresponding to the rated life of the module in the
(i)
luminaire
(j)
Ambient temperature (ta) for the luminaire
(k)
Power Factor
(l)
Intensity Distribution
(m)
Drive Current
(n)
Optical Risk Group
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This data shall be submitted on an Ashghal-approved form. Forms shall be submitted to

Ashghal for approval prior to submitting data for consideration. Further data shall be
provided to evidence compliance with all aspects of this specification. Additional data shall be
provided as and when requested by Ashghal.
15.12
OVERHEAD SIGN GANTRY LANTERN AND INSTALLATION
15.12.1 General
1
The basis for the lanterns for use on the overhead sign gantries or bridges for the illuminating
of overhead guide signs mounted on the sign support structure or on the gantry sign walkway
supported on the gantry sign support brackets. The lanterns shall be complete with lamp,
isolating fuse and associated control gear.
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15.12.2 Sign Gantry Lantern

The lanterns shall be LED type and shall be rated per lamp at 2 x 50 watt (no less than 4,500
lumens/watt), 2 x 70 watt (no less than 6,500 lumens/watt), 2 x 100 watt (no less than 12,500
lumens/watt), 2 x 150 watt (no less than 17,500 lumens/watt) and 2 x 250 watt (no less than
33,150 lumens/watt) LED lamps and shall consist of housing, cover, reflector, refractor,
socket, lamp, fuse, control gear, wiring, latches, screws, washers, pins and other parts
composing a complete unit. At half life, the maintained luminous flux shall be a minimum of
75% of the initial luminous flux.
The lantern shall provide efficient illumination, be optically sealed, mechanically strong and
easy to maintain.
The reflector mounting, wiring terminals and control gear components shall be readily
accessible. When closed for operation, the optical assembly shall be sealed to provide
protection against the ingress of moisture and dust to degree IP55 of IEC529 under all
operating conditions.
The seal between the refractor and the housing shall be adequate to maintain this degree of
protection. The refractor shall be held in such a manner as to allow for expansion and
contraction of the refractor. Cable connections to the lamp holder within the lantern shall be
of the heat resistant type with silicon, glass fibre or other approved insulation.
The optical system shall consist of a hydroformed aluminium primary beam reflector which
shall be precisely profiled and contoured to distribute light across the inner surface of the
refractor. The prismatic refractor shall be of moulded borosilicate thermal shock-resistant
glass. The inner surface shall have an intricate array of prisms to direct light across the face
of the sign. The outer surface shall be smooth to facilitate self-cleaning. The reflector shall be
of a retro-dispersing type designed to eliminate the halo of excessive luminance to assure
more uniform sign luminance.
The terminal board shall be located beneath the reflector at the conduit entry and shall
2
accommodate 10 mm electric cables.
The reflector shall be fastened to the housing by means of a minimum of four stainless steel
screws with keyhole slot to facilitate easy removal and replacement. Levelling pads are to be
provided on the inside and bottom of the main housing to permit accurate installation.
There shall be mounting within of the stainless steel housing to permit the lantern to be
mounted directly to the supporting structure.
The refractor shall be form-fitted to the stainless steel door frame and shall have a single
piece gasket with a sealing pad to effectively seal the assembly and housing. The assembly
shall be fastened to the housing by means of separable hinges at the front and spring
tempered, stainless steel at the rear. The lamp socket shall be provided with grips or other
suitable means to hold the lamp against vibration.
10
The terminals of all ballasts, capacitors and control gears shall be shrouded.
11
Each sign lighting system shall be subject to the approval of the Engineer. Particular attention
shall be given to the mechanical strength of all components, and to the security of their
method of the sign supports.
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15.12.3 Sign Gantry Lantern Control Gear and Lamps

The control gear shall be designed to operate the lamp of the power rating and type indicated
and it shall be able to start the lamp and control it continuously for ambient temperatures up
to +55C. The choke shall be tropicalised and have terminals to accept 240 V supply voltage.
Each terminal shall be brought out to a separate shrouded termination. Multi-lamp gear
operating more than one lamp shall not be employed.
of + or 10% of its marked value. Where non-metallic capacitors are offered these shall be
supplied with a fixing band that shall not damage the shell and be provided with a separate
earth terminal. The permitted operating temperature of the capacitor shall be marked on its
case.
Each lamp shall operate using only one choke and one capacitor. Any combination of two or
more capacitors having the equivalent value of capacitance will not be accepted.
Chokes and capacitors shall comply with the relevant British Standard Specification or an
acceptable International equivalent and shall be fully compatible with the complete
associated operation lamp circuit.
The control gear shall meet the following specifications:
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It shall be suitable for 50 Hz, 240 V AC + 10% operation.
(b)
It shall regulate the output power to 12% for the input voltage noted above.
(c)
It shall have an overall power factor of at least 0.85 when operated under rated lamp
load.
(d)
It shall operate the lamp without affecting adversely the lamp life and performance as
specified herein.
(e)
It shall withstand a 2500 V dielectric test between core and windings.
(f)
The choke shall be encapsulated in an approved resin compound and totally enclosed.
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(a)
The lamps shall be LED type and shall be rated per lamp at 2 x 50 watt (no less than 4,500
lumens/watt), 2 x 70 watt (no less than 6,500 lumens/watt), 2 x 100 watt (no less than 12,500
lumens/watt), 2 x 150 watt (no less than 17,500 lumens/watt) and 2 x 250 watt (no less than
33,150 lumens/watt) LED lamps and shall consist of housing, cover, reflector, refractor,
socket, lamp, fuse, control gear, wiring, latches, screws, washers, pins and other parts
composing a complete unit. At half life, the maintained luminous flux shall be a minimum of
75% of the initial luminous flux.
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15.12.4 Sign Gantry Isolating (Safety) Switch, Conduit and Associated Cables
At each sign gantry location an isolating (safety) shall be provided at walk way level of the
structure. It shall be fabricated galvanized steel complete with a vandal resistant hinged
access door. A three phase mcb isolator shall be located within this housing to control the
power supplies to each lighting sub circuit. The galvanized steel conduit, secured to the
gantry structure by means of purpose made saddles to suit the size of conduit, providing the
cabling routing within the structure shall be secured at the isolating box assembly by means
of a locknut arrangement. The size of the conduit shall be suitable to accommodate the
number of single core or multicore cables required whilst maintaining the stipulated space
factor according to the relevant regulations. A 3-phase mcb isolator shall be located within
the isolating (safety) switch to control the lighting sub circuit upon each gantry structure. The
cabling shall be either single core or multi core 10mm copper conductors within high
temperature grade double insulated or flexible cable.
15.13
PHOTO ELECTRIC CONTROL CELL
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15.13.1 General
Photo electric control cells shall comply with the requirements of BS 5972 and offer a Class II
protection from electric shock as defined in IEC 60598.
Unit must be completely weatherproof, hermetically sealed against the ingress of moisture. It
shall be resistant to vibration or change in temperature. It shall be housed in a strong impact
resistant low profile translucent housing, the surface of which shall be non- oxidizing and
impervious to deterioration.
The photo electric control unit (PECU) shall be guaranteed for a period of not less than six
years, failures within that period of time to be replaced free of charge.
They will be capable of working in an ambient temperature of up to + 60 C.
The operation level should be preset to ON 80/100 Lux the ratio of ON to OFF should be
approximately 1:2. There shall be no means of manual adjustment to the PECUs calibration
and it shall not need to be orientated to operate as required.
There should be a minimum 15 second delay to prevent the unit from functioning due to short
period high illumination such as lightning etc.
The power supply to the PECU shall be 240V 50Hz. A.C with a contact output rating of 30A at
240V (resistive).
The PECU and associated relay or switching device shall have pre matched responses and
housed in the same envelope. The contact rating shall be 1500-Watts (1800 V.A) and should
be fitted with a snap action to prevent chatter. In the case of the load to be switched then the
PECU can switch directly, a contactor shall be used.
The photocell shall be located within the road lighting feeder pillar such that it can be easily
removed. It shall be housed within a small compartment with an acrylic fascia plate set into
the surface of the feeder pillar for the satisfactory operation of the photocell. The control
circuitry for the correct switching of the road lighting will be housed within the adjacent feeder
pillar. The associated specification requirements will be dealt with within that section of the
specification.
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10
The upper LED luminaire cover shall have the facility for installation and wiring of one of the
following devices: an integral miniature photocell, NEMA socket (detachable photocell),
telemetry device. This facility shall be included within the IP testing.
15.14
ROAD LIGHTING COLUMN CUTOUT / ISOLATORS
15.14.1 General
1
Cutouts in columns shall be phenolic moulded, three phase, and suitable for looping two 4
Core 25 mm XLPE/SWA/PVC cables.
Cutouts shall :
Incorporate miniature circuit breakers complying to BS EN 60898 with a minimum
breaking capacity of 4kA.
(b)
Be of the combined single phase and neutral type.
(c)
Incorporate an earth terminal.
(d)
Be suitable for concentric or PVC armoured cables of up to 25mm2 cross-sectional

area with capacity for looping in and out.
(e)
Have all metal parts tinned.
(f)
Be provided with a minimum of 2 fixing screws.
(g)
Be manufactured from material which is non-hygroscopic and non-tracking.
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Terminals and contacts shall have a rating of not less than 40 Amp and be suitable for the
use of miniature circuit breakers 6 A, 10A or16 A ratings, selected from the Table 15.2 below:
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Wattage
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Table 15.2
Ratings of Miniature Circuit Breakers
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For 1 Lamp
For 2 Lamps
50W
70W
100W
150W
250 W
400 W
10
10
10
16
16
The cutouts shall comply with the 16th Edition of the IEE Wiring Regulations.
A cutout used as a means of isolation shall have the facility for padlocking.
The service cutout shall have a moulded enclosure, offering a minimum protection of IP22,
capable of withstanding severe impact.
Separate terminals shall be provided for live, neutral and earth conductors complete with
terminal shields to prevent accidental contact with all live conductors.
Cutouts shall be sized to accommodate the designated cables, but with a minimum of
25mm2 cables.
Cable armouring shall be bonded as an integral part of the cutout, and complete with cable
armour clamp shrouds.
10
The cutout shall be suitable for mounting on a wooden backboard or DIN rails.
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11
Where there is a requirement for the use of an isolator they shall incorporate in-built fused
loop terminals for the feeds to signs, bollards etc.
12
All isolating devices shall be double pole for single-phase systems and four poles for three
phase systems.
13
All isolators shall be rated to suit the local environmental conditions of Qatar where these
differ from those stated in BS EN 60947-3
15.15
FEEDER PILLAR
15.15.1 General
Road lighting feeder pillars shall be totally enclosed weatherproof with fibreglass reinforced
polyester cabinet of ground mounting type complete with accessories suitable for mounting
outdoor..
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15.15.2 Cabinet
The feeder pillar cabinet, unless previously approved by the Engineer, shall be of fibreglassreinforced polyester and ultra violet ray resistant. The cabinet surface shall be totally weather
and corrosion resistant with a completely smooth exterior. The outer 0.5mm - 1.0mm should
consist of pure polyester. The colour of the cabinet shall be grey. The colour shall be
completely light stabilised and impregnated from the surface through the thickness of the
material.
Pillars shall be ground mounting type by means of a steel frame with concrete foundation.
The cabinet shall have a base frame with a minimum ground clearance of 200mm between
the body and the mounting area (bottom). The base frame shall have at least four holes to
bolt down the pillar to the concreted steel frame. The cabinets base frame shall be
removable. The feeder pillar shell shall incorporate lifting devices for the safe movement of
the feeder pillar.
The cabinet top (canopy) shall be arranged so as to prevent the ingress of rainwater and
provide air circulation.
The cabinet shall be provided with a front door complete with internal hinges and fixing
screws fixing at top and bottom. A tamper proof lock will be provided centrally and all locks
shall operate by a standard master key. Two keys for each pillar shall be provided. The door
closing will have a perfect weatherproofing arrangement. The enclosure shall have a
designated IP rating of IP54 in accordance with IEC 60529.
Approximate cabinet size shall be 1000mm high by 620mm length by 300mm width..
Natural ventilation shall be provided to limit the temperature rise to the manufacturers
recommendations. Such ventilation shall not reduce the stated IP rating of the cabinet and
shall be screened to prevent the entry of vermin. Where recommended by the manufacturer
dust filters shall be provided.
A data plate shall be fixed to the inside of the pillar detailing information as deemed
necessary by the PWA and/or the Engineer.
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Detailed distribution board schedules are to be provided within the each feeder pillar these to
be located on the inside of the cabinet and stored in a weather protected plastic pocket
securely fixed to the shell of the housing.
15.15.3 Components of Feeder Pillars

1
1 No. 200Amp mains breaker (MCCB) of three phase 415V - interrupting capacity according
to BS 3871:
240V 85kA
415V 35kA
A facility to lock off the assembly in the open position shall be provided.
1No. 200Amp 4 pole magnetic contactor, three phase with coil voltage of 240V within an IP
54 enclosure. The contacts of the contactor shall be fitted with a snap action to prevent
chatter.
A control circuit shall be provided connected to the control coil of the contactor. The circuit
shall be protected by means of a 4A HRC control fuse within a weatherproof enclosure. The
control circuit shall be such that in the event of a failure of the photocell control unit a time
switch identified below will override the operation. In addition a manual override switch shall
be provided to operate the road lighting at times outside the periods during which the lights
are normally operational.
The time switch shall be a 24-hour dial time switch motor driven single phase 30 Amp. 220 240V 50 Hz. with a clock accuracy of + or 5minutes/year and shall have a 48-hour
synchronous spring reserve to maintain clock operation and output switching during power
supply failure or disconnection. Time switch should be protected with a HRC fuse or MCB.
Arrangement for connecting a photoelectric control switch shall also be made within the pillar.
A 3-phase MCB metal clad or plastic distribution board complete with single pole 240V
MCBs of interrupting capacity according to BS EN 60898. The number and size of the
outgoing circuits shall be as per the feeder pillar schedules. Terminations shall be capable of
accommodating sub circuit cable of size 25mm2. There shall be at least 25% spare outgoing
circuit capacity.
MCBs and protective devices shall be rated to withstand a minimum short-circuit current of
9kA.
Neutral terminal bar shall be provided separately. Neutral conductors shall be insulated from
earth to allow use on TN-S systems. The neutral connections shall have separate
connections for each outgoing cable. Where a neutral busbar is provided it shall be mounted
in parallel with the phase busbars and arranged so that each neutral connection is physically
identified with the appropriate circuit. A separate earth bar shall be provided at the bottom of
the feeder pillar and shall be of sufficient length to accommodate a connection for each
circuit including 25% spare capacity. The neutral busbar shall be coloured black and the
earth busbar coloured green and yellow.
Busbars shall be of full rating having taken into account any holes, they shall be constructed
from high conductivity copper and mounted on insulators and mounted at the rear of the
feeder pillar. Busbars shall be insulated with non-hydroscopic, non-tracking insulation. All live
parts shall be screened.
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Insulated dividing barriers shall be provided between both phase contact assemblies and
between phase and neutral.
10
Each feeder pillar shall accommodate at least 1No. brass cable gland with locknut, earth tag
and PVC shroud for the incoming supply cable together with individual brass cable glands
25mm CW gland according to BS 6121 complete with lock nuts, earth tags and PVC shrouds
for all outgoing cables, including an allowance for spare capacity, for stranded copper cables
up to 25mm 4 core XLPE SWA PVC.
11
Colour-coded leads shall identify all wiring for phase and neutral cables. Outgoing circuits
shall be labelled with the circuit reference and circuit breaker rating. Wherever possible all
internal wiring shall be enclosed in trunking or conduit.
15.16
ROAD LIGHTING CABLES
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15.16.1 Underground Cables
Underground road lighting cable shall be copper stranded 10/16/25mm x 4 core XLPE SWA
PVC cable of stranded copper conductor 600/1000 VAC.
Cables shall be low tension 600/1000 volt multi core stranded copper conductors, insulated
with XLPE compound, core laid-up, extruded PVC tape bedded, steel wire armoured and
PVC sheathed overall underground cables to BS 5467: 1977.
The cable shall be capable of withstanding vigorous climatic conditions of ambient

temperature up to 50C (the temperature can be accompanied by a relative humidity of up to
100% at 30C).
It should also be noted that cables can be buried in sand and laid partly in ducts at a depth of
up to 600mm in footpaths and 750mm in roadways. The ground temperatures can vary from
35-40C in summer to 8-12C in winter. Cable drums may be stored in the open for up to 1
year and will be exposed to direct sunlight. Accordingly, cables shall be designed to withstand
such conditions without deterioration of the electrical or mechanical properties.
Cables shall have the following construction details:

Conductors:
High conductivity stranded copper - shaped conductors shall

comply with BS 6360: 1981 with XLPE insulation.
(b)
Bedding:
Bedding shall be an extruded layer of XLPE compound.
(c)
Colour of Cores:
Red, Yellow, Blue and Black.
(d)
Armouring:
Single layer of galvanized steel wire.
(e)
Finish (over sheath): Extruded black PVC over sheath which conforms to BS 6346:
(a)
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1987 for thickness and to BS 6746: 1987 for properties. The

external surface shall be embossed with the voltage
designation, cable size and manufacturers name
15.16.2 Packing of Cables
1
Underground cables shall be packed in sealed wooden cable drums each of 500 metres
length with a plate stating the following details:
(a)
Manufacturer's name and country of origin
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(b)
Cable type and size
(c)
Length of cable per drum
Page 46
15.16.3 Insulated PVC Sheathed Circular High Temperature (85C)

1
Flexible cable should be of conductors of high conductivity copper stranded wires, 2.5 sq.
mm, insulated with high temperature PVC compound, three cores, green or yellow, blue and
brown, twisted together, filled and sheathed with high temperature PVC compound,
300/500V.A.C. according to BS 6141, Table 15 or equivalent norm.
15.17
MARKER TAPE FOR UNDERGROUND POWER CABLES
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Marker tape shall be installed wherever cables are to be directly buried in the ground to warn
of the presence of power cables.
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15.17.1 General
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15.17.2 Material & Quality
The marker tape shall be of low density polyethylene, of thickness at least 100 micron. Its
width shall be 40cm and be yellow in colour, with black marking indicating the presence of
road lighting cable in both English and Arabic. Its location in respect of the cable position is
identified within the Contract documentation.
The material shall be colour fast, and resistant to chemical action in typical ground conditions
experienced in Qatar. These may vary from extremely wet to extremely dry, and with very
high salinity. The ground temperature may vary from 0 to 40C.
The material shall be mechanically durable. The manufacturer shall demonstrate the
samples complying with this specification have been tested for compliance with BS 2782,
Part 3, Method 326A to 326C or an equivalent standard.
15.18
MARKER POSTS
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15.18.1 General
1
Where instructed by the Engineer, the Contractor shall install marker posts and slabs. These
shall be of reinforced concrete, steel or heavy duty plastic of an approved type suitable for
use in Qatar. Unless instructed otherwise pre-cast reinforced concrete or equally approved
marker posts or slabs shall be installed at intervals of not more than 50m along all
underground cable routes, joint pits (if any), at all changes of direction and at both ends of
road crossings.
15.19
EARTHING
15.19.1 General
1
The integrity of the earthing system within the road lighting network shall be maintained.
Each item of equipment shall be individually effectively earthed within each lighting assembly
and feeder pillar by means of a dedicated earth to a central earthing point. This shall be
regardless of any other terminals available. All connections shall use crimped terminations.
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Page 47
2
For circuit conductors of 16mm and 25mm a circuit protective conductor of cross-section
2
not less than 16mm shall be incorporated.
All removable metal doors or metal frames shall be earth bonded.
Within the feeder pillar the central earthing point shall be connected to the incoming earth
provided by QGEWC.
At each feeder pillar location an earth rod shall be installed complete with an approved earth
pit and cover plate. It shall have a resistance to true earth of not more than 10 ohms. The
size of the earth rod shall be 16mm by 2.5m in length. It shall be driven to a depth that
penetrates the summer water table by at least 1m. It shall be connected to the central
earthing point of the feeder pillar via a bare stranded copper conductor of cross-sectional
2
area 70mm .
At the end of each lighting sub circuit an additional earth electrode as detailed above shall be
connected to the central earthing point within the last lighting column base compartment. The
connection between the earth electrode and the column central earth terminal shall be via a
2
bare stranded copper conductor of cross-section 16mm .
Routing of the earth cable to the ground conductor within the last column of each feeder pillar
outgoing subcircuit shall be via a 100mm. PVC duct within the column foundation.
15.20
INSTALLATION
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The Contractor is responsible for all liaisons, through the Engineer, with the departments
concerned within the PWA, in respect of programming the installation and commissioning of
the complete road lighting system. He shall also ensure through the Engineer that the
relevant departments within the PWA are at all times kept informed of the current progress of
the work. Throughout the road lighting installation works the engineering representative from
the relevant departments within the PWA, must be invited to carry out periodic inspections of
the works. The Contractor shall ensure that his approved subcontractor programmes works
are in the designated sequence in accordance with the approved programme. On completion
of each phase of the works progress to the next phase will be subject to the approval of the
Engineers Representative and/or the relevant departments within the PWA.
A qualified person having a thorough experience in road lighting and associated equipment
shall supervise the execution of all electrical work.
Only workmen who have had experience in the erection of road lighting shall be employed on
the work of erection.
Before carrying out any electrical works to existing services, authorisation must be obtained
in writing from all relevant authorities.
The Contractor shall carry out all electrical tests and ensure satisfactory results as set out in
the ILE Code of Practice for Electrical Safety.
Where an existing installation has been extended the relevant parts of the existing system
and equipment earthing shall be inspected and tested for compliance with the IEE Wiring
Regulations.
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A completion certificate as detailed in the IEE Wiring Regulations shall be issued following
the inspection and testing of the installation and any corrective action found necessary.
15.20.2 Temporary Lighting

Where the existing installation is to be disconnected during the Contract Period, temporary
lighting shall be provided. Any temporary lighting proposals must have the approval of the
PWA prior to installation.
At no time shall design road lighting standards be lower than those existing prior to the start
of the Contract.
The Engineer must approve any form of temporary lighting and associated lighting levels.
Temporary lighting shall not be removed or disconnected until the permanent installation has
been inspected and approved by the Engineer and has been energised.
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15.20.3 Removal of Existing Columns
Prior to any work being undertaken the Contractor shall obtain from the relevant departments
within the PWA a copy of the latest revised record drawing of the existing lighting network
within the contract limits. The Contractor is to identify from these records those columns
affected by the Contract and require removal or relocating. A copy of any record obtained
shall be forwarded to the Engineer for his use.
Existing columns shall be removed under supervision of the Engineers Representative in

consultation with the relevant department within the PWA. Existing cables shall be
disconnected, made safe and protected to the satisfaction of the Engineer in consultation
with the relevant departments within the PWA prior to removal of the columns.
No existing road lighting shall be switched off, dismantled or removed without the prior
approval of the Engineer and the relevant departments within the PWA. Where the existing
road lighting has been removed the Contractor, to ensure safe vehicular and pedestrian
movement within the designated area, shall provide necessary temporary lighting complete at
his cost. Existing signs shall also be relocated at the Contractors cost to ensure compliance
with the current traffic regulations.
All lamps, luminaries and fittings shall be removed before excavating around the column prior
to its removal. Tie ropes shall support the columns at all times.
The Contractor shall carefully excavate existing material from around the column base,
including concrete taking care not to damage any adjacent cables or services. No assembly
shall be removed until it has been fully excavated.
The columns shall be lifted from the foundation by means of a crane approved by the
Engineer. The foundation shall be backfilled with suitable approved material and temporarily
reinstated.
All columns, cables, lamps and luminaries to be removed under the Contract shall be taken
to store as directed by the Engineer and remain the property of the PWA. Where such items
are instructed to be taken to the stores of the PWA, proof of delivery should be obtained by
means of a signed receipt from the relevant departments within the PWA and witnessed by
the Engineers representative.
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Existing road lighting, where it is to be relocated within the Contract, shall be carried out in
accordance with the relevant sections of the contract specifications, as if new. Prior to reinstalling all equipment it shall be inspected and any damage reported to the relevant
departments within the PWA, via the Engineer.
15.20.4 Detailed Drawing for RCC foundation

The foundation for the 3 metre to 12 metre lighting columns shall be in accordance with the
details provided within the Contract Documents. The reinforcement detail shall be detailed by
the Contractor based on the recommendations of the column manufacturer to meet the
column assembly design criteria detailed in paragraph 15.6.7 of this specification. Contractor
shall consider the use of augured foundations in areas where soil and lighting utility
reservation necessitate it, as per the Contract Documents.
The foundation detail for the lighting columns or masts between 16 metres to 30 metres will
be as recommended by the column manufacturer for the climatic conditions applicable to the
State of Qatar taking due consideration of the equipment to be supported. Contractor shall
consider the use of augured foundations in areas where soil and lighting utility reservation
necessitate it, as per the Contract Documents.
Final configuration of the proposed foundation will be subject to the approval of the Engineer
and the PWA.
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15.20.5 Road lighting Column/Lantern Installation
Road lighting columns shall be erected on pre-constructed bases offset from the
carriageway, as defined in the contract Specification, via anchor bolt arrangement.
Prior to erection of the lighting pole no bracket arm or lighting fixtures shall be mounted on
the column shaft.
Only purpose made cranes with nylon slings will be accepted for the purpose of lifting the
columns onto the anchor bolts. Metal chains are not acceptable.
The bottom securing nut/washer arrangement or shims shall be used to align the lighting
column vertical. The location of the base compartment door shall be agreed prior to the
installing of the column shaft, but unless notified otherwise the door opening shall be located
such that any operative working within the column shall face the on-coming traffic.
Once installed, the final alignment and verticality of the column shall be checked in two
directions at 90 degrees to each other by theodolite or other approved method. The final
verticality is to be approved by the Engineers Representative prior to the column bracket and
luminaire as specified being installed and commissioned.
The underground cables shall be terminated into the cut-out/isolator assembly mounted
within the lighting pole base compartment. An additional length of 500mm shall be allowed at
each incoming cable termination and shall remain underground for future reconnections.
Wiring between the terminal block in the luminaire and the components in the base of the
column or each unit shall be using high temperature 3 core, green or yellow, blue and brown,
2.5mm2 copper flexible cables to BS 6141.
All installation requirements described in the ILE Code of Practice Clause 11 shall apply.
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A double insulated 6.0mm2 stranded copper earth wire with clamped tag bonded to earth lug
on column and the column door earth terminal shall be provided.
10
All cable routes shall be clear of control gear and limited to horizontal and vertical runs.
Cables entering terminals shall show no bare wire nor shall the insulation be taken into the
electrical conducting part of the terminal. All cable shall be neatly bunched together and
securely taped.
11
Terminal blocks shall be clearly marked and the wiring shall be so arranged that the
luminaire can be dismantled, for purposes of routine cleaning and lamp replacement, without
any electrical wiring disconnections.
12
After installation each lighting column shall be identified by a reference number in

accordance with the requirements of the PWA.
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15.20.6 Road lighting Feeder Pillar Installation
The road lighting feeder pillar shall be erected on pre-constructed base off set to the
carriageway, as defined in the Contract specification, via anchor bolt arrangement.
Prior to erection no internal equipment shall be installed which could be damaged either in
transit to site or during the erection phase.
The bottom securing nut/washer arrangement or shims shall be used to align the feeder pillar
vertical.
The electrical installation within the feeder pillar shall be undertaken as detailed elsewhere in
the specification.
All underground cables when terminated shall allow for a minimum length of 500mm to be left
underground to allow for future reconnections
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15.20.7 Road lighting Cable Installation

1
The installation of all cables shall be in accordance with the requirements of QCS Section 21.
Excavation of Road lighting Cable trenches for cable size from 10mm to 35mm x 4 core are
to be of the following dimension:
Depth: 600mm
Width: 500mm
3
Cable trenches shall be cleared of all stone and sharp projections and shall be drained. All
cables shall be laid on a bed of 150mm approved fine aggregate sand or quarry scalping.
Cabling to and between columns will be by means of copper stranded 4core
XLPE.SWA.PVC cable. (Size as indicated and based on the connected electrical load and
length of cable from power source) and shall be at the depth of 450mm. A layer of 150mm
dune sand or quarry scalping is to cover the cable. No joints in Cable shall be permitted.
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LV cables laid shall be laid straight between lighting columns with an allowance for 500mm
spare underground cable adjacent to each column. Cables can be placed in the same trench
with a lateral spacing between cables of 50mm. In the event of HV cables being placed in the
same trench then there shall be a separation of at least 300mm. All cables shall have a
clearance of at least 300mm from all other services including telephone or communication
cables.
The Contractor shall arrange for inspection of the cable, trenches and cable installations by
the Engineers Representative, in conjunction with the relevant departments within the PWA
prior to backfilling.
All cables shall be handled, installed and terminated in accordance with the manufacturers
recommendations. The manufacturers recommended ambient temperature limitations for
the handling of cables shall be strictly adhered to.
All cables, once removed from the cable drum, shall be immediately laid in position. No cable
shall remain laying on the surface for more than is practicably possible.
Cabling is to be looped into each column and terminated by means of an approved lighting
column cut out.
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Underground ducts shall be provided where cables
Cross roads or other paved areas with vehicular access.
(b)
Cross unpaved areas regularly used by vehicles.
(c)
Enter buildings.
(d)
Vehicular entrances to properties.
(e)
Pass through corrosive soils or elsewhere as designated, they shall be drawn into
underground pipe ducts.
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15.20.8 Road Crossing Ducts
A steel draw wire or nylon or polypropylene cord shall be inserted in each duct run
immediately after its installation. A 2m surplus shall be left at each end of each run, neatly
coiled and attached to a crossbar preventing the wire or cord from being drawn into the duct.
Underground pipe ducts shall be heavy gauge unplasticised PVC (high impact resistant PVC,
3.6mm wall thickness) conduits with tapered sleeve or spigot and socket joints encased in
concrete as detailed in the Contract drawings and in accordance with the requirements of the
PWA.
All ducts shall have a nominal internal diameter of 150 mm unless designated otherwise.
The internal diameter of ducts used to provide cable entries into structures shall have a
space factor less than 25 %, unless otherwise designated.
All dual systems shall be installed so that no undue strain is placed on cables when pulled in.
Cable manufacturers recommendations shall be followed.
All underground cable ducts shall, so far as possible, be run in straight lines.
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Duct runs crossing roads shall be straight and, wherever possible, perpendicular to the axis
of the road. They shall be laid at a depth of 800mm backfilled and reinstated in accordance
with QCS.
Except in the case of short isolated duct runs such as road crossings, underground cable
duct runs shall terminate in suitable drawpits.
10
Cable ducts passing under roads carrying heavy vehicles shall be completely surrounded
with concrete of grade SRC 30 as per the standard detail.
11
Ducts shall be laid so as to drain naturally towards one or both ends, where adequate
provision for drainage shall be made. Adequate precautions shall be taken to prevent the
cable duct system acting as a stormwater or groundwater drainage system. A minimum fall of
1 in 200 shall be provided for drainage purposes.
12
Any work carried out requiring the use of split ducts shall be carried out in such a manner as
to preserve the withdrawability of the cables concerned.
13
Notwithstanding the type of duct to be used generally, cable ducts laid in ground which is
liable to subsidence shall be of heavy gauge PVC with spigot and socket joints, and shall be
installed on a concrete bed as designated above, but without concrete surround.
14
If two or more cables are to be installed in the same duct, the aggregate of their crosssectional areas shall not exceed 30 % of the cross-sectional area of the duct.
15
All trenches excavated for the laying of cable ducts shall be completely backfilled and
rammed before cable installation work begins.
16
Immediately following the installation of any duct run, the interior of the duct shall be
thoroughly cleaned by twice drawing through the ducts a mandrel, once in each direction.
Following this, the ends of each run shall be sealed with a suitable hardwood or plastic
sealing plug which shall be left in position until cable laying is about to begin.
17
The polished hardwood mandrel shall be 300mm long having spherical ends and a diameter
6mm less than the nominal duct diameter.
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15.20.9 Backfilling and Re-instatement

1
All trenches and pole pit/foundations shall be backfilled, compacted and re-instated in
accordance with the QCS requirements.
15.20.10 Road lighting Cable Terminations and Testing

1
Unless otherwise designated, cable glands shall be of brass and comply with BS 6121 where
applicable, and shall be of a design appropriate to the type of cable being terminated.
Glands for cables with metallic inner sheaths shall incorporate a bonding connection.
Except where it is impracticable to do so, the cable cores shall be taken through the
terminating box directly to the terminals of the equipment, without crosses, and shall be
made off with sweated cast brass cable sockets, or an approved type of hydraulically crimped
socket.
QCS 2014

Part
15: Road Lighting
Page 53
Terminations for armoured cable shall incorporate a method of rating off the armour which
ensures a permanent earth bond between the cables terminated to the satisfaction of the
Engineer. The cable armour shall be bonded to the earth terminal block in each column.
All cable sealing boxes shall be marked on the outside with 15 mm diameter painted discs, in
the appropriate colours, to indicate the disposition of the phase and neutral conductors within
them.
Compression glands installed externally shall be classified IP66 and be provided with closefitting PVC shrouds.
15.20.11 Electrical Power Supply

Upon the completion of the associated work, arrangements will be made via the Engineer to
provide the electrical power to each road lighting feeder pillar based on a 415V 50Hz supply.
Once available, and after inspection, the lighting system shall be tested prior to connection.
The Engineer shall arrange for full consultation with the relevant departments within the PWA
during this phase of the lighting works.
15.21
TESTING AND COMMISSIONING ON SITE
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15.21.1 General
In addition to the requirements of the Contract Specific Specification all testing and
commissioning shall be carried out according to the requirements of the relevant BS , CP,
IEE regulations, or other standards and regulations as may be stated or implied in this
Specification.
Each completed system with the installation shall be tested as a whole under operating
conditions to ensure that each component functions correctly in conjunction with the rest of
the installation.
The Contractor shall afford access at all times to the relevant departments within the PWA to
enable them to inspect work during and after erection and to be present at all tests.
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15.21.2 Electrical Tests

1
As soon as is practicable after the completion of installation the tests described below,
together with such other tests and measurements to prove compliance with the contract
requirements shall be made.
An insulation tester shall be used to measure the insulation resistance between each
conductor and the remaining conductors and between each conductor and the metallic
sheath (if any) and armouring. The test voltage to be applied shall be at least 1000 V.
The above tests shall be carried out both before and after any pressure tests and the
insulation resistance shall not be less than the figures in the appropriate BS.
A voltage test of 15 minutes duration shall be applied in accordance with BS 5467 Appendix
88, BS 6622 Appendix C8 or BS 6346 Table 5, as applicable.
Proposals for the appropriate test in respect of other types of cable shall be submitted for
approval.
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Part
15: Road Lighting
Page 54
An earth continuity test shall be carried out to verify that the cable armouring and metal
sheath, if any, have been properly bonded to earth.
Phase rotation and phase correspondence shall be tested to prove that the cables have been
correctly connected.
Where a new cable has been jointed to an existing cable with the express permission of the
Engineer, the voltage test designated above may be carried out at a reduced voltage if the
existing cable has been in service for more than five years. In such a case the test voltage
shall be determined by applying a factor K to the value given in the appropriate British
Standard as referred to above.
The Contractor shall afford access at all times to the representatives of QGEWC and the
relevant departments within the PWA to enable them to inspect work during and after
erection and to be present at all tests.
10
Upon completion of laying and terminating underground cable runs, the Contractor, in the
presence of the Engineer or his duly authorised representative, shall carry out pressure tests
in accordance with relevant British Standards. The Contractor shall provide all apparatus and
labour required for such tests and within a reasonable time thereafter shall present the
Engineer with certificates of the tests.
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A certificate of Initial Lighting Performance of Installation shall be issued when tests have
been passed as follows:
The initial photometric tests shall be made after the installation has been in lighting
operation for between l00 and 150 hours
(b)
The location of test positions shall be distributed along the length of the installation and
shall be as directed by the Engineer. All service tests throughout the testing period
shall be made at these positions.
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15.21.3 Photometric Performance Testing
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Readings shall be taken with a portable calibrated luminance meter holding a current valid
calibration certificate. The measurements in accordance with the procedures laid down by the
CIE and shall be taken by a qualified lighting engineer who shall confirm that the lighting
performance data as identified in the contract specification has been satisfactorily obtained.
Measurement of the supply voltage at adjacent lighting columns and posts shall be taken at
the time of each test and the illumination measurement shall be adjusted for any variation
from the supply voltage value declared in the contract specification. Allowance shall be made
for the use of control gear taps if necessary immediately before the initial tests are made.
The lamps and all components of the luminaire that may affect the optical performance shall
be cleaned and correctly adjusted.
The Engineer shall witness all photometric testing, unless otherwise notified in writing. A
minimum of 7-days notice shall be given to the Engineer before testing begins. After testing
the certificates shall be submitted to the Engineer for approval. Representatives from the
relevant departments within the PWA shall be invited to witness the lighting performance
testing.
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15.22

Part
15: Road Lighting
Page 55
RECORD DRAWINGS
15.22.1 General
Within thirty days from the date of completion of the whole or any section of the lighting works
the Contractor shall provide fully detailed "as built" drawings and schedules in respect of all
sections of work completed together with all relevant operating and maintenance instructions.
The drawings shall: Fully indicate with accurate dimensions the sizes, types and position of equipment,
cables, ducts, joints, feeder pillars etc., with particular regard for the need to accurately
locate buried cables after completion.
(b)
Show the circuit arrangements for the relevant section of the road lighting installation.
(c)
Show full details, ratings and function of each item of equipment.
(d)
Include any other relevant information to ensure the safe and satisfactory operation of
the particular section of the road lighting works.
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The Contractor shall submit, within the time stated above, two copies of the Record Drawings
for the approval of the Engineer. Upon and after receipt of such approval the Contractor shall
provide records in both digitised and hard copy format of reproducible transparent negative
drawings, and two sets of prints on paper to the Engineer for his retention.
In addition to the foregoing, the Contractor shall provide in each feeder pillar and distribution
unit a good quality print on paper showing the road lighting distribution line diagram of that
particular section. These prints shall be mounted on the inside of the door of each feeder
pillar and distribution unit and shall be covered in clear plastic to prevent undue deterioration.
In order to achieve accurate Record Drawings all relevant information relating to the lighting
works shall be entered on to the stated drawings and kept for immediate use once the work
has been carried out. The marked prints shall be available for inspection at the Contractor's
site office at any reasonable time during the progress of the lighting works.
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END OF PART
QCS 2014

Part
16: Traffic Signals
Page 1
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16
TRAFIC SIGNALS ......................................................................................... 2
16.1
GENERAL ...................................................................................................... 2
16.1.1 Summary
2
16.1.2 References
2
16.1.3 Submittals
2
16.1.4 Quality Assurance
3
16.1.5 Delivery, Storage and Handling
3
16.1.6 General Project/Site Conditions
4
16.1.7 Warranties
4
16.2
SUPPLY OF TRAFFIC SIGNAL EQUIPMENT .............................................. 4
16.2.1 General
4
16.2.2 Identification of Equipment
5
16.2.3 Traffic Signal Posts
5
16.2.4 Traffic Signal Gantries
5
16.2.5 Three-Aspect Traffic Signal Heads
6
16.2.6 Two-Aspect Pedestrian Signal Heads
7
16.2.7 Traffic Signal Controllers
8
16.2.8 Pedestrian Operated Push-Buttons
10
16.2.9 Flexible Traffic Signal Cable
10
16.2.10 Armoured Traffic Signal Cable
10
16.2.11 Loop Cables
11
16.2.12 Loop Feeder Cables
11
16.2.13 Pulling Chamber Cover
11
16.2.14 Unplasticised Polyvinyl Chloride (PVC-U) Ducts
12
16.2.15 General Compatibility
12
16.3
INSTALLATION OF TRAFFIC SIGNAL EQUIPMENT ................................. 12
16.3.1 General
12
16.3.2 Poles, Gantries and Signal Heads
12
16.3.3 Installation of Traffic Signal Controller
13
16.3.4 Cabling
13
16.3.5 Circuit Protection and Earthing Requirements
14
16.3.6 Permanent Electrical Power Supply
15
16.3.7 Inductive Loops for Vehicle Detection
16
16.4
TESTING AND COMMISSIONING .............................................................. 20
16.5
GUARANTEED
MAINTENANCE
OF
TRAFFIC
SIGNAL
EQUIPMENT ............................................................................................... 21
16.5.1 General
21
16.5.2 Operational Maintenance
21
16.5.3 Emergency Maintenance
23
16.5.4 Contractors Vehicles
23
16.5.5 Contractors Equipment
23
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Part
16: Traffic Signals
Page 2
TRAFIC SIGNALS
16.1
GENERAL
16.1.1
Summary
This Part includes the provision of traffic signal equipment and related street furniture at
controlled roadway junctions and pedestrian crossings.
Related Sections
16.1.2
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General
Concrete
Instrumentation, Control and Automation
Electrical Works
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Section 1
Section 5
Section 9
Section 10
Section 21
16
References
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The following standards are referred to on this Part:

BS 1361......................Cartridge fuses for a..c circuits in domestic and similar premises
BS 381C .....................Specifications for colours for identifications
BS 5493......................Code of practice for protective coatings of iron and steel structures
against corrosion.
BS 7430......................Code of practice and regulations for earthing
BS 88..........................Cartridge fuses for voltages up to and including 1000 Vac and 150 Vac
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BS EN 1011................Process of arc welding carbon and carbon manganese steels

BS EN 12368..............Road traffic signals
BS EN 13108..............Fine cold asphalt
BS EN 60529..............Degrees of protection provided by enclosures
BS EN ISO 146 ..........Hot dip galvanised coatings on iron and steel articles
AASHTO Standard specification for supports for highway signs, luminaires, traffic signals
DIN 40050 ..................Enclosures for electrical equipment
DIN 6163 Part 5..........Diffusion lenses for traffic signals
QGEWC (E) Regulations for Electrical Installations
QGEWC (E) Regulations for Protective Multiple Earthing
16.1.3
Submittals
The Contractor shall submit to the engineer for approval shop drawings for each type of
signal pole, gantry and mounting frame for signal heads to be provided under the Contract
along with structural calculations. The drawings shall show materials specification and
finishes for each component proposed for use. All weld types and sizes shall be identified on
the shop drawings.
QCS 2014

Part
16: Traffic Signals
Page 3
The Contractor shall submit to the engineer for approval design calculations for the proposed
signal poles and gantries. The design calculations shall be carried out in accordance with the
AASHTO Standard specification for supports for highway signs, luminaires, and traffic signals
The Contractor shall propose a design for the foundations for each type of signal pole and
gantry and shall submit design calculations and drawings to the Engineer for approval.
The Contractor shall submit to the engineer for approval a schematic wiring diagram for all
the installations. The Contractor shall also submit a wiring layout drawing for the cable loops
and the cross-sectional details of the cut in the road surface.
16.1.4
Quality Assurance
Contractors for the works shall be experienced specialists in the field of traffic control
systems with a minimum of 5 years experience of the installation, commissioning and testing
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of such systems in a similar environment.
The Contractor shall submit a technical submission for the proposed subcontractor giving
details of previous installations date installed, client, technical data for proposed materials,
and experience record of proposed installation staff, supervisors and management.
Installation of traffic signal equipment shall only be conducted by approved specialist

subcontractors. The specialist subcontractors shall be approved by the PWA.
The performance and design requirements work shall be in compliance with QGEWC
Regulations for Electrical Installations.
All equipment supplied shall, in general, conform to the same style, colours and functions as
that already in place in Qatar. The supplier may be required to provide, at his own expense,
samples of his proposed equipment.
All equipment and installation shall be in accordance with the latest edition of the Qatar
Traffic Manual. For all signalled intersections and pedestrian signal control crossings the
timing sequence of signals displayed to drivers during phases shall be as per information
given by the PWA and/or Traffic Police.
16.1.5
Before delivering a traffic signal controller to site, the Contractor shall arrange a factory
acceptance test in his workshop. The programmed and internally complete controller shall
be connected to a labelled light board capable of simulating all traffic signal aspects
controlled by that particular controller. The Contractor shall ensure that all equipment and
devices are available to show that the controller fully complies with operational requirements.
The factory acceptance test shall consist of the following checks:
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(a)
visual check of internal wiring and controller assembly
(b)
operation of green conflict monitor
(c)
intergreen times
(d)
group times
(e)
detector logic (where applicable)
(f)
stage to stage change logic
(g)
lamp switching.
QCS 2014

Part
16: Traffic Signals
Page 4
The Contractor shall be responsible for the delivery of all items to the project site or to any
site as required by the Engineer.
16.1.6
General Project/Site Conditions
All equipment and associated components shall be designed and suitably rated to ensure
proper maintenance, continuous trouble free service under the prevailing climatic conditions.
All equipment and installation shall operate satisfactorily in a temperature range of 0 C to
+55 C and under humidity conditions ranging from 10 % to 100 %.
Warranties
All warranties and guarantees for traffic signal equipment shall commence from the day of
commissioning. The warranty period shall be that as designated by the manufacturer but
shall in any case not be less than 400 days
16.2
SUPPLY OF TRAFFIC SIGNAL EQUIPMENT
16.2.1
General
It shall be the Contractors responsibility to ensure that all equipment supplied is approved.
The Engineer will advise on approved suppliers.
It shall be the Contractors responsibility to honour the designated warranty periods..
The Contractor, shall make himself aware of any lead times required for delivery of
equipment and programme his works accordingly. It shall be the Contractors responsibility to
ensure that equipment is available as needed, any delays to works resulting from the
unavailability of equipment shall be deemed to be the responsibility of the Contractor.
The Contractor shall be responsible for the correct delivery, storage and handling and
storage of all equipment up to the time it is commissioned.
All equipment shall comprise of units of a type that have been used successfully in other
installations in a similar environment, from a minimum period of six months and shall be
subject to approval of the engineer. Particular attention shall be given in the selection and
design of equipment and components to the exclusion of water, moisture and dust.
Components and materials that may perish and deteriorate in the climatic conditions of Qatar
shall be avoided. All equipment shall be so constructed as similar units that shall be readily
available and completely interchangeable both mechanically and electrically.
The location layout of each installation and the number of phases and stages for each traffic
controller shall be as designated Controllers shall provide the signal sequences and phasing
designated for each installation.
The structural design and traffic signal posts and traffic signal gantries shall be in accordance
with provisions of AASHTO standard specification, Supports for Highway Signs, Luminaires,
Traffic Signals, or an approved alternative.
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16.1.7
QCS 2014

Part
16: Traffic Signals
Page 5
Identification of Equipment
The Contractor shall mark or clearly label all modules, units and main parts of a system with
a functional code or title, type number, serial number as approved by the Engineer.
Marking shall maintain legibility throughout the life of the equipment under the prevailing
environmental conditions.
The labelling system shall comply with the GIS system (as defined in the data dictionary)
used by the Government of Qatar and the PWA.
16.2.3
Traffic Signal Posts
Traffic signal poles shall be of the tubular steel type with a flanged base, having an internal
electrical termination point accessible through a lockable inspection window. The supply of a
traffic signal pole shall include; holding down bolts, nuts, washers and shims required for
erection; pole; terminal block; locking cover for inspection window complete with three sets of
keys; all grommets; glands and cable anchor points.
Traffic signal poles shall have dimensions conforming to those given in the contract
Drawings.
The traffic signal poles shall be of mild steel construction. Corrosion protection shall be
through the use of a hot dipped galvanised coating conforming to the requirements of British
Standard BS 5493 and BS EN ISO 1461, depth of galvanised coating shall be 85 microns.
All welded connections shall conform to British Standard BS EN 1011.
The termination point shall consist of a terminal block positioned internally within the traffic
signal pole. The terminal block shall be fully accessible through a lockable inspection
window. The terminal block shall be securely fixed to the traffic signal pole.
The terminal block shall be electrically isolated from the traffic signal pole and shall have a
minimum capacity of 2 x 20 No. connectors. Each connector shall have a minimum rated
capacity of 100 watts at 240 volts.
The connectors on the terminal block shall be in compliance with the requirements of the
QGEWC.
The traffic signal pole shall have the facility to secure incoming cables at a point prior to them
being connected to the terminal block
The traffic signal pole shall be fitted with an electrical earthing stud, such that at least four
earth connections can be made to it.
16.2.4
Traffic Signal Gantries
Traffic signal gantries shall be of the tubular steel type with a flanged base, having an internal
electrical termination point accessible through a lockable inspection window. The supply of a
traffic signal gantry shall include: holding down bolts, nuts, washers and shims required for
erection; pole caps; terminal block; locking cover for inspection window complete with three
set of keys; all grommets, glands and cable anchor points. Traffic signal gantry shall be
styled in accordance with Contract Drawings.
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16.2.2
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Part
16: Traffic Signals
Page 6
The traffic signal gantries shall have minimum dimension conforming to those given in the
Drawings. The design of the gantries is open to submission by the supplier.
The supplier shall provide full details of the materials used and the method of construction
employed when quoting for this item, this shall include workshop fabrication drawings,
material specifications and calculations pertaining to the structural design of the gantry. The
gantry shall be capable of supporting three aspect traffic signal heads, each having a total
weight of 25 kg, inclusive of mountings. The number and position of heads are to be as
designated.
With regard to termination points, cable anchor points and earthing points, these shall be as
specified in Section 6 Part12 of this Specification
The supplier shall furnish full details of the foundation requirements for his proposed gantry,
this shall include details of dimensions, reinforcement, quality of concrete and fixings.
Anchor bolts shall be Grade 8.8 and shall be hot-dip galvanized to BS EN ISO 1461.
The gantry and foundation design shall be such that the gantry is completely detachable from
the foundation, should this be required.
The gantry shall have a system such that it can be adjusted subsequent to installation, to
allow for leveling and turning.
The supplier shall furnish full details of the proposed foundation for his proposed gantry, this
shall include details of dimensions, reinforcement, quality of concrete and fixings. The gantry
and foundation design shall be such that the gantry is completely detachable from the
foundation, should this be required. Anchor bolts shall be Grade 8.8 and shall be hot-dip
galvanised to BS EN ISO 1461. The gantry shall have a system such that it can be adjusted
subsequent to installation, to allow for levelling and truing.
The electrical termination point shall consist of a terminal block positioned internally within
the gantry. The terminal block shall be fully accessible through a lockable inspection window.
The terminal block shall be securely fixed to the gantry.
16.2.5
Three-Aspect Traffic Signal Heads
Three-aspect traffic signal head dimensions shall be as designated. The Contractor shall
submit drawings of the proposed units.
Signal heads shall comprise of a polycarbonate body containing three traffic signal aspects,
coloured red, amber and green and shall include:
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(a)
lamps
(b)
reflectors
(c)
lenses
(d)
transformers
(e)
visors
(f)
anti-phantom devices (if designated)
(g)
brackets, frames and all fixtures and fittings required for mounting
(h)
backing board.
QCS 2014

Part
16: Traffic Signals
Page 7
Signal heads shall be constructed, in as far as is possible, out of high quality polycarbonate
plastic. Any metal fittings shall be suitably protected against corrosion.
The design and construction of signal heads shall allow for all of the following features:
hinged lens panels to allow quick access to the lamps
(b)
flexible, detachable visors
(c)
easily adjustable mounting system
(d)
capability of internally fitting optical arrow mask.
The signal heads shall use, for each aspect, a 10 volt halogen lamp of type SIG 64015/1 50W or SIG 64015 - 50W. The lamp holder and connectors shall be compatible with the type
of lamp used. The lamps shall conform to BS EN 12368. The supply voltage to the signal
head shall be 240 volts ( 5 %) and shall be converted to the lamp voltage by the use of a
standard design transformer (El Type). Each aspect shall have an individual transformer,
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these transformers shall be fitted with noise suppression equipment. The transformers will be
required to operate in ambient temperatures up to 60 C. The transformers shall have a
minimum operational life of five years with an effective switch-on ratio of 3300: 4380.
Signal heads shall be capable of being mounted on the traffic signal pole or gantry as
designated or, in the case of traffic signal gantry, as may be proposed by the Contractor.
The mounting system used shall be such that no predrilling or permanent attachment of
brackets to the signal pole or gantry is required. The mounting system shall be such that the
signal head shall be capable of being adjusted through an arc of 30 degrees about its vertical
axis. It shall be possible to mount two three-aspect traffic signal heads side by side on a
single pole such that the vertical faces being presented to oncoming traffic of each head
remain in the same plane. It shall be possible to mount the signal heads asymmetrical from
the centreline of the pole. The signal head shall be rendered splash proof by means of an
lP54 enclosure. The item description covering signal heads shall include, where necessary,
extra mounting brackets to enable the above facilities.
The optical reflector shall be made of a high grade aluminium, mirror finished. Diffusion
lenses shall be constructed with an internal cobweb pattern and shall be coloured red, amber
or green as defined by the colour limits laid down in the DIN Standard DIN 6163 Part 5.
16.2.6
Two-Aspect Pedestrian Signal Heads
Two-aspect pedestrian signal heads shall have the designated dimensions. The Contractor
shall submit drawings of the proposed units.
Signal heads shall comprise of a polycarbonate body containing two pedestrian signal
aspects, coloured red and green and shall include:
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(a)
lamps
(b)
reflectors
(c)
lenses
(d)
transformers
(e)
visors
(f)
anti-phantom devices (if designated)
(g)
brackets, frames and all fixtures and fittings required to mount the signal head.
QCS 2014

Part
16: Traffic Signals
Page 8
The material, electrical and mounting requirements for the signal head shall be the same as
the requirements for the three aspect traffic signal head.
The optical requirements for the signal head shall be the same as the requirements for the
three aspect traffic signal head with the additional requirement that each aspect of each two
aspect pedestrian signal head be supplied with a 'Walking Man' and 'Stopping Man' optical
mask.
16.2.7
Traffic Signal Controllers
Traffic signal controllers shall be microprocessor based and capable of meeting all the
designated requirements. The Contractor shall submit drawings of the proposed units.
Supply shall include:
(b)
all required additional modules and circuits
(c)
all internal wiring
(d)
all detector modules and control circuits
(e)
plates, fixings and fastenings, glands, seals and clips.
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basic control hardware including relays housings and cabinets
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The controller shall be provided with the following operational modes:

computer control
(b)
standby co-ordinated
(c)
local mode with multi-plan operation
(d)
flashing
(e)
manual mode
(f)
signal on/off mode.
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(a)
(a)
Means will be provided within the controller housing to select and to test each of these
modes of operation.
For pedestrian crossings the controller shall be capable of showing a green flashing man
before the end of each pedestrian phase.
All controllers shall include a dimming feature.
Controllers shall be of a manufacturers type approved by the PWA and/or Traffic Police.
All equipment supplied shall be compatible with the existing traffic signal controllers in use in
the state of Qatar.
Where the supplier cannot provide evidence of his equipment having been previously
successfully used with the above traffic signal controllers, he shall be required to
demonstrate, at his own expense, the compatibility of his equipment.
10
Traffic signal controllers shall be programmed as designated and as agreed with the
Engineer. It shall be the Contractors responsibility to provide competent personnel to
programme the controller.
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QCS 2014
11

Part
16: Traffic Signals
Page 9
Each controller shall be supplied with full documentation which shall include :
(a)
wiring diagrams
(b)
timing charts
(c)
intergreen tables
(d)
stage diagrams
(e)
any other relevant information relating to the operation.
Three copies of the documentation shall be supplied with each controller.

The controller shall be housed in the cabinet of sufficient size to accommodate the controller
and all other associated equipment and shall provide easy access for maintenance and test
purposes. The controller and associated equipment shall be arranged within the cabinet so
that they will not interfere with the entry and exit cables. The cabinet to house signal
controllers shall be constructed of aluminium sheet of thickness 3 mm in accordance with BS
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EN 12368 or with non-metallic materials where the properties for abrasion resistance,
exposure to the elements are equal or better than aluminium cabinet. Cabinets shall be
painted to a colour and specification agreed by the Engineer. The cabinet shall be
weatherproof, rain proof and dust proof and be able to maintain proper operation of
equipment. The Contractor shall construct a suitable foundation for the cabinet. and it shall
allow for the entry and exit of all cables. The cabinet shall be secured to the foundation by
anchor bolts.
The traffic signal controller shall be micro-processor based and capable of meeting all the
requirements of the operational Specification and any further requirements as specified by
the Engineer. The supply of a traffic signal controller shall include for: the basic control
hardware including relays housings and cabinets, all additional modules and circuits required
to meet the operational Specification, all internal wiring, all detector modules and control
circuits, plates fixings and fastenings glands, seals and clips.
14
Traffic signal controllers shall be of an approved type and supplied by an approved

manufacturer taken from the most recent list prepared by the Public Works Authority.
15
Traffic signal controllers shall be programmed according to the operational Specification and
as agreed with the Engineer. It shall be the Contractors responsibility to provide competent
personnel to programme the controller.
16
The traffic signal controller shall also have the following capabilities:
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13
(a)
To give a flashing red pedestrian man before switching to a red man at the end of
pedestrian cycle.
(b)
The controller shall include a timing feature.
(c)
The controller shall support two power supply inputs coming from two different
substations. The purpose is to continuously operate the controller in case of power
failure on one substation by automatically transferring to the other power supply input.
(d)
The controller shall be made to ensure that the dual power supply input is stabilized at
240 volts.
(e)
The controller can be operated manually.
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(f)
The controller shall be capable of providing flashing green before switching to

yellow/amber at the end of vehicle green phase
(g)
The controller shall be capable of providing continuous flashing yellow/amber in the

channelized island.
Each traffic signal controller shall be fully documented, this shall include: wiring diagrams,
timing charts, intergreen tables, stage, diagram and any other relevant information relating to
the operation. Three (3) No. copies of the documentation shall be supplied with each
controller.
16.2.8
Pedestrian Operated Push-Buttons
Pedestrian operated push-buttons shall comply with the requirements and regulations of the
QGEWC.
The push-button shall include traffic signs as per the Qatar Traffic Control Manual either as
an integral part, or be mounted separately on the traffic signal pole or gantry.
Push-buttons shall comprise of a metal or plastic body containing a push-button switch and
an illuminated text panel in Arabic and English.
The unit shall have a light that provides confirmation after a pedestrian has pushed the
button.
The dimensions and position of the push-buttons shall be proposed by the supplier and
Push-buttons shall be constructed of metal or high grade plastics.
16.2.9
Flexible Traffic Signal Cable
Flexible traffic signal cable shall comprise of four cored, PVC coated, internal core PVC
coated, cable. The cable shall be PVC sheathed wiring, catalogue description being NYM-J,
page 2/3 or equivalent.
The cable shall be of a rated voltage and current carrying capacity suitable for the proposed
cable runs. The Contractor shall submit calculations showing the voltage drop for the cable.
Cable shall be supplied in 500 metre lengths and wound onto a suitable cable drum.
Cable shall have a minimum cross-section area of the conductor in each core of 1.5 mm2
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and the overall diameter of the cable shall be 11 mm. The individual core may be either solid
or stranded. Each core shall be uniquely identifiable by coloured PVC sheathing.
16.2.10 Armoured Traffic Signal Cable
1
Armoured traffic signal cable shall comprise of a multi-cored (number of cores as specified),
PVC coated, copper wire armoured, internal core PVC coated, cable. Catalogue description
being, PVC-CWA-PVC or equivalent.
Cable shall be supplied in 500 m lengths, wound onto a suitable cable drum.
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Cable may be supplied in three sizes, 7 core, 12 core or 19 core. The minimum area of the
conductor in each core shall be 1.5 mm2. The individual cores may be either solid or
stranded. Each individual core shall be uniquely identifiably by either having a uniquely
coloured PVC sheathing or by its PVC sheathing having a unique, repetitive marking.
16.2.11 Loop Cables

Loop cables shall consist of a heat resistant coated core cable. Loop feeder cables shall
comprise of a communication type cable, PVC coated having six pair of individually coated
cores. The Loop shall be manufactured by Never Fail Loop Systems, USA (local
representative Traffic Tech (Gulf), P.O. Box 9377, Telephone Number 4621814) or similar
approved.
Loops shall be constructed from polypropylene conduit with 9.5mm inside diameter and
16mm outside diameter. Conduit shall be filled with hot rubberised asphalt which allows the
loop to remain flexible once cooled to prevent incursion of moisture and set the turns of wire
firmly in place. Loops shall have 127mm expansion/contraction joints at intervals along the
loop to allow for movement. Each expansion/contraction joint shall have a 229mm long
schedule 80 polypropylene cover slide to be placed over the joint.
Lead-in wires shall be encased in a non-conductive 2250 psi flex hose constructed with a
seamless extruded polyester fiber braid reinforcement and a non-conductive, seamless
extruded urethane non-perforated jacket. Fill lead-in hose completely with hot rubberised
asphalt. Twist wires in all lead-ins with a minimum of three turns per 305 mm for the entire
length of the lead-in. Attach lead-ins to loop heads with a sch. 80 CVPC tee.
Loop cable shall have one individual core, the conductor of which shall have a crosssectional area of 1.5 mm2. The loop cable such that the coating is able to withstand direct
application of temperatures up to 175 C.
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16.2.12 Loop Feeder Cables
Loop feeder cable shall have six pairs of individual cores, each of which having a conductor
of cross-sectional area of 0.6mm2. Each individual core shall be uniquely identifiable by
either, having a uniquely coloured PVC-U sheathing or by its PVC-U sheathing having
unique, repetitive marking.
The use of alternative types of cable may be permitted with the express written permission of
the Engineer.
Each individual core shall be uniquely identifiable by either having a uniquely coloured PVC
sheathing or by its PVC sheathing having a unique, repetitive marking.
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16.2.13 Pulling Chamber Cover

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Pulling chamber covers shall be of ductile iron.
The pulling chamber covers shall have a square opening of the dimensions shown on the
project drawings.
The pulling chamber covers shall be inscribed with wording to identify the type of service and
the system reference. The exact wording shall be to the approval of the Engineer.
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16.2.14 Unplasticised Polyvinyl Chloride (PVC-U) Ducts

1
Unplasticised Polyvinyl Chloride shall be supplied in two different sizes, 2 inches diameter or
4 inches diameter (50mm or 100mm). The colour shall be dark gray. The PVC-U shall be
either encased burial type or direct burial type. Catalogue description being, PVC-U
Electrical Conduit & Tubing and Utility Duct, NEMA TC-6 or NEMA TC-8 or equivalent.
Unplasticised polyvinyl chloride ducts shall be supplied in 6 metre lengths with solvent weld
socket on one end. The minimum wall thickness shall be 1.52 mm for 2 inches diameter and
2.08 mm for 4 inches diameter.
16.2.15 General Compatibility

All equipment supplied shall, in general, conform to the same style, colours and functions as
that already in place in Qatar. The supplier may be required to provide at his own expense,
samples of his proposed equipment. These samples shall become the property of the PWA,
whether or not an order is placed.
All equipment supplied shall be compatible with the approved traffic signal controllers and
supplied by an approved manufacturer according to the most recent approved list of the
PWA.
Where the supplier cannot provide evidence of his equipment have been previously used
successfully with the above mentioned traffic signal controller, he shall be required to
demonstrate, at his own expense, the compatibility of his equipment.
16.3
INSTALLATION OF TRAFFIC SIGNAL EQUIPMENT
16.3.1
General
It shall be the Contractors responsibility to ensure that all traffic signal installation work is
conducted by skilled, competent personnel.
The Engineers approval of any subcontractor or individual personnel in no way relieves the
Contractor of his responsibility to ensure that traffic signal equipment is correctly installed.
The Engineer shall reserve the right to inspect and approve all installation practices.
Installation of traffic signal equipment shall only be conducted by approved companies taken
from the most recent list prepared by the PWA.
16.3.2
Poles, Gantries and Signal Heads
Signal posts and gantries shall be installed onto their prepared foundations, using two
levelling nuts or an appropriate fixing method approved by the Engineer. The pole or gantry
shall be plumbed square, irrespective of the orientation of surrounding features.
The Contractor shall take every precaution to prevent damage to the pole or gantry's
protective coating, during installation. Where the protection is damaged or breached the
Contractor shall take immediate action to make repairs.
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Where designated, posts and gantries where necessary shall be painted with an approved
paint, colour grey (BS 381C) before installation of signal heads and push-buttons..
Signal heads and push-buttons shall be installed as shown on the contract drawings. Final
positioning and fixing shall not be undertaken without the Engineers approval.
Signal heads, once fixed, shall be covered with an opaque protective material such that it is
clear to motorists that the signals are not in operation.
16.3.3
Installation of Traffic Signal Controller
The Contractor shall install the controller housing in the position defined by the Engineer. The
Contractor shall ensure that the housing is positioned so that when the access doors are
opened to their fullest extent they will not obstruct the sidewalk or cause a danger in any way
to members of the public. The housing shall not be positioned adjacent to the kerb as to
render it liable to damage by vehicles or so that the safety of persons working on the
controller is not endangered.
The Contractor shall organise the connection of the electricity supply to the controller housing
and any other peripheral equipment requiring an electricity supply by direct liaison with the
QGEWC (E) Consumer Section. The Contractor shall ensure that the power supply is
contained within its own separate duct, up to the point at which it enters the controller
housing. The electrical supply shall at no point share the same ducts or chambers as the
traffic signal cabling. The Contractor, where necessary, shall be responsible for providing any
housings required for QGEWC apparatus. Where a separate housing is required it shall be
positioned directly adjacent to the controller housing.
The Contractor shall endeavour to complete as much of the internal wiring of the controller as
possible inside his workshop, such that on-site work within the controller housing are kept to
a minimum. All external cables terminating within the controller shall be clearly labelled as to
their function, destination and nominal voltage. These cables shall, on entering the controller
housing, be clamped and supported such that any stress or strain on the cables themselves
shall not be transmitted to the controllers internal components. Spare or redundant cables
entering the controller housing are to be terminated in such a fashion that they do not
interfere in any way with access to the controllers internal components. The conductors of
these cables are to be electrically isolated and sealed against the ingress of moisture.
It shall be the Contractors responsibility to provide all competent personnel and specialist
equipment to enable the controller to be programmed.
16.3.4
Cabling
The Contractor shall install all cables in the ducts as designated. He shall take all reasonable
care to ensure that no undue stress or strain is placed on the cable during installation and
shall adhere to the cable manufacturers published data with regard to allowable minimum
radius of curvature. The Contractor shall ensure that duct drawstrings remain in place
subsequent to cable installation.
A single dedicated cable shall service each individual traffic signal pole. This cable shall be of
the designated size and shall have a minimum of 10 % spare capacity. On entering the signal
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pole the cable shall be firmly anchored to the pole. At least 3 m of spare cable shall be
allowed for within the signal pole, over and above that length which is required to reach the
termination block.
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Spare or redundant cores within the cable shall be terminated at the termination block and
labelled 'Spare'. The core acting as earth protection shall be connected directly to the body
of the signal pole by means of the poles earthing stud. The cable armouring shall not be
used as the protective earth conductor.
With the exception of loop cable to loop feeder cable connections, the jointing of cables shall
not be permitted. Where jointing of the cables is permitted, this shall be undertaken using a
suitable jointing kit of an approved type which allows the integrity of the protective earth
conductors to be maintained. Loop cable to loop feeder cable joints shall only be located
within an access chamber.
16.3.5
Circuit Protection and Earthing Requirements
The Contractor shall provide protection against dangerous earth-leakage currents by the use
of fuses or excess-current circuit breakers compliant with the QGEWC (E) Regulations for
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Electrical Installations. The Contractor shall ensure that all installations shall be such as to
allow for the operation of the protective devices to operate upon the occurrence of a fault
within the time period specified for fixed equipment installations and that all non-current
carrying metallic parts shall be connected to the earth terminal in such a manner as to ensure
that a hazardous voltage cannot exist on exposed conductive metalwork. All cabinets, posts
and other metal hardware comprised by the traffic signalling equipment shall be bonded via
protective conductors to the main earth terminal with an earthing conductor to the main
terminal by a protective conductor.
The main earthing terminal or bar shall comply with QGEWC (E) Regulations for Electrical
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installation and shall be connected to the earthing point provided by the QGEWC (E) with a
copper earthing conductor in accordance with the Regulations. It shall have a minimum
cross-sectional area of 6.00 mm2 and shall be green/yellow stripe coded. The earthing
conductor is defined as a protected conductor connecting a main earthing terminal or bar of
an installation to an earth electrode of other means of earthing. Where a residual current
circuit breaker is used, the cross sectional area of the earthing conductor shall comply with
the requirements of QGEWC (E) Regulations.
The connection to metalwork shall be made internally to a secure terminal on a part of the
enclosure which is a permanent fixture. The terminal shall be constructed of a material which
will minimise chemical corrosion resulting from contact with the protective conductor or other
metal part. Conductor terminations shall be by the use of soldered or crimped connectors or
screwed terminations, or other approved methods.
Earth and other protective conductors shall be selected and installed so that they comply with
the QGEWC (E) Regulations for Electrical Installations, the BS 7430, BS 7671 and the
Regulations for Protective Multiple Earthing where appropriate. All protective conductors
shall be colour coded green/yellow stripe. Where protective conductor is part of a multicore
cable and a green/yellow stripe colour coded core is not available, the Contractor shall
ensure that the protective conductor is adequately identified. Each cable shall enter the
controller housing via a stuffing gland in the gas plinth gland plate. The stuffing gland shall be
so designed as to prevent the diffusion of gas and support the cable. The earth stud of the
cable terminator shall be correctly bonded to the earth bar in accordance with the QGEWC
(E) Regulations, using a 6.00 mm2 conductor (2.50 mm2 for loop feeder cables).
The earthing requirements at the head of each traffic signal pole shall be as follows:
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the earth terminal of the gland, shall be connected to the earth terminal of the pole
with a protective earth conductor correctly terminated with crimp connectors and
having a minimum cross-sectional area of 6.00 mm2
(b)
the protective conductors from each signal head, pedestrian head, push-button unit or
other equipment shall be connected together at the head of each pole and connected
to the earth terminal in the controller housing by means of one dedicated core of the
armoured signal cable servicing that pole
(c)
the earth connection at the head of the pole specified in (b) above, shall be connected
to the earth stud of the pole with a bonding conductor having a minimum area of
6.0 mm2 and by means of a crimped connector, or similar
(d)
push-button units fixed to a signal pole shall be earthed to the earth stud of the pole
with a separate protective conductor terminated with crimp connectors and having a
minimum cross-sectional area of 6.00 mm2
(e)
There shall be electrical connections by means of conductors having a copper

equipment cross-sectional area of not less than 6.00 mm2 between the earthing
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are, or may reasonably be expected to become, in electrical contact with the

general mass of earth
are so situated that simultaneous contact may reasonably be expected to be
made by any person with such structures, pipes or other metalwork (or any
metalwork in electrical contact therewith).
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terminal and all metal structures, metal pipes and other metalwork (not being
metalwork forming part of a telegraphic, telephone or signalling circuit) which
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These connections shall be made as near as practicable to locations where users or

maintenance staff approach the facility.
Permanent Electrical Power Supply
The Contractor shall be responsible for liaison with QGEWC (E) to provide a power supply to
the traffic signal controller and shall be responsible for all works required to provide this
supply.
The electricity supply shall be 240 V AC 50 Hz single phase.
The Contractor shall organise, with the approval of QGEWC (E), one of the following earthing
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16.3.6
(a)
TN-S System. Where QGEWC (E) will provide an earthing point which affords a
continuous metallic return path to the earth of the supply system. The Contractors
earthing conductor shall be connected to this point
(b)
TN-C-S System (PME). Where QGEWC (E) will provide a combined neutral earth
supply. The earthing Contractors earthing terminal and a lead from the earth terminal
shall be left available for the QGEWC (E) to connect to the incoming supply. A similar
neutral conductor lead shall also be left available for the same purpose
(c)
TT System. Where a means of earthing will not be provided by the QGEWC (E) the
earthing terminal will be connected to an effective earth electrode compliant with the
QGEWC (E) Regulations for Electrical installations. Where the TT System is provided
by the QGEWC (E) the Contractor shall install an earth leakage circuit breaker to
comply with the QGEWC (E) Regulations.
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The Contractor shall ensure that the equipment complies in all respects with the regulations
and requirements of the QGEWC (E).
The Contractor shall be responsible for all cable laying and jointing.
It shall be the responsibility of the Contractor to inform the Engineer of the earliest date when
he will be ready for the QGEWC (E) to make the service connections.
The Contractor shall supply the equipment to be terminated to the QGEWC (E) service with
phase and neutral conductors of not less than 4 mm2 and earthing conductor of not less than
6 mm2. The QGEWC (E), shall connect the controller conductors and earth conductor to the
terminal provided by the QGEWC (E).
The QGEWC (E) cut-out shall incorporate a high breaking capacity fuse carrier and fuse to
BS 88 or BS 1361 of the correct rating. The rating shall be specified by the Contractor to
comply with the type requirements of the QGEWC (E) Regulations. The maximum
permissible earth fault loop impedance shall be those stated in the QGEWC (E) Regulations.
16.3.7
Inductive Loops for Vehicle Detection
Slot cutting shall be carried out by a specialist subcontractor. The Contractor shall be
responsible for marking out all slot configurations and shall supervise the work of the
subcontractor. The slot cutting subcontractor shall make arrangements to provide an
adequate water supply to enable him to carry out the necessary works. The approximate
position of inductive loops and route of feeder cables will be as designated. The Contractor
shall specify the loop configurations at each site, the detailed layout of individual loops and
the number of turns per loop. This information shall be supplied to the Engineer. When loop
configurations are specified by the Engineer, such information as required will be supplied to
the Contractor. In order to obtain a high standard of installation, the Contractor's staff and
subcontractors shall be fully briefed by the Contractor and given written instructions
describing the technical requirements of this specification and method of installation. This
shall cover depth and preparation of slots, backfilling, jointing, ducting under kerbs, earthing
and commissioning of equipment.
Subsurface detector housings for loop detection equipment are not acceptable to the
Engineer. Detector housings shall be positioned so as to reduce the possibility of damage in
the event of a road traffic accident and shall not present an obstruction or visual intrusion. In
cases of doubt, the advice of the Engineer shall be sought. Positions of detector housings
shall be to the approval of the Engineer. Where a remote detector housing is used, each one
shall be connected to the controller by 'Twinflex' cable. The cable will be ducted to the
controller unless the Engineer's agreement is obtained to cutting a slot in the carriageway.
Voltages on this cable shall not exceed 50 V AC or 120 V DC whether between conductors or
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to earth. The Contractor shall provide two sets of keys to all equipment housing supplied as
initial issue. The Contractor shall be responsible for removing all surplus materials from site
at the completion of the works.
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The cable specified may in exceptional circumstances be replace with an armoured multicore
cable (i.e.. triple vehicle extensions with speed discrimination) double vehicle extensions with
speed assessment. The cable specified shall be terminated at the controller with a cable
gland or castellated bar approved by the Engineer. The gland shall be bonded to the earth
point using a 4 mm2 flexible earthing cable terminated with crimp connection tags. The
remote end of the cable shall be connected to the plate and 4 mm2 flexible earthing cable
terminated with crimp connection tags or by other means approved by the Engineer. In
addition one core of the armoured cable shall be used as an earth continuity conductor and
shall be bonded to the earth point on the controller and to both the equipment earth and the
metalwork of the housing at the remote end of the cable. The cable specified shall be
provided with a minimum of 25 percent spare conductor capacity (armoured and nonarmoured multicore cables only).
The detector shall operate satisfactorily with a feeder up to 100 metres in length. The feeder
is defined as the cable between the loop tails and the detector housing. Where adjustments
are required to sensitivity and presence time, these shall be made during initial setting-up and
no further adjustments shall be necessary. The equipment, including loop and feeder, shall
operate correctly within all carriageways of reasonable condition without any reduction in
performance as follows:
air temperature (-10C to 60C)
(b)
relative humidity up to 100 % (non-condensing)
(c)
carriageway flooded under 1 cm water, or dry
(d)
carriageway subjected to continued heavy use by buses and heavy goods vehicles
(e)
sidewalk and kerbs subjected to misuse by vehicles
(f)
feeder assumed to be buried in soil or sand which may be dry or wet
(g)
the detector shall not operate from electrical noise pick-up on the loop or feeders.
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Slot-cutting operations shall not be conducted in wet weather. Wet weather to be defined as
such conditions where the Engineer considers it would be unsafe to carry out slot cutting
operations. Slots shall be cut using a motorised machine fitted with a diamond saw blade.
The layout of the loop configuration shall avoid areas of poor reinstatement in the road
surface caused by other roadworks or works. Slots shall be cut at least one metre from any
such disturbance. Slots shall be cut at least one metre from any ferrous objects such as
manhole covers. In concrete road surface, the Contractor shall not cut slots less than 1.5
metres from transverse joints between adjacent concrete sections. The depth of loop slots
shall be (50 + 7.0 n) mm with a tolerance of + 10.0 mm / - 0.0 mm. In concrete surfaces the
depth shall be (25 + 7.0 n) mm with a tolerance of + 5.0 mm / - 0.0 mm where 'n' is the
number of cables and the first figure is the minimum depth of cover. The depth of each slot
shall be checked with a depth gauge along the whole length of the slot. The Contractor shall
ensure that there are no irregularities in the base of the slot. Where an angle more acute
than 13 degrees in formed at the junction of two adjacent loop slots, then the slot junction
shall be truncated with a saw cut at the apex of the junction; i.e., one blade thickness from
the inside edge of the slot corner, and this cut shall be to the same depth as the adjoining
slots. The junction shall not be truncated with a cold chisel. Slots cut for feeder cables shall
be 20 mm wide (core cables 25 mm) with a tolerance of 3 mm, to give a cover of 65 mm in
bituminous surfaces (45 mm in concrete surfaces) with a tolerance of + 10.0 mm / -0.0 mm.
Only one feeder cable shall occupy each slot.
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The loop feeder cables shall take the most direct route to the indicated cable chamber. This
slot is specified as being 20 mm wide, therefore care shall taken not to obliterate any road
markings in whole or part. In the first instance the most direct route from the loop position to
the kerb line shall be taken. The loop feeder cables shall be joined in the carriageway only
with the approval of the Engineer. The joint slot shall be 10 mm wider and 10 mm longer than
the overall dimensions of the completed joint. The depth of the slot shall be sufficient to give
a minimum 40 mm cover above the joint. The joint slot shall be positioned either at a traffic
lane boundary or at crown of the road so that it is not subjected to the maximum stresses
exerted by road vehicles. Each loop shall be separated from adjacent loops by a minimum of
100 mm. The Contractor's supervisory staff shall check the quality of workmanship before
laying cable and backfilling. All debris and slit shall be cleared from the base of the slot and
the slot blown dry with compressed air before cable laying.
For laying loop cables the cable shall be dry before installation. The Contractor shall ensure
that the cable lies evenly in the bottom of the slot, and shall secure the cable in such a
position if necessary. Sharp implements shall not be used to seat the cable in the slot. Loop
tails shall not extend more than 20 metres from the loop before being joined to the feeder
cable. Loop tails shall be twisted. Each twisted tail shall have a dedicated slot to the joint with
feeder cable. Loop tails shall normally be joined to the feeder cable within cable inspection
chambers. Cables shall not be bent to a radius of less than 12 times their diameter or less
than a radius recommended by the manufacturer whichever is the greater. Where cables
enter the sidewalk a small area of carriageway is to be excavated and a uPVC duct laid
through the kerbs for each feeder cable. The duct shall be level with the base of the slot from
which the feeder cable emerges. The excavated area shall be backfilled with fine aggregate
concrete to the duct invert level. The cables shall then be backfilled with compacted fine cold
asphalt and hot oxidised bitumen R85/40. The kerb stone shall be reinstated. Feeder cables
in soft verge or beneath sidewalks are to be laid in ducts at a minimum depth of 500 mm
below ground level unless otherwise specified by the Engineer. Feeder cables laid unducted
in trenches shall be laid on a 75 mm bed of sand free from stones and other sharp materials
with a further 75 mm of similar sand placed over the cable. Where feeder cables are laid
unducted in soft verges, the cable position shall be indicated with a plastic warning tape laid
at a depth of 150 mm to 200 mm from ground level and vertically above the cable. The tape
shall be printed with suitable warning message repeated at one metre intervals. Where
feeder cables are required to cross French drains or other coarse bed materials in central
reservations, the cable shall be looped and protected with flexible plastic ducting. Ducting is
to be provided by the installation Contractor.
Cable joints shall be approved by the Engineer. Feeder cables shall be electrically connected
to the loop tails with insulated crimp connector using a ratchet type of crimping tool. The
Contractor shall ensure that the cable conductor has been correctly crimped by visually
checking the cable and also by applying a vigorous pull test to the cable on either side of the
joint. The electrical connectors shall be encased in a joint approved by the Engineer and the
Contractor shall ensure that the connectors are staggered to avoid the possibility of any short
circuits.
The Contractor shall ensure that any instructions issued by the cable joint
manufacturer are provided in writing to his installation and supervisory staff. These
instructions shall form part of this specification. The Contractor shall ensure that the joint is
waterproof before backfilling. With the exception of cable joints between loop and feeder
cables, no other joint shall be permitted in the loop/feeder configuration. Cables shall be
terminated in the controller or detector housing using terminal connection blocks which are
adequate in size for the diameter of conductors used. Screws shall not bear directly onto
conductors, either a protective leaf in the terminal or a crimped pin on the end of the
conductor shall be used.
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Immediately before backfilling, the Contractor shall ensure that all slots are clean and dry and
that all silt and debris has been removed from the base of the slot. Loop slots shall be
backfilled with a low viscosity epoxy resin, approved by the Engineer, to give a minimum of
10 mm cover above the uppermost cable. The resin specified shall be poured at a viscosity
of between 500 and 1000 pascal seconds. The Contractor shall provide the Engineer
documentary evidence from the resin manufacturer of the temperature necessary to achieve
this viscosity.
The Contractor shall satisfy the Engineer, before epoxy resin operations
commence, that the specialist subcontractors on-site equipment is able to raise the epoxy
resin and maintain it at the temperature necessary to achieve the viscosity specified. The
remaining volume of loop slot shall be backfilled with blown grade hot oxidised bitumen to the
level of the road surface. Feeder cable slots shall be backfilled with fine cold asphalt
compacted around the cable. The upper 20 mm of the slot shall be filled with hot oxidised
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bitumen. Joint slot shall be backfilled with epoxy resin to a level 10 mm above the completed
joint. The remaining volume shall be filled with hot oxidised bitumen. The hot oxidised
bitumen specified shall be heated to a pouring temperature of 185 C and shall be poured
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from an enclosed container which shall be preheated before use. The fine cold asphalt
specified shall comply with the requirements of BS EN 13108. The asphalt shall be soft and
easily worked when applied, and shall be hand compacted to the satisfaction of the Engineer.
Alternative compounds proposed by the Contractor shall be approved by the Engineer.
The contractor shall be responsible in determining the exact location of the loops and shall
supervise the work of the sub-contractor. The sub-contractor shall mark the locations of the
performed inductive loops. Each shall be separated from adjacent loops by a minimum of
100mm and shall be laid on top of the road base or 230mm form the road surface.
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The cable shall be dry before installation. The sub-contractor shall lay the performed
inductive loops and stretch it as per the marked locations. The T-joint of the loops shall be
positioned to the nearest chamber/pull box/detector hand hole. The loops shall be fixed by
using a clamps and nails to achieve the desired shape
12
The loop wires from the preformed loop to the adjacent chamber/pull box/detector hand hole
shall be twisted together into a pair with minimum of three turns per 305mm and encased in
polypropylene conduit and/or 2250 psi hydraulic hose between the performed loop and the
adjacent chamber/pull box/detector hand hole. Lead-in conduit shall be 100% injected with
hot asphalt sealant to prevent the entrance of water at the chamber/pull box/detector hand
hole.
13
Asphalt shall be manually laid around the loops to protect it from the pavement
machine/equipment.
14
Upon completion of the installation works, the Contractor shall lay the asphalt on the entire
carriageways by using the approved pavement machine.
15
Each loop shall be tested sequentially by three methods: by megger (measured by mega
ohms), by resistance (in ohms), by inductance (measured in micro henries).
16
In case of existing pavement, a groove shall be cut by using a slot cutting machine. The
frames and home-runs shall be placed into the cuts. The cuts shall be filled with hot melted
asphalt-rubber sealant conforming to the manufacturers recommendations.
17
All the installation works shall conform to the manufacturers specifications.
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QCS 2014

Part
16: Traffic Signals
Page 20
16.4
TESTING AND COMMISSIONING
Before delivering a traffic signal controller to site, the Contractor shall arrange a factory
acceptance test in his workshop. The programmed and internally complete controller shall
be connected to a labelled light board capable of simulating all traffic signal aspects
controlled by that particular controller. The Contractor shall ensure that all equipment and
devices are available to show that the controller fully complies with operational requirements.
The factory acceptance test shall consist of the following checks:
visual check of internal wiring and controller assembly
(b)
operation of green conflict monitor
(c)
intergreen times
(d)
group times
(e)
detector logic (where applicable)
(f)
stage to stage change logic
(g)
lamp switching.
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(a)
All traffic signal equipment shall be commissioned to the satisfaction of the Engineer.
It shall be the responsibility of the Contractor to supply all equipment and personnel required
to commission the traffic signal equipment.
On completion of installation, and before commissioning, the Contractor shall undertake the
following tests to the satisfaction of the Engineer and in accordance with the QGEWC (E)
Regulations.
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visual inspection
(b)
continuity test of all protective conductors
(c)
insulation resistance test; insulation resistance shall not be less than 100 megaohms
(d)
polarity check
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(a)
earth loop impedance test.
Where a residual current circuit breaker is installed, tests in accordance with the QGEWC
(E) Regulations shall be complied with. The Contractor shall provide the equipment
necessary to complete the tests and shall provide all other test equipment to demonstrate
that the installation is compliant.
After the traffic signal and controller equipment is installed on site and after it is connected to
all its associated equipment, the Contractor shall arrange for a site acceptance test. The site
acceptance test will recheck all the points covered in the factory acceptance tests and in
addition shall include visual and electrical tests on all posts, gantries, heads, push-buttons
and cabling. The Contractor shall ensure that the area of site covered by the installation
being tested is cleared of all debris, plant and machinery. The Contractor shall be
responsible for the supply of any personnel required to conduct the site acceptance test. The
Contractor shall provide any vehicles required to conduct the site acceptance test. The
Contractor shall ensure that all equipment and devices are available to show that the
controller fully complies with the operational requirements.
QCS 2014
Page 21
Each loop and feeder configuration of the vehicle detection system shall be tested as follows
and the results given in a test certificate for the loop installation. This certificate shall include
all pertinent information for the testing. The Contractor shall submit a pro-forma certificate to
the engineer before carrying out the commissioning.
(a)
With the loop circuit disconnected from the detector, the impedance to earth of the
two loop and feeder conductors shall be measured at a test voltage of 500V DC
applied for at least one minute. This shall not be less than 10 megaohms. The two
ends of the loop circuit shall be connected together for this test
(b)
With the armouring of the feeder cable disconnected from the earth point, the
impedance to earth of the armouring shall be measured at a test voltage of 500V DC
applied for one minute. This shall not be less than 10 megaohms
(c)
With the armouring of the feeder connected to the earth point of the equipment
housing, the impedance to earth of the armouring shall be measured. This impedance
shall not be greater than 0.5 ohms
(d)
The inductance of the loop and feeder circuit shall be measured. This shall be
comparable with the theoretical value previously supplied to the Engineer
(e)
The frequency of operation of each configuration shall be measured. Where two loop
circuits share a common feeder cable their frequency of operation shall be separated
by at least 5 kHz
(f)
The Contractor shall adjust the sensitivity and presence time of each detector to the
requirements specified by the Engineer. The Contractor shall demonstrate correct
operation of the detector at the sensitivity specified
(g)
The Contractor shall ensure that an inductance change caused by vehicles in one
loop shall not induce spurious observations in any adjacent loop system.
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Part
16: Traffic Signals
Any loop or feeder which fails these tests shall be replaced by the Contractor at his expense.
Upon satisfactory completion of the factory acceptance and site acceptance tests, and when
the Engineer is fully satisfied that correct installation and adherence to the operational
requirements has been attained. The PWA will issue a final commissioning certificate. The
installation, or any part thereof shall not be opened to general traffic until this certificate is
received.
16.5
GUARANTEED MAINTENANCE OF TRAFFIC SIGNAL EQUIPMENT
16.5.1
General
During the initial maintenance period complete record of component failures shall be kept by
the Contractor in order to provide information on the reliability of various components.
16.5.2
Operational Maintenance
The Contractor shall provide full operational maintenance coverage for a period of 400 days
subsequent to the issuance of the final commissioning certificate.
The Contractor shall use only maintenance contractors approved for this work by the PWA.
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Part
16: Traffic Signals
Page 22
During the maintenance period, the Contractor shall be responsible for providing coverage for
the following:
(a)
Replacement or repair and installation of any failed equipment
(b)
Daily corrective maintenance
(c)
Quarterly maintenance
Check the cycle length, green time, intergreen time and all other signal timing
parameters as given in the timing chart.
(ii)
Check the timings of the different signal programmes and test the switch over
them manually and by time clock.
(iii)
Test loop detectors for activation and re-tune if necessary.
(iv) Test ELCB and any other circuit breakers.
(v)
Replace any items that show significant wear and/or are operating outside of the
manufacturers tolerances.
(vi) Test operations of pedestrian push buttons
(vii) Check timing of Flashing Units
(viii) Service controller in accordance with manufacturers specifications
(ix) All signal heads, reflectors, optical lenses and backing boards shall be cleaned
(both internally and externally) in accordance with the manufacturers
specifications
(Bi-annual maintenance - The following works are to be carried out in addition to those
described in section (c)
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(i)
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(ii)
(iii)
All signal poles and gantries shall be painted and renumbered. The signal poles
and gantries shall be coated with primer, red-oxide, and two coats of colour grey
paint. The paint specification/colour shall be approved by the Engineer.
All inspection chambers shall be cleaned properly.
Timings for all signals shall be altered as directed by the Engineer at the
beginning and end of the month of Ramadan.
Minor changes to the controllers operational configuration (Changing of phasing
/staging, green times and intergreen times) as deemed necessary by the PWAs
traffic signal engineer.
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(i)
(e)
All protective earth conductors shall be inspected and tested.

All lamp fittings and connectors shall be dismantled and cleaned.
Signal heads shall be checked for correct alignment and all brackets and
clamps tightened.
(iv) All electrical connectors are to be checked and cleaned where necessary.
Annual maintenance - The following works shall be carried out in addition to those
described in sections (c) and (d)
as
(i)
(ii)
(iii)
(iv)
The Contractor shall ensure that personnel are available to maintain equipment such that
failed equipment shall be replaced or repaired within four hours of notification of the fault.
Where controller configuration changes are required, the Engineer shall allow a reasonable
period for the Contractor to respond.
Failed equipment shall be replaced/repaired within 4 hours of notification of the fault.
Where controller configuration changes are required, the Engineer shall allow a reasonable
period for the Contractor to respond.
QCS 2014

Part
16: Traffic Signals
Page 23
Emergency Maintenance
In the case of accidental damage or 'knock downs' or any other equipment failure deemed to
be outside of the Contractors control, shall not be required to take responsibility for repair or
replacement. However it shall be the Contractors responsibility to provide the immediate onsite response to a police or the PWA request.
Upon the PWA having effected a remedy to any emergency maintenance requirement, it
shall be the Contractors responsibility to ensure that all repairs or replacements have been
conducted to a standard such that no warranties become invalid.
If the Contractor feels that any repair or replacement is not of sufficient standard to maintain
his warranty he shall notify the PWA with 14 days of any such repair or replacement having
been conducted.
16.5.4
Contractors Vehicles
The Contractor shall arrange a vehicle mounted hydraulic platform with boom and any
additional vehicle for the use of his staff whenever required throughout the maintenance
period.
The vehicles shall be provided with a flashing amber roof light array.
The contractor shall be responsible for any cost associated with the vehicles.
The hydraulic platform shall be capable of performing the required vertical and horizontal
manoeuvres safely and satisfactorily, including adequate platform capacity and boom
articulation.
The contractor shall gain approval from the Engineer as to the vehicle acceptability prior to
supplying the said vehicle.
16.5.5
Contractors Equipment
The Contractor shall be responsible for supplying any regular or special equipment or tools
required for the satisfactory undertaking of the works. In particular this shall include, but not
limited to:
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16.5.3
(a)
Specialised commission/testing equipment for all the current traffic signal (Siemens,
Futurit, Peek and Tyco) controllers to allow Factory Acceptance Tests (FAT) and Site
Acceptance Tests (SAT).
(b)
Portable keyboard interfaces to allow interrogation and on-site programming of microprocessor signal controllers for all the traffic signal systems.
(c)
Workshop based aspect simulators to allow for Factory Acceptance Tests.
END OF PART
QCS 2014

Part
17: Road Drainage
Page 1
ROAD DRAINAGE................................................................................................... 2
17.1
17.1.1
17.1.2
17.1.3
17.1.4
GENERAL REQUIREMENTS .................................................................................. 2

Scope
2
References
2
Quality Assurance
3
3
17.2
DRAINAGE PIPES & PIPELINES ............................................................................ 3
17.3
EXTENDING PIPELINES ........................................................................................ 4
17.4
ROAD GULLIES ...................................................................................................... 4
17.5
MANHOLE COVERS AND GULLY GRATINGS ...................................................... 4
17.6
SOAKAWAYS ......................................................................................................... 5
17.7
SOAKAWAY BOREHOLES ..................................................................................... 6
17.8
TESTING AND CLEANING SURFACE WATER DRAINS ....................................... 7
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17
TRENCH SOAKAWAYS .......................................................................................... 7

General
7
General
7
Pipe
7
Geotextile Fabric
8
Single Sized Coarse Aggregate
8
Catchpit Chambers
9
Road Crossings
9
Geocellular Stormwater Attenuation / Soakaway Trenches
9
The maximum installation depth, to base of units, shall normally not exceed the
height of
10
17.9.9 Reinstatement above Trenches
10
17.9.10 Testing
10
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17.9
17.9.1
17.9.2
17.9.3
17.9.4
17.9.5
17.9.6
17.9.7
17.9.8
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17.10 GEOCELLULAR TANKS ....................................................................................... 10

17.10.1 Geocellular Units
10
17.10.2 Geocellular Tank Arrangement
10
QCS 2014

Part
17: Road Drainage
17
ROAD DRAINAGE
17.1
17.1.1
Scope
This Part includes:

stormwater drainage works draining the road carriageway and directly adjacent areas,
including:
(i)
road and other pavement gullies and gully pots
(ii)
pipes of minimum 150mm diameter including bedding materials used to connect

gully pots to inspection chambers and intermediate manholes
groundwater drainage using filter drains within the road corridor
(c)
soakaways specifically related to road stormwater and groundwater collection and

disposal
(d)
connections to stormwater drainage systems including culverts, open channels and

closed stormwater drainage pipelines.
(e)
Geocellular attenuation and soakaway trenches and tanks.
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(b)
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This Section
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(a)
Page 2
Geosynthetics
Section 5
Concrete
Section 8
Drainage Works
Section 20
Drainage Works for Buildings
Part 3
External Drainage Works
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Part 18
References
17.1.2
BS EN 124 ..................Gully tops & manhole tops for vehicular and pedestrian areas
BS 4962 ......................Plastic pipes and fittings for subsoil drainage
BS 5911 ......................Concrete pipes ancillary concrete products
BS ISO 14654 ............Epoxy coated steel
ISO 9001 ....................Quality assurance in production and installation
BRE digest 365 - Soakaway Design
QCS 2014

Part
17: Road Drainage
Page 3
Quality Assurance
The manufacturer of all manholes and gully gratings shall be accredited to a third party
quality system such as ISO 9001. The supplier shall submit a copy of his accreditation
showing the scope of products covered.
17.1.4
All manhole covers and gullies shall be clearly marked with the technical standard of
manufacture, the loading class, the name identification mark of the manufacturer and the
mark of the certification body.
17.2
DRAINAGE PIPES & PIPELINES
The materials, manufacture, finish, installation inspection and testing of all drainage pipes
and fittings for roadworks shall comply with the requirements of Part 3 of Section 20, except
as modified by this section of the specification.
The type of pipe to be used and the diameter shall be as designated on the drawings or in the
project specification.
Pipes may be of vitrified clay, concrete, glass reinforced plastic or UPVC. Each of these pipe
types shall meet the designated requirements for standards, materials, manufacture,
strength, length and dimension of tolerances joints, workmanship and finish, inspection and
basis of acceptance given in Part 3 of Section 20.
Unless designated otherwise only one type of pipe shall be used within any individual drain or
service duct between consecutive chambers.
The Contractor shall ensure that plastic pipes are not subject to deterioration due to
exposure to sunlight between manufacture and installation in the ground.
The excavation, bedding, laying and backfilling around pipelines shall be carried out in
accordance with Part 2 of Section 8.
Soft spots below the bottom of an excavation shall be removed as directed by the Engineer
and the resulting void backfilled with granular material to the approval of the Engineer.
Any additional excavation below the bottom of the line required shall be made good with
granular material.
The pipes shall be laid at the designated levels and gradients. The deviation in level from
that designated at any point shall not exceed 20 mm unless agreed otherwise by the
Engineer.
10
Pipes shall be laid so that each one is in contact with the bed throughout the length of its
barrel.
11
Parts and fittings shall be examined for damage and shall be cleaned immediately before
laying. Any pipes that are damaged shall not be used in the works.
12
Measures shall be taken to prevent soil or other material from entering pipes and to anchor
each pipe to prevent moving before the work is complete.
13
The pipe bedding material shall be as designated on the project drawings or in the contract
documents.
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17.1.3
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Part
17: Road Drainage
Page 4
EXTENDING PIPELINES
Where it is designated that existing drains are to be extended and connected to new drain
chambers or channel, the connections shall be made during the construction of the new
drain. The Contractor shall inform the Engineer in writing of the proposed position for the
connection and the detail of the connection. The position of the connection shall be recorded
by the Contractor on a drawing.
The new connecting pipe shall be aligned such that the angle between the existing pipe and
the new pipe is not greater than 60 %.
Before entering or breaking into an existing drain, the Contractor shall obtain approval from
the authority responsible for the pipeline.
17.4
ROAD GULLIES
The type, position, dimensions and clear openings of gullies will be as designated on the
drawings or in the project specifications.
Gullies shall be constructed so that no part of the spout or trap has a cross sectional area
less than 2/3 that of the outlet.
Precast concrete gullies shall comply with BS 5911 Part 2.
Cast iron and steel gully gratings shall be kerb type gullies complying with BS EN 124 unless
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17.3
otherwise shown on the Contract Drawings.

The upper surface of gully gratings shall be flat except where otherwise designated. Slots in
gratings or between gratings and frames shall not be orientated parallel to the direction of
traffic, except where the slots are less than 150 mm long or less than 20 mm wide.
The frames shall be bedded on a 1 to 3 cement sand mortar.
Backfilling to precast gullies shall be carried out to formation level with general fill. Where
mechanical compaction is impractical, the backfill shall be concrete of the designated grade.
Gully connections shall be constructed of minimum

150mm diameter Unplasticised
PVC (PVC-U) pipes in accordance with BS 4660 or ESVC pipes in accordance with BS EN
295. Where required by the Engineer, these shall be bedded and surrounded with concrete
with movement at the joints permitted by the insertion of compressible material which shall
extend to the outside of the concrete surround.
17.5
MANHOLE COVERS AND GULLY GRATINGS
Manhole covers and gully gratings shall be formed from ductile iron with an element of
graphite spheres to produce a molecular structure that gives the required tensile strength and
shock load resistance.
Drainage products may be produced from grey iron and shall be hard wearing, inherently
stable and highly resistant to flexing.
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Part
17: Road Drainage
Page 5
The type of manhole cover; i.e., square, rectangular, double triangular, single cover shall be
as designated on the drawings.
During installation the frames shall be properly bedded and levelled to prevent rocking or any
lateral movement of the frame.
Covers and frames shall be kept together as a supplied unit and interchangeability between
various covers and frames shall not be permitted.
All castings shall be supplied with a black epoxy coating finish.
The tops of all manhole covers shall have a non-slip surface to provide adequate grip.
When so designated, the supplier shall arrange for specific lettering to be cast into the top of
the covers. The lettering shall be up to a maximum of 4 letters or digits.
Manhole covers and gullies shall meet the requirements of BS EN 124, European Standard
for access covers of gully tops for vehicular and pedestrian areas.
10
All manholes covers and gullies supplied shall have been verified as being manufactured to
BS EN 124 by third party assessment body for both quality procedures and technical
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requirements.
The manholes covers or gullies shall meet one of the loading categories specified in BS EN
as
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124.
Table 17.1
Class
Loading, Tonnes
A 15
1.5
B 125
12.5
C 250
25
D 400
40
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Loading Categories for Manhole Covers on Gullies
12
For a manhole entry to sewer and surface / ground water manholes a minimum of 750mm
square clear opening shall be provided. For entry to TSE chambers a minimum of 675mm
square opening shall be provided.
13
For manholes situated in the carriageway a three point cover seating shall be adopted to
prevent any movement or rocking.
14
Where hinged gully gratings are installed the edge with a hinge shall face the traffic to ensure
the cover closes if inadvertently left opened and hit by traffic.
17.6
SOAKAWAYS
Soakaways shall be constructed using precast concrete rings. Concrete works shall comply
with the requirements of Section 5 of the specification. Concrete shall be Grade C50 for the
precast concrete rings and the cover slab, using Sulphate Resisting Portland Cement.
QCS 2014

Part
17: Road Drainage
Page 6
The cover slab shall be of the dimensions and contain the reinforcement as shown on the
drawings or detailed in the Project Specifications.
The structural concrete shall be designed for durability and shall include as a minimum the
following specification:
(a)
minimum cover 40mm
(b)
all surfaces to be painted with an epoxy protective coating meeting the requirements of
Section 5 Part 14 of the specification. The protective coating shall be factory applied
to precast elements.
The soakaways shall have an internal diameter of 1.8 m unless otherwise designated and
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shall be of a minimum depth of 3 m unless otherwise designated.

The precast concrete rings shall be at least 150 mm thick and shall have three evenly spaced
No permanently embedded metal parts shall be left with a cover less than 40 mm from the
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lifting points.
surface. The precast rings shall be constructed with 50 mm diameter holes at 400 mm
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centres in rows spaced 300 mm apart. The holes shall be alternately offset.
The bottom ring shall be founded on insitu blinding concrete 200 mm deep.
The soakaway shall be surrounded by granular material which shall infill the whole void
between the soakaway and the undisturbed ground around the excavation.
The granular material shall be laid in tamps in 150 mm layers and shall nowhere be less than
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225 mm in width.
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The granular material shall be clean durable, sharp-angled fragments roughly cubical or
pyramidal in shape, of un-weathered rock of uniform quality graded and tested in accordance
with Tables 14.3, from a source approved by the Engineer
11
Cast iron covers and frames shall be to BS EN 124 of the designated loading class.
12
Geotextile material lining to the outside of the soakaway excavation shall be in accordance
with Table 17.2 of this Section. The placing and laying of the material shall be in accordance
with the manufacturers instructions and Part 15 of this Section.
13
The geotextile material shall not be left exposed to the sun for a period greater than 7 days
before burying.
17.7
SOAKAWAY BOREHOLES
The Contractor shall drill soakaway boreholes at the locations shown on the drawings. Unless
designated otherwise the boreholes shall be 150mm diameter.
Boreholes shall be initially taken to a depth of 20 m. At this depth the borehole shall be
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thoroughly flushed clean using compressed air and clean water.
QCS 2014

Part
17: Road Drainage
Page 7
The borehole shall then be completely filled with clean water and the rate of dissipation
recorded. If the rate of dissipation is found to be less than required by the design criteria
given in BRE digest 365 - Soakaway Design then the bore holes shall be deepened in 5 m
depth increments and flushed until a satisfactory rate of dissipation is recorded. At the
Engineers discretion the rate of dissipation maybe verified by a constant head permeability
test using proprietary equipment to monitor and record the flow rate and the variation in water
level within the borehole.
TESTING AND CLEANING SURFACE WATER DRAINS
Before completing of the road drainage part of the Works the Contractor shall systematically
clean the whole road drainage system, in accordance with Section 8, Part 10, including
gullies, connecting pipes and soakaways. The entire system shall be clear of debris and silts
and in a sound working order.
Cast iron covers shall be freed from surfacing materials and pivot points shall be greased.
The Contractor shall be responsible for cleaning up any silting of the surface water drainage
system caused by other Contractors working within the Site and the approval of the
Employer.
A CCTV survey shall be carried out of the completed system in accordance with Section 8,
Part 10 of QCS.
17.9
TRENCH SOAKAWAYS
17.9.1
General
Trench soakaways shall be constructed in accordance with the dimensions and grades
shown on the Drawings. The trench soakaway consists of a perforated pipe or geocellular
units laid in a trench. A geotextile fabric lines the trench or surrounds the geocellular units,
with the remaining voids being filled with single sized coarse aggregate.
Reinstatement of trench soakaways shall be in accordance with the Contract drawings.
17.9.2
General
Excavation for the trench shall be in accordance to the requirements of Part 3 of this Section.
17.9.3
Pipe
The pipe shall be a 300mm UPVC for installations outside the carriageway and 300mm
ESVC for installations within the carriageway, perforated pipe supported on single-size
coarse aggregate bedding. Pipe perforations shall be 10mm diameter in staggered rows
around the circumference of the pipe with a pitch of 40degrees. The longitudinal spacing
between each row of holes shall be 200mm.
The manufacture, distribution, laying and jointing of perforated pipes shall generally be in
accordance with the requirements of Section 8.
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17.8
QCS 2014

Part
17: Road Drainage
Page 8
17.9.4
Geotextile Fabric
Filter fabric material lining shall be non-woven geotextile manufactured from UV stabilised,
high tenacity, virgin polypropylene fibres that have been both mechanically and thermally
bonded and in accordance with Table 17.2.
The placing and laying of the material shall be in accordance with the manufacturers
instructions and Part 15 of this specification.
The geotextile material shall not be left exposed to the sun for a period greater than 7 days
before burying.
Unit
Mean Value
(Applied
(a)
Tolerance )
kN/m
8.0 (-0.8)
60 (20)
1500 (-150)
EN ISO 13433
mm
38 (+6)
EN ISO 12956
75 (20)
EN ISO 11058
l/m s
90 (-27)
EN 12224
>90
EN 12225
No loss
EN 14030
No loss
EN 12226
>90
mm
1.1
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.
Test Method
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Table 17.2
Properties of Geotextile Material
Tensile Strength
EN ISO 10319
Tensile Elongation
ta
Property
EN ISO 12236
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EN ISO 10319
CBR Puncture Resistance
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Cone Drop
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Pore Size Mean AOS
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Permeability (H50)
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Weathering 50MJ/m Exposure (1 month EU)
Microbiological resistance
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Resistance to acids & alkalis
Oxidation at 85 days (100 years)

Thickness @ 2kPa
Note:
(a)
EN ISO 9863-1
Applied tolerances are based on 95% Confidence limits
17.9.5
Single Sized Coarse Aggregate
The trench shall be filled by granular material, which shall infill the whole width of the trench
between the undisturbed ground trench sides, or between the geocellular units and the
undisturbed ground, as shown on the drawings. The granular material shall be laid and
tamped in 150 mm layers using mechanical plate compactors. For geocellular unit trenches
the backfill shall be brought up in even layers such that the backfill material does not differ by
more than 150mm in level between sides.
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Part
17: Road Drainage
Page 9
Where geotextile fabric is required to interface between the trench side walls and subgrade
and the soakaway trench fill material, the width of the geotextile must include sufficient
material to conform to trench perimeter irregularities and for a 150mm top overlap. When
overlaps are required between rolls, the uphill roll should lap a minimum of 500mm over the
downhill roll in order to provide a shingled effect. Care shall be exercised to prevent natural
or fill soil from intermixing with the trench granular material. All contaminated granular fill
shall be removed and replaced with clean material.
The granular material shall be clean, durable, sharp-angled fragments roughly cubical or
pyramidal in shape, of un-weathered rock of uniform quality and meet the grading limits in
Table 17.3. The materials source shall be approved by the Engineer based upon the
properties of the materials in accordance with the testing requirements as per Table 17.4.
No reactive carbonate rock or sources with indication of local ground water contamination
shall be used.
100
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37.5
20
60 - 90
0.2 - 1
0
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5 - 30
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10
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% passing by weight
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BS sieve size (mm)
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Table 17.3
Grading Limits for Granular Material
Catchpit Chambers
Catchpit chambers shall be constructed to the dimensions and at the spacing shown on the
drawings.
Chambers shall consist of rectangular precast concrete sections with internal dimension 800
x 1500mm. All concrete works shall comply with the requirements of Section 5 of the
specification. Concrete shall be Grade C50. Sulphate Resisting Cement shall be used.
Chambers shall also conform in all respects to the requirements for surface water drainage
manholes in Section 8.
All surfaces to be painted with an epoxy protective coating meeting the requirements of
Section 5 Part 14 of the specification. The protective coating shall be factory applied to
precast elements.
17.9.7
Road Crossings
Where the trench soakaway crosses a road then non-perforated pipe shall be used extending
1.0 meters beyond the road kerb line.
17.9.8
Geocellular Stormwater Attenuation / Soakaway Trenches
Loads on modular geocellular unitsThe permanent vertical loads to be carried by the units
shall be determined by the designer
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17.9.6
(a)
Lateral loads
(b)
Maximum installation depth
QCS 2014

Part
17: Road Drainage
Page 10
17.9.9
The maximum installation depth, to base of units, shall normally not exceed the height
of Reinstatement above Trenches
Reinstatement material above the trenches shall be of suitable fill, cement bound granular
material, foamed concrete pavement materials or asphalt, or as appropriate in accordance
with the Contract drawings, and shall be constructed in accordance with QCS Section 6.
17.9.10 Testing
On completion of each length of trench soakaway the Contractor shall carry out an infiltration
test. The test shall be carried between completed catchpit chambers. The 2 No. upstream
outlet pipes within the catchpit chamber shall be sealed and the chamber filled with water to a
minimum depth of 1.5 metres. The depth of water shall be recorded each hour for the first
twelve hours of the test and subsequently at time intervals as directed by the Engineer.
The Contractor shall record the results of the test on a standard proforma and present these
to the Engineer on completion.
17.10
GEOCELLULAR TANKS
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Geocellular units used to form storm water attenuation tanks and soakaway tanks shall be in
accordance with clause 14.9.8.
Locations for geocellular tanks
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17.10.2 Geocellular Tank Arrangement
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17.10.1 Geocellular Units
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Geocellular tanks made up of geocellular units are suitable for installation in the following
locations:
The vehicular access to the tank shall be restricted so as to exclude large vehicles, in
excess of the design vehicle load, from the area above the tank.
(b)
Public open spaces: beneath landscaped areas and paths. The landscaping scheme
for the park shall be considered when assessing the loads upon the tank.
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(a)
Loads on modular geocellular units

The design of tanks constructed using modular geocellular units shall:(a)
take account of all applied loads, including accidental loading
(b)
be based on appropriate laboratory tests
(c)
use appropriate factors of safety
(d)
analyse all appropriate limit states (or failure modes)
The determination of the loads to be carried by the geocellular units shall be determined in
accordance with the requirements of BD 31/01.
3
Permanent loads.
Accidental loads
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Part
17: Road Drainage
Page 11
The risk of accidental loading occurring shall be assessed in the design process. Public
parks may be occasionally inadvertently trafficked by HGVs and landscaped area can be
used to park cars. Hard paved area shall be assumed liable to support such occasional
accidental loading and geocellular tanks shall be designed to support accidental loading
without risk of collapse.
Location
Risk
Landscaped area in
public park
Specialist vehicles used for maintenance of geocellular tank and

any separation system upstream of the tank
Illegal parking of private vehicles
Movement of delivery vehicles to kiosks in parks
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Large vehicles used for routine maintenance within park
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Specialist vehicles used for erection / maintenance of lighting

systems
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Erection of marquees / tents / stages / portable cabins for public

events
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Large vehicles delivering equipment for public events

Cranes for installation of equipment
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Generators used for public events

Planned parking of private vehicles during public events
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Access for emergency vehicles fire engines
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If the tank has not been designed to carry accidental loading then special precautions may be
required to prevent it occurring. In public parks, the area above a tank shall be fenced off or
have other barriers / landscaping to prevent vehicle access. Warning signs shall be provided
to state that there is an area with limited load bearing capacity and restricted access for
vehicles.
The location of the tank and any loading restrictions shall be clearly identified in the operation
and maintenance manual for any facility.
Lateral loads
The lateral loads on the units due to earth and water pressure shall be assessed and allowed
for by the designer in accordance with the requirements for the design of retaining walls
given in BS 8002:1994.
6
Flotation or uplift
Where the tank system is located below the water table, the uplift force shall be resisted by
the dead weight of fill above the tank. Other surcharges that are not permanent shall not be
included in the assessment.
The minimum factor of safety against flotation shall be 1.25.
Minimum cover
The minimum cover to units shall be as follows:
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Part
17: Road Drainage
Page 12
Landscaped areas: a minimum of 1.0m to allow for suitable planting over the tank.
The design of landscaping should be undertaken at the same time as the design of the tank
so that the impact of tree roots can be considered. Trees should not be located closer than
the canopy width at mature height from the tank. Trees should not be planted directly over a
tank or in such a position where maintenance work would require the removal of the tree.
8
Maximum installation depth

The maximum installation depth, to base of units, shall normally not exceed the height of
three units, plus the cover as assessed in Sub-Clause 15.
Limit state design
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END OF PART
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Modular geocellular tanks shall be designed as structural components, using limit state
structural design theory in accordance with Section 4.1 of CIRIA Report C680 and BD 31/01.
The design philosophy shall follow the requirements for geotechnical design practice as
described in Eurocode 7 (BS EN 1997-1:2004).
QCS 2014

Part
18: Geosynthetics
Page 1
18
GEOSYNTHETICS ........................................................................................ 2
18.1
GENERAL REQUIREMENTS FOR ALL GEOSYNTHETICS ........................ 2
18.1.1
18.1.2
18.1.3
18.1.4
18.1.5
Scope
References
Submittals
Quality Assurance
Guarantees and Warranties
18.2
REQUIREMENTS FOR GEOTEXTILES ....................................................... 4
2
2
3
3
4
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18.3

18.2.2 Drainage Applications
18.2.3 Earthworks Applications
4
5
6
GEOGRIDS ................................................................................................... 7
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18.3.1 General Requirements for Geogrids

18.3.2 Material Requirements for Geogrids
18.3.3 Installation of Geogrids
7
8
9
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Part
18: Geosynthetics
Page 2
18
GEOSYNTHETICS
18.1
GENERAL REQUIREMENTS FOR ALL GEOSYNTHETICS
18.1.1
Scope
This part of the specification covers the use of geotextiles and geogrids for the;
(b)
reinforcement of embankment foundations over soft or weak soils
(c)
reinforcement of steep earthwork fills
(d)
reinforcement of retaining walls and bridge abutments
(e)
repairs to earthworks embankment failures and landslides
(f)
for erosion control of slopes
(g)
for subsoil and sub-base drainage.
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This Section
Part 3
Part 4
Section 8,
reinforcement of unbound aggregates for roads, hard standing and airfield pavements
Earthworks
Drainage Works
as
(a)
References
The following Standards and other documents are referred to in this part:
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18.1.2
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ASTM D 751 ...............Test Methods for Coated Fabrics

ASTM D 5034 .............Test Method for Breaking Strength and Elongation of Textile Fabrics
(Grab Test)
ASTM D 5035 .............Test Method for Breaking Strength and Elongation of Textile Fabrics
(Strip Method)
ASTM D 4533 .............Test Method for Trapezoidal Tearing Strength of Geotextiles
BS 8006......................Code of practice for strengthened/reinforced soils and other fills
BS 2782......................Method of testing plastics
BS 3502......................Symbols for plastics and rubber materials
BS 4618......................Recommendations for the presentation of plastic design data
BS EN ISO 10321 ......Geosynthetics
DIN 54307 ..................CBR Test
DIN 53854 ..................Weight Test
DIN 53855 ..................Thickness Test
ISO 9001 ....................Quality Management and Quality Assurance Standards
Published Document (PD) 6533, Guide to Methods for Assessing the Durability of
Geotextiles, British Standards Institute.
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Part
18: Geosynthetics
Page 3
18.1.3
Submittals
The manufacturer shall submit comprehensive test results for the geosynthetic for the
designated tests, which shall clearly indicate whether the values are mean values measured
in current production or minimum values which the property does not fall below.
The manufacturers submittal shall clearly state:

(a)
the type of material, (whether a polyethylene, propylene or other)
(b)
its structure whether (a monofilament, multifilament or other)
(c)
the element of manufacture by one or combination of the following processes:
Heat bonding.
Chemical resin bonding
Mechanical bonding.
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(i)
(ii)
(iii)
If the Contractor wishes to propose a material that has been tested to alternative standards,
the Contractor shall submit correlation tests showing the comparable values of the two test
methods. These test results shall be comprehensive giving full details of the sample
conditioning, preparation, method of test and criteria for assessment.
The manufacturer shall submit comprehensive information of previous applications of the

material in similar conditions and environments. This information shall include the project
name, contract details, type/grade of material used, quantity of material used, name of the
contract, client, consultant, and main contractor.
18.1.4
Quality Assurance
The geotextile shall be supplied by a manufacturer who is certified to the ISO 9001. The
Contractor shall submit to the Engineer a copy of the ISO 9001 certificate that clearly states
the scope of the certification.
The geotextile shall be supplied by a manufacturer who provides technical assistance on the
suitability for the application and installation for the material. For the initial use of the material
on site, the Contractor shall arrange for the technical representative of the manufacturer to
be present to demonstrate the correct use of the material.
Where feasible the jointing of geosynthetics shall be as prefabricated joints manufactured

under factory controlled conditions. Joints made during the execution of the work shall be
kept to a minimum.
Joints shall be tested by the same test methods used for the main material.
All joints used in permanent structures designed to carry loads shall be tested in accordance
with BS EN ISO 10319 Part 1 or BS EN ISO 10321.
In situations where relatively small tensions are developed and, if permitted by the Engineer
overlapping joints may be used. These joints shall not be used in the primary tensile direction
of reinforced soil structures but can be in secondary tensile directions only.
Joints where geotextiles are sewn together shall be with one of the methods showing in
figure 5 of BS8006. These joints shall meet the performance characteristics shown in Table
8 BS8006.
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Part
18: Geosynthetics
Page 4
Prior to delivery of the material to site the Contractor shall submit a sample of a sawn joint.
Bodkin joints shall have sufficient cross sectional area and strength to avoid excessive
deformation. A bodkin joint shall not be so large so as to distort the material causing stress
concentrations, bodkin joints shall be pretensioned prior to loading to reduce joint
displacement as the components lock together.
10
Any cuts, tears, splits and perforations to geosynthetics during installation shall be made
good. The method of remedial work shall be prepared and proposed by the Contractor for
11
The geosynthetics shall be suitable for use in the ambient soil temperature in the State of
Qatar.
12
Geosynthetics that are able to ravel shall be heat treated or bonded with an adhesive tape at
the cut. The proposed method of sealing the edges of geotextiles shall be proposed by the
Contractor and shall fully identify the geotextile material, type of scene, stitch configuration,
stitch density, sowing thread and sowing machine to be used.
18.1.5
Guarantees and Warranties
The Contractor shall submit a ten-year guarantee for the geotextile material and the
workmanship. The guarantee shall be worded to reflect the required performance of the
material and shall be approved by the Engineer.
18.2
REQUIREMENTS FOR GEOTEXTILES
18.2.1
All geotextiles shall be supplied in manageable roll or unit sizes and shall be robust enough
to withstand handling and any treatment received during the installation process.
The geotextile shall comply with the minimum properties for geotextile serviceability in Table
18.1 below. The Engineer will direct as to the category that the geotextile shall meet; i.e., very
high, high, moderate or low.
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Table 18.1
Minimum Properties for Geotextile Service Ability
Property
Very
High
High
Moderate
Low
Grab Strength ASTM D 5034
1200
800
600
400
Puncture Strength Modified ASTM D-751/3787, N
500
340
180
135
Burst Strength
3.0
2.0
1.5
1.0
Trapezoidal Tear ASTM D-4533
340
225
180
135
These are the minimum required values below which no test result on production material
should fall.
QCS 2014
Page 5
The Engineer may require the Contractor to carry out tests to different standards, in addition
to the test methods designated above or in the following clauses:
the manufacturers recommendations
strictly adhered to
concerning the installation process shall be
(b)
all geotextiles shall be suitable for use in the environmental conditions in the State of
Qatar
(c)
geotextiles shall be resistant to deterioration on degradation from acids alkalis,

bacteria, brackish or saline water. The manufacturer shall submit comprehensive
results of tests carried out to demonstrate the durability of the materials under such
conditions. These tests shall involve checking the strength properties of the material
before and after prolonged exposure to typical groundwater conditions in the State of
Qatar
(d)
all geotextiles shall be protected from direct sunlight by storing inside the building or
covering with heavy tarpaulins. Geotextiles shall not be exposed to direct sunlight for
a duration longer than 48 h
(e)
joints in Geotextiles shall be sewn where load transfer is required
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Part
18: Geosynthetics
Drainage Applications
Geotextiles for drainage applications shall be needled polypropylene and meet the
performance specifications given in Table 18.2. The performance shall be assessed based
on regular tests on the production material. Unless a permitted variation is stated in Table
18.2, the mean test values shall meet the values in the Table.
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18.2.2
Table 18.2
Performance Specifications for Geotextiles for Drainage Applications

International Classification
According to CBR Test
4400
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CBR test (DIN 54307)

mean value 10 %
780
1335
2695
mean value minus standard deviation

10 %
700
1200
2450
deformation %
30
50
60
65
longitudinal direction kN/m 10 %
12
25
longitudinal direction kN/m 10 %
14
35
Tensile strength (ASTM D 5035)
QCS 2014

Part
18: Geosynthetics
Page 6
International Classification
According to CBR Test
elongation at rupture %
35/45
50/60
45/55
90/65
Fall cone test hole diameter BS EN ISO

10319
50
32
18
6.5
Water permeability at 2 kPa mech. load

9 x 10
at 10 cm water column l/secm 30 %

2
-2
90
-2
13 x 10
-2
15 x 10
80
45
80
60
45
30
d 90%
110
85
65
40
100
140
250
500
0.6
0.95
1.5
3.4
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Pore size (unvibrated)
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Weight DIN 53854 g/m
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150
8 x 10
permeability coefficient cm/s
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Thickness DIN 53855 mm
The manufacturer shall clearly identify to which international classification category the
geotextile conforms according to the CBR test.
The pore size of the geotextile shall be small enough to prevent the significant loss of soil
particles from the retained soil, yet have adequate permeability to allow water transmission
normal to the plain of the geotextile.
The manufacturer shall submit test results that demonstrate the ability of the geotextile to
avoid clogging during water flow due to fine particles. Test results for the US Corps of
Engineers gradient ratio test or similar type of test shall be submitted. The test shall be
carried out using soil of the type where the geotextile is to be installed. Gradient ratios
derived from the test shall be less than 3.
18.2.3
Earthworks Applications
Geotextiles for earthworks reinforcement or base use shall be woven polyester multi-filament
or multi-filament fabrics with a high rupture strength and low axial strain. The geotextile shall
have an adequate high tensile strength in all directions to resist loading imposed by uneven
filling.
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Part
18: Geosynthetics
Page 7
The geotextile shall possess the strength for the required design life with minimal increase in
strain over time. The average geotextile strain shall be limited to 5 %.
Where installed between a sub-base and the underlying soil, the geotextile shall prevent the
granular material being pressed into the subsoil and also prevent an intrusion of fines from
subgrade into the sub-base.
The water permeability of the geotextile shall prevent build up of water pressure under the
separation layer. The short- and long-term permeability of the geotextile must be equal to or
greater than that of the subsoil. The geotextile must not become blocked.
The geotextile shall possess high puncture resistance and a high tearing resistance.
Where used as base stabilisation for embankments the type of construction equipment used
for spreading and compacting initial fill layers shall be suitable so as to avoid damage to the
geotextile. The initial layer of fill placed on the geotextile shall be free from sharp angular or
pointed material that may puncture the geotextile.
Trucks shall not be permitted to drive over the geotextile. The laying of the material shall be
co-ordinated to ensure that trucks do not damage the material.
18.3
GEOGRIDS
18.3.1
General Requirements for Geogrids
The geogrid shall be identified as either uniaxial for single dimension loading or biaxial for
two dimensional loading.
The design of all geotextiles or geogrid applications shall be based on an appropriate in soil
temperature for the state of Qatar.
The type of geogrid to be used shall be as shown on the drawings or as described elsewhere
in the contract documents.
The type of polymer used in the manufacture of the geogrid shall be clearly stated.
The design shall take into account any possible damage to the material during site
installation and a factor shall be introduced into the design.
Prior to installing the geosynthetic the Contractor shall prepare a construction trial outside of
the permanent works. The construction trial shall utilise similar ground conditions from
materials and other factors as the permanent works.
If directed by the Engineer the Contractor shall arrange for geotechnical investigation to be
carried out in the area where the geosynthetics are to be installed. The range and details of
the tests and investigations to be performed shall be directed by the Engineer.
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Part
18: Geosynthetics
Page 8
Material Requirements for Geogrids
Geogrids shall be manufactured from a continuous sheet of polyethylene or polypropylene

which is punched with a regular pattern of holes. The sheet shall be heated and stretched so
that randomly orientated long chain molecules are drawn into an order and align state to
increase tensile strength and tensile stiffness.
The bars or ribs of the geogrid transverse to the direction of primary loading shall provide a
series of bearing points or anchors such that stress is transferred to the grid by surface
friction and also interaction.
The ribs of the geogrid in both the longitudinal and transverse direction shall be
manufactured to a near vertical face to provide good bearing surface for interlocking fill
particles.
Geogrids shall be resistant to deterioration by aqueous solutions of acids, alkalis and salts,
petrol, and diesel fuel.
Geogrids shall not be susceptible to hydrolysis, environmental stress, cracking or micro

biological attack.
The manufacturer shall supply test results for load against strain for the material identifying
all test conditions including strain rate and temperature of materials tested and test method.
The Contractor shall submit full technical details of the geogrid proposed for use in the works.
These details shall include the following:
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18.3.2
grid dimensions
(b)
thickness of longitudinal and transverse ribs
(c)
strength of the material determined as stress strain, at strains of 2 and 5% both
(d)
transverse and longitudinally in accordance with BS EN ISO 10319
(e)
weight in kilograms per metre squared for material
(f)
the supplied roll of dimensions
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the minimum amount of carbon black tested in accordance with BS 2782 Part 4
(g)
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(a)
(h)
the approximate peak strain , expressed as a percentage
(i)
the creep of the material under load determined in accordance with BS EN ISO 10319
for strain shall not exceed 10%
(j)
the cross sectional shape of the ribs and of the rib joints.
All test results shall be expressed as a lower 95% conference limit in accordance with ISO
2602.
8
The Contractor shall submit test results for the durability of geogrids. Tests shall be in
accordance with PD 6533, - Guide To Methods for Assessing the Durability of Geotextiles.
The Contractor shall submit laboratory test results for prolonged exposure tests at similar
temperatures.
10
For each batch or delivery of the geosynthetic the Contractor shall submit the production
quality control test results shall be clearly related to batches delivered to site.
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Part
18: Geosynthetics
Page 9
Installation of Geogrids
Prior to placing geogrids the Contractor shall prepare a detailed method statement for the
sequence of operations.
The methods employed shall ensure that the geosynthetic does not suffer deterioration
during placing and that any joints are formed effectively.
The handling and placement and installation of geogrids shall be carried out strictly in
Where the geogrid has been protected by a wrapping resistant to ultraviolet lights attack no
further protection against sunlight is necessary.
For geogrids, jointing shall be by a bodkin whereby two overlapping sections are coupled
together using a bar passed through the aperture of the grid. Joints shall be formed at the
highest mechanical and durability efficiency possible.
If necessary the Contractor shall construct a temporary access road to the site location at a
convenient location close to the works, the Contractor shall prepare a clean working platform
in storage area to accommodate geosynthetic materials.
The geogrid shall extend across the full width of the embankment or area being treated in
one continuous piece and no part bits of rolls shall be used. This shall be accommodated by
increasing the lap lengths.
Prior to installation of the geogrid , the site shall be cleared in accordance with part 2 of this
specification
Before placing geogrid any abrupt changes in ground profile should be levelled.
10
Any regulating layer of fill placed shall not impair the vertical hydraulic conductivity of the
natural ground.
11
Geogrids supplied in rolls shall be supported at a minimum of 2 points to prevent excessive

bending unless a central steel tube is used for support.
12
Site handling of geogrids shall ensure that damage to the product such as surface abrasions,
splitting, notching or tearing is prevented.
13
The installation of the geogrid shall be consistent with the direction of major stress.
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18.3.3
END OF PART
QCS 2014

Part
19: Miscellaneous
Page 1
19
MISCELLANEOUS ........................................................................................ 2
19.1
STONE PITCHING ........................................................................................ 2
19.1.1
19.1.2
19.1.3
19.1.4
19.1.5
Scope
References
Submittals
Materials
Installation
19.2
GABIONS & PROTECTION MATTRESS ...................................................... 3
19.2.1
19.2.2
19.2.3
19.2.4
19.2.5
Scope
References
Specific Requirements for Gabions
Specific Requirements for Protection Mattress
19.3
BOLLARDS .................................................................................................... 6
19.3.1
19.3.2
19.3.3
19.3.4
Scope
References
Concrete Bollards
Steel Bollards
19.4
RUMBLE STRIPS .......................................................................................... 7
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3
3
4
5
5
6
6
6
7
7
7
7
SPEED CONTROL HUMPS .......................................................................... 8
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19.5
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19.4.1 Scope
19.4.3 Construction
2
2
2
2
2
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19.5.1 Scope
19.5.2 General
19.5.3 Construction of Speed Humps
8
8
9
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Part
19: Miscellaneous
Page 2
19
MISCELLANEOUS
19.1
STONE PITCHING
19.1.1
Scope
Stone pitching slope treatment shall consist of the placement and grouting of stone pitching
on slopes at the designated locations or at the locations directed by the Engineer to the
designated lines, grades, thickness and cross-sections or as directed by the Engineer.
19.1.2
References
The following standards are referred to in this Subpart:
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This Section
Part 3
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AASHTO T96 .............Resistance to Abrasion by Use of the Los Angeles Machine
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BS 812 Part 2 .............Testing Aggregates - physical properties

BS 1881......................Methods of testing concrete
Submittals
Samples of the stone to be used shall be submitted to and approved by the Engineer before
any stone is placed. These samples shall be kept on site and used for reference purposes for
the quality control of delivered material during the work.
19.1.4
Materials
Stone for pitching shall be hard, sound, durable, erosion resistant rock or cobbles.
The nominal weight of the stones shall be between 3 to 4 kg (corresponding to a size of

about 240mm x 140mm x 100mm). The maximum weight of the stones shall be between 32
kg (corresponding to a size of about 420mm x 230mm x 200mm).
Tests for specific gravity and absorption, shall be determined in accordance with BS 812 part
2 Testing Aggregates - physical properties. The minimum apparent specific gravity shall be
2.5 and the maximum absorption shall be 3 %.
The stone shall not have an abrasion loss greater than 45 % when subjected to five hundred
(500) revolutions in a Los Angeles Abrasion Machine in accordance with AASHTO T96.
The size and shape of the stones shall be such to allow for proper placement. The widths of
the stone shall be not less than one and one-half times their respective thickness and lengths
of not less than two times their respective widths.
19.1.5
Installation
The bed upon which the stones are to be placed shall be excavated to the designated grades
and lines or as directed by the Engineer.
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19.1.3
QCS 2014

Part
19: Miscellaneous
Page 3
Prior to commencing any stone pitching operations the Contractor shall prepare a trial laying
of not less than 2 m by 2 m using the materials and methods proposed for the work. The trial
laying shall establish the aesthetic appearance of the work and shall be used for comparison
purposes for acceptance of the final work.
A footing trench shall be excavated along the toe of the slope as designated or as directed by
the Engineer. All footing trenches and excavations shall be approved by the Engineer before
placement of stones or concrete.
Subgrade or base shall be firm and well compacted and approved by the Engineer. A 50 mm
thick layer of mortar shall be laid on the subgrade as bedding for the stones.
Stones shall be placed so as to provide a minimum number of voids; larger stones shall be
placed in the footing trench and on the outside surface of the slope. The flattest face of the
stone shall be laid uppermost parallel to the slope. Spaces between larger stones shall be
filled with the smaller stones.
The surfaces of the stone shall be cleaned of adhering dirt and clay and shall be moistened
immediately prior to grouting.
The space between stones of stone pitching shall be filled with mortar consisting of one part
Portland cement and three parts of fine aggregate, and one-fifth part of hydrated lime with
sufficient water to produce a workable mix as approved by the Engineer.
Sand and cement shall comply with the requirements of Section 5. The compressive strength
of the mortar shall not be less than 15 MPa when tested in accordance with BS 1881 Part
108.
Immediately after placing, the mortar shall be spaded and rodded into place with suitable
spades, trowels or other approved method. All the voids between stones shall be completely
filled.
10
The exposed surface of the rocks shall project not less than 1 cm and not more than 4 cm
above the mortar surface. The mortared stone pitching shall be cured by an approved
method for a minimum period of four days. Immediately after the expiration of the curing
period, the exposed surfaces shall be cleared of all curing mediums.
11
Joints will be provided at a maximum interval of 12 m. Joints shall comprise a gap in the
stone pitching of 15 mm. The method of forming the gap shall be to the approval of the
Engineer.
19.2
GABIONS & PROTECTION MATTRESS
19.2.1
Scope
This work shall consist of supplying, building and placing of stone-filled gabions or protection
mattress as slope or watercourse channel protection.
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This Section
Part 3
Earthworks
19.2.2
References
The following standards are referred to in this Subpart:

BS EN 10244..............Testing zinc coatings on steel wire and for quality requirements
QCS 2014

Part
19: Miscellaneous
Page 4
BS EN ISO 1461.........Hot dip galvanised coatings on iron and steel articles

BS 1052......................Mild steel wire for general engineering purposes
BS 1722 Part 16 .........Organic powder coating to be used as a plastics finish to components
and mesh
ASTM G152 and G153-----Practice for Operating Light-Exposure Apparatus (Carbon-Arc
Type) With and Without Water for Exposure of Nonmetallic Materials.
Gabion boxes and protection mattress shall be made of a hexagonal woven mesh of double
twisted hot dip galvanised steel wire. The nominal mesh size shall be 80mm x 100mm.
Details of type of mesh proposed for use shall be submitted to the Engineer for approval.
Wire shall be coated with a minimum thickness of 0.55 mm of dark green or black PVC
complying with BS 1722 Part 16 Organic powder coating to be used as a plastics finish to
components & mesh.
Wire shall be capable of resisting the effects of immersion in sea water, exposure to
ultraviolet light and abrasion, when tested for a period not less than 3000 h in accordance
with ASTM G152 and G153.
The cages of gabion panels and protection mattress panels shall be selvedged to prevent
unravelling of the mesh. Steel wire core used for selvedges shall have a nominal diameter of
not less than 3.0 mm. Lacing wire shall have a nominal diameter of not less than 2.2 mm for
the wire core. Wire for selvedges and lacing shall otherwise comply with the same
specification for the wire used in the mesh.
Non-metallic material such as extruded polypropylene for gabion boxes may be proposed, for
the Engineer's approval. Samples and manufacturer's certificates shall accompany the
proposal. The Contractor shall demonstrate that non-metallic materials are suitable for use in
the climatic conditions of Qatar.
Gabion and protection mattress dimensions shall be as designated. A tolerance of 5 % on

width and height, and 3 % on length shall be allowed.
Gabions and protection mattress shall have diaphragms at 1 m centres.
Wire used in the fabrication of the gabion and protection mattress shall be mild steel to BS
1052 having an average tensile strength, before coating, of 380 to 500 MPa. The core wire
diameter shall be 3.0 mm before galvanising. Galvanising shall comply with BS EN 10244.
Non-metallic gabion and protection mattress cages of proprietary type shall be constructed
according to the manufacturer's instructions.
10
All the fixing and binding wires shall be coated with PVC layer complying with BS 1722 Part
16.
11
All Gabions and mattresses shall be laid over a layer of geotextile membrane Grade 3000 at
all times.
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19.2.3
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19: Miscellaneous
Page 5
19.2.4
Specific Requirements for Gabions
Stones for gabion filling shall be hard, sound, durable and highly resistant to erosion. The
stone size distribution in each individual box shall be as shown in Table 16.1:
Table 16.1
Stone Size Distribution of Gabions
% of Total (by number)
80 - 125
7 maximum
125 - 200
88 maximum
200 - 250
5 maximum
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Size of Stones mm
Gabions shall be placed and built to the designated lines, levels and patterns on a prepared
horizontal foundation surface, excavated as required and compacted as directed by the
Engineer.
Gabion cages shall be securely wired together at comers and cages, and where there is
more than one course of gabions, the upper course cages shall be laced to the lower course.
Before filling, the cage shall be in its permanent position and laced to adjoining previously
filled cages.
Stones shall be packed by hand inside the cages as tight as practicable with the minimum of
voids. Tie wires shall be fixed inside the compartments and the units tensioned in
accordance with the manufacturer's instructions.
The cages shall be overfilled with stones to allow for subsequent settlement and the lid laced
down with binding wire to the top of each of the four sides and to the top of the diaphragm
panels.
19.2.5
Specific Requirements for Protection Mattress
The material shall be supplied as a large sheet with partition panels at 1 m centres to form a
cellular structure with the sheet turned up to form the sides. A separate sheet shall form the
lid.
The cages of protection mattress panels shall be selvedged to prevent unravelling of the
mesh. Steel wire core used for selvedges shall have a nominal diameter of not less than 3.0
mm. Lacing wire shall have a nominal diameter of not less than 2.2 mm for the wire core.
Wire for selvedges and lacing shall otherwise comply with the same specification for the wire
used in the mesh.
Stones for protection mattress filling shall be hard, sound, durable and highly resistant to
erosion.
The stone size distribution in each individual box shall be dependent on the design thickness
of the mattress as shown on the contract drawings.
The protection mattress shall be a special type of rectangular gabion with a large plan area to
thickness ratio that is divided into compartments by partition panels fixed to the base.
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Part
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The thickness of the protection mattress, the installation slope and the panel size shall be as
designated. The Contractor may elect to use a manufacturers standard size of mattress that
is thicker than that designated.
Protection mattress shall be placed and built to the designated lines, levels and patterns on a
prepared foundation surface, excavated as required and compacted as directed by the
Engineer.
Protection mattress cages shall be securely wired together at comers and cages. Before
filling, the cage shall be in its permanent position and laced to adjoining previously filled
cages. Several assembled units should be placed in position and wired together at their
edges with the wire passed continuously through each mesh in turn with a double turn at
every second mesh.
Stones shall be packed by hand inside the cages as tight as practicable with the minimum of
voids. Tie wires shall be fixed inside the compartments and the units tensioned in
accordance with the manufacturer's instructions.
19.3
BOLLARDS
19.3.1
Scope
Short metal or precast concrete bollards for traffic control in roads or pedestrian areas.
Related Sections
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19.3.2
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BS EN ISO 1461 ........Hot dip galvanised coatings on iron and steel articles.
Concrete Bollards
The use of cast in-situ concrete bollards will not be permitted.
Precast concrete bollards shall be constructed with the dimensions and details shown in the
drawings. The surface finish and colour of the bollards shall be as shown in the drawings, in
the Project Specification, per the designated details or as directed by the Engineer.
All concrete and steel materials and procedures for the precast concrete bollards shall
comply with the requirements of Section 5.
The minimum grade of concrete for bollards shall be C40. Bollards shall be constructed using
OPC cement to BS EN 197-1.
The minimum cover to all embedded steel items in the bollards shall be 50mm with a
tolerance of -0 mm and + 10 mm.
Where precast concrete bollards are specified the Contractor shall design the bollards such
that the durability is ensured for a period of ten years. The Contractor shall submit a
performance guarantee for the bollards for a period of ten years. The guarantee shall provide
for the replacement of the bollard in the event of any deterioration due to exposure to the
elements.
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Part
19: Miscellaneous
Page 7
The supplier shall verify this by a design submission covering the concrete mix design,
special admixtures additives, cover to reinforcement type of reinforcement and protective
coating. The engineer shall approve the material and design for the bollard based on the
particular exposure of the location proposed for use.
Prior to production of the precast bollards the Contractor shall cast a trial bollard for approval
by the Engineer.
19.3.4
Steel Bollards
Metal bollards shall be constructed of steel tube with the dimensions, details, wall thickness
and height shown on the drawings or provided in the Project Specification.
The top of the bollard shall be ground free of any rough edges and fitted with a tight durable
ultraviolet light resistant plastic top.
All metal parts shall be hot dipped galvanised to BS EN ISO 1461 after fabrication.
All metal parts shall also be painted to the colours and pattern as shown on the drawings or
directed by the engineer. The paint system shall be compatible with the hot dipped
galvanising and shall provide a service free life for five years.
Where designated, bollards shall be removable. This shall be achieved by casting a 4 mm
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thick PVC pipe sleeve into the pavement. The bollard shall be a tight fit into this sleeve. If so
designated or directed by the Engineer a locking facility shall be incorporated with the
removable bollard.
RUMBLE STRIPS
19.4.1
Scope
Rumble strips to provide warning to drivers of vehicles that accidentally stray out of the
carriageway.
Related Parts
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19.4
This Section
Part 5
Asphalt Works.
19.4.2
Quality Assurance
The Contractor shall arrange for a trial installation of a rumble strip to demonstrate the
methods and equipment to be used. Approval to proceed with the construction of the rumble
strips will only be permitted after the Engineer has approved this trial in writing.
19.4.3
Construction
Rumble strips shall comprise of shallow formed depressions in the wearing course of the
road shoulders. The depth, plan size and layout of the rumble strips shall be as designated or
Rumble strips shall be formed by one of the following methods:

(a)
cold planing
QCS 2014
(b)

Part
19: Miscellaneous
Page 8
Removal shutter boards.
Cold planing of indentations in the wearing course in the shoulder shall be carried out in
accordance with the requirements of the cold planing of Part 5. Edges shall be square and
true and free from any loose material.
Rumble strips may also be formed by the use of removable shutter boards. The boards shall
be rigidly located on the base or binder course prior to laying the wearing course. The
method of fixing the strip shall be subject to the approval of the Engineer. The laying of the
wearing course shall be carried out in accordance with the requirements of Part 5. Care shall
be taken to ensure full compaction of material around the edges of the shutter boards. The
shutter boards shall be carefully removed not earlier than three days after the laying and
compaction of the asphalt.
19.5
SPEED CONTROL HUMPS
19.5.1
Scope
Speed control humps to limit the speed of vehicles.
Related Parts
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Asphalt Works.
Kerbs, Footways & Paved Areas.
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This Section
Part 5
Part 9
General
Speed control humps shall only be installed at the locations designated on the project
drawings or specified elsewhere within the contract documents.
All speed humps shall be identified by markings on the road surface. The layout of these road
markings shall be as the Qatar traffic control manual or as shown on the project drawings or
elsewhere in the contract documentation.
The profile of the speed hump shall be as shown on the project drawings.
The profile shall represent a smooth gradual rise in elevation.
Speed humps shall be constructed of the same asphalt mix design as the asphalt wearing
course.
The use of prefabricated rubber section speed humps or steel checker plate filled with
concrete speed humps is not permitted.
Speed humps shall be designated as one of two types; for low speed pedestrian areas and
for high speed roads. Low speed pedestrian areas speed humps shall comprise of a ramp
within elevated section constructed of interlocking concrete paving blocks.
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19.5.2
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Part
19: Miscellaneous
Page 9
Construction of Speed Humps
The dimensions and construction details of speed hump shall be as shown on the drawings.
Prior to installation of the speed hump the surface of the wearing course shall be scabbled or
abraded to a rough irregular finish to ensure bond with the speed hump. Tack coat shall be
applied at the base.
Wearing course shall be hand laid for the speed hump. The wearing course shall be
compacted and finished to a smooth profile.
All the asphalt work for the speed hump shall comply with the relevant clauses in part 5 of the
specification. The final profile speed hump shall comply to the profile on the drawings to
within 6mm.
Heavy traffic or construction plant shall not be permitted to drive over speed humps until
7 days after the construction unless the engineer permits otherwise.
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19.5.3
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Part
02: Site Clearance
Page 1
SITE CLEARANCE .................................................................................................. 2
2.1
2.1.1
2.1.2
2.1.3
GENERAL ............................................................................................................... 2
Scope of Work
2
References
2
Submittals
2
2.2
PROTECTION TO EXISTING SERVICES AND INSTALLATIONS.......................... 3
2.3
RECOVERY OF MATERIALS ................................................................................. 4
2.4
CLEARING AND GRUBBING .................................................................................. 4
2.5
REMOVAL OF STRUCTURES ................................................................................ 5
2.6
REMOVAL OF STREET FURNITURE ..................................................................... 6
2.7
REMOVAL OF FENCES .......................................................................................... 6
2.8
2.8.1
2.8.2
2.8.3
2.8.4
REMOVAL OF EXISTING PAVEMENTS ................................................................. 6

6
Cutting Back Pavement
6
Stockpiling Asphalt Pavement
7
Stockpile Site
7
2.9
MEASURES FOR STATUTORY UNDERTAKERS .................................................. 8
2.10
2.10.1
2.10.2
2.10.3
2.10.4
2.10.5
2.10.6
2.10.7
2.10.8
2.10.9
2.10.10
REMOVAL OR TREATMENT TO BURIED UTILITIES ............................................ 8

General
8
Underground Storage Tanks
8
Removal of Culverts
8
Abandoned Pipes and Culverts
9
Total Removal of Pipelines
9
Grouting of Pipelines
9
Plugging of Pipelines
10
Cut-off Walls and Capping Slabs
10
Manholes and Access Shafts
10
Drainage Inlets and Gullies
10
2.11
DISPOSAL OF MATERIALS.................................................................................. 10
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Part
02: Site Clearance
SITE CLEARANCE
2.1
GENERAL
2.1.1
Scope of Work
This Part includes:
Page 2
Excavating for, demolishing and removing wholly or in part and disposing of

designated redundant pavements, fences, buildings, culverts, manholes, inlets, gullies,
pipelines or any other obstructions.
(b)
Associated earthworks to uncover facilities to be demolished, removed or recovered

and to backfill and compact all trenches, holes, pits or excavations resultant from
demolition, removal and recovery works.
(c)
Recovering designated materials for storage and reuse.
(d)
Removing and, where required, recovery of designated water, gas and sewage
pipelines and fittings and of underground cables.
(e)
Disposal of materials not recovered.
(f)
Removal of vegetation and surface boulders and rocks.
Part 3
Part 5
Part 11
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Earthworks
Asphalt Works
Works in Relation to Services
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(a)
Building Demolition
Concrete
Sewerage
Earthworks Related to Buildings
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Section 2
Section 5
Section 8
Section 12
References
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2.1.2
BS 5228......................Code of practice for noise control on construction and demolition sites

BS 6187......................Code of practice for demolition
The Guide for Civil Users of Explosives in Qatar prepared by the former Ministry of Industry
and Public Works.
2.1.3
Submittals
Where existing services are to remain and are in close proximity to the works the Contractor
shall submit to the Engineer details of proposed measures to ensure that the existing
services are kept in a safe and stable condition for the duration of the Works.
Structures and installations to be dismantled or demolished shall be surveyed by the

Contractor to ascertain exposed constructional dimensions and details. The Contractor shall
prepare sketches of the structures and installations and submit these to the Engineer. This
information shall be used by the Engineer to confirm the scope of the dismantling or
demolition and confirm materials or equipment to be recovered.
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Part
02: Site Clearance
Page 3
The method of dismantling and demolition including the sequence of operations and any
special procedural requirements shall be submitted to the Engineer for consideration not less
than seven days before the work is due to begin. Demolition work shall be carried out in
accordance with BS 6187, and the submittal shall include information demonstrating the
Contractors proposed methods to attain compliance.
Before any blasting operation the Contractor shall submit a detailed method statement for the
work. Blasting work shall be carried out in accordance with The Guide for Civil Users of
Explosives in Qatar, prepared by the former Ministry of Industry and Public Works. Approvals
for blasting work shall be obtained as per the requirements of part 3 of the specification for
rock excavation.
The Contractor shall submit for approval his proposed method of grouting pipes to be
abandoned.
Before commencing work on the construction of reinforced concrete cut-off walls and
reinforced concrete capping slabs the Contractor shall submit details for the Engineer's
approval.
2.2
PROTECTION TO EXISTING SERVICES AND INSTALLATIONS
The Contractor shall conduct his operations in such a manner as to avoid hazards to
persons, property and vehicles. After work is started on any structure, work on that structure
shall be continued to completion promptly and expeditiously.
Services to unused installations shall be safely disconnected before demolition. Notification

of disconnection shall be given to the appropriate authorities.
Drains, manholes and gullies that are to remain shall be protected and kept clear of debris at
all times. They shall be left clean and in working order.
Details of any underground caverns, chambers, wells or voids discovered during the
demolition operation shall be reported to the Engineer. Dangerous openings shall be
protected and illuminated.
Precautions shall be taken to prevent leakage or formation of flammable, explosive,

unhealthy or environmentally hazardous gas or vapour.
Pits, drains and manholes shall be checked before entry to ensure that the atmosphere is fit
for respiration.
The quantity of dust in the atmosphere shall be minimised by spraying the demolition works
with water.
The recommendations of BS 5228: Part 2 shall be followed in minimising noise and vibration.
Silencing devices on plant shall be fitted where practicable and ear defenders shall be
provided for site personnel where noisy machinery is used.
The location of any survey stations shall be reported to the Engineer. The Engineer may
require the Contractor to transfer existing survey stations to new locations and carry out a
survey to verify the level and co-ordinates of the new survey stations.
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Part
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Page 4
All existing structures, paving, services, fittings, and other features which are not to be
demolished, dismantled, removed or otherwise dealt with shall be protected from damage by
a means approved by the Engineer.
11
Adjacent structures shall be surveyed for movement, cracks or deformations before and after
demolition. The definition of adjacent structures in this context will be decided by the
Engineer dependent on the type of structure to be demolished and the method of demolition
proposed by the Contractor and the risk of damaging adjacent property.
12
A photographic record of the adjacent structures before and after demolition shall be taken.
13
Where structures, paving, services, fittings or other features are damaged by the Contractor,
they shall be made good to the satisfaction of the Engineer.
2.3
RECOVERY OF MATERIALS
Where required the Contractor shall recover designated materials without undue damage,
carry out any required cleaning and shall deliver the recovered materials to locations
designated by the Engineer and unload and place them into storage.
Where on-site reuse is designated recovered materials shall be stored on site before their
incorporation in the Works.
Materials to be recovered shall be handled and stored in such a manner as to avoid any
damage which will impair their reinstallation and reuse. Where the absence of care results in
damage, the Contractor shall repair the damage at his expense. If repairs are deemed to be
impracticable the Contractor shall provide replacements at his expense.
2.4
CLEARING AND GRUBBING
The Contractor shall excavate and remove surface material such as debris, windblown sand,
vegetation and any other unsuitable material in the areas and to the thickness instructed by
the Engineer. Clearing and grubbing shall be restricted to removal of surface material and
debris and shall not include the excavation of natural ground unless directed by the Engineer.
The removed material shall be loaded and transported to an approved dumping area.
All surface objects, trees, stumps, roots and other protruding obstructions not designated to
remain shall be grubbed and cleared as follows:
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10
(a)
In areas inside of the grading limits of cut and embankment areas, stumps and non
perishable solid objects shall be cut off not less than one metre below the subgrade
level in the area.
(b)
In areas outside of the grading limits of cut and embankment areas, stumps and nonperishable solid objects shall be cut off not less than 500 mm below finished ground
level.
(c)
In areas to be rounded at the top of cut slopes, stumps shall be cut off flush with or
below the surface of the final slope line.
(d)
Grubbing of pits and ditches will be required only to the depth necessitated by the
proposed excavation within such areas.
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Part
02: Site Clearance
Page 5
(e)
Except in areas to be excavated, stump holes and other holes from which obstructions
are removed shall be backfilled with suitable material and compacted.
(f)
Where designated the Contractor shall carefully remove existing trees, plants or
shrubs and carefully transport these to a location designated by the Engineer.
REMOVAL OF STRUCTURES
Unless otherwise directed the Contractor shall demolish and remove all buildings and
structures within the limit of works limits together with all foundations and retaining walls,
piers, partitions and columns down to a plane not less than one metre below the finished
ground level or one metre below the subgrade level in the area.
Upon receipt of notification by the Engineer, the Contractor shall take over all responsibility of
the building or buildings then acquired and vacant and shall proceed with the demolition and
removal thereof.
All structures shall be neatly trimmed off and the reinforcement shall be cut or trimmed off
close to the concrete and made safe; basement floor slabs shall be broken into pieces;
excess debris and other foundations, concrete floor slabs, sidewalks, driveways, signs,
sheds, garages, fences and other facilities shall be removed.
The Contractor shall arrange for the discontinuance and disconnection of any services to the
structure or structures in accordance with the requirements of the agency concerned. The
Contractor shall disconnect and properly seal in an approved manner any sewer outlets that
serve any structure he is to remove. The Contractor shall keep the Engineer informed of his
plans for the performance of any work in connection with the sealing off of such outlets in
order that proper inspection can be provided at the time the work is performed.
Any additional small out-buildings or temporary structures even if not shown on the Drawings
shall also be removed if directed by the Engineer.
Demolition and removal works shall be carried out mechanically or by hand as necessary in
such a manner as to cause no undue damage to the public, property, vehicles, pavements,
services and structures, and the Contractor shall provide temporary works for protection
when necessary, in accordance with any special requirements of the concerned authorities.
Blasting or other operations necessary for the demolition and/or removal of facilities which
may damage new construction shall be completed before placing the new work, unless
otherwise directed by the Engineer.
In all cases the Contractor shall be responsible for all claims resulting from damage, of any
nature, caused by carelessness or negligence on the part of the Contractor, his
subcontractors or agents.
Demolition or removal operations for any particular facilities shall not be started until written
approval is obtained from the Engineer.
10
Throughout the demolition period the Contractor shall provide and maintain sufficient and
adequate temporary supports.
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2.5
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Part
02: Site Clearance
Page 6
REMOVAL OF STREET FURNITURE
Where designated, street furniture shall be recovered, cleaned and either delivered to and
placed into storage at the stores of the designated authority or set aside for re-erection as
part of the Works, or shall be removed and disposed of.
The Works shall include the excavation, removal and disposal of all foundations.
Before proceeding with the removal of any of the above installations the Contractor shall
contact the relevant authority and obtain approval.
The recovery of existing street lighting installations shall form part of the Works and shall be
in accordance with the requirements of the Public Works Authority.
2.7
REMOVAL OF FENCES
Where designated, fencing, including all support posts, gates, other accessories and
foundations shall be removed.
The Contractor shall provide suitable termination's for remaining fencing whether inside or
outside the right-of-way limits.
Unless otherwise directed all fencing, posts, gates and other accessories shall remain the
property of the Employer and shall be carefully dismantled and delivered to and place into
storage on site or at the Employer's stores, the location of which shall be obtained from the
Engineer. The supporting posts and supports shall be carefully cleaned of concrete, avoiding
damage to the posts.
Foundations and sections of fencing which are designated unsuitable for recovery by the
Engineer shall be disposed of.
2.8
REMOVAL OF EXISTING PAVEMENTS
2.8.1
On sections of redundant existing roadway (and detours and diversions that are no longer
needed for traffic) the existing pavement structure together with all kerbs, kerb base and
backing, sidewalk paving, edging or kerb to sidewalk paving including base and backing to
same and other items shall be broken out and removed.
Non-asphaltic pavement, kerbs, kerb base and backing, gutters and other associated debris
shall be disposed of unless such items are designated for recovery.
Where designated side drainage ditches and excavations shall be filled and the roadway
rough graded to restore approximately the original contour of the ground or to produce
natural, rounded slopes. After the rough grading is completed, the area of the old roadbed
shall be scarified or ploughed to mix the remaining road material thoroughly with earth and
then shall be harrowed and smoothed.
2.8.2
Cutting Back Pavement
The Contractor shall cut back all existing construction in such a manner to avoid damage to
the construction which is to remain.
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2.6
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Part
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Page 7
Any damage to the existing pavement and other work areas which are to remain shall be
restored to the satisfaction of the Engineer.
The details and dimensions of the cutting back of the existing pavement construction shall be
as designated subject to a minimum benching step of 300 mm between each pavement
course.
The method of cutting back all existing construction shall be as approved by the Engineer.
Once cut back all pavement edges shall be suitably protected against damage from
construction traffic. Any such damage shall be made good before proceeding with pavement
construction.
2.8.3
Stockpiling Asphalt Pavement
During the recovery and stockpiling operations asphalt pavement containing soil or other
debris shall be kept separate from recovered pavement which does not contain soil or other
debris.
Existing pavement designated for recovery shall be removed and stockpiled by methods
which will minimise losses and prevent it being contaminated with other materials. Especially,
the Contractor shall ensure that the material is reasonably free of soil and other matter when
it is stockpiled.
2.8.4
Stockpile Site
The Engineer may direct that removed asphalt or concrete pavement is stockpiled for
possible future use and the Contractor will transport all removed asphalt or concrete
pavement to the designated stockpile location.
The Contractor shall inform the Engineer at least seven (7) days before he is ready to
commence stockpiling operations and obtain written approval from the Engineer.
If not previously protected, the Contractor shall provide a protective enclosure around the
stockpile site to prevent unauthorised dumping by other Contractors and ensure that material
is not removed without authorisation. The protective enclosure around the stockpile site shall
include a suitable lockable gate for entry.
The Contractor shall assure responsibility for maintenance of the stockpile site during the
time he is depositing and removing material from the stockpile.
Maintenance responsibility shall include but not be limited to:
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(a)
Furnishing plant when directed by the Engineer to spread the material and shape the
stockpile as successive loads of salvaged material are delivered.
(b)
Ensuring by whatever means required that no unauthorised dumping is allowed.
(c)
Consolidating and reshaping of stockpile from time to time and when final operations
are complete.
When directed by the Engineer the Contractor shall permit other contractors access to the
stockpile site to deliver or remove materials.
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Part
02: Site Clearance
Page 8
MEASURES FOR STATUTORY UNDERTAKERS
The Contractor shall take all measures required by any statutory undertaker, the
management of other publicly owned services, or owners of privately owned services or
supplies, for disconnection and proper sealing off of all redundant drains, services and
supplies.
The Contractor shall observe and comply with all the safety regulations that are in force for
work associated with various services.
Before commencing work on the removal or treatment to any utilities the Contractor shall
contact the statutory undertakers and obtain their written approval.
The removal of overhead power lines shall be carried out by the QGEWC or by a specialist
contractor approved by the QGEWC.
2.10
REMOVAL OR TREATMENT TO BURIED UTILITIES
2.10.1
General
Designated existing underground storage tanks, culverts, box culverts, pipelines, pipes,
manholes, inlets, gullies and similar facilities for drainage or other designated utilities shall be
totally or partially demolished as designated, all debris removed, the facility thoroughly
cleaned out and the resultant void backfilled with suitable material (as defined in Section 6
Clause 3.3) and compacted.
Underground utilities, pits, chambers, cesspools and similar facilities shall be demolished to a
depth of one metre below the finished subgrade level in the area, and shall be properly
cleaned out to full depth and backfilled with approved compacted materials.
Where designated, manhole and access shaft covers and frames and drainage inlet covers
and frames shall be carefully removed, cleaned and transported to and placed into storage at
designated storage areas.
Materials not recovered for reuse shall be disposed of.
2.10.2
Underground Storage Tanks
Existing underground storage tanks on the site or under structures designated for removal
shall be removed and disposed of by the Contractor. The Contractor shall take all necessary
precautions during the removal and disposal of any fluid within the tanks and of the tanks
themselves.
2.10.3
Removal of Culverts
Where the total demolition of a culvert is designated the culvert top slab, walls, base slab and
all manhole shafts, shall be broken out and all debris removed and disposed of.
Where the partial demolition of the culvert is designated the top slab of the culvert shall be
removed together with all manhole shafts. The side walls shall be broken out to the
designated level or to a minimum of one metre below the subgrade level or the finished
ground level in the area. The walls shall he neatly trimmed off and the reinforcement shall be
cut or burned off close to the concrete.
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2.10.4
Abandoned Pipes and Culverts
Pipes and culverts no longer required which are designated to be abandoned in place shall
either be filled with grout or concrete, as designated by the Engineer.
All ends of abandoned pipes with a nominal diameter greater than 100 mm and less than 600
mm and all ends of abandoned culverts with a cross-sectional area of 1.0 m2 or less shall be
plugged by either mass concrete or a reinforced blockwork wall.
All ends of abandoned pipes with a nominal diameter of 600 mm or greater and all ends of
abandoned culverts with a cross-sectional area greater than 1.0 m2 shall be provided with a
cut-off wall as designated.
2.10.5
Total Removal of Pipelines
Where designated, pipelines, manholes and fittings together with any plain or reinforced
concrete bed, haunch or surround shall be broken out, removed and disposed of.
Designated pipes and ring fittings to be reused shall be recovered in such a way as to leave
them undamaged and suitable for reuse.
The method of taking apart the pipes and fittings shall be agreed with the Engineer before the
start of the work.
Materials damaged in the process of recovery shall be repaired by the Contractor.
The pipes and fittings recovered shall have all extraneous material including concrete
surround carefully removed, they shall then be thoroughly cleaned and delivered to the
designated storage area and placed into storage.
2.10.6
Grouting of Pipelines
Where designated, abandoned-in-place pipelines 300 mm or less in diameter shall he

completely filled with a sand-cement grout.
The cement, fine aggregate and water used for the grout shall comply with the requirements
of section 5 of the Qatar Construction Specification. The sand used for the grout shall be a
fine graded rounded sand that produces a free flowing grout.
The grout shall comprise of one part cement to two parts fine aggregate with enough water to
produce a free flowing and pumpable mix. The use of admixtures to improve the flow and
setting characteristics of the grout will be permitted subject to the prior approval of the
Engineer.
Each end of the pipe shall be plugged. No grouting shall commence until the Engineer's
approval has been obtained.
The Contractor may propose alternative methods of filling the pipe for the approval of the
Engineer. The Engineer shall retain the right to designate certain pipes that shall be filled with
grout irrespective of any approval to alternative methods of filling.
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Plugging of Pipelines
Designated pipes shall be plugged by mass concrete as per section 5 of Qatar Construction
Specification to a minimum of one metre lateral extent into the pipe.
The method of constructing the plug to ensure a solid watertight seal shall be approved by
the Engineer.
2.10.8
Cut-off Walls and Capping Slabs
Where designated the Contractor shall construct a reinforced blockwork cut-off wall to box
culverts and pipelines and a reinforced concrete capping slab to manholes and access
shafts.
Reinforced blockwork cut-off walls shall extend beyond the edges of the pipe and shall be
founded on a mass concrete of grade 20 as per section 5 of Qatar Construction
Specification.
2.10.9
Manholes and Access Shafts
Unless otherwise designated, manholes and access shafts shall be broken out to a plane not
less than one metre below the subgrade level or the finished ground level in the area or to
immediately below the manhole and/or access shafts cover slab, whichever is the lower.
Manhole and access shaft walls shall be neatly trimmed off and reinforcement shall be cut or
burned off close to the concrete and made safe.
Manholes and access shafts shall be cleaned out and all debris, sediment and refuse and
other unsuitable material disposed of, and backfilled with approved compacted material.
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2.10.7
2.10.10 Drainage Inlets and Gullies
Unless shown otherwise, all redundant drainage inlets, gullies and similar facilities shall be
broken out to full depth.
2.11
DISPOSAL OF MATERIALS
Materials removed but not recovered shall be disposed of in a lawful manner at approved
dumping areas. The Contractor shall be responsible for obtaining the location of the
dumping area as well as the necessary permits and approvals from the relevant authorities.
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Page 1
EARTHWORKS ....................................................................................................... 3
3.1
3.1.1
3.1.2
3.1.3
3.1.4
3.1.5
GENERAL ............................................................................................................... 3
Scope of Work
3
References
3
Definitions
4
Submittals
4
Quality Assurance
6
3.2
EARTHWORKS BY OTHERS ................................................................................. 6
3.3
3.3.1
3.3.2
3.3.3
3.3.4
3.3.5
3.3.6
MATERIALS ............................................................................................................ 6
General
6
Unsuitable Materials
7
Fill and Subgrade Materials
7
Rock Fill
8
Water
9
Performance Indicators
9
3.4
3.4.1
3.4.2
3.4.3
3.4.4
3.4.5
3.4.6
3.4.7
3.4.8
MAIN PLANT FOR EARTHWORKS ........................................................................ 9

General
9
Compaction Trials
10
Rotary Cultivators
10
Water Sprinklers
10
Bulldozers
10
Motor Graders
11
Shovel Tractors
11
Compacting Equipment
11
3.5
3.5.1
3.5.2
3.5.3
3.5.4
3.5.5
3.5.6
EXCAVATION GENERAL ..................................................................................... 12

Removal of Unsuitable Soil and Soft Spots
12
Excavating High Level Areas
12
Rock Excavation
13
Manual Excavation
13
Excavation for Pits and Trenches
14
Double Handling
14
3.6
3.6.1
3.6.2
3.6.3
3.6.4
3.6.5
3.6.6
3.6.7
3.6.8
3.6.9
FILLING GENERAL ............................................................................................... 14

General
14
Filling Around Utilities
15
Fill Supplied by Qatar National Transport Organization (QNTO)
15
Contractors Imported Fill
15
Rock Fill
16
Compaction
17
Filling of Pits and Trenches
18
Work Over Sabkha
18
Trimming Side Slopes
19
3.7
3.7.1
3.7.2
3.7.3
STRUCTURE EXCAVATION AND FILLING .......................................................... 19

General
19
Excavation Supports
20
Dewatering
20
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Excavation for Structures

Use of Materials
Cofferdams
Backfill Adjacent to Structures
20
21
21
22
3.8
3.8.1
3.8.2
3.8.3
FORMATION PREPARATION............................................................................... 22
Scope
22
Protection
23
Rectification
23
3.9
TOPSOIL ............................................................................................................... 23
3.10
3.10.1
3.10.2
3.10.3
3.10.4
3.10.5
TESTING ............................................................................................................... 23
General
23
Testing Degree of Compaction
24
California Bearing Ratio
24
Testing Levels and Evenness of the Formation
25
Testing Formation Works after Completion
25
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3.7.4
3.7.5
3.7.6
3.7.7
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EARTHWORKS
3.1
GENERAL
3.1.1
Scope of Work
This Part includes all the earthworks required to construct and maintain the roadway facilities
as follows:
(b)
Excavating selected material from the roadway and borrow pits for use as specified.
(c)
Placing and compacting of selected material.
(d)
Structure excavation.
(e)
Backfilling.
(f)
Supplying and placing topsoil (sweet soil).
(g)
Laying and compaction of fill for shallow embankments where additional slope
protection measures are not required.
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Removing unsuitable materials.
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(a)
Drainage Works
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Section 8,
Section 12,
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This Section
Part 1, .............. General
Part 2, .............. Site Clearance
Part 4, .............. Unbound Pavement Materials
Part 5, ............. Asphalt Works
Part 6, ............. Concrete Road Pavements
Part 19, ........... Miscellaneous
References
3.1.2
ASTM D1556 .............Standard Test Method for Density and Unit Weight of Soil in Place by
Sand-Cone Method
ASTM D1557 .............Standard Test Methods for Laboratory Compaction Characteristics of
3
3
Soil Using Modified Effort (56,000 ft lbf/ft (2,700 kN m/m ))
ASTM D4718 .............Standard Practice for Correction of Unit Weight and Water Content for
Soils Containing Oversize Particles
ASTM D1883 .............Standard Test Method for CBR (California Bearing Ratio) of
Laboratory Compacted Soils
ASTM D4318 ..............Standard Test Methods for Liquid Limit, Plastic Limit, and Plasticity
Index of Soils
ASTM D6913 .............Standard Test Methods for Particle Size Distribution (Gradation) of
soils using Sieve Analysis
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ASTM D4429 ..............Standard Test Method for (California Bearing Ratio) CBR of Soils in
Place
ASTM D4944 ..............Standard Test Method for Field Determination of Water (Moisture)
Content of Soil by the Calcium Carbide Gas Pressure Tester
ASTM D6938 ..............Standard Test Method for In-Place Density and Water Content of Soil
and Soil-Aggregate by Nuclear Methods (Shallow Depth)
ASTM D1140 ..............Standard Test Method for Amount of Material in Soils Finer than No.
200 (75-m) Sieve
ASTM E1703 ..............Standard Test Method for Measuring Rut-Depth of Pavement Surfaces
Using a Straightedge
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AASHTO T307 ..........Standard Method of Test for Determining the Resilient Modulus of
Soils and Aggregate Materials
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BS 1377 - Part 3 ........Methods of test for Soils for Civil Engineering Purposes: Chemical and
electro-chemical tests
Definitions
LSA: Laboratories and Standardization Affairs Ministry of Environment.
Suitable material: material which is acceptable in accordance with Clause 3.3.3.
Imported material: suitable material obtained from outside of the Site.
Optimum moisture content (OMC): the moisture content of soil at which a specified
compaction effort will produce the maximum dry density when determined in accordance with
ASTM D1557.
Maximum dry density (MDD): The dry density of soil obtained using a specified compaction
effort at the optimum moisture content when determined in accordance with the modified
compaction test ASTM D1557. Unit weight and moisture content of materials containing more
than 5% by mass of oversize fraction tested in accordance with ASTM D1557 should be
corrected following ASTM D4718.
Subgrade: the compacted existing ground or fill for 500mm beneath formation.
Formation: the completed earthworks level shaped in accordance with the Drawings in
readiness to receive the sub-base.
3.1.4
Submittals
The Contractor shall submit to the Engineer for approval his proposals for the compaction of
each type of material to be used in embankments detailing the type of plant, number of
passes and maximum loose depth of layer.
The contractor shall submit to the Engineer for approval method statements for the following:
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3.1.3
(a)
Materials production, handling, storage, identification, marking and traceability to

source of production.
(b)
Quality assurance and quality control plans for all construction activities.
(c)
Quality control testing plan.
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(d)
Equipment and its suitability to fulfill all construction activities to the required quality.
(e)
Personnel capability.
(f)
Safety and environment preservation measures.
Before commencing any structural excavation work greater than 1.5 m in depth, the
Contractor shall submit to the Engineer for his review details of proposals for supporting
excavated faces.
The proposals shall be submitted in the form of calculations and drawings which clearly
indicate the extent of excavation at all points along the structure relative to adjacent
properties, roads and services.
In the case of supported excavations the proposals shall, for the actual soil properties,
comprise detailed drawings of the support system stating method of installation and showing
support member materials, sizes, spacing and engineering calculations to validate the design
of the above, including the maximum theoretical deflections of the support members. The
support system shall be designed in such a manner that no support members extend through
surfaces exposed in the finished construction and no shoring or bracing is placed under
permanent structures.
The engineering calculations shall be in English and shall show lateral earth pressures for the
full excavation depths, faces at various stages of support during installation and removal and
concrete placement, the anticipated equipment loads, anchorage loads of any description,
the maximum design loads to be carried by various members of the support system and strut
preload forces.
If the structure support system proposed includes tie-back anchors, the Contractor's
submittal drawings shall show the profile of the soil in which each anchor is to be installed,
the design load for the full depth of the excavation, the maximum design and proof loads,
surcharge loads of any description; equipment loads, forces at various stages, support during
installation and removal, and the criteria proposed for deformations under proof loads.
In addition to the approval submittal, shop drawings of the support system are to be
submitted. Where a proposed system of tie-back anchors projects onto adjoining property
beyond the vertical projection of the designated limits of the Contract, the permission of the
owner shall be obtained in writing and documentation of such permission shall be included in
the submittal.
Complete working drawings showing the type of dewatering and groundwater control system
proposed shall be submitted for review. The submittal drawings shall show the arrangement,
location and depths of the proposed dewatering system if required. A complete description of
the equipment and materials to be used and the procedure to be followed shall be shown
together with the standby equipment, standby power supply, and the proposed location or
locations of points of discharge of water. Details of methods of cofferdam construction shall
be included in the submittal.
10
The method and the type of equipment to be used for advancing dewatering wellpoints shall
be submitted for review.
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Quality Assurance
The designs of the structure excavation support systems and the dewatering system shall be
prepared by and signed by a professional engineer specializing in this type of design work.
Blasting work shall be carried out by a specialist company with the appropriate license as
detailed in clause 3.5.3.
3.2
EARTHWORKS BY OTHERS
Where earthworks have been carried out by others before commencement of the Works, the
Contractor shall carry out all tests he considers necessary to satisfy him that the work already
executed complies with this specification.
Should the Contractor consider the result of the tests unsatisfactory he shall immediately
provide full details of all such tests carried out for the Engineer's review as to the remedial
work to be undertaken.
The Contractor will be deemed to have satisfied himself as to the adequacy of any previous
earthworks when he proceeds with his own work, and he shall be responsible for repairs to or
replacement of any defective layer or surface where such failure was due to a fault in the
previously executed work which would have been revealed by normal testing procedures.
3.3
MATERIALS
3.3.1
General
All excavated material shall be the property of the Owner and shall not be removed from the
Site without the written consent from the Owner.
Suitable and approved excavated material from any part of the Site shall be hauled and used
for filling in any other section of the Site. The Contractor shall store such material when
necessary until the need arises for its use in filling as required by the phases of construction,
or as directed by the Engineer.
Where the amount of suitable material exceeds the amount of fill required for the Works, the
Contractor shall dispose of the surplus material at designated locations. The Contractor shall
off-load, spread, level, water and carry out other related operations at the disposal site as
directed by the Engineer. The Contractor shall ensure that the disposal site has been
approved by the Municipality concerned.
Any excavation greater than the net volume required for the Works in length or width, shall be
made up with suitable compacted fill material at no cost to the Owner and subject to
inspection and approval of the Engineer.
Any additional excavation to remove unsuitable material at or below the bottom of foundation
level or construction layers shall be replaced with mass concrete.
Before using material resulting from excavation for filling, the Contractor shall carry out field
and laboratory testing to establish the suitability of said material for filling work. Whenever
such excavated material indicates a change in characteristics the Contractor shall carry out
additional testing.
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3.1.5
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Where the contract provides for the supply of fill material by others the Contractor shall
remain responsible for checking each load received to ensure that it is in accordance with the
specification requirements and for rejecting unsuitable material. The Contractor shall be
responsible for maintaining all records of deliveries and documentation relating to the quality
of such material.
3.3.2
Unsuitable Materials
Unsuitable materials shall mean materials other than suitable materials and include;
Material from marshes.
(b)
Tree and plant stumps.
(c)
Perishable material.
(d)
Deposits of sabkha with more than 5% water-soluble salts.
(e)
Material subject to spontaneous combustion.
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(a)
Fill and Subgrade Materials
The subgrade material and the material used for filling and compacting below the formation
level of the roadway, sidewalks, hard shoulder, drainage ditches and other areas on site shall
consist of material approved for filling resulting from the excavation works.
In the event that such material is unsuitable or insufficient, the Contractor shall obtain and
use filling material from borrow pits.
This material shall be clean and free from any unsuitable material and complies with the
requirements listed in Table 3.1.
The maximum particle size of fill material shall be 75 mm unless the material is classified as
rock as per this part of the specification and the placing and compaction are carried out
according to the requirements for rock fill.
Unit weight and moisture content of materials containing more than 5% by mass of oversize
fraction tested in accordance with ASTM D1557 should be corrected following ASTM D4718.
When nuclear gauge is used for field density and moisture content testing, 3 readings shall
be made at each test location within a radius of 2 meters. The average of the 3 readings is
considered to be the density for that test location. Individual density readings shall not be less
than the target relative density by more than 0.5%.
Recycled aggregate produced from excavating natural ground and from demolition wastes
can be used for filling purposes provided that the specifications stated in Section 6 - Part 9
are complied.
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3.3.3
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Page 8
Table 3.1
1
Fill and Subgrade Materials and Construction Specifications
Parameter
Standard
Specification Limits
Percent passing the

75mm sieve
ASTM D6913
100%
Percent passing the

0.075mm sieve
ASTM D1140
30% max.
Liquid limit
ASTM D4318
Method A
30% max.
Plasticity Index
ASTM D4318
10 % max.
- Visible change in
material
ASTM D6938
In Place Moisture
2
Content
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ASTM D4944
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ASTM D1556
Min. 95% of MDD
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Field Density
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2% max.
2% of OMC
ASTM D4429
Acid soluble Chloride

Content
BS 1377 Part 3
Acid soluble sulphate

content
BS 1377 Part 3
3% max.
Organic Matter
BS 1377 Part 3
2% max.
15% min.
- 1 per 200 m
layer
per
- 1 every 75m per

lane per layer
1 per 2000 m
1 per 3000 m
2% max.
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In Place California
Bearing Ratio (CBR)
15% min. at 95% MDD
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ASTM D1883
(Soaked)
Swelling
Loose materials for testing and acceptance shall be sampled from the un-compacted in- place layer.
During compaction.
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- Each Source
- 1 per 1000 m
California Bearing
Ratio (CBR)
Minimum Frequency
Rock Fill
Rock shall be defined as any naturally formed solid matter encountered in excavation having
2
2
a crushing strength of not less than 7 N/mm when dry and not less than 4 N/mm after
submergence in water for 24 hours.
This shall be determined on samples of 100 mm x 100 mm x 100 mm cubes obtained from
3.3.4
the material (equivalent cores in lie u of cubes may be considered for testing at the discretion
of the Engineer and the method of testing and acceptance criteria will be advised by the
Engineer in such cases).
3
Individual masses of solid material found in excavation and weighing less than 500 kg shall
not be considered as rock.
Any artificially formed solid matter such as block work or concrete shall not be considered as
rock.
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The Contractor shall supply any equipment and labor necessary to obtain suitable samples
and carry out testing of rock or suspected rock. The Engineer shall determine the location
and quantity of samples necessary to determine the extent of the rock. These samples shall
be taken in the presence of the Engineer.
In the event that the tests prove that the material is rock, the Engineer shall determine the
extent of such material and shall instruct the Contractor accordingly.
3.3.5
Water
Potable or brackish water shall be used for all earthwork operations except that only potable
water shall be used for compaction of backfill material within one meter from all surfaces of
the structure and for the backfill of all service trenches.
Brackish water shall have a maximum total dissolved solids (TDS) of 5000 ppm, a maximum
chloride content of 1500 ppm and a maximum sulphate content (as SO3) of 2000 ppm.
3.3.6
Upon the request of the Engineer, the following performance indicators shall be determined
from loose in place materials for verification of the pavement structural design following the
AASHTO Mechanistic-Empirical Pavement Design Guide:
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Resilient Modulus (MR) in accordance with AASHTO T307 at optimum moisture

content and maximum density as per ASTM D1557.
(b)
Parameters and moduli required for determining the Permanent Deformation Potential
in accordance with AASTHO Mechanistic Empirical Design Guide.
(c)
Parameters and moduli required for measuring the Fatigue Cracking Potential for
stabilized and surface layers in accordance with AASHTO Mechanistic Empirical
Design Guide.
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(a)
For performance testing, one sample shall be tested every 10,000 m , and for constructions
3
having less than 10,000 m volume, one sample shall be tested every 50% of the total
volume.
3.4
MAIN PLANT FOR EARTHWORKS
3.4.1
General
The Contractor shall provide the Engineer with copies of catalogues, technical data and
charts of the machinery to be used on site before the commencement of the work.
The Engineer will inspect the machinery and tools before the commencement of work. The
machinery and tools used in carrying out earthworks and other related works for the road
construction and in maintenance of the work shall be in good working condition, and the
Contractor shall maintain them in such condition for the whole duration of the Work.
The Contractor shall use power screens equipped with clay reject screen with sufficient
screen area and clay reject conveyor belt when processing subgrade materials. Static
screens shall not be used to produce subgrade materials. Any deviations from this process
must be approved by the Engineer.
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The Contractor shall supply an adequate type and number of machines and tools for the
proper and timely execution of the Works. The number of machines shall not be limited to the
types of equipment or recommended minimum number stipulated in the Contract
Documents, which shall be used for guidance purposes only.
The Contract is awarded on the understanding that the actual numbers of machines and
other plant will not be reduced below the numbers shown in the Contract.
No plant shall be removed from the site without the specific written approval of the Engineer.
3.4.2
Compaction Trials
Before commencing construction of the permanent works, unless otherwise agreed with the
Engineer, the Contractor shall carry out compaction trial, after submitting a method
statement, for each type of fill material and construction situation of the earthworks to
establish an approved rolling/compaction procedure which shall then be used as a minimum
requirement for the permanent works unless otherwise directed or agreed by the Engineer.
The compaction trials shall involve all procedures specified for the permanent works
including testing and any equipment, processes or procedures as proposed by the Contractor
which are not included as a part of these specifications. Compaction trials for each main type
of material shall be carried out on areas having dimensions of approximately 50 meters by 10
meters.
Construction of the permanent works shall not commence until a compaction procedure has
been approved in writing by the Engineer.
3.4.3
Rotary Cultivators
Rotary Cultivators shall have axles rotated by a powerful motor and be equipped with metal
teeth or plates. They shall be designed in such a way as to ensure proper pulverization and
mixing of soil. They must be equipped with apparatus to lift and lower the axles so as to be
always to the required depth.
3.4.4
Water Sprinklers
Water sprinklers shall be borne by trucks with pneumatic tires and shall be equipped with a
pressure pump and water sprinkling distribution equipment. The pump shall be powered in
such a manner that the pump pressure will remain uniform regardless of variations in truck
speed. The distributors shall be so designed as to allow sprinkling and adding of water to the
soil uniformly and in controlled quantities and shall be equipped with an approved gauge to
control the quantity of water added during operation. Special spray bar attachments shall be
provided and used in order to sprinkle water on sloped sections. The activation of the water
system shall be controlled from the cab by the driver.
3.4.5
Bulldozers
Bulldozers may be tracked or pneumatic-tire vehicles and shall be equipped with a blade for
earth moving and levelling. Ripper attachments shall be provided when necessary. The blade
level shall be hydraulically controlled to raise or lower it so that the work surface can be
formed and adjusted as required.
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Motor Graders
Motor graders shall be pneumatic-tire and shall be equipped such that it is possible to lift,
lower and adjust the angle of the blade as required to control the grading operation and to
perform grading without making undulations.
3.4.7
Shovel Tractors
Shovel tractors shall be tractors equipped with a shovel for earth hauling or moving and may
be either on tracks or on pneumatic tires. The shovel shall be hydraulically controlled to raise
and lower it as required.
3.4.8
Compacting Equipment
Rolling compacting equipment shall consist of pneumatic-tire and steel wheeled rollers as
described below:
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3.4.6
Pneumatic-tire rollers shall be equipped with tires of equal size and diameter which
shall be uniformly inflated so that the air pressure of the tires shall not vary
significantly, from one another. The wheels shall be spaced so that one pass will
accomplish one complete coverage equal to the rolling width of the machine. There
shall be a minimum of 6mm overlap between the tracks of the front and rear tracking
wheels. Self-propelled, pneumatic-tire rollers shall have a minimum weight of
9 tons without ballast and a minimum weight of 18 tons with ballast.
(b)
Steel wheeled rollers shall be of the following types:
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(a)
Three-wheeled rollers shall be self-propelled and equipped with a reversing

clutch, a differential drive and with adjustable scrapers to keep the wheel
surface clean.
(ii)
Tandem rollers shall be self-propelled and equipped with reversing clutches and
adjustable spring scrapers fitted to the driving and steering roller to scrape in
both directions.
(iii)
Vibratory steel tandem rollers shall have the requirements of the foregoing steel
tandem rollers with a static weight of at least 5000 kg and a vibrating frequency
between 1500 and 2000 cycles per minute.
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(i)
(iv)
Single drum vibratory steel rollers shall be double axle, self-propelled units with
the rear axle equipped with pneumatic flotation wheels, they shall have vibrating
frequency capabilities between 1500 and 2000 cycles per minute.
Portable vibratory compaction rollers shall be double axle tandem single-drum self-propelled
equipped with a vibrating element delivering an impact of not less than 1590 kg at a
frequency of about 5000 cycles per minute. The roller shall be easily maneuvered, of
adequate width and suitable for rolling ditches with their side slopes having grades of up to
1:3.
Hand plate compactors shall be capable of delivering an impact of between 750 to 1500
kilograms.
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EXCAVATION GENERAL
3.5.1
Removal of Unsuitable Soil and Soft Spots
If during the progress of the work the soil encountered has characteristics, as determined by
tests conducted under the direction of the Engineer, that render it unsuitable for incorporation
in the road embankment, the Contractor shall excavate and remove such unsuitable material
to the extent directed by the Engineer.
Where contractor finds isolated soft spots during excavation, this material shall be removed
to the extent directed by the Engineer.
No excavated suitable material shall be removed from the Site without the approval of the
Engineer. Should the Contractor be permitted to remove suitable material to suit his
operational procedure then he shall make good any consequent deficit of fill material arising
therefrom.
Where the excavation reveals a combination of suitable and unsuitable material the
excavation shall, unless otherwise agreed with the Engineer, be carried out in such a manner
that the suitable materials are excavated separately for use in the Works without
contamination by the unsuitable material.
The hauling of excavated material to areas of fill shall proceed only when sufficient spreading
and compacting plant are operating at the place of deposition to ensure placing and
compaction.
Unsuitable excavated material shall be removed and carted away to an approved dumping
area after approval from the Engineer.
The Contractor shall replace this unsuitable material by other suitable surplus or imported
material in layers not exceeding 150 mm compacted thickness to the density specified.
If the contractor considers in some situations it is impractical to replace unsuitable material

with imported material he may elect to use granular material, which shall comply with the
requirements of part 4 of this specification.
Granular material placed beneath water shall not require compaction, granular material
placed above water shall be compacted and tested as per the requirements of part 4 of this
specification.
10
If any solution cavities are found in lime stone material they shall be brought to the attention
of the Engineer. The Engineer shall advise what treatment is to be carried out in such
situations.
3.5.2
Excavating High Level Areas
The Contractor shall excavate high level areas in all materials including rock for the full width
of the road construction down to the top of the required subgrade.
The Contractor shall then scarify a layer not less than 150 mm deep except that this
requirement shall not apply where rock is present.
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3.5
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The soil shall be pulverized, watered as required, mixed, shaped and compacted to 95 %
maximum dry density, as per ASTM D1557, to a depth of 150 mm.
In all excavations the groundwater level shall be maintained at least 300 mm below the
formation level during the works.
3.5.3
Rock Excavation
Excavation in rock shall be as defined in clause 3.3.4 of the specification.
Excavation in rock may be carried out by a tracked bulldozer and ripper or by the use of
blasting with explosives or any other method approved by the Engineer.
Blasting using explosives shall only be permitted if authorized by the civil defense, police and
any other statutory authority. The Contractors method statement shall be agreed before any
blasting operation.
Blasting work shall be carried out in accordance with The Guide for Civil Users of Explosives
in Qatar prepared by the former Ministry of Industry and Public Works.
For any blasting work involving the use of explosives the Contractor shall use a specialist
company, licensed to carry out such work by the former Ministry of Industry and Public
Works.
The specialist company shall possess the appropriate license for the required scope of work.
The purchase and delivery of each consignment of explosives for blasting work should be
covered by a separate application for a possession license.
The transportation of explosives shall only be carried out after notification to the police and
civil defense.
For each planned blasting operation the Contractor shall arrange for advance notification to
be made to the police and civil defense authorities.
10
After it has been established that the excavated material is rock and after the area where
such rock exists has been defined, the Contractor shall incorporate the rock in the
embankment.
11
When excavated material contains more than 25 % of rock larger than 150 mm in greatest
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diameter the rock shall be crushed, pulverized and further broken down. The resultant
material from the excavation shall be placed on the embankment in accordance with clause
3.6.5.
3.5.4
Manual Excavation
The Contractor shall excavate manually in the vicinity of all services, structures, and any
other areas, and if necessary uncover them, all as directed by the Engineer.
The Contractor shall take all precautions to prevent damages to services, properties and
persons, and any damage resulting from the negligence of the Contractor, his agents, or his
employees. Any such damage shall be repaired by the Contractor at his own expense.
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Excavation for Pits and Trenches
All trenches and pits under roads shall, where possible, be excavated, backfilled and
compacted before road construction commences.
The sides of the excavation shall be adequately supported at all times.
Trenches and pits shall be kept free of water.
In tidal and high water table areas the excavation shall be kept free from standing water at all
times during construction.
Trenches for pipes or ducts shall be excavated to the levels and gradients indicated in the
contract documents.
3.5.6
Double Handling
It shall be the Contractors responsibility to assess at the start of the contract the quantity of
suitable material available from an excavation for use as fill material and the requirement for
imported fill material.
The Contractor shall plan earthworks operations to minimize the handling of fill material and
disruption due to dust and noise from transportation operations.
The Contractor shall not be entitled to any additional payment for double handling of any
excavated material from the site for imported fill.
If it is necessary to double handle the material the Contractor shall take all measures to avoid
degradation or contamination of fill material.
The Engineer may instruct that the tests to assess the properties of the fill material are taken
at any point during the transportation, placing and compaction process.
3.6
FILLING GENERAL
3.6.1
General
Filling low-level areas shall be to the level of subgrade as designated. After completion of
clearing and grubbing, the Contractor shall carry out the necessary levelling in order to
control the thickness of the layers of fill.
The existing natural ground shall then be scarified in place to a minimum depth of 150 mm
for the full width of the embankment except where the material is classified as rock. The
scarified material shall be watered as required, thoroughly mixed, shaped and compacted to
a minimum of 95 % maximum dry density.
Where an existing embankment is being widened, the existing embankment slope shall be
trimmed and compacted into benches of minimum width 1m and depth 500mm before
placing and compacting each layer of new embankment material unless otherwise directed
by the Engineer to suit particular circumstances.
The Contractor shall not proceed with filling and compacting any subsequent layer before
testing and securing the approval of the Engineer for the previous layer.
All fill material for a depth of 500 mm below the formation level must meet the requirements
provided in clause 3.3.3.
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3.5.5
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Filling Around Utilities
Filling around culverts, storm water and sewerage pipes, utility and structures, and between
building plot and footpath areas shall be done in accordance with the specific requirements of
the relevant utility authority and the following additional requirements.
Filling for these areas shall be from surplus excavated material obtained on site and
approved by the Engineer. In the case of insufficiency of such material then approved
material shall be obtained from borrow pits and filled to the designated levels. The maximum
size of particle allowed in the backfill within one meter of culverts, storm water and sewage
pipes, utilities and structures shall be 25 mm.
The Contractor shall take every precaution to protect bridge columns and lighting equipment
when filling between median barriers and any damage to these items arising from the filling
works shall be repaired by the Contractor.
The Contractor shall agree the type of plant or equipment to be used with the Engineer
before undertaking this work.
3.6.3
Fill Supplied by Qatar National Transport Organization (QNTO)
If instructed under the projects specification, fill will be imported from other sources using the
Qatar National Transport Organization (QNTO).
It shall be the responsibility of the Contractor to monitor and control both the quality and the
quantity of this imported fill.
The Contractor shall ensure that all delivery notes for such material are verified and
authenticated and then collated for submission to the Engineer.
3.6.4
Contractors Imported Fill
The project specifications shall designate areas for the Contractor to obtain borrow material
for use in the construction of the Works. It is the Contractor's responsibility to satisfy himself
that there is sufficient borrow material of suitable types.
The Contractor may elect to use alternative sources of borrow material.
It shall be the Contractor's responsibility to obtain all permits or permission and make any
payments that may be required in acquiring the rights to borrow material whether the
Contractor uses the designated areas or elects to use alternative areas. The Contractor shall
ensure that the source of all borrowed material has been approved by the Municipality
concerned.
The Contractor shall obtain and supply to the Engineer representative samples from the
borrow pits he intends to use. The Engineer will be afforded the opportunity to be present
during the sampling operations.
The Contractor will carry out the necessary laboratory and, if required, field testing to
establish the suitability of the material for filling work and will advise the Engineer of the
results. The Engineer will advise the Contractor whether such material is acceptable and
whether the borrow pit is an approved source of borrow material.
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3.6.2
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The Contractor will test samples of the approved borrow pits material actually being imported
onto the site, and should such material fail to meet the requirements of these Specifications,
approval to the use of the borrow pits will be withdrawn and the Contractor shall immediately
cease importation from the borrow pits until such time as the Engineer may approve
alternative sources of material from within the same borrow pits based on sampling and
testing as specified above.
The Engineer will decide whether the material already imported from the concerned borrow
pits can remain as placed on the site, or whether the Contractor shall remove and replace the
said material at his own expense.
Overburden and any unsuitable top layers at the borrow pit shall be stripped and stockpiled to
the satisfaction of the Engineer. Upon completion of excavation the Contractor shall replace
the overburden and unsuitable material, smooth the surface and leave the area clean and
tidy to the satisfaction of the Engineer.
The Contractor's haul and traffic arrangements will be subject to the Engineer's approval
before the work may be commenced.
3.6.5
Rock Fill
Material consisting predominantly of rock fragments of such a size that it cannot be placed in
layers of the thickness allowed without crushing, or further breaking down, may be placed in
the embankment in layers not exceeding twice the average size of the larger fragments.
No layer of rock fill shall exceed 800 mm loose thickness.
Rock fill shall be placed and spread so that the largest boulders and fragments are evenly
distributed, with the voids in-between completely filled with smaller fragments, sand or gravel,
watered in if necessary.
Each layer shall be bladed and leveled by a track laying tractor.
Quality control tests will not normally be performed on this material but each layer must be
approved in writing by the Engineer before the next is placed.
Embankment layers which consist of material that contains rock but also has sufficient
compatible finer material other than rock shall be placed and compacted as for soil
embankments. Quality control tests will be made wherever the Engineer determines they are
feasible.
Compaction shall be carried out by a vibratory roller with the following minimum mass:
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Mass per Meter Width of

Vibration Roll (kg/m)
Depth of Fill
Layer ( mm )
Minimum number of Passes of the

Roller on each Layer
2300 - 2900
400
2900 - 3600
500
3600 - 4300
600
4300 - 5000
700
>5000
800
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Compaction
The Contractor shall carry out the required compaction specified after grading and leveling
the surface to be compacted. In areas to be filled, compaction shall include adding necessary
soil, water and compacting the first layer in addition to subsequent layers up to the proposed
levels.
In areas already excavated down to the required level, compaction shall include adding the
necessary water, and compacting the surface, in accordance with the procedure outlined in
paragraphs 3 to 12 below.
After carrying out the grading, leveling, scarifying and pulverizing of the soil layer the
Contractor shall add the necessary amount of water to permeate the pulverized soil.
The soil shall then be thoroughly turned after each addition of water so as to achieve
homogeneous moisture content in the whole thickness of the layer.
Before compacting, samples of the pulverized soil shall be tested using a 'Speedy Moisture
Device' (ASTM D4944) or similar instrument to measure the moisture content. If the moisture
content is not within 2 % of the optimum moisture content as determined by ASTM D1557,
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the area represented by this sample shall be scarified and aerated or water added until the
moisture content is within 2 % of the optimum moisture content. The soil shall then be
as
primarily leveled in order to commence earth compaction.

After primary levelling referred to above, compaction shall be commenced by means of the
approved rolling pattern.
Filling shall be in layers not exceeding 150 mm compacted thickness.
All areas including embankment roadway, medians, shoulders, sidewalks and verges shall be
compacted to 95 % of Maximum Dry Density as determined by ASTM D1557 unless
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otherwise specified or directed by the Engineer.

The rolling shall be carried out in the direction of the road axis until the soil reaches the
required density. In crowned sections, rolling shall start from both edges of the road in the
direction of the road axis. If the road is super elevated, rolling shall commence from the lower
side and continue to the higher side. In order to compensate for the amount of water loss in
evaporation during the course of compaction, additional quantities of water shall be added as
required.
10
Each layer shall be levelled and rolled to achieve uniform compaction free from undulations,
soft spots and depressions.
11
No layer shall be covered by the next layer until it has been tested, inspected and approved
by the Engineer.
12
The Contractor shall be responsible for reinstatement to the satisfaction of the Engineer of
any layer damaged or disturbed after compaction and approval, by any means or cause,
before placing the next layer.
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Filling of Pits and Trenches
The bottom of all excavations shall be formed to the lines and levels shown on the drawings.
Any pockets of soft soil or loose rock in the bottom of pits and trenches shall be removed and
the resulting cavities and any large fissures filled with suitable material and compacted to a
minimum relative compaction of 95 % based on ASTM D1557.
Prior to proceeding with filling, the base of the excavation shall be compacted to a minimum
relative compaction of 95 % based on ASTM D1557.
The full width of the compaction plant shall fit inside the surface area of the backfilling with
sufficient space to permit adequate compaction. Under no circumstance shall compaction be
carried out with plant straddling backfilled and existing surfaces.
Trenches and pits shall be backfilled in layers not exceeding 150 mm compacted thickness
unless otherwise directed by the engineer.
3.6.8
Work Over Sabkha
Where the road embankment passes over Sabkha areas with a high water table the
contractor shall take special precautions during the construction.
These precautions shall include but shall not be limited to the construction of suitable
temporary haul roads for all construction plant operating in the area.
Haul roads shall be constructed using rock fill and geotextiles as necessary to ensure a safe
stable surface.
The use of geotextiles and geosynthetics shall be in accordance with Part 15 when used for
the permanent embankment.
If directed by the Engineer the Contractor shall construct embankments over Sabkha areas
with a surcharge of excess material that shall remain in place till all appreciable settlement
has stopped. The Contractor shall provide a means of monitoring the settlement. The
Engineer shall decide when appreciable settlement has stopped.
Unless a specific treatment in using geotextiles or geosynthetics is described elsewhere in

the contract, work over Sabkha shall comprise of initially stabilizing the existing Sabkha area
by laying and rolling rock fill layer type 1 according to Table 3.2. This operation should be
continued by adding and rolling type 1 rock fill layer with steel vibratory roller till the layer is
completely stabilized.
A layer of geotextile fabric should be laid over the compacted type 1 pervious backfill.
A layer of 50mm pervious backfill type 2 according to Table 3.2 should be laid over the
stabilized layer to protect the geotextile fabric.
Layer of 200mm thick rock fill type 1 should be laid over type 2 pervious backfill to receive the
required road layers after the above operation.
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Table 3.2
Definition of Type 1 & 2 backfill materials
Percentage Passing
Size (mm)
Type 2
152.0
Max.
125.0
85 - 100
100.0
75 - 90
50.0
45 - 65
37.5
35 - 55
19.0
20 - 35
100
12.5
10 - 25
95 100
9.5
5 - 20
70 100
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03
Trimming Side Slopes
Embankment side slopes shall be trimmed to the profiles and dimensions shown on the
contract drawings.
The earthworks shall be trimmed to within 20 mm of the designated profile.
The side slopes shall be thoroughly compacted after trimming to ensure a hard surface.
Side slopes shall be tested for compaction in accordance with this part of the specification
and the minimum density requirement shall be 95% of the maximum dry density as per
ASTM D1557.
3.7
STRUCTURE EXCAVATION AND FILLING
3.7.1
General
In addition to the work specified, the Contractor shall include all operations necessary to
excavate and backfill as required for the construction of any structures installations and
utilities.
This work shall include necessary, pumping, dewatering, draining, sheeting, bracing, and the
necessary supply and construction of cribs and cofferdams and their subsequent removal.
The Contractor shall take all necessary precautions, to the satisfaction of the Engineer, to
prevent loss of natural cementation in the existing subsoil during, and as a consequence of,
dewatering operations.
This work shall also include the furnishing and placing of approved foundation fill material or
concrete to replace unsuitable material encountered below the foundation elevation of
structures.
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3.6.9
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Excavation Supports
Battered excavation slopes greater than 1.5 m high shall not be used without the express
written permission of the Engineer. Where such permission is not granted or where only a
part of the overall depth of an excavation is permitted to be with battered slopes all faces of
excavations greater than 1.5 m high shall be supported.
The Contractor shall submit his proposals for supporting excavated faces.
Before commencing any structural excavation work greater than 1.5 m in depth, the
Contractor shall obtain the Engineers approval of his proposals for supporting excavated
faces.
3.7.3
Dewatering
At locations where the excavation extends below the groundwater table, a dewatering system
shall be provided. This will effectively reduce the hydrostatic pressure and lower the
groundwater levels below excavation levels, as required for the safe and proper excavation of
the work. It will result in obtaining a stable, dry subgrade for the execution of subsequent
operations.
The Contractor shall design dewatering methods and settling basins so that no critical
amounts of soil, sand or silt are removed during either the initial operations or the
construction operations. Complete working drawings showing the type of dewatering and
groundwater control system proposed shall be submitted to the Engineer for his review.
The Contractor's submitted drawings shall show the arrangement, location and depths of the
proposed dewatering system if required. A complete description of the equipment and
materials to be used and the procedure to be followed shall be shown, together with the
standby equipment, standby power supply, and the proposed location or locations of points of
discharge of water.
Any required dewatering system design shall also include the measures taken to prevent
damage due to settlement of pavement, utilities, sewers, buildings and other structures
outside the excavation but within the area affected by the dewatering procedures.
Dewatering shall not be terminated without the approval of the Engineer and in the case of
structures retained by ground anchors dewatering shall not be terminated until the ground
anchors have been stressed to the full working load and approved by the Engineer.
3.7.4
Excavation for Structures
The Contractor shall notify the Engineer sufficiently in advance of the beginning of any
excavation so that cross-sectional elevations and measurements may be taken of the
undisturbed ground.
Trenches or foundation pits for structures or structure footings shall be excavated to the
designated lines and grades or elevations. They shall be of sufficient size to permit the
placing of structures or structure footings of the full width and length shown. The designated
elevations of the bottoms of footings shall be considered as approximate only and the
Engineer may order, in writing, such changes in dimensions or elevations of footings as may
be deemed necessary, to secure a satisfactory foundation.
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3.7.2
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Boulders, logs, and any other unsuitable material encountered in excavations shall be
removed from the site.
Unless otherwise designated structure excavation shall be carried out for a width of at least
500 mm beyond the horizontal outside limits of the foundation, footing, box culvert or
structural member to which the excavation relates. Concrete blinding or sub-foundations are
not to be considered as structure for the purpose of defining such excavation.
If during the progress of the work, loose or improperly compacted soil or such other material
as the Engineer considers would be detrimental to load distribution of new foundations to the
underlying soil is encountered below the structure foundation level such material shall be
removed within the limits as directed by the Engineer.
The resulting void shall be backfilled with either blinding concrete or with suitable material
compacted to a density not less than 95 % of the maximum dry density as per ASTM D1557.
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The Engineer shall specify the type of backfill to be employed at each location.
After each excavation is completed, the Contractor shall notify the Engineer to that effect,
and no footing, bedding material or pipe culvert shall be placed until the Engineer has
approved the depth of excavation and the character of the material on which the foundations
will bear.
All rock or other hard foundation material shall be cleaned of all loose material and cut to a
firm surface, either level, stepped, or serrated as directed by the Engineer. All seams or
crevices shall be cleaned and grouted. All loose and disintegrated rock and thin strata shall
be removed. When the footing is to rest on material other than rock, excavation to final grade
shall not be made until just before the footing is to be placed.
3.7.5
Use of Materials
All excavated material, so far as it is suitable, shall be used as backfill or roadway fill.
All excavated material shall be approved by the Engineer before being used as fill. All surplus
excavated material and excavated material rejected by the Engineer for use on the site shall
be removed from the site and disposed of in locations approved by the Engineer.
Where the Engineer designates a disposal location this shall be within a 50 km radius of the
site of the Works.
3.7.6
Cofferdams
Suitable and practically watertight cofferdams shall be used wherever water-bearing strata
are encountered above the elevation of the bottom of the excavation.
Cofferdams or cribs for foundation construction shall, in general, be carried well below the
bottoms of the footings and shall be well braced and as nearly watertight as practicable. In
general, the interior dimensions of cofferdams shall be such as to give sufficient clearance
for the construction of forms and the inspection of their exteriors, and to permit pumping
outside of the forms. Cofferdams or cribs which are tilted or moved laterally during the
process of sinking shall be righted or enlarged so as to provide the necessary clearance.
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When conditions are encountered which, as determined by the Engineer, render it

impracticable to dewater the foundation before placing the footing, the Engineer may require
the construction of a concrete foundation seal of such dimensions as he may consider
necessary, and of such thickness as to resist any possible uplift. The concrete for such a seal
shall be placed as directed by the Engineer. The foundation shall then be dewatered and the
footing placed.
If weighted cribs are employed and the weight is used to overcome partially the hydrostatic
pressure acting against the bottom of the foundation seal, special anchorage's such as
dowels or keys shall be provided to transfer the entire weight of the crib to the foundation
seal. When a foundation seal is placed under water, the cofferdam shall be vented or ported
at low water level as directed.
As an alternative to a cofferdam, the Contractor may propose a wellpoint dewatering system,

for approval by the Engineer, to keep structural excavation works dry. Such proposal shall
include, but not be limited to, sufficient calculations, sketches and drawings, to justify the
wellpoint positions and lengths in addition to pumping capacity required. The use of a
wellpoint dewatering system may not preclude the use of support or shoring within the
excavation to provide adequate stability and safety to the satisfaction of the Engineer.
3.7.7
Backfill Adjacent to Structures
Excavated areas around structures shall be backfilled with suitable excavated materials or
imported materials as approved by the Engineer. Backfill materials shall be placed in
horizontal layers not over 150 mm in depth and compacted to a minimum of 95% of the
maximum dry density obtained by ASTM D1557.
Material used for backfill adjacent to structures shall have a sulphate content of less than
2.5 g/L when tested in accordance with BS 1377.
Each layer shall be moistened or dried as required and thoroughly compacted as specified.
The maximum size of particle allowed in the backfill within one meter of structures shall be 50
mm.
Backfill and embankment behind walls of any culvert shall not be placed until the top slab of
the culvert has been placed and cured.
Backfill to culvert walls shall be carried out simultaneously behind opposite walls.
3.8
FORMATION PREPARATION
3.8.1
Scope
This work shall consist of the preparation of the graded formation upon which sub-base, base
course or pavement materials are to be placed, all in accordance with these Specifications.
All subgrade shall be compacted to the previous requirements of these Specifications.
Preparation and surface treatment of the formation shall be carried out after all duct and pipe
installations in the subgrade have been completed.
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Any non-compliant subgrade material shall be excavated, replaced, and compacted to the
required density.
3.8.2
Protection
Once prepared, the formation shall be maintained in the finished condition until the first
succeeding course of sub-base, base, or asphalt pavement material has been placed.
The Contractor shall take all precautions necessary to protect the formation from damage:
hauling over finished subgrade shall be limited to that which is essential for construction
purposes.
Any equipment used for hauling over the prepared subgrade which in the opinion of the
Engineer is causing undue damage to the prepared subgrade or to the underlying materials
shall be removed from the Works at the request of the Engineer.
All cuts, ruts and breaks in the surface of the subgrade shall be repaired by the Contractor
before placing any subsequent layer. The Contractor shall protect the prepared subgrade
from both his own and public traffic.
The Contractor shall maintain the subgrade by blading and rolling as frequently as may be
necessary to preserve the subgrade in a completely satisfactory condition.
3.8.3
Rectification
Any surface area of the formation which is too high shall be graded off, scarified and recompacted to the full depth of the affected layer.
Any surface area of the formation which is too low shall be scarified and corrected by the
addition of subgrade material of the same classification and moisture content.
The Contractor shall carry out additional testing as required by the Engineer to ensure that
the standard of compaction is satisfactory through the full depth of a layer or previously
placed layers.
3.9
TOPSOIL
Topsoil (sweet soil) shall be fertile, free draining, non-toxic soil capable of sustaining healthy
plant growth.
The material proposed for use as topsoil shall be approved by the Agricultural Department of
the Ministry of Municipal Affairs and Agriculture.
Topsoil shall be loosely placed at the designated thickness.
3.10
TESTING
3.10.1
General
For verification of material, moisture content, compaction, thickness and other properties of
the materials or workmanship the Engineer shall at all times have access to all portions of the
works and sites. All sampling and testing of material and work shall be carried out under the
direction of the Engineer.
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The minimum frequency of testing shall follow the frequencies mentioned in Table 3.1 unless
more frequent tests are shown elsewhere in the contract documents or directed by the
Engineer. Other testing shall be carried out as directed by the Engineer.
3.10.2
Testing Degree of Compaction
Testing shall be done in accordance with ASTM methods of testing, or other approved
equivalent test or designated procedure.
The density-in-place of earthworks layers shall be tested by the sand replacement method
(ASTM D 1556) or nuclear method (ASTM D6938).
Nuclear density gauge testing should only be carried out by personnel who have approved
user certification issued by the Ministry of Environment.
Each in-situ density nuclear gauge shall be calibrated and a calibration form issued. The
Contractor shall maintain on site and with the instrument a copy of the Ministry of
Environment safety and training manual for the use of nuclear density gauges.
When nuclear gauge is used for field density and moisture content testing, the density and
moisture content for each material shall be verified by measurements in accordance with
ASTM D1556 and ASTM D2216, respectively. The mean value of the replicate readings shall
be used as the calibration point value for each material.
When determining the laboratory maximum dry density the method described in ASTM
D1557 shall be applied.
No person or company will be permitted to determine in situ density by means of a nuclear

type density measuring device without complying with the requirements of the Ministry of
Environment. Refer to clause 1.5 of part 1 of this Section.
The density of any layer requiring compaction shall be determined in accordance with the
specifications mentioned in Table 3.1.
If a layer does not conform to the required density, additional tests may be taken to
determine the limits of the failing area, after which the Contractor shall rework the area until
the specified density is obtained. The Contractor shall allow enough time in his daily work
program to permit the performance and checking of the above tests, before he proceeds into
any subsequent operations.
3.10.3
California Bearing Ratio
The soaked value of the California Bearing Ratio shall be determined on specimens
compacted at the optimum moisture content and 95 % of the maximum dry density as per
ASTM D1557 after soaking for 4 days in accordance with ASTM D1883. CBR value shall
comply with the minimum requirement as per Qatar Highway Design Manual (QHDM).
The test surcharge to be used for the equivalent pavement thickness shall be designated by
the Engineer.
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Part
03: Earthworks
Page 25
Testing Levels and Evenness of the Formation
The Engineer shall test the levels and evenness of the finished formation surface to ascertain
compliance.
The Contractor shall make available to the Engineer a three-meter straight-edge and a crown
template of sturdy and approved design and the necessary labor to assist in the checking
operations.
When tested in accordance with ASTM E1703 by a three-meter straight-edge placed at right
angles to, or parallel to, the road centerline or when tested by a crown template placed
centrally at right angles to the road centerline, the maximum gap between the road formation
surface and the testing edge shall not be greater than 20 mm. Measurements shall be carried
out at maximum spacing of 50m of road length for each lane.
The subgrade shall be prepared to the levels shown on the contract drawings to a tolerance
of between 15 mm and 20 mm when checked by a level instrument.
Variation in the falls to cross-sections of the road shall not exceed 0.4 %.
These tests shall be made at any point requested by the Engineer. In the event of any failure,
the Contractor shall correct the unevenness of the surface and resubmit the area for approval
by the Engineer.
3.10.5
Testing Formation Works after Completion
All completed works shall be inspected at any time as directed by the Engineer in order to
verify the compliance of the executed work to the requirements of the contract as per
requirement of Part 5 in Section 3.
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3.10.4
END OF PART
QCS 2014

Part
04: Unbound Pavement Materials
Page 1
UNBOUND PAVEMENT MATERIALS ..................................................................... 2
4.1
4.1.1
4.1.2
4.1.3
4.1.4
4.1.5
GENERAL ............................................................................................................... 2
Scope
2
References
2
Definitions
3
Submittals
3
Quality Assurance
4
4.2
4.2.1
4.2.2
4.2.3
4.2.4
4.2.5
4.2.6
4.2.7
4.2.8
MATERIALS ............................................................................................................ 4
Sources of Materials
4
Storage and Handling of Materials
4
Inspection Testing and Control
5
Fine Aggregate
5
Coarse / Combined Aggregate
6
Recycled Aggregate
7
Water
8
8
4.3
4.3.1
4.3.2
4.3.3
MAIN EQUIPMENT ................................................................................................. 8

General
8
Paving Machines
9
Central Mixers
9
4.4
MIX DESIGNS ......................................................................................................... 9
4.5
SCREENING AND MIXING ..................................................................................... 9
4.6
SPREADING AND COMPACTION ........................................................................ 10
4.7
CORRECTIVE ACTION......................................................................................... 11
4.8
PROTECTION OF SURFACE ............................................................................... 11
4.9
4.9.1
4.9.2
4.9.3
TESTING ............................................................................................................... 12
General
12
Thickness
12
Evenness and Level
12
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Part
Page 2
UNBOUND PAVEMENT MATERIALS
4.1
GENERAL
4.1.1
Scope
This Part includes materials, equipment and construction requirements for unbound layers
(aggregate Subbase and Road Base courses).
Related Parts are:

General
Earthworks
Asphalt Works
References
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4.1.2
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Part 1
Part 3
Part 5
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ASTM C88 ..................Standard Test Method for Soundness of Aggregates by Use of Sodium
Sulphate or Magnesium Sulphate
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ASTM C131 ................Standard Test Method for Resistance to Degradation of Small-Size

Coarse Aggregate by Abrasion and Impact in the Los Angeles
Machine
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ASTM C136 ................Standard Test Method for Sieve Analysis of Fine and Coarse
Aggregates
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ASTM C535 ................Standard Test Method for Resistance to Degradation of Large-Size

Machine
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ASTM D1556 ..............Standard Test Method for Density and Unit Weight of Soil in Place by
Sand-Cone Method
ASTM D1557 ..............Standard Test Methods for Laboratory Compaction Characteristics of
Soil Using Modified Effort (56,000 ft-lbf/ft3 (2,700 kN-m/m3))
ASTM D1883 ..............Standard Test Method for CBR (California Bearing Ratio) of
Laboratory-Compacted Soils
ASTM D2216 ..............Test Methods for Laboratory Determination of Water (Moisture)
Content of Soil and Rock by Mass
ASTM D2419 ..............Standard Test Method for Sand Equivalent Value of Soils and Fine
Aggregate
ASTM D4318 ..............Standard Test Methods for Liquid Limit, Plastic Limit, and Plasticity
Index of Soils
ASTM D4429 ..............Standard Test Method for CBR (California Bearing Ratio) of Soils in
Place
ASTM D4791 ..............Standard Test Method for Flat Particles, Elongated Particles, or Flat
and Elongated Particles in Coarse Aggregate
ASTM D4944 ..............Standard Test Method for Field Determination of Water (Moisture)
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Part
Page 3
ASTM D5821 ..............Standard Test Method for Determining the Percentage of Fractured
Particles in Coarse Aggregate
ASTM D6913 .............Standard Test Methods for Particle Size Distribution (Gradation) of
Soils Using Sieve Analysis
ASTM D6938 ..............Standard Test Method for In-Place Density and Water Content of Soil
ASTM E1703 ..............Standard Test Method for Measuring Rut-Depth of Pavement Surfaces
Using a Straightedge
AASHTO T307 ...........Standard Method of Test for Determining the Resilient Modulus of
Soils and Aggregate Materials
BS 1377 Part 3 ...........Methods of test for Soils for Civil Engineering Purposes: Chemical and
Definitions
Optimum moisture content (OMC): the moisture content of soil at which a specific
compaction effort will produce the maximum dry density when determined in accordance with
the ASTM D1557.
Maximum dry density (MDD): The dry density of soil obtained using a specified compaction
effort at the optimum moisture content when determined in accordance with the modified
compaction test ASTM D1557. Unit weight and moisture content of materials containing more
than 5% by mass of oversize fraction tested in accordance with ASTM D1557 should be
corrected following ASTM D4718.
Subgrade: the compacted existing ground or fill for 500mm beneath formation.
Formation: the compacted subgrade level shaped in readiness to receive the Subbase or
Road Base courses.
Subbase: It is the layer between the subgrade and the Road Base. It consists of compacted
selected granular materials.
Road Base: It is the layer directly beneath the asphalt course layers and above the subbase
or subgrade layer. It consists of compacted selected materials. It can be untreated or treated
with suitable stabilizing admixtures.
4.1.4
Submittals
The Contractor shall submit recent test results for the proposed sources of materials for all
quality requirements of the Contract. The Contractor shall submit a test certificate that proves
that the raw materials that are purchased/used comply with specifications. The testing may
be performed by an approved private laboratory or by the laboratory associated with the plant
itself.
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4.1.3
(a)
Materials production, handling, storage, identification, marking and traceability to

(b)
Quality assurance and quality control plans for all construction activities.
QCS 2014

Part
Page 4
(c)
Materials production, handling, storage, identification and marking, traceability to

(d)
(e)
Equipment and its suitability to fulfill all construction activities to the required quality.
(f)
(g)
Quality Assurance
If requested the Contractor shall arrange for the Engineer to visit the source of the materials
and jointly take samples for testing. The Contractor shall carry out testing as directed by the
Engineer.
4.2
MATERIALS
4.2.1
Sources of Materials
The Contractor shall notify the Engineer of the proposed sources of materials. The
Contractor shall ensure that the sources of all aggregates have been approved by the
Municipality concerned.
The Engineer shall approve the sources before delivery of materials to the site.
Where a proposed source of material is not approved, the Contractor shall propose an
alternative source of material.
4.2.2
Storage and Handling of Materials
Materials shall be so stored and handled as to assure the preservation of their quality and
fitness for use in the works. Even after source approval has been given materials may again
be inspected and tested before use in the work.
Stored material shall be located so as to facilitate prompt inspection.
All storage sites shall be restored to their original condition before acceptance of the Works.
Handling and stockpiling of aggregates shall at all times be such as to eliminate segregation
or contamination of the various sizes. Stockpiles shall be kept flat, and the formation of high
cone-shaped piles shall not be permitted. When conveyor belts are used for stockpiling
aggregates the Engineer may require the use of baffled chutes or perforated chimneys.
When trucks are used to construct stockpiles, the stockpiles shall be constructed one layer at
a time with trucks depositing their loads as close to the previous load as possible. The use of
tractors or loaders to push material deposited at one location to another location in the
stockpile shall not be allowed during the construction of the stockpile and their use shall be
limited to levelling the deposited material only.
The Contractor shall take all necessary protection measures in the storage, handling and
stockpiling of materials to prevent contamination of materials by dust. The measures that the
Contractor proposes to take shall be subject to the approval of the Engineer.
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4.1.5
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Part
Page 5
Inspection Testing and Control
Loose materials for testing and acceptance shall be sampled from the un-compacted in-place
layer.
For verification of plant weights and measures, character of materials used in the preparation
of the mixes, testing and other quality control requirements, the Engineer shall at all times be
provided access to all portions of the mixing plant, aggregate plant, storage yards, crushers
and other facilities used for producing and processing the materials of construction.
The Engineer shall have authority to take samples and perform tests on any material
supplied to the site from any source whatsoever in order to establish compliance and to
accept or reject as he deems necessary. Samples shall also be taken from completed work
to determine compliance. The frequency of all sampling and testing shall be as designated by
the Engineer.
The Contractor shall provide suitable facilities at the quarry or plants to carry out all
necessary tests on the raw materials and mixes.
The Contractor shall arrange for obtaining specimens of materials and samples taken from
stockpiles, including the provision of any necessary equipment and plant. This work shall be
performed in the presence of the Engineer if so directed by the Engineer.
Materials that are not in compliance shall be rejected and removed immediately from the site
of the works unless otherwise instructed by the Engineer.
Where defects in the materials or the completed work have been corrected, the Contractor
shall not proceed with subsequent work until approval has been given by the Engineer.
4.2.4
Fine Aggregate
Fine aggregate (passing the 4.75 mm sieve) shall consist of crushed mineral aggregate
and/or natural sand.
The fine aggregate shall be clean and free from clay-balls and other extraneous or
detrimental materials.
Where the source of fine aggregate does not meet the requirements listed in Table 4.1, the
Contractor may, with the Engineer's approval, add fine aggregate and filler to correct the
gradation or to change the characteristics of the material passing the 0.425mm sieve so as to
meet the requirements. Such additional material shall be added in a manner which ensures a
completely homogeneous material.
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4.2.3
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Part
Page 6
Table 4.1
Specifications of fine aggregates for Road Base and Subbase layers
Parameter
Minimum Frequency
Standard
Road Base
Subbase
Liquid Limit
ASTM D4318
25%max.
25% max.
Plasticity Index
ASTM D4318
6 % max.
6 % max.
- Each source
- Visible change in material
ASTM D2419
35 min.
25 min.
Organic content
BS 1377
Part 3
0.5% max.
0.5% max.
- 1 test every 1000m
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Sand equivalent
Coarse / Combined Aggregate
Coarse aggregate (retained on the 4.75 mm sieve) shall consist of crushed stone or crushed
gravel and shall be free from organic matter, clay and other extraneous or detrimental
materials.
The required properties of coarse aggregates for Road Base and Subbase layers are listed in
Table 4.2.
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Table 4.2
Specifications of coarse aggregates for Road Base and Subbase layers
Standard
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Parameter
Fractured Faces
ASTM D5821
Road Base
Subbase
50% min.
50% min.
- Each source
ASTM D4791
10% max.
15% max.
Loss by Abrasion
ASTM C131
ASTM C535
30% max.
40% max.
ASTM C88
15% max.
Flat and Elongated

Particles (5:1)
Soundness
(5 cycles by MgSO4)
Minimum Frequency
- Visible change in
material
20% max.
Loose materials for testing and acceptance shall be sampled from the un-compacted inplace layer.
The required properties of combined aggregate for Road Base and Subbase layers are listed
in Table 4.3.
Unit weight and moisture content of materials containing more than 5% by mass of oversize
fraction tested in accordance with ASTM D1557 should be corrected following ASTM D4718.
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Part
Page 7
When nuclear gauge is used for field density and moisture content testing, 3 readings shall
be made at each test location within a radius of 2 meters. The average of the 3 readings is
considered to be the density for that test location. Individual density readings shall not be less
than the target relative density by more than 0.5%.
When nuclear gauge is used for field density and moisture content testing, the density and
moisture content for each material shall be verified by measurements in accordance with
ASTM D1556 and ASTM D2216, respectively. The mean value of the replicate readings shall
be used as the calibration point value for each material.
In case abnormally high relative density values are encountered, it will be required to reevaluate the related field and laboratory density values.
Gradation requirements of combined aggregate for Road Base and Subbase layers are listed
in Table 4.4.
4.2.6
Recycled Aggregate
Recycled aggregate produced from excavating natural ground and from demolition wastes
can be used in subgrade and subbase layers provided that the specifications stated in
Section 6 - Part 9 are complied.
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Table 4.3
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Specifications of combined aggregates for Road Base and Subbase layers
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Standard
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Parameter
Minimum Frequency
Road Base
Subbase
2.05 Mg/m
min.
2.15 Mg/m
min.
ASTM D1557
Gradation
ASTM D6913
Table 4.4
Table 4.4
ASTM D1883
(Soaked)
80% min.
70% min.
Swelling
ASTM D6938
Field Density
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California Bearing
Ratio (CBR)
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Maximum Dry Density
In Place Moisture
2
Content
ASTM D1556
ASTM D6938
ASTM D4944
- Each source.
- Visible change in
material
- 1 test per 1000m
0.5% max.
1.0% max.
100% of MDD
100% of MDD
- 1 per 200 m per

layer
1.5% of OMC
2% of OMC
- 1 every 75m per

lane per layer
1 per 2000 m
1 per 3000 m
In Place California
Bearing Ratio (CBR)
ASTM D4429
80% min.
70% min.
Acid soluble Chloride

Content
BS 1377 Part 3
2% max.
2% max.
Acid soluble
content
BS 1377 Part 3
sulphate
3% max.
3% max.
Loose materials for testing and acceptance shall be sampled from the un-compacted in- place layer.
During compaction.
QCS 2014

Part
Page 8
Table 4.4
Gradation limits for Road Base and Subbase layers
Road Base
Subbase
50.0 mm
100
100
37.5 mm
95 100
90 100
19.0 mm
70 92
70 90
9.5 mm
50 70
45 - 75
4.75 mm
35 55
30 60
0.600 mm
12 25
10 30
0.075 mm
08
0 12
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Sieve Size
Water
Sea, brackish or saline water shall not be used in the mixing, spreading and compacting
operations for Road Base / Subbase layers.
4.2.8
Upon the request of the Engineer, the following performance related indicators shall be
determined from loose in place materials for verification of the pavement structural design
following the AASHTO Mechanistic-Empirical Pavement Design Guide:
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4.2.7
Resilient Modulus (MR) in accordance with AASHTO T307 at optimum moisture

content and maximum density as per ASTM D1557.
(b)
Parameters and moduli required for determining the Permanent Deformation Potential
in accordance with AASTHO Mechanistic Empirical Design Guide.
(c)
Parameters and moduli required for measuring the Fatigue Cracking Potential for
stabilized and surface layers in accordance with AASHTO Mechanistic Empirical
Design Guide.
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(a)
For performance testing, one sample shall be tested every 10,000 m , and for constructions
3
having less than 10,000 m volume, one sample shall be tested every 50% of the total
volume.
4.3
MAIN EQUIPMENT
4.3.1
General
Unless otherwise stipulated herein the provisions of Section 6, Part 3 (Earthworks), in respect
of the main machinery and tools used in earthworks construction, shall be adhered to,
subject to the modifications and additions in this clause.
The Contractor shall not be allowed to use any equipment or plant before obtaining the
approval of the Engineer, and the Contractor shall undertake sound technical methods in
operation and to engage skilled and trained operators, mechanics and labor to carry out the
works.
QCS 2014

Part
Page 9
The Engineer shall have the right to stop the use of any equipment or plant which he deems
to be inferior to the quality required and to instruct the removal of such equipment and to
have it replaced by suitable equipment or to alter the method of operation at any time he so
desires.
The Contractor shall immediately comply with such instructions without being entitled to any
indemnities or extensions as a result of such instructions.
The Engineer shall have the right to expel any operators, mechanics or labor and to instruct
suitable replacement thereof at any time he deems such action is necessary.
4.3.2
Paving Machines
Paving machines shall be self-propelled and shall be capable of spreading the Subbase and
Road Base materials in one operation so as to make it ready for compaction with minimum
shaping.
The paving machines shall be provided with a screed that strikes off and distributes the
material to the required width and level.
The width of each spread shall not be less than a traffic lane wide.
The screed shall be adjustable to the required width being laid.
Screed action includes any practical motion that produces a finished surface texture of
uniform appearance.
4.3.3
Central Mixers
A central mixing plant shall be either of an approved drum or pugmill type with a moisture
control system so that the material may be spread without further mixing or processing.
Means shall be provided for regulating the flow of material to the mixer. The various feeds
shall be calibrated to allow adjustments to the mix design to be carried out.
4.4
MIX DESIGNS
Aggregate Subbase and Road Base courses shall consist of crushed mineral aggregates or
natural mineral aggregates of the designated gradation and thickness.
The maximum dry density and the optimum moisture content of the material shall be
ascertained as per the test procedure given in ASTM D1557 and this shall be used to assess
the degree of compaction of the mix after rolling.
The pavement layer designated as sub-base may be substituted by any of the materials
designated to be laid on it subject to the approval of the Engineer.
4.5
SCREENING AND MIXING
Screening shall be required for the materials used in Subbase and Road Base courses to
ensure that the designated gradation is attained.
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Screens shall be of the size and number required to remove oversize aggregate and to
separate the materials into two or more fractions so that they may be combined to meet the
required gradation.
A central mixing plant shall be used for the mixing of materials.
Mixing of separate materials on the roadway by motor grader will not be permitted.
4.6
SPREADING AND COMPACTION
Before commencing the construction of the Subbase and Road Base courses, a written
approval for the Engineer must be obtained that the subgrade is in compliance.
The optimum moisture content of the material shall be noted from the mix design and the
actual moisture content determined at the plant after mixing.
If the natural moisture content is less than the optimum moisture content, the necessary
amount of water must be added to obtain the optimum content.
Allowance shall be made for the quantity of moisture which may be lost by evaporation in the
process of raking, levelling and compacting, depending on atmospheric temperature.
The compacted layer shall have moisture content within 1.5% of the optimum moisture
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content for Road Base layers and within 2% for Subbase layers.
The moisture content shall be uniform in all parts of the section where the work is being
carried out and in the various depths of the layer thickness.
Subbase and Road Base courses shall be laid by a paving machine with a spreader box.
Loose samples of materials for testing and acceptance shall be obtained from behind the
paving machine upon the approval of the Engineer.
Compaction shall start immediately the material has been laid and as per the approved rolling
pattern.
10
Work on the Subbase and Road Base courses shall not be permitted during rainy weather.
11
Material shall be spread to a thickness that would result in layers not more than 150 mm thick
after compaction. Where the finished compacted thickness exceeds 150 mm placing shall
be executed in composite layers each layer not exceeding 150 mm in compacted thickness
12
The course shall not be rolled when the underlying material is soft or yielding or when the
rolling causes a wave-like motion in this course.
13
When the rolling develops irregularities, the irregular surface shall be loosened, then refilled
with the same kind of material as used in constructing the course and again rolled.
14
Along places inaccessible to rollers, the Subbase and Road Base courses material shall be
tamped thoroughly with suitable mechanical tampers to achieve the required density and
finish.
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15

Part
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Rolling must continue until a relative density of not less than 100 % of the maximum dry
density has been obtained as determined by the moisture-density relationship in ASTM
D1557.
Care shall be taken so that layers already compacted under the layer being executed are not
damaged, or that the formation is not damaged.
17
This aspect must be given special attention in places where rolling equipment makes turns to
change direction.
18
Any such damage resulting in mixing the various layers constituting the different subgrades,
Subbase and Road Base courses shall be carefully made good by the Contractor at his own
expense and to the satisfaction of the Engineer.
4.7
CORRECTIVE ACTION
Any material that fails to meet test requirements shall either be reworked or removed and
replaced and then retested to check for compliance.
Any soft spots, irregularities or depressions that develop in the surface of the Subbase or
Road Base courses, shall either be corrected by loosening the surface of such areas and
adding further material, or by removing the material in such areas and replacing with further
approved material.
In the event of heave occurring during compaction, caused either by excessive build-up of
pore water pressure or the groundwater table being sufficiently high to affect construction
techniques, either of the following procedures shall be adopted subject to the approval of the
Engineer:
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16
Sufficient time shall be allowed to elapse enabling the excess pore water to dissipate
before further construction or compaction is carried out
(b)
The affected material shall be removed, and approved alternative construction layers
substituted.
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(a)
For correction of low density or incorrect level, the top 75 mm shall be scarified, reshaped
with material added or removed as necessary and re-compacted to the designated
requirement. The area treated shall not be less than 30 metres long and 2 metres wide or
such area determined by the Engineer as necessary to attain compliance.
Where the surface of the sub-base is covered in a very thin smooth skin composed of fine
particles cemented together acting as a barrier to the prime coat the top 75 mm shall be
scarified, reshaped, watered if necessary, and re-compacted prior to the application of prime
coat.
The Contractor shall carry out additional testing if required by the Engineer to ensure that the
standard of compaction is satisfactory through the full depth of the layer.
4.8
PROTECTION OF SURFACE
The Contractor shall protect the Subbase and Road Base courses so that it shall be
maintained sound during work progress, after its completion and before receiving the
bituminous layers or before laying the surface overlay thereon.
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Any damage caused to the layer if exposed to traffic or natural conditions resulting in damage
to its surface shall be made good at the expense of the Contractor and to the satisfaction of
the Engineer.
The Engineer has the right to stop all hauling over completed or partially completed Subbase
and Road Base courses when in his opinion such hauling is causing damage.
Following the completion of the Subbase or Road Base courses the Contractor shall perform
all maintenance work necessary to keep the course in a condition for priming.
4.9
TESTING
4.9.1
General
Loose materials for testing and acceptance shall be sampled from the un-compacted in-place
layer.
All testing shall be conducted in accordance with ASTM, AASHTO and BS standards listed in
section 4.2.
Testing frequency for the properties of Subbase or Road Base layers are listed in Tables 4.1,
4.2 and 4.3.
At any stage in the mixing, transportation, spreading or compaction process, the Engineer
may instruct that these tests are carried out.
Before the application of any prime coat or any other paving course, the aggregate Subbase
or Road Base courses shall have been tested for compliance with the requirements of this
clause on testing and approved by the Engineer.
4.9.2
Thickness
The thickness of the material shall be derived from checking the level by dipping from string
lines stretched across the roadway between pins or kerbs. Unless agreed otherwise with the
Engineer dipping shall be carried out at intervals of not less than 10m.
The thickness of the material shall be measured at the location where the material is
removed from the roadway for gradation analysis.
Wherever the thickness of compacted aggregate Subbase or Road Base courses is found to
vary from the thickness specified in the project drawings or specification by more than 10 %
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the area involved shall be satisfactorily corrected to provide the required thickness
constructed to the designated grade level.
4.9.3
Evenness and Level
The final surfaces of the Subbase or Road Base courses shall be tested by means of a 3
meter long straight edge in accordance with ASTM E1703 and no rises or depressions in
excess of 10 mm shall appear in the surface. Measurements shall be carried out at
maximum spacing of 30m of road length for each lane.
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Part
Page 13
The finished surface shall also be checked by dips or spot levels and shall be constructed to
the designated grade levels to within 10 mm.
Where these requirements are not met, the Contractor shall determine the full extent of the
area which is out of tolerance and shall make good the surface of the course by scarifying to
a minimum depth of 75 mm or 4 times the maximum particle size, whichever is greater,
reshaping by adding or removing material as necessary, adding water if necessary and recompacting.
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END OF PART
QCS 2014

Part
05: Asphalt Works
Page 1
ASPHALT WORKS.................................................................................................. 3
5.1
5.1.1
5.1.2
5.1.3
5.1.4
5.1.5
GENERAL ............................................................................................................... 3
Scope
3
References
3
Definitions
7
Submittals
7
Quality Assurance
8
5.2
5.2.1
5.2.2
5.2.3
5.2.4
5.2.5
5.2.6
5.2.7
5.2.8
5.2.9
5.2.10
MATERIALS ............................................................................................................ 8
Unacceptable Materials
8
Fine Aggregate
9
Coarse Aggregate
9
Recycled Aggregate
10
Mineral Filler
10
Asphalt Binder
11
Prime Coat
13
Tack Coat
13
13
Inspection and Control
14
5.3
5.3.1
5.3.2
5.3.3
MARSHALL MIX DESIGN ..................................................................................... 14

General
14
Marshall Mix Design Criteria
15
Quality Control Testing
17
5.4
DENSE BITUMEN MACADAM .............................................................................. 20
5.5
SUPERPAVE MIX DESIGN ................................................................................... 22
5.6
PERFORMANCE EVALUATION OF ASPHALT CONCRETE ................................ 24
5.7
5.7.1
5.7.2
5.7.3
5.7.4
5.7.5
5.7.6
5.7.7
5.7.8
5.7.9
5.7.10
DELIVERY, SPREADING AND FINISHING ........................................................... 25

Delivery of Mixes
25
Spreading and Finishing
25
Compaction of Mixes
26
Transverse Joints
27
Longitudinal Joints
28
Paving Edges
28
Breakdown Rolling
28
Intermediate Rolling
29
Finish Rolling
29
Protection of Laid Courses
29
5.8
COLD PLANING .................................................................................................... 29
5.9
5.9.1
5.9.2
5.9.3
5.9.4
5.9.5
PRIME COAT ........................................................................................................ 30

General
30
Equipment Required
30
Surface Preparation
30
Application
30
Maintenance and Traffic
31
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Page 2
TACK COAT .......................................................................................................... 31

General
31
Equipment Required
31
Surface Preparation
32
Application
32
32
5.11
5.11.1
5.11.2
5.11.3
THICKNESS AND LEVEL...................................................................................... 32

Thickness
32
Transverse Evenness
33
Evenness and Rideability
33
5.12
PAVEMENT EVALUATION TECHNIQUES ........................................................... 35
5.13
5.13.1
5.13.2
5.13.3
5.13.4
5.13.5
5.13.6
PRODUCTION OF ASPHALT CONCRETE COURSES ........................................ 35

Weather Limitations
35
Equipment Required
35
Survey and Preparation
35
Heating of Asphalt Binder
36
Heating of Mineral Aggregate
36
Proportioning and Mixing
36
5.14
HAULING EQUIPMENT......................................................................................... 37
5.15
5.15.1
5.15.2
5.15.3
OTHER EQUIPMENT ............................................................................................ 37

Spreading and Finishing Equipment
37
Rolling Equipment
38
Liquid Asphalt Distributor
39
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5.10
5.10.1
5.10.2
5.10.3
5.10.4
5.10.5
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APPENDIX .......................................................................................................................... 40
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Part
05: Asphalt Works
Page 3
ASPHALT WORKS
5.1
GENERAL
5.1.1
Scope
Materials, equipment, and construction of bituminous paving works including prime coating
and tack coating.
Related Parts
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Part 1, ............. General

Part 3, ............. Earthworks
Part 4, ............. Unbound Pavement Materials.
References
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5.1.2
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ASTM C40 ..................Standard Test Method for Organic Impurities in Fine Aggregates for
Concrete
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ASTM C50 ..................Standard Practice for Sampling, Sample Preparation, Packing and
Marking of Lime and Limestone Products
ASTM C51 ..................Terminology Relating to Lime and Limestone (as used by the industry)
se
ASTM C88 .................Standard Test Method for Soundness of Aggregates by Use of Sodium
Sulphate or Magnesium Sulphate
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ASTM C117 ................Standard Test Method for Materials Finer than 75-m (No. 200) Sieve
in Mineral Aggregates by Washing
ASTM C127 ...............Standard Test Method for Density, Relative Density (Specific Gravity),
and Absorption of Coarse Aggregate
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ASTM C128 ...............Standard Test Method for Density, Relative Density (Specific Gravity),
and Absorption of Fine Aggregate
ASTM C131 ...............Standard Test Method for Resistance to Degradation of Small Size
Machine
ASTM C136 ...............Standard Test Method for Sieve Analysis of Fine and Coarse
Aggregates
ASTM C142 ...............Standard Test Method for Clay Lumps and Friable Particles in
Aggregates
ASTM C150 ................Specifications for Portland Cement
ASTM C535 ...............Standard Test Method for Resistance to Degradation of Large Size
Machine
ASTM D5 ....................Standard Test Method for Penetration of Bituminous Materials
ASTM D6 ....................Standard Test Method for Loss on Heating of Oil and Asphaltic
Compounds
ASTM D36 ..................Standard Test Method for Softening Point of Bitumen (Ring-and-Ball
Apparatus)
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Part
05: Asphalt Works
Page 4
ASTM D75 .................Standard Practice for Sampling Aggregates

ASTM D92 .................Standard Test Method for Flash and Fire Points by Cleveland Open
Cup Tester
ASTM D113 ................Standard Test Method for Ductility of Bituminous Materials
ASTM D140 ...............Standard Practice for Sampling Bituminous Materials
ASTM D242 ................Standard Specification for Mineral Filler for Bituminous Paving
Mixtures
ASTM D402 ................Standard Test Method
(Bituminous) Products
for
Distillation
of
Cutback
Asphaltic
ASTM D546 ................Standard Test Method for Sieve Analysis of Mineral Filler for
Bituminous Paving Mixtures
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ASTM D946 ...............Standard Specification for Penetration Graded Asphalt Cement for
Use in Pavement Construction
ASTM D977 ................Standard Specification for Emulsified Asphalt
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ASTM D979 ................Standard Practice for Sampling Bituminous Paving Mixtures
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ASTM D995-95...........Standard Specification for Mixing Plants for Hot-Mixed, Hot-Laid

qa
ASTM D1188: ............Standard Test Method for Bulk Specific Gravity and Density of
Compacted Bituminous Mixtures Using Coated Samples
ASTM D2027 ..............Standard Specification for Cutback Asphalt (Medium-Curing Type)
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ASTM D2041 .............Standard Test Method for Theoretical Maximum Specific Gravity and
Density of Bituminous Paving Mixtures
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ASTM D2042 ..............Standard Test Method for Solubility of Asphalt Materials in

Trichloroethylene
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ASTM D2172 .............Standard Test Methods for Quantitative Extraction of Bitumen from
ASTM D2419 .............Standard Test Method for Sand Equivalent Value of Soils and Fine
Aggregate
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ASTM D2726 .............Standard Test Method for Bulk Specific Gravity and Density of Non
Absorptive Compacted Bituminous Mixtures
ASTM D2872 .............. Standard Test Method for Effect of Heat and Air on a Moving Film of
Asphalt (Rolling Thin Film Oven Test)
ASTM D2950 ..............Standard Test Method for Density of Bituminous Concrete in Place by
Nuclear Methods
ASTM D2995 ..............Standard Practice for Estimating Application Rate of Bituminous
Distributors
ASTM D3319 ..............Standard Practice for the Accelerated Polishing of Aggregates Using
the British Wheel
ASTM D3549 ..............Standard Test Method for Thickness or Height of Compacted
Bituminous Paving Mixture Specimens
ASTM D4318 .............Standard Test Methods for Liquid Limit, Plastic Limit, and Plasticity
Index of Soils
ASTM D4402 .............Standard Test Method for Viscosity Determination of Asphalt at
Elevated Temperatures Using a Rotational Viscometer
ASTM D4791 .............Standard Test Method for Flat Particles, Elongated Particles, or Flat
and Elongated Particles in Coarse Aggregate
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Part
05: Asphalt Works
Page 5
ASTM D5361 ..............Standard Practice for Sampling Compacted Bituminous Mixtures for
Laboratory Testing
ASTM D5444 ..............Standard Test Method for Mechanical Size Analysis of Extracted
Aggregate
ASTM D5546 .............Standard Test Method for Solubility of Asphalt Binders in Toluene by
Centrifuge
ASTM D5581 ..............Standard Test Method for Resistance to Plastic Flow of Bituminous
Mixtures Using Marshall Apparatus (6 inch-Diameter Specimen)
ASTM D5821 .............Standard Test Method for Determining the Percentage of Fractured
Particles in Coarse Aggregate
ASTM D6307 ..............Standard Test Method for Asphalt Content of Hot-Mix Asphalt by
Ignition Method
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ASTM D6373 ..............Standard Specification for Performance Graded Asphalt Binder
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ASTM D6521 .............Standard Practice for Accelerated Aging of Asphalt Binder Using a
Pressurized Aging Vessel (PAV)
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ASTM D6648 .............Standard Test Method for Determining the Flexural Creep Stiffness of
Asphalt Binder Using the Bending Beam Rheometer (BBR)
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ASTM D6723 ..............Standard Test Method for Determining the Fracture Properties of
Asphalt Binder in Direct Tension (DT)
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ASTM D6926 .............Standard Practice for Preparation of Bituminous Specimens Using

Marshall Apparatus
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ASTM D6927 ..............Standard Test Method for Marshall Stability and Flow of Bituminous
Mixtures
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ASTM D6931 ..............Standard Test Method for Indirect Tensile (IDT) Strength of
Bituminous Mixtures
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ASTM D7173 .............Standard Practice for Determining the Separation Tendency of

Polymer from Polymer Modified Asphalt
ASTM D7175 .............Standard Test Method for Determining the Rheological Properties of
Asphalt Binder Using a Dynamic Shear Rheometer
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ASTM D7405 .............Standard Test Method for Multiple Stress Creep and Recovery
(MSCR) of Asphalt Binder Using a Dynamic Shear Rheometer
ASTM E11 .................Standard Specification for Woven Wire Test Sieve Cloth and Test
Sieves
ASTM E274 ................Standard Test Method for Skid Resistance of Paved Surfaces Using a
Full-Scale Tire
ASTM E303 ................Standard Test Method for Measuring Surface Frictional Properties
Using the British Pendulum Tester
ASTM E950................. Standard Test Method for Measuring the Longitudinal Profile of
Travelled Surfaces with an Accelerometer Established Inertial Profiling
Reference
ASTM E965 ................Standard Test Method for Measuring Pavement Macrotexture Depth
Using a Volumetric Technique
ASTM E1926............... Standard Practice for Computing International Roughness Index of
Roads from Longitudinal Profile Measurements
AASHTO M82.............Standard Specification for Cutback Asphalt (Medium-Curing Type)
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Part
05: Asphalt Works
Page 6
AASHTO M92.............Standard Specification for Wire-Cloth Sieves for Testing Purposes

AASHTO M140...........Standard Specification for Emulsified Asphalt
AASHTO M208...........Standard Specification for Cationic Emulsified Asphalt (ASTM D239702)
AASHTO M320...........Standard Specification for Performance-Graded Asphalt Binder
AASHTO M332...........Standard Specification for Performance-Graded Asphalt Binder Using
Multiple Stress Creep Recovery (MSCR) Test, Single User Digital
Publication
AASHTO R28 .............Standard Practice for Accelerated Aging of Asphalt Binder Using a
Pressurized Aging Vessel (PAV)
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AASHTO R35 ............ Standard Practice for Superpave Volumetric Design for Hot-Mix Asphalt
(HMA)
AASHTO T44 .............Standard Method of Test for Solubility of Bituminous Materials
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AASHTO T48 .............Standard Method of Test for Flash and Fire Points by Cleveland Open
Cup
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AASHTO T240 ...........Standard Method of Test for Effect of Heat and Air on a Moving Film of
Asphalt Binder (Rolling Thin-Film Oven Test)
qa
AASHTO T313 ...........Standard Method of Test for Determining the Flexural Creep Stiffness
of Asphalt Binder Using the Bending Beam Rheometer (BBR)
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AASHTO T283 ........... Standard Method of Test for Resistance of Compacted Asphalt Mixtures
to Moisture-Induced Damage
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AASHTO T314 ...........Standard Method of Test for Determining the Fracture Properties of
Asphalt Binder in Direct Tension (DT)
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AASHTO T315 ...........Standard Method of Test for Determining the Rheological Properties of
Asphalt Binder Using a Dynamic Shear Rheometer (DSR)
AASHTO T316 ...........Standard Method of Test for Viscosity Determination of Asphalt Binder
Using Rotational Viscometer
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AASHTO T350 ...........Standard Method of Test for Multiple Stress Creep Recovery (MSCR)
Test of Asphalt Binder Using a Dynamic Shear Rheometer (DSR)
AASHTO PP60 ........... Standard Practice for Preparation of Cylindrical Performance Test
Specimens Using the Superpave Gyratory Compactor (SGC)
AASHTO PP61 .......... Standard Practice for Developing Dynamic Modulus Master Curves for
Hot Mix Asphalt (HMA) Using the Asphalt Mixture Performance Tester
(AMPT)
AASHTO TP79 .......... Standard Method of Test for Determining the Dynamic Modulus and
Flow Number for Hot Mix Asphalt (HMA) Using the Asphalt Mixture
Performance Tester (AMPT)
BS 812-110 ................Testing aggregates Methods for determination of aggregate crushing
value (ACV)
BS EN 12697-13 ........Bituminous mixtures. Test methods for hot mix asphalt. Temperature
measurement
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05: Asphalt Works
Page 7
Definitions
Base Course: One or more bituminous layers beneath Wearing Course and above the
unbound Road Base Layer. It usually consists of a mixture of aggregates and bituminous
materials and functions as a structural portion of pavement.
Wearing Course: Top surface bituminous course, which resists skidding, traffic abrasion, and
the disintegrating effects of climate.
5.1.4
Submittals
The Contractor shall submit for approval a proposed Job Mix Formula (JMF) together with all
applicable design data at least one month before beginning the work. The JMF shall give a
combined gradation showing a single definite percentage passing each sieve as well as a
percentage of each material to be used in the mix. The JMF shall also establish the mixing
and compaction temperature values and a compaction reference density. The Engineer will
test samples of the materials proposed for use in order to check their quality and to check the
proposed mix design. The Contractor shall report all the values obtained in the laboratory
design and shall submit these together with a copy of the plotted curves resulting from the
tests in an approved form to the Engineer. The Engineer may require verification of the
submitted design before giving approval. The Engineer shall approve the optimum binder
content based upon the design values submitted by the Contractor and shall notify the
Contractor of the value. No asphalt works will be allowed to commence before the
Contractor receives written approval from the Engineer for his JMF.
The asphalt mix design submission shall include a copy of valid calibration certificates from a
calibration service agency approved by the Laboratories and Standardization Affairs (LSA) for
the batching plant and the relevant laboratory equipment such as but not limited to balances,
proving rings, and load devices. Approval certificates for mix designs will not be issued if the
above requirements have not been complied with.
Based on the Engineer request, the Contractor shall submit the pertinent certifications of
materials, equipment, plants, personnel and processes in relation to the project. Certificates
must be issued by a competent authority approved by the Engineer.
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5.1.3
(a)
Bituminous and asphalt materials production, storage, transportation, identification and

marking procedure and traceability to source of production.
(b)
Quality assurance and quality control plans for laying, compaction and all construction
activities.
(c)
(d)
Equipment and its suitability to fulfil all construction activities to the required quality.
(e)
(f)
The Contractor shall provide the Engineer with a complete report on the origin and
composition of all stone and/or gravel aggregates to be used in the work (Aggregate
Resources Report). All materials shall comply with the specified requirements for the various
aggregates.
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Page 8
Delivery of materials produced from commercial manufacturing process shall be

accompanied by the manufacturers certification and test reports from local approved
laboratory showing the materials compliance with the specification for which it is stipulated.
After receiving the approval of specific sources of material the Contractor cannot change
these sources without prior written approval of the Engineer.
5.1.5
Quality Assurance
The Contractor shall notify the Engineer of the sources of materials and the Engineer shall
approve the sources. All materials shall be tested and approved before use.
Where the quality of material from a source of material does not comply with the designated
requirements, the Contractor shall furnish material that does comply from other sources.
Delivery of materials produced from commercial manufacturing processes shall be
accompanied by the manufacturer's certification and test report showing that the materials
comply with the designated requirements.
No change shall be permitted in the source of any of the materials until the technical
submissions listed in the specification have been made and approved by the Engineer.
All processed materials shall be tested and approved before being stored at the site or
incorporated in the works and may be inspected and tested at any time during the progress
of their preparation and use. Questionable materials, pending laboratory testing subsequent
approval shall not be unloaded and incorporated with materials previously approved and
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accepted.
It is the full responsibility of both the asphalt mixture producer and the Contractor to obtain a
certificate which proves that the asphalt binder complies with the specifications. Furthermore,
both the asphalt mixture producer and the Contractor shall perform all the required tests in an
approved private laboratory to make sure that the asphalt binder being purchased complies
with the specifications. The LSA will, at any time, take samples from the asphalt mixtures
producers plants and test them as part of its quality practice.
5.2
MATERIALS
5.2.1
Unacceptable Materials
Materials that do not conform to the designated requirements shall be rejected and
immediately removed from the site of the works unless otherwise instructed by the Engineer.
No rejected material, the defects of which have been corrected, shall be used until approval
has been given by the Engineer.
Bituminous paving courses shall consist of coarse aggregate, fine aggregate, filler material,
and bitumen binder. Mixture of two different types of rocks, e.g. igneous and sedimentary
having different engineering properties shall not be permitted.
During execution of works, variations in the specific gravity of any individual fraction of
aggregates used in the asphalt mixes by more than 1% shall cause the Engineer to request
for evaluation of aggregates consistency and compliance and/or mix design validation.
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05: Asphalt Works
Page 9
Fine Aggregate
Fine aggregate is that portion of the mineral aggregate passing the 2.36mm ASTM sieve for
the Marshall mix design and passing the 4.75mm sieve for the Superpave mix design.
Fine aggregate shall consist of crushed hard durable rock and shall be of such gradation that
when combined with other aggregates in proper proportions, the resultant mixture will meet
the required gradation. Fine aggregate shall be non-plastic and chemically stable.
The source of natural fine aggregate is considered to be the crusher site at which it is
produced. Crushed fine aggregate shall be produced by crushing clean coarse aggregate
and shall not be thin, flaky or elongated. Sampling of fine aggregate shall be in accordance
with ASTM D75.
Fine aggregate shall be clean and free from organic matter, clay, cemented particles and
other extraneous or detrimental materials.
Unless permitted elsewhere in the contract, the aggregate type for wearing course shall be
Gabbro. The aggregate type for Base Course shall be either Gabbro or Limestone.
The Contractor shall ensure that the sources of all fine aggregates have been approved by
the Municipality concerned.
The specifications of fine aggregates for asphalt mixtures are listed in Table 5.1.
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5.2.2
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Table 5.1
Fine Aggregate Specifications for Marshall Mixes
Standard
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Parameter
Plasticity index
Sand equivalent value
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ASTM D 4318
4% max.
Minimum Frequency
(stockpile)
Non Plastic (hot bins)

45% min.
- Each source
ASTM C88
18% max.
Acid soluble chloride content
- Visible change in
material
BS 1377 Part 3
0.1% max.
Acid soluble sulphate content
BS 1377 Part 3
0.5% max.
Clay lumps and friable particles
ASTM C142
None
Organic Impurities
ASTM C40
No Impurities
ASTM D2419
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Soundness by magnesium
sulphate
5.2.3
Coarse Aggregate
Coarse aggregate is that portion of the mineral aggregate retained on the 2.36mm ASTM
sieve for the Marshall mix design and retained on the 4.75mm ASTM sieve for the
Superpave mix design. Coarse aggregate shall consist of crushed natural stones and gravel.
Crushed particles shall be cubic and angular in shape and shall not be thin, flaky or
elongated. The gradation shall be such that when combined with other aggregate fraction in
proper proportions, the resultant mixture will meet the required gradation.
The source of crushed aggregate is considered to be the crushing site from which it is
produced. Sampling of coarse aggregate shall be in accordance with ASTM D75.
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Page 10
Coarse aggregate shall be clean and free from organic matter, clay, cemented particles and
other extraneous or detrimental material.
The specifications of coarse and combined aggregates for asphalt mixtures are listed in
Table 5.2.
Unless permitted elsewhere in the contract, the aggregate type for wearing course shall be
Gabbro. The aggregate type for Base Course shall be either Gabbro or Limestone.
If directed by the Engineer, the polished stone value (PSV) should be determined for wearing
course aggregates of main lane as per ASTM D3319. The PSV shall not be less than 45.
5.2.4
Recycled Aggregate
Recycled aggregate produced from excavating natural ground can be used in asphalt
mixtures for temporary roads and for roads, which serve agricultural areas provided that the
specifications stated in Section 6 - Part 9 are complied.
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Water absorption
Aggregate Crushing
Value (ACV)
100% min.
85% min.
85% min.
85% min.
ASTM D4791
15 % max.
15% max.
10 % max.
- Visible change
in material
ASTM C88
15 % max.
15% max.
10 % max.
- 1 test every
3
2000m
30% max.
30% max.
25% max.
2.0% max.
2.0% max.
1.5% max.
25 % max.
25 % max.
20% max.
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ASTM C131
ASTM C535
ASTM C127
BS 812
Part 110
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Los Angeles Abrasion
100% min.
- Each source
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Flat and Elongated

Particles (5:1)
Soundness
(5 cycles by MgSO4)
100% min.
Minimum
Frequency
Table 5.7, Job Mix gradation and Table

5.10 tolerances
ASTM C136
Gradation (Combined)
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One or more Fractured

ASTM D5821
Faces
1
Two or more Fractured
ASTM D5821
Faces
Base Course Base Course Wearing
(Class A)
(Class B)
Course
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Parameter
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Table 5.2
Coarse and Combined Aggregate Specifications for Marshall Mixes
Higher values can be recommended by the engineer based on the design ESAL.
5.2.5
Mineral Filler
Mineral filler when separately supplied from an external source shall consist of finely ground
mineral matter in accordance with ASTM D242 such as rock dust, hydrated lime, cement or
other material which can satisfy the Engineer will produce asphalt mixes of at least equal
quality. It shall be free from organic substances and clay, shall be thoroughly dry and free
from agglomerations, shall be non-plastic and shall meet the grading requirements shown in
Table 5.3.
Hydrated lime shall conform to the definitions given in ASTM C51. Sampling, packaging and
marking of hydrated lime shall be in accordance with ASTM C50. Storage and use of the
hydrated lime shall at all times be such as to protect the material from the weather.
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Table 5.3
ASTM Sieve
% Mass Passing
600 m
100
300 m
95 - 100
150 m
90 100
75 m
70 100
The grading of mineral filler shall be carried out in accordance with ASTM D546.
When cement is used as mineral filler, it shall meet the requirements of ASTM C150.
5.2.6
Asphalt Binder
The asphalt binder specified for use in the asphalt mixes shall be either of the following:
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Penetration grade 60-70: This binder type shall be graded in accordance with ASTM
D946. The 60-70 binder specifications are listed in Table 5.4. Sampling shall be in
accordance with ASTM D140. The 60-70 penetration graded binder is generally
equivalent to PG 64-10 performance graded binder.
(b)
PG 76-10: Based on the Engineer approval, the PG76-10 binder can be used in
asphalt mixes. This binder type shall be a polymer-modified binder (PMB) meeting
AASHTO M320 and ASTM D6373 specifications in addition to separation test criteria
as listed in Table 5.5. Sampling shall be in accordance with ASTM D140.
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(a)
Prior to the commencement of the mix design, the Contractor shall provide a certificate
indicating conformance of binder with the specifications stated above. This certificate shall be
obtained from an approved laboratory.
The asphalt binder shall be prepared by the refining of petroleum and shall be uniform in
character. Blending of asphalt binders from different refineries will be permitted only with the
written approval of the Engineer.
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Table 5.4
Specifications of Bitumen Penetration Grade 60 70
60 70 Pen
Parameter
Standard
Minimum Frequency
Min.
Max.
Penetration (0.1 mm) at 25C
- Each source
ASTM D5
60
70
-100g, 5 Sec
Softening Point Ring & Ball
- 1 test per 75t of asphalt
ASTM D36
46
Apparatus, C
binder per layer
Flash Point, Cleveland Open
Cup, C
ASTM D92
230
Ductility at 25 C, cm
ASTM D113
100
Solubility Trichloroethylene, %
ASTM D2042
99
Loss on heating, %
ASTM D6
0.2
Penetration of Residue of
original after TFOT, %
ASTM D5
52
ASTM D113
50
Ductility of Residue after

TFOT at 25 C, 5cm/min, cm
- Each source
- 1 test per 450t of asphalt
binder per layer
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Table 5.5
Specifications of Performance Graded Binders / Polymer Modified Binders (PMB)
Standard
Specification
AASHTO ASTM
Tests on Original Binder
Average 7 days maximum pavement
< 76
o
design temperature, ( C)
Minimum pavement design
>-10
o
temperature,( C)
o
Flash Point Temperature, Minimum ( C)
T48
D92
230
Rotational Viscosity, Maximum 3 Pa.s,
T316
D4402
135
o
Test Temperature ( C)
Dynamic Shear, G*/sin, Minimum, 1.00
T315
D7175
76
o
kPa , Test Temperature ( C) at 10 rad/s
Solubility, min, %
T44
D5546
99
1
Separation Test: Absolute Difference
o
D7173
20
between G* @ 76 C and 10 rad/s of Top
and Bottom Specimens, Maximum, %
Requirements of the Rolling Thin Film Oven Residue ( T240 / D2872)
Mass Loss, Maximum, Percent
T240
D2872
1
Dynamic Shear, G*/sin, Minimum, 2.20
T315
D7175
76
o
Pressure Aging Vessel Residue (D6521 / R28)
o
PAV Aging Temperature , ( C)
R28
D6521
110
Dynamic Shear, G*.sin, Maximum 5000
T315
D7175
37
o
Creep Stiffness, S, Maximum 300 MPa
and m-value, Minimum 0.300 at 60
T313
D6648
0
o
seconds , Test Temperature ( C)
2
Direct Tension , Failure Strain, Minimum,
T314
D6723
0
1.0% (loading rate of 1.0 mm/min),Test
o
Temperature( C)
Minimum
Frequency
Parameter
- Each source
- Visible change in
material
- Each source
- Visible change in
material
- 1 test per 450t of
asphalt binder per
layer
Absolute Difference = Abs(100x(top-bottom)/top).

If the creep stiffness is below 300 MPa, the direct tension test is not required. If the creep stiffness is
between 300 and 600 MPa, the direct tension failure strain requirement can be used in lieu of the creep
stiffness requirement. The m-value requirement must be satisfied both cases.
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- 1 test per 450t of

asphalt binder per
layer
Based on the Engineer approval, when bitumen grades PG76-10 H, V or E are specified for
heavy, very heavy, and extra heavy loading, the bitumen shall meet the requirements of
AASHTO M332 and will be required to indicate elastic response in percent recovery when
tested in accordance with AASHTO T350 / ASTM D7405.
Binders modified using Crumb Rubber and other binders containing particulate materials,
which are graded according to AASHTO M320 and/or AASHTO M332, shall not include
particles with longest dimensions of more than 250m. In addition, the requirements listed in
Table 5.5 shall be satisfied.
QCS 2014

Part
05: Asphalt Works
Page 13
Prime Coat
Liquid asphalt for use as prime coat shall be MC-70 medium curing cutback asphalt in
accordance with ASTM D2027 or AASHTO M82.
The prime coat shall be a cutback consisting of a 60/70 penetration grade bitumen and
kerosene. The residue from the distillation test, carried out to 360 C in accordance with
ASTM D402, shall be a minimum of 55 % (by volume), as determined by the difference
method. Sampling shall be in accordance with ASTM D140. One sample shall be tested
every 5 tons.
5.2.8
Tack Coat
Emulsified asphalt for use as tack coat in asphalt works may be CSS 1h or CRS-2 cationic
emulsified asphalt in accordance with AASHTO M 208 or SS 1h anionic emulsified asphalt in
accordance with ASTM D977 or AASHTO M140 unless otherwise designated.
Emulsified asphalt shall be of the slow-setting cationic or anionic type of the CSS-1h or SS1h grades respectively and shall conform to the designated requirements. Sampling shall be
in accordance with ASTM D140. One sample shall be tested every 5 tons.
5.2.9
Materials shall be so stored and handled as to assure the preservation of their quality and
fitness for use. Materials, even though approved before storage or handling, may again be
inspected and tested before use in the Works.
Stored material shall be located so as to facilitate their prompt inspection. All storage
locations on land not owned by the Contractor shall be restored to their original condition at
the Contractor's expense.
Handling and stockpiling of aggregates shall at all times be such as to eliminate segregation
or contamination of the various sizes and to prevent contamination of materials by dust.
Stockpiles shall be kept flat and the formation of high cone-shaped piles shall not be
permitted. When conveyor belts are used for stockpiling aggregates, the Engineer may
require the use of baffle-chutes or perforated chimneys.
Where trucks are used to construct stockpiles, the stockpiles shall be constructed one layer
at a time with trucks depositing their loads as close to the previous load as possible. The use
of tractors or loaders to push material deposited at one location to another location in the
stockpile shall not be allowed during the construction of the stockpile, and their use shall be
limited to levelling the deposited material only.
Stockpiles of aggregate located at permanent asphalt plant sites shall be separated by bin
walls and shall be constructed on asphalt or concrete floors. Stockpile locations and
procedures at temporary asphalt plant sites shall be as approved by the Engineer.
Intermediate storage of hydrated lime and commercial mineral filler for equipment feeding the
asphalt plant shall be silos of adequate size to ensure a minimum of one day's continuous
operation.
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5.2.7
QCS 2014

Part
05: Asphalt Works
Page 14
Inspection and Control
For verification of weights and measures, character of materials and determination of

temperatures used in the preparation of the asphalt mixes, the Engineer shall at all times
have access to all portions of the mixing plant, aggregate plant, storage yards, crushers and
other facilities used for producing and processing the materials of construction.
The Engineer shall have authority to instruct sampling and testing of any material supplied to
the site from any source whatsoever in order to establish their compliance and to accept or
reject as he deems necessary. Samples shall also be taken from completed work to
determine compliance. The frequency of all sampling and testing shall be as designated.
The Contractor shall arrange for obtaining specimens of materials, asphalt mixes and
samples cut from the paving courses after compaction, including the provision of necessary
equipment and plant for obtaining these specimens and samples. This work shall be
performed in the presence of the Engineer. The Engineer shall take possession of the
samples upon their removal from the roadway unless the Contractor is authorised otherwise
In particular, the Contractor shall provide a portable coring machine and bits for taking 150
mm diameter full depth cores of all bituminous paving courses. The coring machine shall be
available to the Engineer upon request.
In addition to the foregoing, one set of three laboratory compacted specimens and one
uncompacted coated sample for each mix type and mixer plant for each days production,
shall be delivered to LSA no later than 12 hours after compaction of the specimens together
with the mix type and project details.
Upon the first erection of the batching plant and at least once every three months thereafter,
the plant shall be calibrated by a calibration service organisation approved by the LSA.
5.3
MARSHALL MIX DESIGN
5.3.1
General
The types of bituminous paving mixes shall be as designated on the project drawings or in
the contract documents.
The LSA shall act as the engineer for the approval of asphalt mix designs and materials
submitted by the Contractor.
The contractor shall prepare the mix design with all necessary supporting documentation
which shall include the results of the Contractors own laboratory procedures.
The Contractor shall carry out a trial batching and trial laying of the particular mix design.
The testing and sampling of the mix design by the LSA will take place for both the laboratory
verification and the trial batching and laying.
Based on the results of the trial batching and laying the contractor may be required to make
amendments to the mix design. Providing the mix design conforms to the specification the
mix shall be approved by the LSA.
The LSA shall issue a certification for the job standard mix to the Contractor.
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5.2.10
QCS 2014

Part
05: Asphalt Works
Page 15
The approved Job Mix Formula may be amended as a result of experience in the execution
and performance of the permanent asphalt works. Such an amendment may be submitted by
the Contractor for the Engineer's approval in which case the Contractor shall submit full
details of the proposed amendment together with such data as is necessary to support his
submittal. Amendment may also be directed by the Engineer.
Approval by the Engineer of the Job Mix Formula or amendments thereto shall in no way
relieve the Contractor of his obligations under the Contract, and the Contractor shall be
responsible for the soundness of the asphalt paving mixes and the satisfactory execution and
performance of the asphalt paving courses.
5.3.2
Marshall Mix Design Criteria
The Asphalt Institute MS-2 Mix Design Methods for Asphalt Concrete and Other Hot-Mix
Types shall be used in designing the bituminous mixtures using Marshall design method.
The recommended compacted layer thicknesses are shown in Table 5.6.
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80 to 100 mm
60 to 80 mm
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Base Course
(Class B)
Wearing
Course(WC)
45 to 55 mm
When tested according to ASTM C136, the combined mineral aggregate shall conform to
Table 5.7 for asphalt concrete mixes.
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Base Course
(Class A)
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Table 5.6
Recommended Compacted Layer Thicknesses
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Table 5.7
Combined Aggregate Gradation for Asphalt Concrete Marshall Design Mixes
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ASTM Sieve Size
37.5 mm
25.0 mm
19.0 mm
12.5 mm
9.5 mm
4.75 mm
2.36 mm
0.850 mm
0.425 mm
0.180 mm
0.075 mm
Percentage Passing (By Weight)
Base Course
(Class A)
100
80 - 100
62 - 92
45 - 75
30 - 55
20 - 40
15 - 30
10 - 226 - 15
2-8
Base Course
(Class B)
100
80 - 100
63 - 85
57 - 77
40 - 60
25 - 45
15 - 30
10 - 22
6 - 15
2-8
Wearing Course
100
86-100
69 - 87
58 - 78
40 - 60
25 - 45
15 - 30
10 - 22
6 - 15
2-8
The "Laboratory Designed Mixture" for all types of bituminous coated courses shall comply
with the requirements given in Table 5.8. Note that any deviation from these requirements
shall be approved by LSA.
QCS 2014

Part
05: Asphalt Works
Page 16
Table 5.8
Design Criteria for Marshall Design Mixes
Base Course
(Class A)
Aggregate Properties
Flow (mm)
Marshall Quotient (Stability/Flow)
(kN/mm)
75
75
75
3.2 4.4
3.4 4.4
3.4 4.4
9.5 min.
9.5 min.
11.5 min.
2 to 4
2 to 4
2 to 4
4.75 min.
4.75 min.
4.75 min.
4 to 8
4.5 to 8
Voids in Mix (Air Voids) (%)

Voids in Mineral Aggregate VMA (%)
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3.2 min.
50 to 75
75 min.
0.8 to 1.5
50 to 75
ta
50 to 70
Voids in Marshall Specimen at 400

Blows per face at optimum binder
content (%)
Retained Stability (%)
(Filler/Binder) Ratio
5 to 8
Table No.5.9
as
Voids Filled with Asphalt VFA (%)
Stability minimum (kN)
Table 5.7
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Aggregate Grading
Number of Compaction blows at each
end of specimen (see paragraph 5)
Binder Content (% of total mix)
inclusive of tolerances
Base Course
Wearing Course
(Class B)
Tables 5.1 and 5.2
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Parameter
3.4 min.
4.0 min.
75 min.
0.8 to 1.5
75 min.
0.75 to 1.35
Note: Relevant ASTM standards shall be used for testing.
Base Course (Class B) and Wearing Course samples shall be prepared and tested using
Marshall apparatus in accordance with ASTM D6926 and ASTM D6927, respectively, while
Base Course (Class A) samples shall be prepared and tested in accordance with ASTM
D5581. However, based on the Engineer approval, samples having aggregate sizes larger
than 25mm can be prepared and tested according to ASTM D6926 and ASTM D6927 by
substituting all aggregate sizes over 25mm with an equal weight of aggregate sizes in the
next lower grading sizes.
Upon the request of the Engineer, the Tensile Strength Ratio (TSR) in accordance with
ASTM D6931 shall be obtained for the mix for quality control purposes. The TSR acceptance
limits shall be determined at mix design stage and approved by the Engineer.
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Table 5.9
Minimum Percent Voids in Mineral Aggregate (VMA)
Minimum VMA, Percent
Nominal Maximum
1, 2
Particle Size (mm)
1.18
2.36
4.75
9.5
12.5
19.0
25.0
37.5
50
63
Design Air Voids, Percent

3.0
21.5
19.0
16.0
14.0
13.0
12.0
11.0
10.0
9.5
9.0
4.0
22.5
20.0
17.0
15.0
14.0
13.0
12.0
11.0
10.5
10.0
5.0
23.5
21.0
18.0
16.0
15.0
14.0
13.0
12.0
11.5
11.0
QCS 2014

Part
05: Asphalt Works
Page 17
Standard Specification for Wire Cloth Sieves for Testing Purposes, ASTM E11 (AASHTO M92).
The nominal maximum particle size larger than the first sieve to retain more than 10 percent.
3
Interpolate minimum voids in the mineral aggregate (VMA) for design air voids values between
those listed.
2
After the Job Mix Formula has been established and approved, all mixes furnished shall
conform thereto within the following tolerances:
Table 5.10
Base Course
(Class A)
Base Course
(Class B)
Wearing
Courses
Aggregate retained on 4.75mm sieve

or larger
5%
4%
4%
Aggregate passing 4.75mm sieve

and retained on 850m sieve
4%
3%
3%
Aggregate passing 850m sieve and

retained on 75m sieve
3%
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Job Mix Tolerances For Field Mixtures
2%
2%
1.0%
1.0%
0.2%
0.2%
Binder Content
0.3%
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1.5%
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Description
The Job Standard Mix Density shall be obtained by making six standard Marshall specimens
from samples of the approved Job Standard Mixture determining the bulk specific gravity of
each and comparing them with the mean value of the six. Any individual result which differs
from the mean by more than 0.015 shall be rejected, and provided that not more than two
results are so rejected the mean of the remaining result shall be designated the Job
Standard Mixture Density. The absolute density shall be considered as the theoretical
specific gravity calculated in accordance with ASTM D2041.
5.3.3
Quality Control Testing
The Contractor shall submit a testing plan to the Engineer for approval that demonstrates
how he shall prove compliance with the requirements for compaction, mix composition, level,
evenness and all other requirements of Section 6. Each lot shall be approved by the
Engineer before placing any subsequent asphalt concrete course. In cases where the asphalt
course is laid in more than one layer, each layer shall be tested and approved before placing
the subsequent asphalt concrete layer.
In addition to the following requirements one set of three laboratory-compacted specimens

and one uncompacted coated sample for each mix type and mixer plant for each days
production shall be delivered to the LSA no later than 12 h after compaction of the
specimens. Details of compaction date, time and temperature of mix shall be provided with
the specimens together with mix type and project details.
The Contractor shall cut samples from each completed asphalt course during the progress of
the work and before final acceptance as directed by the Engineer. The Engineer shall
determine the location of the samples.
When testing for compaction at joints the edge of the core shall not be more than 50 mm or
less than 25 mm from the joint.
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QCS 2014

Part
05: Asphalt Works
Page 18
Compacted samples shall be taken by coring in accordance with ASTM D5361, for testing by
an approved laboratory. The core diameter shall be 150 mm. where the Contractor fails to
provide cores as required by the Engineer, the Engineer may arrange for the taking of cores
on behalf of the Contractor at his cost. Samples shall be taken of the asphalt mix for the full
depth of the course. A sample shall comprise a pair of adjacent cores and the average
density of these shall be the density of the sample.
Whenever deficiencies are noted in loose mix samples or core samples, the Engineer may
direct the taking of additional cores at the Contractor's expense in order to define the area of
pavement involved.
Hot asphalt mix of the same type shall be placed and compacted in holes left by sampling.
The mixture shall be compacted to the percentage compaction required for the layer using a
vibrating hammer.
Quality control testing of the asphalt mixtures during construction shall follow the frequencies
shown in Table 5.12 for Marshall Mixtures:
Base Course (Class B) and Wearing Course samples shall be prepared and tested using
Marshall apparatus in accordance with ASTM D6926 and ASTM D6927, respectively, while
Base Course (Class A) samples shall be prepared and tested in accordance with ASTM
D5581. However, based on the Engineer approval, samples having aggregate sizes larger
than 25mm can be prepared and tested according to ASTM D6926 and ASTM D6927 by
substituting all aggregate sizes over 25mm with an equal weight of aggregate sizes in the
next lower grading sizes.
10
Upon the request of the Engineer, the Tensile Strength Ratio (TSR) in accordance with
ASTM D6931 shall be tested for quality control purposes. The TSR acceptance limits shall be
based on the mix design obtained limits approved by the Engineer.
11
If it appears from the analysis of samples of loose mix or cores that the asphalt content or
aggregate gradation are beyond the permissible tolerances specified for the Job Mix Formula
(established for each respective asphalt course mix) and that, such variation affects the
characteristics of the asphalt mix conformity to the designated requirements is concerned,
this shall be considered a major defect in the work. The portion of the asphalt course
represented by these samples shall be rejected.
12
The density of the compacted mixes shall be related to the daily Marshall density determined
by making minimum four Marshall specimens from samples collected from behind the paver.
The density of each sample shall be determined and compared with the mean value. Any
3
individual result, which varies from the mean by more than 0.015gm/cm shall be rejected.
The daily Marshall density shall not differ from the Job Mix Design Density by more than
1.0%.
13
The field density, as determined from each core sample and related to the daily Marshall
Density, obtained as shown above, shall be as follows:
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Table 5.11
Layer
Relative Density (%)
Base Course
Wearing Course
97 101.8
98 101.8
QCS 2014

Part
05: Asphalt Works
Page 19
14
The finished road surface shall be inspected visually techniques and if directed by the
Engineer the structural ability of the pavement in terms of layer modulus shall be assessed
by using the Falling Weight Deflectometer (FWD) and Light weight Deflectometer (LWD).
15
For safety purposes the pavement surface friction shall be measured by the pendulum
portable tester or locked wheel tester in accordance with ASTM E303.
Table 5.12
Quality Control Testing of the Marshall Mixtures
Item / Parameter
Standard
Aggregate conformance
Minimum Frequency
Sections 5.2.1, 5.2.2 and 5.2.3

Section 5.2.5
Every 300t
Section 5.2.7
Tack Coat conformance
Section 5.2.8
Asphalt Binder conformance
Section 5.2.6
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Prime Coat conformance
Mineral Filler conformance
Rate of application for Tack Coat
ASTM D2995
Sampling of bituminous mixtures
ASTM D979
BS EN 12697
Part 13
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ASTM D2726
3
ASTM D1188
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Daily Bulk density (See paragraph 12)
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Binder content
Gradation of extracted aggregates
Marshall Stability, Flow and

Stability/Flow Ratio
Voids in mineral aggregate (VMA)

Voids filled with asphalt (VFA)
Voids in Marshall Specimen at 400
Blows per face at optimum binder
content (%)
(Filler/Binder) Ratio
In-place air voids
10 C of JMF
temperature in truck
135 C min. at paver
120 C min. prior
rolling
1.0% of Job
Standard Density
Table 5.7, Job Mix
gradation and Table
5.10 tolerances
Job Mix value with
Table 5.10 tolerances
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Temperature of bituminous mixture
0.45 0.75 kg/m

at 60 85 C
2
0.15 0.38 kg/m
at 10 60 C
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ASTM D2995
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Rate of application for Prime Coat
ASTM D5444
ASTM C117
ASTM D2172
ASTM D6307
ASTM D6927
4
ASTM D5581
ASTM C127
ASTM C128
2
ASTM D2726
3
ASTM D1188
ASTM D2041
2
ASTM D2726
3
ASTM D1188
Table 5.8
Table 5.9
Table 5.8
- 1 per 250 m
- 1 every 75m per
lane
Test based
Each truck
Daily
- Each source
- Visible change in
material
- 1 test per 300t per
layer for Base
Course
layer for Wearing
Course
ASTM D2172
ASTM D6307
ASTM C136
ASTM D2041
2
ASTM D2726
3
ASTM D1188
5 8%

layer for Base
Course
layer for Wearing
Course
QCS 2014

Part
05: Asphalt Works
Item / Parameter
Retained Stability (%) (Paragraph 16)
Field density (nuclear gauge)
Field density (2 cores)
Page 20
Standard
ASTM D6927
4
ASTM D5581
75 min.
ASTM D2950
Table 5.11
ASTM D5361
2
ASTM D2726
3
ASTM D1188
ASTM D5361
ASTM D3549
Thickness
Minimum Frequency
1 test per 3000t per
layer
At 50m intervals in
alternate wheel tracks
layer for Base Course
layer for Wearing
Course
Table 5.11
Section 5.11.1
Evenness of surface
Section 5.11.2 & 5.11.3
As per polymer manufacturer recommendation and mix design for polymer modified binders
If water absorption 2%
3
If water absorption > 2%
4
For samples containing more than 25mm size aggregates
5
For acceptance of in-situ compaction
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The Retained Stability is the percentage of the average stability of 3 samples conditioned for
24 hours at 60 1C water bath and the average stability of 3 samples conditioned for 4
hours in 60 1C air bath. These two sets of samples shall be prepared at the optimum
binder content by applying 75 blows and kept at ambient temperature for 17 20 hours and
shall have similar average densities.
17
Each day the produced mixes shall be tested for checking their compliance with the approved
Job Standard Mix criteria. When unsatisfactory results or changed conditions make it
necessary, a new job-standard following approval of new mix design shall be established.
5.4
DENSE BITUMEN MACADAM
The mix properties for Dense Bitumen Macadam are listed in Table 5.13.
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Table 5.13
Properties of Mix for Dense Bitumen Macadam
Parameter
Number of Compaction blows at each end of specimen
75
75
3.2 4.0
3.5 4.1
7.5
10.0
2-4
24
3.7
4.9
7 - 11
69
Voids in Mineral Aggregate VMA (%)
14 - 20
14 - 20
Binder Content (% of total mix) inclusive of tolerances
Stability minimum (kN)

Flow (mm)
Marshall Quotient (Stability/Flow) (kN/mm), min
Base
Wearing
Course
Course
Voids Filled with Asphalt VFA (%)
47 - 60
48 - 60
Retained stability
75 min.
75 min.
When tested according to ASTM C136, the combined mineral aggregate shall conform to
Tables 5.14, 5.15 and 5.16.
QCS 2014

Part
05: Asphalt Works
Page 21
Table 5.14
Aggregate Gradation for Dense Bitumen Macadam Road Base (Unbound)
B.S Sieve
(mm)
50.0 mm
37.5 mm
28.0 mm
14.0 mm
6.3 mm
3.35 mm
0.300 mm
0.075 mm
Aggregate, Crushed Rock or Gravel

Percentage by mass passing
100
95 - 100
70 - 94
56 - 76
44 - 60
32 - 46
7 - 21
2- 8

Percentage by Mass Passing for Finished Thickness of Base Course
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70 - 90 mm
100
95 - 100
71 - 95
58 - 82
44 - 60
32 - 46
7 - 21
2 - 8
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50.0
37.5
28.0
20.0
14.0
10.0
6.3
3.35
0.300
0.075
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80 - 100 mm
100
95 - 100
70 - 94
56 - 76
44 - 60
32 - 46
7 - 21
2 - 8
as
B.S Sieve
(mm)
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Table 5.15
Aggregate Gradation for Dense Bitumen Macadam Asphalt Base Course
50 - 70 mm
100
95 - 100
65 - 85
52 - 72
39 - 55
32 - 46
7 - 21
2 - 8
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Table 5.16
Aggregate Gradation for Dense Bitumen Macadam Asphalt Wearing Course
B.S Sieve
(mm)
28.0
20.0
14.0
10.0
6.3
3.35
1.18
0.075

Percentage by Mass Passing for Finished Thickness of Wearing Course
50 - 60 mm
100
95 - 100
70 - 90
55 - 75
40 - 60
25 - 40
15 - 30
2 - 6
40 - 50 mm
100
95 - 100
70 - 90
45 - 65
30 - 45
15 - 30
2 - 6
30 - 40 mm
100
95 - 100
55 - 75
30 - 45
15 - 30
2 - 6
QCS 2014

Part
05: Asphalt Works
Page 22
SUPERPAVE MIX DESIGN
Based on the Engineer approval, the Superpave Mix Design Method can be used to design
the asphalt mixtures for Wearing Course and Base Course layers. The design of the
Superpave asphalt mixtures shall follow the method outlined in AASHTO R35 and SP-2
Asphalt Institute Superpave Mix Design Method in liaison with LSA.
The contractor shall prepare the mix design with all necessary supporting documentation
which shall include materials production and handling specifications, plant quality procedures,
construction quality control and quality assurance procedures, quality control tests, mix
acceptance criteria and performance evaluation testing program. All documentations shall be
submitted to LSA for review and approval.
Based on the Engineer approval, the PG76-10 binder can be used in asphalt mixes. This
binder type shall be a polymer-modified binder (PMB) meeting AASHTO M320 and ASTM
D6373 specifications and the criteria listed in Table 5.5.
Based on the Engineer approval, when bitumen grades PG76-10 H, V or E are specified for
heavy, very heavy, and extra heavy loading, the bitumen shall meet the requirements of
AASHTO M332 and will be required to indicate elastic response in percent recovery when
tested in accordance with AASHTO T350.
Based on the Engineer approval, the guidelines shown in the Appendix can be used for the
mix design. Note that software (ePAVE3) shall be validated prior use.
The recent editions of the references shown in the Appendix are recommended to be used
for preparation of mix design and quality control schemes.
Table 5.17 can be used as a guide for sampling and testing frequency for quality control of
Superpave mixtures.
Performance tests shown in Table 5.18 can be used to evaluate performance of Superpave
asphalt concrete mixtures.
Before producing bituminous concrete mixtures, the Contractor shall submit in writing to the
Engineer for approval, detailed information for each mix which he proposes to furnish. The
information shall include, but not be limited to the following:
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5.5
(a)
Copy of mix certificate approval obtained from LSA and the mix design report.
(b)
The source(s) of the aggregate for each mix as well as the pertinent test data and a
written certification that the aggregates conform to all of the quality requirements.
(c)
Type of Asphalt modifier intended to be used in the project along with the Certificate of
Conformity of the modified asphalt binder to the required grade according to the
Superpave Performance Based Grading System.
(d)
Pertinent test data on the type and properties of the aggregates, asphalt binder,
modified asphalt binder, mineral filler, and chemical admixtures/asphalt modifiers to be
furnished.
(e)
The type and location of plant to be used for mixing each mix.
(f)
Any other support data and information special to the project (e.g. technical data
sheets of a polymer in case it was used).
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Table 5.17
Sampling and Testing Frequency of Superpave Field Mixtures
Item / Parameter
Standard
Specification
Minimum Frequency
Aggregate Conformance
Sections 5.2.1, 5.2.2, 5.2.3 and Table 6 - Appendix
Mineral Filler conformance
Section 5.2.5
Every 300t
Prime Coat conformance
Section 5.2.7
Tack Coat conformance
Section 5.2.8
Asphalt Binder conformance
Section 5.2.6
2
0.45 0.75 kg/m
2
Rate of application for Prime Coat
ASTM D2995
- 1 per 250 m
at 60 85 C
- 1 every 75m per
2
0.15 0.38 kg/m
lane
Rate of application for Tack Coat
ASTM D2995
at 10 60 C
Sampling of bituminous mixtures
ASTM D979
Test based
10 C of JMF
temperature in truck
Min. JMF compaction
BS EN 12697
temperature +20 C at
Temperature of bituminous mixture
Each truck
Part 13
paver
Min. JMF compaction
temperature prior rolling
(sec. 1.5.4 Appendix)
ASTM D2172
Binder content (%)
JMF value 0.40
ASTM D6307
Table 9
Gradation of extracted aggregates
ASTM D5444
Appendix
Effective Specific Gravity of
ASTM D6857
- Each source;
Gsb < Gse < Gsa
Aggregates (Gse)
ASTM D2041
- Visible change in
1.5
Voids in mineral aggregate (VMA)
AASHTO T312
material
ASTM
D6857
or
1 test per 500t per
Voids in Mix (Va)
1.3
ASTM D2041
layer for Base
(Min 2 Gyratory specimens at Ndes)
(Eq. 2)
Course
Density (% of Gmm) at Nmax
Table 5
ASTM D2726
(Min 1 Gyratory specimens at Nmax)
Appendix
layer for Wearing
ASTM D6857 /
Course
ASTM D2041
Table 5
Dust to binder ratio (P0.075 / Pbe)
ASTM D2172 /
Appendix
ASTM D6307
ASTM D5444
Indirect tensile strength (IDT)
ASTM D6931
IDT of JMF min.
ASTM D6931
Sec. 1.5.8
Moisture Sensitivity (Retained IDT)
Sec. 1.5.8
Weekly
Appendix
Appendix
Dynamic Modulus at 10 Hz, 45 C,
Min. 1920 MPa
AASHTO PP60
0kPa confinement
AASHTO TP79
Every 10,000t
Flow Number (Fn) at 54.4 C, 600kPa Procedures A, B
Min.
740
deviatory stress, and 0kPa
AASHTO PP61
confinement
ASTM D5361
In-place air voids
6 8%
ASTM D2726
layer for Base
Course;
ASTM D5361
Thickness
Section 5.11.1
layer for Wearing
ASTM D3549
Course
At 50m intervals in
Field density (nuclear gauge) (%Gmm)
ASTM D2950
92 94%
alternate wheel
tracks
Evenness of surface
Section 5.11.2 & 5.11.3
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5.6
PERFORMANCE EVALUATION OF ASPHALT CONCRETE
Based on the Engineer request, the asphalt mixture performance properties can be
determined.
The performance properties of asphalt mixtures shall be measured for every asphalt
concrete layer at least on the following frequencies:
Prior asphalt laying on a laboratory prepared sample at the asphalt binder content
specified in the JMF.
(b)
Asphalt mix sampled from behind the paver every 10000t of mix.
The purpose of the performance testing is to allow for pavement performance evaluation and
verification of pavement structural design through the AASHTO Mechanistic-Empirical
Pavement Design Guide. Performance models, references, test conditions are shown in table
5.18 below:
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(a)
Table 5.18
Test
Reference
Test Conditions
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Performance
Model
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Performance Models Criteria
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100X150mm cylindrical
AASHTO PP60, sample under uniaxial
Dynamic Modulus
TP79 Procedure stress, zero confining
Master Curve
A, & PP61
pressure and sinusoidal
deviator stress
AASHTO PP60 100X150mm cylindrical
& TP79
sample under triaxial
Procedure B
stress
Fatigue Model
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Rutting Model
Aging Model
AASHTO T321
ASTM D7175
Applications / Use
The E* is used in mechanistic

analysis to evaluate the structural
responses of the asphalt
concrete layers
To evaluate the rutting

characteristics of the asphalt
mixture in the form of a rutting
model or Flow Number (FN)
64x50x380mm beam
specimen is subjected to
a 4-point bending with
free rotation and
horizontal translation at
all load and reaction
points
The initial flexural stiffness is

measured at the 50th load cycle.
Fatigue life or failure shall be
defined as the number of cycles
corresponding to 50% reduction
in the initial stiffness.
Conduct asphalt binder

A-VTS test in the
Rheometer (DSR) to
measure G* and in
accordance with ASTM
D7175 at multiple
temperatures
Viscosity-temperature relationship
(A-VTS) of the asphalt binder is
determined in order to assess the
impact of binder aging on the E*
property of the asphalt mix at
various stages of the pavement
life
Modelling methods adopted by Asphalt Institute and Shell or equivalent shall be used. The
contractor shall submit a proposal includes performance modelling testing and interpretation
procedures to the Engineer for approval.
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DELIVERY, SPREADING AND FINISHING
5.7.1
Delivery of Mixes
Sufficient plant capacity, haul vehicles and storage shall be provided so that adequate
supplies of mixture are delivered to site to ensure that continuous paving can be achieved.
The dispatching of the hauling vehicles to the job site shall be so scheduled that all material
delivered may be placed in daylight, unless the Engineer has approved the use of artificial
light. Delivery of material shall be at a uniform rate and in an amount well within the capacity
of the paving and compacting equipment.
All precautions shall be taken to protect the mix from the weather during transit and while
waiting to discharge.
Hauling vehicles shall not be permitted to carry out tight turns on the laying surface.
The mixture at delivery to the paver shall be within 10 C of the Job Mix Formula temperature
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and above an absolute minimum temperature of 135 C. Material which has fallen below the
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minimum temperature of 135 C before discharge shall be rejected and immediately removed
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from site. Delivery temperature shall not exceed the maximum temperature specified for
mixing at the plant
Should a significant proportion of the mixture delivered to the paver fail to meet this
requirement, or should cold lumps be found in the mixture, the Engineer shall order that
paving operations be suspended until measures are taken, to the approval of the Engineer, to
ensure compliance.
5.7.2
Spreading and Finishing
The Contractor shall prepare a paving plan and obtain approval of the Engineer to ensure
adequate equipment and paving sequences.
Based on the approved paving plan and prior to the commencement of delivery of the mix the
Contractor shall erect and maintain an approved reference guide wire for controlling the
levels of the laid mix. The reference guide wire shall be supported at intervals of not more
than 5m.
The mix shall be laid upon an approved surface and only when weather conditions are
suitable and as designated. Upon arrival at the point of use, the asphalt mix shall be spread
and struck off to the grade, elevation and cross-section shape intended, either over the entire
width or over such partial width as may be required. If the material does not conform to the
requirements, it shall not be used and shall be discarded.
The laid material shall be compacted as soon as rolling can be effected without causing
undue displacement and while the temperature does not fall below 120 C for unmodified
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asphalt mixes. Materials still uncompacted and below this temperature shall be rejected.
5
The compaction temperature for the laid polymer-modified asphalt binder mixes shall be
selected based on one of the following:
(a)
As specified in the JMF.
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(b)
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As established from the trial section.
The Contractor shall supply accurate calibrated thermometers suitable for measuring the
inner and surface temperature of the material. The material temperature shall be checked
immediately before rolling and at least every 30 minutes thereafter during forward progress.
A record of these temperatures shall be passed to the Engineer at the end of each days
work.
While paving is in progress, the output of the batching plant shall be exclusively reserved for
the operations and no mixture shall be supplied to other sites or projects.
If during laying, the paver is repeatedly delayed because of lack of mixture or if the paver
stands at one location for more than thirty minutes (for any reason), a transverse joint shall
be constructed. Paving shall not recommence until the Engineer is satisfied that paving will
proceed uninterrupted and until at least four loaded vehicles have arrived at the paving site.
The asphalt course shall be constructed to proposed levels and shall be homogeneous,
providing after compaction an even surface free from undulations, rises or depressions and
within the tolerances stipulated.
10
In no case shall construction of a new asphalt concrete course begin until the previously laid
course has been tested and approved.
11
When the same asphalt course is to be laid in more than one layer the second layer shall be
placed as soon as practicable after the first layer has been finished, rolled and cooled, and
the Engineer may at his discretion request cleaning of the first layer and the application of a
tack coat thereon if he so deems necessary.
12
Transverse joints in succeeding layers shall be offset at least 2 m. Longitudinal joints shall
be offset at least 300 mm.
13
The use of motor grader or hand spreading of the asphalt mix shall not be permitted except
in places where it is impractical to use pavers and shall be only with the specific permission
of the Engineer. The asphalt mix shall comply with all conditions regarding trueness of level,
thickness, and homogeneity of the mix.
14
Automatic electronic screed controls shall be required on all pavers and shall be used with a
9 m long articulated averaging beam or grade wire control as approved by the Engineer.
5.7.3
Compaction of Mixes
At least three rollers shall be required at all times, one self-propelled pneumatic-tire and two
self-propelled steel-wheeled. As many additional rollers shall be used by the Contractor as
necessary to provide specified asphalt course density and surface characteristics in an
orderly, efficient and continuous manner.
Before beginning construction of the permanent works, unless otherwise agreed with the
Engineer, the Contractor shall carry out compaction trials for each type and thickness of
asphalt course to establish an approved compaction procedure which shall then be used as a
minimum requirement for the compaction of the permanent works unless otherwise directed
or agreed by the Engineer.
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The compaction trials shall involve all procedures specified for the permanent works
including testing as specified for the asphalt course under consideration and any equipment,
processes or procedures proposed by the Contractor which are not designated. Construction
of the permanent works shall not commence until a compaction procedure has been
approved in writing by the Engineer. Such approval shall in no way relieve the Contractor of
his responsibilities and obligations stipulated in the Contract.
Immediately after the asphalt mix has been spread and struck off, the surface shall be
checked and any irregularities adjusted and then compacted thoroughly and uniformly by
rolling.
To prevent adhesion of the mix to steel-wheeled rollers, the wheels shall be kept properly
moistened but excess water shall not be permitted.
After the longitudinal joints and edges have been compacted, rolling shall start longitudinally
at the sides of the road and shall gradually progress towards the centre. On super elevated
sections, rolling shall begin on the low side and progress to the high side, overlapping on
successive trips by at least one-half the width of tandem rollers and uniformly lapping each
proceeding track. The rollers shall move at a slow but uniform speed with the drive wheels
nearest the paver. The speed shall not exceed 4-5 km/h for steel-wheeled rollers or 8 km/h
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for Pneumatic-tire rollers. The operating speed shall be approved by the Engineer.
The line of rolling shall not be changed suddenly or the direction of rolling reversed suddenly.
If rolling causes displacement of the material, the affected areas shall be loosened at once
with hand tools and restored to the original grade of the loose material before being rerolled.
Heavy equipment or rollers shall not be permitted to stand on the finished surface before it
has been compacted and has thoroughly cooled.
When paving in a single width, the first lane placed shall be rolled in the following order:
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Transverse joints.
(b)
Longitudinal joints.
(c)
Outside edge.
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Initial or breakdown rolling, beginning on the low side and progressing towards the high
side.
(d)
(a)
(e)
Intermediate rolling.
(f)
Final rolling.
When paving in echelon, 50 mm to 100 mm of the edge which the second paver is following
shall be left unrolled. When paving in echelon the edges between the first and the second
paver shall not be exposed more than 15 minutes nor 50m by distance without being rolled.
Particular attention shall be given to the construction of the transverse and longitudinal joints
in all courses.
5.7.4
Transverse Joints
Transverse joints shall be carefully constructed and thoroughly compacted to provide a

smooth riding surface. Joints shall be checked with a straightedge to assure smoothness and
true alignment. Joints shall be formed with a bulkhead, such as a board, to provide a straight
line and vertical face.
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Page 28
If the joint has been distorted by traffic or by other means, it shall be trimmed to line and the
face shall be painted with thin coating of emulsified asphalt before the fresh material is
placed against it. To obtain thorough compaction of these joints the material placed against
the joint shall be tightly pushed against the vertical face with a steel-wheeled roller.
The roller shall be placed on the previously compacted material transversely so that not more
than 150 mm of the rear rolling wheel rides on the edge of the joint. The roller shall be
operated to pinch and press the mix into place at the transverse joint. The roller shall
continue to roll along this line, shifting its position gradually across the joint, in 150 to 200 mm
increments, until the joint has been rolled with the entire width of the roller wheel. Rolling
shall be continued until a thoroughly compacted, neat joint is obtained.
5.7.5
Longitudinal Joints
Longitudinal joints shall be rolled directly behind the paving operations. The first lane placed
shall be true to line and grade and have a vertical face. The material being placed in the
abutting lane shall then be tightly pushed against the face of the previously placed lane.
Rolling shall be done with a steel-wheeled roller.
The roller shall be shifted over onto the previously placed lane so that not more than 150 mm
of the roller wheel rides on the edges of the newly laid lane. The rollers shall then be
operated to pinch and press the fine material gradually across the joint. Rolling shall be
continued until a thoroughly compacted, neat joint is obtained.
When the abutting lane is not placed in the same day, or the joint is distorted during the day's
work by traffic or by other means, the edge of the lane shall be carefully trimmed to line,
cleaned and painted with a thin coating of emulsified asphalt before the adjacent lane is
placed.
The longitudinal joints in the surface course shall be along the same line as the traffic lane
markers.
5.7.6
Paving Edges
The edges of the asphalt course shall be rolled concurrently with or immediately after rolling
the longitudinal joint.
Care shall be exercised in consolidating the course along the entire length of the edges.
Before it is compacted, the material along the unsupported edges shall be slightly elevated
with hand tools. This will permit the full weight of the roller wheel to bear on the material to
the extreme edges of the mat.
5.7.7
Breakdown Rolling
Breakdown rolling shall immediately follow the rolling of the longitudinal joints and edges.
Rollers shall be operated as close to the paver as possible to obtain adequate density without
causing undue displacement. In no case shall the mix temperature be allowed to drop below
120 C before breakdown rolling.
If the breakdown roller is steel wheeled, it shall be operated with the drive wheel nearest the
finishing machine. Pneumatic-tire rollers may be used as breakdown rollers.
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Intermediate Rolling
Pneumatic-tire rollers or Steel wheeled rollers shall be used for the intermediate rolling.
The intermediate rolling shall follow the breakdown rolling as closely as possible and while
the paving mix is still hot. Rollers shall be used continuously after the initial rolling until all of
the mix placed has been thoroughly compacted. Turning of rollers on the hot paving mix
which causes undue displacement shall not be permitted.
5.7.9
Finish Rolling
The finish rolling shall be performed with three-axle tandem rollers unless otherwise
permitted by the Engineer. Finish rolling shall be accomplished while the material is still warm
enough for the removal of roller marks.
All rolling operations shall be conducted in close sequence.
In places inaccessible for the operation of standard rollers as specified, compaction shall be
performed by manual or mechanical tampers of such design as to give the desired density.
After final rolling, the smoothness, levels, crossfalls, density and thickness shall be checked
and any irregularity of the surface exceeding the specified limits and any areas defective in
texture, density or composition shall be corrected as directed by the Engineer, including
removal and replacement as directed by the Engineer.
5.7.10
Protection of Laid Courses
Sections of the newly finished work shall be protected from traffic of any kind until the mix
has been properly compacted and cooled. In no case shall traffic be permitted less than 24 h
after completion of the asphalt course unless a shorter period is authorised by the Engineer.
5.8
COLD PLANING
The cold planing plant shall be to the approval of the Engineer.
Cold planing plant shall have sufficient power, traction and stability to maintain the required
depth of cut and slope. The control of the depth of cut and the slope shall be by an automatic
system based on reference wires.
Cold planing shall be carried out to straight crossfalls to the designated thickness. Planing
shall be to a tolerance of 5 mm of the designated amount. The average thickness of
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5.7.8
planing achieved shall be at least the thickness designated.

4
In areas where there is severe deformation of the existing pavement, it may be necessary to
vary the depth of planing.
Existing kerbs, gullies, manholes and other features shall not be disturbed by the planing
process. This may require the use of smaller plant or removal by hand tools.
Any joints at the edge of planed areas shall be cut vertically and straight using asphalt saws.
Cold planing shall be carried out in a longitudinal direction.
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After planing the prepared surface shall be thoroughly brushed and suction swept by
mechanical means to the satisfaction of the Engineer. The surface shall be free from
gouges, ridges, continuous grooves and shall have a reasonably uniform finish.
Cold planing shall be performed so that at the end of a days work the termination line does
not present a hazard to traffic that may use the road.
10
Any cracks noted in the pavement shall be blown clean with compressed air. The Engineer
will inspect the planed surface and may instruct that further work is carried out for treating
cracks in the pavement.
5.9
PRIME COAT
5.9.1
General
The work shall consist of furnishing and applying liquid asphalt and blotter material, if
required, to a previously prepared and approved subgrade or granular base/sub-base course
as designated and to the full designated width.
Prime coat shall not be applied when the ambient temperature is less than 13 C nor during
rain, fog, dust storms or other unsuitable weather.
5.9.2
Equipment Required
The equipment used by the Contractor shall include a liquid asphalt distributor as described
in clause 5.17.3.
If the surface is covered in wind-blown dust or fine aggregate then a power broom shall be
provided. The power broom shall be self-propelled and equipped with a cylindrical, rotating
nylon bristle brush of not less than 760 mm in diameter and not less than 1800 mm in length.
The brush shall be capable of being angled to the right and left with adjustable ground
pressure. Where necessary for the proper preparation of the surface, motor graders, rollers
and water trucks shall also be provided.
5.9.3
Surface Preparation
Immediately before applying the prime coat, all loose dirt, earth and other objectionable
material shall be removed from the surface with a power broom of approved design and/or a
power blower as required, and any ruts, soft spots or unacceptable irregularities in the
surface shall be repaired in accordance with the instructions of the Engineer. If the Engineer
so requires, the surface shall be lightly bladed and rolled immediately before the application
of the prime coat, in which case brooming or blowing may not be required.
Priming will not be permitted when there is free water present on the surface.
5.9.4
Application
After preparing the road surface as above, the prime coat shall be applied by means of the
distributor at the temperature and rate shown in Table 5.12. Hand-spraying of restricted,
inaccessible areas is permitted, subject to the approval of the Engineer.
The surface of structures, kerbstones and other appurtenances adjacent to areas being
treated shall be protected in such a manner as to prevent their being spattered or marred.
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The prime coat shall usually be applied to 1/3 or 1/2 of the road width at a time. When
applied in two or more lanes, there shall be a slight overlap of asphalt material along
adjoining edges of the lanes. It should be noted that no overlapping is allowed at the
transverse joints and that thick paper shall be used at the joint to protect the previous
application and the joining application shall begin on the paper. The paper used shall be
removed and satisfactorily disposed of by the Contractor after use. Care shall be taken that
the application of prime coat material at the junctions of spread is not in excess of the
specified amount. Excess bituminous material shall be removed from the surface.
5.9.5
Traffic shall not be permitted on the primed surface until the asphalt material has penetrated
and dried and, in the judgement of the Engineer, will not be picked up under traffic. If it
becomes necessary to permit traffic before that time, but in no case sooner than 48 hours
after the application of the asphalt material, blotter material shall be applied as directed by
the Engineer and traffic shall be permitted to use the lanes so treated.
Blotter material shall be spread from trucks operated backward so that the wheels will not
travel in uncovered wet asphalt material. When applying blotter material to an asphalt treated
lane that adjoins a lane that has not been treated, a strip at least 200 mm wide along the
adjoining edge shall be left devoid of blotter material in order to permit an overlap of asphalt
material.
The Contractor shall maintain the primed surface in good clean condition and before the
application of the next course, any surface irregularities shall be corrected and all excessive
blotter material, dirt or other objectionable materials shall be removed.
5.10
TACK COAT
5.10.1
General
This work shall consist of furnishing and applying diluted emulsified asphalt to a previously
prepared Base or Wearing courses, to provide bond for a superimposed course to the full
designated width.
Tack coat shall not be applied when the ambient temperature is less than 13C nor during
rain, fog, dust storms or other unsuitable weather.
5.10.2
Equipment Required
The equipment used by the Contractor shall include liquid asphalt distributor as well as a
power broom and a power blower. Power broom shall be self-propelled and equipped with a
cylindrical, rotating nylon bristle Brush of not less than 760 mm in diameter and not less than
1800 mm in length. The brush shall be capable of being angled to the right and left with
adjustable ground pressure. In addition, the Contractor shall supply and use efficient and
approved equipment for diluting the emulsified asphalt with water.
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Surface Preparation
The full width of the surface to be treated shall be cleaned with a power broom or power
blower to remove dust, dirt or other objectionable materials. All faulty or unsuitable patches,
excess cracks or joint filler and all surplus bituminous material shall be corrected in
accordance with the instructions of the Engineer. The surface shall be dry when treated.
5.10.4
Application
Immediately after cleaning the surface, the tack coat shall be applied by means of the
distributor at the temperature and rate directed by the Engineer. Hand spraying of restricted,
inaccessible areas is permitted, subject to the approval of the Engineer.
The diluted emulsion shall be applied at a rate shown in Table 5.12. The Contractor shall
ensure that excessive application of tack coat is avoided.
The surface of structures, kerbstones and other fixed objects adjacent to areas being treated
shall be protected in such a manner as to prevent their being spattered or marred.
5.10.5
After application, the surface shall be allowed to dry until it is in a proper condition of
tackiness to receive the superimposed course. Tack coat shall be applied only so far in
advance of the superimposed course placement as is necessary to obtain this proper
condition of tackiness.
Until the superimposed course is placed, the Contractor shall protect the tack coat from
damage.
If the tack coat is unavoidably damaged by rain or dust, it shall be allowed to dry, shall be
cleaned again by a power broom or power blower and, if required by the Engineer, a
subsequent light application of tack applied to the surface. Where, in the opinion of the
Engineer, a tack coat is not necessary between layers of freshly placed courses, he may give
instructions in writing to omit the tack coat. Any cleaning required in these areas shall be
carried out before the application of the next course.
5.11
THICKNESS AND LEVEL
5.11.1
Thickness
Cores shall be taken to determine the thickness of asphalt paving courses. As determined
from each core, the thickness of a paving course shall not be less than that specified by more
than 5 mm in the case of a single-layered construction. Furthermore, the thickness of the
Wearing course shall not be less than that specified by more than 5 mm and the total
thickness of all asphalt paving courses combined shall not be less than that specified by
more than 10 mm.
In addition, the variations in the falls to cross sections of the road shall not vary from the
required value by more than 0.3 %. Any asphalt paving course containing deviations or
variations exceeding these tolerances shall be corrected or removed and replaced by the
Contractor, in accordance with the instructions and to the satisfaction of the Engineer.
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5.10.3
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Where any individual course is marginally out of tolerance on the low side, the Engineer may
allow adjustment in the succeeding course to correct the overall thickness of the pavement.
The tolerances herein specified shall not invalidate the tolerances set forth for the evenness
of surface of the asphalt paving course.
As directed by the engineer the laid thickness shall be checked by cutting test pits and/or
using Ground Penetrating Radar (GPR) for the determination of the structural capacity of the
pavement.
5.11.2
Transverse Evenness
The Engineer shall test the evenness of surface for each course of the various asphalt
paving courses to determine compliance.
The Contractor shall put at the disposal of the Engineer a 3m long straight edge and a crown
template of sturdy and approved design and enough labour to assist in the checking
operations. The maximum allowable differences between the pavement surface and the
straight edge shall be 3mm. Transverse measurements shall be carried out every 20m of
road length for each lane.
Any layer containing deviations or variations exceeding the tolerances specified here shall be
corrected or removed and replaced in accordance with the instructions of the Engineer and to
his satisfaction.
5.11.3
Evenness and Rideability
Smoothness is a measure of the evenness and rideability of the pavement surface. It shall be
measured on the driving surface of the completed pavement for all major roads before
opening to the traffic.
Any section containing deviations or variations exceeding the criteria specified here or by the
Engineer shall be corrected or removed and replaced in accordance with the instructions of
the Engineer and to his satisfaction at the Contractors cost.
The minimum length of the rectification work undertaken shall be 100m.
All rectified segments shall be re-tested following the completion of rectification work at no
additional cost to the client.
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(a)
Evenness
The evenness of the driving surface of road pavements shall be measured with a 3m rolling
straight edge along any line or lines parallel to the center line of the pavement on sections of
300m selected by the Engineer, whether or not it is constructed in shorter lengths. Sections
shorter than 300m forming part of a longer pavement shall be assessed using the number of
irregularities for a 300m length prorated to the nearest whole number. Where the total length
of pavement is less than 300m the measurements shall be taken in 75m lengths.
The number of deviations (from the bottom face of the straight edge) over the length of the
section greater than or equal to 4mm shall be counted. None of the measured deviations
shall exceed 6mm. The evenness of the driving surface of the tested section shall be within
the relevant limits given in Table 5.19.
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Table 5.19
Evenness of Driving Surface
(b)
Section Length (m)
Allowed number of deviations 4mm
300
20
75
Rideability
For major roads the International Roughness Index (IRI) shall be used to monitor the
roughness and condition of the pavement surface. The acceptable IRI for ride quality shall be
decided by the Engineer.
The rideability of the driving surface of the completed pavement shall be measured in terms
of the International Roughness Index (IRI) which shall be tested with a certified and
calibrated Inertial Profiler meeting the requirements of ASTM E950Class 1.
The testing method shall be in accordance with ASTM E950. The IRI shall be calculated
according to ASTM E1926.
10
Calibration checks on the inertial profiler shall be conducted using test methods in
accordance with the manufacturers recommendations, at the beginning of the day of
operation and at any other time the operator may suspect changes of system performance
since the last calibration.
11
Calibration checks on the inertial profiler and all other quality checks shall be submitted in a
method statement to the Engineer for approval.
12
The selected measuring speed shall be the posted speed and within the range
recommended by the manufacturer and shall remain nearly constant during testing, not to
exceed +/-5 km/h of the selected speed.
13
The profiler system shall stabilize at the test speed prior to entering the test sections. This
requires bringing the profiler vehicle to the desired test speed at least 100 m prior to the
beginning of the test location. Any Features along the test section such as bridges, culverts,
milepost or other pertinent information shall be identified. The test shall be conducted in the
paving direction.
14
The start and end point of the test section shall be automatically identified by using a photo
detector. The coordinates of the test section shall be identified by using a GPS.
15
Three runs of data collection (both wheel tracks in each lane) shall be conducted. The
processing of the data for IRI shall include calculating the average IRI value of the three runs
for the two wheel tracks. The processed data shall be reported on 25m and 400m subsections calculated using the Moving Average statistical method and applying a 250mm
filtering.
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PAVEMENT EVALUATION TECHNIQUES
Pavement evaluation tests shall be carried out for the completed pavement structure at any
point of the road as directed by the Engineer to assess the serviceability condition of the
pavement and verify compliance with specifications.
Pavement evaluation methods can be grouped into two main categories, destructive and
non-destructive.
The Contractor shall allow and provide all necessary arrangements for the execution of all
pavement evaluation test required by the Engineer.
As directed by the Engineer the structural ability of the pavement in terms of load-deflection
response and layer modulus shall be assessed by using the Falling Weight Deflectometer
(FWD).
The pavement surface friction shall be measured based on the Engineer request using the
portable pendulum tester (ASTM E303), locked wheel tester (ASTM E274) or the sand patch
method (ASTM E965).
5.13
PRODUCTION OF ASPHALT CONCRETE COURSES
5.13.1
Weather Limitations
Production and spreading of asphalt Concrete mix shall not be permitted when the ambient
temperature is less than 8 C, nor during rain, fog, dust-storms or other unsuitable weather.
5.13.2
Equipment Required
The equipment required for construction of the asphalt concrete courses shall include but not
be limited to the equipment mentioned in Clauses 5.3 to 5.6 of this Part, together with such
miscellaneous equipment and tools as required for the satisfactory preparation and
performance of the work.
All equipment shall be checked, calibrated and approved by the Engineer before use. The
equipment shall be satisfactorily maintained and shall be used in an approved manner.
Adequate equipment and labour shall be used so that there is continual production and
distribution of the asphalt course being constructed.
5.13.3
Survey and Preparation
The area to be paved shall be true to line and grade and shall have a properly prepared
surface before the start of paving operations.
When an asphalt concrete pavement course is to be placed on top of an existing pavement,

the existing pavement surface shall be prepared as designated by the Engineer.
Priming or tacking of surfaces to be paved shall be carried out as designated.
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The surface of kerbs, vertical faces of existing pavements and all structures in actual contact
with asphalt mixes shall be painted with a thin and complete coating of tack coat as
instructed by the Engineer to provide a closely bonded, watertight joint.
All openings or structures in the road for water, drainage and other specified utilities shall be
constructed and their positions and levels determined before the start of paving operations.
5.13.4
Heating of Asphalt Binder
The 60/70 penetration grade bitumen shall be heated to a temperature of between 150 to 165
degrees centigrade.
Bitumen of other penetration grade shall be heated to yield viscosity's in the range of 150 to
300 centistokes (175 to 150 seconds Saybolt-Furol) when delivered to the mixer, as
determined from the Temperature Viscosity Chart of the product used.
Penetration Graded Asphalt Binders shall not be used if foaming occurs or shall it be heated
above 175 C at any time.
Polymer-modified binder shall be heated to a temperature specified by the supplier.
5.13.5
Heating of Mineral Aggregate
When using 60/70 penetration grade asphalt binder the materials shall be thoroughly dried
and heated so that their temperature is 165 to 180 degrees centigrade.
When using asphalt binder of other penetration grade the materials shall be thoroughly dried
and heated so that their temperature is within 8 C of the temperature needed to satisfy the
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viscosity requirements of the asphalt cement.

The moisture content of the heated and dried materials shall not exceed 1%.
The quantity of materials fed through the drier shall in all cases be held to an amount which
can be thoroughly dried and heated within the limits specified.
The heated materials shall be screened into sizes such that they may be combined into a
gradation meeting the requirements of the Job Mix Formula and the hot aggregate storage
bins shall be such as to minimise segregation and loss of temperature of aggregate.
Hot bins shall be drawn and cleaned of material at the end of each day's operation.
5.13.6
Proportioning and Mixing
The heated ingredients together with the mineral filler and bitumen shall be combined in such
a manner so as to produce a mixture which complies with the requirements of the Job Mix
Formula. Plant settings, once established, shall not be changed without the approval of the
Engineer.
Mineral filler, in a cool dry state, shall be proportioned into the mixer either with the aggregate
or after the introduction of the bitumen to avoid loss of fines that may occur in dry mixing as a
result of turbulence in the mixer.
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In batch type plants a dry mixing period of not less than four seconds shall precede the
addition of the bitumen to the mix. Excess wet mixing shall be avoided. Wet mixing shall
continue as long as it is necessary to obtain a thoroughly blended mix but shall not exceed 75
seconds nor be less than 30 seconds.
Once approved, mixing times shall not be altered unless so ordered or further approved by
the Engineer.
5.14
HAULING EQUIPMENT
Vehicles used for the transport of aggregates or bituminous mix shall have tight, clean and
smooth insulated metal bodies and shall be free from dust, screenings, petroleum oil and
volatile or other mineral spirits which may affect the material being hauled. The vehicle metal
bed shall, if required, be sprayed with a minimum amount of soapy water or lime solution to
prevent the bituminous mix from adhering to the bed. After spraying, the truck shall be raised
and thoroughly drained and no excess solution shall be permitted. Use of diesel or other
solvents to spray in the truck bed is prohibited.
Provision shall be made for covering truck loads with canvas or other suitable material of
such size that the bituminous mix is fully covered.
Any truck causing excessive segregation of material by its spring suspension or other
contributing factors, or that shows oil leaks in detrimental amounts, or that causes undue
delays, shall, upon the instruction of the Engineer, be removed from the work until such faults
are corrected.
End dump trucks shall be equipped with chains on the tail gates for control when dumping
the mix into the paving machine. Hauling trucks shall not be routed over wet or muddy
access ways such that tires accumulate dirt that is deposited on the laying surface.
The Contractor shall provide an adequate number of trucks of such size, speed and condition
to ensure orderly and continuous progress of the work all to the approval of the Engineer.
5.15
OTHER EQUIPMENT
5.15.1
Spreading and Finishing Equipment
The asphalt mixture shall be fed to the paver by end tipping of the truck or by means of a
windrow elevator. The equipment for spreading and finishing the asphalt mixtures shall be of
an approved mechanical, self-powered electronic controlled floating screed type, capable of
spreading and finishing the mixture true to line, grade and required crown.
The pavers shall be self-propelled and equipped with hoppers and distributing screws of the
reversing type to place the mixture uniformly in front of adjustable electronic controlled
screeds. The pavers shall be so designed to allow a minimum paving width of 2 m, although
paving in widths of less than 3 m will require the approval of the Engineer.
Pavers shall be equipped with such provisions and attachments to suit paving widths
specified for road widening as well to as to suit paving on sloped sections. They shall be
equipped with fast and efficient steering devices and shall have reverse as well as forward
travelling speeds. The operational speed of the pavers shall be adjustable from 3 to 6 m/min
in accordance with the instructions of the Engineer.
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The pavers shall employ mechanical devices as equalising runners, straight edge runners,
evener arms or other compensating devices to maintain trueness of grade and to confine the
edges of the pavement to true lines without the use of stationary side forms. The equipment
shall include blending or joint levelling devices for smoothing and adjusting longitudinal joints
between lanes. The assembly shall be designed and operated in such a manner that it will
place the material at the required compacted thickness.
Electronic screeds shall include automatic feed controls to maintain a constant level of
material along the full length of the screed, automatic grade control and automatic slope
control. Unless waived by the engineer, on projects with smoothness (IRI) requirements, the
paver shall carry minimum 9.0m long average beam equipped with an ultrasonic sensors
capable of sensing a pavement section at several spatially separated spots. The automatic
slope control shall be equipped with a proportioning manual override to enable smooth
transition of changing slope rate. Automatic screed controls shall be approved by the
Engineer before use.
Screeds shall be provided with devices for heating the screeds to the temperature required
for the laying of the mixture without pulling or marring. Pavers shall also be provided with the
standard attachable screed extensions. All screeds shall be of the vibrating type that permits
material to be tamped into position.
The term "screed" includes any cutting, crowning or other physical action that is effective in
producing a finished surface of the evenness and texture specified, without tearing, shoving,
or gouging.
If, during construction, it is found that the spreading and finishing equipment in operation
leaves in the pavement surface tracks or indented areas or other objectionable irregularities
that are not satisfactorily corrected by scheduled operations, the use of such equipment shall
be discontinued and other satisfactory spreading and finishing equipment shall be provided
by the Contractor.
5.15.2
Rolling Equipment
Rolling equipment shall consist of vibratory steel-wheeled rollers, dead weight steel-wheeled
rollers and pneumatic-tire rollers as required for proper compaction and finishing of the
asphalt surface. Unless otherwise permitted, rollers shall be equipped with reversible or dual
controls to allow operation both forward and backward with the operator always facing in the
direction of movement.
Steel-wheeled rollers shall be two-axle tandem rollers or three-axle tandem rollers. These
rollers shall be self-propelled and equipped with power units of not less than four cylinders
and under working conditions shall develop contact pressures under the compression wheels
of 45 to 65 kg/cm of width. Each two-axle roller shall have a minimum weight of 10,000 kg
each and three-axle roller shall have a minimum weight of 13,000 kg. Vibrating steel-wheeled
rollers shall have dual drums with a minimum weight of 7000 kg. Vibrating frequency shall be
between 2000 and 3000 cycles per minute with individual controls for each tandem drum.
Rollers shall be in good working condition and shall be equipped with a reversing clutch.
Rollers shall be equipped with adjustable scrapers to keep the wheel surface clean and with
efficient means of keeping them wet to prevent mixes from sticking. These surfaces shall
have no flat areas or projections which will mark the surface of the asphalt courses. The
three-axle rollers shall be equipped with a centre axle which may be operated either fixed or
floating. The three-axle tandem roller shall be so constructed that when locked in a position
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for all treads to be in one plane, the roller wheels are held with such rigidity that, if either front
or centre wheel is unsupported the other two wheels will not vary from the plane by more than
6 mm. All steel-wheeled rollers shall be in good condition and the Contractor shall furnish to
the Engineer the manufacturers technical data for each roller and no roller shall be used
except after approval of the Engineer.
Pneumatic-tire rollers shall be self-propelled. The rollers shall be equipped with pneumatic
tires of equal size and diameter which are capable of exerting varying average contact
pressure. Pneumatic-tire rollers shall be in good condition and with enough ballast space to
provide uniform wheel loading as may be required. The Contractor shall furnish to the
Engineer charts or tabulations showing the contact areas and contact pressures for the full
range of tire inflation pressures and for the full range of tire loading for each type and size
compactor tire furnished and used in pneumatic-tire rollers. The total operating weight and
tire pressure may be varied by the order of the Engineer to obtain contact pressures which
will result in the required asphalt course density.
5.15.3
Liquid Asphalt Distributor
The liquid asphalt distributor truck shall be of the pressure type with insulated tanks. The use
of gravity distributors will not be permitted. The distributor shall have pneumatic tires of such
width and number that the load produced on the road surface shall not exceed 100 kg/cm tire
width.
Spray bars shall have a minimum length of 2.4 m and shall be of the full circulating type.
Spray bar extensions shall also be of the full circulating type. The spray bar shall be
adjustable to maintain a constant height above the surface to be treated.
The spray bar nozzles shall be slotted and shall be of such design so as to provide a uniform
unbroken spread of asphalt material on the surface. The valves shall be operated by levers
so that one or all valves may be quickly opened or closed in one operation. The distributor
shall be equipped with a hose and nozzle attachment to be used for spotting areas
inaccessible to the distributor. The distributor and booster tanks shall be so maintained at all
times as to prevent dripping of liquid asphalt material from any part of the equipment.
The distributor shall be equipped with devices and charts to provide for accurate and rapid
determination and control of the amount of liquid asphalt material being applied and with a
tachometer of the auxiliary wheel type reading speed in m/min. The spreading equipment
shall be provided with a separate power unit for the pump or a variable displacement pump
driven by a hydrostatic transmission so that a uniform application of liquid asphalt material, in
2
controlled amounts, may be made ranging from 0.15 to 5.0 kg/m . The distributor shall have
satisfactory heating equipment and thermometers in order to provide the full range of
application temperatures for the liquid asphalt material being used.
Before commencing the work and as required by the Engineer, the liquid asphalt distributor
shall be checked and calibrated such that the rate of transverse spread or longitudinal spread
shall not vary more than 10 % from the required rate of application.
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APPENDIX
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APPENDIX - ASPHALT WORKS........................................................................... 42
1.1
DEFINITIONS ........................................................................................................ 42
1.2
INTRODUCTION ................................................................................................... 44
1.3
1.3.2
1.3.3
SUPERPAVE DESIGN PARAMETERS ................................................................. 44

Traffic
44
Nominal Maximum Aggregate Size (NMAS)
45
1.4
SELECTION OF HMA PROPERTIES & REQUIREMENTS ................................... 46
1.5
1.5.2
1.5.3
1.5.4
1.5.5
1.5.6
1.5.7
1.5.8
1.5.9
OVERVIEW OF SUPERPAVE MIX DESIGN PROCESS....................................... 47

Step1: Selection of Materials
47
Step2: Selection of a Design Aggregate Structure (DAS)
48
Work Instructions of Step 2 Selection of DAS
50
Step 3: Selection of the Design Asphalt Content
51
Work Instruction of Step 3- Selection of DAC
52
Nmax and Ndes Verification
52
Step 4: Evaluation of the Strength and the Moisture Sensitivity of the Mixture
53
Work Instructions of Step 4 Evaluation of Strength and the Moisture Sensitivity 54
1.6
1.6.2
1.6.3
JOB MIX DESIGN PROPOSAL ............................................................................. 54

Acceptance of Job Mix Formula
55
Construction Quality Control:
56
1.7
REFERENCES ...................................................................................................... 57
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APPENDIX - ASPHALT WORKS
1.1
DEFINITIONS
Superpave: Is an abbreviation of Superior

system consist the following steps:
Performing
Asphalt Pavement.
(a)
Performance-Based Asphalt Binder Grading System
(b)
Performance-Based Specifications of Materials & HMA.
(c)
Test methods and practices for material selection & mix design.
(d)
Performance prediction of HMA.
Superpave
Asphalt Binder Content (Pb): the percent by weight of asphalt binder in the total mixture.
Initial Trial Asphalt Binder (Pbi): the percent by weight of the asphalt binder in the total
mixture for each trial blend in the selection of the Design Aggregate Structure (DAS).
Bulk Specific Gravity (G1, 2, to n; Gsb, Gmb): the ratio of the weight in air of a unit volume
of a permeable material (including both permeable and impermeable voids connected to
the surface of the aggregate particle) at a stated temperature relative to the weight in air of
an equal volume of gas-free distilled water at the stated temperature. This definition
generally applies to individual aggregate stockpiles (Gl through Gn), the blended
aggregate (Gsb, AASHTO T84, T85 and T100) or the compacted mix (Gmb, AASHTO T166 or
T275).
Effective Binder Content (Pbe): the volume of the asphalt binder that is not absorbed into
the aggregate but remains in the mixture to coat the aggregate particles.
Effective Specific Gravity (Gse): the ratio of the weight in air of a unit volume of a
permeable material (excluding voids permeable to binder) at a stated temperature relative to
the weight in air of an equal volume of gas-free distilled water at the stated temperature.
Maximum Specific Gravity (Gmm): the ratio of the weight of a given volume of voidless
(Va=0) loose HMA at a stated temperature (usually 77 F (25C)) to a weight of an equal
volume of gas-free distilled water at the same temperature (AASHTO T209).
Voids in Mineral Aggregate (VMA): It is the total space between the aggregate particles
in the compacted paving mixture which includes 1) the air voids (Va) and 2) the effective
binder volume . The VMA is defined as the volume of void space between the aggregate
particles before adding the binder. Note: mineral aggregate is the aggregate which does not
include any or organic material but it is the material that consists of minerals and compounds
such as calcium, silicon, etc .
Air Voids (Va): The total volume of the small pockets of air between the coated aggregate
particles throughout a compacted paving mixture, expressed as percent of the bulk
volume of the compacted paving mixture.
10
Voids Filled with Asphalt (VFA): the percentage portion of the volume of intergranular void
space between the aggregate particles (i.e. VMA) that is occupied by the effective asphalt
binder volume. It is expressed as the ratio of (VMA-Va) to the VMA.
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Volume of Absorbed Binder (Vba): the volume of binder absorbed into the aggregate (equal
to the difference in aggregate volume when calculate with the bulk specific gravity and
effective specific gravity).
12
Dust to Binder Ratio (P0.075/Pbe): ratio by weight of the percentage of the aggregate
passing the 0.075 mm sieve (P200) to the effective binder content (Pbe).
13
Standard Axle: is 8.2 ton (18,000 lb) single axle with dual wheels; the center to center
distance of dual wheels is 34.29 cm (13.5 in); the tire pressure is 0.517 MPa (75 psi).
14
ESAL's: is an abbreviation of Equivalent Single Axle Load. The equivalency factor is the
number of repetition of the standard axle required to induce the same damage as the given
axle. AASHTO Road Test has shown that an equivalent number of the standard axle
can represent the damaging effect of the passage of an axle of any mass. This means that
the ESAL is the number of applications of the standard axle that is equivalent in the damage
to the pavement to an axle of any mass. The relationship is non-linear and is a fourth
degree. For example, one application of a 16.2 ton single axle (36,000 lb twice as the
standard axel) was found to cause damage equal to approximately sixteen applications of
the standard axle; or one application of a 16.2 tons axle were required to cause the same
damage or reduction in the pavement serviceability as sixteen applications of the
standard axle. Also, one application of a 5.47 ton single axle (12,000 lb two thirds of the
standard axel) was found to cause damage equal to approximately 0.2 applications of the
standard axle; or five applications of a 5.47 tons axle were required to cause the same
damage or reduction in the pavement serviceability as one applications of the standard
axle.
15
Standard Sieves: Superpave standard sieve sizes are 50.0, 37.5, 25.0, 19.0, 12.5, 9.5,
4.75, 2.36, 1.18, 0.6, 0.3, 0.15 and 0.075 mm
16
Maximum Aggregate Size (MS): one standard size larger than the nominal maximum
aggregate size (This definition applies only to Superpave mix design.)
17
Nominal maximum aggregate size (NMAS): one standard size larger than the first sieve
that retains more than 10 percent of the aggregate (this definition applies only to Superpave
mix design).
18
Nini, Ndes and Nmax: These are the number of gyrations of the gyratory compactor at
three compaction levels simulating the construction traffic for N ini, the design traffic for Ndes
and the maximum anticipated densification by the highest traffic for Nmax
19
Design Aggregate Structure (DAS): the aggregate blend meeting all Superpave
requirements.
20
Design Asphalt Content (DAC): the percent by weight of the asphalt binder in the total mix
selected at 4.0 % air voids in the mix meeting all Superpave requirements.
21
ePAVE3: is a user-friendly menu driven Excel program for the Superpave mix design
system. It is a decision making program that includes all the computations, requirements
and comparisons to design hot mix asphalt for a given project. ePAVE3 includes Superpave
requirements based on the latest (to date) Asphalt Institute Superpave Mix Design
Superpave Series No. 2 (SP-2), third Edition 2001 and last edition of AASTO 2005
including M323 specification "Standard Practice for Designing Superpave HMA", and R35.
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Polymer: An organic substance that is originated from petroleum gases. It is the product of
a complicated chemical process. The word polymer originally consists of two words
poly which means numerous and meros which means parts; therefore, polymer means
the substance with many parts. Polymers can be either copolymers or homopolymers. The
most common polymers that are used to modify the asphalt binder for road applications are
either Elastomers such as SBS or Plastomers such as EVA and Polyethylene.
23
Neat and Polymer Modified Binder (PMB): neat binder is a black or dark brown material
produced from refining of petroleum oil in petroleum refineries. The polymer modified binder
is a neat binder that has been modified by the addition of polymers. The purpose of blending
polymer and other chemical substances is to improve the neat binder Rheological properties
to achieve the Performance Grade (PG) requirements of Superpave grading system. This
process is complicated and involves accurate control of the process parameters such as
mixing mechanism, temperature, time, concentration and blending details
1.2
INTRODUCTION
This guide, which is based on ref. 1, should be considered as a guide to assist Engineers,
consultants and contractors to design Hot-Mix Asphalt (HMA) using Superpave system. It is
the contractor full responsibility to select the applicable parameters for his project in liaison
with the Engineer and LSA. This system was developed using the last editions of the Asphalt
institute Superpave Mix Design, 2001, and AASHTO, 2005.
1.3
SUPERPAVE DESIGN PARAMETERS
Before starting any HMA design using Superpave system for any project, the mixture and
materials specifications and requirement must be identified. Superpave mix design system
requires three parameters in order to design a mix. These Parameters are:
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Expected traffic volume in the project.
(b)
Nominal Maximum Aggregate Size (NMAS).
(c)
Location of the project.
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(a)
The contract documents shall specify and define the design parameters for the project. A
brief description of the basic design parameters is given in the following sections.
1.3.2
Traffic
In Superpave, Traffic is defined as the total anticipated project level equivalent single
axle load (ESALs) on the design lane for a period of 20 years. To simplify the design
process, traffic class designations for each ESALs that appears in the Superpave system is
specified herein. If the contract documents do not specify the ESALs applicable to the
project, the Engineer can use the information provided in Table 1 to select the traffic classes
needed to establish Superpave criteria.
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Table 1
ESAL and Traffic Designation
Class Designation
ESALs Range
Applications
Less than 300,000
Agricultural roads with light traffic , local

and city streets without trucks
Light
300,000 to 3 million
Agriculture, Feeder and collector roads
Medium
3 million to 10 million
Main roads and city streets
Heavy
10 million to 30 million
Highways and Expressway
Very Heavy
More than 30 million
Heavily trafficked highways, industrial

areas ...
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Very Light
VL
Nominal Maximum Aggregate Size (NMAS)
Six Nominal Maximum Aggregate Sizes (NMAS) are identified in the Superpave system;
these are 37.5, 25.0, 19.0, 12.5, 9.5 and, 4.75 mm as specified in Table 2.
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1.3.3
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Table 2
SUAERPAVE Standard NMAS mixtures
Maximum Size
(MS)
37.5 mm
50.0 mm
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Nominal Maximum Size

(NMAS)
37.5 mm
19.0 mm
25.0 mm
12.5 mm
19.0 mm
9.5 mm
12.5 mm
4.75 mm
9.5 mm
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25.0 mm
The selection of design NMAS for a specific layer is based on the general rule that the
NMAS does not exceed half to one-third (1/2 to 1/3) the layer thickness. If the
contract documents do not specify the NMAS for the project, the Engineer can use the above
criteria and the information provided in Table 3 to select the NMAS of the project.
Table3
Recommended NMAS for Different Layer Types
Layer
Recommended NMAS
Sand Mix
4.75 mm
Wearing coarse
9.5 or 12.5 or 19.0 mm
Base coarse
25.0 or 37.5 mm
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1.4
SELECTION OF HMA PROPERTIES & REQUIREMENTS
Based on the specified design parameters (Traffic in ESAL, NMAS, geographic

location of the project and location of required layer to be designed), the mixture properties
and requirements can be selected. These properties include compaction level, which can be
identified from Table 4 and the properties of HMA, which can be identified from Table 5.
Table 4
Superpave Gyratory Compactive Effort (SGCE)
Ndes
Nmax
VL (< 0.3)
50
75
L (0.3 to 3)
75
M to H (3 to < 30)
100
VH (> 30)
Nini
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Gyrations
Traffic
(ESAL, million)
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205
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Table 5
Superpave Criteria for the Mixture Design
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Criteria
Voids in the Mineral

Aggregate (VMA %min)
Important Note: mixtures
with VMA greater than 2.0%
above the minimum should
be avoided.
Voids Filled with Asphalt, %
VL
Ninitial
< 91.5
< 90.5
96.0
Nmax
< 98.0
Nominal
Maximum
Size, mm
H
< 89.0
Ndesign
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Required Density (% Gmm)
Traffic Class Designation (or ESAL,

million)
37.5
11.0 %
25.0
12.0 %
19.0
13.0 %
12.5
14.0 %
9.5
15.0 %
4.75
16.0%
37.5
64-80
64-78
64-75
25.0
67-80
65-78
65-75
19.0
70-80
65-78
65-75
12.5
70-80
65-78
65-75
9.5
70-80
65-78
65-75
4.75
70-80
65-78
65-75
VH
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Traffic Class Designation (or ESAL,

million)
Criteria
VL
VH
Dust Proportion (DP) Ratio, if gradation line is

above the PCS
For all NMAS DP = 0.6 - 1.2, for NMAS 4.75

DP = 0.9 - 2.0
Dust Proportion (DP) Ratio, if gradation line is

below the PCS.
0.8 1.6
Average Indirect Tensile Strength of the Dry Set

in the Moisture Sensitivity Evaluation, kPa
Report
OVERVIEW OF SUPERPAVE MIX DESIGN PROCESS
According to SP-2 and AASHTO R 35, there are four major steps in the volumetric mix
design process. These steps consist of
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1.5
Material Selection, (Type of binder and aggregate).
(b)
Selection of Design Aggregate Structure (DAS).
(c)
Selection of Design Asphalt Content (DAC).
(d)
Evaluation of Strength and Moisture Sensitivity of the Mix.
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Step 4:
Strength and Moisture Sensitivity
Evaluation
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(a)
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Step 3:
Selection of DAC
Step 2:
Selection of DAS
Step 1:
Selection of Materials
(Binder, Aggregate and Modifiers)
ePAVE3 program should be used to assist in the preparation of the mix design and obtain the
mix deign report summarizing the computations and test results. ePAVE3 mix design report
shall be submitted to the Engineer for acceptance then to LSA for approval.
1.5.2
Step1: Selection of Materials
This process includes the selection of the asphalt binder PG (ABPG) and the aggregates that
meet all Superpave criteria.
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The selection of ABPG necessitates an understanding of the climatic condition (e.g.,

temperature) in which the pavement will be constructed and operated. This includes both
the average seven-day maximum high temperature and the single-day minimum low
temperature for the last twenty years and the latitude for that particular geographic location.
To account for traffic volume and speed or both, adjustments should be made to the selected
ABPG using AASHTO M332.
The requirements of the aggregate are selected based on the anticipated traffic and position
of the layer within the pavement. The quality criteria for Superpave aggregates are
summarized in Table 6. In order to be used in Superpave mixtures, the aggregate blends
must meet two sets of criteria known as source properties and consensus properties. Source
property requirements apply to each aggregate stockpile, but consensus properties apply
to the combined blend of multiple stockpiles. The consensus properties are mandatory
for all Superpave aggregate blends while; source properties are left to the contracts.
(b)
Coarse Aggregate Angularity, (CAA)

Fine Aggregate Angularity, (FAA)
Flat and Elongated Particles (F&E)
Sand Equivalent, (SE)
ASTM D5821
AASHTO T304-Method A
ASTM D4791
AASHTO T176
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i.
ii.
iii.
iv.
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Consensus Properties (Superpave Requirements):
ta
(a)
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Source Properties (QCS Requirements):
AASHTO T96
AASHTO T104
AASHTO T112
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Toughness
Soundness
Clay lumps & friable particles
Others.
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i.
ii.
iii.
iv.
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QCS General Specifications, source properties are considered specific to the geology
of a particular region and the experience with local materials.
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Table 6
Superpave Criteria for Aggregate Consensus Properties
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Traffic Class Designation (or ESAL, million)
Layer Depth,
mm
Property
H(10to<30)
M (3 to<10)
L (0.3 to 3)
VL (< 0.3)
100/100
95/90
85/80
75/-
55/-
< 100 mm
100/100
80/75
60/-
50/-
-/-
> 100 mm
45
45
45
40
< 100 mm
45
40
40
40
> 100 mm
50
45
45
40
40
SE, % min
10
10
10
10
F&E, % max
VH(>30)
CAA, %
min.
FAA, %
min.
Note: CAA values (X/Y) denotes that X% of the coarse aggregate has one fractured face and Y%
has two or more fractured faces
1.5.3
Step2: Selection of a Design Aggregate Structure (DAS)
Once a group of aggregates has been identified, these aggregates are combined at
different percentages to produce at least three distinct blends conforming to Superpave
gradation requirements presented in Table 7 according to designed NMAS.
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Table 7
Aggregate Gradation Requirements Control Points
Nominal Maximum Aggregate Size, mm - Control Point (Percent Passing)
Sieve Size
25.0 mm
Min.
Max.
50.0 mm
100
37.5 mm
90
25.0 mm
Min.
19.0 mm
Max.
Min.
Max.
12.5 mm
Min.
9.5 mm
Max.
Min.
Max.
4.75 mm
Min.
Max.
100
100
90
90
100
100
19.0 mm
90
90
100
100
12.5 mm
90
90
100
100
100
9.5 mm
90
4.75 mm
2.36 mm
15
41
19
45
23
49
28
1.18
0.075 mm
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100
95
100
90
90
100
58
32
67
30
60
10
10
12
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90
Primary Control Sieve (PCS) shown in Table 8 can be used to determine if the nominated
blend is fine or coarse gradation. If the gradation line passes below the PCS, it is considered
as coarse graded and it is considered fine gradation if the line passes above the PCS.
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37.5 mm
12.5mm
19mm
25mm
37.5 mm
2.36mm
2.36mm
4.75mm
4.75mm
9.5mm
Primary Control Sieve Size
47%
47%
40%
47%
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9.5mm
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Table 8
Gradation Classification - PCS Control Points
39%
%Passing PCS
Typically, three blends are developed ranging from the coarse to the fine side of the
Superpave control points for a given nominal maximum size (note: control points and PCS
differ for different NMAS). After selecting a blend (i.e. from the three trial blends), the
aggregate consensuses properties must be confirmed to meeting Superpave criteria by
actual testing.
The most difficult part of designing an aggregate structure is the creation of the VMA
necessary to meet the volumetric criteria. The procedure is typically a trial and error
process; however, there are some general guidelines that will assist in obtaining the
VMA. The following recommendations may be tried to increase VMA:
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(a)
Move the gradation away from the maximum density line;
(b)
Use highly angular particles;
(c)
Use particles with a rough surface texture;
(d)
Reduce the percent of natural sand and use more percent of the crushed sand;
(e)
Reduce the amount of P200 used in the HMA; and
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Use S-shaped gradation curve.
A good design aggregate structure is one that is economical and meets Superpave
volumetric criteria.
1.5.4
Work Instructions of Step 2 Selection of DAS
To select the design aggregate structure, do the following:

Obtain representative hot bin specimens from the plant.
(b)
Determine the consensus properties, water absorption, bulk and apparent specific
gravities for each aggregate fraction.
(c)
Grade the specimens using Superpave standard sieve set.
(d)
Input the values from two and three into ePAVE3 or combine manually. to
develop three blends that meet the Superpave criteria (i.e. within the control points for
the design NMAS)
(e)
Estimate the initial trial asphalt binder content using ePAVE3 or by using formulas
presented in ASSHTO R35.
(f)
For unmodified asphalt binders, determine the mixing and compacting temperature for
the proposed asphalt binder as follows:
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(a)
Measure the rotational viscosity using AASHTO T316 or ASTM D4402 at 135 C
and 165 C.
(ii)
Input the measured viscosities into ePAVE3. ePAVE3 will generate the viscositytemperature relationship.
(iii)
From the graph, determine:
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(i)
The mixing temperature at a rotational viscosity of 0.17 0.02 Pa.s.
The compaction temperature at a rotational viscosity of 0.28 0.03 Pa.s.
For modified asphalt binders, determine the mixing and compaction temperature in
accordance with one of the methods presented in NCHRP 648.
(h)
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(g)
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Prepare enough hot mix to make two 150 mm (or 100 mm) gyratory specimens and
two specimens to measure the Maximum Specific Gravity (Gmm) for each blend at the
estimated initial trial asphalt content.
Note: small specimen size of 100 mm is used for mixes having NMAS of 19.0 mm or below.
(i)
Leave the mix in the oven for two hours at the compaction temperature then
compact two 150.0 mm (or 100 mm) specimens for each blend using the Superpave
Gyratory Compactor (SGC) to Ndes according to AASHTO T312 (minimum number of
specimens is six).
(j)
For the specimens that were compacted to Ndes, measure the bulk specific gravity
(Gmb), and obtain the specimen height at Nini and Ndes from the gyratory compactor
that is automatically recording the specimen height for each gyration.
(k)
Measure the Maximum Specific Gravity (Gmm) for two specimens for each blend
according to ASSHTO T209.
(l)
Input the measured values into ePAVE3. ePAVE3 will perform the computations,
display results, and check them against the criteria of the project.
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Check the results given by ePAVE3 for the three blends and select the most
conforming blend as the DAS; in case none of the three blends meets Superpave
criteria, repeat the design by developing additional aggregate blends from the same
source ; if the criteria is not met change the sources.
Preparation of the binder and aggregate mixtures for the gyratory compactor (SGC) should
be timed such that a minimum of 20 minutes is allowed between batches. Batched
specimens should be conditioned in a closed draft oven for a minimum of 2 hours 5
minutes prior to compacting them in the SGC. Refer to AASHTO R30 for more details. The
short time oven aging is performed to permit time for the aggregate to absorb the
binder. All specimens including those for SGC and maximum specific gravity tests, should
be cured the same amount of time.
1.5.5
Step 3: Selection of the Design Asphalt Content
The selected aggregate blend (DAS) will then be mixed with four different proportions of the
binder as follows:
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Estimated asphalt binder content corrected to give 4.0% air voids.
(b)
Estimated asphalt binder content corrected to give 4.0% air voids minus 0.5 %.
(c)
Estimated asphalt binder content corrected to give 4.0% air voids plus 0.5 %.
(d)
Estimated asphalt binder content corrected to give 4.0% air voids plus 1.0 %.
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(a)
A sufficient amount of the proposed aggregate blend will need to be prepared to

permit two specimens to be compacted in the SGC according to Superpave system for
gyrations equal (Ndes), and the maximum specific gravity to be determined at each of the
four binder contents.
Preparation of the binder and aggregate mixtures for the SGC specimens should be timed
such that a minimum of 20 minutes is allowed between batches. Batched specimens should
be conditioned in a closed draft oven for a minimum of 2 hours 5 minutes prior to
compacting them in the SGC. Refer to AASHTO R30 for more details. The short time oven
aging is performed to permit time for the aggregate to absorb the binder. All
specimens including those for SGC and maximum specific gravity tests, should be cured the
same amount of time.
The procedure used for design in the laboratory will need to closely match the field conditions
at the time of construction. Failure to consistently test the materials at the same time interval
may result in a highly erratic all specific gravity values and possibly failure to achieve the
required VMA. After the necessary testing has been accomplished, the calculation of the
volumetric parameters can begin. The averaged results of the various volumetric calculations
need to be plotted relative to the corresponding binder content. The design binder content is
selected as that which satisfies the specified volumetric criteria at 4 percent air voids (refer to
AASHTO R35 for more details).
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1.5.6
Work Instruction of Step 3- Selection of DAC
To select the deign asphalt content, do the following:

After selecting the most conforming blend (DAS) from step 2, prepare enough
hot mix to make two 150 mm (or 100 mm) gyratory specimen and two specimens to
measure the Maximum Specific Gravity (Gmm) for four trial mixes using DAS of the
selected blend and four asphalt binder levels as specified in item (5.5.4) herein.
(b)
Compact two 150.0 mm (or 100 mm) specimens for each mix using the Superpave
Gyratory compactor to Ndes according to AASHTO T312 (total number of specimens
are eight)
(c)
For the specimens that were compacted to Ndes, measure the bulk specific gravity
(Gmb), and obtain the specimen height at Nini and Ndes from the gyratory compactor
that is automatically recording the specimen height for each gyration.
(d)
Input the measured values into ePAVE3. The program will perform all calculations,
produce the results and compare the results with required mix design properties for the
project.
(e)
ePAVE3 will generate the design curves, these are:

% air voids vs. asphalt content.
(ii)
% VMA vs. asphalt content.
(iii)
% VFA vs. asphalt content.
(iv)
% Gmm at Nini vs. asphalt content.
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(i)
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(a)
From the percentage, air voids vs. asphalt content curve determine the design asphalt
content (DAC) which corresponds to 4.0 % air voids.
(g)
Use the %VMA vs. asphalt content, %VFA vs. asphalt content % and %Gmm vs.
asphalt content graphs to obtain the VMA, FVA and the % Gmm @ Nini values at the
design asphalt content.
(h)
Input the DAC, %VMA, %VFA % and Gmm @ Nini into the appropriate cells in
ePAVE3.
ePAVE3 will perform the computations, display results, and check them
against the criteria of the project.
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(f)
(i)
If the mix properties at the design asphalt content conform to the Superpave criteria
then go to the Nmax verification; if not then analyze, evaluate and modify the
design as needed until the mix properties at the design asphalt content (DAC)
conform to the criteria.
1.5.7
Nmax and Ndes Verification
After conforming to Superpave criteria, then do the Nmax verification as follows:

(a)
Prepare enough hot mix at the selected gradation from (DAS) step 2 and the selected
design asphalt content (DAC) from step 3, to compact two 150 mm (or 100 mm)
specimens and two Gmm specimens.
(b)
Compact the specimens to Nmax using the gyratory compactor according to AASHTO
T312.
(c)
Measure the Gmb at Nmax for the two specimens that were prepared using SGC and
measure the Gmm.
QCS 2014
Page 53
(d)
Input the values into ePAVE3, which will perform the computations, provide the results,
and compare them with the Superpave criteria.
(e)
Check the results of ePAVE3, if acceptable then the design is concluded if not
then redesign the mix.
After conforming that the mix properties at Nmax meet Superpave criteria, then do the Ndes
verification as follows:
Prepare enough hot mix at the selected gradation from (DAS) step 2 and the selected
design asphalt content (DAC) from step 3, to compact two 150 mm (or 100 mm)
specimens and two Gmm specimens.
(b)
Compact the specimens to Ndes using the gyratory compactor according to AASHTO
T312.
(c)
Measure the Gmb at Ndes for the two specimens that were prepared using SGC and
use the Gmm from the previous step. Obtain the specimen height at Ndes and Nini from
the gyratory compactor that is automatically recording the specimen height for each
gyration.
(d)
Input the values into ePAVE3, which will perform the computations, provide the results,
and compare them with the Superpave criteria.
(e)
Check the results of ePAVE3, if acceptable then the design is concluded if not
then redesign the mix.
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(a)
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Part
05: Asphalt Works
Step 4: Evaluation of the Strength and the Moisture Sensitivity of the Mixture
The identification of the combination of a design aggregate structure and design binder
content is now complete. The mixture now needs to demonstrate that it is capable of
resisting the moisture induced damage. This evaluation is performed in accordance with
AASHTO T283.
Moisture sensitivity evaluation requires that a total of six specimens consisting of the
proposed aggregate blend and binder at the design binder content, be prepared and
compacted to approximately 7 0.5% air voids. This group of specimens is divided into
two subsets with three of the specimens being identified as the control specimens and
the other three being identified as conditioned specimens.
At the end of the conditioning period all of the specimens are loaded to failure in indirect
tension. Report the average Indirect Tensile Strength (IDT) of the dry subset in the mix
design report (see Table 5); and if the ratio of the average strength of the conditioned subset
to the control subset (retained strength) is more than or equal to 80% , then the mixture
passes the test. If the retained strength is less than 80%, then the mixture fails. The retained
strength can be increased by substituting part of the material finer than 0.075 mm by
mineral admixtures or by using chemical anti-stripping agents. Prepare another six (6)
specimens and test them as previously described. If this procedure does not improve the
retained strength to more than 80%, then the design process should be repeated using
different source.
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1.5.8
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1.5.9
Work Instructions of Step 4 Evaluation of Strength and the Moisture Sensitivity
To check the Strength and the moisture sensitivity of the designed mix, do the following:
Prepare enough hot mix to make six 150 mm (or 100 mm) gyratory compactor
specimens using the selected gradation (DAS) and the design asphalt content (DAC).
(b)
Use the Nmax verification densification data to identify the number of gyrations required
to achieve 7.0 0.5% % air voids (i.e. %Gmm = 92.5 to 93.5 %).
(c)
Compact six 150.0 mm (or 100 mm) specimens using the Superpave Gyratory
Compactor according to AASHTO T312 compactor (total number of specimens are
six) to a number of gyrations that will provide approximately 7.0 0.5 % air voids.
(d)
Use ASSHTO T283 to test the six specimens.
(e)
Input the measured values into ePAVE3. ePAVE3 will perform the computations and
provide the results and compare them with the Superpave criteria
(f)
Check the results given by ePAVE3. Report the average IDT of the Dry group in the
mix design report (see Table 5). If the ratio of the average IDT of the conditioned
subset to the control subset is 80% or more, then the mixture passes the test if not
consider redesigning the mix and use some additives.
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(a)
JOB MIX DESIGN PROPOSAL
A proposed Job Mix Formula (JMF) shall be formulated by the Contractor and submitted to
the Engineer and LSA for approval. The JMF shall be prepared by the Contractor in precise
compliance with Superpave system. The Contractor shall select his sources of aggregate
and bituminous material and, after sufficient quantities have been stockpiled or are available
for use, obtain representative specimens of the materials and test to determine if they
conform to the requirements of the specifications.
Before producing bituminous concrete mixtures, the Contractor shall submit in writing to the
Engineer, detailed information for each mix which he proposes to furnish. The information
shall include, but not be limited to the following:
The source(s) of the aggregate for each mix.
(b)
Copy of mix certificate approval obtained from LSA.
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(a)
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1.6
(c)
Pertinent test data and a written certification that the aggregates conform to all of the
quality requirements specified herein and in section 5.2.
(d)
Type of Asphalt modifier intended to be used in the project. The Asphalt binder
modifier shall be an approved modifier; along with the Certificate of Conformity of the
modified asphalt binder to the required grade according to the Superpave Performance
Based Grading System.
(e)
Pertinent test data on the type and properties of the asphalt binder, modified asphalt
binder, mineral filler, and chemical admixtures/asphalt modifiers to be furnished.
(f)
Superpave mix design report in ePAVE3 format.
(g)
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Part
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Page 55
Type of Asphalt modifier intended to be used in the project. The Asphalt binder
modifier shall be an approved modifier; along with the Certificate of Conformity of the
modified asphalt binder to the required grade according to the Superpave Performance
Based Grading System.
(i)
Pertinent test data on the type and properties of the asphalt binder, modified asphalt
binder, mineral filler, and chemical admixtures/asphalt modifiers to be furnished.
(j)
Superpave mix design report in ePAVE3 format.
(k)
(l)
The proposed beginning date for producing bituminous concrete mixtures.
(m)
Any other support data and information special to the project (e.g. technical data
sheets of a polymer in case it was used).
(h)
The Engineer shall be provided access to the materials sampling and testing operations at all
times.
At the same time that the above information is provided, the Engineer shall obtain one
hundred (100) kilogram specimens of each individual aggregate size, eight (8) liters of
bituminous material and, when used, sufficient quantities of the mineral filler and the
chemical admixture/asphalt modifier to complete two (2) proposed mix design checks,
all representing the materials which the Contractor proposes to furnish. The final job
mix formula shall be made by using hot-bins aggregate.
1.6.2
Acceptance of Job Mix Formula
The Engineer shall review the JMF to determine that it contains all required information. If it
does not contain all required information, it shall be returned within seven (7) days to the
Contractor for further action and resubmission by the Contractor.
If the proposed JMF contains all required information but fails to meet all of the requirements
specified, it shall not be accepted by the Engineer and will be returned to the Contractor
within fourteen (14) days. The Contractor shall prepare and submit to the Engineer a new
JMF conforming
to the requirements specified and propose a new date for beginning
production of the bituminous mixtures.
When the Engineer is satisfied that the JMF proposed by the Contractor conforms to all the
requirements of the specifications, he shall order the Contractor to construct a minimum of
two hundred (200) meter long field test strip; but, not exceeding one day's production. The
test strip is used for three purposes:
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(a)
To check the contractor ability to produce the approved mix within tolerances.
(b)
To check the contractor ability to construct and compact the mix to satisfy job
specifications.
(c)
To check the riding quality according to project specifications.
The Engineer shall evaluate the test strip as to its constructability and compactability and the
mix for conformance to the laboratory tested JMF within the tolerances listed in Table 9. Five
(5) specimens shall be obtained from the test strip and tested.
If the Engineer is not satisfied with the results of the test strip, he shall state his
objections in writing and request a revised JMF and a new test strip.
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Part
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Page 56
When the Engineer is satisfied that the JMF proposed by the Contractor conforms to all
requirements of the specifications and the test strip results are acceptable, he will issue
written acceptance to the Contractor to begin producing the proposed mixes. Production of
bituminous concrete mixtures shall not begin until the Engineer has given written acceptance
of the Job Mix Formula.
Acceptance of the JMF by the Engineer does not relieve the Contractor of his obligation to
produce bituminous concrete mixtures conforming to all specified requirements.
1.6.3
Construction Quality Control:
Testing to control the quality of bituminous concrete mixtures produced shall be the
responsibility of the Contractor.
For each class of bituminous concrete produced and each day's production, the Contractor
shall perform one (1) complete Superpave analysis at Ndes including gradation and asphalt
binder content, air voids, %VMA, %VFA, DP ratio, Indirect tensile strength on a specimen
obtained from the discharge gate or hauling vehicle. In addition, the Contractor shall
evaluate on a weekly basis the strength and moisture sensitivity of the mix from a specimen
obtained from the discharge gate or hauling vehicle.
No mixture conditioning is required when

assurance testing on plant-produced mixture.
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quality
control
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Table 9
Superpave Job Mix Formula Tolerances for HMA Plant Mix
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Mix Composition Property
Asphalt Binder Content (Pb)
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Gradation Passing 4.75 mm and Larger Sieves

Gradation Passing 2.36mm to 150m Sieve
Tolerance Limit
0.40
5
4
1.2
Air Voids (Va)
1.3
Voids in Mineral Aggregate (VMA)
1.5
Gradation Passing 75m Sieve
Field Density
92 to 94 (%Gmm)
or
quality
QCS 2014
Page 57
REFERENCES
Hot Asphalt Mix Design System Using Superpave System Detailed in Asphalt Institute
SP-2 and the AASHTO 2005 Standards MOT Saudi Arabia, 2006.
2)
AASHTO M323: Standard Specification for Superpave Volumetric Mix Design.
3)
(NCHRP) Report 567: Volumetric Requirements for Superpave Mix Design.
4)
(NCHRP) Report 409: Quality Control and Acceptance of Superpave-Designed Hot

Mix Asphalt.
5)
(NCHRP) Report 539: Aggregate Properties and the Performance of SuperpaveDesigned Hot-Mix Asphalt.
6)
(NCHRP) Report 513: Simple Performance Tester for Superpave Mix Design.
7)
(NCHRP) Report 648: Mixing and Compaction Temperatures of Asphalt Binders in

Hot-Mix Asphalt.
8)
AASHTO T320: Standard Method of Test for Determining the Permanent Shear Strain
and Stiffness of Asphalt Mixtures Using the Superpave Shear Tester (SST).
9)
AASHTO T321: Standard Method of Test for Determining the Fatigue Life of
Compacted Hot-Mix Asphalt (HMA) Subjected to Repeated Flexural Bending.
10)
AASHTO T322: Standard Method of Test for Determining the Creep Compliance and
Strength of Hot-Mix Asphalt (HMA) Using the Indirect Tensile Test Device.
11)
AASHTO T340: Standard Method of Test for Determining the Rutting Susceptibility of
Hot Mix Asphalt (APA) Using the Asphalt Pavement Analyzer (APA).
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1.7

Part
05: Asphalt Works
END OF PART
QCS 2014

Part
06: Concrete Road Pavements
Page 1
CONCRETE ROAD PAVEMENTS .......................................................................... 3
6.1
6.1.1
6.1.2
6.1.3
GENERAL REQUIREMENTS .................................................................................. 3

Scope
3
References
3
Quality Control of Concrete Strength
4
6.2
6.2.1
6.2.2
6.2.3
TRIAL LENGTH ....................................................................................................... 5

General Requirements for Trial Length
5
Assessment of Trial Length
6
Approval and Acceptance of Trial Length
7
6.3
6.3.1
6.3.2
6.3.3
6.3.4
6.3.5
6.3.6
6.3.7
6.3.8
6.3.9
6.3.10
6.3.11
6.3.12
6.3.13
6.3.14
6.3.15
6.3.16
6.3.17
6.3.18
6.3.19
6.3.20
6.3.21
6.3.22
6.3.23
6.3.24
6.3.25
6.3.26
6.3.27
6.3.28
6.3.29
6.3.30
6.3.31
6.3.32
6.3.33
6.3.34
6.3.35
6.3.36
REQUIREMENTS FOR PAVEMENT QUALITY CONCRETE .................................. 7

Materials and Mix Designs for Pavement Quality Concrete
7
Workability of Pavement Quality Concrete
7
Trial Mixes
8
Separation Membrane
8
General Requirements for Steel Reinforcement
8
Jointed Reinforced Concrete Slabs
9
Continuously Reinforced Concrete Slabs (CRCP or CRCR)
10
General Requirements for Transverse Joints
10
Transverse Contraction Joints
11
Transverse Expansion Joints
11
Transverse Warping Joints
11
Transverse Construction Joints
11
General Requirements for Longitudinal Joints
12
Longitudinal Construction Joints
13
Dowel Bars
13
Joint Grooves
16
Groove Formers and Bottom Crack Inducers
17
Joint Filler Board
18
Preparation and Sealing of Joint Grooves
18
Sealing with Applied Sealants
19
Sealing with Compression Seals
20
Joint Seals
21
Joints at Manhole and Gully Slabs
21
Inspection of Dowel Bars
22
Side Forms, Rails and Guide Wires
22
Delivery, Storage and Batching of Concreting Materials
23
Mixing Concrete
24
Transport and Delivery
24
General Requirements for Construction by Machine
24
Construction by Fixed Form Paving Machines
25
Construction by Slip-Form Paving Machine
26
Construction by Small Paving Machines or Hand Guided Methods
26
Surface Textures
28
Strength
29
Trial Mixes
29
Trial Length
29
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Part
Page 2
Surface Finish
30
6.4
6.4.1
6.4.2
6.4.3
6.4.4
6.4.5
6.4.6
6.4.7
6.4.8
6.4.9
6.4.10
6.4.11
6.4.12
6.4.13
REQUIREMENTS FOR CEMENT BOUND MATERIALS ....................................... 30

General Requirements for Cement Bound Materials
30
Batching and Mixing
31
Transporting
31
Laying
31
Compacting
32
Curing
32
Preliminary Trial
33
Cement Bound Material Category 1 (CBM1)
33
34
34
34
Testing of Cement Bound Materials
35
Special Requirements for Cement Bound Materials
35
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6.3.37
QCS 2014

Part
Page 3
CONCRETE ROAD PAVEMENTS
6.1
6.1.1
Scope
This part of the specification covers the; materials, mix designs, production and laying of
pavement quality concrete, lean mix concrete and cement bound materials.
Related Sections and Parts are:
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This Section
Part 3 ............... Earthworks
Part 4 ............... Unbound Pavement Materials
Part 5 ............... Asphalt Works
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Section 5 - Concrete
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Part 16 ............ Miscellaneous - Pavement Quality Concrete

References
The following standards are referred to in this part of the specification
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6.1.2
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BS 1377: Part 9 ..........Methods of testing soils in-situ tests

BS 1881...................... Methods of testing concrete Hot applied joint sealants for road pavements
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BS 2499 & BS EN 14188
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BS 1924: Part 1 & 2.... Stabilised materials for civil engineering purposes
BS 2752...................... Chloroprene rubber compounds
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BS 3900: Part F12 ...... Determination of resistance to neutral salt spray

BS 3963...................... Method for testing the performance of concrete mixers
BS EN ISO 11600 ...... Two part polysulphide sealants
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BS 4449...................... Reinforcing bars

BS 4482...................... Cold drawn steel wire for reinforcing concrete
BS 4483...................... Reinforcing mesh

BS 5212: Part 1 & 2.... Cold applied joint sealants for concrete pavements
BS EN 206 & BS 8500
Supply of concrete
BS 7542...................... Methods for test of curing compounds for concrete

BS 812........................ Testing methods for aggregates
ASTM D3406 .............. Specification for joint sealant - hot applied elastomeric types
ASTM 7116 ................ Specification for joint sealant - hot applied elastomeric types (jet
fuel resistant)
ASTM D2628-91......... Specification for preformed joint seals
DTP ............................ Manual of contract documents for highway works -Volume 1
specification for highway works
QCS 2014

Part
Page 4
6.1.3
Quality Control of Concrete Strength
Sampling and testing for, and compliance with the specified characteristics strength of
designed mixes shall be in accordance with BS EN 206 & BS 8500, except that it shall be at
the following rates of sampling and testing and meet the following requirements:
(a)
Concrete cubes of the appropriate size shall be made, cured and tested in accordance
with BS 1881 respectively from concrete delivered to the paving plant, each group
being from a different delivery of concrete. At least 3 cubes shall be made per group
2
for each 600 m of concrete slab and not less than 6 groups shall be made each day,
2
for each type of mix. For areas less than 600 m , at least 4 cubes shall be made for
2
each 100 m or less. This rate of sampling and testing may be reduced at the
Engineer's discretion.
For areas of 600 m or more, one cube shall be tested in compression at 7 days and
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(b)
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the other two at 28 days after mixing. Groups of four consecutive results at 28 days
shall be used for assessing the strength for compliance with BS EN 206 & BS 8500.
2
For areas less than 600 m , two cubes shall be tested at 7 days and two tested at 28
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days and assessed in accordance with BS EN 206 & BS 8500.

The ratio R between 7 and 28 day strengths shall be established for the mix to be used
in the slab by testing pairs of cubes at each age on at least six batches of the
proposed mix or it shall be quoted by the supplier of the concrete. The average
strength of the 7 day pair of cubes shall be divided by the average strength of the 28day pair of cubes for each batch and the ratio R shall be the average of these six
values. The ratio R shall be expressed to three decimal places.
(d)
If during the construction of the trial length or during normal working, the average value
of any 4 consecutive 7 day test results falls below the strengths required then the
cement content of the concrete shall be increased by 5 % by mass or by an amount
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(c)
The values in columns 3 and 4 of Table 6.1 may only be used with the permission of
the Engineer when sufficient test results on trial mixes for calculating the ratio are not
available. Once sufficient results are available from normal working the ratio R shall be
calculated from the results available on Site.
(e)
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agreed by the Engineer. The increased cement content shall be maintained at least
until the four corresponding 28-day tests have been assessed. If the cement content is
increased, the concrete mix shall be adjusted to maintain the required workability.
(f)
To assess the time for use of a concrete slab by traffic, the strength development rate
may be predetermined by trial mixes. Alternatively pairs of cubes shall be made for
2
each 600 m or less and stored alongside the pavement in containers or in such a way
that their sides are well insulated. If thermal insulation is used for accelerated curing
the cubes shall be similarly insulated. Pairs of cubes shall be tested at intervals
decided by the Engineer. Tests for compliance with the specified strength shall be
made in the normal way.
QCS 2014

Part
Page 5
Table 6.1
7 Day Cube Strength
All Mixes, R
available
PC Mixes, R not
available
PFA or ggbs mixes, R

2
not available N/mm
C40
43R
35
29
C30
33R
27
22
C20
22R
18
14
C15
17R
13
11
C10
10R
C7.5
7R
5.5
4.5
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Grade of Concrete
TRIAL LENGTH
6.2.1
General Requirements for Trial Length
Except in rapid construction projects, at least one month prior to the construction of the trial
length of surface slabs or CRCR (Continuously Reinforced Concrete Road Base) the
Contractor shall submit for the Engineer's approval a detailed description of the proposed
materials, mix proportions, plant, equipment and construction methods.
No trials of new materials, plants, equipment or construction methods; nor any development
of them shall be permitted either during the construction of the trial length or in any
subsequent paving work, unless they form part of further approved trials.
The Contractor shall demonstrate the materials, mix proportions, plant, equipment and
method of construction that are proposed for concrete paving, by first constructing a trial
length of slab, at least 150m but not more than 300 m, long for mechanised construction, and
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6.2
at least 30m long for hand guided methods, or otherwise as directed by the Engineer.
The mix proportions decided by trial mixes may be adjusted during the trial but shall not be
changed once the trial length has been approved except with the agreement of the Engineer.
The trial length shall be constructed in two parts over a period comprising at least part of two
separate working days, with a minimum of half the proposed trial lengths constructed each
day. The trial length shall be constructed at a similar rate to that which is proposed for the
main construction in the permanent works.
At least two transverse joints and one longitudinal joint of each type that are proposed for
unreinforced concrete slabs and jointed reinforced concrete slabs in the main construction in
the permanent works shall be constructed and assessed in the trial length.
If in the trial length expansion joints are not demonstrated, the first 2 expansion joints and at
least the first 150 m of longitudinal construction joint for mechanised paving, or 30 m for hand
guided method of construction laid in the main construction in the permanent works, shall be
considered the trial length for these joints.
QCS 2014

Part
Page 6
One construction joint shall be demonstrated in each trial length of CRCP or CRCR.
6.2.2
Assessment of Trial Length
The trial length shall comply with the Specification in all respects, with the following additions
and exceptions provided in (a) through (d) below.
(a)
Surface Levels and irregularity

(i)
in checking for compliance the levels shall be taken at intervals of not more than
2.5 m along any line or lines parallel to the longitudinal centre line of the trial
length.
The maximum number of permitted irregularities of pavement surfaces shall
comply with the requirements for asphalt pavements as per Part 5
for 300 m lengths. Shorter trial lengths shall be assessed pro-rata based on
values for a 300 m length.
(b)
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(ii)
Joints
At least 3 cores of minimum diameter 100 mm shall be taken from the slab at
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joints to check the lateral and vertical location of joint grooves and bottom crack
inducers.
After a minimum of 24 hours following construction the removable part of the
joint groove former shall be taken out and at least three joints and the sides of
the groove shall be inspected for compaction. If there are voids the size and
number should be compared with a similar size section of the photograph for 3%
excess voidage in BS 1881. If there is excess voidage, additional
compaction shall be provided and further joints inspected. The joints so
exposed shall be temporarily or permanently sealed
(iii)
Alignment of dowel bars shall be inspected in any two consecutive transverse

joints. If the position or alignment of the dowel bars at one of these joints does
not comply after the next 3 consecutive joints of the same type have been
inspected then the method of placing dowels shall be deemed to be satisfactory.
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(ii)
(iv)
(c)
Density
(i)
(d)
If there are deficiencies in the first expansion joint constructed as a trial,

the next expansion joint shall be a trial joint. Should this also be deficient further
trial expansion joints shall be made as part of a trial length which shall not form
part of the Permanent Works, unless agreed by the Engineer.
Density shall be assessed from at least 3 cores drilled from each part of the trial
length.
Position of Reinforcement and Tie Bars

(i)
Compliance for the position of steel reinforcement and for the position and
alignment of tie bars shall be checked by drilling additional cores from the slab
unless they can be determined from cores taken for density assessment.
QCS 2014

Part
Page 7
Approval and Acceptance of Trial Length
Approval of the materials, mix proportions, plant, equipment and construction methods will be
given when a trial length complies with the specifications. The Contractor shall not proceed
with normal working until the trial length has been approved and any earlier defective trial
lengths have been removed, unless they can be remedied to the satisfaction of the Engineer.
When approval has been given, the materials, mix proportions, plant, equipment and
construction methods shall not thereafter be changed, without the approval of the Engineer
except for maintenance of plant. Any changes in materials, mix proportions, plant,
equipment, and construction methods shall entitle the Engineer to require the Contractor to
lay a further trial length as described in this Clause to demonstrate that these changes will
not adversely affect the permanent works.
Trial lengths which do not comply with the Specification, with the exception of areas within
the pavement surface which can be remedied shall be removed immediately upon notification
of deficiencies by the Engineer and the Contractor shall construct a further trial length.
6.3
REQUIREMENTS FOR PAVEMENT QUALITY CONCRETE
6.3.1
Materials and Mix Designs for Pavement Quality Concrete
The constituent materials and mix designs for pavement quality control shall be as per
Section 5: Part 16.
6.3.2
Workability of Pavement Quality Concrete
The workability of the concrete at the point of placing shall enable the concrete to be fully
compacted and finished without undue flow. The optimum workability for the mix to suit the
paving plant being used shall be determined by the Contractor and approved by the
Engineer.
The workability shall be determined by the compacting factor test, or the Vebe test or
alternatively for concrete grade C20 or below, by the slump test, all in accordance with BS
1881, at the minimum rate of one determination per 300 m2 of slab laid or 6 times per day,
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6.2.3
whichever is greater. For areas less than 300 m2 the rate shall be at least one determination
to each 20 m length of slab or at least 3 times per day.
3
Alternatively the volumetric method of determining the Compacting Factor in BS 1881 may be
used. Tests for workability shall be carried out at the point of placing, in conjunction with
tests for strength and any tests for air content. The workability shall be maintained at the
optimum within the following tolerances.
Compacting Factor (CF)
Slump
Vebe
+0.03
+20mm
+3 seconds or as agreed by the Engineer as a results of trial
mixes.
Any alteration to the optimum workability necessitated by a change in conditions shall be

agreed beforehand by the Engineer.
QCS 2014

Part
Page 8
If any determination of workability gives result outside the tolerance, a further test shall be
made immediately on the next available load of concrete. The average of the two consecutive
results and the difference between them shall be calculated. If the average is not within the
tolerance or the difference is greater than 0.06 for CF or 20 mm for slump, or 6 seconds for
Vebe or other value agreed with the Engineer, subsequent samples shall be taken from the
delivery vehicles, which shall not be allowed to discharge into the Works until compliance
with the Specification has been established.
Trial Mixes
For concrete grades C15 and above the Contractor shall carry out laboratory trials of
designed mixes with the materials from all sources to be used in the Works, in accordance
with BS EN 206 & BS 8500 unless recent data relating entirely to the proposed mix is
The trial mixes shall be repeated if necessary until the proportions of ingredients are
determined which will produce a concrete which complies in all respects with the
Specification.
Apart from minor adjustments to the mix as permitted by BS EN 206 & BS 8500 any changes
in sources of materials or mix proportions that are proposed by the Contractor during the
course of the Works shall be assessed by making laboratory trial mixes and the construction
of a further trial length unless otherwise approval is given by the Engineer.
6.3.4
Separation Membrane
A separation membrane shall be used between jointed reinforced concrete surface slabs or
unreinforced concrete surface slabs and the sub base.
Separation membranes shall be impermeable plastic sheeting 125 microns thick laid flat
without creases. Where an overlap of plastic sheets is necessary, this shall be at least
300 mm. There shall be no standing water on or under the membrane when the concrete is
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6.3.3
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placed upon it.
Under CRCP and CRCR a waterproof membrane shall be provided, which shall be a
bituminous spray before concreting. Where a bituminous spray has been used to cure
cement bound material or wet lean concrete then only those areas which have been
damaged shall be resprayed after making good. The waterproof membrane shall be
bituminous cutback in accordance with clause 5.12 of this Section.
6.3.5
General Requirements for Steel Reinforcement
Reinforcement shall comply with any of the following standards and be in prefabricated
sheets or cages, or bars assembled on site and shall be free from oil, dirt, loose rust and
scale:
(a)
(Carbon steel bars for the reinforcement of concrete) BS 4449
(b)
(Cold-reduced steel wire for the reinforcement of concrete) BS 4482
(c)
(Steel fabric for the reinforcement of concrete) BS 4483
QCS 2014
(d)

Part
Page 9
When deformed bars are used they shall conform to Type 2 bond classification of BS
4449.
Spacing of bars shall not be less than twice the maximum size of aggregate used. Laps in
longitudinal bars shall be not less than 35 times bar diameters or 450 mm which ever is
greater. In continuously reinforced concrete slabs (CRCP or CRCR) only one third of the
laps may be in any one transverse section, except in single bay width construction where half
the laps may be in any one transverse section. There shall be a minimum of 1.2 m
longitudinally between groups of transverse laps or laps in prefabricated reinforcement
sheets. Alternatively the reinforcement may be butt welded by a process approved by the
Engineer.
Laps in a transverse reinforcement shall be a minimum of 300 mm. Where prefabricated
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reinforcement sheets are used and longitudinal and transverse laps would coincide, no lap is
required in the transverse bars within the lap of the longitudinal reinforcement. These
transverse bars may be cropped or fabricated shorter so that the requirements for cover are
met.
If the reinforcement is positioned prior to concreting, it shall be fixed on approved metal
supports and retained in position at the required depth below the finished surface and
distance from the edge of the slab so as to ensure that the required cover is achieved.
Reinforcement assembled on site shall be tied, or firmly fixed, by a procedure agreed with the
Engineer, at sufficient intersections to provide sufficient rigidity to ensure that the
reinforcement remains in the correct position during construction of the slab.
Alternatively, when a reinforced concrete slab (JRC, CRCP or CRCR) is constructed in two
layers, the reinforcement in the form of prefabricated sheets may be placed on or into the
bottom layer which shall be spread and compacted to such a level that it will support the
reinforcement without distortion at the required position in the slab. The sheets shall be tied
together at overlaps and after the second layer has been spread and compacted, the
reinforcement shall have the required cover.
When a reinforced concrete slab is constructed at maximum width the transverse

reinforcement in the centre of each slab width shall be a minimum of 12 mm nominal
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diameter bars at 600 mm centres. This reinforcement shall be at least 600 mm longer than
one third of the width of the slab and be lapped to other transverse reinforcement bars or
sheets, or be continuous across the whole width of each slab.
6.3.6
Jointed Reinforced Concrete Slabs
The reinforcement shall be so placed that after compaction of the concrete, the cover below
the finished surface of the slab is 50 + 10 mm for slabs less than 200 mm thick, 60 + 10 mm
for slabs 200 mm or more but less than 270 mm thick and 70+20 mm for slabs 270 mm thick
or more.
The negative vertical tolerance shall not be permitted beneath road stud recesses.
Where traffic signal detector loops are to be installed, the minimum cover to the
reinforcement from the surface shall be 100 mm.
QCS 2014

Part
Page 10
The vertical cover between any longitudinal joint groove forming strip and any reinforcement
or tie bars shall be at a minimum of 30 mm.
Any transverse bars shall be at right angles to the longitudinal axis of the carriageway. Any
transverse reinforcement shall terminate at 125+25 mm from the edges of the slab and
longitudinal joints, where tie bars are used.
No longitudinal bars shall lie within 100 mm of a longitudinal joint. The reinforcement shall
terminate 300 mm + 50 mm from any transverse joint, excluding emergency construction
joints.
Continuously Reinforced Concrete Slabs (CRCP or CRCR)
The reinforcement shall be Grade 460 deformed steel bars as detailed on the Contract
Drawings.
The reinforcement shall consists of bars assembled on site, or of prefabricated sheets.
Except where otherwise shown on the Drawings the longitudinal bars shall be parallel to the
centre line of the road.
The reinforcement shall be positioned so that, after compaction of the concrete, it shall be at
the mid depth of the specified thickness of the slab + 25 mm. No longitudinal bar shall lie
In reinforcement assembled on site, longitudinal bars shall be placed immediately above any
transverse bars, which shall be at right angles to the longitudinal axis of the carriageway.
Any transverse reinforcement shall terminate 125+25 mm from the edges of the slab and
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within 100mm of a longitudinal joint.
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6.3.7
longitudinal joints where tie bars are used.

General Requirements for Transverse Joints
Transverse joints shall be provided in unreinforced and jointed reinforced concrete slabs and
shall be contraction, expansion or warping joints at the spacing shown on the Drawings such
that for unreinforced concrete slabs the length/width ratio shall be not greater than 2.0.
Joints in the surface slab and sub-base shall be staggered so that they are not coincident
vertically and are at least 1m apart.
Transverse joints shall be straight within the following tolerances along the intended line of
the joint, which is the straight line transverse to the longitudinal axis of the carriageway at the
position proposed by the Contractor and agreed by the Engineer, except at road junctions or
roundabouts where the positions shall be as shown on the Drawings:
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6.3.8
(a)
Deviations of the filler board or bottom crack inducer from the intended line of the
joint shall be not greater than 10 mm.
(b)
The best fit straight line through the joint groove as constructed shall be not more
than 25 mm from the intended line of the joint.
(c)
Deviations of the joint groove from the best fit straight line of the joint shall be not
greater than 10 mm.
QCS 2014
(d)

Part
Page 11
When top groove formers and bottom crack inducers are used, the joint groove
as constructed shall be located vertically above the bottom crack inducer within a
horizontal tolerance of 25 mm.
Transverse joints on each side of a longitudinal joint shall be in line with each other and of
the same type and width. The position of the joints relative to manholes and gullies shall be in
accordance with the Drawings.
Transverse joints shall have a sealing groove which shall be sealed in compliance with
Clause 6.3.20 of the specification.
6.3.9
Transverse Contraction Joints
Contraction joints shall consist of:

Either a sawn joint groove, or
(b)
a wet formed joint groove and a bottom crack inducer
(c)
dowel bars
(d)
a sealing groove.
Expansion joints shall consist of:
(b)
dowel bars
(c)
a sealing groove.
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(a)
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Transverse Expansion Joints
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(a)
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The filler board shall be positioned vertically within the prefabricated joint assemblies along
the line of the joint and at such depth below the surface as will not impede the passage of the
finishing beams on the paving machines.
The joint filler board together with the sealing groove shall provide a complete separation of
adjacent slabs and any spaces around dowel bars and between the sub-base and the filler
board shall be packed with a suitable compressible material after fixing the joint assembly.
6.3.11
Transverse Warping Joints
Warping joints shall consist of:
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(a)
Either a sawn joint groove, or
(b)
a wet formed joint groove and a bottom crack inducer
(c)
tie bars
(d)
a sealing groove.
6.3.12
Transverse Construction Joints
Construction joints made at the end of a working day in unreinforced concrete slabs and
jointed reinforced concrete slabs shall be expansion joints or contraction joints. In the event
of mechanical breakdown of the concreting machinery, or at the onset of adverse weather,
emergency joints may be formed.
QCS 2014

Part
Page 12
Emergency joints in unreinforced concrete slabs shall be either contraction or expansion

joints not less than 2.5 m from the preceding or succeeding joint position.
Emergency joints in jointed reinforced concrete slabs shall be not less than 2.5 m from the
preceding or succeeding joint position. The stop end formwork shall be sufficiently rigid to
ensure that dowel bars, tie bars or reinforcement will be held in position in compliance with
the specification, and placed in such a position that it permits the longitudinal reinforcement
to project through the joint for a distance of at least 750 mm.
Construction joints in continuously reinforced concrete slabs (CRCP and CRCR) in an

emergency shall not be constructed within 1.5 m of any lap in the longitudinal reinforcement
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without the approval of the Engineer. The stop end formwork shall be sufficiently rigid to
ensure that the longitudinal reinforcement and the tie bars projecting through the joint are
held in the correct position.
General Requirements for Longitudinal Joints
Longitudinal joints shall be provided in surface slabs between or at the centre of traffic lanes
within the allowable positions as shown on the Drawings, so that bay widths are not greater
than 4.2 m (or 5.0 m with limestone aggregate) for unreinforced slabs, or 6 m (or 7.6 m with
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6.3.13
limestone aggregate) for reinforced concrete surface slabs with transverse reinforcement.
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Longitudinal joints shall be provided in CRCR between lanes or at the centre of lanes, within
a tolerance of +150 mm so that bay widths are not greater than 6 m (or 7.6 m with limestone
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aggregate).
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Joints in the surface slab, road base or sub-base shall be staggered so that they are not
coincident vertically and are least 300 mm apart. The positions of all longitudinal joints in any
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slab shall be agreed by the Engineer prior to construction of the slab.

Wet-formed longitudinal joints shall consists of wet-formed joint grooves, bottom crack
inducer and tie bars except where transverse reinforcement is permitted in lieu.
Longitudinal joints shall be constructed in the positions agreed by the Engineer within the
following tolerances:
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(a)
Deviations of the bottom crack inducer from the intended line of the joint parallel
to the axis of the road shall not be greater than +13 m.
(b)
The joint groove shall be located vertically above the bottom crack inducers within
a horizontal tolerances of +25 mm.
(c)
The best fit line along the constructed joint groove, shall be not more than 25 mm
from the intended line of the joint.
(d)
Deviations of the joint groove from the best fit line of the joint shall be not greater
than 10 mm.
QCS 2014

Part
Page 13
Tie bars may be replaced by continuous transverse reinforcement across the joints in
continuously reinforced concrete slabs, which are constructed in more than one lane width in
one operation, provided that the transverse reinforcement is a minimum of 12 mm diameter
bars at 600 mm centres.
6.3.14
Longitudinal Construction Joints
Longitudinal construction joints between separate slabs shall have tie bars with a joint
groove. Alternatively, if split forms are used, the transverse reinforcement, if 12 mm diameter
or more, may be continued across the joint for a minimum of 500 mm or 30 times the
diameter of the transverse reinforcement bars, whichever is greater.
A joint sealing groove is not required in construction joints in continuously reinforced concrete
road bases. Where the edge of the concrete slab is damaged it shall be made good to the
approval of the Engineer before the adjacent slab is constructed.
6.3.15
Dowel Bars
Dowel bars shall be Grade 250 steel complying with BS 4449 and shall be free from oil, dirt,
loose rust and scale. They shall be straight, free of burrs and other irregularities and the
sliding ends sawn or, if approved by the Engineer, cropped cleanly with no protrusions
outside the normal diameter of the bar. For expansion joints, dowel bars shall be 25mm
diameter at 300 mm spacing, 600 mm long for slabs up to 239 mm thick and 32 mm diameter
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for slabs 240 mm thick or more. For contraction joints, dowels shall be 20 mm diameter at
240 mm thick or more.
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300 mm spacing 400 mm long for slabs up to 239 mm thick and 25 mm diameter for slabs
Dowel bars shall be supported on cradles in prefabricated joint assemblies positioned prior to
construction of the slab. For contraction joints, as an alternative to prefabricated assemblies,
dowel bars may be mechanically inserted with vibration into the concrete by a method which
shall ensure full recompaction of the concrete around the dowel bars and the surface finished
by a diagonal finishing beam. Or a longitudinal oscillating float travelling across the slab.
Dowel bars shall be positioned at mid-depth from the surface level of the slab 20 mm.
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They shall be aligned parallel to the finished surface of the slab, to the centre line of the
carriageway and to each other within the following tolerances:
(a)
for bars supported on cradles prior to construction of the slab and for inserted
bars in two layers construction prior to placing the top layer:
(i)
All bars in a joint shall be within 3 mm per 300 mm length of bars.
(ii)
Two thirds of the bars shall be within 2 mm per 300 mm length of bar.
(iii)
No bar shall differ in alignment from an adjoining bar by more than 3 mm per
300 mm length of bar in either the horizontal or vertical plane.
(b)
for all bars, after construction of the slab:

(i)
Twice the tolerances for alignment as in (i) above.
QCS 2014

Part
(ii)
Page 14
Equally positioned about the intended line of the joint within a tolerance of 25
mm.
Cradles supporting dowel bars shall not extend across the line of the joint.
Dowel bars, supported on cradles in assemblies, when subjected to a load of 110N applied at
either end and in either the vertical or horizontal direction (upwards and downwards and both
directions horizontally) shall not deflect more than the following limits:
Two thirds of the number of bars of any assembly tested shall not deflect more than 2 mm
per 300 mm length of bar.
The remainder of the bars in that assembly shall not deflect more than 3 mm per 300 mm
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length of bar.
The assembly of dowel bars and supporting cradles, including the joint filler board in the case
of expansion joints shall have the following degree of rigidity when fixed in position:
For expansion joints the deflection of the top edge of the filler board shall be not
greater than 13 mm, when a load of 1.3 kN is applied perpendicular to the vertical
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face of the joint filler board and distributed over a length of 600 mm by means of
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a bar or timber packing at mid depth and midway between individual fixings, or
300 mm from either end of any length of filler board, if a continuous fixing is used.
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The residual deflection after removal of the load shall be not more than 3 mm.
The joint assembly fixings to the sub-base shall not fail under the 1.3kN load
applied for testing the rigidity of the assembly but shall fail before the load
reaches 2.6 kN.
11
The fixings for contraction joints shall not fail under a 1.3 kN load and shall fail
before the load reaches 2.6 kN when applied over a length of 600 mm by means
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12
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of a bar or timber packing placed as near to the level of the line of fixings as
practicable.
Failure of the fixings shall be deemed to be when there is displacement of the
assemblies by more than 3 mm with any form of fixing, under the test load. The
displacement shall be measured at the nearest part of the assembly to the centre
of the bar or timber packing.
13
Dowel bars shall be covered by a thin plastic sheath over the whole length of the bar. The
sheath shall be tough, durable and of an average thickness not greater than 1.25 mm. The
sheathed bar shall comply with the following pull out test:
QCS 2014
14

Part
Page 15
Four bars shall be taken at random from stock and without any special
preparation shall be covered by sheaths.
The dowel bars which have been
sheathed shall be cast centrally into concrete specimens 150x150x450 mm,
made of the same mix proportions to be used in the pavement, but with a
maximum nominal aggregate size of 20 mm and cured in accordance with
BS 1881.
At 7 days a tensile load shall be applied to achieve a movement
of the bar at least 0.25 mm.
The average bond stress to achieve this movement
shall be not greater than 0.14 N/mm2.

15
For expansion joints a closely fitting cap 100 mm long consisting of waterproofed cardboard
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or an approved synthetic material shall be placed over one end of each

dowel bar. An expansion space 10 mm greater than the thickness of the joint filler board shall
be formed between the end of the cap and the end of the dowel bar.
Tie Bars
17
Tie bars in transverse or longitudinal joints shall be Grade 250 steel or Grade 460 deformed
steel bars complying with BS 4449, in accordance with the requirements given below and
Table 6.2. Deformed bars shall have Type 2 bond classification. Tie bars shall be free from
oil, dirt, loose rust and scale. Tie bars which are to be cranked and later straightened shall be
Grade 250.
18
Tie bars projecting across a longitudinal joint shall be protected from corrosion by a flexible
polymeric corrosion resistant coating, bonded onto the previously cleaned centre section,
leaving between 250 mm and 300 mm of each of the bars uncoated.
19
Where tie bars are cranked for construction joints and later straightened the coating shall be
shown to be capable of being straightened through 90 degrees without cracking. The coating
shall also be able to withstand 250 hours immersion in a salt fog cabinet complying with BS
3900 : Part F12, without showing any visible cracking, or corrosion of the protected part of
the bar. Any damage observed on the coating after straightening shall be made good before
the concrete is placed.
20
Tie bars in warping joints and wet-formed longitudinal joints shall be made up into rigid
assemblies with adequate supports and fixings to remain firmly in position during the
construction of the slab.
21
Alternatively, tie bars at longitudinal joints may be mechanically inserted by vibration from
above using a method which ensures recompaction of the concrete around the tie bars.
22
At longitudinal construction joints, tie bars may be adequately fixed to side forms or inserted
into the side of the slab by a method which ensures recompaction of the concrete around the
tie bars and adequate bond and which shall be approved by the Engineer.
23
Tie bars shall be positioned and remain within the middle third of the slab depth,
approximately parallel to the surface and approximately perpendicular to the line of the joint,
with the centre of each bar on the intended line of the joints within a tolerance of 50 mm,
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16
and with a minimum cover of 30 mm below any top crack inducer or joint groove for slabs
200 mm thick or more, or 20 mm for slabs up to 200 mm thick.
QCS 2014
24

Part
Page 16
At transverse construction joints in continuously reinforced concrete, tie bars shall be 1.5 m
long and of the same grade and size as the longitudinal reinforcement, and shall be fixed at
twice the normal spacing midway between the longitudinal reinforcement bars so that
750 mm 50 mm extends each side of the joint at the same level as the longitudinal
reinforcement and be tied to the transverse reinforcement. Where paving from a construction
joint is not resumed within 5 days, and extra longitudinal reinforcement bar at 8 m long shall
be lapped and tied to each tie bar. These extra bars may be combined with the tie bars.
Where the spacing between longitudinal reinforcement and the extra 8 m long bars is less
than 90 mm, the nominal size of aggregate shall be 20 mm for a sufficient number of
concrete batches to complete that section of pavement.
Where tie bars are used in longitudinal joints in continuously reinforced concrete they shall be
placed at the same level as the transverse reinforcement and tied to the longitudinal
reinforcement.
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25
Length (mm)
Spacing (mm)
460
1500
Twice the
spacing of
main
reinforcement
12
250 or
460 deformed
1000
750
600
600
12
250 or
460 deformed
1000
750
300
600
12
250 or
460 deformed
1000
750
600
600
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As for main
reinforcement
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Transverse
construction joints
in continuously
reinforced concrete
Emergency
construction joints
in jointed reinforced
concrete slabs
other than at
contraction or
expansion joints
Grade of Steel
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Diameter (mm)
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Joints
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Table 6.2
Tie Bar Details
Warping joints
Longitudinal.
All joints, except
where transverse
reinforcement is
permitted in lieu
Note: The transverse reinforcement may be continued across the joint in reinforced concrete
with the approval of the Engineer if the bars are of a minimum nominal diameter of
12 mm and the bars are protected from corrosion and the cover is as required in this
Clause.
6.3.16
Joint Grooves
Transverse contraction or warping joint grooves shall be sawn in the hardened concrete.
QCS 2014

Part
Page 17
Transverse joint grooves which are initially constructed less than the full width of the slab
shall be completed by sawing through to the edge of the slab and across longitudinal joints as
soon as any forms have been removed and before an induced crack develops at the joint.
Sawn transverse joint grooves shall be undertaken as soon as possible after the concrete
has hardened sufficiently to enable a sharp edged groove to be produced without disrupting
the concrete and before random cracks develop in the slab. The grooves shall be between
1/4 and 1/3 of the specified depth of the slab and of any convenient width not less than 3mm.
The sealing groove may be constructed at the same time to be sawn to the required width
later. Unless otherwise approved by the Engineer, expansion joint sealing grooves shall be
sawn immediately before sealing.
Construction Joint Grooves in Surface Slabs shall be formed by fixing a groove-former, strip
or cork seal along the top edge of the slab already constructed, before concreting the
adjacent slab. Where the edge of the concrete is damaged it shall be ground or made good
to the approval of the Engineer before fixing the groove forming strip.
Alternatively the subsequent slab may be placed adjacent to the first and a sealing groove
sawn later in the hardened concrete to the minimum depth required in Table 6.3 or to the
manufacturer's instructions if greater, and to sufficient width to eliminate minor spalling of the
joint arris, up to a maximum of 25mm for longitudinal joints and 40mm for transverse joints.
The joints shall be sealed.
6.3.17
Groove Formers and Bottom Crack Inducers
Except where joint grooves are sawn, a bottom crack inducer shall be provided at each
contraction, warping or longitudinal joint position.
The bottom crack inducer shall be an approved triangular or inverted Y-shaped fillet, with a
base width not less than the height, made of timber or rigid synthetic material. It shall be
firmly fixed to the sub-base so as to remain in position during the whole process of
constructing the slab.
The combined depth of groove formers and bottom crack inducers shall be between 1/4 and
1/3 of the depth of the slab and the difference between the depth of the groove former and
the height of the bottom crack inducer shall not be greater than 20mm.
The groove former for wet formed transverse joint grooves shall be made of an approved
rigid material of a width not greater than the required width of sealing groove as in Table 6.3.
The groove former shall be smooth sides with rounded protrusions no greater than 3mm. Any
removable part of the groove former may be tapered with a maximum difference in width of
2mm in 20mm depth.
Groove forming sealing strips for wet formed longitudinal joints shall be of firm compressible
strips of ethylene vinyl acetate foam of a minimum density of 90kg/m3, or synthetic rubber, or
equivalent material subject to approval by the Engineer. They shall have a minimum
thickness of 5mm and shall be sufficiently rigid to remain vertical and straight in the concrete
without curving or stretching. They shall be inserted continuously along the joint.
For CRCP Universal Beam Anchorage Transverse Joints one side of the beam shall be
separated from the CRCP slab by an expansion joint filler board against the vertical face and
ethylene vinyl acetate foam or similar compressible material, between 5 mm and 10mm thick,
stuck under the top flange.
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QCS 2014

Part
Page 18
Joint Filler Board
Joint filler board for expansion joints and manhole and gully slab joint shall be 25mm
thickness unless otherwise shown in the Drawings, within a tolerance of 1.5mm.
It shall be self expanding cork seal or a firm compressible material or a bonded combination
of compressible and rigid materials of sufficient rigidity to resist deformation during the
passage of the concrete paving plant.
The depth of the joint filler board for manhole and gully slabs shall be the full depth of the
slab minus the depth of the sealing groove. In expansion joints, the filler board shall have a
ridged top as shown on the Drawings, except where a sealing groove former is permitted by
the Engineer.
Holes for dowel bars shall be accurately bored or punched out to form a sliding fit for the
sheathed dowel bar.
6.3.19
Preparation and Sealing of Joint Grooves
All transverse joints in surface slabs, except for construction joints in CRCP shall be sealed
using one of the joint seals described. Additionally longitudinal joints which are sawn or
widened shall be sealed.
Joint grooves shall be prepared in accordance with BS 5212: Part 2 and in compliance with
(a) through (g) below:
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that part of the groove former used to form the sealing groove or any temporary seal
shall be removed cleanly without damaging the joint arises to a minimum depth of
25 mm where compression seals are used or otherwise to such depth as will provide
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(a)
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6.3.18
if joint grooves are not initially constructed to provide the minimum dimensions for the
joint seals as given in Table 6.3, they shall be widened by sawing. Joint grooves
formed by tapered formers need not to be widened. The sealing grooves shall be
cleaned out immediately after sawing using high pressure water jets, to remove all
slurry from the joint, before the slurry hardens.
if rough arrises develop when grooves are made they shall be ground to provide a
chamfer approximately 5mm wide. If the groove is at an angle up to 10 degrees from
the perpendicular to the surface, the overhanging edge of the sealing groove shall be
sawn or ground perpendicular. If spalling occurs or the angle of the former is greater
than 10 degrees the joint sealing groove shall be sawn wider and perpendicular to the
surface to encompass the defects up to a maximum width, including any chamfer, of
40 mm for transverse joints and 25mm for longitudinal joints. If the spalling cannot be
(c)
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an applied seal to the dimensions as will provide in Table 6.3.
so eliminated then the arris shall be repaired by an approved thin bonded arris repair
using cementitious materials.
(d)
for applied sealants the sides of the joint sealing groove shall be scoured by dry
abrasive blasting. This shall not be carried out before the characteristics compressive
2
strength of the concrete is expected to reach 15 N/mm . When compression seals are
used, the sides of the groove may be ground or wire brushed.
QCS 2014

Part
Page 19
(e)
for hot and cold applied sealants, compressible caulking material, debonding strip or
tape or cord compatible with the sealant, of a suitable size to fill the width of the sealing
groove shall be firmly packed or stuck in the bottom of the sealing groove to such a
depth so as to provide the correct depth of seal as described in Table 6.3 with the top
of the seal at the correct depth below the surface of the concrete.
(f)
all grooves shall be cleaned of any dirt or loose material by air blasting with filtered, oil
free compressed air. The groove shall be clean and dry at the time of priming and
sealing.
(g)
for applied sealants the joint grooves shall be primed with the relevant primer for the
hot or cold applied sealant in accordance with the manufacturer's recommendations
and with BS 5212: Part 2, except that when necessary the joint grooves may be
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primed and sealed earlier than 14 days after construction, as soon as the grooves
have been grit-blasted and cleaned.
Sealing with Applied Sealants
Sealing shall be carried out continuously along the full length of joint in any one rip, except for
remedial areas. When hot or cold applied sealants are used the sealant shall be applied
within the minimum and maximum drying times of the primer recommended by the
manufacturer. Priming and sealing with applied sealants shall not be carried out when the
naturally occurring temperature in the joint groove to be sealed is below 10 C except
between 8 C and 10 C it may be carried out when the temperature is rising.
Hot applied sealants shall be heated in and applied from a thermostatically controlled,
indirectly heated dispenser with the recirculating pump. The sealant shall not be heated to a
temperature higher than the safe heating temperature nor for a period longer than the safe
heating period, both as specified by the manufacturer. The dispenser shall be cleaned out at
the end of each day and reheated materials shall not be used.
The components of cold-applied sealants shall be thoroughly mixed in the correct proportions
in accordance with the manufacturer's instructions using an automatic metering and mixing
dispenser approved by the Engineer or, for hand application, using a power operated paddle
mixer for sufficient time to produce homogenous mix without entrapped air. As soon as
possible after mixing and within the worklife of the sealant, the material shall be dispensed
into the joint, or applied using a caulking gun, to the correct level below the concrete surface.
The tack-free time shall be achieved within 3 hours, for machine dispensed material, or within
12 hours for hand applied material.
Test certificates shall be supplied from an approved testing laboratory stating that the sealant
complies with the relevant standard. Site testing of cold applied sealants shall be in
accordance with BS 5212: Part 2. Hot-applied sealants shall be sampled at the same rate
and checked for dimensions as in BS 5212: Part 2 and by the penetration test of the relevant
standard for the material.
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6.3.20
QCS 2014

Part
Page 20
Table 6.3
Dimensions of Applied Joint Seals
Hot
Applied
(mm)
Impregnated
Foam
Compression
Strips (mm)
Depth of Seal
Below the
Concrete
Surface(mm)
13 (Note 2)
20
30
30
10
13
15
20
20
10
15
20
25
25
13
30
30
40
40
30
5+2
5+2
5+2
7+2
5+2
10
10
13
30
20
15
20
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Cold
Applied
(mm)
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Contraction:
15 and under
Over 15 to 20
Over 20 to 25
Expansion All
Transverse
Warping
Longitudinal
Joints (if
sealed)
Gully and
Manhole Slabs
Minimum
Width (mm)
30
0 to 5
0 to 3
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Type and
Spacing of
Joints (m)
The depth of seal is that part in contact with the vertical face of the joint groove.
The depth of seal below the surface shall be taken at the centre of an applied
seal relative to a short straight edge, 150mm long, placed centrally across the
joint within 7 days of sealing.
Note: (2)
For cork seals other than in construction joints, grooves shall be 20 mm wide and
50 mm deep.
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Note: (1)
Sealing with Compression Seals
When compression seals are used, the widths of the seal shall be selected in relation to the
width of the sealing groove, the bay lengths and manufacturer's recommendations so that the
estimated maximum width of the joint opening shall be not more than 70% of the original
width of the seal, the estimated maximum width being calculated on the basis of a movement
of 4mm per 10m run of slab.
The maximum calculated width of sealing groove shall be 30mm.
The depth of groove shall be such that the contact face of the seal with the side of the groove
shall be not less than 20mm and that the top of the seal shall be a minimum of 3mm below
the surface of the concrete.
Compression seals shall be inserted into the grooves without prior extension or rotation and,
where recommended by the manufacturer, with a lubricant adhesive which is compatible with
the seal and the concrete. The adhesive shall be applied to both sides of the sealing groove
or the seal, or to both. The seal shall be positioned with its axis perpendicular to the concrete
surface. Excess adhesive on top of the seal shall be removed to prevent adhesion of the top
faces of the seal under compression.
Except when compression seals are used in longitudinal joints the transverse joint seal shall
be continuous across the slab and the longitudinal joint groove forming strips shall be cut to
the required depth after the concrete has hardened for the transverse seal to be inserted.
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6.3.21
QCS 2014

Part
Page 21
If compression seals are used in longitudinal joints where the grooves have been sawn after
construction of the slab they shall be continuous across transverse joints, with the transverse
seals butted and fixed to the longitudinal seals with adhesive.
6.3.22
Joint Seals
Joint seals shall consist of hot or cold applied sealants or compression seals or self
expanding cork seals.
Hot-applied sealants shall comply with ASTM Standard D3406, or D7116 (for fuel-resistant
sealant).
For joints between concrete surface slabs and bituminous surfacing, polymer modified
bitumen sealing strips shall be used and applied in accordance with the manufacturer's
instructions. Hot-applied sealants complying with BS 2499 & BS EN 14188 may be used for
such joints and in joints in asphalt kerbs laid on concrete pavements.
Cold applied sealants shall be Type N complying with BS 5212: Part 1 except that Type F
shall be used for lay-bys and hardstandings.
For joints in kerbs and joints other than in pavements, seals may be any of the pavement
sealants if they have the suitable characteristics for the application. Also, gunning grade cold
applied plasticised bituminous rubber sealant or gunning grades of two part polysulphidbased sealants complying with BS EN ISO 11600 may be used.
Alternatively, polyurethane-based sealing compounds may be used provided their

performance is not inferior to BS EN ISO 11600 material.
Compression seals shall be pre-compressed neoprene impregnated expanding foam sealing

strip, or rubber seals made of polychloroprene elastomers complying with BS 2752 and
conforming to the requirements of ASTM Standard D2628-91.
Compression seals shall be shaped so that they will remain compressed at all times and
shall have a minimum of 20mm contact face with the sides of the sealing groove. If lubricant
adhesive is used, it shall be compatible with the seal and the concrete and shall be resistant
to abrasion, oxidisation, fuels and salt.
Self Expanding Cork seals may be used in longitudinal joints, joints for manhole and gully
slabs and for transverse joints in short lengths of individual slabs or for replaced slabs.
6.3.23
Joints at Manhole and Gully Slabs
Manhole covers, gullies and their frames shall be isolated from the pavement slabs and be
contained in separate small slabs, which shall be larger than the exterior of the manhole and
gully shafts, including any concrete surround less than 150mm below the underside of the
sub-base layer. The joint around the manhole or gully slab shall be vertical and incorporate
joint filler board but without dowel bars and tie bars.
Gully slabs in unreinforced concrete slabs shall be adjacent to or straddle a transverse joint,
extending the gully slab as necessary to a maximum of 2m. Where this is impractical, an
extra tied warping joint shall be provided adjacent to or within the gully slab and at least 2m
from the next transverse joint. If the edge of an isolator slab is within 1m of any longitudinal
joint the isolator slab shall be extended to that joint.
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QCS 2014

Part
Page 22
Manhole slabs in unreinforced concrete slabs shall be adjacent to or straddle transverse or

longitudinal joints. If the manhole is within the middle third of the bay length a warping joint
shall be constructed on one side of the manhole slab across the whole width of the bay to the
nearest longitudinal joint.
Reinforcement as shown on the Drawings shall be placed in the main concrete slabs in the
corners between the manhole and gully slab and the transverse or longitudinal joints. Extra
reinforcement as described in the Contract shall be placed in reinforced concrete slabs
around the manhole or gully slabs.
Manhole and gully slabs shall have oblique corners, minimum 200mm long, at approximately
45 degrees to the axis of the pavement at all corners which are not adjacent to a transverse
or longitudinal joint in the main slab.
Reinforcement as shown on the Drawings shall be placed in the gully or manhole slab and
concrete grade C40 shall be placed by hand in the space between the main slab and the
manhole frame. The concrete shall be fully compacted and finished.
A sealing groove shall be made directly above the joint filler board and sealed.
6.3.24
Inspection of Dowel Bars
The position and alignment of dowel bars at contraction and expansion joints shall be
checked by measurement relative to the side form or guide wires.
When the slab has been constructed, the position and alignment of dowel bars and any filler
board shall be measured after carefully exposing them across the whole width of the slab.
When the joint is an expansion joint the top of the filler board shall first be exposed
sufficiently in the plastic concrete to permit measurement of any lateral or vertical
displacement of the board. During the course of normal working these measurements shall
be carried out at a rate of one joint per 1500m length of slab or one per 5 working days
whichever occurs the sooner. For small areas the rate shall be decided by the Engineer.
If the position or alignment of the bars in a single joint in the slab is unsatisfactory then the
next two joints shall be inspected. If only one joint of the three is defective, the rate of
checking shall be increased to one joint per day until the Engineer is satisfied that
compliance is being achieved. In the event of non-compliance in two or more successive
joints, the Contractor shall revert to the construction of trial lengths and make any necessary
alterations to the concrete mix, paving plant or methods until the dowel bar position and
alignment is satisfactory.
After the dowel bars have been examined, the remainder of the concrete shall be removed
500mm on each side of the line of the joint, and reinstated to the satisfaction of the Engineer.
Alternatively if the dowels are examined in the penultimate joint of a day's work that joint shall
be made a construction joint for the next day's work and the remainder of the concrete in the
last slab may be discarded.
6.3.25
Side Forms, Rails and Guide Wires
All side forms and rails shall be made of steel and be sufficiently robust and rigid to support
the weight and pressure caused by the paving equipment. Side forms for use with wheeled
paving machines shall incorporate metal rails firmly fixed at a constant height below the top
of the forms.
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QCS 2014

Part
Page 23
The forms shall be secured by using not less than three pins for each 3m length having one
pin fixed at each side of every joint. Forms shall be tightly joined together by a locked joint,
free from play or movement in any direction. Forms shall be cleaned and oiled immediately
before each use. The rails or running surface shall be kept clean in front of the wheels of any
paving machine. The forms shall be straight within a tolerance of 3mm in 3m.
The forms shall be bedded on low moisture content cement mortar or concrete grade C7.5
and set to the pavement surface level as shown on the Drawings within a tolerance of +3mm.
The bedding shall not extend under the slab. There shall be no vertical step between the end
of adjacent forms greater than 3mm. The horizontal alignment for forms shall be to the
required alignment of the pavement edge as shown on the Drawings within a tolerance of +
10mm. The mortar or concrete bedding shall be broken out after use.
Side forms shall not be removed earlier than 6 hours after the completion of the construction
of the slab. Care shall be taken to prevent damage to the concrete and any projecting tie
bars during the removal of the forms. If the removal of forms results in any damage to the
concrete the period of 6 hours shall be increased to that which is necessary to avoid further
damage and the Contractor shall make good the damaged areas.
Unless otherwise agreed by the Engineer, a guide wire shall be provided along each side of
the slab to be constructed by slip form paving plant. Each guide wire shall be at a constant
height above and parallel to the required edges of the slab as shown on the Drawings, within
a vertical tolerance of + 3mm. Additionally one of the wires shall be at a constant horizontal
distance from the required edge of the pavement as shown in the drawings within a lateral
tolerance of + 10mm.
6.3.26
Delivery, Storage and Batching of Concreting Materials
Aggregate for roadworks shall be delivered to and stored on the Site in one of the following
ways:
in separate nominal single sizes of coarse aggregate and fine aggregate.
(b)
as graded coarse aggregate of appropriate size and fine aggregate.
(c)
(a)
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as all-in aggregate for grades C20 to below.
If the Contractor proposes to blend aggregate off the site from two separate sources, he shall
obtain the Engineer's approval for the blending process, and for the arrangements for
inspection during the course of the work.
Aggregate brought on to the Site shall be kept free from contact with deleterious matter. Fine
aggregate nominally below 5 mm sieve size shall have been deposited at the site for at least
8 hours before use.
Batching plant and storage for aggregate shall comply with the following requirements as
appropriate to the method of delivery:
(a)
if separate gradings of aggregate are stockpiled, separate accommodation shall

be provided for each nominal size of coarse aggregate or blend of fine
aggregate. The base for stockpiles shall be suitably surfaced to prevent
contamination of the aggregate. Drainage of the stockpile bases shall be
provided.
QCS 2014

Part
Page 24
(b)
aggregate shall be measured by mass and provision shall be made for batching
each nominal size or blend of aggregate separately, to the tolerances specified in
BS EN 206 & BS 8500.
(c)
all-in aggregate shall be delivered and stockpiled in such a manner and to a

height that avoids segregation.
Mixing Concrete
Mixing concrete shall conform to the requirements of Section 5 Part 7 except as amended
herein.
Concrete shall be mixed on site in a stationary batch type mixer in compliance with BS EN
206 & BS 8500 unless with the approval of the Engineer, ready mixed concrete is supplied
from an approved source.
The drums or blades of all mixers shall be operated at the speed using for testing, in
accordance with BS 3963 for the mix proportions required, within a tolerance of 1 revolution
per minute. The mixing blades of a pan mixer shall be maintained within the tolerances
specified by the manufacturers of the mixer and the blades shall be replaced when it is no
longer possible to maintain the tolerances by adjustment. All drums or pans which have
been out of use for more than 30 minutes shall be thoroughly cleaned before any fresh
concrete is mixed in them.
The rated output of the batching and mixing plant shall exceed by at least a third the amount
of concrete that is required at a constant rate to enable the paving train to move forward
continuously, at the planned rate of progress.
6.3.28
Transport and Delivery
Transportation, delivery of concrete shall conform to the requirements of Section 5 Part 8.
6.3.29
General Requirements for Construction by Machine
The concrete slab shall be constructed in a continuous process by either slip-form or by fixed
form paving plant or by small paving machines or hand guided methods.
The slab may be constructed in either one or two layers. In two layer construction the
thickness of the top layer shall be not less than 50mm or twice the maximum size of the
coarse aggregate whichever is greater, and shall be at least 15 mm thick than the depth of
the groove former, if used.
While the concrete is still plastic its surface shall be brush-textured and the surface and
edges shall be cured.
The spreading, compacting and finishing of the concrete shall be carried out as rapidly as
possible and the paving operation shall be so arranged as to ensure that the time between
the mixing of the first batch of concrete in any transverse section of the slab and the
application of the sprayed curing membrane to the surface of that section shall not exceed
those given in Table 6.4.
Each bay in jointed concrete surface slabs shall be consecutively numbered near the verge
next to a transverse joint while the concrete is plastic. In continuously reinforced concrete
pavement the slab shall be marked with the chainage at intervals not greater than 50m apart.
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6.3.27
QCS 2014

Part
Page 25
Construction by Fixed Form Paving Machines
A fixed form paving train shall consist of separate, powered machines which spread compact
and finish the concrete in a continuous operation.
Concrete shall be discharged without segregation into a hopper spreader which is equipped
with the means of controlling its rate of deposition onto the sub-base or onto the lower layer.
The concrete shall be spread in each layer without segregation and to a uniform
uncompacted density over the whole area of the slab.
The deposited concrete shall be struck off to the necessary level by the underside of the
hopper as it is traversed across the spreading machine.
The machine shall be capable of being rapidly adjusted for changes in average and
differential surcharge necessitated by changes in slab thickness or crossfall. When the slab
is constructed in two layers, the spreading of the concrete in the top layer shall follow the
completion of the bottom layer within the times given in Table 6.4.
Prior to being compacted, the surface level of each loose spread layer shall be adjusted to
the correct surcharge by means of rotating strike-off blades or a screw device.
The concrete shall be compacted by vibration or by a combination of vibration and

mechanical tamping throughout the full depth of the slab. Poker vibrators shall be used in
each layer adjacent to the side forms and the edge of a previously constructed slab.
The initial regulation and finish to the surface of the slab shall be effected by means of a
beam oscillating transversely or obliquely to the longitudinal axis of the pavement. This beam
shall be readily adjustable for both height and tilt.
When grooves are wet-formed the concrete shall be recompacted around the former by a
hand held vibrating plate compactor drawn along or on each side of the joint, prior to
regulation of the surface by the diagonal finishing beam. Or recompacted and finished if the
former is inserted after the finishing beam.
The regulation and finishing of the surface of the slab shall be carried out by a machine which
incorporates twin oblique oscillating finishing beams which shall be readily adjustable for both
height and tilt. The beams shall weigh not less than 170 kg/m, be of rectangular section and
span the full width of the slab. The leading beam shall be vibrated. The beams shall be
supported on a carriage, the level of which shall be controlled by the average level of not less
than four points evenly spaced over at least 3.5m of the supporting rail, beam or slab, on
each side of the slab that is being constructed. After the final regulation and before texture is
applied any excess concrete on top of the groove former shall be removed.
10
When a concrete slab is constructed in more than one width, flanged wheels on the paving
machines shall not be run directly on the surface of any completed part of the slab. The
second or subsequent slabs shall be constructed either by supporting machines with flanged
wheels on flat bottom section rails weighing not less than 15 kg/m laid on the surface of the
completed slab, or by replacing the flanged wheels on that side of the machines by smooth
flangeless wheel.. Flangeless wheels or rails shall be positioned sufficiently far from the
edge of the slab to avoid damage to that edge.
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6.3.30
QCS 2014

Part
Page 26
Construction by Slip-Form Paving Machine
A slip-form paving train shall consist of powered machines which spread, compact and finish
the concrete in a continuous operation.
The slip-form paving machine shall compact the concrete by internal vibration and shape it
between sliding side forms or over fixed side forms by means of either a conforming plate or
by vibrating and oscillating finishing beams.
The concrete shall be deposited without segregation in front of the slip-form paver across its
whole width and to a height which at all times is in excess of the required surcharge. The
deposited concrete shall be struck off to the necessary average and differential surcharge by
means of a strike-off plate or a screw auger device extending across the whole width of the
slab. The equipment for striking off the concrete shall be capable of being rapidly adjusted
for changes of the average and differential surcharge necessitated by changes in slab
thickness or crossfall.
The level of the conforming plate and finishing beams shall be controlled automatically from
the guide wires by sensors attached at the four corners of the slip form paving machine. The
alignment of the paver shall be controlled automatically from the guide wire by at least one
sensor attached to the paver. The alignment and level of ancillary machines for finishing,
texturing and curing of the concrete shall be automatically controlled relative to the guide wire
or to the surface and edge of the slab.
Slip-form paving machines shall have a vibration of variable output, with a maximum energy
output of not less than 2.5 kW per metre width of slab per 300mm depth of slab for a laying
speed of up to 1.5m per minute or pro rata for higher speeds. The machines shall be of
sufficient mass to provide adequate reaction on the traction units to maintain forward
movements during the placing of concrete in all situations.
Where grooves are wet-formed the concrete shall be compacted around the former by a
separate vibrating plate compactor with twin plates. The groove former shall be compacted to
the correct level by a vibrating pan which may be included with the transverse joint finishing
beam. In addition a hand held vibrating float, at least 1m wide, shall be drawn over the
surface along the joint. Alternatively the surface shall be regulated with a longitudinal
oscillating float travelling across the slab. Any excess concrete on top of the groove former
shall be removed before the surface is textured.
Where a concrete surface slab is constructed in more than one width or where the edge
needs to be matched for level to another section of surface slab, and the surface levels at the
edges are not achieved, paving shall be carried out over separate fixed side forms to support
the edge to the required levels.
6.3.32
Construction by Small Paving Machines or Hand Guided Methods
As an alternative to fixed form or slip-form paving trains, the concrete slab may be
constructed using parts of trains, small paving machines, truss type finishing beams or hand
guided methods. Hand tamping beams may only be used for short lengths or infill bays or
tapers. Reinforcement, dowel bars and tie bars shall be supported in position, except where
two layer construction is used and reinforcement is placed on the bottom layer in a method of
construction approved by the Engineer.
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6.3.31
QCS 2014

Part
Page 27
The concrete shall be spread uniformly without segregation or varying degrees of

precompaction, by conveyor, chute, blade or auger. The concrete shall be struck off by a
screed or auger so that the average and differential surcharge is sufficient for the surface of
the slab to be at the correct levels after compaction of the concrete.
The concrete shall be compacted by vibrating finishing beams across the slab and with
vibrating pokers adjacent to the side forms or the edge of a previously constructed slab. In
addition, internal poker vibration shall be used for slabs thicker than 200mm and may be
used for lesser thicknesses. When used, the pokers shall be at points not more than 500mm
apart over the whole area of the slab, or drawn continuously across the slab in front of the
finishing beams.
The finishing beams shall be metal with a contact face at least 50mm wide. They shall be
rigid or supported by a frame or truss without sag across the width of slab being paved. The
beams shall be supported on rails or forms or an adjacent slab and shall be moved forward
at a steady speed of 0.5m to 2m per minute whilst vibrating, to compact the concrete and to
produce a smooth surface finished to the correct crossfalls, crowns and levels relative to the
top of the forms or adjacent slab.
Any irregularities at wet-formed joint grooves shall be rectified by means of a vibrating float at
least 1.0 m wide drawn along the line of the joint. The whole area of the slab shall be
regulated by two passes of a scraping straight edge not less than 1.8m wide or by a further
application of a twin vibrating finishing beam. All slabs shall be checked for level using a
straight edge at least 4m long. Any excess concrete on top of the groove former shall be
removed before the surface is textured.
The surface shall be brush textured.
The surface shall be cured within the time to completion given in Table 6.4
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Table 6.4
Maximum Working Times
Temperature of
concrete at discharge
from the delivery
vehicle
Reinforced Concrete Slabs

Consumed in Two layers
Mixing first
layer to
finishing
concrete
Not more than 25 C
All other Concrete Slabs
between
layers
Mixing first
layer to
finishing
concrete
between
layers in 2
layer work
3 hours
1/2 hour
3 hours
1 1/2 hours
Exceeding 25 C
2 hours
1/2 hour
2 hours
1 hour
Exceeding 30 C
unacceptable
for paving
unacceptable
for paving
QCS 2014

Part
Page 28
Surface Textures
After the final regulation of the surface of the slab and before the application of the curing
membrane, the surface of concrete slabs to be used as running surfaces shall be brush
textured in a direction at right angles to the longitudinal axis of the carriageway.
The texture shall be applied evenly across the slab in one direction by a brush not less than
450 mm wide. The texture shall be uniform both along and across the slab.
Curing
Immediately after the surface treatment, the surface and exposed edges of surface slabs
shall be cured for a minimum period of 7 days (unless the Engineer agrees to a shorter
period). This will be by the application of an approved resin based aluminised curing
compound, or polythene sheeting or an approved sprayed plastic film which hardens into a
peelable plastic sheet. It shall be removed before road marking and opening to traffic.
Resin based aluminised curing compound shall contain sufficient flake aluminium in finely
divided dispersion to produce a complete coverage of the sprayed surface with a metallic
finish. The compound shall become stable and impervious to evaporation of water from the
concrete surface within 560 minutes of application and shall have an efficiency index of 90%
when tested as described in BS 7542.
The curing compound shall not react chemically with the concrete to be cured and shall not
crack, peel or disintegrate within three weeks after application.
Prior to application, the contents of any containers shall be thoroughly agitated. The curing
compound shall be mechanically applied using a fine spray onto the surface at a rate of at
least 0.221L/m2. For the sides of slip-formed slabs or when the side forms are removed
within 24 hours and for small areas where mechanical application cannot be used, the
compound shall be sprayed by hand lance at a rate of at least 0.271/m2. The rate of spread
shall be checked during construction of each trial length and subsequently whenever required
by the Engineer.
The mechanical sprayer shall incorporate an efficient mechanical device for continuous
agitation and mixing of the compound in its container during spraying.
Continuously reinforced concrete road bases shall also be cured. Wet lean concrete road
bases and sub-bases shall also be cured.
10
REQUIREMENTS FOR WET LEAN CONCRETE
11
Materials and Mix Designs
12
The constituent materials and the grades of concrete for wet lean mix shall comply with the
requirements of Section 5: Part 16.
13
Placing
14
Wet lean concrete shall be spread uniformly without segregation and without varying degrees
of pre-compaction.
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6.3.33
QCS 2014

Part
Page 29
The concrete shall be struck off to a level so that the surcharge is sufficient to ensure that
after compaction the surface is at the required level.
16
Compaction
17
The spread wet lean concrete shall be compacted using internal or external vibration, or
combination of both to meet the required density.
18
Compaction and finishing to level shall be completed within the times given in Table 6.4.
19
Joints
20
At transverse and longitudinal construction joints between two separately constructed slabs,
the previously laid slab end or edge shall present a vertical face before construction of
subsequent slabs.
21
Longitudinal joints in wet lean concrete shall be staggered by at least 300mm from the
position of longitudinal joints in any superimposed concrete slab, and by 1m for transverse
joints.
6.3.34
Strength
From each sample, three cubes of the appropriate size shall be made, cured and tested in
compliance with BS 1881.
One of each group shall be tested at 7 days and the other two at 28 days. The cubes shall
be assessed for compliance on groups of four 28-day test results in accordance with BS EN
206 & BS 8500 for compliance with the grade required.
If the average value of any four consecutive results of tests at 7 days falls below the required
values the cement content of the mix shall be increased by an amount agreed with the
Engineer which shall be maintained until the corresponding 28-day test results have been
assessed.
6.3.35
Trial Mixes
Trial mixes complying with the requirements for pavement quality concrete shall be required
for designed mixes for Grade C15 and above, unless recent data relating to the proposed
mix is approved by the Engineer.
6.3.36
Trial Length
At least 10 days before the start of the main wet lean concrete works a trial length of at least
400 m2 for mechanised construction and 30m for hand guided methods shall be constructed.
The trial length shall be laid to assess the suitability of the proposed material, plant,
equipment and construction methods to meet the requirements of the Specification.
The main construction in the permanent works shall not start until the trial length has been
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15
QCS 2014

Part
Page 30
If any trial length does not conform to the Specification another trial length shall be
constructed. Trial lengths not complying with the Specification shall be removed unless they
can be rectified to comply with the Specification to the satisfaction of the Engineer.
After approval has been given, the material plant, equipment and construction methods shall
not be changed without the approval of the Engineer.
Any proposed changes shall entitle the Engineer to require the Contractor to lay a further trial
length to assess the suitability of the proposed changes.
6.3.37
Surface Finish
The surface of the wet lean concrete after compaction and finishing and before overlaying
shall be free from ridges, loose material, pot holes, ruts or other defects.
The surface texture shall comply with the sub-Clause for pavement quality concrete, Section
5: Part 16.
6.4
REQUIREMENTS FOR CEMENT BOUND MATERIALS
6.4.1
General Requirements for Cement Bound Materials
Cement bound materials shall be made and constructed as described in the following
clauses.
Cement bound materials shall be tested in accordance with this specification for the
requirements of Table 6.5
Cement water and aggregates shall comply with the requirements of the Section 5: Part 16.
Cement for use in all cement bound materials and aggregates for use in CBM3 and CBM4
shall be delivered and stored in compliance with the requirements of Section 5: Part 16.
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Table 6.5
Cement Bound Materials Field Requirements
Category
Mixing Plant
Method of
Batching
Moisture
Content
Minimum
Compaction
CBM 1
mix in place or
mix in the plant
volume or mass
NOTE 1
NOTE 2
CBM 2
mix in place or
mix in the plant
volume or mass
NOTE 1
NOTE 2
CBM 3
mix in the plant
mass
NOTE 1
NOTE 2
CBM 4
mix in place or
mix in the plant
volume or mass
NOTE 1
NOTE 2
NOTE 1
NOTE 2
to suit the requirements for strength surface, level regularity and finish
95% of cube strength
QCS 2014

Part
Page 31
Table 6.6
Cement Bound Materials Specimen Requirements
Category
Curing
Compressive Strength
Testing
CBM 1
BS 1924 Part 2 1990
CBM 2
CBM 3
Individual
(Note2)
(MPa)
BS 1924 Part 2 1990

or BS 1881Part 116
4.5
2.5
BS 1924 Part 2 1990
BS 1924 Part 2 1990

or BS 1881 Part 116
7.0
4.5
BS 1881 Part 111
BS 1881 Part 116
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Average
(Note1)
(MPa)
BS 1881 Part 116
10.0
6.5
15.0
10.0
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CBM 4
The average strength of 5 cubes shall not be less than the stated figure
The strength of any individual cube shall not be less than the stated figure
as
NOTE 1
NOTE 2
Minimum 7 days Cube

Strength
Batching and Mixing
Batching and mixing shall be carried out in the appropriate manner described in Table 6.5.
Where the mix-in plant method is used and materials are batched by mass, the materials
shall be batched and mixed in compliance with BS EN 206 & BS 8500. Where continuous
mixers are used and materials are batched by mass, the continuous mixers shall comply and
6.4.3
Transporting
Plant-mixed cement bound material shall when mixed be removed at once from the mixer,
transported directly to the point where it is to be laid and protected from the weather both
during transit from the mixer to the laying site and whilst awaiting tipping.
6.4.4
Laying
All cement bound material shall be placed and spread evenly in such manner as to prevent
segregation and drying.
Spreading shall be undertaken either concurrently with placing or without delay.
Road base cement bound material shall be spread using a paving machine or a spreader box
approved by the Engineer and operated with a mechanism which levels off the cement bound
material to an even depth.
Cement bound material shall be spread in one layer so that after compaction the total
thickness is as specified.
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6.4.2
QCS 2014

Part
Page 32
At longitudinal or transverse construction joints, unless vertical forms are used, the edge of
compacted cement bound material shall be cut back to a vertical face where the correct
thickness of properly compacted cement bound material has been obtained.
In the case of cement bound sub bases under a concrete surface slab or continuously
reinforced concrete road base, longitudinal construction joints in the sub-base shall be
staggered by at least 300mm from the position of the longitudinal joints in the concrete
surface slab or continuously reinforced concrete road base, and by 1m for transverse joints.
6.4.5
Compacting
Compaction shall be carried out immediately after the cement bound material has been
spread and in such a manner as to prevent segregation.
Special care shall be taken to obtain full compaction in the vicinity of both longitudinal and
transverse construction joints.
Compaction shall be carried out in compliance with Table 6.5 and be completed within
2 hours of the addition of the cement. The 2 hours may be varied at the discretion of the
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Engineer if the preliminary trial indicates that this is necessary or appropriate. After
compaction has been completed, compacting equipment shall not bear on cement bound
material for the duration of the curing period.
The surface of any layer of cement bound material shall on completion of compaction and
immediately before overlaying, be well closed, free from movement under compaction plant
and from ridges, cracks, loose material, pot holes, ruts or other defects. All loose, segregated
or otherwise defective areas shall be removed to the full thickness of the layer and new
cement bound material laid and compacted.
6.4.6
Curing
Immediately on completion of compaction, the surface of concrete or wet lean concrete or

cement bound road bases and sub-bases shall be cured for a minimum period of 7 days
(unless the Engineer agrees to a shorter period) by one of the following methods:
Covering with an impermeable sheeting with joints overlapping at least 300 mm and set to
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prohibit egress of moisture. The sheeting shall be removed at the end of the curing period.
3
Bituminous spraying which shall only be applied when there is no visible water. When the
cement bound material is likely to be exposed to high temperatures and solar radiation, the
bituminous spray shall be blinded with light coloured material.
Spraying with a curing compound.
Spraying with an approved plastic film which when hardened shall be removed before
applying any other pavement layer.
Whichever method is used, immediately prior to overlaying with any bituminous layer in
cationic bituminous tack coat shall be applied at a rate between 0.351/m2 to 0.551/m2.
QCS 2014

Part
Page 33
6.4.7
Preliminary Trial
At least 10 days before the start of the main cement bound material works a trial area of at
least 400 m2 shall be laid to asses the suitability of the proposed materials, mix proportions,
mixing, laying, compaction plant and construction procedures.
When applicable the area shall include one longitudinal and one transverse construction joint.
The location and area of the trial shall be subject to the approval of the Engineer.
The rate of testing for the trial area shall not be less than that required in this section of the
specification.
The trial area will only be accepted for main construction in the Permanent Works if it
complies with the Specification.
The main construction in the Permanent Works shall not start until the trial has been
After approval has been given, the materials, mix proportions, mixing, laying compaction
plant and construction procedures shall not be changed without the approval of the Engineer
who may require the Contractor to lay a further trial area to assess the suitability of the
proposed changes.
6.4.8
CBM1 shall be made from material which has a grading finer than the limits of Table 6.7
In addition to the requirements of Table 6.6 the average compressive strength determined
after immersion in water of five test specimens of CBM1 shall not be less than 80% of the
average compressive strength of five control specimens when subjected to the test
procedure described in BS 1924: Part 2: 1990, clause 4.3.
After the 7 days immersion period the specimens shall not show any signs of cracking or
swelling.
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NOTE:
Table 6.7
Material for CBM1 - Limit of Grading
BS Sieve Size (mm)
Percentage by Mass Passing
50
100
37.5
95
20
45
10
35
25
0.600
0.300
0.075
The particle size distribution shall be determined by the washing and sieving
method of BS812:
QCS 2014

Part
Page 34
CMB2 shall be made from gravel sand, a washed or processed granular material, crushed
rock, all in aggregate, blastfurnace slag or any combination of these. The material shall fall
within the grading limits of Table 6.8.
The material shall have 10 % fines value of 50 kN or more when tested in accordance with
BS 812 with samples in a soaked condition.
In addition to the requirements of Table 6.6 the average compressive strength determined
after immersion in water of five test specimens of CBM2 shall not be less than 80% of the
average compressive strength of five control specimens when subjected to the test
procedure described in BS 1924: Part 2: 1990, clause 4.3. After the 7 days immersion period
the specimen shall not show any signs of cracking or swelling.
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Table 6.8
Material For CBM2 - Range Of Grading
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6.4.9
20
100
95-100
45-100
35-100
25-100
2.36
15-90
0.600
8-65
0.300
5-40
0.075
0-10
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37.5
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BS Sieve Size
method of BS 812.
NOTE:
6.4.10
CBM3 shall be made from aggregates as in the sub-Clause 6.5.9.
The grading of the aggregate shall be within the limits of Table 6.9.
6.4.11
CBM4 shall be made from aggregates as in sub-Clause 6.5.9
The grading of the aggregate shall be within the limits of Table 6.9.
QCS 2014

Part
Page 35
Table 6.9
Material for CBM3 and CBM4 - Range of Grading
Percentage by Mass Passing.
BS Sieve Size (mm)
50
100
37.5
95-100
100
20
45-80
95-100
25-5-
35-55
0.600
8-30
10-35
0.150
0.8*
0-8*
0.075
0.5
0-5
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20 mm
method of BS 812.
*0-10 for crushed rock fines
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NOTE:
40 mm
Testing of Cement Bound Materials
Samples shall be provided in accordance with BS 1924: Part 1: 1990 Clause 5 from the laid
cement bound material before compaction. One group of five samples shall be provided from
five locations equally spaced along a diagonal that bisects each 800 mm2 or part thereof laid
each day. The number of groups may be increased if required by the Engineer.
One 150 mm cube shall be made from each sample taken in accordance with sub-clause 1
of this clause. The cubes shall be made in accordance with BS 1924: Part 2: 1990, clause
4.2.5 without further mixing of the material and within 2 hours of the addition of the cement.
Cubes shall be cured and tested in accordance with Table 6.6.
To determine the wet density of cubes the mould shall be weighed prior to making the cube
and the mass recorded. Immediately after completion of compaction, the cube and mould
shall be weighed and the mass recorded. These masses together with the nominal volume of
the mould shall be used to derive the wet density of the cube.
The in-situ wet density of a layer of cement bound material shall be taken as the average of
the wet densities at five locations equally spaced along a diagonal that bisects each 800 m2
or part thereof laid each day. The wet density at each location shall be the average of two
readings obtained using a nuclear density gauge complying with BS 1377: Part 9. The two
readings shall be taken at 180 degrees to each other using the same source rod hole. The
source rod shall be lowered to within 25mm of the bottom surface of the layer. Readings
shall be taken within two hours of completing final compaction.
6.4.13
Special Requirements for Cement Bound Materials
Where specified in the contract documents or on the project drawings cement bound road
base in flexible composite construction shall be laid in individual widths with longitudinal
construction joints in locations as detailed below:
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6.4.12
(a)
Single All purpose. One longitudinal construction joint at the centre lane line marking.
QCS 2014

Part
Page 36
(b)
Dual 2 lane All-purpose. One longitudinal construction joint at the lane line marking.
(c)
Dual 3 lane All-purpose. Two longitudinal construction joints, one at each of the lane
line markings.
(d)
Dual 2 lane Motorway. Two longitudinal construction joints, one at the lane line
marking and one at the edge line marking between hard shoulder and left hand
lane.
(e)
Dual 3 lane Motorway. Three longitudinal construction joints, one at each lane line
marking and one at the edge line markings between hard shoulder and left hand lane.
(f)
Dual 4 lane Motorway. Four longitudinal construction joints, one at each lane line
marking and one at the edge line marking between hard shoulder and left hand lane.
Longitudinal constructions joints shall not be more than 150 mm from the centre of the centre
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Longitudinal construction joints shall not be located within the left hand lane or dual
carriageways. At tapers and other changes in section the construction joint layout shall be
agreed with the Engineer, and where necessary joints shall also be permitted within 150 mm
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of the mid-point of the traffic lane.
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END OF PART
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line, lane line, or edge line marking, with individual widths not exceeding 4.75 m.
QCS 2014

Part
07: Asphalt Plants
Page 1
ASPHALT PLANTS ................................................................................................. 3
7.1
ASPHALT BINDERS DELIVERY, HANDLING AND STORAGE .............................. 3
7.2
7.2.1
7.2.2
7.2.3
7.2.4
7.2.5
7.2.6
ASPHALT PLANTS PRODUCTION CONTROL ...................................................... 4

Factory Production Control (FPC)
4
Factory Production Control Quality Plan
4
Organizational Structure
5
Internal Audits
5
Management Review
5
Document Control
5
7.3
7.3.1
7.3.2
7.3.3
7.3.4
7.3.5
7.3.6
PRODUCT REALISATION ...................................................................................... 6

Constituent Materials
6
Customer Supplied Product
6
Process Control
6
Handling, Storage and Delivery
7
Plant Calibration and Maintenance
7
Plant Quality Control Laboratory
8
7.4
7.4.1
7.4.2
7.4.3

General
9
Incoming constituent materials
9
Finished Asphalt Mixture
9
7.5
7.5.1
7.5.2
NON-CONFORMITY ............................................................................................. 10
General
10
Non-conformity of Material or Asphalt Mixtures
10
7.6
INSPECTION, MEASURING AND TEST EQUIPMENT ......................................... 11
7.7
PLANT GENERALLY ............................................................................................. 11
7.8
7.8.1
7.8.2
7.8.3
7.8.4
7.8.5
7.8.6
7.8.7
7.8.8
7.8.9
7.8.10
7.8.11
7.8.12
7.8.13
7.8.14
7.8.15
7.8.16
ASPHALT PLANT .................................................................................................. 12

General
12
Automatic Operation
12
Cold Bins System
12
Drier
13
Dust Collector
13
Screens
13
Hot Bins
13
Asphalt Binder Storage
14
Thermometric Equipment
14
Control of Mixing Time
14
Pugmill
14
Temporary Storage of Mix
15
Safety Requirements
15
Weigh-Box
15
Scales or Meters
16
Plant Control System
16
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APPENDICES
APPENDIX A .................................................................................................................... 17
APPENDIX B .................................................................................................................... 22
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APPENDIX C .................................................................................................................... 25
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ASPHALT PLANTS
7.1
ASPHALT BINDERS DELIVERY, HANDLING AND STORAGE
Before loading, the bitumen manufacturer shall examine the shipping container and remove
all remnants of previous cargos that may contaminate the material to be loaded.
The manufacturer shall furnish with each shipment two (2) copies of the delivery ticket
containing the following:
Consignees details.
(b)
Net liters.
(c)
Net weight.
(d)
Type and amount of anti-stripping agent (if any).
(e)
Identification number (truck, car tank, etc.)
(f)
Destination.
(g)
Date.
(h)
Loading temperature, and the recommended delivery temperature range.
(i)
Specific gravity.
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(a)
The bitumen manufacturer shall deliver a signed Certificate of Compliance to cover the
quality and quantity of material and the condition of container for each shipment. Test results
shall be provided with the shipment.
Bituminous materials furnished without a Certificate of Compliance should not be introduced

into the work until the Contractor has had sufficient time to sample and test the delivered
materials.
The delivery tanker shall be insulated with a rock wool or similar material. Burner tubes shall
be designed so that the bituminous material is evenly heated with no hot spots within the
tanker. Temperature gauges shall be calibrated and positioned such that the maximum
temperature in the tanker shall be indicated. The temperature of unmodified and modified
bitumen during delivery shall be maintained in accordance with the manufacturer
recommendations. Tankers shall be designed to enable the safe sampling of the bitumen
from the top of the tanker or from a sampling valve. Sampling shall not take place whilst the
tank is under pressure.
The Contractor shall obtain acceptance samples of bituminous material according to ASTM
D140 at the applicable point of acceptance.
For bituminous material used in direct application on the road, samples shall be taken from
each shipping container at the time of discharge into distributors or other conveyances on the
project.
For bituminous material initially discharged into storage tanks on the project, samples shall
be taken from the line between the storage tank and the distributor or the asphalt plant after
each delivery. Samples shall be taken after a sufficient period of circulation has taken place
to ensure samples are representative of the material in the storage tank.
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The manufacturer of bituminous materials shall test all materials produced and the test
results retained for reference. Each shipment of bituminous material delivered to the asphalt
plant shall be sampled. The samples shall be numbered consecutively and identified by
project, type and grade of bituminous material, date of delivery and use. Samples testing
frequency shall be based on LSA and the Engineer approval.
10
Each bitumen delivery and storage tank and its associated delivery pipe and control valve
must be independently and uniquely identified with the tank number.
11
Storage tanks must also display the grade of bitumen held in the tank.
12
Adequate and reliable means of gauging the bitumen tank contents and ullage must be
available at the discharge point.
13
Vent pipes must be fitted in bitumen tanks and located where they do not pose a risk to any
personnel or delivery vehicles and must be kept clear at all times.
14
It is recommended that bitumen tanks should be fitted with a correctly designed drain valve to
enable the safe emptying of the tank for cleaning and maintenance. In the absence of a drain
valve, a specific risk assessment must be carried out prior to any uplift of product.
15
Samples must not be taken from the bitumen delivery vehicle or hoses at the delivery site
unless equipment is fitted to do so safely.
16
If there is a requirement to take bitumen samples a purpose designed valve should be

permanently fitted to the tank (or corresponding pipework).
7.2
ASPHALT PLANTS PRODUCTION CONTROL
7.2.1
Factory Production Control (FPC)
The Organization shall establish and operate a permanent factory production control system
to ensure delivery of the quality requirements of the project specification whilst
maintaining a regime of continuous improvement and ensure the competence and
training of staff and operators. The Organization shall document and maintain the FPC
system in which procedures, regular inspections and tests and/or assessments and the
use of the results to control raw and other incoming materials or components, equipment,
the production process and the product.
A sample plant inspection checklist, which includes the minimum items to be covered as part
of LSA inspection, Engineer inspection and producer internal audit system, is provided in
Appendix C.
7.2.2
Factory Production Control Quality Plan
The Organization shall establish and maintain FPC documentation for each asphalt
production site used to supply the works.
The FPC documentation shall include a means for identifying and detailing the specific
processes that directly affect the quality of the asphalt. This shall particularly address:
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(a)
Producers organizational structure relating to conformity and quality.
(b)
Document control.
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(c)
Control procedures for constituent materials and purchaser supplied product.
(d)
Process control
(e)
Requirements for the handling and storage of the product.
(f)
Plant calibration and maintenance.
(g)
Quality control laboratory calibration and maintenance.
(h)
Requirements for inspection and testing of processes and products.
(i)
Procedures for handling non-conformity.
Organizational Structure
The responsibility, authority and inter-relation of all personnel who manage, perform and
verify work affecting conformity and quality shall be defined in the quality plan, particularly for
personnel who have authority to:
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7.2.3
Initiate action to prevent the occurrence of product non-conformity.
(b)
Identify and record any product quality problems.
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(a)
The producer shall identify a person with appropriate authority, knowledge and experience to
supervise Factory Production Control and to ensure that the requirements of the quality plan
are implemented and maintained. The person identified may exercise such supervision over
a group of plants.
The management structure shall be documented. Names, affiliations, and positions of

principal staff shall be listed. The organization chart shall clearly define relationships with
other partner organizations where applicable.
7.2.4
Internal Audits
The Organization shall carry out internal audits to verify which activities comply with the
planned arrangements and to determine the effectiveness of the Factory Production Control
system. Audits shall be scheduled on the basis of the status and importance of the activity.
The audits and follow up action shall be carried out in accordance with documented
procedures. The results of the audits shall be documented and brought to the attention of the
personnel having responsibility in the area audited. The management personnel responsible
for the area shall take timely corrective action on the nonconformities found by the audit and
shall keep a record of the action taken.
The frequency of such audits shall be that each area of process is audited at least annually.
7.2.5
Management Review
The system shall be reviewed at least annually by management to ensure its continuing
suitability and effectiveness.
7.2.6
Document Control
The producer shall establish and maintain documented procedures to control all documents
and data that relate to the requirements of these specifications.
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The producer shall maintain all documents related to daily production quality records, test
methods, practices, procedures, and specifications.
Records relating to Factory Production Control shall be maintained and accessible by the
Organization and shall be produced if requested by the Engineer or any authorized audit
body.
Management review, internal audits, 3rd party assessment, and inspection and testing of
finished asphalt shall be kept for a minimum of ten years. All other quality records shall be
kept until at least five years after the completion of the project, or longer as the Organization
requires.
7.3
PRODUCT REALISATION
7.3.1
Constituent Materials
Adequate supplies of constituent materials shall be available to ensure that the

planned rates of production and delivery can be maintained.
The specification and tolerances for incoming constituent materials shall be established
and communicated to suppliers by appropriate traceable and confirmable means.
The control procedures shall verify that suppliers of incoming materials are capable of
providing the required quality of materials.
Different material types or grades shall be transported and stored in such a manner
as to avoid intermingling, contamination or deterioration which may adversely affect the
quality of the product.
The general requirements of this clause shall be translated into more detailed plant
specific requirements within the FPC and include the following:
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Procedures for the control of aggregates delivered to a depot or plant site.
(b)
Requirements for labelling of storage bays and silos.
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Requirements for heating, temperature control and insulation of binder tanks, pipes
and pumps.
(c)
(a)
(d)
Requirements for controlling delivery of binders into the correct tanks, including
stirrers/agitators and labelling of tanks, and the selection of the correct tanks for use.
(e)
Requirements for the control of additives.
(f)
Requirements for the manufacture of polymer modified binders at site by the

Organization or its supplier, where applicable.
7.3.2
Customer Supplied Product
Any constituent material supplied by the customer for inclusion in the asphalt shall be
handled, stored and maintained free of contamination by the Organization.
7.3.3
Process Control
The FPC quality plan shall include the following items of process control:
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A description of the flow of materials and the processes carried out on them from receipt at
the plant to delivery to the job site. This shall incorporate a flow diagram.
A statement of the production control processes necessary to maintain and regulate the
quality of material in conformity with the specification. This will include the procedure for the
control of batching instructions.
A schedule for monitoring the performance of the process, which is shown in Table A-1 in
Appendix A, resulting in a record of plant performance against stated tolerances.
A detailed method statement for the production of polymer modified binder including storage
and quality control, and the procedure for the handling of nonconforming product.
7.3.4
Handling, Storage and Delivery
The FPC quality plan shall contain procedures to ensure that the asphalt mixture is handled,
stored, discharged and delivered at the specified temperature range, minimizing segregation
and degradation.
The asphalt mixture shall be identifiable and traceable with regard to its production data and
can be referenced from information on the delivery ticket from its manufacture to its point of
installation. The quality plan shall however make clear the point to which the Organizations
responsibility for handling storage and delivery extends.
The quality plan shall describe the characteristics of any hot storage system and define its
mode of operation. The Organization shall ensure thorough checks, inspections and records
that such systems are used correctly and that bituminous mixtures maintain their suitability
for use.
Bituminous materials shall not be heated during the process of its manufacture or during
construction so as to cause damage to the materials as evidenced by the formation of
carbonized particles.
7.3.5
Plant Calibration and Maintenance
The FPC quality plan documentation shall identify those items of measuring equipment which
require calibration and the frequency of such calibration which shall comply with the
requirements of QCS 2014, or its revisions, and the contract specification.
Calibration procedures shall be provided, including the permitted tolerances for the
equipment to remain in service. The quality plan shall state the required accuracy of all plant
calibrations and shall identify any that require traceability to national reference standards (e.g.
mass or weight).
The plant shall be maintained to ensure that it continues to be capable of producing asphalt
to the required specifications and tolerances. Table A-2 gives guidance with regard to
schedules for calibration and checks.
The FPC quality plan documentation shall identify those items and areas of the plant where
constant use and wear will affect the quality of production including, but not limited to, the
dryer drum, hot elevator, screen deck and meshes, hot bins, weighing and mixing apparatus,
and state the inspection and maintenance schedules for these items in order to maintain
them to the condition necessary to ensure the quality of production.
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A maintenance schedule shall be available and maintenance records shall be kept.
7.3.6
Plant Quality Control Laboratory
The asphalt plant shall have a quality control testing laboratory capable of conducting the
following tests:
Sieve analysis (ASTM C117, C136, and D5444).
(b)
Specific gravity for coarse and fine aggregates (ASTM C127, C128).
(c)
Theoretical maximum specific gravity and density of asphalt mixtures (ASTM D2041).
(d)
Quantitative extraction of asphalt binder from asphalt mixtures (ASTM D2172).
(e)
Bulk specific gravity and density of compacted asphalt mixtures (ASTM D1188,
D2726).
(b)
Qualified laboratory manager.
(c)
Qualified technicians.
(d)
Calibrated equipment.
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Efficient quality management system.
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The asphalt plant laboratory shall have a database includes but not limited to the following:
(a)
Production data.
(b)
Testing data.
(c)
Materials type and materials traceability to source data.
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The asphalt plant laboratory shall have the following:
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(a)
The plant laboratory shall keep records of materials and asphalt mixtures properties on a
daily basis.
The laboratory shall maintain a position description for each technical operational position
shown on the laboratorys organization chart. Position descriptions shall identify the position
and include a description of the duties, required skills, and education and experience
associated with the position.
The laboratory shall maintain technical staff training records, qualifications, work experience,
licensure, certifications, and current position for each supervisory technical staff member.
The laboratory shall maintain a procedure which describes the methods used for laboratory
personnel training to perform tests in accordance with standard procedures. Records of
laboratory personnel training shall be maintained.
The laboratory shall maintain a procedure describing the method used to evaluate staff
competency to ensure that each test covered by the scope of this standard is performed in
accordance with standard procedures. This description shall include the frequency of
competency evaluations for each technician and indicate what position or employee is
responsible for evaluating staff competency and maintaining records. The procedure shall
ensure that each technician receives a performance evaluation for each test that technician
performs.
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The laboratory shall calibrate, standardize, and check all significant equipment associated
with tests which the laboratory performs.
10
The laboratory shall have a procedure for the storage, retention, and disposal of test
samples.
7.4
7.4.1
General
All necessary facilities, equipment and personnel shall be available to carry out the required
Inspection and testing shall be carried out at least as frequently as indicated in Tables A-3 to
A-7. Sampling shall be randomised so as not to introduce undue bias in the assessment of
compliance. Due care shall be taken to adequately cover both large and small volumes of
material.
At least 10% of quality control tests related to constituent materials and finished mixtures
shall be carried out by an approved thirty party laboratory. Third party testing schedule shall
be liaised with the Engineer.
The results of all tests carried out on materials shall be recorded. Tests taken specifically for
the resolution of problems arising from process control shall be kept separately and need not
be used for the purpose of calculating compliance with the technical specifications.
All sampling and testing shall be carried out in accordance with the relevant standard
procedures required by the specification.
7.4.2
Incoming constituent materials
Incoming constituent materials shall be inspected and tested using procedures detailed in the
quality plan and to a schedule complying with this clause and the requirements of QCS 2014,
or its revisions, and the contract specification.
The required inspections of materials in storage shall be maintained to establish that no

deterioration has occurred.
Detailed requirements shall be as follows:
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(a)
Aggregates: see Table A-3.
(b)
Filler: see Table A-4.
(c)
Additive: see Table A-5.
(d)
Binders: see Table A-6.
(e)
Finished Asphalt Mixture: see Appendix B.
7.4.3
Finished Asphalt Mixture
The finished asphalt mixture shall be inspected and tested using procedures detailed in the
quality management system documentation and to a schedule complying with the
requirements of QCS 2014 and the contract specification.
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Appropriate statistical records shall be maintained in order to monitor and verify process
capability and product characteristics.
Individual batch readings shall be recorded as part of the quality records. The plant
pyrometer shall be calibrated in accordance with ASTM E2847 and checked daily against a
calibrated laboratory thermometer, the record of which shall be maintained in the plant
control cabin/office. The temperature of the finished asphalt shall be the average load
temperature however no batch or part of the load shall exceed the maximum JSM
temperature for the mix. Measurement shall be in accordance with QCS 2014.
As a regular audit check on the efficacy of the plant quality control laboratory, 10% of
samples analysed for mix composition by the plant control laboratory shall have a duplicate
sample analysed in an independent laboratory, which is ISO17025 accredited in related tests.
The duplicate sampling may be done simultaneously as part of the Organizations other
testing obligations conducted by an approved independent laboratory. The duplicate results
shall be regularly reviewed and any differences falling outside the reproducibility limits
published in the test standard applicable to the ASTM test methods employed shall be
investigated.
The results of all tests carried out on materials shall be recorded. Tests taken specifically for
the resolution of problems arising from process control shall be kept separately and need not
be used for the purpose of calculating compliance with the technical specifications.
All sampling and testing shall be carried out in accordance with the relevant standard
procedures required by the specification.
Sampling frequencies, operating compliance level (OCL) and test frequencies are provided in
Appendix B.
7.5
NON-CONFORMITY
7.5.1
General
The producer shall establish and maintain documented procedures to ensure that constituent
materials or asphalt mixture which when identified by in-process inspection does not conform
to specified requirements is prevented from use or installation. This control shall provide for
identification, evaluation, separation from conforming product (when practical) and disposal
of the nonconforming material or asphalt mixture.
The non-conformance process shall include:
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(a)
Constituent materials upon arrival at the plant or storage site.
(b)
Constituent materials in storage.
(c)
The manufacturing process.
(d)
Handling, storage and delivery of the finished product.
7.5.2
Non-conformity of Material or Asphalt Mixtures
Where non-conforming constituent materials or finished asphalt mixtures are identified, the
cause of the non-conformance shall be investigated and identified to effect appropriate
corrective actions to prevent a reoccurrence. Such corrective actions shall be incorporated
into the FPC quality plan.
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Corrective actions may involve reworking the material, adjusting the process, redirection to
another use where it may be acceptable, recycling for further use or rejection and disposal.
The FPC quality plan shall identify the action to be taken in process control when nonconforming product is identified from analysis.
The FPC quality plan shall state the process under which the installation contractor and the
supervising agency will be notified of non-conforming analysis results.
7.6
INSPECTION, MEASURING AND TEST EQUIPMENT
The Organization shall control, calibrate and maintain suitable measuring and test equipment
as required by this guidance document and QCS 2014.
To ensure the testing of incoming constituent materials and finished asphalt conforms to the
relevant test method specification, the Organization, or where an independent laboratory is
employed by the Organization to conduct its quality control testing, shall ensure within the
FPC quality plan that the measuring and test equipment used is maintained in a known state
of calibration and maintenance.
The equipment control procedures shall demonstrate the following:
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Accuracy and frequency of calibration, which should be in accordance with the relevant
test standard.
(b)
Equipment is used in accordance with a documented procedure.
(c)
Equipment is uniquely identified.
(d)
Calibration records to be maintained.
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(a)
PLANT GENERALLY
The machinery and tools used in constructing the various items involved in asphalt works
shall be in good working condition and free of oil and fuel leaks. The Contractor shall
maintain and preserve them for the whole duration of the work. The Engineer shall approve
the machinery and tools before works begin and the Contractor shall supply adequate
quantities of such machinery in order to execute the work with due speed and precision.
Equipment approved for use shall not be removed from the Site without the approval of the
Engineer.
If required the Contractor shall furnish the Engineer with the manufacturer's catalogues,
specifications and other published data for the equipment and machinery he proposes to use.
On first erecting an asphalt plant and at least once each three months thereafter, the plant
shall be calibrated by a calibration service organisation approved by the LSA. Production
shall not be permitted if the weigh batch calibration does not comply with the requirements of
ASTM D995-95.
The Engineer shall have the right to stop the use of any equipment or plant which he deems
to be inferior to the quality required or detrimental to the permanent works and to instruct the
removal of such equipment and to have it replaced by suitable equipment.
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7.7
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The Contractor shall immediately comply with such instructions without being entitled to any
indemnities or extensions as a result of such instructions. The Contractor shall not be
allowed to use any equipment or plant before obtaining the approval of the Engineer, and the
Contractor shall undertake to follow sound technical methods in operation and to engage
skilled and trained operators, mechanics and labour to carry out the works. The Engineer
shall have the right to expel any operators, mechanics or labour and to instruct suitable
replacement thereof at any time he deems such action is necessary.
The Contractor shall comply with any special plant requirements published by the concerned
authority.
7.8
ASPHALT PLANT
7.8.1
General
All plant used by the Contractor for the preparation of asphalt hot mixes shall be batch type
plants conforming to the requirements as detailed below.
The Engineer may permit the use of continuous drier drum type asphalt plants after a fully
detailed technical submission by the Contractor itemising the differences from the
specification. In such cases after approval of the technical submission the Contractor shall
carry out a full scale laying trial with testing of the hot and laid mix and monitoring of the plant
operation by the Engineers staff to assess the suitability of the proposed plant.
No laboratory verification or plant trial shall be carried out by the LSA unless an automatic
compaction apparatus is available at the producers laboratory.
7.8.2
Automatic Operation
The plant shall be designed, co-ordinated and operated so as to continually produce an

asphalt mix within the job mix tolerances specified.
The plant shall be equipped and operated so that the proportioning of the hot aggregate, filler
and bitumen, together with the dry and wet mixing cycles are all controlled automatically.
Positive interlock shall be provided so that proportioning, mixing and discharge are
accomplished by one operation without manual control of the separate phase.
The use of manual and semi-automatic plants for the production of asphalt is not permitted
unless specific approval is given in writing by the Engineer.
7.8.3
Cold Bins System
The plant shall include a sufficient number of cold storage bins so that there is at least one
bin for each different stockpile of material being used.
Intermixing of material from different stockpiles in one bin or on the ground before putting into
the bin is prohibited.
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The cold bins and loading equipment used shall be compatible to prevent overflow between
the bins. Baffle plates shall also be used between bins to prevent overflow of one bin into
another. Each cold bin shall include an accurate means for continuously feeding the required
amount of mineral aggregate so that uniform production is achieved. The settings on the cold
bins shall be approved by the Engineer and shall be checked and calibrated as often as he
may deem necessary to ensure their continued accuracy. Change of settings shall be made
only with the approval of the Engineer.
7.8.4
Drier
A drier of satisfactory design shall be provided. The drier shall be capable of uniformly drying
and heating the aggregate to the moisture and temperature required without leaving any
visible burned oil or carbon residue on the aggregate when discharged from the drier.
7.8.5
Dust Collector
The plant shall be provided with a dust collector designed to waste, or to return all or part of
the material collected to the asphalt plant.
The asphalt plant shall have an efficient fugitive emission collection and control system to
control dust or fume emissions from the drying, screening, weighing and mixing operations.
The collection system shall be so designed to prevent the emission of dust and fumes into
the atmosphere in accordance with the environmental standards of Qatar.
The collected dust from the drying process shall pass through a coarse collector which will
pass the coarse particles, substantially greater than 0.075mm, back to the hot elevator or to
a silo for the controlled return to the asphalt mix. The reclaimed dust substantially less than
0.075mm shall be collected and passed into a storage silo for the controlled return as mineral
filler to the asphalt mix through the filler weighbox or sent to waste.
The plant shall be equipped with a filler silo for recovered filler. An additional dry storage silo
shall be provided for imported mineral filler with a provision of a separate weighing hopper to
proportion this filler into the mix.
7.8.6
Screens
Plant screens shall be capable of screening all aggregates to the specified sizes and
proportions. They shall have capacities equal to or greater than the maximum rated capacity
of the plant. They shall have an operating efficiency such that the aggregate deposited in any
bins shall not contain more than 10 % oversize or undersize material. This screen tolerance
shall not invalidate the job mix tolerances specified.
7.8.7
Hot Bins
The plant shall include at least three storage bins for hot aggregate of sufficient size to supply
the pugmill when it is operating at full capacity. They shall be arranged to ensure separate
and adequate storage of appropriate fractions of the aggregate. Each compartment shall be
provided with an overflow pipe that shall be of such size and at such location as to prevent
any backing up of material into other bins or against the screens. Bins shall be so
constructed that samples can be readily obtained therefrom. The hot bins shall be equipped
with continuous level indicators to provide information about the level of each ingredient of
the JMF and to avoid shortage or overflow of aggregate from one bin to another.
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Asphalt Binder Storage
Tanks for storage of asphalt binders shall be equipped for heating the material using positive
and automatic control at all times, to a temperature within the specified range. The heating
shall be accomplished by hot thermal oil, electricity or other approved means such that no
direct flame shall come in contact with the bitumen or heating tank.
The circulating system for the asphalt binder shall be of adequate size to ensure proper and
continuous circulation during the entire operating period. Suitable means shall be provided
either by double jacketed steam or hot oil or other insulation for maintaining the specified
temperature of the bituminous material in the pipeline, meters, weigh buckets, spray bars,
and other containers and flow lines.
The storage tank capacity shall be sufficient for at least one day's operation. Circulation
return lines to the asphalt storage tanks should be submerged to the same elevation in the
storage tanks as the feeder line. Two or three vertical slots may be cut in the return line
above the high level mark to break vacuum when reversing the pump.
The Contractor shall provide a sampling outlet in the asphalt binder feed line connecting the
plant storage tanks to the asphalt binder weighing or metering box. The outlets shall consist
of valves installed in such a manner that samples may be withdrawn slowly at any time during
plant operation. The locations of the sampling outlets shall be readily accessible and free
from obstructions. Drainage receptacles shall be provided for flushing the outlets before
sampling.
7.8.9
Thermometric Equipment
An armoured thermometer reading from 38 C to 204 C shall be fixed in the bituminous feed
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7.8.8
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line at a suitable location near the discharge valve. Similar devices shall be fixed in the
heating and storage tanks.
The plant shall be further equipped with either an approved dial-scale, mercury-actuated
thermometer, an electric pyrometer, or other approved thermometric instruments placed at
the discharge chute of the drier and in the hot fines bin so as to register automatically or
indicate the temperature of the heated aggregates. For better regulation of the temperature
of the aggregates, replacement of any thermometer by an approved temperature recording
apparatus may be required by the Engineer and he may further require that daily temperature
charts be submitted to him by the Contractor.
7.8.10
Control of Mixing Time
The Plant shall be equipped with positive means to govern the time of mixing and to maintain
it constant unless changed at the direction of the Engineer.
7.8.11
Pugmill
The batch mixer shall be an approved twin pugmill type, capable of producing a uniform
mixture within the job-mix tolerances. It shall be so designed as to permit a visual inspection
of the mix. The mixer capacity shall be not less than 600 kg per batch and shall be so
constructed as to prevent leakage of contents.
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The bitumen system shall deliver an even flow of binder into the mixer to ensure an even
distribution of bitumen binder throughout the mix during the wet mixing cycle.
The mixer shall be fully enclosed with sufficient air extraction to prevent emissions of dust
and fumes. The mixing cycle shall be controlled such that from charging of the mixer until the
closing of the mixer door at the completion of the cycle there shall be no leakage of
aggregate, filler or bitumen from the weighing hoppers. The system shall permit a dry mixing
period, defined as the interval of time between opening of the weigh box gate and the start of
application of bitumen, if required by the mixing process.
The wet mixing period is defined as the interval between the discharge of the bitumen binder
into the mixer and the mixer gate is opened to discharge the mix, and shall be not less than
30 seconds. The wet mix time shall be capable of being incrementally set at intervals of not
more than five seconds up to a wet mix time of three minutes. A mechanical batch counter
shall register the completely mixed batches.
The mixer shall be equipped with a full set of mixer paddles in a suitable arrangement, in
accordance with the manufacturers specification, to produce a proper and uniformly mixed
batch. All paddle arms and tips, and mixer liners shall be in good condition. Mixing shall
cease if any mixer arms or tips are missing, and shall not resume until replaced and
inspected.
7.8.12
Temporary Storage of Mix
Plants may be equipped with skips or elevators for delivering batched mix to hoppers or silos
before discharging to hauling units. The skips or elevators shall not be sprayed with diesel or
other solvents; where necessary they may be sprayed with a minimum amount of lime water,
soap or detergent solution. Hoppers or silos shall be of such design that no segregation or
loss in temperature of the mix occurs.
7.8.13
Safety Requirements
Adequate and safe stairways to the mixer platform and guarded ladders to other plant units
shall be placed at all points required for accessibility to all plant operations. Accessibility to
the top of truck bodies shall be provided by means of a platform or other suitable device to
enable the Engineer to obtain mixture temperature data. To facilitate handling scale
calibration equipment and sampling equipment, a hoist or pulley system shall be provided to
raise or lower the equipment from the ground to platform or vice-versa. All gears, pulleys,
chains, sprockets and other dangerous moving parts shall be thoroughly guarded and
protected. Ample and unobstructed passage shall be maintained at all times in and around
the truck loading space. This space shall be kept free from drippings from the mixing
platform.
Accessibility to the top of loaded truck body shall be provided by means of a platform to
enable obtaining asphalt mixture samples and temperature readings and to check truck body
condition. All necessary safety measures shall be provided for accessing the top of loaded
truck body.
7.8.14
Weigh-Box
The plant shall include means for accurately weighing each size of aggregate in a weigh-box
or hopper, suspended on scales, ample in size to hold a full batch without hand raking or
running over.
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QCS 2014

Part
07: Asphalt Plants
Page 16
The weigh-box or hopper shall be so constructed that they will not be thrown out of alignment
or adjustment. All edges, ends and sides of weighing hoppers shall be free from contact with
any supporting rods and columns or other equipment that will in any way affect the proper
functioning of the hopper.
There shall also be sufficient clearance between hoppers and supporting devices to prevent
accumulations of foreign materials. The discharge gate of the weigh-box shall be so hung
that the aggregate will not be segregated when dumped into the mixer and shall close tightly
when the hopper is empty so that no material is allowed to leak into the batch in the mixer
during the process of weighing the next batch.
Weighing boxes and hoppers shall be free hanging and placed on high precision load cells or
strain gauges.
7.8.15
Scales or Meters
Scales or meters used for proportioning aggregates, mineral filler and bitumen shall be
accurate to 1 % of the indicated quantity. Scales and meters shall be substantially
constructed. Scales and meters that require frequent adjustment shall be replaced. Scales
shall be constructed and located so as to prevent vibration in the dial pointer.
Weighing sequence of hot aggregates shall progress from coarse to fine.
Bituminous material shall be automatically proportioned by either weighing or metering. The

minimum gradation shall be not more than 1 litre or 1 kg. Bituminous scales and weigh
buckets shall be such that the required amount of bitumen is provided in a single weighing
and delivered to the pugmill without loss due to overflow, splashing or spillage.
Bituminous weigh buckets shall be satisfactorily insulated to prevent loss of heat in the
bitumen or accumulation of bitumen in the bucket. Bituminous metering devices shall be
rotating positive displacement pumps and shall be capable of providing the designated
quantity of material for each batch.
All scales and meters shall be approved by the Engineer and shall be checked and calibrated
as detailed in Clause 5.3. Production shall not be permitted if the weight batch calibration
does not comply with the requirements of ASTM D955-95.
7.8.16
Plant Control System
The asphalt plant operations shall be fully automated and connected to a centralized control
system. Preferably, the plant operating software shall be capable to store the detailed
production history.
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Part
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APPENDIX A
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QCS 2014
QCS 2014

Part
07: Asphalt Plants
Page 18
Table A-1: Process control minimum inspection schedule

Inspection/Test
Purpose
Identify
contamination,
intermingling, level
ground for tipping,
stock availability
Aggregate stockpiles
As FPC quality plan
Cold feed bins
As FPC quality plan
Aggregate dryer
As FPC quality plan
Dried
heated
aggregate
Aggregate
temperature
Control for
conformance
Aggregate screens
As FPC quality plan
Identify mechanical
and physical defects
As FPC quality plan
Identify mechanical
and physical defects
Hot bin gradations
Check screening
efficacy
Daily
Weekly
Monthly or as
FPC quality plan
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Continuously
in production
Weekly or as
FPC quality plan
Weekly
as
Hot aggregate bins
Ensure correct
feeding to plant and
maintenance of bins
Maintenance
inspection to ensure
effective heating and
drying
Minimum frequency
Control Area
As FPC quality plan
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Weighing apparatus
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Identify mechanical
and physical defect
Tank temperature
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Bitumen
Binder properties
Check weighing
efficacy against truck
scale
Check storage
conformance
Daily
In accordance with
storage
recommendations
As FPC quality plan

or in case of doubt
Temperature
monitoring
equipment for
drying/heating and
asphalt mix
process
Test of
accuracy
comparison
with calibrated
reference
thermometer
To ascertain the
equipment is
functioning correctly
Asphalt mix
Mix temperature
Ensure temperature
conformance
Weekly
Weekly
Each batch or
continuously in
production
QCS 2014

Part
07: Asphalt Plants
Page 19
Table A-2: Minimum plant calibration and check requirements

Inspection/Test
Purpose
Weighing
equipment
Testing of weighing
accuracy - calibration
Organoleptic* inspection
Admixture/additive
dispensers
Test for accuracy as

described in procedures.
To ensure that
weighing equipment is Daily
1
To ensure accuracy
within quality plan
requirements
a) on installation
b) every 3 months
c) in case of doubt.
To ensure that
dispenser is
First batch of the day

containing admixture
To ensure accuracy
within quality plan
requirements
a) on installation
b) every 3 months
Batching system
(on batch plants)
Comparison of actual
mass of constituents in
the batch with the
intended mass using the
method prescribed in the
quality plan
a) on installation
b) every 3 months
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Flow meters
Comparison of the actual To ensure accuracy

amount with the metered within quality plan
amount by reconciliation
requirements
Visual inspection as
described in procedures
Minimum frequency
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Item of Plant
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To ensure the batching

1
a) on installation
accuracy in
b) every 3 months
accordance with the
quality plan
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Comparison of actual
mass in a measured
Proportioning
period of time with the
system (cold feed) intended mass using the
method prescribed in the
quality plan
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Temperature
monitoring
equipment
(infrared
pyrometer)
Visual as described in
procedures
Test of accuracy
comparison with
calibrated reference
thermometer
Test of accuracy calibration
Temperature
monitoring
equipment (contact
probe or
thermocouple for
drying heating
process)
Visual as described in
procedures
Test of accuracy calibration
To ensure the
accuracy in
accordance with the
quality plan
To ensure the
equipment is
To ensure the
equipment is
a) on installation
b) every 12 months
Daily
Weekly
1
To ensure correct
temperatures are
recorded
a) on installation
b) every 12 months
To ensure the
equipment is
Daily
To ensure correct
temperatures are
recorded
a) on installation
b) every 3 months
QCS 2014

Part
07: Asphalt Plants
Page 20
Table A-3: FPC Inspection and test guidance for aggregate stockpiles
Inspection/Test
Purpose
Minimum frequency
Tests for aggregate properties
To check suitability for

intended use
As required by QCS 2014,

or its revisions
Tests for aggregate consistency

by sieve analysis
Each size: Weekly

To check consignment quality Each consignment: in
case of doubt
Inspection of delivery ticket
To check consignment is
as ordered and from
correct source
Each delivery
To check suitability
for intended use
Tests for filler consistency
To check consignment
or production quality
As required by QCS 2014,

or its subsequent revisions
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Tests for filler properties
Minimum frequency
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Purpose
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Inspection/Test
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Table A-4: FPC inspection and test guidance for Filler
Gradation: Weekly
Plasticity: Weekly
as
Filler: Non plastic
To confirm characteristics
of product or check
compliance with
specification
Each delivery or weekly

for reclaimed filler dust
To check consignment is
as ordered and from
correct source
Each delivery
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Appropriate tests to
determine specified
properties
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Table A-5: FPC inspection and test guidance for additives

Inspection/Test
Appropriate tests to
determine intrinsic
properties
Organoleptic*
check of
consignment
Purpose
Minimum frequency
To confirm characteristics
of product or check
compliance with
specification
To check that consignment
is as ordered and from the
correct source
a) Source approval prior

to initial use and
b) as stated in the quality plan
For comparison with

normal appearance
Each delivery, if
practicable; otherwise in
accordance with quality
plan.
Each delivery
QCS 2014

Part
07: Asphalt Plants
Page 21
Table A-6: FPC Inspection and test guidance for bitumen binder
Inspection/Test
Purpose
Minimum frequency
Tests for bitumen properties
To check suitability for

intended use
As required by QCS 2014 and

project particular specification
To check consignment is as
ordered and from the correct
source
To check that binder is within
specified temperature limits
Each delivery or production batch
Temperature
(a) Each delivery or production

batch
(b) Each tank recorded daily
To assess compliance with

specification
1 per 450 tons of binder delivered

in normal production
Grade Properties (PG76- 10)
To assess compliance with

specification
1 per 450 tons of binder delivered

in normal production
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Grade Properties (60/70)
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Prior to production if stored for

more than 3 days without further
deliveries or production batches
For comparison with normal

perceptible properties
Each delivery or daily survey of

tanks
as
Organoleptic* Check
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Table A-7: FPC minimum inspection/test frequencies for product quality control
Minimum frequency
Every load
Suitability of delivery
vehicles by visual
assessment
Cleanliness of delivery
vehicles by visual
assessment
To check adequacy of
insulation
a) Prior to first use

b) In case of doubt.
To avoid contamination
To control use of release agent
Every load prior to loading
Mixed asphalt temperature
To assess conformity
Grading and binder content
a) As required under Table

1
b) Whenever samples
are taken
In accordance with QCS
2014
Other characteristics included

in technical specifications
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For comparison with normal

appearance with regard to
grading, evenness of mixing
and adequacy of binder
coating
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Organoleptic* check on
mixed asphalt
Purpose
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Inspection/Test
In accordance with QCS

2014
* Organoleptic check: a broader evaluation made with the senses: sight, touch, smell, hearing etc. rather
than a visual inspection.

Part
07: Asphalt Plants
Page 22
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APPENDIX B
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QCS 2014

Part
07: Asphalt Plants
Page 23
MINIMUM SAMPLING FREQUENCIES AND TOLERANCES FOR THE FACTORY PRODUCTION

QUALITY CONTROL OF FINISHED ASPHALT
General
This Appendix includes sampling frequencies and tolerances for mixture composition for use
in the evaluation of conformity of mixed asphalt during production. It is consistent with QCS
2014 but is specifically intended as guidance for the Organization (Asphalt Producer) to
maintain the quality control of the finished asphalt mixture at the point of manufacture and
does not impede on the requirements of QCS 2014, or its revisions, or the contract
specification. The sampling and frequencies are the minimum that should be considered for
control but it is to discretion of the Organization to ensure sufficient samples, tests and
assessments are made in order for the asphalt mixture conforms to specification
requirements.
The properties of asphalt mix characteristics shall conform to the requirements of QCS 2014
and the contract specification. Should these not properties be found not to conform to the Job
Mix Formula the design should be assessed.
The guidance provides for three levels of minimum frequency. The minimum frequency which
shall be carried out for all production circumstances and higher frequencies which are
appropriate where it is necessary to give a greater assurance of consistency where the
measured level of conformity has decreased.
A guide to assessment of production quality control test conformity is given.
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Asphalt mixture composition Job Mix Tolerances shall be in accordance with QCS 2014, as
indicated in Table B.1:
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Testing tolerances and conformity assessment
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Table B.1: Job Mix Tolerances

Base Course
Intermediate
Course
Wearing Courses
Aggregate retained on 4.75mm

sieve or larger
5%
4%
4%
Aggregate passing 4.75mm sieve

4%
3%
3%

3%
2%
2%
1.5 %
1.0 %
1.0 %
Binder Content
0.3 %
0.2 %
0.2 %
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Description
Operating Compliance Level

1
The Operating Compliance Level (OCL) shall be applicable to each single plant and shall be
determined on an ongoing basis from the number of non-conforming compositional test
results within the last 32 analyses of all asphalt mixtures tested. In addition, the OCL shall
take into account the consistency of production with assessment of the mean deviation from
target as detailed in Table B.2.
QCS 2014

Part
07: Asphalt Plants
Page 24
In the event of 5 or more of the previous 32 results being non-conforming, and/or variance of
the mean deviation from target from the prescribed tolerances, the plant shall be subject to
an immediate and comprehensive review of equipment and procedures.
Mean Deviation from Target

For each analysis the deviation from target shall be determined for each of the sieves sizes
and binder content indicated in Table B.1. A running mean of the deviations for the last 32
analyses of each asphalt mixture shall be maintained.
Should the running mean of the deviations exceed the values stated in Table B.2, this shall
be deemed to be non-conforming asphalt mixture in accordance with Clause 25.4.2 and the
appropriate corrective quality control action taken. The Operating Compliance Level shall be
lowered by one level for as long as the mean deviation stays outside tolerance.
Intermediate
Course
Aggregate passing 12.5 mm
ta
1.5
1.0
1.0
0.3
0.2
0.2
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Test Frequency
Aggregate passing 75 m sieve

Soluble Binder Content
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(Superpave)
(Marshall)
Wearing Course
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Aggregate passing 19 mm
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Base Course
Description
The frequency for sampling shall be determined weekly and shall be maintained at the
operating compliance level minimum frequency indicated in Table B.3.
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Table B.2: Mean deviation from target tolerances
Table B.3: Determination of Operating Compliance Level and Sampling Frequency
Number of nonconforming
analyses in last 32
Operating Compliance
Level
0-2
1 per 250t per mix or part thereof
3-6
Minimum Sample Frequency
New plants commencing production, plants restarting after relocating, a major repair or
overhaul, or those recommencing commercial production after a period exceeding 3 months
cessation shall operate under OCL until 32 results have accumulated after which the
frequency shall revert to the OCL achieved.
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APPENDIX C

Part
07: Asphalt Plants
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QCS 2014

Part
07: Asphalt Plants
Page 26
Table C-1: Sample of plant inspection checklist

Aggregate Stockpiles
Yes
Are aggregate stockpiles separated by walls or clear space

with signed labelling?
Are the stockpiles free of significant contamination and

segregation? (Plant drain-out aggregate is acceptable if the
aggregate size is similar and uncoated.)
Aggregate Cold Feed
6
7
8
ta
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Is the aggregate collecting conveyor in good condition, with no

holes or splits, or evidence of tracking (side movement) and
the belt scrapers are in good order?
Has each aggregate size its own designated and labelled

bin/hopper?
Are bins/hoppers in good condition with no holes, with bin wall
divider plates between each?
Is aggregate overflow between hoppers being prevented by
divider plates?
If meshes (grizzlies) are fitted over the bins/hoppers, are they
in reasonable condition and fit for purpose?
Are the feeder gates, feeder belts and vibrators in good
condition?
Are there no-flow paddles/sensors on each feeder and are
they working?
Date of the last feeder calibrations:
Dryer
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Is the truck tipping area at the stockpile level? (Non-level

surfaces can cause trucks to tip over.)
Do the aggregate delivery and test records conform to the
approved mix designs?
Have the aggregates been sampled and tested in accordance
with requirements?
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Is the aggregate in good condition with no signs of degradation

on the stockpile due to vehicle/plant movements?
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No
Is there any significant aggregate spillage under the dryer

conveyor, the dryer drum or around the base of the hot
elevator?
Are the dryer lifters and flights are in good condition without
undue bending or deformation and none missing. (when dryer
is cold and stopped)
Is the drum exit chute temperature pyrometer, thermocouple

or probe clean, working and in calibration?
Date of last pyrometer, thermocouple or probe calibration:
Has the drum exit chute

temperature equipment been
checked recently with a
referenced laboratory probe?
Date:
Drum chute:
Laboratory probe:
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QCS 2014

Part
07: Asphalt Plants
Page 27
Dust Collection
1
Does the pre-skimmer or knockout box return the collected

fine sand to the plant hot elevator?
a: returned to a silo for re-use?
Is the bag house

extracted dust:-
b: directly fed back into the asphalt

plant?
Date of last certified plant stack emission test?
Is the plant stack emission is visually clean with no obvious

dust or smoke??
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Does the laboratory monitor the gradation of the coarse preskimmer or knockout box fines and bag house filler?
Is there a dust emission monitoring system on the plant?
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Aggregate Screening
Is there any spillage around the screen deck area?
Did the last screen inspection indicate any defects?
Date of last screen deck inspection:
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Are there any loose screen meshes that need tightening or

support bars that are loose and need welding?
Is there evidence of side seal seepage which could
contaminate screened aggregate or wear other parts?
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Are there any signs of damage or wear, especially adjacent to

screen bearings or shafts?
Is there any significant dust emission from the screen housing
lids, covers or doors?
Is there any evidence of holes, splits or tears in the screen
meshes and is there any apparent and significant pegging or
blockages?
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Is there any indication of hot bin oversize or undersize in hot

bin drain-outs?
Bin 1 Aggregate size 0 / X mm
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Hot Aggregate Bins

1
Bin 2 Aggregate size X / X
mm
mm
mm
mm
mm
10
c: wasted?
Are the individual hot stone bin overflow chutes/pipes blocked

or damaged?
Are there holes or damaged seams or welds in the hot bin
walls, especially in the corners and in the lower half of the
bins?
Do the hot stone bin doors stick or seize? Is there evidence of
holes in or leakage from the doors?
QCS 2014

Part
07: Asphalt Plants
Page 28
Weighing and Measuring Apparatus
Are the calibrations of the aggregate, filler and bitumen

weighing apparatus current and in date?
Aggregate weighing apparatus calibration date:
Bitumen weighing apparatus calibration date:
Filler weighing apparatus calibration date:
Mixed asphalt pyrometer calibration date:
Has the mixed asphalt pyrometer been

checked recently with a referenced
laboratory probe?
1
2
Date:
Pyrometer:
Laboratory probe:
Do the printed batch weights equal the weight indicators and

are total load batch weights similar to the truck scale net
weight?
Does the bitumen bucket/kettle pass the static load test?

(Hold a fully weighed batch of bitumen for at least 30 seconds
and note any change in weight. Repeat when empty and note
any major change in tare)
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Is the bitumen bucket/kettle adequately insulated and heated?

Seepage or leakage from the charge and the discharge
pipes? Check the butterfly valve underneath for direct gravity
discharge systems.
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Does the aggregate and filler weighing apparatus pass the

static load test?
Is there any bitumen seepage or leakage from the charge and
the discharge pipes, and the butterfly valve underneath on
direct gravity discharge bitumen bucket/kettle systems?
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Bitumen Storage and Pumping
Where fitted, are breather vents clear on the bitumen weigh

bucket/kettle and delivery pipe to the mixer?
Are the bitumen tanks and are all tanks clearly labelled
according to the grade of binder stored?
Are stored binder tank temperatures compliant with
specification or supplier recommendations?
Where PMB is stored, are the stirrers operational and in good
condition?
Is there a supplier defined procedure for the storage and use
of polymer modified binders?
Are all tanks, pipes, pumps and flow meters properly
insulated and the surrounds clean and in good order?
Is there any evidence of excessive bitumen or oil
seepage/leaks from pump(s), valves or manifolds?
Are bitumen tank temperatures monitored and recorded daily
by the plant staff?
Are the bitumen binders tested for foaming when heated to
175C?
Is there a control or procedure for tank/binder grade selection
according to asphalt mix recipe to avoid using the incorrect
grade?
3
4
5
6
7
8
9
10
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Weighing efficacy:
QCS 2014

Part
07: Asphalt Plants
Page 29
Asphalt Mixing
4
5
6
7
8
Is there excessive overflow from the aggregate overflow

chutes?
Check the required batch weights on the mix card.
Are batch deviations within acceptable guide tolerance?
Are inspection hatches secure and sealed to prevent dust

emission?
Are electric cables, hydraulic and air lines well maintained and
in good order?
Are all mixer arms, paddles and tips, liners and door seals
present and in good condition?
Is the aggregate weighing sequence, coarse size to fine size?
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Are the weighing apparatus and mixer external surrounds in

clean and good order with no apparent seepage or leakage of
aggregate, filler or bitumen?
Batch aggregate component 1.5% of total batch weight
10
Bitumen deviation 0.1% of total batch weight
11
Mineral filler deviations 0.1% of total batch weight
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sec.
14
What is the delay time after aggregate discharge for filler:
sec.
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On completion of the mixing cycle, does the mixer fully

empty?
16
What is the total wet mixing time in seconds?

(From the complete discharge of the bitumen and filler to the
emptying of the finished batch)
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Are the in-flight adjustments being made automatically by the

plant control system?
What is the delay time after aggregate discharge for bitumen:
12
18
19
20
21
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On visually inspecting single batches of asphalt, is the

appearance consistent from side to side and front to back,
and not segregated?
Does each batch conform to the mix temperature
specification requirement?
17
Does the plant indicated mixed asphalt temperature

correspond with a laboratory check?
Where used, is the skip hopper acceptably clean?
Are the empty hot storage silos acceptably clean without cold
asphalt sticking to the sides and corners?
Loading
1
2
3
Are all trucks acceptably clean prior to loading without any

evidence of diesel being used as a release agent?
Are all trucks equipped with load cover sheets or canvasses?
Are the loaded trucks free of significant segregation?
sec.
QCS 2014
4
5

Part
07: Asphalt Plants
Page 30
Is the asphalt temperature acceptably consistent and within

range tolerance throughout the load front to back?
Has the correct delivery ticket been issued to the driver with
accurate asphalt description, truck reference or number, site
address, driver name, and ticket number?
Is the plant sampling technician equipped with all necessary
PPE including safety helmet, steel-capped boots, overalls,
gloves, hi-visibility jacket, and protective eye glasses?
Are the plants sampling procedures being following by the
technician to ensure a representative sample?
(Ask for and retain a copy of the sampling procedures.)
Are plant sample details, including truck delivery details, are
recorded on each plant sample?
Request plant compliance rate for each product supplied to the

project or contract for record purposes.
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END OF PART
QCS 2014

Part
08: Recycled and Stabilised Road Materials
Page 1
RECYCLED AND STABILISED ROAD MATERIALS ............................................................ 2
8.1
8.1.1
8.1.2
8.1.3
8.1.4
8.1.5
GENERAL
SCOPE
REFERENCES
DEFINITIONS
SUBMITTALS
QUALITY ASSURANCE
2
2
2
3
4
4
8.2
COLD STABILISED MATERIAL - GENERAL
8.3
MATERIALS
8.4
8.4.1
8.4.2
8.4.3
8.4.4
8.4.5
8.4.6
8.4.7
8.4.8
CEMENT TREATED BASE (CTB)

PREPARATION AND MIX DESIGN FOR CEMENT TREATED BASE
SITE TRIALS FOR CEMENT TREATED BASE AND BITUMEN STABILISED MATERIAL
INSITU STABILISATION AND COMPACTION OF CEMENT TREATED BASE
EXSITU PRODUCTION OF CEMENT TREATED BASE
LAYING AND COMPACTION OF CEMENT TREATED BASE
JOINTS IN CEMENT TREATED BASE
SAMPLING AND TESTING - CEMENT TREATED BASE
EVENNESS AND LEVEL
8.5
8.5.1
8.5.2
8.5.3
8.5.4
8.5.5
8.5.6
8.5.7
8.5.8
BITUMEN STABILISED MATERIAL (BSM)

PREPARATION AND MIX DESIGN FOR BITUMEN STABILISED MATERIAL
SITE TRIALS FOR BITUMEN STABILISED MATERIAL
INSITU STABILISATION AND COMPACTION OF BITUMEN STABILISED MATERIAL
EXSITU PRODUCTION OF BITUMEN STABILISED MATERIAL
LAYING AND COMPACTION OF BITUMEN STABILISED MATERIAL
JOINTS IN BITUMEN STABILISED MATERIAL
SAMPLING AND TESTING - BITUMEN STABILISED MATERIAL
EVENNESS AND LEVEL
12
12
13
13
14
15
16
16
17
8.6
DETERMINATION OF THE FOAMING CHARACTERISTICS OF BITUMEN

(EXPANSION RATIO AND HALF LIFE)
SCOPE
DEFINITIONS
APPARATUS
METHOD
REPORTING
SITE QUALITY CONTROL
18
18
18
18
19
19
20
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6
7
7
9
9
10
10
12
8.6.1
8.6.2
8.6.3
8.6.4
8.6.5
8.6.6
APPENDIX ............................................................................................................................................ 21
GUIDANCE FOR THE DESIGN OF RECYCLED AND STABILISED MATERIALS (MIX DESIGNS)
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RECYCLED AND STABILISED ROAD MATERIALS
8.1
GENERAL
8.1.1
Scope
This Part includes materials, equipment, mix design guidelines and other requirements for
the construction of insitu and exsitu recycled pavement layers.
Incorporation of stabilized or cement bound materials in pavement layers shall be based on

pavement structural design criteria such as layer(s) strength characteristics, load distribution,
layer(s) thickness equivalency, layers strength balance and the target level of pavement
performance.
Use of recycled and stabilized materials and their associated construction and quality
assurance and quality control processes shall be approved by the Engineer.
Related Parts are:

General
Earthworks
Asphalt Works
Part 4
Water
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References
AASHTO T180: ..........Standard Method of Test for Moisture-Density Relations of Soils
er
ASTM C150: ..............Standard Specification for Portland Cement
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ASTM C977: ..............Standard Specification for Quicklime and Hydrated Lime for Soil
Stabilization
ASTM C1097: ............Standard Specification for Hydrated Lime for Use in Asphalt Cement
or Bituminous Pavements
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ASTM D422: ..............Standard Test Method for Particle-Size Analysis of Soils

ASTM D946: ..............Standard Specification for Penetration-Graded Asphalt Cement for
Use in Pavement Construction
8.1.2
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Section 5
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Part 1
Part 3
Part 5
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Section 6
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ASTM D1556: ............Standard Test Method for Density and Unit Weight of Soil in Place by
Sand-Cone Method
ASTM D1632: ............Standard Practice for Making and Curing Soil-Cement Compression
and Flexure Test Specimens in the Laboratory
ASTM D1633: ............Standard Test Methods for Compressive Strength of Molded SoilCement Cylinders
ASTM D2216: ............Standard Test Methods for Laboratory Determination of Water
(Moisture) Content of Soil and Rock by Mass
ASTM D2922: ............Standard Test Methods for Density of Soil and Soil Aggregate in Place
by Nuclear Methods (Shallow Depth)
ASTM D4215: ............Standard Specification for Cold-Mixed, Cold-Laid Bituminous Paving
Mixtures
ASTM D4318: ............Standard Test Methods for Liquid Limit, Plastic Limit, and Plasticity
Index of Soils
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ASTM D4944: .............Standard Test Method for Field Determination of Water (Moisture)
ASTM D4944: ............Standard Test Method for Field Determination of Water (Moisture)
ASTM D6926: ............Standard Practice for Preparation of Bituminous Specimens Using
Marshall Apparatus
ASTM D6931: ............Standard Test Method for Indirect Tensile (IDT) Strength of
Bituminous Mixtures
ASTM D6938: ............Standard Test Method for In-Place Density and Water Content of Soil
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ASTM D7382: ............Standard Test Methods for Determination of Maximum Dry Unit
Weight and Water Content Range for Effective Compaction of
Granular Soils Using a Vibrating Hammer
ASTM E2583: ............Standard Test Method for Measuring Deflections with a Light Weight
Deflectometer (LWD)
MCHW Specification for Highways Works Series 900, UK
ta
TG2 Technical Guideline: Bitumen Stabilised Materials: Asphalt Academy, South Africa
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TRL 611: A Guide to the Use and Specification of Cold Recycled Materials
Definitions
Stabilisation is the permanent modification of soils and aggregates, including recycling

existing pavements, to enhance the engineering properties thereby improving the load
bearing capacity and performance of a new pavement structure.
Aggregate: Granular material used in construction. Aggregate may be natural, manufactured

or recycled.
Primary Aggregate: aggregate extracted directly from the ground in quarries or pits, or
dredged from rivers or the sea. They can be either hard rock such as gabbro and limestone,
or sand and gravel.
Secondary Aggregate: materials produced as a by-product of other mining or quarrying

activities or as a by-product of other industrial processes, e.g. blast furnace slag, incinerator
ash, or the ash from power stations.
Recycled Aggregate: materials produced by the recycling of construction and demolition

waste. These can be crushed concrete, bricks or glass, asphalt planings (i.e. the asphalt
layers of roads removed during roadworks, also known as RAP Recycled Asphalt
Pavement).
Cold Stabilised Material (CSM): materials produced for pavement construction structural
layers using recycled or secondary aggregates.
Bitumen Stabilised Material (BSM):

bitumen or bitumen emulsions.
Cement Treated Base (CTB): granular aggregate materials bound with cement or hydrated
lime hydraulic binder.
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8.1.3
granular aggregate materials bound with foamed
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Exsitu Stabilisation: mixing processes that are carried out away from the construction
location in a remote mixing plant.
10
Insitu Stabilisation: mixing processes that are carried out at the construction location by
specialised stabilisation equipment.
11
Optimum Moisture Content: the moisture content of soil at which a specific degree of
compaction will produce the maximum dry density when determined in accordance with the
AASHTO T180.
12
Maximum Dry Density: the dry density of soil obtained using a specific degree of compaction
at the optimum moisture content when determined in accordance with AASHTO T180.
8.1.4
Submittals
The Contractor shall submit recent test results for the proposed sources of materials for all
quality requirements of the Contract. The contractor shall submit a test certificate that proves
that the raw materials that are purchased/used comply with specifications. The testing may
be performed by an approved private laboratory or by the laboratory associated with the
plant itself.
The contractor shall submit to the Engineer for approval method statements, which includes
but not limited to the following:
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Quality assurance and quality control plans of all construction activities
(b)
Material, handling, storage, identification and marking, traceability to source of

production and testing.
(c)
Equipment suitability to fulfil all construction activities to the required quality
(d)
Personnel capability
(e)
Safety and environment preservation plans
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(a)
The Contractor will be required to produce detailed method statements for the chosen
method of recycling rehabilitation and shall include all stages of the process for approval by
the Engineer. This shall include the credentials and details of experience of the stabilising
contractor, the site investigation report, the stabilised material mix design and the equipment
to be used for the entire process. A separate method statement shall be submitted for each
of the production and construction activities of each layer.
8.1.5
Quality Assurance
If requested the Contractor shall arrange for the Engineer to visit the source of the materials
and jointly take samples for testing. The Contractor shall carry out testing as directed by the
Engineer.
8.2
COLD STABILISED MATERIAL - GENERAL
Cold Stabilised Material (CSM) comprises base and binder courses produced by the process
of in-place recycling (insitu) or in a fixed or mobile mixing plant (exsitu) where the aggregate
source shall be obtained by cold pulverisation of all, or part, of the existing road structure,
blended if necessary with other aggregate and bound with cementitious / hydraulic (CTB) or
bituminous binders (BSM), separately or in combination, or by the use of primary
aggregates.
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Cold Stabilised Material (CSM) shall be designed and produced to form the foundation or
main structural layer of the road pavement.
For Bitumen Stabilised Material (BSM) the primary active binder (stabilising agent) shall be
foamed bitumen, with cement as an adhesion agent as required by the design. For Cement
Treated Base (CTB) the primary active binder shall be cement, hydrated lime or a blend of
both in accordance with the mix design. The aggregate grading may be adjusted by the
addition of inactive mineral filler.
Insitu and exsitu methods of stabilisation rehabilitation are permissible with the approval of
the Engineer on a site by site basis.
Stabilisation design and installation processes shall be in accordance with internationally

recognised standards and specifications, and shall meet the necessary pavement structural
design according to the appropriate traffic classification.
The Cold Stabilised Material shall be designed to achieve the specified level of the
appropriate end performance property to the requirements of the total pavement design. The
minimum layer thickness shall be as required by the design method used, as approved by
the Engineer.
The asphalt type and thickness above the CSM shall be as required by the pavement design
method and shall also be sufficient to prevent reflective cracking and early life trafficking, to
8.3
MATERIALS
The method statement submitted by Contractor shall contain details of all aggregates to be
used in the CSM.
Aggregates may include:
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Material planed or excavated from a road or other paved area.
(b)
Primary, secondary or recycled aggregate from other sources.
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Mineral filler from primary or secondary sources.
(c)
(a)
The aggregate including added inactive filler shall not contain deleterious material that
adversely affects the performance of the mixture. This includes clay materials, friable
materials, organic and metallic materials, or other extraneous or detrimental material.
The aggregate gradation for CSM shall follow the requirements stated in the mix design
method, as approved by the Engineer, and shall generally follow the recommended
gradations in Table 8.1 Recommended Gradations for Cold Stabilised Materials.
For BSM, material passing the 0.425mm sieve shall have a maximum liquid limit of 25% and
the plasticity index shall not exceed 6.
Bitumen specified for use in BSM shall be 60/70 penetration grade in accordance with ASTM
D946 and shall only be obtained from approved sources. The temperature of the bitumen
prior to foaming shall be greater than 175C but less than 195C. Bitumen shall not contain
any additives which may suppress foaming.
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Table 8.1 Recommended Gradations for Cold Stabilised Materials

Bitumen Stabilised
Job Mix Control
Cement Treat Base (CTB)
Material (BSM)
Sieve Tolerances
100
100
100
100
-2
37.5
85
100
87
100
25
72
100
77
100
19
60
100
67
99
12.5
50
100
67
90
9.5
42
90
48
80
6.3
35
80
40
62
4.75
30
72
35
56
10
2.36
21
56
25
42
1.18
14
44
18
0.6
35
14
0.425
31
12
0.3
27
10
0.15
21
0.075
2.0
18.0
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Sieve Size
(mm)
Page 6
28
26
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17
4.0
10.0
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Cement specified for use in BSM and CTB shall be Portland cement in accordance with
ASTM C150 and shall only be obtained from approved sources. Sulfate resisting cement
shall be used if instructed by the Engineer.
Hydrated lime for use in BSM shall be in accordance with ASTM C1097 and for CTB shall be
in accordance with ASTM C977, and shall only be obtained from approved sources.
Water for use in CSM shall in accordance with Section 5 Part 4.
8.4
CEMENT TREATED BASE (CTB)
8.4.1
Preparation And Mix Design For Cement Treated Base
The Contractor shall produce a detailed existing pavement investigation report and the
proposed stabilised material mix design which shall be submitted for approval by the
Engineer, in liaison with Qatar Quality Standards, at least 30 days prior to the
commencement of the stabilisation works. The pavement investigation report shall consist of
cores and trial pits excavated to the existing subgrade and include tests for, but not limited
to, California Bearing Ratio, Dynamic Cone Penetrometer, gradation, plasticity index and
liquid limit, and other tests required by the selected design method.
All equipment and method statements shall be submitted for approval by the Engineer at
least 30 days prior to commencement of works.
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The mix design method for the CTB mix shall be as approved by the Engineer. Methods may
include that stated in this part, MCHW Specification for Highways Works Series 900: UK, or
other similar and equivalent recognised international design methods for cement or hydraulic
bound materials.
The CTB mix shall have a minimum individual 7 day compressive strength > 2.1 MPa with a
maximum average 7 day compressive strength of 4.2 MPa when tested in accordance with
ASTM D1633.
The mix design shall derive the gradation tolerance parameters of the pulverised material,
moisture content at the point of compaction and target flow rates for the active filler, binder
and added water at the point of mixing, appropriate to the production or stabilisation method
used for the approval of the Engineer.
8.4.2
Site Trials For Cement Treated Base And Bitumen Stabilised Material
The CTB mix design shall be subjected to full preliminary trials and testing at least 10 days
prior to commencement of the full works and shall determine:
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The effectiveness of the production and laying plant for exsitu processes;
(b)
The number of passes of the stabilisation machine necessary to achieve uniform

pulverisation and mixing for insitu processes;
(c)
The field moisture content control required to achieve specified compaction

requirements;
(d)
The compaction routine and rolling patterns necessary to meet the specified
compaction requirements;
(e)
The reference density;
(f)
The effectiveness of the contractors inspection and test plan.
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(a)
The length of the trial section shall be at least 150 metres and the full width of the
carriageway proposed for stabilisation to ensure joints and full width compaction can be
achieved without excessive segregation or other significant defects.
The trial area shall be sprayed with bituminous prime coat at a rate of 0.45 to 0.75 kg/m2
and allowed to cure for a minimum of 24 hours without trafficking unless otherwise
authorised by the Engineer.
Tests from the trial areas shall be submitted to the Engineer for approval at least 3 days prior
to commencement of the works. No works may proceed until all tests and final method
statements have been submitted and approved by the Engineer.
Where materials and processes are demonstrably similar, mix designs and trials tests from
previous projects may be approved at the discretion of the Engineer, in liaison with Qatar
Quality Standards.
8.4.3
Insitu Stabilisation And Compaction Of Cement Treated Base
The insitu CTB stabilisation/recycling shall be produced by specialist equipment specifically

designed for the purpose of insitu recycling processes.
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The material shall be pulverised and stabilised in a single layer if its compacted thickness is
300 mm or less. If the compacted thickness is greater than 300 mm, the material shall be
pulverised and stabilised in the minimum number of layers between100 mm and 300 mm
thick. Where more than one layer is required, the Contractor shall satisfy the Engineer that
the lower layer has achieved adequate stability before proceeding with the overlying layer.
Where required by the Engineer the stability of a layer in any area shall be assessed after a
curing period of at least 24 hours by channelled trafficking using a rigid three-axle tipper
truck loaded to a gross mass of 24 tonnes (assumed equivalent to three standard axles).
The vertical deformation shall be measured in all wheel-tracks at monitoring points on each
of 5 transverse sections set 1 metre apart after 5, 15, 30 and 40 passes of the truck. The
mean vertical deformations at the above trafficking increments shall be plotted against the
respective number of truck passes and the mean vertical deformation corresponding to 100
standard axles shall be interpolated. The layer shall be deemed acceptable if the mean
vertical deformation corresponding to 100 standard axles is less than 10 mm.
The active filler (cement/hydrated lime) shall be supplied to the recycler by a specifically
designed and calibrated mobile slurry mixer to ensure the dustless addition of the
cement/hydraulic binder. The addition shall be continuously monitored with records taken to
confirm the target addition rate, 10%, according to the mix design.
Mixing uniformity shall be continuously inspected visually by the contractor and work shall
stop when the cement or hydrated lime is seen to agglomerate or not fully mix in during the
production process.
Should either the slurry mixer supply to the mixer fail to operate or deliver the correct
proportions to the recycler, all work shall cease until this has been corrected. Prior to
resuming work, the process shall be checked fully by trialling in a short sacrificial trial strip
exceeding 50 metres to ensure the process is fully operational and under control.
The recycler shall proceed in a continuous operation to the full depth of the layer being
recycled as required by the pavement design.
The CTB moisture content prior to compaction shall be within 2 % of the target determined
during the mix design procedure to achieve maximum density.
Initial rolling shall be carried out using a single-drum vibrating roller with a static mass that is
appropriate with the thickness of the layer being compacted. The vibration mode must be set
on high amplitude to achieve maximum penetration of compactive effort.
10
The rolling pattern should first concentrate on the middle section between the rear wheel
paths of the recycler, then across the full cut width to achieve uniform density. The travel
speed of the roller shall not exceed 3 km/h.
11
When initial compaction is complete, the surface shall be struck off to level by a grader and
the surface again checked for level and any defects or damage caused during the operation
which shall be corrected prior to final compaction.
12
Where the recycler has a screed finisher which achieves the required level, initial
compaction shall follow the recommendations of the recycler supplier.
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Where a second adjacent strip is to be laid immediately an additional insitu stabilisation, the
recycler shall overlap the previously stabilised strip by 300mm, ensuring the strip is not
excessively over or under bindered, or watered.
14
Upon completion of compaction the surface shall be sprayed with bituminous prime coat at a
2
rate of 0.45 to 0.75 kg/m and allowed to cure for a minimum of 24 hours without trafficking
unless otherwise authorised by the Engineer. Where the surface is to be opened to traffic
prior to surfacing with asphalt, the prime coat shall be blinded with fine aggregate or sand
2
applied at a rate of 5.5 to 7.0 kg/m .
15
Traffic, including delivery vehicles shall not be permitted on the uncompacted or semicompacted recycled material. The exposed longitudinal joint shall be protected from damage
by construction plant and vehicles.
8.4.4
Exsitu Production Of Cement Treated Base
The exsitu production of CTB shall be produced by specialist recycling and stabilisation
production equipment specifically designed for the purpose of exsitu processes.
The active filler (cement/hydrated lime) shall be supplied to the mixer by specifically
designed and calibrated weighing apparatus to ensure the correct addition of the
cement/hydraulic binder. The addition shall be continuously monitored with records taken to
confirm the target addition rate, 10%, according to the mix design.
stop when the cement or hydrated lime is seen to agglomerate or not fully mix in during the
production process.
CTB shall not segregate significantly during production and all measures shall be taken to
avoid this occurrence.
CTB shall be conveyed from the mixer to its place in the Works as rapidly as possible in
covered vehicles which will prevent segregation or drying out and ensure that the material is
of the required workability and moisture content at the point of delivery to the paving
equipment.
Where CTB is produced on an exsitu production plant, the material shall be laid and fully
compacted within 2 hours of production, ensuring that the moisture content is within the
required limits at the time of laying. CTB that exceeds 2 hours shall be rejected.
8.4.5
Laying And Compaction Of Cement Treated Base
Exsitu produced CTB materials shall be laid with paving machines and compaction plant as
detailed in Section 6 Part 5, but may include additional specialist equipment deemed
appropriate indicated in the detailed method statement.
The CTB moisture content prior to compaction shall be within 2 % of the target determined
Material shall be laid to a thickness that would result in layers not more than 150 mm thick
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Final compaction for CTB shall follow the general requirements Section 6 Part 6 using a
combination of tandem steel wheeled rollers and pneumatic tyred rollers in accordance with
the approved method statement.
Where the surface of the recycled layer has been graded to level, it may be dampened with
a water spray prior to compaction. Care shall be taken not to use excessive watering.
Where a second adjacent strip is to be laid immediately by echelon paving of exsitu material,
the requirements of Section 6 Part 5 shall be followed.
2
2
8.4.6
Joints In Cement Treated Base
Transverse joints shall be made by cutting back at least 2 metres to the position of
conforming level and compaction, and cleaned to remove any loose material. The joint shall
be fully compacted and left level and smooth.
Longitudinal joints shall be formed as follows:
For paver laid materials, fresh joints may be formed by compacting 500mm at the edge of
the initial stabilised strip with a single roller pass and abutting the adjacent new strip prior to
cross compaction. Joints are deemed to be fresh when the pavement materials on both
sides of the joint have been stabilised and are able to be compacted within 1 hour. The
500mm partially compacted strip together with the exposed edge shall be lightly moistened
prior to placement of the second strip.
For paver laid materials and where the stabilised layer has been laid previously or is deemed
unworkable, the existing strip shall be cut back by 150mm to its full depth and cleaned to
remove any loose material prior to paving the new adjacent strip.
Longitudinal construction joints in CTB shall always be formed at the lane line marking
positions where practically possible.
8.4.7
Sampling And Testing - Cement Treated Base
The Contractor shall produce an inspection and test plan for the complete process which
shall include daily production control and the finished stabilised pavement for approval by the
Engineer.
Bulk samples shall be taken from the stabilised material to the full depth of the layer.
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Sample increments will be wrapped tightly in plastic bags to prevent moisture loss and
protected from the heat and sun in an ambient temperature of no greater than 20C.
Samples shall be provided from the laid CTB before compaction, as approved by the
Engineer. One group of five samples shall be provided from five locations equally spaced
along a diagonal that bisects each 800m2 or part thereof laid each day. The number of
groups may be increased if required by the Engineer. Each group shall be combined to
provide samples for reference density, compressive strength and laboratory determined
moisture content.
For each group, 3 specimens for reference density and compressive strength testing shall be
compacted in accordance with AASHTO T180within 2 hours of the addition of the cement
and cured in accordance with ASTM D1632, and tested in accordance with ASTM D1633.
To determine the reference density of test specimens the mould shall be weighed prior to
making the specimen and the mass recorded. Immediately after completion of compaction,
the specimen and mould shall be weighed and the mass recorded. These masses together
with the nominal volume of the mould shall be used to derive the reference density of the
specimen.
The in-situ density of a layer of cement bound material shall be taken as the average of the
densities at five locations equally spaced along a diagonal that bisects each 800 m2 or part
thereof laid each day. The in-situ density at each location shall be the average of two
readings obtained using a nuclear density gauge in compliance with ASTM D6938. Readings
Testing for CTB shall be required as Table 8. 2 Sampling and Testing Requirements for
Cement Treated Base
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TEST
SPECIFICATION
FREQUENCY
ASTM D422
Pre-Stabilised Pulverised
Materials
Design mix gradation
1/1000m
ASTM D4318
Materials
Less than design mix

determination
1/1000m
ASTM D4318
Materials
Less than design mix

determination
1/1000m
ASTM
D1556/D6938
Compacted Stabilised
Material
100% reference density
5/800m
ASTM D4944
Pre-compacted Stabilised
Material
2% OMC
1/800m
ASTM E2583
Material
Report Values
5/800m
Compressive
Strength
ASTM D1633
Material
Individual >2.1 MPa

Average of 3 <4.2 MPa
1/800m
Reference
density
AASHTO T-180
Material
1/800m
Moisture
Content
ASTM D2216
Laid Stabilised Material
2% OMC
1/800m
Sieve
Analysis
Liquid Limit
Plasticity
Index
METHOD
SAMPLE POINT
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Table 8. 2 Sampling and Testing Requirements for Cement Treated Base
Field Density
Field
Moisture
Content
Surface
Modulus
Note 1 The surface modulus determined in accordance with ASTM E2583 shall be reported as
directed by the Engineer for data collection. It shall not form part of the acceptance or rejection
criteria.
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Evenness And Level
The transverse regularity of the surface of the CTB shall be tested by means of a 4 metre
long straight edge. No irregularity in excess of 10 mm shall be permitted.
The longitudinal regularity of the surface of the CTB shall be tested by means of a rolling
straight edge. No irregularity in excess of 10 mm shall be permitted.
reshaping by adding or removing material as necessary, adding water if necessary and
recompacting the layer. The minimum length of rectification shall be 50 metres.
Acceptance of the stabilised pavement is subject to completion of all testing and inspection
requirements to the satisfaction of the Engineer.
8.5
BITUMEN STABILISED MATERIAL (BSM)
8.5.1
Preparation And Mix Design For Bitumen Stabilised Material
The Contractor shall produce a detailed existing pavement investigation report and the
proposed stabilised material mix design which shall be submitted for approval by the
Engineer, in liaison with Qatar Quality Standards, at least 30 days prior to the
commencement of the stabilisation works. The pavement investigation report shall consist of
cores and trial pits excavated to the existing subgrade and include tests for, but not limited
to, California Bearing Ratio, Dynamic Cone Penetrometer, gradation, plasticity index and
liquid limit, and other tests required by the selected design method.
All equipment and method statements shall be submitted for approval by the Engineer at
least 30 days prior to commencement of works.
The mix design method for the BSM mix shall be as approved by the Engineer. Methods
may include that stated in this part, or MCHW Specification for Highways Works Series 900:
(UK), or other similar and equivalent recognised international design methods for Bitumen
Stabilised Material.
The aggregate gradation for BSM shall follow the guideline in Error! Reference source not
ound. unless otherwise stated in the approved alternative design method.
The Design Mixture for BSM shall have minimum bitumen content of 2.5% with an active
filler content no greater than 1%, by mass of total mix.
The Binder Expansion Ratio (ER) shall be greater than 10 times and the Binder Half Life
(T) greater than 12 seconds.
The Indirect Tensile Strength dry (ITSdry - 100mm specimens) shall be greater than 225
kPa and the Indirect Tensile Strength wet (ITSwet - 100mm specimens) shall be greater
than 100 kPa when tested in accordance with ASTM D6931. The Tensile Strength Ratio
(TSR) shall be greater than 80%
The Unconfined Compressive Strength of the mixture shall be between 1200 and 3500 kPa
when tested in accordance with ASTM D1633.
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8.4.8
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8.5.2
Site Trials For Bitumen Stabilised Material
The BSM mix design shall be subjected to full preliminary trials and testing at least 10 days
prior to commencement of the full works and shall determine:
the effectiveness of the production and laying plant for exsitu processes;
(b)
the number of passes of the stabilisation machine necessary to achieve uniform

pulverisation and mixing for insitu processes;
(c)
the field moisture content control required to achieve specified compaction

requirements;
(d)
the compaction routine and rolling patterns necessary to meet the specified
compaction requirements;
(e)
the reference density;
(f)
the effectiveness of the contractors inspection and test plan.
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(a)
The length of the trial section shall be at least 150 metres and the full width of the
carriageway proposed for stabilisation to ensure joints and full width compaction can be
achieved without excessive segregation or other significant defects.
The trial area shall be sprayed with bituminous prime coat at a rate of 0.45 to 0.75 kg/m and
allowed to cure for a minimum of 24 hours without trafficking unless otherwise authorised by
the Engineer.
Tests from the trial areas shall be submitted to the Engineer for approval at least 3 days prior
to commencement of the works. No works may proceed until all tests and final method
statements have been submitted and approved by the Engineer.
Where materials and processes are demonstrably similar, mix designs and trials tests from
previous projects may be approved at the discretion of the Engineer, in liaison with Qatar
Quality Standards.
8.5.3
Insitu Stabilisation And Compaction Of Bitumen Stabilised Material
The insitu BSM stabilisation/recycling shall be produced by specialist equipment specifically

designed for the purpose of insitu recycling processes.
The material shall be pulverised and stabilised in a single layer if its compacted thickness is
300 mm or less. If the compacted thickness is greater than 300 mm, the material shall be
pulverised and stabilised in the minimum number of layers between100 mm and 300 mm
thick. Where more than one layer is required, the Contractor shall satisfy the Engineer that
the lower layer has achieved adequate stability before proceeding with the overlying layer.
Where required by the Engineer the stability of a layer in any area shall be assessed after a
curing period of at least 24 hours by channelled trafficking using a rigid three-axle tipper
truck loaded to a gross mass of 24 tonnes (assumed equivalent to three standard axles).
The vertical deformation shall be measured in all wheel-tracks at monitoring points on each
of 5 transverse sections set 1 metre apart after 5, 15, 30 and 40 passes of the truck. The
mean vertical deformations at the above trafficking increments shall be plotted against the
respective number of truck passes and the mean vertical deformation corresponding to 100
standard axles shall be interpolated. The layer shall be deemed acceptable if the mean
vertical deformation corresponding to 100 standard axles is less than 10 mm.
The bitumen tanker shall a consistent flow of binder to the recycler. The addition shall be
continuously monitored with records taken to confirm the target addition rate, 10%,
according to the mix design.
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The active filler (cement) shall be supplied to the recycler by a specifically designed and
calibrated mobile slurry mixer to ensure the dustless addition of the cement/hydraulic binder.
The addition shall be monitored with records taken to confirm the correct addition rate
according to the mix design.
stop when bitumen streaks or blotches are observed, or where cement is seen to
agglomerate or not fully mix in during the production process.
Should either the slurry mixer or the binder supply to the mixer fail to operate or deliver the
correct proportions to the recycler, all work shall cease until this has been corrected. Prior to
resuming work, the process shall be checked fully by trialling in a short sacrificial trial strip
exceeding 50 metres to ensure the process is fully operational and under control.
The recycler shall proceed in a continuous operation to the full depth of the layer being
recycled as required by the pavement design.
The BSM moisture content prior to compaction shall be within 2 % of the target determined
10
Initial rolling shall be carried out using a single-drum vibrating roller with a static mass that is
appropriate with the thickness of the layer being compacted. The vibration mode must be set
on high amplitude to achieve maximum penetration of compactive effort.
11
The rolling pattern should first concentrate on the middle section between the rear wheel
paths of the recycler, then across the full cut width to achieve uniform density. The travel
speed of the roller shall not exceed 3 km/h.
12
When initial compaction is complete, the surface shall be struck off to level by a grader and
the surface again checked for level and any defects or damage caused during the operation
which shall be corrected prior to final compaction.
13
Where the recycler has a screed finisher which achieves the required level, initial
compaction shall follow the recommendations of the recycler supplier.
14
Where a second adjacent strip is to be laid immediately an additional insitu stabilisation, the
recycler shall overlap the previously stabilised strip by 300mm, ensuring the strip is not
excessively over or under bindered, or watered.
15
rate of 0.45 to 0.75 kg/m2 and allowed to cure for a minimum of 24 hours without trafficking
applied at a rate of 5.5 to 7.0 kg/m2.
16
Traffic, including delivery vehicles shall not be permitted on the uncompacted or semicompacted recycled material. The exposed longitudinal joint shall be protected from damage
by construction plant and vehicles.
8.5.4
Exsitu Production Of Bitumen Stabilised Material
The exsitu production of BSM shall be produced by specialist recycling and stabilisation
production equipment specifically designed for the purpose of exsitu processes.
The bitumen shall be supplied to the mixer by specifically designed and calibrated metering
apparatus to ensure the correct addition of the binder. The addition shall be continuously
monitored with records taken to confirm the target addition rate, 10%, according to the mix
design.
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The active filler (cement) shall be supplied to the mixer by specifically designed and
calibrated weighing apparatus to ensure the correct addition of the cement/hydraulic binder.
The addition shall be continuously monitored with records taken to confirm the target
addition rate, 10%, according to the mix design.
stop when bitumen streaks or blotches are observed or where cement is seen to
agglomerate or not fully mix in during the production process.
BSM shall not segregate significantly during production and all measures shall be taken to
avoid this occurrence.
BSM shall be conveyed from the mixer to its place in the Works as rapidly as possible in
covered vehicles which will prevent segregation or drying out and ensure that the material is
of the required workability and moisture content at the point of delivery to the paving
equipment.
Where BSM is produced on an exsitu production plant, the material shall be laid and fully
compacted within 2 hours of production, ensuring that the moisture content is within the
required limits at the time of laying. BSM that exceeds 2 hours shall be rejected.
8.5.5
Laying And Compaction Of Bitumen Stabilised Material
Exsitu produced BSM materials shall be laid with paving machines and compaction plant as
detailed in Section 6 Part 5, but may include additional specialist equipment deemed
appropriate indicated in the detailed method statement.
The BSM moisture content prior to compaction shall be within 2 % of the target determined
Material shall be laid to a thickness that would result in layers not more than 150 mm thick
Final compaction for BSM shall follow the general requirements Section 6 Part 5 using a
combination of tandem steel wheeled rollers and pneumatic tyred rollers in accordance with
the approved method statement.
Where the surface of the recycled layer has been graded to level, it may be dampened with
a water spray prior to compaction. Care shall be taken not to use excessive watering.
Where a second adjacent strip is to be laid immediately by echelon paving of exsitu material,
the requirements of Section 6 Part 5 shall be followed.
2
2
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8.5.6
Joints In Bitumen Stabilised Material
Transverse joints shall be made by cutting back at least 2 metres to the position of
conforming level and compaction, and cleaned to remove any loose material. The joint shall
be fully compacted and left level and smooth.
Longitudinal joints shall be formed as follows:

For paver laid materials, fresh joints may be formed by compacting 500mm at the
edge of the initial stabilised strip with a single roller pass and abutting the adjacent
new strip prior to cross compaction. Joints are deemed to be fresh when the pavement
materials on both sides of the joint have been stabilised and are able to be compacted
within 1 hour. The 500mm partially compacted strip together with the exposed edge
shall be lightly moistened prior to placement of the second strip.
(b)
For paver laid materials and where the stabilised layer has been laid previously or is
deemed unworkable, the existing strip shall be cut back by 150mm to its full depth and
cleaned to remove any loose material prior to paving the new adjacent strip.
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(a)
Longitudinal construction joints in BSM shall always be formed at the lane line marking
positions where practically possible.
8.5.7
Sampling And Testing - Bitumen Stabilised Material
The Contractor shall produce an inspection and test plan for the complete process which
shall include daily production control and the finished stabilised pavement for approval by the
Engineer.
Bulk samples shall be taken from the stabilised material to the full depth of the layer.
Sample increments will be wrapped tightly in plastic bags to prevent moisture loss and
protected from the heat and sun in an ambient temperature of no greater than 20C.
Samples shall be provided from the laid BSM before compaction, as approved by the
Engineer. One group of five samples shall be provided from five locations equally spaced
2
along a diagonal that bisects each 800m or part thereof laid each day. The number of
groups may be increased if required by the Engineer.
For each group, 3 specimens for strength based testing shall be compacted within 2 hours of
the addition of the bitumen binder. Reference density and UCS shall be compacted and
cured in accordance with AASHTO T-180, and tested in accordance with ASTM D1633. ITS
testing shall be compacted in accordance with ASTM D6926 and tested in accordance with
ASTM D6931.
The foamed bitumen expansion ratio and half life shall be determined at the commencement
of works each day if required by the Engineer.
To determine the reference density of test specimens the mould shall be weighed prior to
making the specimen and the mass recorded. Immediately after completion of compaction,
the specimen and mould shall be weighed and the mass recorded. These masses together
with the nominal volume of the mould shall be used to derive the reference density of the
specimen.
The in-situ density of a layer of cement bound material shall be taken as the average of the
2
densities at five locations equally spaced along a diagonal that bisects each 800 m or part
thereof laid each day. The in-situ density at each location shall be the average of two
readings obtained using a nuclear density gauge in compliance with ASTM D6938. Readings
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Testing for BSM shall be required as Table 8.3 Sampling and Testing Requirements for
BSM.
Table 8.3 Sampling and Testing Requirements for BSM
METHOD
SAMPLE POINT
SPECIFICATION
LIMIT
FREQUENCY
ASTM D422
Pre-Stabilised
Pulverised Materials
Design mix
gradation
1/1000m
Liquid Limit
ASTM D4318
Pre-Stabilised
Maximum 25
1/1000m
Plasticity Index
ASTM D4318
Pre-Stabilised
Maximum 6
1/1000m
Field Density
ASTM
D1556/D6938
Material
100% reference
density
5/800m
Field Moisture
Content
ASTM D4944
Pre-compacted
Stabilised Material
2% OMC
1/800m
Surface
Modulus
ASTM E2583
Material
Report Test
1
Values
5/800m
Binder
Expansion Ratio
This Part:8.6
Pre-mixing/
stabilisation
>10 times
1/first 500
2
m /day
Binder Half Life

()
This Part:8.6
> 12 seconds
1/first 500
2
m /day
Unconfined
Compressive
Strength
ASTM D1633
(150mm)
1200 to 3500 kPa
1/800m
Moisture
Content
ASTM D2216
Laid Stabilised
Material
2% OMC
1/800m
Indirect Tensile
Strength
ASTM D6931
(100mm)
Pre-compacted
Stabilised Material
ITSdry >225 kPa

ITSwet >100 kPa
1/day if
2
>800m
Pre-compacted
Stabilised Material
> 80%
1/day if
2
>800m
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Tensile Strength
Retained (TSR)
ITSwet / ITSdry
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Pre-mixing/
stabilisation
Pre-compacted
Stabilised Material
Sieve Analysis
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TEST
Note 1 The surface modulus determined in accordance with ASTM E2583 shall be reported as
directed by the Engineer for data collection. It shall not form part of the acceptance or rejection
criteria.
8.5.8
Evenness And Level
The transverse regularity of the surface of the BSM shall be tested by means of a 4 metre
long straight edge. No irregularity in excess of 10 mm shall be permitted.
The longitudinal regularity of the surface of the BSM shall be tested by means of a rolling
straight edge. No irregularity in excess of 10 mm shall be permitted.
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reshaping by adding or removing material as necessary, adding water if necessary and
recompacting the layer. The minimum length of rectification shall be 50 metres.
Acceptance of the stabilised pavement is subject to completion of all testing and inspection
requirements to the satisfaction of the Engineer.
8.6
DETERMINATION OF THE FOAMING CHARACTERISTICS OF BITUMEN

(EXPANSION RATIO AND HALF LIFE)
8.6.1
Scope
The foaming characteristics of bitumen are defined by the Expansion Ratio and Half Life of
the bitumen in its expanded state. The expanded state of the bitumen is achieved when a
small percentage of water is introduced into hot bitumen. The objective is to determine the
percentage of water required that will produce the best foam characteristics for a particular
source of bitumen. The aim is to produce foamed bitumen with the largest expansion ratio
with the longest half-life possible.
8.6.2
Definitions
The expansion ratio is a measure of the viscosity of the foam and provides an indication of
how well the binder will disperse in the mix. It is calculated as the ratio of the maximum
volume of foam relative to the original volume of bitumen. The half-life is a measure of the
stability of the foam and provides an indication of the rate of collapse of the foam during
mixing. It is calculated as the time taken in seconds for the foam to collapse to half of its
maximum volume.
8.6.3
Apparatus
The following equipment shall be required:

For mix design only: Foamed Bitumen Laboratory Unit, capable of producing foamed
bitumen at a rate of between 50g and 200g per second. The method of production
shall closely simulate that of full scale production of foamed bitumen on the recycling
machine. The apparatus shall have a thermostatically controlled kettle capable of
holding a mass of 10kg of bitumen at a constant temperature between the range of
160C and 200C, 5C. The unit shall have an expansion chamber similar to that on
the recycling machine in which cold water is injected into hot bitumen. Water injection
shall be variable from 0 to 5% (by mass of the bitumen) with an accuracy of 0.25%.
The plant shall capable of accurately discharging a predetermined mass of foamed
bitumen directly into the mixing bowl of an electrically driven laboratory mixer with a
minimum capacity of 10kg.
(a)
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(b)
Cylindrical metal container, 250mm diameter and at least 20 litre capacity.
(c)
Calibrated Dip Stick, calibrated for the cylindrical metal container with 500g of bitumen
as 1 unit measure. Prongs are attached to the dip stick at every 5 or 6 times the unit
volume.
(d)
A stop-watch with 60 second dial.
(e)
Heat resistant gloves.
(f)
An electronic balance to weigh up to 10kg, accurate to 1g.
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8.6.4
Method
Preparation
(a)
The foamed bitumen laboratory unit discharge rates are checked in accordance with
the manufactures specifications. If the unit is being used for the first time then the
pump rate and water flow rates need to be calibrated as per the manufactures
specifications. Check that 500g of bitumen is being discharged at the predetermined
settings.
(b)
Ensure that the cylindrical metal container and dip stick are reasonably clean.
Discharge foamed bitumen, at least twice, into cylindrical metal container prior to
testing in order to pre-heat the container. Decant excess bitumen from the container
into a suitable waste receptacle.
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Testing
Heat the bitumen in the kettle of the foamed bitumen laboratory unit with the pump
circulating the bitumen through the system until the required temperature is achieved
(normally starting with 160 C). Maintain the required temperature for at least 5
minutes prior to commencing with testing.
(b)
Set the water flow-meter to achieve the required water injection rate (normally starting
with 2 % by mass of the bitumen).
(c)
Discharge foamed bitumen into the preheated steel drum for the calculated spray time
for 500 g of bitumen. Immediately after the foamed bitumen discharge stops, start a
stopwatch.
(d)
Using the calibrated dipstick measure the maximum height the foamed bitumen
achieves in the drum. This maximum volume is recorded as the expansion. Continue
to measure the time in seconds that the foam takes to dissipate to half of its maximum
volume. This is recorded as the foamed bitumens half-life.
(e)
Repeat the above procedures three times or until similar readings are achieved.
(f)
The expansion and half-life are determined at different percentages of water.

Typically, values of 2 %, 3 % and 4 % by mass of bitumen are used.
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(a)
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Plot a graph of the expansion ratio versus half-life at the different water injection rates
on the same set of axes. The optimum water addition is chosen as an average of the
two water contents required to meet the minimum criteria. (Figure 7.1 Determination of
Optimum Foaming Water)
(g)
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(h)
If the required properties are not met at 160C, further testing should be carried out
with the bitumen at higher temperatures (typically 170C and 180C).
8.6.5
Reporting
The foamed bitumen characteristics and optimum water content are reported as;
Optimum water content (%):
Expansion (times):
Half-life (sec):
Percentage by mass of bitumen;

Ratio of maximum expansion to original volume of bitumen;
Time taken from maximum expansion to half this volume.
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Site Quality Control
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The above method may be used to determine the expansion ratio and half-life of foamed
bitumen dispensed by the production plant or recycler.
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Figure 7.1 Determination of Optimum Foaming Water
8.6.6

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Part
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APPENDIX
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QCS 2014
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GUIDANCE FOR THE DESIGN OF RECYCLED AND STABILISED

MATERIALS (MIX DESIGNS)
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GENERAL
PREPARATION OF SAMPLES FOR MIX DESIGN PROCEDURES
MIX DESIGN PROCEDURE FOR CEMENT STABILISED MATERIALS
MIX DESIGN PROCEDURE FOR BITUMEN STABILISED MATERIALS (BSMS)
DETERMINATION OF THE FLUID / DENSITY RELATIONSHIP
PREPARATION FOR STABILISING W ITH BITUMEN EMULSION (BSM-EMULSION)
PREPARATION FOR STABILISING W ITH FOAMED BITUMEN (BSM-FOAM)
MANUFACTURE OF 100MM DIAMETER SPECIMENS
DETERMINATION OF THE STRENGTH OF 100MM DIAMETER SPECIMENS
MANUFACTURE OF 150MM DIAMETER SPECIMENS
DETERMINATION OF THE STRENGTH OF 150MM DIAMETER SPECIMENS
STRENGTH TEST PROCEDURES
SELECTION OF THE AMOUNT OF BITUMEN TO BE ADDED FOR BSM
DETERMINATION OF THE SHEAR PROPERTIES OF BSM
DETERMINATION OF TRIAXIAL SHEAR PARAMETERS USING SIMPLE TRIAXIAL TEST
USING LABORATORY TEST RESULTS FOR ESTIMATING STRUCTURAL LAYER COEFFICIENTS
PROFORMA REPORT SHEET FOR ITS TESTING
LABORATORY EQUIPMENT REQUIREMENTS
8.7
8.7.1
8.7.2
8.7.3
8.7.4
8.7.5
8.7.6
8.7.7
8.7.8
8.7.9
8.7.10
8.7.11
8.7.12
8.7.13
8.7.14
8.7.15
8.7.16
8.7.17

Part
23
23
25
27
28
29
29
32
34
34
36
37
38
40
40
45
46
47
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8.7

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GENERAL
The detailed procedures for carrying out stabilisation mix designs in a laboratory are
described below. Procedures for both cement (or lime) and bitumen stabilisation are
included as well as guidelines for interpreting the test results for bitumen stabilised materials
(BSMs). Comprehensive lists of laboratory equipment are provided. In addition, a chart has
been included showing how laboratory test results can be utilised to indicate the relevant
structural coefficient for a BSM (for use in the AASHTO 1993 pavement design method).
Preparation Of Samples For Mix Design Procedures
Field Sampling: Bulk samples are obtained from test pits excavated as part of the field
investigations. Each layer in the upper pavement ( 300mm) must be sampled separately
and at least 150kg of material recovered from each layer that is likely to be included in any
mix design procedure. Representative samples shall be obtained and prepared either from
the excavation process at source or by laboratory crushing and screening.
Standard soil tests: Carry out the following standard tests on the material sampled from each
individual layer:
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8.7.1
Sieve analysis to determine the grading (ASTM D 422);
(b)
Atterberg limits to determine the liquid limit and plasticity index (ASTM D 4318); and
(c)
Moisture / density relationship (AASHTO T-180).
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(a)
Sample blending: Where necessary, blend the materials sampled from the different layers to
obtain a combined sample representing the material from the full recycling depth. The in-situ
density of the various components must be considered when blending materials, as
illustrated in
Figure 7.1 Determination of Optimum Foaming Water Repeat the standard soil tests
described above to determine the grading and plasticity index of the blended sample.
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Existing upper
pavement structure
60mm Asphalt
3
(in situ density 2300 kg/m )
200mm Subbase
3
(in situ density 2000 kg/m )
Recycling depth 200mm

=
60mm Asphalt
+
140mm Gravel
The materials are blended in proportion to layer thickness and insitu density as follows:
Per square metre
Proportion by mass
Per 10kg sample
Material
(kg)
(%)
(g)
0.06 x 2300 =
Asphalt (60mm at 2300 kg/m3)
138/418 = 0.33
0.33 x 10000 = 3300
138
0.14 x 2000 =
Gravel (140mm at 2000 kg/m3)
280/418 = 0.67
0.67 x 10000 = 6700
280
Total
418
1.00
Figure 7.2 Example of Density Proportioning
10000
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Representative proportioning: Separate the material in the representative sample into the
following four fractions:
Retained on the 19.0mm sieve;
Passing the 19.0mm sieve, but retained the 12.5 mm sieve;
Passing the 12.5 mm sieve, but retained on the 4.75mm sieve; and
Passing the 4.75mm sieve.
Reconstitute representative samples in accordance with the grading up to the portion

passing the 19.0mm sieve. Substitute the portion retained on 19.0mm sieve with material
that passes the 19.0mm sieve, but is retained on the 12.5 mm sieve. The example in Table
8.4 Material Combination explains this procedure:
Sieve analysis
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Table 8.4 Material Combination
Quantity of material to be included in a 10kg sample
Percentage passing
(from sieve analysis)
19
90.5
12.5
72.3
4.75
53.6
Passing 4.75mm
Passing 12.5mm
Retained 4.75mm
(53.6/100 x 10000)
= 5360g
((72.3-53.6)/100 x
10000)
= 1870g
Passing 19mm
Retained 12.5mm
((100-72.3)/100 x 10000)
= 2770g
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Sieve
size
(mm)
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Sample quantities: The guidelines shown Table 8.5 Test Quantities should be used for the
quantity of material required for the respective tests:
Table 8.5 Test Quantities

Test
Sample quantity required
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If there is insufficient material (i.e. passing the 19mm sieve but retained on the 12.5mm
sieve) for substituting that retained on the 19mm sieve, then lightly crush the material
retained on the 19.0mm sieve to provide more of this fraction.
Moisture / density relationship (AASHTO T180)
5 x 7kg
Unconfined Compressive Strength (150mm specimens)
20kg per stabiliser content
Bitumen stabilisation mix design (100mm specimens)
Minimum 10kg per stabiliser content
Bitumen stabilisation mix design (150mm specimens )
Minimum 20kg per stabiliser content
Determination of moisture content
Approximately 1kg
Hygroscopic moisture content: Two representative air-dried samples, each approximately

1kg, are used to determine the hygroscopic (air dried) moisture content of the material.
(Note: Larger sample size should be used for more coarsely-graded materials.) Weigh the
air-dried samples, accurate to the nearest 0.1g, and then place them in an oven at a
temperature of between 105C and 110C until they achieve constant mass. The
hygroscopic moisture content (W air-dry) is the loss of mass expressed as a percentage of the
dry mass of the sample. Determine the hygroscopic moisture using equation 1:
QCS 2014

Part
where:
W air-dry
= (Mmoist Mdry) / Mdry x 100
[Equation 1]
W air-dry
= hygroscopic moisture content
[% by mass]
Mmoist
= mass of moist material
[g]
Mdry
= mass of dry material
[g]
Page 25
8.7.2
Mix Design Procedure For Cement Stabilised Materials
Determination of the Moisture / Density Relationship: This test is carried out using standard
compaction effort to determine the Optimum Moisture Content (OMC) and Maximum Dry
Density (MDD) of the cement stabilised material.
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Step 1: Weigh out the required mass of stabilising agent for each of five 7kg samples
prepared as described in 8.7.1. The amount of stabilising agent required (expressed as a
percentage by mass of the dry sample) should be close to the anticipated optimum for the
material being treated. In the absence of previous tests, the following can be used as a
guideline:
Subbase layers:
2% for coarse material (> 50% retained on 4.75mm sieve)
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3% for fine material (< 50% retained on 4.75mm sieve)

4% for coarse material (> 50% retained on 4.75mm sieve)
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Base layers:
6% for fine material (< 50% retained on 4.75mm sieve)
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Step 2: Add the stabilising agent to the raw material and mix immediately prior to the
addition of water. In order to simulate conditions on the road, compaction of the stabilised
material is delayed for one hour after mixing the untreated material with stabilising agent and
water. The mixed material is placed in an air-tight container to prevent loss of moisture and
is thoroughly mixed every fifteen minutes.
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Manufacture of Specimens for Strength Testing: The procedure described below is for the
manufacture specimens that are of 150mm in diameter and 127mm in height. These
specimens will be used to determine the Unconfined Compressive Strength (UCS) and
Indirect Tensile Strength (ITS) of the material.
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Step 3: Determine the OMC and MDD for the stabilised material in accordance with the
modified moisture-density relationship test procedure (AASHTO T-180).
Step 1: Place the 20kg sample, prepared as described in 8.7.1, into a suitable mixing
container.
Step 2: Determine the dry mass of the sample using equation 2:
where:
Msample
= (Mair-dry/ (1 + (W air-dry x 100))
[Equation 2]
Msample
= dry mass of sample
[g]
Mair-dry
= air-dried mass of the sample
[g]
W air-dry = moisture content of air-dried sample

[% by mass]
Step 3: Determine the required amount of stabilising agent using equation 3:
where:
Mcement
= (Cadd / 100) x Msample
[Equation 3]
Mcement
= mass of lime or cement to be added
[g]
Cadd
= percentage of lime or cement required
[% by mass]
Msample
= dry mass of the sample
[g]
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Step 4: Determine the percentage water to be added for optimum mixing purposes using
equation 4 and then the mass of water to be added to the sample using equation 5:
where:
W add
= W OMC - W air-dry
[Equation 4]
Mwater
= (W add / 100) x (Msample + Mcement)
[Equation 5]
W add
= water to be added to sample
[% by mass]
W OMC
= optimum moisture content
[% by mass]
W air-dry
= moisture content of air-dried sample
[% by mass]
Mwater
= mass of water to be added
[g]
Msample
[g]
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Mcement = mass of lime or cement to be added

[g]
Step 5: Mix the material, cement and water until uniform. Allow the mixed material to stand
for one hour with occasional mixing, as described above, before compacting three 150mm
diameter specimens using modified AASHTO (T-180) compaction effort. (Note: Two 150mm
diameter specimens are normally manufactured for each test.)
= (Mmoist - Mdry) / Mdry x 100))
W mould
= moulding moisture content
[% by mass]
Mmoist
[g]
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W mould
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where:
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Step 6: Samples are taken during the compaction process and dried to a constant mass (at
105 to 110C) to determine the moulding moisture content (W mould). Determine the moulding
moisture using equation 6:
[Equation 6]
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Mdry
[g]
Steps 7 to 9: Repeat the above steps for at least three different stabiliser contents.
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Step 10: Remove the specimens from the moulds either by dismantling the split moulds or, if
ordinary moulds are used, extruding the specimens carefully with an extrusion jack, avoiding
distortion to the compacted specimens.
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Step 11: Record the mass and volume of each specimen and determine the dry density
using equation 7:
where:
DD
= (Mbriq / Vol) x (100 / W mould +100) x 1000
[Equation 7]
DD
= dry density
[kg/m]
Mbriq
= mass of specimen
[g]
Vol
= volume of specimen
[cm ]
W mould
[%]
Note: With certain materials lacking cohesion, it may be necessary to leave the specimens in the
moulds for 24 hours to develop strength before extracting. When this is necessary, the
specimens in the moulds should be kept in a curing room or covered with damp cloth (hessian).
Curing the Specimens: Cure the specimens for seven days at 95% to 100% relative humidity
and at a temperature of 20C to 25C in a suitable curing room.
An alternative curing method is to place the specimen in sealed plastic bags and cure in an
oven at:
70C to 75C for 24 hours for cement; or
QCS 2014

Part
Page 27
60C to 62 C for 45 hours for lime.

After the curing period, remove the specimens from the curing room (or plastic bags) and
allow to cool to ambient temperature, if necessary. Specimens for unconfined compressive
strength (UCS) tests should be submerged in water at 22C to 25C for four hours prior to
testing.
Strength Tests: The Unconfined Compressive Strength (UCS) test and the Indirect Tensile
Strength (ITS) test procedures are described under 8.7.11.
Determination of the Optimum Stabiliser Content: The ITS and UCS strengths achieved are
plotted against the percentage stabilising agent added using the average UCS or ITS of the
three specimens for each stabiliser content, ignoring any obvious incorrect result that may
have been caused by damage to the specimen before testing. The required application rate
of stabilising agent is that percentage at which the minimum required criteria are met.
8.7.3
Mix Design Procedure For Bitumen Stabilised Materials (Bsms)
Active Filler Requirements: Bitumen stabilisation is normally carried out in combination with a
small amount (1% by mass) of active filler (cement or hydrated lime) to enhance the
dispersion of the bitumen and/or the breaking time (where bitumen emulsion is used as the
stabilisation agent). The PI of the material is used as an initial guideline for the use of
hydrated lime or cement in the mix:
as
qa
ta
rw
.l.
l
Table 8.6 Guide to Addition of Active Filler
se
Plasticity Index: < 10
ov
er
Carry out Preliminary Level 1 tests

(explained below) to determine the need to
add cement or hydrated lime.
Plasticity Index: > 10

Pre-treat with hydrated lime (ICL value)
(The initial consumption of lime (ICL value)
must first be determined using the
appropriate pH test.)
et
it
Pre-treatment of material with a PI > 10 requires that the lime and water be added at least 2
hours prior to the addition of the bitumen emulsion or foamed bitumen. (The treated material
must be placed in an air-tight container to retain moisture and the moisture content checked
and, if necessary, adjusted prior to adding the bitumen stabilising agent.) Such materials are
not subjected to Preliminary Level 1 tests.
Preliminary Level 1 Tests: Where the PI < 10, the need for an active filler and the type of
active filler (cement or hydrated lime) that is appropriate for the material must first be
determined by carrying out Level 1 tests on three different mixes. The same amount of
bitumen (residual bitumen for bitumen emulsion treatment) is added to all three mixes,
determined from the fractions passing the 4.75mm and 0.075mm sieves, as shown in Table
8.7 Suggested bitumen addition relative to key aggregate fractions.
QCS 2014

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Table 8.7 Suggested bitumen addition relative to key aggregate fractions

Percentage passing sieve size (%)
0.075mm
> 50
2.0
5.0 7.5
2.25
7.5 10.0
2.5
> 10.0
2.75
< 5.0
2.25
5.0 7.5
2.5
7.5 10.0
3.0
< 50
< 5.0
rw
.l.
l
4.75mm
Bitumen addition
(% of dry aggregate)
> 10.0
3.5
ta
The first mix contains no active filler, 1% cement is added to the second mix and 1%
hydrated lime is added to the third mix. 100mm diameter specimens are manufactured,
cured and tested to determine the relevant ITSDRY, ITSWET and TSR values as described
in 8.7.12.
as
qa
Where the TSR value for the mix with no active filler added is in excess of 60%, the mix
design should be undertaken with no active filler. (This situation is usually confined to
materials consisting of good quality crushed stone, often including a high proportion of
reclaimed asphalt pavement (RAP) material.)
er
se
Where the TSR value of the mix with no active filler added is less than 60%, the mix with the
type of active filler that produces a significantly higher TSR value (> 5%) indicates whether
cement or hydrated lime should be used. If the TSR values for both active fillers are of the
same order (difference < 5%) then either type of active filler is suitable.
Determination Of The Fluid / Density Relationship

The Optimum Fluid Content (OFC) and the Maximum Dry Density (MDD) of the stabilised
material is determined using standard compaction effort.
8.7.4
et
it
ov
Note. Should cement and/or hydrated lime be not readily available and tests indicate the
need for an active, the use of 15% (by volume) quarry fine aggregate (5mm to 0mm) or
similar material with > 10% passing the 0.075mm sieve may be used as a substitute in the
mix designs.
Note: For foamed bitumen stabilisation, the OFC and MDD can be assumed to be the same
as the OMC and MDD, as determined for representative samples of the untreated material.
The OFC for bitumen emulsion treated material is the percentage by mass of bitumen
emulsion plus additional moisture required to achieve the maximum dry density in the treated
material. As described below, the OFC is determined by adding a constant percentage of
bitumen emulsion whilst varying the amount of water added.
Step 1: Measure out the bitumen emulsion as a percentage by mass of the air-dried material
for each of five prepared samples following the procedure described in 8.7.1. The
percentage of bitumen emulsion added is normally between 2 and 3% residual bitumen (e.g.
for 3% residual bitumen, add 5% of a 60% bitumen emulsion).
Step 2: The bitumen emulsion and water is added to the material and mixed until uniform
immediately prior to compaction.
Step 3: Determine the OFC and MDD for the stabilised material in accordance with the
modified moisture-density relationship test procedure (AASHTO T-180).
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8.7.5

Part
Page 29
Preparation For Stabilising With Bitumen Emulsion (Bsm-Emulsion)

Step 1: Place the required quantity of sample into a suitable mixing container (10kg for the
manufacture of 100mm diameter specimens, or 20kg for the manufacture of 150mm
diameter specimens).
Step 2: Determine the dry mass of the sample using equation 1.
Step 3: Determine the required percentage of active filler (lime or cement) using equation 3.
Step 4: Determine the required percentage (by mass) of bitumen emulsion using equation 8:
= (RBreqd / PBE) x Msample
[Equation 8]
Memu
= mass of bitumen emulsion to be added
[g]
RBreqd
= percentage of residual bitumen required
[% by mass]
PBE
= percentage of bitumen in emulsion
[% by mass]
where:
Memul
Mwater
= {((W OFC W air-dry) / 100) x Msample} Memul
Mwater
[g]
W OFC
= optimum fluid content
[% by mass]
W air-dry
[% by mass]
Memul
= mass of bitumen emulsion to be added
[g]
qa
ta
[Equation 9]
as
where:
rw
.l.
l
Msample = dry mass of the sample

[g]
Step 5: Determine the amount of water to be added for optimum compaction purposes using
equation 9:
er
se
Msample = dry mass of the sample

[g]
Step 6: Mix the material, active filler, bitumen emulsion and water together until uniform.
Immediately manufacture specimens following the relevant procedure for either 100mm or
150mm diameter specimens, as described in 8.7.7 and 8.7.9 respectively.
ov
Repeat above steps for at least four mixes with different bitumen emulsion contents.
et
it
Recommended bitumen addition interval for different specimen sizes

Difference in amount of bitumen added (%) to
Specimen diameter (mm)
each mix
100 (Level 1)
0.25
0.1
150 (Level 2)
For 100mm diameter specimens, use Error! Reference source not found. as a guideline
or the amount of bitumen addition that the material will require for effective stabilisation.
For 150mm diameter specimens, use the results of Level 1 tests from 8.7.8 as the maximum
addition of bitumen (i.e. the three other mixes will be in intervals of 0.1% less than this
value).
8.7.6
Preparation For Stabilising With Foamed Bitumen (Bsm-Foam)
Determination of the foaming properties of the bitumen: The foaming properties of each
bitumen type is characterised by:
Expansion Ratio. A measure of the viscosity of the foamed bitumen, calculated as the ratio
of the maximum volume of the foam relative to the original volume of bitumen; and
Half Life. A measure of the stability of the foamed bitumen, calculated as the time taken in
seconds for the foam to collapse to half of its maximum volume.
QCS 2014

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The objective is to determine the temperature and percentage of water addition that is
required to produce the best foam properties (maximum expansion ratio and half-life) for a
particular source of bitumen. This is achieved at three different bitumen temperatures (not
exceeding 195C) with the following procedure:
Step 1: Heat the bitumen in the kettle of the Wirtgen WLB10 S laboratory unit with the pump
circulating the bitumen through the system until the required temperature is achieved
(normally starting with160C). Maintain the required temperature for at least 5 minutes prior
to commencing with testing.
Step 2: Calibrate the discharge rate of the bitumen and set the timer on the Wirtgen WLB10
S to discharge 500g of bitumen (Qbitumen).
Step 3: Set the water flow-meter to achieve the required water injection rate (normally
starting with 2% by mass of the bitumen).
rw
.l.
l
Step 4: Discharge foamed bitumen into a preheated ( 75C) steel drum for a calculated
spray time for 500g of bitumen. Immediately after the foam discharge stops, start a
stopwatch.
ta
Step 5: Using the dipstick supplied with the Wirtgen WLB10 S (which is calibrated for a steel
drum of 275mm in diameter and 500g of bitumen) measure the maximum height the foamed
bitumen achieves in the drum. This is recorded as the maximum volume.
qa
Step 6: Use the stopwatch to measure the time in seconds that the foam takes to dissipate
to half of its maximum volume. This is recorded as the foamed bitumens half-life.
Step 7: Repeat the above procedure three times or until similar readings are achieved.
as
Step 8: Repeat steps 3 to 7 for a range of at least three water injection rates. Typically,
values of 2%, 3% and 4% by mass of bitumen are used.
ov
er
se
Step 9: Plot a graph of the expansion ratio versus half-life at the different water injection
rates on the same set of axes (see the example in graph below). The optimum water
addition is chosen as an average of the two water contents required to meet these minimum
criteria.
Repeat Step 1 to 9 for two other bitumen temperatures (normally 170C and 180C).
et
it
The temperature and optimum water addition that produces the best foam is then used in the
mix design procedure described below.
Note: The absolute minimum foaming properties that are acceptable for effective
stabilisation (material temperature of 25C) are:
Expansion ratio:
10 times
Half-life:
12 seconds
If the minimum requirements cannot be met, the bitumen should be rejected as unsuitable
for use.
QCS 2014
Page 31
Prepare the material for foamed bitumen treatment as follows:

Step 1: Place 20 to 25kg of sample prepared as described in 8.7.1 into the Wirtgen WLM30
pugmill mixer.
Step 2: Determine the dry mass of the sample using equation 2.
Step 3: Determine the required percentage of active filler (lime or cement) using equation 3.
Step 4: Determine the percentage water to be added for optimum mixing moisture content
as calculated using equation 10. The amount of water to be added to the sample is
determined using equation 11.
[Equation 10]
Mwater
= (W add / 100) x (Msample + Mcement)
[Equation 11]
W add
= water to be added to sample
[% by mass]
W OMC
W air-dry
[% by mass]
Mwater
[g]
Msample
rw
.l.
l
= 0.75W OMC - W air-dry
ta
where:
W add
[% by mass]
[g]
qa

[g]
Step 5: Mix the material, active filler and water in the mixer until uniform.
er
se
as
Note: Inspect the sample after mixing to ensure that the mixed material is not packed
against the sides of the mixer. If this situation occurs, mix a new sample at a lower moisture
content. Check to see that the material mixes easily and remains in a fluffed state. If any
dust is observed at the end of the mixing process, add small amounts of water and remix
until a "fluffed" state is achieved with no dust.
= (Badd /100) x (Msample + Mcement)
[Equation 12]
Mbitumen
= mass of foamed bitumen to be added
[g]
Badd
= foamed bitumen content
[% by mass]
Msample
[g]
Mbitumen
et
it
where:
ov
Step 6: Determine the amount of foamed bitumen to be added using equation 12:

[g]
Step 7: Determine the timer setting on the Wirtgen WLB10 S using equation 13:

Part
where:
= Mbitumen / Qbitumen
[Equation 13]
= time to be set on WLB10 S timer
[s]
Mbitumen
= mass of foamed bitumen to be added
[g]
Qbitumen = bitumen flow rate for the WLB10 S

[g/s]
Step 8: Position the mixer adjacent to the foaming unit so that the foamed bitumen can be
discharged directly into the mixing chamber.
Step 9: Start the mixer and allow it to mix for at least 10 seconds before discharging the
required mass of foamed bitumen into the mixing chamber. After the foamed bitumen has
discharged into the mixer, continue mixing for a further 30 seconds or until uniformly mixed.
Step 10: Determine the amount of water required to bring the sample to the OMC using
equation 14.
QCS 2014

Part
where:
Page 32
Mplus
= (W OMC W sample) / 100 x (Msample +

Mcement)
[Equation 14]
Mplus
[g]
W OMC
[% by mass]
W sample
= moisture content of prepared sample
[% by mass]
Msample
[g]
Mcement = mass of lime or cement added

[g]
Note: This moisture adjustment is to be carried out when 150mm diameter specimens are
to be manufactured. Where 100mm diameter specimens are to be manufactured, the
moisture content of the material is to be adjusted to 90% of OMC.
Step 11: Add the additional water and mix until uniform.
rw
.l.
l
Step 12: Transfer the foamed bitumen treated material into a container and immediately
seal the container to retain moisture. To minimise moisture loss from the prepared sample,
manufacture the specimens as soon as possible following the relevant procedure for either
100mm or 150mm diameter specimens, as described in 8.7.7 and 8.7.9 respectively.
ta
Repeat the above steps for at least four mixes with different foamed bitumen contents.
100 (Level 1)
se
150 (Level 2)
Difference in amount of bitumen added (%)

to each mix
as
Specimen diameter (mm)
qa
Recommended bitumen addition interval for different specimen sizes
0.25
0.1
er
For 100mm diameter specimens, use Error! Reference source not found. as a guideline
or the amount of bitumen addition that the material will require for effective stabilisation.
et
it
ov
For 150mm diameter specimens, use the results of Level 1 tests in 8.7.8 as the maximum
addition of bitumen (i.e. the three other mixes will be in intervals of 0.1% less than this
value).
Manufacture Of 100mm Diameter Specimens
For Level 1 mix designs ITS tests are carried out on 100mm diameter specimens. Six
specimens are manufactured for each sample at the different bitumen contents. The two
primary objectives of undertaking the Level 1 mix design are to determine:
8.7.7
the optimum bitumen content for the BSM, and
the need for an active filler.
Specimens may be made using either Marshall or vibratory compaction methods.
Marshall Compaction shall be carried out as follows:

Step 1: Prepare the Marshall mould and hammer by cleaning the mould, collar, base-plate
and face of the compaction hammer.
Note: the compaction equipment must not be heated but kept at ambient temperature.
Step 2: Weigh sufficient material to achieve a compacted height of 63.5mm 1.5mm
(usually 1150g is adequate). Spade the mixture with a spatula 15 times around the perimeter
and 10 times on the surface, leaving the surface slightly rounded.
QCS 2014

Part
Page 33
Step 3: Compact the mixture by applying 75 blows with the compaction hammer. Care must
be taken to ensure the continuous free fall of the hammer. Remove the mould and collar
from the pedestal, invert the specimen (turn over). Replace it and press down firmly to
ensure that it is secure on the base plate. Compact the other face of the specimen with a
further 75 blows.
Step 4: Take approximately 1kg representative samples after compaction of the second and
fifth specimen and dry a constant mass (at 105 to 110C). Determine the moulding moisture
using equation 15:
where:
W mould
= (Mmoist Mdry) / Mdry x 100
[Equation 15]
W mould
[% by mass]
Mmoist
[g]
rw
.l.
l
Mdry
[g]
Step 5: After compaction, remove the mould from the base-plate and extrude the specimen
by means of an extrusion jack. Measure the height of the specimen and adjust the amount
material if the height is not within the required limits.
qa
Vibratory Compaction shall be carried out as follows:
se
as
Step 1: Fix the mounting head and appropriate tamping foot to the vibratory hammer and fit
hammer onto guide rods. Place 5kg surcharge weight onto mounting head (total mass of
assembly [Hammer + foot + surcharge] = 25kg) and fasten tightly. Using the pulley system
raise the vibratory hammer to an adequate height that will allow operator to work safely
beneath the vibratory hammer and lock in position.
ov
er
Step 2: Clean the mould, collar and base plate. Fix the mould to the base of the compaction
frame.
Note: the compaction equipment must not be heated but kept at ambient temperature.
et
it
Step 3: Weigh sufficient material to achieve a compacted height of 63.5mm 1.5mm

(usually 1150g is adequate). Spade the mixture with a spatula 15 times around the perimeter
and 10 times on the surface, leaving the surface slightly rounded.
Step 4: Lower the vibratory hammer into the mould, checking that the vibratory hammer is
perpendicular to the base of the mould. Apply 15 seconds of vibratory compaction to the
sample in the mould.
ta
Note: With certain materials lacking cohesion, it may be necessary to leave the specimen in
the mould for 24 hours, allowing sufficient strength to develop before extracting.
Step 5: Raise hammer to the safe position, remove mould, invert mould and secure to base.
Step 6: Lower vibratory hammer to surface of material in mould and ensure vibratory
hammer rests freely on sample and is perpendicular to the base of the mould. Apply further
15 seconds of vibratory compaction to sample in the mould.
Step 7: Take approximately1kg representative samples after compaction of the second and
fifth specimen and dry to constant mass (at 105 to 110 oC). Determine the moulding
moisture using equation 15.
Step 8: After compaction, remove the mould from the base-plate and extrude the specimen
carefully by means of an extrusion jack.
QCS 2014

Part
Page 34
Curing procedure: Compacted specimens shall be cured by placing the specimens on a steel
mesh and curing in a forced-draft oven until a constant mass is obtained (normally 72 hours
at 40C). Remove from oven after curing and allow to cool to ambient temperature.
When specimens have cooled to ambient temperature determine the bulk density for each
specimen:
Step 1. Determine the mass (Mbriq).
Step 2. Measure the height at four evenly-spaced places around the circumference and
calculate the average height (h).
Step 3. Measure the diameter (d).
Step 4. Calculate the bulk density using equation 16:
x h) x 1000
BD
Mbriq
= mass of specimen
= average height of specimen
[Equation 16]
= (4 x Mbriq
[kg/m]
rw
.l.
l
where:
BD
[g]
[cm]
qa
ta
d
= diameter of specimen
[cm]
Note: Exclude from further testing any specimen whose bulk density differs from the mean
bulk density of the batch by more than 50 kg/m.
The bulk density may alternatively be determined by using the weigh-in air / weigh-in water
method for those specimens designated for soaked testing.
8.7.8
Determination Of The Strength Of 100mm Diameter Specimens
The 100mm diameter specimens are tested for indirect tensile strength under dry and
soaked conditions to determine the ITSDRY and the ITSWET values. To prevent moisture loss,
specimens should be tested as soon as they are prepared. The results are used to indicate
the optimum bitumen content and the need for active filler. In addition, these test results are
used as a guide for the classification of the BSM.
8.7.9
Manufacture Of 150mm Diameter Specimens
Level 2 mix designs ITS tests are carried out on specimens that are 150mm diameter and
95mm in height. These specimens are cured to simulate the equilibrium moisture content
achieved in the field. This method of curing provides more realistic values for classification of
the bitumen stabilised materials.
The procedures described allow for the manufacture of four 150mm diameter specimens to a
compacted height of 95mm. If additional specimens are required, the sample quantity shall
be increased.
Specimens may be made using either Modified AASHTO (T-180) or vibratory compaction
methods.
MODIFIED AASHTO (T-180) compaction shall be carried out as follows:
et
it
ov
er
se
as
Step 1: Prepare and treat at least 24kg of sample for each selected bitumen content.
Step 2: Where required, add sufficient moisture to bring sample to optimum compaction
moisture content and mix until uniform. Immediately after mixing, place material in an airtight container.
QCS 2014

Part
Page 35
Step 3: Take approximately 1kg representative samples after compaction of the first and
third specimen and dry to a constant mass (at 105 to 110C). Determine the moulding
moisture using equation 15.
Step 4: Compact at least 4 specimens using a 150mm diameter split-mould, applying
modified AASHTO (T-180) compaction effort (4 layers approximately 25mm thick, 56 blows
per layer using a 4.536kg hammer with a 457mm drop).
Step 5: Carefully trim excess material from specimens, as specified in the AASHTO T180
test method.
Step 6: Carefully remove the specimen from the spilt-mould and place on a steel mesh.
Vibratory compaction shall be carried out as follows:
ta
rw
.l.
l
Step 1: Fix the mounting head and appropriate tamping foot (150mm diameter) to the
vibratory hammer and fit hammer onto guide rods. Place 10kg surcharge weight onto
mounting head (total mass of assembly [hammer + foot + surcharge] = 30kg) and fasten
tightly. Using the pulley system raise the vibratory to an adequate height that will allow
operator to work safely beneath the vibratory hammer and lock in position.
qa
Step 2: Clean the 150mm diameter spilt mould, collar and base plate. Fix the mould to the
base of the compaction frame.
= ( x d x h / 4) x (MDD) /1000
Mmix
= Mass of mixed material
[Equation 17]
[g]
[cm]
= required height of layer (4.75cm for ITS)
[cm]
er
Mmix
ov
where:
se
as
Step 3: Weigh sufficient material to achieve a compacted height of 47.5mm 1.5mm. An

approximation of the quantity required can be calculated using equation 17. Spade the
mixture with a spatula 15 times around the perimeter and 10 times on the surface, leaving
the surface slightly rounded.
Apply
et
it
MDD
= maximum dry density
[kg/m]
perpendicular to the base of the mould.
25 seconds of vibration for bitumen emulsion stabilised materials

35 seconds of vibration for foamed bitumen stabilised materials.
Step 5: Raise hammer to safe position.

Step 6: For the second layer, if necessary, adjust for the amount of material to be added
such that the final compacted thickness is 95mm. Using a chisel, scarify the entire surface
area of the top of the compacted layer to a maximum depth of 10mm. Add the required
amount of material and ensure the material is as level as possible.
perpendicular to the base of the mould.
Apply
25 seconds of vibration for bitumen emulsion stabilised materials

35 seconds of vibration for foamed bitumen stabilised materials.
Step 8: Raise hammer to safe position. Remove mould from base plate and open the split
mould to remove the specimen.
QCS 2014

Part
Page 36
Step 9: Take approximately 1kg representative samples after compaction of the first and
third specimens and dry to a constant mass. Determine the moulding moisture using
equation 15.
Curing procedure: Place the specimens in an oven at 40C for 24 hours (or until the moisture
content has reduced to at least 50% of OMC). Thereafter place each specimen in a sealed
plastic bag (at least twice the volume of the specimen) and place in an oven at 40C for a
further 48 hours.
Remove specimens from the oven after 48 hours and remove the respective plastic bags,
ensuring that any moisture in the bags does not come into contact with the specimen. Allow
to cool to ambient temperature.
When specimens have cooled to ambient temperature determine the bulk density for each
specimen:
rw
.l.
l
Step 1: Determine the mass (Mbriq).
qa
ta
Step 2: Measure the height at four evenly-spaced places around the circumference and
calculate the average height (h).
Step 3: Measure the diameter (d).
as
Step 4: Calculate the bulk density using equation 16:
se
Note: Exclude from further testing any specimen whose bulk density differs from the mean
bulk density of the batch by more than 50 kg/m.
The bulk density may alternatively be determined by using the weigh-in air / weigh-in water
method for those specimens designated for soaked testing.
8.7.10
Determination Of The Strength Of 150mm Diameter Specimens
The 150mm diameter specimens are tested for indirect tensile strength under equilibrium
moisture content and soaked conditions to determine the ITSEQUIL and the ITSSOAK values. To
prevent moisture loss, specimens should be tested as soon as they are prepared. The
results are used to refine the optimum bitumen content and amount of active filler that was
initially determined from the 100mm diameter specimens. In addition, these test results are
used to classify the BSM with additional confidence.
Additional ITS tests should be carried out using 150mm diameter specimens to determine
the sensitivity of the mix to minor variations in both the amount of added bitumen and active
filler.
et
it
ov
er
If, for example, Level 2 test results indicated an optimum bitumen addition (OBA) of 2.2%
with an active filler addition of 1%, then the following further tests should be undertaken:
Step 1: To check the sensitivity of the bitumen addition, follow the Level 2 procedure in 8.7.9
to manufacture, cure and test the following mixes:
QCS 2014

Part
Added bitumen (%)
2.2 (Level 2 OBA)
2.1
2.0
1.9
Page 37
Active filler (%)

1
1
1
1
ITS test results will allow the optimal bitumen addition (OBA) to be refined.
Step 2: To check the sensitivity of the amount of active filler added, follow the Level 2
procedure in 8.7.9 to manufacture, cure and test the following mixes:
Active filler (%)
0.9
0.7
0.5
Added bitumen (%)

OBA
OBA
OBA
rw
.l.
l
ITS test results will indicate the minimum amount of active filler required in the mix.
Strength Test Procedures
The Unconfined Compressive Strength (UCS) of a cement stabilised material is determined

by measuring the ultimate load to failure of a 127mm high and 150mm diameter specimen
that is subjected to a constant loading rate of 140kPa/s (153kN/min), as follows:
qa
ta
8.7.11
as
Step 1: Place the specimen on its flat side between the plates of the compression testing
machine. Position the specimen such that it is centred on the loading plates.
se
Step 2: Apply the load to the specimen, without shock, at a rate of advance of 140kPa/s until
the maximum load is reached. Record the maximum load P in kN, accurate to 0.1kN.
er
Step 3: Immediately after testing a specimen, break the specimen up and take a sample of
approximately 1000g to determine the moisture content (W break). This moisture content is
used to determine the dry density of the material using equation 21.
= (4 x P) / ( x d ) x 10000
[Equation 18]
= unconfined compressive strength
[kPa]
= maximum load to failure
[kN]
[cm]
UCS
UCS
et
it
where:
ov
Step 4: Calculate the UCS for each specimen to the nearest 1 kPa according to equation 18.
Indirect Tensile Strength (ITS) of a stabilised material is determined by measuring the

ultimate load to failure of a specimen (both 100mm and 150mm diameter specimens) that is
subjected to a constant deformation rate of 50.8 mm/minute on its diametrical axis, as
follows:
Step 1: Place the specimen onto the respective ITS jig for the 100mm and 150mm diameter
specimens. Position the sample such that the loading strips are parallel and centred on the
vertical diametrical plane.
Step 2: Place the load transfer plate on the top bearing strip and position the jig assembly
centrally under the loading ram of the compression testing device.
Step 3: Apply the load to the specimen, without shock, at a rate of advance of 50.8 mm per
minute until the maximum load is reached. Record the maximum load P in kN, accurate to
0.1kN.
QCS 2014

Part
Page 38
Step 4: Immediately after testing a specimen, break it up and take a sample of

approximately 1000g to determine the moisture content (W break). This moisture content is
used in equation 21 to determine the dry density of the material in the specimen.
Step 5: Immediately after testing a specimen, measure the temperature of the broken face
using a digital thermometer. Record the temperature, accurate to 0.1C.
Step 6: Calculate the ITS for each specimen to the nearest 1 kPa using equation 19:
where:
ITS
= (2 x P) / ( x h x d) x 10000
[Equation 19]
ITS
= indirect tensile strength
[kPa]
= maximum applied load
[kN]
= average height of the specimen
[cm]
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d
[cm]
Step 7: To determine the soaked ITS, place the specimens under water at 25C 1C for 24
hours. Remove specimen from water, surface dry and repeat steps 1 to 5.
Record the results and determine the following as required:
ITSDRY = average of 3 specimens cured to constant mass

ITSWET = average of 3 ITSDRY specimens soaked for 24 hours.
150mm specimens:
ITSEQUIL = average of 2 specimens cured at equilibrium moisture
ITSSOAK = average of 2 ITSEQUIL specimens soaked for 24 hours
Step 8: Determine the Tensile Strength Retained (TSR). The TSR is the relationship
between the average soaked and unsoaked ITS values for a specific batch of specimens,
expressed as a percentage using equation 20:
= Average soaked ITS / Average unsoaked ITS x 100
[Equation 20]
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TSR
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100mm specimens:
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Step 9: Using the moisture content determined in each test described above, calculate the
dry density using equation 21:
where:
DD
Mbriq
= (Mbriq / Vol) x (100 / (W break + 100) x 1000
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Vol
[Equation 21]
= dry density
[kg/m]
= mass of cured specimen
[g]
= volume of specimen
[cm ]
W break
= moisture content of the specimen
[%]
Report the results using the template sheet shown in 8.7.16 as a guide.
8.7.12
Selection Of The Amount Of Bitumen To Be Added For Bsm
Plot the results of the respective soaked and unsoaked ITS test results against the relevant
bitumen content that was added. The added bitumen content that best meets the desired
BSM classification is selected as the optimum amount of bitumen to be added, as shown in
the example below (Figure 7.3 Determination of BSM class and added bitumenFigure 7.3
Determination of BSM class and added)
QCS 2014

Part
Page 39
Interpretation of ITS Tests

BSM1
BSM2
BSM3
Purpose
ITSDRY
100 mm
> 225
175 to 225
125 to 175
Indicates the optimum bitumen

content
ITSWET
100 mm
> 100
75 to 100
50 to 75
Indicates need for active filler.
TSR
100 mm
N/A
N/A
N/A
Indicates problem material where

TSR < 50 and ITSDRY > 400 kPa
ITSEQUIL
150 mm
> 175
135 to 175
95 to 135
Used for classifying the BSM and

for optimising the bitumen and
active filler content.
ITSSOAK
150 mm
> 150
100 to 150
60 to 100
Check value on ITSWET
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Specimen
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Test
Figure 7.3 Determination of BSM class and added bitumen
The TSR value is useful for identifying problem materials. If the TSR is less than 50%, it is
recommended that active filler is used. If such treatment does not increase the ITSWET value
with a maximum application of 1% lime or cement, then the nature of the material being
stabilised should be investigated:
Where the material is granular, a TSR value below 50% combined with an ITSDRY value in
excess of 400 kPa suggests contamination (normally attributed to clay or deleterious
materials). In this situation, it is suggested that material is pre-treated with hydrated lime and
the Level 1 tests repeated.
Where the material is 100% RAP, a TSR value below 50% combined with an ITSDRY value in
excess of 500 kPa indicates that the treated material is partly stabilised and partly
continuously bound (cold mix). In this situation, the material probably requires blending with
crusher dust to ensure that the stabilisation process dominates the mix.
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Level 2 testing using 150mm diameter specimens should be undertaken to verify the
relevant ITS values for BSM classification.
8.7.13
Determination Of The Shear Properties Of Bsm
Triaxial testing is carried out to determine the cohesion and angle of internal friction of BSM
specimens. Testing is normally carried out at the bitumen content selected from the results
of ITS tests carried out on 150mm diameter specimens (see above). Additional tests at
different bitumen contents can always be carried out to investigate the sensitivity of the
shear properties.
Specimens for triaxial testing shall be produced as follows:
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Step 1: Prepare and treat 50kg of sample (adequate for manufacture of 4 specimens) with
either bitumen emulsion or foamed bitumen at the optimum bitumen content. Include any
active filler requirements.
Step 2: Where required, add moisture to bring sample to optimum compaction moisture
content and mix until uniform. Place the mixed material in an air-tight container.
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Step 3: Take approximately1 kg representative samples of each specimen to determine the

moulding moisture using equation 15.
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Step 4: Compact at least four (4) specimens using a 150mm diameter split mould with an
effective internal height of 300mm, using equation 17 to calculate the approximate quantity
for each layer.
Specimens may be made using either Modified AASHTO (T-180) or vibratory compaction
methods.
Compaction using modified AASHTO (T180) shall be in 12 layers, each approximately 25mm
thick, compacted with 56 blows using a 4.536kg hammer with a 457mm drop. Carefully trim
any excess material from the specimen.
Compaction using vibratory compaction shall be in 5 layers, each approximately 60mm thick,
using a hammer assembly of 30kg total mass. Each layer is compacted for:
25 seconds for BSM-emulsion, or

35 seconds for BSM-foam
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The height of each compacted layer is measured and, if necessary, an adjustment made for
the quantity of material used for the next layer to achieve the required height for the
respective layers.
6
The specimens shall be cured using the same procedure for 150mm diameter specimens.
8.7.14
Determination Of Triaxial Shear Parameters Using Simple Triaxial Test
This method describes the determination of triaxial shear parameters (cohesion and internal
angle of friction) of Bitumen Stabilised Materials by measuring the resistance to failure
(monotonic) of a cylindrical 150 mm diameter and 300 2 mm height specimen prepared
according to Vibratory Hammer Compaction Procedure.
QCS 2014
Page 41
Apparatus:
(a)
Triaxial Cell comprising a galvanised steel casing 5 mm thick comprising a ring handle
and simple mechanical clamps top and bottom, a base with bottom platen for sitting
specimen, top disk and a latex tube at least 320 mm in height.
(b)
Testing System comprising a Material Testing System (MTS) or its equivalent system
must at least comprise of an actuator, reaction frame, a control panel and data
acquisition system. The system must be capable of providing ramp loads with
minimum loading capacity of 100 kN and a minimum stroke of 40 mm. The actuator
should be operated by a servo-controlled hydraulic pressure system with a closed loop
feedback system that is capable of both displacement and load controlled testing if
required.
(c)
Measuring devices should include but not limited to a load cell (100 kN Capacity) for
measuring load, an actuator displacement transducer (> 40 mm stroke) for measuring
displacement (deformation) and pressure regulator, gauges, and valves for lateral
pressure.
(d)
Additionally air compressor, loading ram and silicon oil or grease.
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Part
The specimen must be prepared and cured according to Vibratory Hammer Compaction
Procedure as stated previously.
The triaxial testing of the specimens must be planned to take place within 48 72 hours after
completion of the curing procedure. This delay must be kept as constant as possible. The
following steps describe the procedure taken to assemble specimen in the simple triaxial cell
and the cell in the loading frame:
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Place the specimens, casing with tube, top disk and base plate in a climate chamber
and condition them overnight at 25C.
(b)
Lightly grease the sides of the top disk and base plate to reduce friction as much as
possible.
(c)
Place the specimen in the middle of the base plate.
(d)
Carefully introduce the casing, comprising the tube, around the specimen. Take care
not to damage the edges of the specimen during this procedure.
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Clamp the casing in position on to the base plate using simple mechanical clamps on
the casing.
(e)
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(a)
(f)
Put the top disk on top of the specimen.
(g)
Place the cell in the hydraulic loading frame; adjust actuator position until visual
contact is made with the loading ram.
(h)
Connect the air supply to the cell; open the regulator and valve on the cell pressure
port until the cell pressure is stable at the desired level.
(i)
Set monotonic test parameters on the MTS controller including displacement rate of
strain (2.1%), full-scale for the loading (10.0V = 98.1 kN) and half-scale for the
displacement (10.0V = 40mm), and run the test
Monotonic Triaxial Test: Select four specimens of comparable density, moisture content and
conditioned at 25C. Assemble the specimen in the triaxial cell according to 4 ensuring the
tube is air tight.
QCS 2014

Part
Page 42
Operate the testing system in displacement control mode. Ensure that there is
sufficient space between the actuator and the reaction frame to accommodate the
triaxial cell. Place the triaxial cell in the hydraulic loading frame.
(b)
Adjust the actuator position until visual contact is made with the loading ram. Monitor
the load cell reading to prevent loading of the specimen during this process. Connect
the air supply to the cell pressure port. Open the valve on the cell pressure port and
open the regulator until the cell pressure is stable at the desired level. The cell
pressures for a series of monotonic tests are 0 kPa, 50kPa, 100 kPa and 200 kPa.
(c)
Test the first specimen without confinement pressure (0 kPa). Begin the test by
compressing the specimen at a constant rate of displacement of 2.1%. Record the
load versus displacement during the test with a minimum sampling rate of 10 Hz, as
well as the cell pressure, temperature and specimen identifier.
(d)
Stop the test and the recording when the total displacement exceeds 18 mm (6%
strain) or when the specimen bulges excessively before the end displacement is
reached.
(e)
Repeat this procedure for other three specimens until all specimens have been tested
at the four levels of confinement pressures.
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(a)
Remove the specimens after completion of test after completion of a test. Hold the actuator
to its current position, close the valve on the cell pressure port and release the cell pressure
by disconnecting the pressure supply tube to the cell (if possible speed up the pressure
release by applying suction). Return the actuator to a position whereby the cell can easily be
removed from the loading frame. Remove the top disk. Clean the top disk and wipe off any
grease. Unclamp the casing and lift the casing with tube from the cell base. Clean the tube
from possible remains of the deformed specimen (it is not necessary to remove the tube
from the casing). Remove the tested specimen from the base plate. Place it in the plastic
bag and seal. Clean the base plate and wipe off any grease.
When all the specimens have been tested, remove the tested specimens one by one from
the plastic bags. Break the tested specimens up and sample between 500 and 1000 gr. of
material from the middle of the specimen. Use this sample to determine the moisture content
of each specimen.
Calculations:
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(a)
Determine the applied failure load Pa,f for each specimen tested. The applied failure
load is defined as the maximum applied load during the test. Calculate the applied
failure stress a,f :
a,f
where:
a,f
= applied failure stress
[kPa]
Pa,f
= applied failure load
[N]
= end area of a cylindrical specimen at beginning of

test
[m ] or mm ??
QCS 2014

Part
Page 43
Calculate the major principle stress at failure 1,f for each tested specimen:
(b)
where:
1,f
= a,f + dw
1,f
= major principle stress at failure
[kPa]
a,f
= applied failure stress
[kPa]
dw
= pressure resulting from dead weight of top disk and

loading ram
[kPa]
The relationship between 1,f and confinement stress (3)is determined by:
(c)
1,f
= A.3+B
A
where:
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Values of A and B can be determined by performing a linear regression analysis on the

four combinations of 1,f and 3 per mix.
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where:
Values of [] and C [kPa] can be calculated as follows:
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(d)
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Report the following in the table format as illustrated in
10
Table 8. 8 Format Report for Simple Triaxial Test below:
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Specimen number or identifier;
(b)
Confinement pressure (3);
(c)
Applied stress at failure (a,f);
(d)
Major principal stress at failure (1,f);
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(a)
Cohesion, C [kPa];
Angle of internal friction, []; and
(g)
Coefficient of variance, R
(f)
11
Plot the Mohr Circles and the Mohr-Coulomb failure envelope as shown in Figure 7.4
Example of Mohr Circle Plot, noting:
(a)
The centre of Mohr circle must be on the abscissa and is given by (1,f + 3)/2;
(b)
The radius of such circle is (1,f - 3)/2;
(c)
Angle of internal friction is the angle of the Mohr-Coulomb failure envelope (failure
line);
(d)
The failure line intersects with ordinate at the cohesion value.

Part
Page 44
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Figure 7.4 Example of Mohr Circle Plot
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[kPa]
Principle
stress at
Failure
1,f
Cohesion
Internal
Friction
Angle
Correlation
Coefficient
[kPa]
[kPa]
[]
[R ]
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Applied
Stress at
Failure
a,f
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Confining
Pressure,
3
[kPa]
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Specimen
No.
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Table 8. 8 Format Report for Simple Triaxial Test
QCS 2014
Page 45
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Notes:
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Using Laboratory Test Results For Estimating Structural Layer Coefficients
The minimum Retained Tensile Strength (%) requirement should be 75%.

The following minimum compaction requirements are recommended:
8.7.15

Part
Material Type
Percentage of Modified AASHTO

compaction T180
BSM3
BSM2
BSM1
> 97%
> 100%
> 102%
The material passing the 0.075mm sieve to be >2% for BSM-emulsion and >4% for
BSM-foam.
The maximum recommended addition of cement (active filler) is 1% by mass.
Materials with a Plasticity Index > 10 to be pre-treated with hydrated lime to reduce
the PI to <6.
QCS 2014
Page 46
Proforma Report Sheet For Its Testing
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The report sheet shown below may be used for all ITS tests, regardless of whether the tests
were carried out for mix design purposes or for testing field samples.
8.7.16

Part
QCS 2014

Part
Laboratory Equipment Requirements
Laboratory Equipment For Soils Testing
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8.7.17
Page 47
QCS 2014
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Additional Laboratory Equipment for Cement or Lime Stabilisation

Part
Page 48
QCS 2014
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Additional Laboratory Equipment for Bitumen Stabilisation

Part
END OF PART
Page 49
QCS 2014

Part
09: Recycled Aggregate for Roadworks
Page 1
RECYCLED AGGREGATE FOR ROADWORKS ................................................................... 2
9.1
9.1.1
9.1.2
9.1.3
9.2
9.3
9.4
9.4.1
9.4.2
9.5
9.6
GENERAL ---------------------------------------------------------------------------------------------- 2
Scope
2
References
2
Definitions
3
SOURCE ----------------------------------------------------------------------------------------------- 3
APPLICATIONS -------------------------------------------------------------------------------------- 3
RECYCLED AGGREGATE FOR EARTH WORKS RELATED TO ROADS ------------ 4
Requirements of Materials
4
Compaction of Fill Material
5
RECYCLED AGGREGATE FOR SUB-BASE MATERIAL ---------------------------------- 5
RECEYCLED AGGREGATE FOR BASE MATERIAL OF MINOR ROADS IN
VILLAGE AREAS AND TEMPORARY ROADS ----------------------------------------------- 6
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QCS 2014

Part
Page 2
RECYCLED AGGREGATE FOR ROADWORKS
9.1
GENERAL
9.1.1
Scope
The conditions of this part cover the requirements of recycled aggregate obtained from
demolition and excavation waste for use in roadworks.
Related Parts are:
General
Earthworks
9.1.2
References
The following standards are referred to in this Part :
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Part 1,
Part 3,
Part 4,
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ASTM C88 ..................Standard Test Method for Soundness of Aggregates by Use of

Sodium Sulfate or Magnesium Sulfate
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ASTM C131 ................Standard Test Method for Resistance to Degradation of Small-Size

Machine
of
particle
size
distribution
Sieving
method
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BS EN 933 Part 1 .......Determination

Aggregates
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ASTM C535 ................Standard Test Method for Resistance to Degradation of Large-Size

Machine
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BS 1377 Part 4 ...........Methods of test for Compaction-related tests, California Bearing Ratio
(CBR) of Laboratory-Compacted Soils
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ASTM D2419 ..............Standard Test Method for Sand Equivalent Value of Soils and Fine
Aggregate
BS 1377 Part 3 ...........Standard Test Methods for Classification tests, Liquid Limit, Plastic
Limit, and Plasticity Index of Soils
BS EN 933 Part 3. ......Methods of test for Determination of particle shape - Flakiness index
BS EN 933 Part 4. ......Methods of test for Determination of particle shape - Shape index
BS EN 933 Part 5 .......Methods of test for Determination of percentage of crushed and
broken surfaces in coarse aggregate particles.
BS EN 933-11:2009 ...Tests for geometrical properties of aggregates. Classification test for
the constituents of coarse recycled aggregate
BS EN 1097-2:2010...Tests for mechanical and physical properties of aggregates. Methods
for the determination of resistance to fragmentation
QS 29 / 2012 ..............The general Conditions For Recycled Aggregate Obtained From
Building Demolition
QCS 2014

Part
Page 3
Definitions
Demolition Waste: Waste Material obtained from Excavated and/or demolished concrete
structures.
Concrete Demolition Waste : Waste Produced by demolition of concrete structures in

general.
Demolition Waste from Hard Concrete : Waste obtained from demolition of hard concrete
members such as columns, foundations and other mass concrete blocks.
Excavation Waste : Waste obtained from excavated materials.
Mixed Demolition Waste : Waste material obtained from both excavated and demolished
concrete structures.
Mixed Aggregate : Recycled fine and coarse Aggregate combined together.
Recycled Aggregate: a materials produced by the reprocessing of reclaimed construction

and demolition waste. These include but are not limited to asphalt planings (i.e. the asphalt
layers of roads removed during roadworks, also known as RAP Reclaimed Asphalt
Pavement), fill, selected fill, granular subbase and rock from construction excavations.
9.2
SOURCE
The debris pieces of blocks collected from road demolitions in various places should be
stock piled at suitable location where different types of materials can be separated.
The clean, tough, hard, durable, free from organic material and uncoated particles containing
no harmful materials in quantities sufficient to adversely affect construction works shall be
stock piled separately according to the required nominal sizes. The material free from pieces
of steel, plastic and wood.
The sources of aggregate should be regularly and thoroughly investigated to ensure the
quality of material is satisfactory. The aggregate shall be non-plastic and chemically stable.
9.3
APPLICATIONS
Carefully selected recycled aggregate can be used in many applications as shown below.
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9.1.3
(a)
For Non-structural Concrete (Grade SRC 20) for backing of kerbs, channels, edging
and quadrant in road work.
(b)
For manufacture of Hollow & Solid Blocks and Paving blocks for pedestrians.
(c)
For Earth works related to roads.
(d)
For Aggregate of sub-base materials.
(e)
For Minor Roads of village areas and temporary roads.
Recycled materials from construction or a construction process, or from existing pavement

layers shall be separated according to type for processing. The separate processed
materials shall be stored in stockpiles of no greater than 4000 tons and quarantined for
testing and approval by the Engineer prior to use.
QCS 2014

Part
Page 4
Samples shall be taken of the recycled aggregate constituents for classification by handsorting the coarse aggregate particles in accordance with BS EN 933-11. The test shall be
carried out by a suitably trained laboratory technician who has demonstrated competence in
classifying the constituent classes in accordance with the test method.
Testing frequency shall be according to parts 3 and 4 of this section unless otherwise stated
by the Engineer.
Recycled aggregate shall be free from non-aggregate constituents such organics and shall
have a minimum amount of deleterious material which may affect its reuse.
The Percentage use of recycled aggregate shall not exceed the following:
A maximum of 50% of recycled fine, and/or coarse and/or mixed aggregates whether
obtained from Concrete or mixed waste can be used for concrete works of less than
20 MPa strength or any other construction works but not for asphalt layers.
(b)
It is not allowed to use recycled Aggregate obtained from concrete or mixed demolition
wastes in asphalt mixes. Only Recycled Aggregate from excavated material can be
used in asphalt mixes.
(c)
A maximum of 100% of recycled aggregate obtained from excavated material can be

used in any of the above mentioned construction works.
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(a)
RECYCLED AGGREGATE FOR EARTH WORKS RELATED TO ROADS
9.4.1
Requirements of Materials
Recycled material shall be tested according to the relevant parts of BS 1377 and shall be
within the limits of following table:
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9.4
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Table 9.5
Specifications of Recycled Aggregate for use in
Earth Works Related to Roads
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Requirement
Grading
Particle Size
Organic Material (%)
Liquid Limit (%)
Plasticity Index (%)
Material Passing 0.075 mm (%)
Water Soluble Salts (%)
Acid Soluble Salts (%)
Soaked CBR Value
Swell (%)
Tree and Plant Stumps
Perishable Materials
Materials Subject to Spontaneous
Combustion
Material From Sabkha and Marshes
General Fill
(Filling on low level
areas)
Standard
Selected Fill
( Sub-grade)
Standard
Less than 75mm

2 max
40 max
11 max
40 max
5 max
Less than 75mm

2 max
35max
10 max
35 max
5 max
10 max
Free
Free
10 max
More than 15
2 max
Free
Free
Free
Free
Free
Free
QCS 2014

Part
Page 5
Compaction of Fill Material
All Fill materials shall be placed in loose layers within the effective range of compaction of
the approved plant. The maximum permissible loose layer thickness shall be limited to
200mm.
The fill material shall be watered and mixed as necessary to ensure that prior to compaction,
the moisture content of the whole layer 3% of the optimum moisture content obtained at the
laboratory compaction test (LCT). The compaction of layer shall continue until a density of at
least 95% of the maximum dry density of LCT.
No layer shall be covered by the next layer until it has been tested, inspected and approved
by the Engineer.
9.5
RECYCLED AGGREGATE FOR SUB-BASE MATERIAL
The following table illustrates the material requirements for unbound materials for roadworks.
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9.4.2
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Table 9.6
Requirements of Recycled Aggregate for Roadworks Unbound Layers
Raw Materials
Requirement
Coarse Aggregate
Standard
Standard
Less than 4.75mm
More than 4.75mm
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Fine Aggregate
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Grading
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Particle Size
Less Than 4.0mm
More than 4.0mm
Organic Material (%)

Liquid Limit (%) material
passing 0.425 or 0.500mm
Plasticity Index (%)material
passing 0.425 or 0.500mm
MaterialPassing0.075mm (%)
0.5 max
Free
Water Soluble Chlorides (%)
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OR
Production
25 max
Sub-Base
Class C
Free
25 max
6 max
-
1.0 max
1.0 max
Acid Soluble Chlorides (%)
2.0 max
2.0 max
Water Soluble Sulphates (%)

Acid Soluble Sulphates SO 3(%)
Soaked CBR Value
Swell (%)
Tree and Plant Stumps
Perishable Marshes
Materials subject to
Spontaneous combustion
Material from Sabkha and
Marshes
Clay Balls
Ratio of Passing 0.075mm &
0.425mm (%)
1.5 max
3.0 max
Free
Free
1.5 max
3.0 max
80 min
1.0 max
Free
Free
Free
Free
Free
Free
Free
Free
Free
66
35 max
35 max
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Flakiness Index (%)
6 max
-
Aggregate
QCS 2014

Part
Page 6
Raw Materials
Production
Requirement
Coarse Aggregate
Elongation Index (%)
40 max
40 max
Los Angeles Abrasion (%)
40 max
40 max
Soundness - magnesium
sulphates, 5 cycles (%)
20 max
20 max
Sand Equivalent Value
25 min
Sub-Base
Mix Designs
The recycled aggregate shall be used in aggregate sub-base and base courses. The
fine and course aggregate shall be combined proportionately in order to achieve the
following class of grading:
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(a)
Aggregate
Fine Aggregate
Percentage Passing
(by Weight)
Class C
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63.0
50.0
37.5
25.0
19
9.5
4.75
2.36
0.425
0.075
100
90-100
50-85
35-65
25-50
15-30
5-15
Screening and Mixing
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63.0
40.0
20.0
10.0
4.0
2.0
0.500
0.063
ASTM Sieve (mm)
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BS EN Sieve (mm)
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Table 9.7
Gradation of Recycled Aggregate for use in Subbase Layers
(a)
Screening is required for recycled materials used in the road base and sub base to
ensure that the designated gradation is attained.
(b)
Central Mixing plant is required for the mixing of materials.
9.6
RECEYCLED AGGREGATE FOR BASE MATERIAL OF MINOR ROADS IN

VILLAGE AREAS AND TEMPORARY ROADS
Recycled Aggregate for use in Asphalt layers of temporary and minor roads in village areas
shall be reclaimed from excavated natural soil which is mechanically and chemically stable
and of specifications in the following table:
QCS 2014

Part
Page 7
Table 9.9
Specification of Recycled Aggregate for use in
Asphalt Layers for Village and Temporary Roads
Recycled Aggregate
Requirement
Standard
Less than 2.36 mm
Standard
More than 2.36mm
0.5 max
0.5 max
4 max
2.0 max
3.0 max
Free
-
2.0 max
2.0 max
3.0 max
Free
Free
Free
35 max
40 max
40 max
25 max
-
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18 max
30 min
The different sizes of material shall be separated by screening and re-combined together to
produce the all-in Recycled crushed aggregate, which shall achieve the following grading
limits :
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Coarse Aggregate
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Grading
Particle Size
Organic Material - including wood and materials
prone to disintegration (%)
Water Absorption Saturated surface dry (%)
Liquid Limit
Plasticity Index (%)
MaterialPassing0.075mm (%)
Acid Soluble Chlorides (%)
Acid Soluble Sulphates SO 3 (%)
Materials subject to Spontaneous combustion
Materials from Sabkha and Marshes
Clay Balls
Flakiness Index (%)
Elongation Index (%)
Los Angeles Abrasion (%)
Crushing Value (%)
Soundness - magnesium sulphates, 5 cycles (%)
Sand Equivalent Value
Fine Aggregate
Table17.8
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Gradation of Recycled Crushed Aggregate for use in

Asphalt Layers for Village and Temporary Roads
BS EN Sieve (mm)
63.0
40.0
20.0
10.0
4.0
2.0
0.500
0.063
BS Sieve (mm)
Percentage Passing (by weight)
50.0
37.5
19.0
9.5
4.75
2.36
0.600
0.075
100
95-100
60-80
40-60
25-40
15-30
8-22
5-12
Recycled aggregate for use in Asphalt layers of minor roads in village areas and temporary
roads shall be nonplastic.
The material shall wet during transporting and spreading in order to avoid segregation.
END OF PART
QCS 2014
Section 07: Green Constructions

Part
01: Introduction
Page 1
INTRODUCTION ..................................................................................................... 2
1.1
1.1.1
1.1.2
1.1.3
1.1.4
GREEN CONSTRUCTION ...................................................................................... 2

Green Construction and Sustainability
2
Reference
2
Green Construction Regulations and Environmental Assessment Tools
2
Green Building Definition
2
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QCS 2014

Part
01: Introduction
Page 2
INTRODUCTION
1.1
GREEN CONSTRUCTION
1.1.1
Green Construction and Sustainability
Buildings, infrastructure and the environment are inextricably linked. Energy, water, materials
and land are all consumed in the construction and operation of buildings and infrastructure.
These built structures in turn become part of living environment, affecting living conditions,
social well-being and health. It is important to explore environmentally and economically
sound design and development techniques in order to design buildings and infrastructure that
are sustainable, healthy and affordable, and encourage innovation in buildings and
infrastructure systems and designs.
The concept of sustainability in building and construction has evolved over many years. The
initial concept was on how to deal with the issue of limited resources, especially energy, and
on how to reduce impacts on the natural environment. Emphasis was placed on technical
issues such as materials, building components, construction technologies and energy related
design concepts. Recently non-technical issues become appreciated such as economic,
social sustainability and cultural heritage aspects of the built environment. Also, there are
greater attention to create more green buildings by upgrading the existing buildings through
the application of new developments or the invention and use of innovative technologies for
energy and material savings.
1.1.2
Reference
The following documents are referred to in this section:
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Global Sustainability Assessment System (GSAS) - v2.1 2013, Gulf Organization for
Research and Development, Qatar, formerly known as (QSAS) (Note: QCS reference shall
be limited only to this particular version of GSAS and non-other)
Green Construction Regulations and Environmental Assessment Tools
Many countries have developed their own standards for green building or energy efficiency
for buildings and Building Environmental Assessment tools. Now there are many of building
rating systems tools and guidelines in the world currently in use. A new sustainability
assessment system known as GSAS (GLOBAL Sustainability Assessment System) is
referred to herein in this document.
1.1.4
Green Building Definition
Green building is the process through which buildings are designed, constructed and
operated to reduce natural resources consumption, eliminate environmental degradation and
enhance social and economic aspects of humans.
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1.1.3
END OF PART
QCS 2014

Part
02: QCS Green Building
Page 1
QCS GREEN BUILDING ......................................................................................... 2
2.1
2.1.1
2.1.2
SCOPE .................................................................................................................... 2
General
2
References
2
2.2
2.2.1
2.2.2
2.2.3
QCS GREEN BUILDING REQUIREMENTS ............................................................ 3

Types of Buildings
3
QCS Green Building Categories & Criteria
3
Submittal Requirements
5
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QCS 2014

Part
Page 2
QCS GREEN BUILDING
2.1
SCOPE
2.1.1
General
This section specifies minimum environmental performance requirements that apply to the
design, construction and operations of new buildings.
The minimum environmental performance requirements apply to 8 building typologies only

(Section 2.2.1) and have been specified for eleven environmental performance criteria (Table
1).
The environmental performance criteria apply to all new buildings for those building
typologies specified and shall apply to:
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Buildings under design but not yet constructed (i.e. pre-construction);
(b)
Buildings under construction; and
(c)
Buildings constructed prior to hand over.
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(a)
For buildings under construction or constructed and not handed over, the minimum
environmental performance requirements shall apply as far as is reasonably possible without
the need to undertake a major re-design and retrofit. Where building owners, designers or
contractors, etc. judge that any re-design or retrofit to meet the environmental performance
requirements specified herein is not reasonable, the relevant Qatari authorities / government
agencies reserve the right to ask for a justification to explain such a decision.
The Engineer shall specify the applicable Green Building Assessment System for the QCSs
Building typologies and to assess compliance with QCSs Green Building Requirements.
The minimum environmental performance requirements specified herein have been derived
from the Global Sustainability Assessment System (GSAS) v2.1-2013.
The Engineer shall ensure compliance with QCSs minimum sustainable building
requirements or higher specified by the relevant authorities or the Engineer.
QCS 2014 encourage the use of any environmental or sustainability performance criteria in
addition to those environmental performance criteria specified to help design, construct and
operate better buildings.
2.1.2
References
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Global Sustainability Assessment System (GSAS) v2.1-2013, Gulf Organisation for Research
and Development, Qatar
QCS 2014

Part
Page 3
QCS GREEN BUILDING REQUIREMENTS
The values listed herein for the Commercial, Health Centres, Education, Mosques, and Light
Industries Schemes and Typologies shall be considered as the minimum requirements for
the applicable criteria (Table 3).
2.2.1
Types of Buildings
COMMERCIAL: Types include Spaces that Serves various functions such as offices,
2
conference rooms, foyers, retail spaces, and ancillary areas, with built up area of 10000 m
or more.
GOVERNMENTAL BUILDINGS: Types include Capitol, Diplomatic Buildings, Statehouses,

Courthouses, Municipalities, Post offices, etc.
PUBLIC BUIDLINGS: Types include:
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2.2
RAIL BUILDINGS: Types include spaces that serve various functions of a railway
station such as but not necessarily limited to platform/concourse, offices, station
control room, ticketing, retail, food/beverage areas, and ancillary areas.
(b)
SPORTS: Facilities include indoor or outdoor competition areas, fitness suites, locker
facilities, retail spaces, offices, restaurants, and common areas
(c)
EDUCATION BUILDINGS: Types include educational facilities for students in

th
kindergarten through 12 grade as well as college and university facilities. This
includes classrooms, libraries, auditoriums, cafeterias, kitchens, offices, and other
spaces that are part of academic buildings.
(d)
MOSQUES AND OTHER RELIGIOUS BUILDINGS: Types include the building

containing the congregational worship areas.
(e)
HOSPITALS AND HEALTH CENTERS BUILDINGS: Types include specialist

hospitals, general hospitals, out-patient hospitals, and primary care health centres.
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(a)
LIGHT INDUSTRIES BUILDINGS: Types include both operational and office areas as well as
the general building as a whole.
2.2.2
QCS Green Building Categories & Criteria
The minimum QCSs requirements unless other values specified by the relevant authorities.
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Table 1: Green Building Categories & Criteria

QCS Category
ENERGY
Criteria
Energy Demand
Performance
Minimum Requirements *
EPC 1.0
Energy Delivery
Performance
Building Typologies
Commercial, Governmental
Education, Mosques &
other religious buildings,
Light Industry, Health
Centres, Railways, Sports
WPC 1.0
WATER
Water Consumption
Commercial,
Governmental, Education,
Mosques, Light Industries,
Health Centres,
Railways, Sports

Part
QCS Category
Criteria
Page 4
Minimum Requirements *
PMV 2.0
80 ADPI
Comply with ASHRAE
Standards
Comply with ASHRAE
Standards
PMV 2.0 office spaces
Natural Ventilation Can be

Utilized(x)
0 < X ) month of the year(
Commercial,
Governmental, Education,
Mosques,
Light Industry
Comply with ASHRAE

Standard
Natural Ventilation Can be
Utilized(x)
0 < X (month of the year)
Comply with ASHRAE
Standard
no existence of equipment
with efficiency less than
specified in ASHRAE 90.12010
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VOC_emi_total 100%
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Low-Emitting Materials
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Support of National
(GCC) Economy
% of Construction Expenditure
Benefiting National Economy
(x)
20 X
Cultural Identity &

Heritage
To be defined & assessed by

Certification Authority
MANAGEMENT
& OPERATION
Recycling Management
Recycling Management Plan

demonstrates Compliance
MATERIALS
Regional Materials
Performance Indicator (X)

X < 30
Railways
Sports
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Natural Ventilation
Mechanical Ventilation
CULTURAL &
ECONOMIC
VALUE
Health Centres
worst case heat load 1.6

Exposed Spectator Seating
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INDOOR
ENVIRONMENT
Commercial, Light Industry,

Governmental
Education, Mosques
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Thermal Comfort
Building Typologies
QCS 2014
Health Centres
Sports
Railways (above ground)
Commercial, Education,
Mosques,
Light Industry
Health Centres, Railways
Education,
Mosques,
Light Industry
Health Centres, Sports,
Railways
Education,
Mosques,
Light Industry
Health Centres, Railways,
Sports
Education,
Mosques,
Light Industry
Health Centres, Railways
Education,
Mosques,
Light Industry
Health Centres, Sports,
Railways
Education,
Mosques,
Light Industry
Health Centres, Railways,
Sports
QCS 2014

Part
Page 5
2.2.3
Submittal Requirements
Building owners, designers or contractors, etc. shall provide the relevant authorities with a
report that shows how the minimum environmental requirements have been met. The report
shall include:
All raw data used to performance calculations;
(b)
All calculations used to derive results against the environmental criteria specified (and /
or copies of relevant GSAS calculator tools where appropriate);
(c)
All specifications where relevant of construction materials, equipment, fixtures and

fittings, etc;
(d)
Details of suppliers / service providers with evidence that purchases have been made
or services commissioned, etc.
(e)
All other information necessary to demonstrate how the environmental performance

requirements have been met.
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(a)
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END OF PART
QCS 2014
Page 1
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ENERGY [E] ............................................................................................................ 2

Scope
2
Reference
2
Abbreviations
2
Scope
3
Description
3
Measurement Principle
4
Measurement ( EPCnd)
4
Score ( EPCnd)
4
Scope
4
Description
5
5
Measurement (EPCdel)
5
Score (EPCdel)
6
3
3.1.1
3.1.2
3.1.3
3.2.1
3.2.2
3.2.3
3.2.4
3.2.5
3.3.1
3.3.2
3.3.3
3.3.4
3.3.5

Part
03: Energy
QCS 2014

Part
03: Energy
Page 2
ENERGY [E]
3.1
GENERAL
3.1.1
Scope
The Energy category consists of factors associated with energy demand of buildings, the
efficiency of energy delivery, and the use of fossil energy sources that result in harmful
emissions and pollution.
Impacts: Negative impacts resulting from energy use and unsustainable practices
include:
(i)
Climate Change
(ii)
Fossil Fuel Depletion
(iii)
Air Pollution
(iv)
Human Comfort & Health
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Designing the building to lower its energy demand
(ii)
Selecting efficient building systems
(iii)
Lowering the demand on non-renewable sources of energy thereby reducing

harmful emissions and depletion of fossil fuels
(iv)
Minimizing the amount of harmful substances produced by the energy delivery

systems and the energy supply network
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(i)
Energy is sub-categorised as follows:

(i)
Energy Demand Performance
(ii)
Energy Delivery Performance
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(c)
Mitigate Impact: Factors that could mitigate environmental impacts due to energy use
include:
(b)
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(a)
Reference
3.1.2
Global Sustainability Assessment System (GSAS) V2.1 2013, Gulf Organization for
Research and Development , Qatar (Note: QCS reference shall be limited only to this
particular version of GSAS and non-other).
3.1.3
Abbreviations
The following abbreviations are defined for use in this section.
EPC
EPCnd
EPCdel
EPCp
fop
Energy Performance Coefficient

Energy Demand Performance
Energy Delivery Performancet
Primary Energy Performance
Operation factor for a particular Building category
QCS 2014

Part
03: Energy
Edelivery
Page 3
The delivered energy is defined as the supplied energy To the

technical building systems through the system boundary, to satisfy
2
the uses of the building in KWh/m /yr.
The reference value used in the GSAS scoring method for the
2
Delivered energy for the building type in KWh/m /yr.
2
The total primary energy consumed for the building in KWh/m /yr.
the reference value used in the GSASscoring method for primary
2
Energy for the building type in KWh/m /yr.
2
The emitted mass of CO2 in g/m /yr. calculated from the net
delivered
Energy and emission coefficient. The emission
coefficient includes the CO2 emissions associated with the primary
energy consumed for the building.
the reference value used in the GSASscoring method for CO2
emissions for the building type in g/m2/yr.
2
the building thermal energy demand in kwh/m /yr. which takes into
account the energy losses (transmission and ventilation), heat
gains (solar, internal and system heat losses), and the dynamic
parameter (loss utilization factor).
the reference value used in the GSAS Scoring method for energy
2
demand for the building type in kwh/m /yr.
2
The emitted masses of NOX & SOX in gm./m /yr. calculated from
the net delivered energy and emission coefficients.
the reference values used in the GSAS scoring method for NOX &
2
SOX emissions for the building type in gm./m /yr.
Eref_del
EP
Eref_p
CO2
CO2ref
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Qref_nd
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NOX,SOX
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NOXref,SOXref
ENERGY [E.1] ENERGY DEMAND PERFORMANCE
3.2.1
Scope
The energy demand performance shall

buildings:
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3.2
be measured for the following categories of
Table 1: Building Typologies

Commercial
Governmental
Education
Mosques & other religious buildings
Light Industry
Health Centres
Railways Buildings
Sports
3.2.2
Description
Establish energy demand performance levels for the building in order to reduce
environmental and economic impacts associated with excessive energy use.
QCS 2014

Part
03: Energy
Page 4
The Engineer shall Calculate Building performance in relation to the baseline as specified
below. All calculations will adhere to the GSAS Energy Application document.
3.2.4
Measurement ( EPCnd)
The Engineer shall calculate the EPCnd value based on building data and cooling energy
needs of the project as per the energy performance standard calculation tool (EPSCT).
Calculated EPCnd = Qdesign / Qref_nd The Qdesign is calculated according to the GSAS Energy
Application document.
Commercial & Governmental (with baseline reference) Qref_nd = 125 [kWh/m/yr].
Education: With Baseline reference Qref_nd = 122* fop.education [kWh/m/yr]. where fop.education is
the operation factor for education typologies. The Qdesign and fop,school are calculated according
to the GSAS Energy Application document.
Mosques & other religious buildings: With Baseline reference Qref_nd = 170 [kWh/m/yr] . The
Qdesign is calculated according to the GSAS Energy Application document.
Health Centers: The Qref_nd are area weighted average calculated according to the reference
guidelines document.
Railways: The Qref_nd are area weighted average calculated according to the refference
guidelines document.
Sports : the Engineer shall determine energy demand performance in two steps. Step 1, the
project will use the Energy Performance Calculator to determine the Energy demand (Q nd.fc,I)
for each functional component (FC) of the project. Step 2, the project will enter the Qnd,fc,I for
each FC in the composition sheet in the energy calculator to determine the aggregated
criterion score for the entire sports facility.
Light Industry : With Baseline reference Qref_nd = 475 [kWh/m/yr.]
3.2.5
Score ( EPCnd)
The Recommended minimum requirement * value for EPCnd shall be as per table 2:
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3.2.3
Note : (*) minimum QCSs requirements unless other values specified by the relevant
authority
Table 2: EPCnd Values
EPCnd Value
0.8 < EPCnd 1.0
3.3
ENERGY [E.2]: ENERGY DELIVERY PERFORMANCE
3.3.1
Scope
The energy delivery performance shall be measured for the following categories of buildings:
QCS 2014

Part
03: Energy
Page 5

Commercial
Governmental
Education
Light Industry
Health Centres
Railways Buildings
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Sports
Description
The Engineer shall establish delivered energy performance levels of the project in order to
reduce environmental and economic impacts associated with excessive energy use.
3.3.3
The Engineer shall calculate the building performance in relation to the baseline as specified
below. All calculations will adhere to the GSAS Energy Application document.
3.3.4
Measurement (EPCdel)
The Engineer shall complete the Energy Performance Standard Calculation Tool (EPSCT) to
determine the EPCdel value based on building data, HVAC specifications, lighting system,
and DHW system and energy generation.
Calculated EPCdel =Edel

Application document.
Commercial & Governmental : with Baseline reference Eref_del = 89 [kWh/m/yr].
Education With Baseline reference Eref_del = 88* fop_education [kWh/m/yr]. where fop_education is the
operation factor forEducation Typologies. The Edelivery and fop,education are calculated according
to the GSAS Energy Application document.
Mosques & other religious buildings: With Baseline reference Eref_del = 82 [kWh/m/yr]. The
Edelivery is calculated according to the GSAS Energy Application document.
Light Industry: With Baseline reference Eref_del = 165 [kWh/m/yr].
Sports Facilities: The Engineer shall determine energy delivery performance in two steps.
Step 1, the Engineer shall use the Energy performance calculator to determine the delivered
energy (Edel,fc,i) for each functional component (FC) of the project. Step 2, the Engineer shall
enter the Edel,fc,I for each FC in the energy score calculator to determine the aggregated
criterion score for the entire sports facility.
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3.3.2
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/ Eref_del the Edel is calculated according to the GSAS Energy
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Part
03: Energy
Page 6
3.3.5
Score (EPCdel)
The Recommended minimum requirments* EPCdel value shall be categorised as per table
4.
authority
Table 4: EPCdel minimum required value
0.8 < EPCdel 1.0
EPCdel Value
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END OF PART
QCS 2014
Page 1
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WATER [W] .............................................................................................................................. 2

SCOPE
2
REFERENCE
2
SCOPE
2
DESCRIPTION
3
MEASUREMENT PRINCIPLE
3
MEASUREMENT (WPC)
3
*
SCORE
4
RAILWAY TEMINALS
5
4
4.1.1
4.1.2
4.2.1
4.2.2
4.2.3
4.2.4
4.2.5
6

Part
04: Water
QCS 2014

Part
04: Water
Page 2
WATER [W]
4.1
GENERAL
4.1.1
Scope
The Water category consists of factors associated with water consumption and its
associated burden on municipal supply and treatment systems.
(a)
Impacts: Environmental impacts resulting from water consumption and unsustainable

practices include:
(i)
Mitigate Impact: Factors that could mitigate environmental impact and lower demand
on water include:
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(b)
Water depletion
Specifying efficient plumbing fixtures
(ii)
Creating a system for the collection and storage of rainwater
(iii)
On-site treatment of water for later reuse
(iv)
Designing a landscaping plan that minimizes the need for irrigation.
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(i)
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The recommended criteria is Water Performance Coefficient (WPC) [W.1]

Reference
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4.1.2
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Global Sustainability Assessment System (GSAS) - V2.1 2013, Gulf Organization for
Research and Development, Qatar (Note: QCS reference shall be limited only to this
particular version of GSAS and non-other).
4.2
WATER CONSUMPTION
4.2.1
Scope
The Water consumption will be measured for the following categories of buildings listed in
table 1:
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[W]

Commercial
Governmental
Education
Light Industry
Health Centres
Railways Buildings
Sports
QCS 2014

Part
04: Water
Page 3
Description
Minimize water consumption in order to reduce the burden on municipal supply and
treatment systems.
4.2.3
The Engineer shall demonstrate conservation in the use of water in relation to the baseline
and targets outlined in the Water Consumption Calculator.
4.2.4
Measurement (WPC)
The Engineer shall determine cumulative water consumption [Water Performance Coefficient
(WPC)] using the Water Consumption Calculator. Cumulative water consumption is
determined by several input parameters including:
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4.2.2
The project site area and the number of full time staff, students, or residents and
visitors occupying the building
(b)
Specifications for plumbing fixtures
(c)
Landscaping and irrigation plan
(d)
Rain and storm water collection and reuse plan
(e)
Grey and black water treatment and reuse plan
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(a)
Based on input parameters provided by the project, the application conducts multiple
calculations to determine the buildings estimated water consumption. Three estimated
calculation values, Water Consumption for occupants (WCcal_occupant), Water Consumption for
irrigation (WCcal_irrigation), Water Supply from reuse strategies (WScal_reuse) are computed by
the calculator. The annual net water demand is calculated by subtracting water supply
(WScal_reuse) from the summation of water consumptions (WCcal_occupant + WCcal_irrigation). Then,
the net water demand is compared against the summation of the two reference water
consumption values (WCref_occupant + WCref_irrigation) to generate the Water Performance
Coefficient (WPC).
For each building type, the equations to calculate reference values apply to all buildings
regardless of operating duration, occupancy density and site area. A different reference
value will be calculated for project buildings with varying site and operational characteristics,
and the resulting WPC will therefore be applicable across the entire spectrum of each
building type.
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(a)
The Referenced Water Consumption for Occupants is:

WCref_occupant = A x Operating Hours x Occupants
Where:
Operating Hours = 8 (hours per day) x 20 (days per month) x 12 (months per year)
QCS 2014

Part
04: Water
Page 4
Occupants = The total number of full time employees per day + the total number of
visitors per day
(b)
The Referenced Water Consumption for irrigation is:

2
WCref.,irrigation = B x 365 (days per year) x 24 (hours per day) x Site Area (m )
Reference values A and B can be found for the different typologies in the following table:
0.006519
0.000034
Education
0.008423
0.000001
Mosques & other

religious buildings
0.003888
0.000002
Light Industry
0.005355
0.000004
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Commercial &
Governmental
Table 2: Reference values A and B
N/A
N/A
Additional input parameters required:
(b)
Number of staff and students occupying the building
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(a)
Mosques:
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These typologies have multiple occupant reference values which are listed in further detail
in the following sections.
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* Number of worshippers visiting the mosque, both on a daily basis and during times of
full occupancy.
The Referenced Water Consumption for Occupants is:
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(a)
WCref_occupant = A No. Operating Hours_d No.Occupants_d) + (No. Operating

Hours_f x No. Occupants_f)
Notes:
(i)
Where No.Occupants_d is the number of daily worshippers, No.Occupants_f

is the number of occupants during full occupancy.
(ii)
No.Operating Hours_d are normalized as 6 (hours per day) x 30 (days per

month) x 12 (months per year)
(iii)
No.Operating Hours_f are normalized as 2 (hours per day) x 30 (days of

Ramadan) + 52 (Friday prayers per year)
Light Industry
Number of full time employees and visitors occupying the building
4.2.5
Score
The minimum Requirement values by QCS for Water Performance Coefficient shall be:
QCS 2014

Part
04: Water
Page 5
authority
1
COMMERCIAL & GOVERNMENTAL

Table 3: minimum score for commercial Typology
WPC(X) Value
0.87 < X 1.0
EDUCATION
Table 4: minimum score for Education Typology
WPC(X)
MOSQUES
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0.85 < X 1.0
Table 5: minimum score for Mosques Typology
0.89 < X 1.0
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WPC(X)
LIGHT INDUSTRIES
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Table 6: minimum score for Light Industry Typology
HEALTH CENTRES
0.84 < X 1.0
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0.84 < X 1.0
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RAILWAY TEMINALS
Table 8: minimum score for Railways Typology
WPC(X)
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Table 7: minimum score for Health Centres Typology
WPC(X)
0.84 < X 1.0
SPORTS FACILITIES
Table 9: minimum score for Sports Typology
WPC(X)
END OF PART
0.0 X < 0.5
QCS 2014
Section 07 : Green Constructions

Part
05 : Indoor Environment
Page 1
INDOOR ENVIRONMENT [IE] ................................................................................................. 2
5.1
5.1.1
5.1.2
GENERAL ................................................................................................................................ 2
SCOPE
2
REFERENCE
2
5.2
5.2.1
5.2.2
5.2.3
5.2.4
5.2.5
INDOOR ENVIRONMENT [IE.1] THERMAL COMFORT ........................................................ 3

SCOPE
3
DESCRIPTION
3
3
MEASUREMENT (THERMAL COMFORT)
3
*
SCORE
4
5.3
5.3.1
5.3.2
5.3.3
5.3.4
5.3.5
INDOOR ENVIRONMENT [IE.2] Natural Ventilation ............................................................... 5

SCOPE
5
DESCRIPTION
5
5
MEASUREMENT (NATURAL VENTILATION)
6
SCORE*
6
5.4
5.4.1
5.4.2
5.4.3
5.4.4
5.4.5
INDOOR ENVIRONMENT [IE.3] : Mechanical Ventilation ...................................................... 7

SCOPE
7
DESCRIPTION
7
7
MEASUREMENT (MECHANICAL VENTILATION)
7
*
SCORE (MECHANICAL VENTILATION)
8
5.5
5.5.1
5.5.2
5.5.3
5.5.4
5.5.5
INDOOR ENVIRONMENT [IE.4] Low-Emitting Materials ........................................................ 8

SCOPE
8
DESCRIPTION
8
8
MEASUREMENT (VOC)
8
SCORE (VOC)
9
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QCS 2014

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Page 2
INDOOR ENVIRONMENT [IE]
5.1
GENERAL
5.1.1
Scope
The Indoor Environment category consists of factors associated with indoor environmental
quality such as thermal comfort, air quality, acoustic quality, and light quality..
(ii)
(iii)
Air Pollution
(iv)
rw
.l.
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Climate Change
Mitigate Impact: Factors that could improve indoor environmental quality include:
Monitoring air temperature and quality and adjusting or calibrating as
appropriate
(ii)
Maximizing the time period that the building can utilize natural ventilation
(iii)
Designing an adequate mechanical ventilation system
(iv)
Ensuring adequate illuminance levels for visiual performance and comfort
(v)
Maximizing the use of natural lighting in interior spaces
(vi)
Providing for occupant comfort by minimizing glare
(vii)
Maximizing views to the exterior for all occupants
(viii)
Controlling the amount of noise produced by or transferred from the building

interior and exterior
(ix)
Specifying materials with low VOC levels
(x)
Controlling indoor pollutants and sources of airborne contamination
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qa
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(i)
The QCSs requirements for Sub-Indoor Environment criteria Includes:
(c)
(i)
(b)
Impacts: Impacts resulting from ineffective control and design of the indoor
environment include:
et
it
(a)
(i)
Thermal Comfort
(ii)
Natural Ventilation
(iii)
Mechanical Ventilation
(iv)
Low-Emitting Materials
The Public and Government Buildings are to be considered as commercial for the purpose of
Indoor Environment calculation as applicable.
5.1.2
Reference
QCS 2014

Part
Page 3
Global Sustainability Assessment System (GSAS) - v2.1 2013, Gulf Organization for
Research and Development (GORD), Qatar (Note: QCS reference shall be limited only to
this particular version of GSAS and non-other), And American Society of Heating,
Refrigerating and Air-Conditioning Engineers (ASHRAE)
5.2
INDOOR ENVIRONMENT [IE.1] THERMAL COMFORT
5.2.1
Scope
The Indoor Environment for Thermal Comfort shall be measured for the following categories
of the buildings:
Table 1: Building Typology
.l.
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Commercial
rw
Governmental
Education
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Health Centres
as
Railways Terminals
qa
Light Industry
se
Sports Facilities
Description
The Project shall provide a thermaly comfortable environment to ensure the comfort and
health of building occupants.
5.2.3
The Engineer shall calculate the system capacity and either PMV or ADPI Values for the
hottest hour of the year for the worst case for all applicable occupied spaces
Sport Facilities.
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5.2.2
The Project shall also Calculate the heat loads for all critical seats for the hottest outdoor
conditions for scheduled events.
5.2.4
Measurement (Thermal Comfort)
The Project shall complete the Thermal Comfort Calculator (Considering GSAS Assessment
System or any other recommended system) in order to compute PMV or ADPI values and
demonstrate that system Capacity can meet the peak cooling loads for the worst case for all
typical occupied spaces.
(a)
System Capacity : The capacity of the system should be properly sized to meet the
peak cooling loads of critical spaces. All projects will calculate the peak cooling loads
for the hottest hour of the year.
QCS 2014

Part
Page 4
(b)
PMV values: The project will evaluate all critical spaces and perform thermal comfort
assessment for the hottest hour of the year. Calculate PMV values of different
positions in critical spaces such as different positions relative to window and diffuser
locations and select the worst PMV value for assessment.
(c)
ADPI values: The project will evaluate the selected worst case for each typical space
and perform thermal comfort assessment for the hottest hour of the year in terms of
Air Diffusion Performance Index.
The following table outlines the measurement type and typical spaces used in the calculation
according to the appropriate typology:
Table 2: measurement type and typical spaces
Mosques
ADPI
Light Industry
PMV
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Office , Operational Areas
PMV
Typical Occupied Spaces
PMV or ADPI for the worest

case Heat Load
Office spaces (a),Exposed

Spectator Seating (b)
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Score
Prayer Halls
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5.2.5
Classrooms, Offices, Special

Functional Spaces.
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Health Centres
Sports
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ADPI
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Education
Office, Reception Areas
ta
PMV
as
Commercial
TYPICAL SPACES
MEASUREMENT TYPE
qa
TYPOLOGY
Note: (*) minimum QCSs requirements unless other values specified by the relevant
authority
The score values for Commercial, Light Industry Typologies
Table 3: Commercial & Light Industry Typologies
PMV
1.5 < PMV 2.0 Under the system capacity meeting the peak load
The score values for Education, Mosques Typologies

Table 4: Education, Mosques Typologies
ADPI
80 ADPI< 85 Under the system capacity meeting the peak load
QCS 2014

Part
Page 5
The score values for Health Centres Typology

Table 5: Health Centers
The Building will Comply with ASHRAE Standards- Design Manual for Hospital and Clinics
The score values for Sports Typology

Table 6: Railways Typology
a.
for office spaces (a)
for Exposed Spectator Seating (b)
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b.
1.5 < PMV 2.0 Under the system capacity meeting the peak load
PMV
1.185 < b 1.600 worest case heat load
rw
ADPI
INDOOR ENVIRONMENT [IE.2] NATURAL VENTILATION
5.3.1
Scope
The Indoor Environment for Natural Ventilation shall be measured for the following
categories of the buildings.
as
qa
ta
5.3
se

Commercial
er
Governmental
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Education
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Light Industry
Health Centres
Rail Buildings
Sports
5.3.2
Description
The Project shall encourage effective natural ventilation strategies in conjunction with
mechanically ventilated systems.
5.3.3
The Engineer shall maximize the number of days that the building can utilize natural
ventilation, either through user operable windows or through controlled opening
QCS 2014

Part
Page 6
5.3.4
Measurement (Natural Ventilation)
All projects using operable windows will complete the Natural Ventilation Calculator to
determine the number of months that all typical spaces can utilize natural ventilation by
verifying minimum fresh air supply to guarantee indoor air quality as recommended in
ASHRAE 62.1-2010. All projects using mechanical ventilation systems will demonstrate
thorough calculation and/or simulations the number of months a project can utilize natural
ventilation. Exclude all circulation areas from this measurement.
The following table outlines the typical spaces used in the calculation according to the
appropriate typology:
Table 7: Typical Spaces for Natural Ventilation
Mosques
Prayer Halls
Light Industry
Health
Centres
Office areas
qa
as
LIGHT INDUSTRY
Operational Areas associated with the industrial process are not included as
part of this criterion.
HEALTH CENTRES
All Projects will undertake a full thermal model analysisto calculate the air flow
provided by the natural ventilation to determine if each typical space can
gurantee indoor air quality as recommended in ASHRAE 62.1-2010.Circulation
areas and Clinical areas can be excluded from this calculation in line with
guidance HTM 03-01.
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(i)
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(i)
(b)
Staff areas, Library/Seminar rooms, Dining rooms
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(a)
ta
Classrooms, Libraries
rw
Office, Reception areas
Education
Typical Spaces
.l.
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Typology
M
Commercial
(ii)
Typical Spaces to be assessed against the ASHRAE Standards include: Satff

areas , Office accommodation, Library /Seminar rooms , Dining rooms .Natural
ventilation in accordance to ASHRAE must achieve fresh air rates of 5
l/s/person.
5.3.5
SCORE*
The recommended minimum Score for the QCS,s Targeted Typologies :

(*) minimum QCSs requirements unless other values specified by the relevant authority
Table 8: Commercial,Governmental,Sport, Education , Mosques,Light Industry Typologies
Number of Months Natural Ventilation Can
be Utilized
0 < months of the year 1
Table 9: For Health Centres, Rail Terminals

The Building will Comply with ASHRAE 62.1-2010 Standards- Design Manual for Hospital
and Clinics
QCS 2014

Part
Page 7
5.4
INDOOR ENVIRONMENT [IE.3] : MECHANICAL VENTILATION
5.4.1
Scope
The Indoor Environment for Mechanical Ventilation shall be measured for the following
categories of the buildings
Commercial
Governmental
.l.
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Education
Mosques
rw
Light Industry
Health Centres
qa
ta
Railways
Description
The Project shall provide effective mechanical ventilation to ensure occupant comfort and
health.
5.4.3
The Engineer shall ensure that mechanical ventilation in all primary occupancy areas meets
the minimum requirements of ASHRAE 62.1-2010 and the system requirements in ASHRAE
90.1-2010.
5.4.4
Measurement (Mechanical Ventilation)
The mechanical system shall meet the minimum requirements of ASHRAE 62.1-2010,
ASHRAE 90.1-2007. These requirements include, but are not limited to:
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5.4.2
(a)
Mechanical equipment must meet minimum Efficiency standards, and be properly

verified and labeled.
(b)
Mechanical systems must have proper control systems, including the use of zoning,
proper dead bands, off-hour controls, and automatic shut-offs.
Note: In the Calculation of the required fresh air supply, both EN-ISO and ASHRAE should
be used, and the larger of the two standards should be used in the verification of over
ventilation.
2
MEASUREMENT
(a)
LIGHT INDUSTRY
(i)
(b)
Operational Areas associated with the industrial process are not included as
part of this criterion.
RAILWAYS
This Criteria applies to both underground or overground stations.
QCS 2014

Part
Page 8
5.4.5
Score (Mechanical Ventilation)
The Recommended minimum Requirements by QCS as shown in (Table 11):

Note: (*) minimum QCSs requirements unless other values specified by the relevant
authority
Table 11: Minimum Value
Outdoor Air Volume (X)
15 % of ASHRAE 62.1-2010 requirement;

AND no existence of equipment with efficiency less than
specified in ASHRAE 90.1-2010
INDOOR ENVIRONMENT [IE.4] LOW-EMITTING MATERIALS
5.5.1
Scope
The Indoor Environment for Low-Emitting Materials shall be measured for the following
categories of the buildings.
rw
.l.
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5.5
ta
qa
Commercial
Education
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Mosques
as
Governmental
Light Industry
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Health Centers
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Railways
Sports
Description
The project shall meet the minimum emissions targets for indoor materials and finishes to
ensure the comfort and health of occupants and installers.
5.5.3
The Engineer shall choose materials and finishes that minimize Volatile Organic Compounds
(VOC) emissions.
5.5.4
Measurement (VOC)
The Engineer shall complete the Low-Emitting Materials Calculator to evaluate the measured
VOC contents of specified indoor materials.
The Engineer shall develop a plan to specify materials with low VOC emission rates as found
in the Low-Emitting Materials Calculator.
et
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5.5.2
Exclude materials used in spaces that are exposed to the exterior.

3
RAILWAYS: This Criteria applies to both underground and overground stations.
QCS 2014

Part
Page 9
5.5.5
Score (VOC)
Recommended minimum Requirements by QCS as shown in (table 6)

Table 13: VOC score value
85% < X 100 %
VOCemi,total (X)
(*) minimum QCSs requirements unless other values specified by the relevant authority
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END OF PART
QCS 2014
Section 07: Green Building

Part
06: Cultural & Economic Value
Page 1
Cultural & Economic value [ce] ................................................................................................ 2
6.1
6.1.1
6.1.2
GENERAL ................................................................................................................................ 2
SCOPE
2
REFERENCE
2
6.2
6.2.1
6.2.2
6.2.3
6.2.4
6.2.5
CULTURAL & ECONOMIC VALUE- SUPPORT OF NATIONAL gcc ECONOMY [ce.1] ....... 2
SCOPE
2
DESCRIPTION
3
3
MEASUREMENT (SUPPORT OF NATIONAL GCC ECONOMY)
3
SCORE
3
6.3
6.3.1
6.3.2
6.3.3
6.3.4
6.3.5
CULTURAL & ECONOMIC VALUE - Heritage & Cultural Identity [ce.2] ................................ 3
SCOPE
3
DESCRIPTION
4
4
MEASUREMENT (HERITAGE AND CULTUAL IDENTITY )
4
SCORE
4
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QCS 2014

Part
Page 2
CULTURAL & ECONOMIC VALUE [CE]
6.1
GENERAL
6.1.1
Scope
The Cultural and Econmic Value category consists of factors associated with cultural
conservation and support of the local economy.
Impacts: Impacts resulting from lack of cultural conservation and economic planning
include:
(i)
Loss of Cultural Identity
(ii)
Economic stagnancy or decline
Encouraging designs to align with cultural identity and traditions
(ii)
Designing for a seamless integration into the existing cultural fabric
(iii)
Planning for the use of local materials and workforce
The recommended sub-criteria Includes:

(i)
Support of National Economy
(ii)
Heritage & Cultural Identity
ta
rw
(i)
qa
(c)
Mitigate Impact: Factors that could mitigate impact include:
as
(b)
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(a)
Reference
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6.1.2
et
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GSAS (Global Sustainability Assessment System) - v 2.1-2013, Gulf Organization for

Research and development, Qatar (Note: QCS reference shall be limited only to this
particular version of GSAS and non-other), [Refer to Section 7 Part 1 for the entire list of
reference]
CULTURAL & ECONOMIC VALUE- SUPPORT OF NATIONAL GCC

ECONOMY [CE.1]
6.2.1
Scope
The Cultural & Economic Value for Support of National Economy will be measured for the
following categories of the buildings.
6.2

Commercial & Governmental
Education
Mosques
Light Industry
Health Centers
Sports
Railways
QCS 2014

Part
Page 3
Description
The Project shall maximize the percentage of construction expenditures for goods and
services originating from the national GCC economy (Gulf Cooperation Council- GCC)
6.2.3
The Engineer shall maximize the percentage of construction expenditure benefitting the
national GCC economy.
6.2.4
Measurement (Support of National GCC Economy)
The Engineer shall complete the Support of National GCC Economy Calculator to determine
the amount of construction expenditure benefitting the national economy, as a percentage of
total construction costs. Construction expenditures include, but are not limited to, the
following:
.l.
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6.2.2
Laborers/Contractors
(b)
Building Materials
(c)
Construction Materials
(d)
Construction Tools/Equipment
(e)
Temporary Facilities/Rental Spaces
as
qa
ta
rw
(a)
RAILWAYS: This criteria applies to both underground and overground stations
6.2.5
Score
The recommended minimum score by QCS for % of Construction Expenditures Benefitting

National Economy is as follows (Table 2).
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Table 2: Recomended Minimum Score for QCS Building Typologies

Expenditures
Benefitting
X 30%
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% of Construction
National Economy (X)
CULTURAL & ECONOMIC VALUE - HERITAGE & CULTURAL IDENTITY

[CE.2]
6.3.1
Scope
The Cultural & Economic Value for Heritage and Cultural Identity shall be measured for the
following categories of the buildings.
6.3

Commercial
Governmental
Education
Mosques
Health Centers
Sports
Railways
QCS 2014

Part
Page 4
Description
The Project shall encourage design expression that will align with and strengthen cultural
identity and traditions.
6.3.3
The Engineer shall develop a concept brief outlining design strategies. The Qatar Heritage
organization and/or an independent expert panel assigned by the Certification Authority will
assess the design and determine whether the project meets the goals outlined in the mission
statement.
6.3.4
Measurement (Heritage and Cultual Identity )
All projects shall develop a concept brief to demonstrate the following through drawings and
descriptions of the design strategy:
.l.
l
6.3.2
Enhancement, strengthening and reflection of cultural identity and traditions
(b)
Harmonization with cultural values of the region
rw
(a)
qa
ta
The compliance range will be defined by an Expert Heritage Panel assigned by the
Certification Authority
RAILWAYS: This criteria applies to both underground and overground stations
6.3.5
Score
as
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Table 4: Recomended Minimum Score for QCS Building Typologies
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To be defined by Certification Authority
END OF PART
QCS 2014

Part
07: Management & Operations
Page 1
MANAGEMENT & OPERATION [MO] ..................................................................................... 2
7.1
7.1.1
7.1.2
GENERAL ................................................................................................................................ 2
SCOPE
2
REFERENCE
2
7.2
7.2.1
7.2.2
7.2.3
7.2.4
MANAGEMENT & OPERATION - [MO.1] RECYCLING MANAGEMENT .............................. 3

SCOPE
3
DESCRIPTION
3
3
SCORE
3
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QCS 2014

Part
Page 2
MANAGEMENT & OPERATION [MO]
7.1
GENERAL
7.1.1
Scope
The Management and Operations Category consists of factors associated with building
design management and operations
Impacts: Environmental impacts resulting from ineffective building management and
operations include:
(i)
Climate Change
(ii)
(iii)
Water Depletion
(iv)
Materials Depletion
(v)
Land use and Contamination
(vi)
Water Pollution
(vii)
Air Pollution
(viii)
rw
ta
qa
as
Mitigate Impact: Factors that could mitigate impact include:

Creating a Commissioning plan to meet all the sustainable goals of the project
(ii)
Providing facilities for the collection ,storage ,and proper removal of organic
waste
(iii)
Providing facilities for the collection ,storage ,and proper removal of recyclables
(iv)
Providing leak detection systems
(v)
Providing energy and water use sub-metering systems
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(i)
(vi)
Providing an automated building control system to optimize building

performance
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(b)
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(a)
(vii)
Managing hospitality resources to reduce waste and support sustainable food

sources
(viii)
Promote and educate users about the sustainable initiatives of the building
(ix)
Providing a beneficial legacy to the community
7.1.2
Reference

Global Sustainability Assessment System (GSAS) - v 2.1-2013, Gulf Organization for
Research and development, Qatar (Note: QCS reference shall be limited only to this
particular version of GSAS and non-other), [Refer to Section 7 Part 1 for the entire list of
reference]
QCS 2014

Part
Page 3
7.2
MANAGEMENT & OPERATION - [MO.1] RECYCLING MANAGEMENT
7.2.1
Scope
Recycling Management shall be measured for the following categories of the buildings:
Table1: Building Typology
Commercial
Governmental
Education
Light Industry
Health Centers
.l.
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Sports
rw
Railways
Description
The Project shall encourage space planning to designate containment facilities for the
buildings recyclable waste streams in order to minimize waste taken to landfills or
incineration facilities.
7.2.3
The Project shall develop and implement a Recycling Mangement Plan for the collection,
storage, and removal of recycling.Measurement
The Engineer shall demonstrate that a central sorting and storage area is located close to a
truck loading area, and that sufficient storage has been provided for the recyclable material
produced. The sorting and storage area must be properly isolated and ventilated to reduce
negative health impacts for users and visitors on the site. Outline the collection procedures
for recyclable materials in the project to demonstrate that recyclable materials will be easily
collected and sorted. The Engineer shall also demonstrate how recyclable materials will be
handled at an off-site facility.
7.2.4
Score
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7.2.2
Table 2: Recommended minimum Requirement for QCSs Building Typologyies

Recycling Mangement Plan Shall demonstrate Compliance
End of Part
QCS 2014
Page 1
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MATERIALS [M] ....................................................................................................................... 2

SCOPE
2
REFERENCE
2
SCOPE
2
DESCRIPTION
3
3
MEASUREMENT
3
SCORE
3
8
8.1.1
8.1.2
8.2.1
8.2.2
8.2.3
8.2.4
8.2.5

Part
08: Materials
QCS 2014

Part
08: Materials
Page 2
MATERIALS [M]
8.1
GENERAL
8.1.1
Scope
The Material category consists of factors associated with material extraction, processing,
manufacturing, distribution, use/reuse, and disposal.
(ii)
Climate Change
(iii)
(iv)
Air Pollution
rw
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Material depletion
ta
Mitigate Impact: Factors that could mitigate environmental impact due to material use
include:
Using local Materials to reduce transportation needs
(ii)
Using responsibly sourced materials
(iii)
Using materials with high recycled contents
(iv)
Recycling and Reusing materials, on-and off-site
(v)
Reusing structural elements, on-and off-site
(vi)
Designing for ease of disassembly and reuse/recycling
Reference
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as
qa
(i)
8.1.2
(i)
er
(b)
Impacts: Environmental impacts resulting from material use and unsustainable

practices include:
ov
(a)
et
it
Global Sustainability Assessment System (GSAS) - V2.1 2013, Gulf Organization for
Research and Development, Qatar (Note: QCS reference shall be limited only to this
particular version of GSAS and non-other),
8.2
MATERIALS [M.1] REGIONAL MATERIALS
8.2.1
Scope
The Regional Materials shall be measured for the following categories of the buildings
Commercial
Governmental
Education
Mosques
Light Industry
Health Centres
Sports
Railways
QCS 2014

Part
08: Materials
Page 3
Description
Encourage the use of regionally manufactured and assembled building elements and
materials in order to reduce the carbon footprint of the materials
8.2.3
All projects shall use materials that are regionally manufactured and assembled
8.2.4
Measurement
All projects shall complete the Regional Materials Calculator to compute a Performance
Indicator based on the weight and sourcing distance of all applicable materials. Materials
sourcing distance can either be regional (less than or equal to 200 kilometres) or external
(over 200 kilometres). All projects will only consider materials permanently installed in the
project. Exclude mechanical, electrical, and plumbing assemblies, as well as specialty items
and equipment.
8.2.5
Score
ta
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.l.
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8.2.2
qa
Table 2: Recommended minimum Score for QCSs Building Typologies
20 X 30
as
Performance Indicator (X)
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END OF PART
QCS 2014
Section 08: Drainage Works

Part
01: General
Page 1
GENERAL ............................................................................................................... 2
1.1
1.1.1
1.1.2
1.1.3
1.1.4
1.1.5
1.1.6
1.1.7
1.1.8
SUMMARY .............................................................................................................. 2
Scope
2
References
2
Definitions
2
System Description
3
Submittals
3
Quality Assurance
5
Site in Private Lands
5
Inspection and Handover Procedure
5
1.2
1.2.1
1.2.2
TESTING OF MATERIALS ...................................................................................... 5

Materials Generally
5
100 Day Acid Test
6
1.3
1.3.1
1.3.2
1.3.3
1.3.4
1.3.5
1.3.6
IMPLEMENTATION ................................................................................................. 7
Site Information
7
Health and Safety
7
10
Inspection of Works
10
CCTV Survey
11
Compensation for Damage to Property
12
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QCS 2014

Part
01: General
Page 2
GENERAL
1.1
SUMMARY
1.1.1
Scope
This Section includes specifications for the construction and rehabilitation of sewerage,
surface water drainage and treated sewage effluent pipelines, piping, pipeline appurtenances
and sewage treatment plants.
This Part includes general requirements basic to this Section and common to its Parts.

Pipeline Cleaning and Inspection Survey
Section 1,
General
Section 5,
Concrete
Section 6,
Roadworks
Section 9,
Section 10,
Section 21,
Electrical Works.
as
qa
ta
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This Section
Part 10,
.l.
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References
Documents of the following agencies are referred to in this Section:
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1.1.2
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American National Standards Institute, ANSI

American Society for Testing and Materials, ASTM
American Water Works Association, AWWA
British Standards Institution, BS
Euro Norms, EN
Ministry of Municipal Affairs & Agriculture, Roads Department, Highway Maintenance Section
National Joint Health and Safety Committee for the Water Services, UK
International Organization for Standardization, ISO
Swedish Standards Commission, SS
Water Research Centre, WRC, UK
2
The following standards or revised/updated versions and other documents are referred to in
this Part:
BS 6100 ......................Glossary of building and civil engineering terms
BS 8010 ......................Pipelines
BS EN 752 ..................Drain and Sewer Systems outside buildings
1.1.3
Definitions
The following definitions apply generally to this Section. These and other definitions included
in this Section are based, where applicable, on BS 6100, Part 2.
(a)
Surface water: Water that flows over, or rests on, the surface of buildings, other
structures or the ground; the definition is extended to include groundwater.
QCS 2014

Part
01: General
Page 3
(b)
Sewage: Contents of a sewer that does not solely convey surface water.
(c)
Treated sewage effluent (TSE): Effluent from a sewage treatment works following
completion of treatment of sewage and disinfection of the treated sewage effluent to
attain a water quality standard suitable for reuse for selected purposes.
1.1.4
System Description
Unless otherwise specified herein or elsewhere in the Specification, designated in the Project
Specification, or directed by the Engineer, the material, equipment and systems to be
provided under this Section shall:
be capable of providing the required level of service
under the climatic conditions in Qatar as stated in Section 1
(ii)
in handling the process fluids and materials of the prevailing and indicated
(iii)
quality and quantity and variations thereof
(iv)
under the prevailing and indicated characteristics and quality of the natural and
(b)
1.1.5
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process environments and process materials
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(v)
(i)
comply with the provisions of BS EN 752, BS 8010, and BS 8301.
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(a)
Submittals
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General
The Contractor shall submit to the Engineer for approval all drawings and data including
samples, calculations, schedules, certificates and other submittals specified in Section 1, this
Section, the Project Specification, and required by variations. Submittals shall be in
accordance with the procedures specified in Section 1, in this Part and in the other Parts of
this Section.
The Contractor, shall be responsible for preparing final record drawings relating to the civil,
structural and architectural aspects of the Works. Mechanical, Electrical and ICA record
drawings shall be provided by the Contractor as required by Section 1 Part 21.
During the course of the Works, the Contractor shall maintain a detailed record of all
changes in order to facilitate accurate preparation of record drawings and to ensure that
these drawings are in all respects a true record of the installation.
The Contractor shall provide the Engineer or his nominated representative drawings and a
photocopy of each schedule correctly and neatly modified in red ink to truly represent the
Works constructed. These shall be submitted to the Engineer or his nominated
representative for approval before the contract completion date.
If any drawing is not approved, it shall be returned to the Contractor with marked indications
of the additional information required.
In addition the Contractor shall complete the Drainage Affairs Network Record Sheets in the
prescribed format but not necessarily limited to, the following Record Sheets as applicable in
both hard copy and electronic copy in a widely used Data Exchange Format (DXF) textual
(i.e. .mdb, .xls or similar approved) format. Electronic format record sheets shall be obtained
from the Engineer or his nominated representative.
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(2 b)
Pumping Station Hoist Inventory Sheet
c)
Pumping Station Motor Inventory Sheet
d) Valve Inventory
d)
Pumping Station Penstock Inventory Sheet
e) Valve Chamber Survey (3 pages)
e)
Pumping Station Data Sheet
f) TSE Pipeline Record
f)
Pumping Station Pump Inventory Sheet
g) Rising Main Record
g)
Pumping Station Shaft Inventory Sheet
h) TSE Tower Record
h)
Pumping Station Valve Inventory Sheet
i) TSE Distribution Chamber
i)
Pumping Station Ventilation Inventory Sheet
j) Overflow Pipe Record
j)
Pumping Station Fan Inventory Sheet
k) TSE/Rising Main Fittings Record
k)
Pumping Station Generator Sheet
l) House Connection Record
l)
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Record
Pumping Station Control Panel Inventory

Sheet 1
m) Pumping Station Control Panel Inventory
Sheet 2
n) Pumping Station Control Panel Inventory
Sheet 3
o) Pumping Station Actuator Sheet
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b) Discharge Chamber
pages)
c) Sewer Record
a)
PUMPING STATIONS
Pumping Station Well Inventory Sheet
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a) Manhole Record (2 pages)
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m) Pumping Station Record
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n) Gully Record
p)
Pumping Station Air Conditioner Sheet
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o) CCTV record sheet and video tape
The Contractor shall be deemed to have included all provisions within his Tender should the
above list be altered by PWA from time to time.
Individual Record Sheets shall be prepared for each length of sewer, TSE pipeline, rising
main and overflow pipe, each manhole and house and gully connection, and shall be
submitted to the Engineer or his nominated representative for approval after which they shall
become the property of the Employer.
Record sheets for pipelines (c, f, g, i, j, k, l & n above as appropriate), and record sheets for
any other work that is to be covered up, shall be presented for approval prior to covering up
the works. Backfilling will not be permitted prior to the record sheets being approved.
10
Record sheets for work of an exposed nature that can be later verified by the Engineer or his
nominated representative may be submitted up to 14 days after the work has been carried
out.
11
Photocopies of record sheets relating to work carried out since the previous valuation shall
be submitted with each interim valuation application.
12
No valuation of sections of work will be considered in the absence of completed record

sheets for the work in question.
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A Certificate of Completion will not be issued until a complete set of Record Sheets endorsed
by the Engineers Site Representative has been presented to the Engineer.
14
Blank hard copy Record Sheets, as detailed in sub-clause 6 above will be supplied by the
Engineer.
15
The Contractor shall accurately locate by co-ordinates to the Qatar National Grid, the centre
of all covers of manholes and chambers constructed under this project or to which any work
whatsoever has been undertaken under this project. The Contractor shall also locate by coordinates the position of buried bends and fittings on pressure mains. Where pipelines are
not laid to straight lines between chambers or fittings the co-ordinates of every pipe joint shall
be recorded prior to covering up the pipeline. Where flexible pipes are used coordinates
shall be at 10m intervals.
16
All Survey works shall be undertaken by Survey Company approved by Engineer.
1.1.6
Quality Assurance
Materials and products shall be furnished by approved suppliers as designated in the

Contract and Project Specifications.
Survey work for obtaining record sheet data and the compilation of the data shall be carried
out by approved prequalified surveying companies designated in the Contract or Project
Specification.
1.1.7
Site in Private Lands
The Employer will serve the necessary notices to permit pipelines to be constructed in private
land in accordance with the agreed programme of work. The Contractor shall not enter those
lands without the Engineers permission. The Contractor shall temporarily fence the Site in
private lands to the satisfaction of the Engineer and the Contractors operations shall be
confined within the fenced area. The Contractor shall use the Site for the purposes of
constructing the Works only.
1.1.8
Inspection and Handover Procedure
The inspection and handing over of the Works to the Employer shall be in accordance with
the procedure specified in Section 1, and, Clauses 1.3.4 and 1.3.5 of this Part.
1.2
TESTING OF MATERIALS
1.2.1
Materials Generally
All materials to be used in contact with sewage or its atmosphere must be shown to
withstand corrosion. In the absence of satisfactory evidence of equivalent testing results,
materials will be required to pass the 100 day acid test as detailed in Clause 1.2.2 of this
Part.
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100 Day Acid Test

General
Based on the results at 100 days, materials shall be deemed to be unsuitable for use in
contact with sewage or sewer atmosphere in the opinion of the Engineer the tested samples
fail to satisfy any of the following requirements:
withstand corrosion and in the absence of satisfactory evidence of equivalent testing results
will be required to pass successfully the 100 day acid test as detailed in this Specification.
The test shall be carried out by an approved laboratory, experienced in undertaking the test.
withstand corrosion. Such materials may be divided into two categories:
Category 1 Materials - material which serve a purpose other than protection (e.g. pipes and
pipe jointing materials)
Category 2 Materials materials which protect other (usually structural) corrodible materials
(e.g. coating to step irons, GRP manhole liners, acid resistant mortar).
Sample preparation and testing shall, as far as is possible, simulate the conditions to which
the materials will ultimately be subjected.
Samples shall be taken and prepared in a manner to be approved by the Engineer. Care
shall be taken in preparation of samples of non-homogenous materials to ensure that only
the face that will be exposed to the corrosive environment in the sewer is exposed to the acid
during the testing.
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Samples in Category I materials shall be cut from pipe/pipe joint samples selected by
the Engineer and cut ends adequately protected by a gel coat.
(b)
Samples of Category II materials shall be generally prepared by coating a corrodible

material with the protective coating to be tested.
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(a)
For each test two samples shall be prepared and indelibly marked with an identifying number.
One sample shall be partially immersed in 10% V/V sulphuric acid maintained at a
temperature of 50 C for 100 days. The concentration of acid shall be maintained by

preventing evaporation. In addition the strength of the acid shall be regularly checked and
the level and strength adjusted as necessary. The second sample shall be kept as a control.
10
The test sample shall be visually inspected at weekly intervals. Interim reports on the
condition of the sample shall be submitted to the Engineer by the laboratory following visual
inspections of the samples after 25, 50 and 75 days. Such reports shall include reference to
any changes in surface condition and colour of the samples, changes in colour of the liquid,
and any presence of any particles in the liquid.
11
If the interim report after 75 days is satisfactory the Contractor may request the Engineers
approval to use of the material prior to completion of the 100 day acid test. Such approval
shall be solely at the discretion of the Engineer, and the use of the materials shall be entirely
at the Contractors risk. Any costs associated with the replacement of such materials, should
they subsequently fail the acid test, shall be borne by the Contractor.
QCS 2014
On completion of the test period, the sample tested in sulphuric acid shall be split or the
coating removed to determine the internal condition of the sample. The final test report shall
give full details of:
(a)
The test procedure adopted.
(b)
The surface condition of the samples before, during and after testing, listing the times
at which significant changes in appearance were noted.
(c)
The internal condition of the sample.
(d)
Any changes in the solution.
Materials shall be deemed to be unsuitable for use in acid environments if the acid tested
samples fail to satisfy any of the following requirements:
Category 1 Materials - the surface of the samples shall not be significantly different in
texture from the non-immersed control sample.
(b)
Category 2 Materials -the underlying corrodible material shall not show any sign of
corrosion.
(a)
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The surfaces of the samples shall not be significantly different in texture from the nonimmersed control sample. No change in surface hardness will be permitted, and no splits,
cracks, blisters or delamination will be allowed.
1.3
IMPLEMENTATION
1.3.1
Site Information
Notwithstanding any relevant information included or referred to in the Project Specification

or furnished by the Engineer, the Contractor shall be responsible for obtaining his own
information on ground and subsoil conditions at the Site and the locations of all pipelines and
services within or near the Site.
The Contractor shall complete a services information sheet for each section of the Works
and shall submit the completed sheet for the Engineers approval at least seven days before
work is due to begin on that section. Work shall not begin on that section until the respective
services information sheet has been approved by the Engineer.
Blank services information sheets will be provided by the Engineer.
1.3.2
Health and Safety
The requirements of this Clause are pursuant to or in addition to the health and safety
requirements in Section 1 and Section 11. Safety requirements in relation to specific classes
of work are specified in other Parts of this Section.
The recommendations contained in Working with Sewage The Health Hazards Pbulished
by the Health & Safety Executive http://www.hse.gov.uk/pubns/indg198.htm shall be
adhered to in respect of all work to be carried out in operational sewers, pumping stations
and sewage treatment works.
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Arrangements shall be made with Drainage Operation and Maintenance Department, Public
Works Authority before entering in or working on existing sewers and associated works. A
Permit to Work must be obtained from Asset Affairs Drainage Operations and Maintenance
Department prior to any works taking place .
The Contractors attention is drawn to the hazards involved in working in confined spaces
including sewers, manholes, inspection chambers, wet wells, pumping stations and ancillary
structures. The Contractor shall be responsible for ensuring that adequate precautions are
taken to ensure safe working conditions as well as the availability of safe tools and facilities.
The Contractor shall issue his risk assessment to the Engineer for his approval prior to
applying for a Permit to Work at the site. This risk assessment shall meet but not be limited
to the requirements of this Part of this Section.
The Contractor shall appoint a Safety Officer who shall be suitably qualified and experienced.
The Contractor shall ensure that the Safety Officer is available on Site during the mobilisation
period and thereafter to train the Contractors personnel in safety operations. The work shall
not proceed unless such training has been accomplished to the Engineers approval.
The Safety Officers main responsibilities shall be to
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ensure that all the Contractors employees follow the agreed safety procedures
(b)
ensure that all employees are supplied with the appropriate safety/protective
equipment and that it is used and maintained as per agreed procedures
(c)
assist in carrying out of refresher safety training courses for working in confined
spaces
(d)
investigate all accidents and dangerous occurrences, and where applicable, submit
reports recommending actions to be taken to prevent a recurrence.
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(a)
The Contractor shall provide and erect approved safety barriers around all unattended open
manholes and trenches. All manholes shall be covered with suitable temporary steel sheets.
Advance warning notice road signs shall be erected at least 50 m either side of areas where
work is in progress.
The need for adequate protection to the general public in the vicinity of the Works is
stressed.
Care must be exercised when working in or near live sewers, and tests must be made to
verify that no hydrogen sulphide or other toxic gases are present, before anyone enters an
existing manhole or confined space.
10
Particular attention is drawn to the dangers of poisoning, asphyxiation or explosion while

working in, or near, or inspecting pipelines, manholes, chambers, treatment units, pumping
stations, or any confined space. In this connection the Contractor must obtain appropriate
safety equipment and acquaint all personnel with the dangers involved, and precautions to be
taken, and shall regularly discuss with the Engineer's Representative the sufficiency of safety
precautions on site.
11
The following minimum precautions must be taken before entry into a manhole, chamber or
other confined space:
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(a)
Sufficient numbers of covers of manholes or chambers upstream and downstream of

the entry point shall be removed to ensure adequate ventilation.
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Page 9
The manhole or confined space must be thoroughly ventilated by mechanical air

blower prior to entry.
(c)
Before entering the confined space the atmosphere shall be checked for the presence
of toxic gases, flammable gases, and oxygen level.
(d)
The mechanical air blower must be kept close by the manhole or confined space that
has been entered.
(e)
No naked lights, matches or lighters shall be used in a sewer or in close proximity to

an open manhole or chamber. All equipment shall be intrinsically safe.
(f)
The hydrogen sulphide level in the manhole or confined space must be continually
monitored. If the level rises the manhole or confined space must be evacuated
immediately.
(g)
All persons entering a manhole or confined space must wear a safety harness properly
rigged to the lifting frame.
(h)
At least two top men must be available to operate the air blower and lifting tackle in the
event of an emergency. The top men shall keep in touch with the men in the sewer,
manhole, chamber or confined space by calling or signalling to them at frequent
intervals. No person shall enter the confined space alone.
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(b)
Before entering any confined space, the atmosphere shall be checked for the presence of
toxic gases, flammable gases and oxygen level. The Contractor shall have on site in working
order, sufficient calibrated gas monitors to continually monitor the atmosphere in all confined
spaces and in all areas adjacent to sewage where men are working.
13
The Contractor will not be permitted to work in manholes, pipelines, or pumping stations if
such gas monitors are not in use.
14
The following equipment is to be made available throughout the Contract at each and every
entry point to a confined space.
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15
1 No.
1 No.
1 No.
1 No.
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Safety Harness (not a safety belt) and ropes

Lifting frame and tackle for safety harness
Gas monitor
Mechanical air blower with compressor and generator
Gas monitors shall incorporate the following features:

(a)
(a) Continuous monitoring of oxygen level, with visual and audible high and low level
alarms.
(b)
(b) Continuous electrochemical monitoring of Hydrogen Sulphide with indication of the

gas concentration, and audible and visual alarms under the following conditions:
(c)
(i)
Time weighted average providing 8 hours exposure at the threshold limit value.
(ii)
Time weighted average providing 10 minutes of exposure at short term

exposure limit, or ceiling value.
(iii)
Exposures to ten times the threshold limit value.
(c) Continual monitoring for flammable gas at intervals not exceeding 2 minutes.
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Page 10
1.3.3
The following requirements are pursuant to or in addition to the requirements in Section 1.

The Contractor shall locate, by co-ordinates to the Qatar National Grid, the locations of the
elements of the Works. Pipelines shall be located by the position of the centre of manholes
and chamber covers. Pressure pipelines shall be located by the position of bends and fittings.
The execution of surveys, recording of data and preparation of record sheets shall comply
with the following requirements:
surveys shall be based on Qatar National Grid survey control points
(b)
co-ordinates shall be located to within 0.1 m
(c)
co-ordinates shall be determined by radial (polar) observations using theodolite and

electronic distance measuring (EDM) equipment. The co-ordinates shall be checked
by independent methods and the error shown to be within acceptable limits
(d)
if required, additional temporary control points may be established as follows:
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(a)
observations for additional temporary control points shall consist of at least two
(ii)
rounds of angles (on two faces) with a different zero setting for each round.
(iii)
where applicable, distances shall be determined by trigonometric methods and
(iv)
at least two rounds of vertical angles (on two faces) shall be observed.
(v)
positions of additional temporary control points shall be determined by
(vi)
reference to not less than three Qatar National Grid survey control points and
shall be proven to have standard errors of not more than 0.08 m.
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(i)
On completion of work, all observations, computations, sketches and any other

documentation used in determining the co-ordinates shall be submitted to the Engineer. A
daily log giving the number of additional control stations and manholes surveyed shall be
maintained and submitted. A comprehensive report on the work carried out including
methods used, problems encountered, solutions used and a full summary of the results shall
be submitted.
The Engineers approval of the setting out shall be obtained before work on each element
commences.
The Contractor shall be deemed to have included all provisions within his tender for the
topographical survey information which should include: - features (fittings), manhole
chamber co-ordinates/levels in a widely used Data Exchange Format (DXF), accurate
positional survey drawings (i.e. either.DWG or.DXF) layout files together with equally widely
used DXF textural (i.e. xls, .txt or similar approved).
1.3.4
Inspection of Works
The Contractor shall provide a safe and convenient means of access to the Works to enable
the Engineers inspections to be carried out.
The Contractor shall submit to the Engineer notice of work requiring inspection on a
completed Notice of Inspection Required form not less than 24 hours before requiring
inspection of those works. Blank forms will be provided by the Engineer.
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Requests for inspection by the Engineer shall be submitted for the following:
setting out
(b)
formation level of excavation
(c)
pipelaying, bedding and testing
(d)
base slabs
(e)
manhole precast chamber rings in place before internal linings and external coatings
are applied
(f)
manhole concrete surround
(g)
formwork and reinforcing steel before concreting
(h)
before backfilling of permanent Works
(i)
before reinstatement
(j)
any other constructional operation that the Engineer may require.
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Works covered up or in any way made unavailable for inspection before the submission of
the Notice of Inspection Required form or the Engineers approval to proceed shall be
uncovered at the Contractors expense.
Prior to inspection, the Contractor shall submit his Quality Control plan (QC plan) / Inspection
and Test Plan (ITP) in accordance with Section 1 Clause 7.6.3.
1.3.5
CCTV Survey
The Contractor shall on written instruction of the Engineer undertake a CCTV survey on
designated lengths of pipelines laid during the execution of the Works, including pipeline
cleaning where necessary and submission of a Survey Report, as part of the final inspection
of the Works.
The Certificate of Completion for the Works or part thereof shall not be issued until the CCTV
Survey, including provision of the Survey Report, and any subsequent sewer remedial works
have been completed to the satisfaction of the Engineer.
Should any length of the surveyed between adjacent manholes, or the manholes indicate
failure to comply with the requirements of the Contract, the whole cost of any pipeline
cleaning, the CCTV Survey, Survey Report and any subsequent remedial works carried out
to the satisfaction of the Engineer shall be borne by the Contractor.
The CCTV Survey shall be carried out by an approved specialist subcontractor designated in
the Project Specification. The subcontractor shall provide suitable documentation to verify
previous experience in undertaking CCTV Surveys to the satisfaction of the Engineer.
Pipeline cleaning and CCTV surveys and reporting shall be carried out as specified in Part 10
of this Section.
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1.3.6
Compensation for Damage to Property
Before commencing any work on site, the Contractor shall undertake an extensive condition
survey of all properties adjacent to the proposed works. A detailed report including sketch
plans, schedules of defects and photographs shall be submitted to the Engineer for
agreement.
The Contractor shall not mark boundary walls to properties in any way whether deliberately
for identification purposes or accidentally. All markings, howsoever caused, shall be repaired
and repainted. Sufficient area of wall shall be repainted to avoid a patchy appearance.
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END OF PART
QCS 2014

Part
10: Pipeline Cleaning and Inspection Survey
Page 1
10
PIPELINE CLEANING AND INSPECTION SURVEY .................................... 2
10.1
GENERAL ...................................................................................................... 2
10.1.1
10.1.2
10.1.3
10.1.4
10.1.5
10.1.6
10.1.7
Scope
References
Submittals
Specialist Subcontractor
Programme of Work
Topographic Survey of Sewers
Safety Requirements
10.2
SEWER CLEANING ...................................................................................... 6
10.2.1
10.2.2
10.2.3
10.2.4
10.2.5
10.2.6
10.2.7
Scope
Cleaning of Sewer Pipelines
Jetting
Winching
Bucketing
Balling or Kiting and Pipeline Internal Gauging
General Cleanliness of Areas during Sewer Cleaning
10.3
SEWER INSPECTION - CCTV SURVEY AND SONAR SCANNING .......... 10
10.3.1
10.3.2
10.3.3
10.3.4
10.3.5
10.3.6
10.3.7
10.3.8
Scope of Work
Survey Requirements
Survey Equipment
Survey Vehicle
Photographs
Site Coding Sheets
Excavation
Survey Reporting
10.4
OVERPUMPING AND FLOW DIVERSION ................................................. 16
10.4.1
10.4.2
10.4.3
10.4.4
10.4.5
10.4.6
10.4.7
10.4.8
10.4.9
Source of Flow
Pipe Stoppers
Stopping Off Flow
Pumping Plant
Sewage Flooding
Overpumping of Flow
Temporary Diversion of Flow
Entrances to Private Properties
Odour and Noise Control During Flow Diversion and Overpumping
10.5
CONTRACTORS QUALITY CONTROL PROCEDURE .............................. 18
6
7
8
9
9
9
9
10
10
11
13
14
14
15
15
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2
2
3
3
4
4
16
17
17
17
17
18
18
18
18
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PIPELINE CLEANING AND INSPECTION SURVEY
10.1
GENERAL
10.1.1
Scope
This Part includes the specification for all work necessary to clean and carry out inspection
surveys of sewerage pipelines. The specification applies equally to the cleaning and
inspection survey of surface water and ground water pipelines.
Section 1,
General.
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General
Earthworks
Pipe Installation
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This Section
Part 1,
Part 2,
Part 4,
Part 11,
10
References
The following document is referred to in this Part:
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10.1.2
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Water Research Centre (WRC) Manual of Sewer Condition Classification

Water Research Centre (WRC) Sewer Rehabilitation Manual
Submittals
The Contractor shall submit complete data and details for pipelines cleaning and inspection
survey for the Engineers approval as follows:
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10.1.3
programme of work, detailed method statement, and schedule of equipment to be

used on the project, general plant and specialist equipment
(b)
proposed methods of flow diversion and overpumping
(c)
specific data for the proposed specialist equipment before beginning any sewer
cleaning and inspection as follows:
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(a)
original catalogues for all the proposed specialist equipment, which complying
with the Specifications. These catalogues shall be considered as an integral
part of the Contractors method statement. All equipment to be provided for
sewer cleaning and closed circuit television (CCTV) survey and sonar scanning
shall be reliable and in good working condition
(ii)
typical video recordings preferably on CD ROM of similar work carried out

previously by CCTV camera and sonar scanner. Such recordings, if acceptable,
will be retained by the Engineer as the standard for appraisal of subsequent
recordings
(iii)
video graphic printer
(iv)
still pictures in digital format (Tiff, JPEG) for computer data storage and
(i)
retrieving
(d)
specific data to be submitted while carrying out and at the completion of the work:
(i)
site coding sheets as designated under Clause 10.3.6 in this Part
QCS 2014
Page 3
(ii)
the master and a copy of each video recording as designated in Clause 10.3.2 in
this Part
(iii)
still colour pictures using video graphic printer of the inside of sewers,
manholes, inspection chambers, and grease and oil interceptors, and the
interior of pumping stations as required and as specified in Clause 10.3.5 of
this Part.
The Contractor shall submit a method statement to the Engineer for approval four weeks in
advance of commencing activity on site. The method statement shall comprise but not
necessarily be limited to:
Equipment set-up and locations of proposed access points
(b)
Anticipated cut off periods for services
(c)
Procedures for notifying affected residences and businesses
(d)
Procedures for verification of active services
(e)
Procedures for complying with traffic control
(f)
Procedures for seeking permits to work.
(g)
Safety procedures in particular working with scaffolding and entering confined spaces.
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(a)
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Part
The Contractor shall employ an approved specialist subcontractor designated in the contract
document.
The Contractor shall provide the following information on sewer cleaning and inspection
survey contracts carried out by the proposed subcontractor during the last five years:
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10.1.4
project location
(b)
name and address of client
(c)
start and completion dates
(d)
cost of the works undertaken by the subcontractor
(e)
length, diameter and material of sewers
(f)
reference letter from the client or engineer
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a sample document of the reports produced for at least two projects.
(g)
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(a)
All operators employed by the subcontractor shall be fully skilled in the specified works.
The operator for interpreting the video recordings and preparing the site coding sheets shall
be fully conversant with picture interpretation, defect coding and classification. A copy of the
operators current certificate of qualification for sewer surveys and fault classification issued
by Water Training International of the U.K. or an equivalent body for the types of sewers to be
inspected shall be submitted to the Engineer for approval before beginning the survey. If the
Engineer determines that the Operators qualifications and experience are not acceptable,
the Contractor shall provide an acceptable replacement before beginning the survey.
10.1.5
Programme of Work
The sewage pipelines may be frequently surcharged and ready access to them may not be
available. The Contractor shall make due allowance for such disruptions in his programming
of operations. The Contractor shall cause minimum disruption to the utilisation of the
pipelines and the period of overpumping shall be kept to the minimum necessary. Before
starting the cleaning and inspection survey in any sewer length, the Contractor shall submit
an applications to CED Drainage Division O & M Section for a permit to work in the sewers.
QCS 2014

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Page 4
Topographic Survey of Sewers
A topographic survey of the pipelines to be cleaned shall be carried out by the Contractor and
a schedule provided to the Engineer. Some manhole covers may be buried under
landscaping, debris, or the surface of roads, footpaths, or other pavements. These manholes
shall be located by the Contractor on the basis of the Employers record drawings using
appropriate techniques and apparatus. The topographic survey of the sewer system shall
include resurveying where affected by any rehabilitation works on completion of the sewer
cleaning and inspection surveys as directed by the Engineer.
The survey shall include details of manholes, chambers, and oil and grease interceptors
including topographic levels of covers and inverts, locations and co-ordinates.
The Contractor shall locate accurately and survey all junctions and lateral connections into
manholes, or directly into sewers, whether or not the existence or location of such junctions
and lateral connections are shown on the Employers record drawings.
The Contractor shall survey the original ground surface, taking levels at 50 m intervals or as
directed by the Engineer along the route of the sewer, determine existing pipe diameters and
invert levels, and the details shall be recorded in a schedule to the Engineers approval.
These details shall, when finally and mutually agreed, be signed by the Contractor and
authorized by Engineer as truly representing the configuration of the particular areas.
10.1.7
Safety Requirements
The Contractors attention is drawn to the hazards involved in working in confined spaces
including sewers, sewer manholes, inspection chambers, wet wells, pumping stations and
ancillary structures. The Contractor shall be responsible for ensuring that adequate
precautions are taken to ensure safe working conditions.
The Contractor shall give evidence of having carried out training in avoiding the following
risks associated with working in confined spaces in sewerage pipelines:
presence of toxic, flammable and explosive gases
(b)
persons falling
(c)
falling objects
(d)
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(e)
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10.1.6
Training shall include the following:

(a)
definition of confined spaces
(b)
atmospheric hazards
(c)
purpose and practical use of gas monitoring equipment
(d)
practical use and maintenance of safety equipment such as breathing apparatus,

safety harnesses, life lines and lifting frames
(e)
personal protective equipment such as hard hats, gloves and safety boots
(f)
health hazards
(g)
hygiene procedures
(h)
basic first aid procedures
(i)
pre-entry procedure
(j)
entry procedure
QCS 2014

Part
(k)
exit procedure
(l)
rescue procedure.
Page 5
All training courses shall involve both class room instruction and hands-on practical training
which should include both entry and rescue drills.
Safety and Protective Equipment. The Contractor shall safeguard his work force against
physical injury caused by falling or being struck by falling objects. Precautions shall include,
but are not limited to, the provision of the following equipment for each person working in
confined spaces:
(a)
safety helmet with chin guard
(b)
safety boots
(c)
safety harness
(d)
PVC gloves/gauntlets
(e)
overalls
(f)
rubber boots
(g)
ear, eye, and face protection, where applicable.
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In addition to the above, each gang working in a confined space shall have with them:
four sets of 15 m life lines with spring shackle one end, eye at other
(b)
portable ladder
(c)
lifting frame complete with ropes and shackles for hand operation
(d)
powerful hand lamp, explosion proof (intrinsically safe)
(e)
ventilation blower together with portable generator and flexible ducting
(f)
position pressure respiration face masks with associated portable compressor or air
line system supplying air via compressed cylinders
(g)
gas detectors capable of detecting both high and low oxygen, hydrogen sulphide and
methane gas explosion proof (intrinsically safe).
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All safety and protection equipment shall be regularly maintained and inspected by a
competent person. Gas monitors shall be calibrated in accordance with the manufacturers
recommendations and a certificate issued with the date of calibration.
Each group of workers engaged in working in sewers, manholes, pumping stations and
ancillary structures shall be provided with, and shall be familiar with the operation of gas
testing equipment suitable for checking hydrogen sulphide, combustible gases, and lack of
oxygen. Before entering confined spaces the atmosphere within such spaces shall be tested
and certified as safe for entry by the responsible person to ensure that there is no build up of
hydrogen sulphide or combustible gases, nor lack of oxygen. When working in sewers where
accumulation of sludge or silt exists, the Contractor's attention is drawn to the fact that, when
disturbed, sludge may release toxic gases. Adequate ventilation facilities shall be provided
and continuous monitoring shall be made while work is in progress in live sewers or
structures containing sludge or silt.
Should anyone working in a confined space complain of nausea or dizziness, all personnel
shall be removed from that location immediately. Work may resume only when it is certified
safe to do so, using breathing apparatus if necessary.
QCS 2014
Page 6
The Contractor shall safeguard his work force against health hazards while working in sewers
and inform his work force of the dangers of bacterial infection while working in a sewage
contaminated environment, and shall impress upon them the importance of personal
hygiene. All members of the work force shall be fit, and everyone who will be expected to
work in sewers shall not suffer from:
(a)
Any heart defect.
(b)
Any history of fits or blackouts.
(c)
Deafness or loss of balance.
(d)
Claustrophobia.
(e)
Recurrent back ailments.
(f)
Shortage of breath on light exertion.

Part
All members of the work force shall be vaccinated against tetanus, typhoid, paratyphoid,
hepatitis A and B and cholera, and shall each carry an up-to-date medical record on their
person. The Contractor shall provide a medical certificate of fitness for all his personnel.
11
The Contractor shall keep personal hygiene and emergency equipment within easy access of
each working group. Emergency equipment which shall include but not be limited to:
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Barrier cream.
(b)
Disinfectant.
(c)
First-aid kit with eye bath.
(d)
Stretcher.
(e)
Life lines 15 m long with spring shackle one end, eye at other.
(f)
Lifting harnesses.
(g)
Two sets of breathing apparatus with air bottle.
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(a)
The address and telephone number of the nearest hospital with emergency facilities shall be
posted in each working location.
13
The Contractor shall be solely responsible for liability for any claim or legal action arising as a
result of an accident and shall not be absolved of any liability under the Contract for his
having conformed to the above requirements.
14
The Contractor shall provide and erect approved safety barriers around all unattended open
manholes and cover them with suitable temporary steel sheets. Advance warning notice road
signs shall be erected at least 50 m in front and behind the area being worked in one day. At
the end of each day works all manhole covers shall be replaced.
10.2
SEWER CLEANING
10.2.1
Scope
The cleaning of sewer pipelines and appurtenances includes but is not limited to the following
elements:
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(a)
location of manholes and chambers using suitable detection techniques and removal
of overburden where necessary
(b)
cleaning of manholes and chambers with either or both water jetting or wire brushing
or other means approved by the Engineer
(c)
removal of any grit and debris from manhole bases and benching
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Page 7
(d)
providing cutoff walls and overpumping where necessary
(e)
water jetting including vacuum suction of debris
(f)
bucket and winch dredging, balling, kiting, pipeline internal gauging, or any other
cleaning process as approved by the Engineer
(g)
flushing with water
(h)
removal of all sand, grit and debris jetted or dredged from the sewers and disposal of
same to a disposal site required by the Engineer
(i)
controlling of odour and nuisance arising out of rehabilitation works, flow diversion or
overpumping.
Cleaning of Sewer Pipelines
Cleaning of sewers and manholes before inspection surveys shall include one or more of the
above operations. The Contractor should note that pipelines, manholes, may have structural
defects cracks etc., and may have been completely filled with sand, grit, sediment and other
debris and the requirement to accurately measure the vertical inside diameter of the sewer
necessitates that the invert of the sewer to be free of all sediment. The Contractor shall allow
for the removal of all such material and disposal of same to a disposal site approved by the
Engineer. Cleaning of sewers shall progress downstream.
Sewer cleaning shall be thorough and shall only be carried out by methods approved by the
Engineer to remove all deposits, foreign matter, solid or semi-solid and hard intruding
material and all other debris including sand, silt, slime, sludge, sediment, grease, roots, loose
flaky or soft pipe wall materials, loose concrete from walls and underside of cover slabs and
benching of manholes from within sewers and manholes. The liquid biological element of the
sludge may be returned to the sewer system after suitable filtering methods to be agreed with
the Engineer.
Where cast iron junction pieces have been used, the Contractor shall ream out or grind off
the corrosion products to produce a pipe of diameter equal to the adjacent pipes. Care shall
be taken to grind off all burrs which may otherwise puncture in-situ lining tubes during
subsequent renovation works.
Pump station wells shall be cleaned where necessary to permit pipeline cleaning.
The designated sewer/manhole sections shall be cleaned using hydraulically propelled, highvelocity jet, or mechanically powered equipment. The equipment and methods selected shall
be satisfactory to the Engineer. The equipment shall be capable of removing dirt, grease,
rocks, sand, and other materials and obstructions from the sewer lines and manholes. If
cleaning of an entire section cannot be successfully performed from one manhole, the
equipment shall be set up on the other manhole and cleaning again attempted. If, again,
successful cleaning cannot be performed or the equipment fails to traverse the entire
manhole section, it will be assumed that a major blockage exists and the cleaning effort shall
be temporarily abandoned until further notification by the Engineer.
If the Contractors cleaning equipment becomes lodged in a sewer it shall be removed by the
Contractor at his own expense. This shall include excavation, repair of sewer, backfill and
surface restoration.
All sludge, dirt, sand, rocks, grease, and other solid or semi-solid material resulting from the
cleaning operation shall be removed at the downstream manhole of the section being
cleaned. Passing material from manhole section to manhole section, which could cause line
stoppages, accumulations of sand in wet wells, or damage pumping equipment, shall not be
permitted.
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10.2.2
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Page 8
Roots shall be removed in the designated sections where root intrusion is a problem. Special
attention should be used during the cleaning operation to assure almost complete removal of
roots from the joints. Procedures may include the use of mechanical equipment such as
rodding machines, bucket machines and winches using root cutters and porcupines, and
equipment such as high-velocity jet cleaners.
All solids or semi-solids resulting from the cleaning operations shall be removed from the site
and disposed of at an approved off-site disposal facility. All materials shall be removed from
the site no less often than at the end of each workday. Under no circumstances will the
Contractor be allowed to accumulate debris, etc., on the site of work beyond the stated time,
except in totally enclosed containers and as approved by the Engineer.
10
Acceptance of sewer line cleaning shall be made upon the successful completion of the
television inspection and shall be to the satisfaction of the Engineer. If CCTV inspection
shows the cleaning to be unsatisfactory, the Contractor shall be required to reclean and
reinspect the sewer line until the cleaning is shown to be satisfactory.
10.2.3
Jetting
Jetting shall be carried out using motorised jetting vehicles specially designed for the work
involved and complete with an integral water tank. Jetting shall be carried out at an
appropriate water pressure such that no damage to pipes occurs. The jetting pump shall
have the capability to vary the water pressure at the jetting nozzle and be equipped with a
sufficient length of suitable armoured bore hose and jetting heads to accommodate all
possible working conditions and pipe size in the sewer system. Jetting pressure to be
Brackish water shall not be used for cleaning. Treated sewage effluent may be used subject
to the approval of the Engineer.
The hose shall be mounted on a power operated drum reel having variable speed and
direction controls and a meterage indicator. The hose shall be equipped with a variety of
nozzles totalling 15 to 30 including rear jets only, rear plus forward jets, rear plus side jets,
and other such configurations necessary to ensure adequate cleaning of the pipeline.
Manhole jacks and hose guide rollers shall be used to prevent damage to the hose.
During all jetting operations the channel of the downstream sewer manhole shall be provided
with a cut off wall and all decumulated grit and debris shall be removed.
Hydraulically propelled equipment shall be of a movable dam type and be constructed in such
a way that a portion of the dam may be collapsed at any time during the cleaning operation to
protect against flooding of the sewer. The movable dam shall be the same diameter as the
pipe being cleaned and shall provide a flexible scraper around the outer periphery to ensure
removal of grease. Sewer cleaning balls or other equipment which cannot be collapsed shall
not be used.
Mechanically powered rodding machines shall be either a sectional or continuous rod type
capable of holding a minimum of 200 m of rod. The rod shall be specifically heat-treated
steel. To ensure safe operation, the machine shall be fully enclosed and have an automatic
safety clutch or relief valve. Buckets, scrapers, scooters, porcupines, brushes and other
mechanical equipment may also be utilised.
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Page 9
All equipment and devices shall be operated by experienced personnel so that sewer lines
are not damaged in the process of cleaning. When hydraulically propelled tools (which
depend upon water pressure to provide their cleaning force), or tools which retard the flow in
the sewer line are used, all necessary precautions shall be taken to ensure that the water
pressure created does not damage or cause flooding of property being served by the sewer.
When possible, the flow of sewage in the sewer shall be utilised to provide the necessary
pressure for hydraulic cleaning devices. When additional water from water mains is
necessary to avoid delay in normal work procedures, the water shall be conserved and not
used unnecessarily.
10.2.4
Winching
The jetting machine shall incorporate a power-driven cable drum having not less than 200 m
of 13 mm steel cable. The cable drum shall be mounted on an A-frame, fixed to the vehicle
or trailer high enough off the ground to allow the bucket to be lifted above ground level. The
backpull machine shall incorporate a power-driven cable drum with not less than 200 m of
nylon rope or light steel cable. The working machine shall have a swinging arm fixed to the
top of the A-frame. The swinging arm shall be capable of lifting the bucket clear of the ground
and rotating it away from the manhole for emptying. A chute with rollers and a shaker bar
may be used subject to the approval of the Engineer.
10.2.5
Bucketing
A range of bucket sizes shall be provided to suit the various pipe diameters. The buckets
shall be cylindrical in cross-section with bails at each end having centre eye lugs and shall be
of the clam shell type with the bottom made of two hinged halves such that when the bucket
is pulled in the reverse direction, bottom first, the jaws open permitting debris to pass
through. When the bucket is pulled forward the jaws shall close, thereby retaining any
material in the bucket or which subsequently enters. Both ends of the bucket shall be able to
dig into and scrape sediments and debris from the sewer invert.
10.2.6
Balling or Kiting and Pipeline Internal Gauging
Balls shall be of inflatable rubber or other material approved by the Engineer having an
outside spiral thread and a swivel connection. With a hydraulic head differential of
approximately 0.6 m, the ball shall rotate rapidly and produce a scouring jet on its periphery.
Suitable cable or rope shall be attached to the swivel connection fed from a cable drum
mounted on an A-frame complete with braking facilities. A manhole jack and cable guide
roller shall be used to feed the cable into the sewer. If the flow in the sewer is insufficient to
produce adequate scouring velocity, the Contractor shall provide the additional supply of
water to overcome the deficiency.
Kites may be used as an alternative to balls for sewers 600 mm diameter and above.
Pipeline internal gauges shall not be used unless attached to lines in both upstream and
downstream manholes.
During all balling, kiting or gauging operations, the channel of the downstream manhole shall
be provided with a cut off wall and accumulated debris removed.
Sewer cleaning balls or other equipment which cannot be collapsed shall not be used.
10.2.7
General Cleanliness of Areas during Sewer Cleaning
The Contractor shall take all necessary precautions to ensure that during the sewer cleaning
operations there is no spillage of sewage and debris onto the streets and other areas. When
spillage occurs, the Contractor shall immediately remove all spillage and clean all surfaces to
their original condition.
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Page 10
10.3
SEWER INSPECTION - CCTV SURVEY AND SONAR SCANNING
10.3.1
Scope of Work
CCTV survey and sonar scanning shall be carried out only after satisfactory cleaning of the
pipeline as specified in Clause 10.2 of this Part. The CCTV survey and sonar scanning shall
include but not be limited to:
Production of colour video tape recording on compact disc (CD) and coding.
(b)
Accurate profiling of the cross-section of sewers and measurement of deflections.
(c)
Still colour pictures from a video graphic printer of the inside of sewers and manholes,
inspection chambers and grease and oil interceptors, as directed by the Engineer.
(d)
Recording the complete survey on a computer database in accordance with WRC

Manual of Sewer Condition Classification.
(e)
Pictures to be printed in a digital format (Tiff) for computer data storage and retrieval.
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(a)
Survey Requirements
The rate of travel of the camera shall be such as to enable all details to be extracted from the
video tape recording.
The axis of the camera shall be arranged to coincide with the centreline of the pipe.
The picture transmitted by the CCTV scanning camera (a scanning camera which can view
lateral connections to sewers) and sonar scanner shall be free from interference and loss of
vertical and horizontal hold. The picture shall be in focus, properly illuminated, of good
contrast and without distortion. If vision is obscured at any time by the fouling of the lens, or
lighting system, or if travel is impeded by obstructions, the camera shall be withdrawn and the
defect rectified immediately.
The Contractor shall record the complete survey on a video tape format conforming with the
recording equipment manufacturers specification. The recording shall provide a continuous
display of data on the monitor screen comprising the following information:
automatic update of camera meterage
(c)
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10.3.2
(d)
gradient of sewer
(e)
nominal diameter of sewer and the actual measured horizontal, vertical and diagonal
diameters at close intervals as directed by the Engineer
(f)
manhole/pipe type length reference number
(g)
sewer use
(h)
time of start of survey
(i)
location reference.
date, day, month and year

direction of survey - upstream or downstream
(b)
The video recording shall be stopped whenever the camera is stationary for more than
5 seconds and shall have manual override capability.
The completeness of the video tapes shall be an accurate record of the sewer system which
identifies and locates sewer defects, provides information that permits accurate analysis of
the cause, extent, nature and severity of sewer deterioration and the measurement of
horizontal, vertical and diagonal diameters of sewer and their locations.
QCS 2014

Part
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Portions of video tape marred by interference, or otherwise unacceptable shall be erased and
the relevant portion of sewer shall be resurveyed and rerecorded. The Engineers decision as
to the acceptability of any video recording shall be final.
Still colour photographs as designated under Clause 10.3.5.
The photographic negatives, the master video tapes, and a copy of the video tapes shall be
handed over to the Engineer and shall become the property of the Employer.
10
If a self-propelled camera is used, it shall incorporate features to enable it to be winch drawn

without affecting the quality of the video recording.
11
The location of any conditions that may result in a limitation of rehabilitation techniques that
could be used and/or prevent proper installation of designated rehabilitation materials in the
pipelines shall be noted. The Contractor shall propose corrective measures and/or alternative
methods of rehabilitation for the approval of the Engineer.
10.3.3
Survey Equipment
The CCTV survey and sonar scanning equipment shall be modern and of advanced design
and shall be tested and calibrated immediately before beginning work. The equipment shall
be tested as designated herein by the manufacturers or an approved independent test
laboratory at intervals of not more than 6 months. Original certificates of compliance with the
specifications of this Part shall be submitted to the Engineer before beginning work. The
equipment shall include but not limited to the following:
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CCTV camera and sonar scanner suitable for mounting on the same trolley as and
when required
(b)
colour TV camera with swivel, lift and radial device and able to focus on points of
interest
(c)
camera light head assembly with sufficient illumination for the diameter of sewer
pipes
(d)
camera wheeled/tracked crawler assembly, self-propelled/flexible-shaft driven and

remotely operated with forward, reverse, left, right stop and load indication
(e)
cable reel of minimum 200 m cable length with fully automatic and microprocessor
controlled cable handling facility
(g)
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(a)
(h)
colour TV monitor
(i)
high-resolution scanning device including high speed pipe profiler and software to
interpret the signals
(j)
video cassette recording system with audio video information system
(k)
all standard and optional accessories recommended by the manufacturers.
power winch with either lockable or ratcheted drums

CCTV/Sonar central control units
(f)
The picture quality of the camera shall be tested using the Marconi Resolution Chart No. 1 or
equivalent clearly defined with no tinting to show white, yellow, cyan, green, magenta, red,
blue and black.
The quality of the CCTV electronics, camera and monitor shall be such that the following
criteria are satisfied and if any of the criteria are not met during the survey the lengths of
sewer so affected shall be resurveyed at the Contractors expense:
(a)
Shades of Grey. The grey scale shall show equal changes in brightness ranging from
black to white with a minimum of five stages
QCS 2014

Part
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(b)
Colour. With the monitor control adjusted for correct saturation, the six colours plus
black and white shall be resolved with the primary and complementary colours in
order of decreasing luminance. The grey scale shall appear in contrasting shades of
grey with no tint
(c)
Linearity. The background grid shall show squares of equal size, without
convergence or divergence over the whole picture. The centre circle shall appear
round and have the correct height/width ratio within 5 %
(d)
Resolution. The live picture shall be clearly visible with no interference and capable
of registering a minimum number of TV lines/picture height lines. The resolution shall
be checked with the monitor colour control turned down. For tube type cameras this
shall be 350 lines and for CCD type cameras it shall be 250 lines
(e)
Colour Consistency. The colour on the live picture and that on the video picture shall
be consistent with that described for the Marconi Resolution Chart No. 1.
The camera shall be capable of taking clear pictures in any direction; i.e., 90 to the left and
90 to the right (total 180 in horizontal axis) and also 360 in the circumference of the pipe
without using extra revolving mirror attachment.
The camera shall continuously transmit distance at each meter length, electronically matched
to the movement of the camera with a maximum tolerance of 0.1 % on the control TV
monitor and the resultant video tapes.
The camera shall indicate the degree of inclination of the sewer line with tolerance of 0.2 %
on the TV monitor with a printout of the slope.
The camera crawler assembly shall be adjustable for deployment in sewers of varying
diameters. When required, both sonar scanning and CCTV equipment shall be mounted on
the same crawler assembly.
The video tape recording of the transmission for CCTV and Sonar scanning units shall be
provided to accurately record on video tapes, of quality approved by the Engineer. In the
central control unit, the operator shall have remote facilities to control the camera, the cable
drum and power winch.
Each unit shall carry sufficient number of guides and rollers to ensure that, when surveying all
bonds are supported away from pipe and manhole structures and all CCTV cables and lines
used to measure the cameras location within the sewer are maintained in a taut manner and
set at right angles, where possible, to run through or over the measuring equipment.
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At the start of each and every working shift, the camera shall be positioned centrally and at
right angles to the test card at a distance where the full test card just fills the monitor screen,
ensuring that the edges of the test card castellation coincide with the edges of the horizontal
and vertical scan (raster). The card shall be illuminated evenly and uniformly without any
reflection. The illumination shall be to the same colour temperature as the colour
temperature of the lighting that will be used on the CCTV survey equipment in the pipe. The
test shall be recorded for subsequent use by the Engineer, the recording time to be at least
30 seconds. The type of camera used is to be identified on the test recording. The recording
must show the camera being introduced into the test device and reaching its stop position.
Other test devices may be used subject to approval by the Engineer.
11
The Contractor shall note that the Engineer may periodically check both the live and recorded
picture colour consistency against the colour bar. Any differences will necessitate re-survey
of the lengths affected at the Contractors expense.
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The adjustment of focus and iris shall allow optimum picture quality to be achieved and shall
be remotely operated. The adjustment of focus and iris shall provide a minimum focal range
from 50mm in front of the cameras lens to infinity. The distance along the pipe in focus from
the initial point of observation shall be a minimum of twice the vertical height of the pipe. The
illumination must be such as to allow an even distribution of the light around the pipe
perimeter without the loss of contrast, flare out of picture or shadowing.
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Where the CCTV survey equipment is towed by winch and bond through the pipe, all winches
shall be stable with either lockable or ratcheted drums. All bonds shall be steel or of an
equally non-elastic material to ensure the smooth and steady progress of the CCTV survey
equipment. All winches shall be inherently stable under loaded conditions.
10.3.4
Survey Vehicle
The CCTV and sonar scanning vehicles shall be equipped with the following three separate
compartments:
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drivers cabin
(b)
operator and viewers compartment (seating for minimum three persons)
(c)
Camera and sonar scanner equipment storage compartment.
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(a)
The operator and viewers compartment shall be insulated against noise and extremes in
temperature and be provided with means of controlling external and internal sources of light
in a manner capable of ensuring that the monitor screen display complies with the specified
requirements.
The equipment storage compartment shall have adequate space for equipment, both
operational and stored. Equipment used in sewers shall not be stored in compartment.
The vehicle shall be equipped with air-conditioner for the drivers cabin and the operators
room. A wireless communication system between the operator inside the vehicle and the
helper outside the vehicle shall be provided.
The vehicle shall be complete with all equipment and apparatus necessary to carry out a
complete sewer inspection survey. Colour monitors, a sonar processor unit, replay and onboard reporting, video recorders, video printers, computers and computer printers to
generate survey reports and data base shall be provided. The operator/viewers compartment
shall be designed for optimum productivity.
The vehicle shall be equipped with the following road safety equipment:
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(a)
a minimum of two amber regulation flashing beacons fixed at diagonal corners of the
vehicle, which shall operate continuously while the vehicle is stationary on the
highway in a working situation
(b)
traffic signs and cones, which shall be displayed in accordance with the
recommendations of the Traffic Police Section, with a minimum of:
(c)
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(i)
four reflective boards: Arrow
(ii)
two reflective boards: Men Working (in English and Arabic)
(iii)
two reflective boards: Road Narrows (in English and Arabic)
(iv)
20 reflective cones
(v)
12 battery operated flashing road lamps.
a sufficient number of bright coloured overalls with fluorescent over-jackets or belts,

which shall be worn by all operatives while working on roads.
Relevant safety equipment specified in Clause 10.1.7 shall be made available.
QCS 2014

Part
Page 14
10.3.5
Photographs
After sewer cleaning and in parallel with the CCTV inspection, excellent quality still colour
photographs 90 mm x 130 mm with the date and submitted in TIFF format an album with
captions providing a detailed description, the precise location and reference numbers as
designated shall be taken of:
the inside the sewer to show the typical conditions for each length of sewer. A
minimum of three photographs per manhole length shall be taken at every junction
piece, faulty joint, broken pipe, and other points of interest as directed by the
Engineer
(b)
the interior of each manhole, chamber and grease/oil trap. A minimum of three
photographs shall be taken of each structure showing the general extent of corrosion
to the structures walls, bases, benching and the underside of cover slabs as directed
by the Engineer
(a)
Photographs shall be taken of the internal condition of the pipes at the beginning of a defect,
at service connections and such other places as the Engineer shall direct. Where defects
exist at adjacent points, photographs should not be taken at intervals of less than 2m unless
absolutely necessary to show the second defect. Where photographs are not otherwise
required, a general condition photograph shall be taken at every l0m.
Photographs must clearly and accurately show what is displayed on the monitor which shall
be in proper adjustment.
Photographs shall be clearly identified in relation to the location (minimum requirement

manhole start and finish numbers or pipe length reference numbers) survey direction,
chainage, photograph number, and date when the photograph was taken. The annotation
shall be clearly visible and in contrast to its background, shall have a figure size no greater
than 5mm, and be type printed. The annotation shall be so positioned as not to interfere with
the subject of the photograph.
Hard copy of the photographs shall be supplied in suitable A4 sized plastic holders and
bound in ring binders or lever arch files. The photographs shall be presented in chronological
order and each file shall contain a contents page providing clear cross-referencing to the
report. The minimum requirements of the contents page shall be locations (district, street
name and road number), photograph numbers and dates when photographs were taken.
10.3.6
Site Coding Sheets
Site coding sheets detailing the condition of each pipe length and manhole shall be
completed in the format of the WRC Manual of Sewer Condition Classification and as
approved by the Engineer. These sheets shall be submitted to the Engineer with the video
tape to which they refer. A draft copy of the coding sheets shall be submitted weekly to the
Engineer for his approval. When requested by the Engineer, more frequent reports of
selected parameters shall be submitted.
The site coding sheets shall be standardised to the approval of the Engineer to indicate the
following minimum requirements:
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(a)
location reference to sewer length concerned
(b)
nominal diameter of sewer
(c)
actual measured horizontal, vertical and diagonal diameters of sewer and their
locations, as a continuous computer printout at close intervals and as directed by the
Engineer
(d)
date of survey
(e)
direction of survey
QCS 2014
(f)
time of start of survey
(g)
sewer gradient
(h)
trial hole records
(i)
coded reference to any defects encountered
(j)
location of defects
(k)
location of any junctions or laterals encountered
(l)
location of any still photographs taken.
Page 15
In addition to the final report and any interim reports on a section of the pipe as defined
above, the Contractor shall provide the Engineer with the following:
(a)
One copy of the completed survey report coding forms at the end of each working
shift.
(b)
One copy of sheets containing the pipe reference number, distance, orientation and
deflection measurements of the pipes surveyed at the end of each working shift.
(c)
One copy of photographs and recordings on a weekly basis as the work progresses or
as previously agreed with the Engineer in writing.
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Part
Excavation
When directed by the Engineer, the Contractor shall excavate and expose sections of sewer
for examination.
The Contractor shall carry out such excavations expeditiously and shall break or expose the
sewer section upon removal from the trench for detailed physical examination and testing.
Excavations shall be carried out in accordance with Part 2 of this Section.
When directed by the Engineer, the Contractor shall reinstall the sewer section or replace the
sewer section with new pipe of same size and material in a manner to completely conform to
the original installation and shall backfill, compact and reinstate the excavation in accordance
with Part 4 of this Section.
10.3.8
Survey Reporting
The Contractor shall complete the CCTV survey and sonar scanning in appropriate lengths
as directed by the Engineer before handing over the records for that line. All records for a
particular length shall be handed over at one time unless directed otherwise by the Engineer
and all recordings on one tape shall be of the same length. The report shall include the
following, all as designated herein:
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10.3.7
(a)
site coding sheets
(b)
correctly labelled video tapes of approximately one hour duration
(c)
pictures on compact discs in a digital format (Tiff)
The report shall be completed using a computer based database with software that shall be
fully compatible with the Oracle database used by the Ministry of Municipal Affairs &
Agricultures ARC INFO GIS system and approved by the Engineer. One copy on a 3.5 inch
diskettes of all computer generated data shall be provided with the report. Four copies of
draft report shall be submitted for Engineers approval followed by final report incorporating
appropriate responses to the Engineers comments.
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Part
Page 16
The Contractor shall enter the information obtained from the survey into a computer
database in accordance with the WRC manual of sewer classification which shall allow for
the storage, retrieval and analysis of this information. Furthermore the database shall link the
survey information with an electronic drawing of the pipeline which shall allow the viewing of
still images representative of the major problems identified by the survey.
The Contractor shall supply 2 copies of each recording in CD format.
The condition survey report shall include the following:

Pipe condition classification in accordance with the WRC format.
(b)
Manhole/pipe length reference numbers.
(c)
Date of survey.
(d)
Road name/location.
(e)
Direction of survey.
(f)
Time of start of survey.
(g)
Weather conditions.
(h)
Pipe dimensions.
(i)
Materials of construction.
(j)
Depth of flow.
(k)
Profiling of pipe cross sections to give a complete circumferential profile and

deflections within the pipe.
(l)
Clock position of all connections including meterage from manhole.
(m)
Whether or not connections are dry and running.
(n)
Location and description of obstructions, structural defects, missing pieces of pipe,

open and/or offset joints, ovality, leakage or evidence thereof, corrosion, erosion,
break-in connections, protruding connections, mineral deposits, roots, previous
repairs, sags and other abnormalities with respect to the pipelines condition with
counter distance in metres from the start manholes centreline.
(o)
Photographs as specified herein.
(p)
Recommendations, including options and alternative methods to extend the service life
by a further 50 years by lining, replacement or other refurbishment.
Estimated cost and programme for carrying out the recommendations.
(q)
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(a)
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If the Engineer requires separate survey reports for any section of the survey or requires
some or all of the section to be grouped together in a single survey report he shall notify the
Contractor accordingly.
10.4
OVERPUMPING AND FLOW DIVERSION
10.4.1
Source of Flow
Manholes and sewers being worked on shall be completely isolated and by-passed such that
they do not contain any sewage. This shall be achieved by plugging, pumping and bypassing
or diverting the flow.
When flow in a sewer line is plugged, pumped and bypassed or diverted sufficient
precautions must be taken to protect the sewer lines from damage that might result from
sewer surcharging. Further, precautions must be taken to ensure that sewer flow control
operations do not cause flooding or damage to public or private property being served by the
sewers involved.
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Part
Page 17
The Contractor shall submit his proposed method of overpumping or flow diversion to the
The Contractor shall co-ordinate and agree all his activities on live facilities with the Drainage
Affairs Maintenance Department staff responsible for upkeep of the drainage system. A
signed Permit to Work shall be obtained from Maintenance Department prior to the
commencing the work.
10.4.2
Pipe Stoppers
The flow shall be stopped off using pipe stoppers of a type approved by the Engineer. The
stopper shall be of circumferential compressible rubber rings fully inserted inside the pipe
before tightening. Inflatable type stoppers for sewers less than 300 mm diameter shall be of
a type approved by the Engineer.
Stoppers shall be suitable for the sizes and classes of pipe in which they are used and must
not cause damage to existing pipes. Stoppers must be able to withstand the maximum
possible differential head at each location and shall be fully restrained in accordance with the
The Contractor shall be solely responsible for maintaining such stoppers in good working
condition and for the consequences of any failure thereof.
Where a section of the sewerage system is isolated for work involving man-entry to the
isolated area, a minimum of two stoppers shall be used at each boundary location isolating
the area from the main sewer and subsidiary sewers. At least one of these stoppers at each
location should be of an approved pneumatic type.
10.4.3
Stopping Off Flow
For the length of sewer being surveyed, the Contractor shall plug off the outlet of the
downstream manhole and the inlet to the upstream manhole. The next upstream manhole
shall be used as a pumping sump with the outlet to that manhole also being plugged off.
All service connections discharging into the plugged off sewer shall be satisfactorily isolated
the overpumping system shall be provided to the approval of the Engineer.
Interruption of service will not be permitted.
10.4.4
Pumping Plant
Overpumping shall be carried out using suitable mobile pump sets of adequate capacity and
head to the approval of the Engineer.
The Contractor shall provide sufficient number of standby pumps of adequate capacity.
Where required by the Engineer, a temporary sump shall be provided to prevent surcharging
of upstream sewers.
The pumps shall be controlled by suitable level controls installed to operate at levels to be
approved by the Engineer and shall be capable of dealing with the flow in the sewer and any
material likely to be transported in it without being blocked.
10.4.5
Sewage Flooding
Full-time attendance with mobile phone facilities shall be provided by the Contractor at each
pumping location such that in the event of mechanical breakdown, flooding or blockage,
immediate assistance will be summoned.
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Part
Page 18
Overpumping of Flow
Pumped sewage flows shall be discharged to a manhole downstream of the sewer length
being cleaned or surveyed. The open end of the pump delivery pipe shall be laid in order to
minimise turbulence of the pumped flow. No sewage shall be dumped onto any surfaces
outside the sewer system.
The pump delivery pipe shall be of suitable armoured material which in all locations subject to
traffic flow shall be suitably protected with preformed steel plates bridging the pipe or by other
means approved by the Engineer. Such protection shall be adequate to allow passage of
vehicular traffic over the pipe.
10.4.7
Temporary Diversion of Flow
Where temporary sewer diversion is required the Contractor shall notify the Engineer
accordingly and submit his proposals for implementation of such diversion.
The Contractor shall obtain all other permissions and approvals from relevant authorities
prior to commencement of such diversion. On completion of temporary diversionary works
the temporary pipelines shall be removed or be adequately sealed and inlet and outlet
manholes reinstated to their original condition.
10.4.8
Entrances to Private Properties
The Contractor shall not cause any obstruction to the access of private properties. If the
obstructions are unavoidable, the Contractor shall provide and maintain in good order
alternative access to the approval of the Engineer.
10.4.9
Odour and Noise Control During Flow Diversion and Overpumping
The Contractor shall take necessary precautions for controlling odour and noise with
prescribed limits approved by the Engineer and for preventing nuisance and inconvenience to
the local residents and the public during the flow diversion and overpumping operations.
The Contractor shall include in his method statement, the measures to be taken for noise
and odour control.
The Contractor shall provide special measures to prevent the odour release to the approval
of the Engineer.
The Contractor shall install temporary chemical dosing system to contain the odour release if
other measures fail.
For odour control, the measurement of hydrogen sulphide shall not be more than 1 ppm
measured at a distance of 1m from the point of discharge to the adjacent property.
10.5
CONTRACTORS QUALITY CONTROL PROCEDURE
The Contractor shall operate a quality control system, to be approved by the Engineer, which
will effectively gauge the accuracy and consistency of the CCTV survey report produced by
the operator from the monitor picture.
The system shall be such that the accuracy of reporting should be a function particularly of:
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10.4.6
(a)
The number of faults not recorded (omissions).
(b)
The correctness of the coding and classification of each fault recorded.
The minimum levels of accuracy to be attained shall be as follows:
QCS 2014

Part
(a)
Header accuracy
95%
(b)
Detail accuracy
85%
(c)
Lowest acceptable tolerance
Page 19
75%
The Engineer shall be entitled in accordance with Section 1 Part 8 and this section to audit
periodically the control system and be present when assessments are being computed.
When requested by the Engineer, the Contractor shall forward to the Engineer sufficient
details and information for this audit assessment.
Should any report fail to achieve the specified percentages for a particular pipe length, the
Engineer shall require the Contractor to re-code and re-submit the report. If the accuracy
check fails, the Contractor shall repeat the full quality control check on 10 surveys, 5 surveys
either side of the survey which has failed. If any further failures are found to be outside the
tolerances laid down above within these additional checks, the process will be repeated until
an acceptable standard is reached. Any reports that have failed will be re-coded by another
qualified surveyor and submitted to the Engineer to replace those in his possession.
Quality selection is achieved by using two parameters:
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Population - the anticipated number of surveys carried out by one surveyor over a
period of time (normally I year).
(b)
Sample size - the number of surveys required to be checked to satisfy the quality
control validity.
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(a)
The sample surveys for quality control are to be selected by the use of computer generated
random numbers (ERNI) or other such equivalent method and shall be 5% of the total
population. Each surveyor shall have a different set of random numbers, which are sorted
into chronological order, and are renewed once the population size has been reached. The
random numbers shall not be disclosed to the surveyor until they have been used up.
On site the surveyor logs certain information on the surveys being carried out and in the order
in which they are surveyed.
10
The in-office staff then count, through the surveys that have taken place and copy those
reports that coincide with the random numbers.
11
Copy of the relevant section of the recording shall also be made available.
12
Information on the recording and its contents are entered on a survey selection log.
13
Header information - All header information shall be checked to ensure that left and right
justified entries are correctly entered, alpha or numeric symbols are correctly used and all
compulsory boxes filled in. The percentage of accurate entries shall be ascertained and any
that fall below the value specified shall be rejected. All decimal percentage points shall be
rounded down to the nearest whole number.
14
Detail information - Each error/omission is treated on an equal basis whether or not it is a

minor or major error or omission. During the checking each error/omission is highlighted on
the report from which the following totals are calculated for each survey report:
15
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(a)
The number of actual entries that should have been made.
(b)
The number of actual errors/omissions made.
These totals are entered on the right of the survey report being checked. Individual column
totals are also calculated and entered on to the survey accuracy log.
QCS 2014

Part
Page 20
16
The accuracy of each survey is arrived at by taking the number of actual errors/omissions
away from the number of actual entries that should have been made and dividing the result
by the number of actual entries that should have been made and multiplying by 100 to create
a percentage.
17
This percentage is entered on the survey detail rating form.
18
The ongoing accuracy of the surveyor (the confidence level) is calculated by taking the
mean of 5 percentage results (each 5 representing one control unit).
19
Both the individual survey percentages and the mean results are entered onto the surveyors
accuracy graph which has two boundaries:
Specified mean - the level of accuracy expected.
(b)
Specified tolerance - the level to which the accuracy can fall before specific action is
taken.
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END OF PART
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Any surveyor whose quality control results fall below the specified mean on more than 2
occasions or the specified tolerance at any time shall be deemed to have failed his quality
control criteria and shall be invalidated from acting as a team leader on this Contract until he
has attended and passed an approved course for pipe condition classification.
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(a)
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Part
11: Sewer Rehabilitation
Page 1
11
SEWER REHABILITATION ........................................................................... 3
11.1
GENERAL ...................................................................................................... 3
11.1.1
11.1.2
11.1.3
11.1.4
11.1.5
11.1.6
Scope
References
Definitions
Submittals
Quality Assurance
Warranty
11.2
11.2.1
11.2.2
11.2.3
11.2.4
11.2.5
Work Programme Review, Cleaning, Inspection

Safety
Preparation for Installation of Linings
Annulus Grout
11.3
SEALING OF PIPES AND MANHOLES ...................................................... 11
11.3.1
11.3.2
11.3.3
11.3.4
Scope
Sealing Compounds
Joint Sealing of Pipes
Sealing of Manholes
11.4
SLIPLINING OF SEWERS .......................................................................... 15
11
11
12
14
15
15
16
18
18
19
CURED-IN-PLACE LINER INSTALLATION (INVERSION METHOD) ......... 20
11.6.1 Scope
11.6.2 Materials
11.6.3 Installation of Cured-In-Place Liner
11.7
9
9
9
11
11
DEFORMED PIPE LINER INSTALLATION ................................................. 18
11.5.1 Scope
11.5.2 Materials
11.5.3 Installation
11.6
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11.4.1 General
11.4.2 Materials
11.4.3 Installation of Sliplining
11.5
3
3
5
6
8
9
20
21
22
SPIRAL WOUND PROFILE LINER ............................................................. 23
11.7.1 Scope
11.7.2 Materials
11.7.3 Installation of Spiral Wound Profile Liner
23
23
25
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Part
Page 2
11.8
PIPE CRACKING OR BURSTING ............................................................... 26
11.8.1
11.8.2
11.8.3
11.8.4
11.8.5
Scope
General
Materials
Installation Equipment
Installation
11.9
INSPECTION AND TESTING OF PIPE LINES AFTER

REHABILITATION ....................................................................................... 29
11.10
MANHOLE REHABILITATION..................................................................... 30
26
26
26
27
27
30
30
30
31
31
31
32
MANHOLE LINING ...................................................................................... 32
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11.11.1 Scope
11.11.2 Materials
11.11.3 Installation of Lining
11.11.4 Inspection and Testing
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11.11
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11.10.1 Scope
11.10.2 General
11.10.3 Materials
11.10.4 Rehabilitation of Manhole Walls and Bases
11.10.5 Rehabilitation of Manhole Shafts and Slabs
11.10.6 Manhole Cover, Frame and Sealing Plate Reinstallation or
Replacement
32
32
32
33
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Part
Page 3
11
SEWER REHABILITATION
11.1
GENERAL
11.1.1
Scope
This Part includes the specifications for all work necessary to rehabilitate sewers, manholes
and chambers including, but not limited to:
(b)
manhole rehabilitation
(c)
manhole lining
(d)
sliplining of sewers
(e)
deformed pipe lining
(f)
cured-in-place pipe (inversion method)
(g)
spiral wound profile liner
(h)
pipe cracking or bursting.
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General
Earthworks
Metal Works
Painting and Protective Coatings
Sewer Cleaning and Inspection Survey
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This Section
Part 1
Part 2
Part 4
Part 6
Part 7
Part 8
Part 10
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sealing of sewers and manholes
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(a)
References
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11.1.2
ASTM C923 M ............Specification for Resilient Connectors Between Reinforced Concrete

Manhole Structures Pipes and Laterals [Metric]
ASTM D543 ................Resistance of Plastics to Chemical Reagents
ASTM D618 ................Methods of Conditioning Plastics and Electrical Insulating Materials
ASTM D638 ................Standard test method for tensile properties of plastics.
ASTM D746 ................Standard test method for brittleness temperature of plastics and
elastomers by impact.
ASTM D790 ................Standard Test Methods for Flexural Properties of Unreinforced and
Reinforced Plastics and Electrical Insulating Materials
ASTM D883 ................Definition of Terms Relating to Plastics
ASTM D991 ................Standard test method for rubber property-volume resistivity of
electrically conductive and antistatic products.
ASTM D1238 ..............Standard test method for melt flow rates of thermoplastics by extrusion
plastometer.
QCS 2014

Part
Page 4
ASTM D1248 ..............Specification for Polyethylene Plastics Moulding and Extrusion

Materials
ASTM D1505 .............Standard test method for density of plastics by the density gradient
technique.
ASTM D1525 ..............Standard test method for Vicat softening temperature of plastics.
ASTM D1600 ..............Abbreviations of Terms Relating to Plastic Pipes
ASTM D1693 ..............Test for Environmental Stress-Cracking of Ethylene Plastics
ASTM D1784 ..............Specification for Rigid PVC Compounds and Chlorinated PVC (CPVC)
Compounds
ASTM D2122 ..............Method for Determining Dimensions of Thermosetting Pipe and
Fittings by Acetone Immersion
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ASTM D2152 ..............Test Method for Degree of Fusion of Extruded PVC Pipe and Moulded
Fittings by Acetone Immersion
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ASTM D2240 ..............Standard test method for rubber property-Durometer hardness.
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ASTM D2412 ..............Test Method for Determination of External Loading Characteristics of

Plastic Pipe by Parallel-Plate Loading
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ASTM D2444 ..............Test Method for Impact Resistance of Thermoplastic Pipe and Fittings
by means of a Tup (Falling Weight)
ASTM D2657 ..............Practice for Heat-Joining Polyolefin Pipe and Fittings
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ASTM D2837 ..............Obtaining Hydrostatic Design Basis for Thermoplastic Pipe Materials
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ASTM D3035 ..............Specification for Polyethylene (PE) Plastics Pipe (SDR-PR) Based on
Controlled Outside Diameter
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ASTM D3350 ..............Specification for Polyethylene Plastics Pipe and Fittings Materials
ASTM D3753 ..............Specification for Glass-Fiber-Reinforced Polyester Manholes
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ASTM D4703 ..............Standard practice for compression moulding thermoplastic materials

into test specimens, plaques or sheets.
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ASTM F412 ................Definitions of Terms Relating to Plastic Piping Systems

ASTM F477 ................Specification for Elastomeric Seals for Joining Plastic Pipe
ASTM F585 ................Practice for Insertion of Flexible Polyethylene Pipe into Existing
Sewers
ASTM F714 ................Specification for Polyethylene (PE) Plastic Pipe (SDR-PR) Based on
Outside Diameter
ASTM F1216 ..............Rehabilitation of Existing Pipelines and Conduits by the Inversion and
Curing of a Resin-Impregnated Tube
ASTM F1248 ..............Standard test method for determination of environmental stress crack
resistance (ESCR)of polyethylene pipe.
ASTM F1533 ..............Standard specification for polyethylene (PE) pipe
ASTM F1606 ..............Standard practice for rehabilitation of existing sewers and conduits
with deformed polyethylene (PE) liner.
ASTM F1697 ..............Standard specification for poly (vinyl chloride) (PVC) profile strip for
machine spiral-wound liner pipe rehabilitation of existing sewers and
conduits
QCS 2014

Part
Page 5
ASTM F1698 ..............Installation of Poly (Vinyl Chloride) (PVC) Profile Strip Liner and
Cementitious Grout of Rehabilitation of Existing Man-Entry Sewers
and Conduits
ASTM F1741 ..............Standard practice for installation of machine spiral wound poly (vinyl
chloride) (PVC) liner pipe for rehabilitation of existing sewers and
conduits.
ASTM F794 ................PVC Large Diameter Ribbed Gravity Sewer Pipe and Fittings based on
Controlled Inside Diameter
BS 2494......................Materials for elastomeric seals for joints in pipework and pipelines
BS 4346......................Joints and fittings with unplasticized PVC pressure pipes
BS 5556......................Specifications for general requirements for dimensions and pressure
ratings for pipes of thermoplastic materials
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BS 5955......................Code of practice for plastic pipe work
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BS 8010......................Pipelines
BS EN 752..................Sewerage
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BS EN 1401................Plastic piping systems
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BS EN 13244..............Polyethylene pipes (type 50) in metric diameter for general purposes
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BS EN 1852-1 ............Plastic piping system for non-pressure underground drainage and

sewerage polypropylene (PP)
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CP 312, ......................Plastic pipe work
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ISO 161 ......................Thermoplastic Pipes for the Transport of Fluids Nominal Outside
Diameters and Nominal Pressures
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ISO 9000 ....................Quality Systems

ISO 9967 ....................Method for Determination of Long Term Ring Stiffness
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WRc ...........................Sewer Rehabilitation Manual
Definitions
The following terms have the meanings hereby assigned to them except where the Contract
clearly renders these meanings inapplicable:
11.1.3
(a)
Sliplining: insertion of a new liner pipe into an existing pipeline of larger diameter
followed by grouting of the annulus.
(b)
Cured-in-place, inversion, in-situ or soft lining: the creation of a new pipe within an
existing pipeline by insertion of a resin impregrated polyester felt liner by inversion
under pressure lining inversion under pressure, the liner then being cured in-situ.
(c)
Spiral wound profile lining: insertion of helically wound, profile walled thermoplastic
sections to form a liner, followed by grouting of the annulus.
(d)
Deformed pipe lining: a continuous deformed pipe which reverts to its predeformed
shape after installation.
QCS 2014

Part
Page 6
(e)
Pipe cracking or bursting: replacement of an existing pipeline between manholes or

inspection chambers or a combination thereof with a new pipe of equivalent or
greater size whereby the new pipe is inserted behind the pipe breaking machine as
fragments of the existing pipe are displaced to the sides.
(f)
Length of sewer: length of sewer pipe between two consecutive manholes or

inspection chambers.
(g)
Service connection: the connection of the property sewer with the main sewer pipeline.
11.1.4
Submittals
The Contractor shall submit complete data and details of sewer rehabilitation for the
Engineers approval as follows:
name and experience of specialist subcontractor
(b)
a programme of work, detailed method statement, and schedule of plant to be used in

the Works, detailing the working practices, and specialist equipment.
(c)
proposed method of overpumping or flow diversion as applicable to undertake sewer

rehabilitation.
(d)
specific data for proposed materials and equipment for the Engineers approval 14
days prior to commencement of any sewer rehabilitation works as follows:
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(a)
test certificates and technical literature to show that the sealants, liners, and
lining systems materials proposed meet the requirements stated in the
specifications
(ii)
original catalogues specific to the requirement for all proposed equipment. All
equipment shall be suitable and made of such materials to withstand the
prevailing climatic conditions of Qatar and the corrosive environment.
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Specific data to be submitted while carrying out and at the completion of the work:
records of sealing of sewers in each length of sewer, including joint sealing
verification results
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(e)
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(i)
(ii)
(f)
CCTV video tapes, pictures in digital format (TIFF) and site coding sheets
prepared in accordance with Part 10 of this Section showing the initial condition
and the completed work including the restored condition.
The Contractor shall submit to the Engineer following data for 15 sewer rehabilitation
projects carried out by the proposed subcontractor during the last five years:
(i)
project location
(ii)
name and address of client
(iii)
start and completion dates
(iv)
cost of the works
(v)
length, diameter and material of pre-rehabilitated sewers
(vi)
length, diameter and liner material for each type of rehabilitation system
(vii)
reference letter from the client or the engineer.
QCS 2014
Page 7
The Contractor shall submit the following data to supplement (d) of this sub-clause:
Manufacturers name.
(ii)
Suppliers name.
(iii)
Installers name (Subcontractor)
(iv)
Product name (if applicable).
(v)
Product description.
(vi)
Manufacturers technical data.
(vii)
Test results or certificates.
(viii)
Checked and approved liner pipe thickness design and stiffness calculations.
(ix)
Storage instructions.
(x)
Installation instructions.
(xi)
Installation records in the same project area
(xii)
Proposed grout mixture where applicable.
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(i)
Manhole and joint sealing materials and manhole rehabilitation materials

Manufacturers name.
(ii)
Suppliers name.
(iii)
Installer name (Subcontractor)
(iv)
Product name (if applicable).
(v)
Product description.
(vi)
Manufacturers technical data.
(vii)
Test results or certificates.
(viii)
Storage instructions.
(ix)
Application instructions.
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(b)
Sewer Liner
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(a)

Part
The Contractor shall submit method statements to the Engineer for approval 4 weeks in
advance of commencing the site activity. These shall comprise but not necessarily be limited
to:
(a)
Sewage bypass pumping and/or diversion plan which shall include an emergency
response plan to be followed in the event of a failure of the bypass pumping and/or
diversion plan.
(b)
Detailed construction plan including:

(i)
Equipment set-up and locations of proposed access points.
(ii)
Anticipated cut off periods for services.
(iii)
Procedures for verification of active service connections.
(iv)
Procedures for notifying affected residences and businesses.
(v)
Procedures for complying with traffic control.
(vi)
Procedures to be adopted to obtain permits to work from the Drainage Affairs.
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(vii)
Safety procedures in particular working with scaffolding, entering confined

spaces and operations with hot media.
(viii)
Sewer cleaning procedures.
(ix)
Liner installation procedures.
(x)
Procedures for sealing annular space between liner pipe and host pipe where
applicable.
(xi)
Methods of sealing any annular space between liner pipe and host pipe at
manholes.
(xii)
Procedures for manhole liner-pipe liner joint sealing.
(xiii)
Procedures for manhole rehabilitation.
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Liner insertion locations.
(b)
Sewage bypass pumping and/or diversion locations.
(c)
Liner end sealing at manholes and GRP lamination to manhole wall and benching
liners.
(d)
Any required modification to existing manholes.
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(a)
Representative samples, as agreed with the Engineer, must be submitted for at least the
following items before work commences.
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The Contractor shall submit drawings to the Engineer for approval in advance of
commencing the site activity. These shall comprise but not necessarily be limited to:
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(xiv) Procedure for any required modifications (temporary or permanent) to existing

manholes (such as widening of access opening, removal of cover slabs,
removal of intermediate landings, ladders, removal of manholes benching etc).
Proposed liner system.
(b)
Liner to host pipe sealing materials.
(c)
Manhole rehabilitation materials.
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(d)
(a)
Manhole liner to pipe liner sealing materials.
Quality Assurance
The system shall be design to comply with the appropriate provisions of BS 2782, BS 3412,
BS 5556, BS EN 752 and BS 8010.
The Contractor shall employ approved prequalified specialist subcontractors designated in

the Project Specification.
The specialist subcontractor shall conduct this work in accordance with the quality
management procedures conforming to ISO 9000.
Key operators employed of the subcontractor shall be competent in the relevant sewer
rehabilitation methods and techniques.
11.1.5
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Warranty
The Contractor shall provide the Engineer with a seven year unconditional warranty against
failure of all GRP manhole linings whether caused by defective materials or workmanship.
The warranty shall be valid from the date of completion of the installation and submitted to
the Engineer as a precondition to the issuance of the Certificate of Completion.
11.2
11.2.1
Work Programme Review, Cleaning, Inspection
When designated in the Project Specification, the Contractor shall allow in his programme of
work for the requirement that he shall work at many locations at any one time. However, at
least one team shall be fully engaged on each length of sewer, and shall finish all
rehabilitation works required on that length of sewer including manholes and chambers
before beginning work on a new length of sewer.
The Contractor shall provide methods statements for each of the rehabilitation methods and
systems he proposes to use for each of the functional requirements designated in the Project
Specification.
As cleaning and inspection work proceeds, the Contractor shall submit weekly sewer and
manhole condition reports to the Engineer. In the reports, the Contractor shall include his
confirmation that his proposed method of rehabilitation meets the required performance
criteria. Should the originally proposed method not meets the performance requirements for
lengths of sewer, or manholes, the Contractor shall submit his proposals to meet the
performance requirements for such lengths of sewers or manholes to the Engineer for
approval.
The Engineer and the Contractor shall agree on the locations and systems to be used for
rehabilitation if necessary, and if necessary the Contractor shall review and revise his
programme of work and submit to the Engineer for approval. The Engineers approval shall
not relieve the Contractor of his obligations under the Contract.
Sewer cleaning, inspection and overpumping work shall be satisfactorily completed before
undertaking sewer rehabilitation.
11.2.2
Safety
The Contractor shall carry out all operations in accordance with the safety requirements
specified in Section 1 and Part 10 of this Section.
11.2.3
Preparation for Installation of Linings
The following installation procedures shall be adhered to unless approved otherwise by the
Engineer:
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11.1.6
(a)
before installing lining in sewers the Contractor shall ensure that the sewers are clean
of debris in accordance with Part 10 of this Section. Sewers shall also be gauged to
ensure that they can accommodate the liners.
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the Contractor shall inspect by CCTV the section or sections to be lined and shall
record salient features including any obstructions and service connections, in
(c)
the Contractor shall overpump the sewage flow around the section or sections of the
pipeline that are to be lined. The overpumping shall be carried at in accordance with
Part 10 of this Section. Leaks in the pipes due to groundwater infiltration shall be
stopped by grouting or other appropriate methods approved by the Engineer.
(d)
the Contractor shall clear the pipeline of obstructions, solids, dropped joints, or tree
roots or collapsed pipe that will prevent the insertion of the liner. Where inspection or
gauging reveals an obstruction that is not at the location of the entry shaft, the
Contractor shall remove the obstruction by means of a cutting machine inserted into
the sewer line. Where this is not possible, the Contractor shall make an excavation to
expose and remove or repair the obstruction as directed by the Engineer.
(e)
a temporary tie-in shall be made between the relined section and the existing system
and the bypass plug removed at the end of each working day.
(f)
Prior to dispatch of any product and/or material from source the Contractor shall notify
the Engineer in writing in sufficient time to allow the Engineer the opportunity to inspect
and test the product and/or material prior to delivery.
(g)
To allow the Engineer to inspect the Works the Contractor shall give the Engineer a
minimum of 24 hours notice of carrying out the following activities on site.
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(b)
Sewer cleaning.
(ii)
CCTV survey.
(iii)
Sewage bypass pumping and/or diversion.
(iv)
Liner installation.
(v)
Manhole rehabilitation.
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(i)
No lining work shall be permitted until the prepared sewer has been inspected and
(i)
Where it is necessary to carry out any modification to existing manholes to enable

manhole and/or sewer cleansing, CCTV survey or sewer rehabilitation, the Contractor
shall carry out any such modification to the Engineers approval. Following completion
of the works in a manhole, the Contractor shall return the manhole to its original or
better condition to the approval of the Engineer including reinstatement to surfaces
disturbed as a result of manhole modification/sewer rehabilitation. Modification to
manhole may include removal of manhole cover slab, intermediate landing slabs,
platforms and manhole benching. Removal of intermediate landing slabs/platforms
may be considered as permanent (i.e. may not necessarily be reinstated) provided the
GRP wall liner is extended to cover the exposed area due to slab removal and welded
to the existing liner, and the GRP ladder is adjusted and re-installed as a continuous
ladder throughout the manhole height.
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(h)
(j)
Unless specifically itemised and listed in the BOQ, modifications to manholes which
may be necessary to carry out the sewer rehabilitation and associated works shall be
deemed to be included in the sewer rehabilitation rates.
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11.2.4
Delivery, storage and handling of products and materials shall be in accordance with the
manufacturers recommendations and the following provisions.
Delivery storage and handling shall at all times be performed in a manner to avoid
product damage.
(b)
The liner shall not come in contact with any sharp projections that may cause damage
during transportation loading and unloading. Cover liner during transportation.
(c)
Store materials on a flat level area and raised above the ground on timber bearers.
(d)
Store materials under opaque cover and out of direct sunlight at all times. Maintain a
free flow of air around materials at all times.
(e)
The Contractor shall visually inspect all products upon delivery to site and report any
damage to the Engineer.
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(a)
Any products damaged during delivery, storage and handling shall be marked by the
Contractor and set aside.
Proposals for repair of any damaged products shall be submitted in writing to the Engineer
for approval.
Any damaged products deemed unsuitable for repair by the Engineer shall be removed from
site and replaced.
11.2.5
Annulus Grout
Low strength grout filling the annular space between the host pipe and the liner (where
applicable) shall be a cementitious mixture incorporating suitable admixtures as approved by
2
the Engineer and shall have a minimum compressive strength of 12N/mm .
Generally, the equipment shall be capable of performing the specified operations in lines
where flows do not exceed the maximum line flows for joint testing/sealing.
11.3
SEALING OF PIPES AND MANHOLES
11.3.1
Scope
Complete or an initial step of rehabilitation by the remote sealing of sewer pipe joints using a
sealing packer. The materials specified herein shall also be applicable in sealing of manaccess sewers and manholes.
11.3.2
Sealing Compounds
The sealing material shall comply with BS 2494 and shall perform effectively in the intended
application and under expected field conditions.
Mixing and handling of sealing materials shall be in accordance with the manufacturers
recommendations.
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Chemical sealing compounds shall have the following properties and characteristics:
while being injected, the chemical sealant shall be able to react/perform in the
presence of either, or both, surface water or groundwater, if present
(b)
the cured material shall withstand submergence in either, or any combination of,
surface water, groundwater, sea water or sewage without degradation
(c)
the resultant sealant formation shall prevent the passage of water through the sewer
pipe joint
(d)
the sealant material, after curing, shall be flexible
(e)
in place, the formed sealant shall be able to withstand wet/dry cycles without
adversely affecting the seal
(f)
the formed sealant shall be non-biodegradable
(g)
the cured sealant shall be chemically stable and resistant to the chemical constituents
sewage and the sewer environment
(h)
packaging of component materials shall
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(a)
be compatible with site storage and handling requirements
(ii)
ensure worker safety
(iii)
cause minimal spillage during handling
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(i)
mixing of the component materials shall be compatible with field operations
(j)
cleanup shall be effected without inordinate use of flammable or hazardous chemicals
(k)
residual sealing materials shall be removed from the sewer to prevent any blockage of
the sewage flow.
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(i)
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Part
Chemical resin for sealing pipe joints and manholes shall be a hydrophilic polyurethane
compound suitable for injection.
The material must be salt-water grade, able to react with saline ground water to form a
flexible seal.
11.3.3
Joint Sealing of Pipes
Joints shall be sealed using the internal joint sealing method. Where bell cracks or chips are
evident from pipe section offset, sealing shall be undertaken where the offset is small enough
to allow proper seating of the sealing packer on both sides of the joint to be sealed.
Longitudinally cracked or broken pipe shall be replaced.
The sealing equipment shall comprise a CCTV survey system, chemical sealant containers,
pumps, regulators, injection sealing packers, hoses, valves and all other necessary
apparatus and tools required for sealing sewers of the various diameters. The packer shall
be cylindrical and shall be so sized and have cables attached at each end to enable it to be
pulled freely through the pipeline. The packer device shall be constructed in a manner to
allow an amount of sewage to flow as designated in the Project Specification.
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Joint shall be sealed by injecting chemical sealing compound into or through faulty joints
using a system of pumps, hoses, and sealing packers. Jetting or driving pipes from the
surface that could damage the pipelines or impair their structural integrity will not be
permitted. Uncovering the pipe by excavation of pavement and soil will not be allowed. The
packer shall be positioned over the faulty joint by means of a measuring device and the
CCTV camera in the pipeline. The Contractor shall ensure that the packer is accurately
positioned over the joint. The packer ends shall be expanded using controlled pressure. The
expanded ends shall seal against the inside periphery of the pipe to form a void area at the
faulty joint which shall be completely isolated from the remainder of the pipeline. Sealant
compound shall be pumped into the isolated area through the hose system at controlled
pressures in excess of groundwater pressure, if any.
Upon completing sealing of each joint, the packer shall be completely deflated then reinflated
and the joint retested. Should the void pressure meter not read zero after deflation, the
Contractor shall clean his equipment of residual grout material or make the necessary
equipment repairs/adjustments to produce accurate void pressure readings. Joints that fail to
meet the specified test criteria shall be resealed and retested until the test criteria can be
met.
Residual sealing materials protruding into the pipe shall be removed. The sealed joints shall
be left flush with the pipe surface. Excessive residual sealing materials which accumulate in
the pipeline shall be removed.
Records shall be kept of joints sealing performed in each length of sewer to identify the
length of sewer in which joints were, the location of each joint sealed, and the joint sealing
verification test results.
Not more than one month before the expiration of the Period of Maintenance and as a
precondition to the Engineers issuance of the Maintenance Certificate for the Contract,
sewers shall be retested as follows:
an initial retest area consisting of specific lengths of sewers will be selected by the
Engineer. Length of sewers to be retested shall be randomly selected throughout the
project area and shall be representative of the majority of the sealing work originally
performed. The initial retest area shall consist of at least 5 %, but not exceed 10 %, of
the length contained in the Contract
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(b)
within the initial retest area, the Contractor shall retest all previously sealed joints as
specified. Any joints failing the retest shall be resealed at no extra cost to the Employer
(c)
if the failure rate of the joints exceeds 5 % of the retested joints, an additional retest
area of equivalent size will be selected by the Engineer and all previously sealed
joints shall be retested. The additional testing and sealing, where necessary, shall
continue until a failure rate of less than 5 % is achieved
(d)
additional testing or sealing required beyond the initial retest area shall be
accomplished at the Contractors expense. The Contractor shall provide adequate
number of crews at Site so that the retesting will proceed at a rapid rate.
The pumping unit, metering equipment and the packer device shall be designed so that
proportions and quantities of materials can be regulated in accordance with the type and size
of the leak being sealed.
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Sealing of Manholes
During cleaning and inspection work the condition of manholes shall be observed and their
structural soundness shall be evaluated by the Contractor and reported in the cleaning and
inspection reports. Sealing work shall only be carried out on manholes which the Engineer
considers structurally sound and which experience extraneous water leakage.
Cracks and openings to be sealed shall be marked out in detail on the concrete elements by
the Contractor and agreed with the Engineer before proceeding with sealing operations.
Sealing equipment shall consist of chemical sealant containers, pumps, regulators, injection
packers, hoses, valves, and all other necessary apparatus and tools. The chemical injection
pumps shall be equipped with pressure meters for monitoring pressure during the injection of
the chemical sealants. Where necessary, fluid bypass lines equipped with pressureregulated bypass valves shall be incorporated into the pumping system.
Structural cracks shall be repaired out as follows:
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11.3.4
holes shall be carefully drilled close to the damaged section from within the manhole
and shall extend through the entire manhole wall
(b)
if leakage is occurring through cracks due to high groundwater table, fewer holes shall
be drilled provided all leakage is stopped from these holes. A watertight seal between
the holes and the injection device shall be provided. Hoses, shall be attached to the
injection device from an injection pump. Chemical sealing materials shall then be
pumped through the hose until material refusal is recorded on the pressure gauge
mounted on the pumping unit or a predetermined quantity of sealant has been injected
(c)
care shall be exercised during the pumping operation to ensure that excessive
pressures do not develop and causing damage to the manhole structure
(d)
upon completion of the injection, the packers shall be removed and the remaining
holes filled with mortar and trowelled flush with the surface of the manhole walls or
other surfaces
(e)
the mortar used shall be of the quick-setting type with non-shrinking characteristics
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any GRP internal lining which has been disturbed shall be repaired in accordance with
(f)
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(a)
Not more than one month before the expiration of the Period of Maintenance and as a
precondition to the Engineers issuance of the Maintenance Certificate for the Contract,
manholes shall be visually inspected by the Contractor in the presence of the Engineer.
Sealing work that has become defective shall be repaired at no additional cost to the
Employer.
All manhole sealing shall be done during high groundwater conditions, unless the points of
leakage have been previously identified.
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SLIPLINING OF SEWERS
11.4.1
General
The scope of work consists of rehabilitating sewers by the insertion of liner pipe into existing
sewers. The finished liner shall extend the full distance detailed in the project specific
documentation, which may be for localised repair, or extend the full sewer length. In either
case the lining shall be completely sealed and watertight.
Procedures set out in ASTM F 585 shall be followed, except as otherwise specified in this
Part.
The Contractor is not constrained on the type of lining method he puts forward, but the
Contractor will have to demonstrate, through previous project documentation, that the
proposed method has a proven track record and that it is fully applicable to the conditions to
be found in the Gulf region.
The Contractor shall design the liner to support all combinations of imposed loads including
earth, traffic, hydrostatic etc and have a minimum service life of 50 years. For the purpose of
calculations, it shall be assumed the ground water table is at ground level. Host pipes shall
be considered to be fully deteriorated. The liner shall have a minimum allowable long term
2
stiffness of 2500N/m and be designed to have a factor of safety of 2.
The normal requirement will be that the liner shall provide the least possible thickness or
decrease in diameter to meet the requirements of this section and consequently it is
preferable to be of the close fit type.
Liner shall be of a light colour to enhance Closed Circuit Television (CCTV) clarity for
inspection purposes.
Leak repair shall be carried out when required to create an environment to enable the
rehabilitation works to be executed successfully. If the rehabilitation method adopted can be
successfully implemented under wet conditions, the Contractor is not obliged to repair the
leaks.
The finished liner shall be continuous over the entire length of an insertion run between two
manholes or access points and shall be free from visual defects.
The beginning and end of the liner pipe shall be sealed to the rehabilitated pipeline and to
manhole liner using a material that is compatible with the liner.
11.4.2
Materials
The sewer liner pipe and fittings shall be manufactured from a polyethylene compound
conforming to ASTM D1248 and meeting the requirements for Type II or III, Class B or C,
Grades P23 or P34, Category 5. Pipe made from this compound shall have a minimum longterm hydrostatic strength rating of 8.6 MPa in accordance with ASTM D2837. When the
environmental stress crack resistance (ESCR) of the compound is measured in accordance
with ASTM D1693, Condition C, the compound shall withstand not less than 192h in 100 %
solution Igepal CO-630 at 38 C before reaching a 20 % failure point (F20).
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11.4
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The standard dimension ration (SDR), defined as the specified outside diameter (OD) divided
by the minimum wall thickness, shall be demonstrated by calculation to be sufficient to
support the worst combination of internal and external loads. The wall thickness tolerance
shall be within plus 12 %.
Liner pipe shall be provided with joints designed so that neither the outside diameter of the
pipe is increased nor the internal diameter of the pipe is decreased at the joint.
Liner pipes shall be suitable for use in ambient air temperatures up to 55 C and with sewage
0
up to 45 C.
11.4.3
Installation of Sliplining
Where excavations for insertion of liner are made, the Contractor shall locate the excavations
on the basis of the location of the sewers to be sliplined, pulling distances, and traffic
conditions subject to Engineers approval. Excavation locations shall be such as to minimise
traffic disruption, and the number of excavations reduced by inserting the pipe in both
directions from a single opening. Insertion shafts shall be designed to avoid imposing a
bending radius of less than 35 times the outside diameter of the liner. Insertion shafts shall
be sloped gradually from the ground surface to the soffit of the sewer. The Contractor shall
provide sufficient sheeting and bracing to the excavation as required. The soffit of the
existing sewer shall be exposed and the crown of the pipe shall be removed as necessary for
insertion of the liner. Care shall be taken not to disturb the bottom portion of the existing
pipe.
Jointing shall be by thermal butt-fusion welding in accordance with the manufacturers

recommendations. All fusion jointing shall be carried out by trained personnel with equipment
designed for butt-fusion welding of thermoplastic pipe.
Sections of liner shall be jointed above ground either at the Site or at a remote location.
Where the insertion shaft is not at a manhole the jointing shall be accomplished using a
stainless steel full-encirclement clamp. If such jointing cannot be achieved, then a new
manhole shall be constructed. Recommended minimum lengths of clamps to afford adequate
pullout protection are given in Table 11.1.
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Table 11.1
Minimum Length of Clamps
OD of Liner Pipe
Minimum Length of Clamp
(mm)
(mm)
90
190
115
250
135
250
170
380
180
380
220
380
270
500
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OD of Liner Pipe
Minimum Length of Clamp
325
500
340
500
405
760
455
760
475
760
560
760
661
760
Alternative pipe jointing methods shall be subject to the approval of the Engineer.
The liner shall be inserted with a power winch and steel cable connected to the end of the
liner using of an appropriate pulling head. Where necessary a second pulling head may be
attached to the other end of the liner for attachment of a tag line to pull the liner back out of
the sewer.
Pulling shall be continued form start to completion without interruption, and precautions shall
be taken during insertion to protect the liner pipe so that any ragged edges of a broken sewer
pipe will not score the outside of the liner.
The manufacturers recommendations regarding relaxation of the liner shall be followed

before sealing the annular space between the liner and existing sewer pipe. The annular
space between the polyethylene liner and the existing sewer shall be sealed using a method
Where an existing manhole is used as an entrance shaft the manhole shall be reinstated to
good condition or it shall be replaced with a new manhole in accordance with Part 4 of this
Section.
10
Foam sealant shall not protrude into the manhole and the sealant shall be finished over with
a quick-setting, non-shrinking type of cement grout. Finishing inside the manhole shall be
accomplished using a quick-setting cement type grout to raise the manhole trough to the
invert of the liner pipe and reform the manhole benching as required. Exposed cement type
grout surfaces shall be protected against corrosion by lining with GRP in accordance with
Clause 4.4.1 of this Section.
11
Precautions shall be taken to prevent collapsing of the liner owing to excessive grouting
pressure.
12
The liner shall be secured in the upstream manhole. Each existing service connection shall
be excavated and reconnected to the new liner pipe using either polyethylene heat fusion
saddles or strap-on saddles as conditions require. A neoprene gasket shall be inserted
between the liner and the strap-on saddle. Saddles shall be secured to the liner pipe using
stainless steel bands. Connections of saddle fittings to existing service connections shall be
made using elastomeric boots, full-encirclement clamps, or other methods approved by the
Engineer.
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Before backfilling any existing sewers that had been broken to open, the pipe shall be
repaired and the annular space between the existing sewer and the new liner sealed using
cement or expandable foam to the approval of the Engineer.
14
At locations where the liner pipe has been exposed, the pipe and fittings shall be encased in
Grade 20 SRC concrete.
11.5
DEFORMED PIPE LINER INSTALLATION
11.5.1
Scope
The scope of the work consists of rehabilitating sewers by the insertion of a deformed
thermoplastic pipe into existing sewers. The deformed pipe on the application of pressure
and temperature or on release of deforming stress induced by swaging reverts to its predeformed shape to form a tight fit inside the host pipe without the formation of an annulus.
11.5.2
Materials
The HDPE liner material shall be designed for use in gravity sewers and shall be in strict
conformance with all applicable sections of ASTM F1533.
The liner shall be made from High Density Polyethylene resins complying with ASTM D1248,
Type III, Grade P34 and Cell Classification PE 345434C, D or E per ASTM D3350. The
Contractor shall submit to the Engineer for approval certified test results from the liner pipe
manufacturer to verify that the resin material used for extrusions of the liner meets the
specified requirements, including the quality control records during the liner extrusion
process.
At the time of manufacture, each lot of liner shall be inspected for defects with samples being
taken in accordance with ASTM D4703 and tested in accordance with ASTM D1693, ASTM
D2837 and ASTM F714.
For testing purposes a production lot shall consist of all liner having the same marking
number. It shall include all items produced during any given work shift and must be identified
accordingly to differentiate it from previous or following production.
Each deformed liner coil in compliance with ASTM F1533 shall be clearly marked by the
manufacturer with the following information:
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(a)
ASTM F1533 designation.
(b)
Nominal outside diameter.
(c)
SDR.
(d)
Approximate coil length.
(e)
Standard material designation code.
(f)
Manufacturers name.
(g)
Manufacturers production code from which plant location, machine and date of
manufacture can be identified.
(h)
The project or contract number.
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Liner minimum wall thickness shall be determined by strength and minimum stiffness
requirements.
The liner shall be fabricated from materials which will be resistant to internal exposure to
sewage, sewage gases and reagents listed in Table 1 above, when tested in accordance with
the provisions of ASTM D543, to a temperature of 40C.
The HDPE material used in the production of the liner shall meet, or exceed, the physical
properties given in Table 11.5 below.
Table 11.5
Deformed Pipe Liner Properties
Test Method
Value
ASTM D1505
950kg/m
Flow rate
ASTM D1238
Tensile strength @ ultimate
ASTM D638
Tensile strength @yield
ASTM D638
Ultimate elongation
ASTM D638
Flexural modulus
ASTM D790
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stress
crack
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Environmental
resistance
ASTM D1693
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F0, hours condition C
Density
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30N/mm
20N/mm
600%
1000N/mm
10,000 hrs
ASTM F1248
10,000 hrs
ASTM D746
-117 C
Vicat softening temperature
ASTM D1525
125 C
Hardness, Shore D
ASTM D2240
50
ASTM D991
10 ohm-cm
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Brittleness temperature
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Volume resistivity
15
0.20mm/m/ C
Thermal expansion
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Compressed ring ESCR F0
At the time of installation the liner shall be homogeneous throughout, uniform in colour, free
of cracks, holes, foreign materials, blisters and deleterious faults.
11.5.3
Installation
The Contractors method statement shall be submitted to the Engineer for approval. In the
method statement the Contractor shall describe the means of deforming the liner in-situ and
of providing, maintaining, monitoring, and controlling the reforming environment until the liner
has reverted to its original circular shape and the temperature returns to the normal sewer
ambient temperature.
Calculations demonstrating the adequacy of the pulling capacity of the winch shall be
prepared and submitted by the Contractor for the Engineers approval.
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The liner shall be positioned at the upstream manhole without excavation and shall be
winched directly from the coil through the upstream manhole and the host pipe.
Due care shall be exercised during winching to avoid damage to manholes and snagging.
Guides or rollers shall be used within the manholes to avoid the risk of snagging.
The pulling winch shall be equipped with a tension gauge capable of controlled operation at
variable speed.
The pipe shall be cut flush at manhole inlet and outlet points using a rotary cutter and the
joints sealed.
The Contractor shall adopt working practices for plastic pipes accordance with BS 5955.
The Contractor shall obtain detailed installation instructions and procedures from the
manufacturer for the actual installation of the deformed and reformed system. The
requirements of ASTM F1606 shall also be satisfied.
When the deformed pipe liner is in place it shall be cut and the pipe end closing assembly
used for heat and pressure control within the liner shall be attached and secured at both pipe
ends. Temperature and pressure measuring instruments shall be attached to both ends of
the deformed HDPE liner to provide a continuous monitor of the temperature and pressure
being applied to the liner.
10
Through the use of steam and air pressure the deformed pipe shall be reformed to conform
to the existing pipe wall.
11
The reformed HDPE liner shall be cooled in accordance with the manufacturer
recommendations.
12
Temperatures and pressures shall be monitored and recorded throughout the installation
process to ensure that each phase of the process is achieved at the manufacturers
recommended temperature and pressure limits
13
For each length of liner two samples shall be taken at locations determined by the Engineer.
The sampling method shall include the use of a former to replicate the host pipe. The
samples shall be clearly labelled with date taken and location. The samples shall be tested
for average inside diameter, average outside diameter and minimum wall thickness in
accordance with ASTM D2122, pipe stiffness at 5% deflection in accordance with ASTM
D2412 and for the properties given in Table 3. The stiffness so measured shall meet, or
exceed the stiffness requirements determined by calculation for that section of sewer line or
the minimum specified stiffness whichever is greater. Any material may be rejected for failing
to meet any of the requirements of this specification.
14
The water tightness of the liner shall be gauged throughout the forming process.
11.6
CURED-IN-PLACE LINER INSTALLATION (INVERSION METHOD)
11.6.1
Scope
The scope of work consists of rehabilitating sewers by the installation of a resin impregnated
flexible felt tube inverted into existing sewers. When cured, the new material shall extend
over the length of the inversion as a continuous, tight-fitting, watertight lining.
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Materials
The liner material shall be designed for use in gravity sewers and shall be in strict
conformance with all applicable sections of ASTM F1216.
The felt liner tube shall be a thermoplastic polyester tube consisting of one or more layers of
flexible needled felt or an equivalent woven and/or non/woven material capable of carrying
resin, and with sufficient needling and crosslapping and strength to withstand the installation
pressures and curing temperatures.
The felt tube shall be compatible with the resin and catalyst systems to be utilised.
The finished liner shall consist of a felt layer (or layers) impregnated with a thermosetting
resin and fabricated to fit tight against the host pipe. An allowance shall be made for
circumferential stretching during installation where applicable.
Each felt liner tube shall be clearly marked by the manufacturer with the following
information:
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11.6.2
Manufacturers name.
(b)
Manufacturers production code from which plant location, machine and date of
manufacture can be identified.
(c)
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(a)
The lining technique shall comprise using a suitable preliner to prevent loss of resin.
The resin used shall be a general purpose, unsaturated, thermosetting, vinylester resin able
to cure in the presence or absence of water and a catalyst system compatible with the
insertion process that provides physical properties given in Table 11.6.
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Table 11.6
Cured in Place Liner Properties
Test Method
Value
Property
Flexural strength
ASTM D790
31N/mm
Short term flexural modulus
ASTM D790
1724N/mm
Long term flexural modulus
ASTM D790
862N/mm
Tensile strength
ASTM D638
21N/mm
The installed and cured liner shall be chemically resistant to exposure to sewage and sewage
gases as experienced with the high temperatures in Qatar.
At the time of installation the liner shall be free of all visible tears, holes, cuts, foreign
materials and other defects.
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10
The liner shall be fabricated to a size that when installed will neatly fit the internal
circumference of the sewer being renovated. Allowance shall be made for circumferential
stretching during insertion. The minimum length shall be that deemed necessary by the
Contractor to effectively span the distance from inlet to outlet of the respective manholes
unless otherwise designated in the contract specification. The Contractor shall verify the
lengths on Site before impregnation. Individual inversion runs may be made over one or
more lengths of sewer as determined on Site by the Contractor and approved by the
Engineer.
11.6.3
Installation of Cured-In-Place Liner
The following installation procedure shall be adhered to unless otherwise proposed in the
Contractors method statement and approved by the Engineer:
the Contractor shall designate a location or locations where the reconstruction tube will
be vacuum impregnated before installation. The Contractor shall allow the
Engineer to inspect the materials and wet-out procedure. A catalyst system
compatible with the resin and reconstruction tube shall be used
(b)
the Contractor shall provide facilities to control the temperature of the wet-out
reconstruction tube to prevent premature setting of the resin
(c)
the wet-out reconstruction tube shall be inserted through an existing manhole or

other approved access by means of an inversion process and the application of an
inversion medium of sufficient pressure and volume sufficient to fully extend it to the
designated or termination point
(d)
the inversion pressure shall be adjusted to be sufficient to cause the

impregnated tube to invert from manhole to manhole and hold the tube tight to the
pipe wall and to produce dimples at side connections and flared ends at the
manholes. Care shall be taken during the elevated curing temperature so as not to
overstress the felt fibre
(e)
after inversion is complete, the Contractor shall provide a suitable curing

environment. Monitoring and control equipment shall be provided to permit
observation and maintenance of the curing environment. Temperature and other
factors of the curing environment shall be those recommended by the resin
manufacturer
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(a)
(f)
should excessive infiltration into the sewer be present, a preliner shall be inserted
into the sewer line to prevent washout of the resin.
Initial curing shall be deemed to be completed when inspection of the exposed portions of
cured pipe appear to be hard and sound and the remote temperature sensor indicates that
the temperature is of a magnitude to realise an exotherm. The curing period shall be that
recommended by the resin manufacturer, as modified for the cured-in-place inversion
process, during which time the Contractor shall maintain the quality of the curing environment
to the levels recommended by the resin manufacturer.
The Contractor shall cool the hardened liner to a temperature below 38 C before relieving
the pressure. Cooling may be accomplished by the introduction of cool water into the
inversion standpipe to replace water being drained from a small hole made in the
downstream end. Care shall be taken in the release of the static head so that a vacuum will
not be developed that could damage the newly installed liner.
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Where the new liner fails to make a tight seal due to broken or misaligned host pipe at the
manhole wall, the Contractor shall apply a seal at that point. The seal shall be of a resin
mixture compatible with the liner and the host pipe.
After the new liner has been cured in place, the Contractor shall reconnect existing active
service connections as directed by the Engineer. Unless otherwise designated in the contract
specific documentation, shall be done without excavation. In the case of non -man-entry
pipes from the interior of the system by means of CCTV cameras and a cutting devices that
re-establish the service connection and seal the joint at the point of entry of the service
connection.
The Contractor shall obtain detailed installation instructions and procedures from the
manufacturer for the actual installation of the cured in place liner system. The requirements
of ASTM F1216 shall also be satisfied.
The section of pipeline to be lined shall have been cleaned, surveyed and repaired to the
requirements of this section of the standard specification prior to liner installation.
For each length of liner two samples shall be taken at locations determined by the Engineer.
Sampling method shall include the use of a former to replicate the host pipe. The samples
shall be clearly labelled with date taken and location. The samples shall be tested for
average inside diameter, average outside diameter and minimum wall thickness in
accordance with ASTM D2122, pipe stiffness at 5% deflection in accordance with ASTM
D2412 and for the properties given in Table 2. The stiffness so measured shall meet, or
exceed the stiffness requirements determined by calculation for that section of sewer line or
the minimum specified stiffness whichever is greater. Any material may be rejected for failing
to meet any of the requirements of this specification.
The watertightness of the pipe shall be gauged while curing and under a positive head.
10
The beginning and end of the liner pipe shall be sealed to the rehabilitated pipeline and to the
manhole liner using a material that is compatible with the liner.
11
Wrinkles in the finished pipe which exceed 5% of the pipe diameter are unacceptable and the
liner shall be removed and a replacement liner installed to the approval of the Engineer.
11.7
SPIRAL WOUND PROFILE LINER
11.7.1
Scope
The scope of work consists of rehabilitation of sewers by the installation of helically wound,
profile walled thermoplastic pipe.
11.7.2
Materials
The physical properties of the PVC-U material used in the production of the liner shall
conform to the cell classifications 12454C or 1236C, as defined by ASTM D1784.
Notwithstanding this requirement, the material shall meet or exceed the following physical
properties, as given in Table 11.2:
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Table 11.2
Physical Properties of PVC-U Material
Property
2400 MPa
Flexural Modulus (Long Term)
800 MPa
Tensile Strength (Short Term)
45 MPa
Tensile Strength (Long Term)
20 MPa
Heat Distortion Temperature
70 C
Specific Gravity
1.4
Allowable Long-term Strain
2%
Hardness (Shore D)
80
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Flexural Modulus (Short Term)
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The base material for the liner shall consist of a profile walled strip, extruded from PVC-U or
other thermoplastic material, approved by the Engineer in accordance with ASTM F 1697. All
materials shall be resistant to internal exposure to potable water, sea water, sewage, sewer
gases, and reagents listed in Table 11.3, when tested in accordance with the provisions of
ASTM D543, to a temperature of 35 C:
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Table 11.3
Resistance of Liner Material
Concentration
5%
Phosphoric Acid
10 %
Sulphuric Acid
10 %
Detergent
0.1 %
Soap
0.1 %
Nitric Acid
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Reagent
Where high liner stiffness is required to resist external loads, the strength of the liner may be
enhanced by the provision of plastic-coated stainless steel reinforcement wound into the liner
at the time of installation. The steel reinforcement shall consist of stainless steel type 316L
and shall be coated with a low density polyethylene coating or other material approved by the
Engineer, not less than 1 mm thick. The steel shall meet or exceed the following physical
properties given in Table 11.4:
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Table 11.4
Physical Properties of Steel
Property
Value
Tensile Strength
250 MPa
Modulus of Elasticity
195 GPa
Coefficient of thermal expansion
9 x 10 / C
-6
For each length of liner a sample shall be prepared prior to the winding machine being placed
into the manhole. A length of pipe shall be formed from the same batch of material to be
used in the installation. The length of sample shall be such that three lengths may be cut and
tested in accordance with ASTM D2412 for pipe stiffness at 5% deflection and for the
properties given in Table 4. The stiffness so measured shall meet, or exceed the stiffness
requirements determined by calculation for that section of sewer line or the minimum
specified stiffness whichever is greater. Any material may be rejected for failure to meet any
of the requirements of this specification.
Each liner shall be clearly marked by the manufacturer with the following information:
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Manufacturers name
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Manufacturers production code from which plant location, machine and date of manufacture
can be identified
The project or contract number
At the time of installation the liner shall be homogenous throughout, uniform in colour, free of
cracks, holes, foreign materials, blisters and deleterious faults.
This method may only be used for pipes of 250mm diameter or greater.
11.7.3
Installation of Spiral Wound Profile Liner
The installation of spiral wound liner shall follow the recommendations of ASTM F-1698.
Spirally wound profile liners shall be installed using a winding machine placed at the bottom
of the manhole, with the liner being introduced at a diameter of approximately 25 mm less
than the minimum diameter of the pipeline to be rehabilitated. After the liner has been
installed, the annular gap shall be filled with a cementitious grout or the liner shall be
expanded until it comes into intimate contact with the host pipe.
Jointing of the liner shall be accomplished by the use of an adhesive material suitable for use
with the liner material. The adhesive shall be fully resistant to the corrosive sewer
environment and shall be applied to the strips at temperatures of 35 to 50 C. Alternatively
the liner shall be joined using a mechanical locking strip. The strip shall have mechanical and
chemical resistance properties that are not less than those of the liner material. The joint
shall be continuous and watertight for the full length of the sewer. The interface between the
liner and manhole shall be sealed with material specified in Clause 11.10.3.
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Grouting of the annulus shall be carried out using the differential pressure method. The liner
shall be filled with water and maintained at a constant pressure that is greater than the
grouting pressure. Failure to maintain pressure in the pipeline will indicate that a defect
exists. The water pressure shall be monitored via a gauge fitted to the grout plug, whereas
the grouting pressure shall be monitored via a gauge fitted at the end of the grout hose.
When water direct from a potable supply is used, an anti-siphon device shall be used to
prevent contamination. Grouting shall be continued until there is a consistent flow of grout at
the upstream manhole. Should grout pressure build up, before a show of grout is observed,
the injection shall be stopped immediately to prevent damage to the liner. A sample of the
grout shall be taken during grouting and its curing time monitored.
Alternative grouting methods that are specific to a particular lining system will be allowed only
with the approval of the Engineer.
11.8
PIPE CRACKING OR BURSTING
11.8.1
Scope
Rehabilitation of sewers by the replacement of existing pipes with polyethylene (PE) or

polypropylene (PP) pipes by breaking the existing pipes, expanding the hole size and
inserting the replacement pipes in one operation with a minimum of disturbance to the
surrounding ground and no surface disruption.
11.8.2
General
The Contractor shall satisfy the Engineer that the pipe bursting procedures will not have
detrimental effects on adjacent utilities or structures, particularly from vibration arising from
use of pneumatic bursters. The Contractor shall be responsible for such damage and shall
bear the cost of rectification.
The Contractor shall comply with the requirements of service authorities and shall be
deemed to have identified the location of services which may be affected by the Works.
Unless otherwise required by the service authorities, where services are known to be located
within one meter of the pipe to be burst, the Contractor shall expose the service in advance
of pipe bursting. A minimum free space of 500 mm shall be created beneath the service over
a length to be agreed between the Contractor and the service authorities.
11.8.3
Materials
The materials used for replacement of the existing pipes shall be polyethylene or
polypropylene unless otherwise specified in the contract documents.
The method of jointing the pipes shall be as the manufacturers recommendations for the
application. Unless otherwise specified or approved by the Engineer pipe joints shall be
designed to be watertight against external water pressure assuming that groundwater
extends to the ground surface.
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11.8.4
Installation Equipment
Pipe bursting equipment shall be hydraulically or pneumatically powered incorporating an

expander at the nose of the machine which will fragment the existing pipe and expand the
space uniformly to a diameter sufficient to allow the replacement pipe to be inserted. The
annular space between the expander and the replacement pipe shall not exceed 20 mm
unless otherwise agreed by the Engineer.
The method of inserting the replacement pipe shall be such that stresses transmitted to the
replacement pipe shall not damage the pipes or exceed the tensile capacity of the
replacement pipe.
Pipe bursting equipment shall be capable of
(b)
Dealing with small quantities of unreinforced concrete of maximum 150 mm nominal

thickness found surrounding pipes, joints, saddles and service connections and for
bursting pipes laid on a concrete cradle without being deflected off line and level.
(c)
Working under a hydrostatic pressure of groundwater.
(d)
Operating at maximum depth of 10.0 m from surface level.
(e)
Operation without jamming of moving parts or other malfunction due to the ingress of
groundwater or sand particles.
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Working from existing manholes so that they can be used as launch and reception
shafts wherever possible. Provision shall be made for remote starting and stopping.
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Where the Contractor has not previously used the equipment or demonstrated the pipe
bursting technique to the satisfaction of the Engineer then he shall demonstrate the suitability
of the equipment as follows:
construct in open ground at a location approved by the Engineer, a 50m long
temporary section of pipe of the same bore and material as the sewer to be
rehabilitated at similar depth, complete with unbenched chambers at each end;
(b)
backfill the excavation;
(c)
demonstrate the pipe bursting procedure.

on completion of the pipe installation flood the site to artificially bring the water table to
the ground surface and demonstrate that infiltration requirements of Part 4 of this
Section are met.
(d)
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(a)
Should difficulties be encountered in completing the trial installation the Contractor shall
modify his proposal for approval by the Engineer before recommencing work.
Measures shall be taken to ensure that the replacement pipe does not become separated
from the pipe expander should the system employ an insertion technique which allows the
replacement pipe to slide within the pipe expander.
11.8.5
Installation
Shafts for launch and reception shall be existing manholes and excavations made over
existing inspection chambers and service connections where the latter are proposed to be
reconnected to the pipeline. Service connections to be abandoned or redirected to upstream
or downstream chambers or manholes shall not be excavated.
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Unless specifically approved by the Engineer pipe bursting shall not be carried out by
constructing shafts adjacent to manholes. Where necessary, the channel, benching and
walls of existing manholes shall be altered to receive the pipe bursting equipment. All
manhole alterations shall be made good.
The Contractors attention is drawn to the potential problems arising from the inflow of
groundwater and loss of ground from the outside of manholes. His proposed method of
working shall take these into consideration and shall be subject to the Engineers approval
and shall ensure that no inflow of groundwater or loss of ground occurs. Where manholes
are located in roads, the Contractor shall obtain permission from the Roads Division prior to
carrying out any wellpoint dewatering operations around the manhole. In the event that
means of stabilising the ground around the manhole and connecting pipelines are not
approved by the Engineer, the Contractor shall not use pipe bursting methods at that location
unless any other alternative method is approved by the Engineer.
Existing service connections shall be disconnected from the existing pipeline in advance of
pipe bursting and reconnected on completion of the installation of the replacement pipe. In
the interval, the Contractor shall maintain service by temporarily connecting service
connections to the sewerage system downstream of the section, by overpumping, or by such
other method the Contractor may propose for the Engineers approval.
Sewer lengths to be rehabilitated shall be checked for the presence of collapses occurring
subsequent to cleaning by gauging between shafts. Where a collapse is detected its position
shall be determined and an additional shaft shall be excavated if the debris cannot be
removed.
Pipe bursting shall not commence unless sufficient lengths of replacement pipes are
available on Site to complete the length of pipe to be rehabilitated.
Where pipe bursting is delayed for a period exceeding 7 days following cleaning, the pipeline
shall be reinspected.
Winching shall conform to the following requirements:

Details of the proposed winching method shall be submitted to the Engineer for
approval at least 7 days before the insertion date
(a)
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(b)
Winches shall be of the constant load type fitted with a direct reading load gauge. At
the end of each days work, the Contractor shall provide the Engineer with a copy of
the winching loads recorded at the start of any pull and during the pull at increments of
20 m of winching distance and at any restart following temporary stops
(c)
Winches shall be fitted with an automatic device to disengage when the load
exceeds a preset maximum load.
(d)
The Contractor shall supply sufficient cable in one continuous length to ensure the
pull is continuous between approved winching points
(e)
Winches, cables and cable drums shall be provided with safety cages and supports
(f)
The Contractor shall provide a system of guide pulleys and bracings at each manhole
(g)
Nose cones fixed to the head of pipe expanders shall be fitted with a swivel attachment
to prevent twist transmission between the winch cable and the nose cone
QCS 2014
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(h)
Where the Contractor proposes to use a lubricant to ease the pull, the type of
lubricant, method of introduction, removal and quantity to be used shall be submitted
for the Engineers approval before beginning winching
(i)
Trench sidewall support in the insertion trench shall remain completely separate from
the pipe support system and shall be designed so as not to be in contact with the pipe
or the winch cable.
Replacement pipe shall be inserted in accordance with the following requirements:

the maximum force shall be within the stress limit of the pipe
(b)
continuous length pipelines shall not be used. The maximum pipe length for insertion
shall be 1.5 m where pipe bursting is undertaken between excavated shafts and either
700 mm or 800 mm where pipe bursting is undertaken from manhole to manhole
(c)
where a device is employed to exert force on the rear of the inserted pipe lengths, the
force applied to the inserted pipe shall be evenly distributed around the wall of the
pipe
(d)
Where lengths of pipe are joined and a device is employed to exert force to the rear of
the inserted pipe lengths, precautions shall be taken to ensure that no buckling,
crushing, twisting, or damage to the joint of the pipe takes place. Where, in the
opinion of the Engineer, excessive deformation of the pipe has taken place, the pipe
shall be replaced at the Contractors expense.
(a)
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Where the lining is to be joined using Snap-Lock or similar fittings, the Contractor shall
comply with the manufacturers recommendations for jointing. Means of verifying the critical
dimensions of the joints shall be provided on site by the Contractor. The joint shall be fitted
with a suitable sealing ring and shall be designed to be watertight against an excess external
water pressure of 20 metres head.
11.9
INSPECTION AND TESTING OF PIPE LINES AFTER REHABILITATION
The completed sewer shall meet the leakage requirements of pressure tests or air tests as
specified in Part 4 of this Section.
After completion of each length of sewer, the Contractor shall flush the pipeline and
undertake a CCTV and deflection survey and provide video tapes, pictures on digital format
and site coding sheets to the Engineer.
Where necessary the Contractor shall remove any debris and carry out any remedial work
identified. Upon completion of remedial work and removal of debris the section shall be
resurveyed and the Engineer provided with the latest CCTV video tapes. Further additional
CCTV surveys resulting from the need to again clean or carry out further remedial work shall
be at no additional cost to the Employer.
The rehabilitated sewer shall be returned to service only after the written approval of the
Engineer.
During the guarantee period any defects which will affect the integrity or strength of the pipe
shall be repaired at the Contractors expense, in a manner mutually agreed by the Engineer
and the Contractor.
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MANHOLE REHABILITATION
11.10.1 Scope
1
The scope of work consists of the materials and types and methods of repair for the
rehabilitation of manholes.
11.10.2 General
Manhole rehabilitation shall comprise but not be limited to any combination of the following:
Rehabilitation of walls or bases by plugging, patching, and removing, providing or
replacing mortars, coatings, sealants and liners, to improve structural condition,
prevent infiltration, provide corrosion protection or external tanking protection.
(b)
Repair of shaft and cover slab and reconstruction to the required level
(c)
Reinstallation or replacement of manhole frame and cover
(d)
Installation of manhole sealing plate.
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11.10.3 Materials
Materials used shall be suitable proprietary materials for manhole rehabilitation and the
specific application in which they are used. The materials shall be supplied in factory-labelled
containers. All materials shall be mixed and applied in accordance with the manufacturers
instructions.
Materials used for plugging holes and stopping infiltration in manholes shall be either:
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Premixed hydraulic cement consisting of Portland cement, graded silica aggregates,

special plasticising and accelerating agents with a set time of approximately 50 s and
a 10 min compressive strength of approximately 3.5 MPa and free of chlorides,
gypsum, plasters, iron particles, or gas-forming agents
(b)
Siliconate-based liquid accelerator mixed with neat Portland cement with a set time of
approximately 50 s.
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(a)
Materials used for patching, filling and repairing non-infiltration holes, cracks, and breaks in
concrete and masonry manholes shall comprise a premixed Portland cement-based
hydraulic cement consisting of Portland cement, graded silica aggregates, special plasticising
and accelerating agents with a set time of approximately 3 min or 15 min to suit application
and a one-hour compressive strength of approximately 4.2 MPa. It shall not contain
chlorides, gypsum, plasters, iron particles, or gas-forming agents.
Materials used for waterproofing membrane, corrosion protection, and strengthening of

concrete and block work manholes shall be:
(a)
liquid polymer modified water based waterproof coating which shall provide a secure
mechanical and chemical bond with a curing time of approximately 1.5 h and a
cured compressive strength of approximately 40 MPa. The coating shall be applied
with a brush to surfaces without cracks or voids wider than 1.5 mm
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100 % solids, three-component system consisting of a two-component epoxy resin

and a special blend of fillers which shall provide a secure mechanical and chemical
bond with an initial curing time of approximately 4 h and a cured compressive
strength of approximately 76 MPa. The resin with fillers shall be applied with a trowel
to a thickness of 3 mm to 12 mm. Epoxy resin (without fillers) used for waterproofing
and corrosion protection shall be applied with a brush.
Remove all defective linings together with 100mm of adjoining good lining in existing
manholes and other structures, including areas of lining covering leakage points.
Break out defective concrete to sound concrete surface.
Apply approved epoxy bonding agent and reinstate concrete using an approved concrete
repair material.
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11.10.4 Rehabilitation of Manhole Walls and Bases
Surfaces of manhole walls and bases shall be thoroughly cleaned to remove all loose
material and surface contaminants. Cleaning shall be accomplished by pressure jetting,
sandblasting, or applying a 10 % solution of muriatic acid or hydrochloric acid. Where an acid
solution is used the surface shall be thoroughly rinsed and neutralised before the application
of mortars and coatings.
After surface preparation and before the application of mortars and coatings, infiltration shall
be stopped by sealing as specified in Clause 11.3.4.
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11.10.5 Rehabilitation of Manhole Shafts and Slabs

The Contractor shall take all necessary precautions to prevent debris from damaging the
manholes and the sewer.
Shafts and cover slabs shall be repaired and rehabilitated with suitable sound materials
Rings shall be provided as appropriate to reconstruct the shaft to the required elevation.
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11.10.6 Manhole Cover, Frame and Sealing Plate Reinstallation or Replacement

1
The Contractor shall remove covers, frames, and sealing plates. Where the Engineer
determines that cover, frames and sealing plates are to be replaced, the Contractor shall
dispose of them.
The Contractor shall adjust the level and slope of the manhole cover as required. The
manhole shall be raised by building precast concrete rings.
Covers and frames determined by the Engineer to be in good condition shall be grit blasted
and coated on all exposed faces with a zinc primer and coal-tar epoxy paint finish as
specified for System C in Part 8 of this Section. Replacement covers, frames and sealing
plates shall be as specified in Part 6 of this Section.
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The Contractor shall reinstall or replace the manhole cover and frame using either of the
following methods in accordance with the Contract Drawings and clause 4.4 of this Section.
Sealing plates shall be installed as specified in Part 6 of this Section.

1
Completed rehabilitation works shall be visually inspected in the presence of the Engineer.
Work that has become defective shall be redone at no additional cost to the Employer.
11.11
MANHOLE LINING
11.11.1 Scope
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glass fibre reinforced manhole liners.
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11.11.2 Materials
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GRP liner materials shall be as specified in Part 7 of this Section.

11.11.3 Installation of Lining
The cover slab and manhole cover shall be removed and disposed of off Site. The manhole
cover and frame shall be thoroughly cleaned, treated with two coats of bituminous paint and
delivered to CED store and placed into storage.
Step irons shall be removed and the walls made good and prepared with 3:1 sand/cement
mortar.
Concrete surfaces to be lined shall be cleaned and lightly abraded prior to the application of
the GRP. The GRP lining shall be built up by applying isophthalic or vinyl ester resin. A layer
of ECR glass 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. After a period to allow pregel 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 veil shall then be used to complete the lining.
Top surfaces of benching shall incorporate silica sand to form a non-slip surface.
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.
GRP ladders of an approved pattern as specified may be purpose made to suit the depth of
each manhole. Fixings for ladders shall be approved stainless steel stud anchors. Fixing
holes shall be grouted with epoxy mortar and sealed as above. Rungs or treads shall be
ribbed to provide a non-slip surface.
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1
After the manhole lining has been installed, the manhole shall be visually inspected in the
presence of the Engineer and subject to the approval of the Engineer.
Before the expiration of the Period of Maintenance, the Contractor shall visually inspect the
lined manholes in the presence of the Employer or Engineer. Work that has become
defective shall be redone at no additional cost to the Employer.
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END OF PART
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Part
12: Vacuum Sewerage System
Page 1
12
VACUUM SEWERAGE SYSTEM .................................................................. 2
12.1
GENERAL ...................................................................................................... 2
2
2
2
3
3
4
4
4
5
5
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12.1.1 Scope
12.1.2 References
12.1.3 Definitions
12.1.4 System Description
12.1.5 Submittals
12.1.7 Warranty
12.1.8 System Operation
12.1.9 Commissioning
12.1.10 Maintenance
SYSTEM DESIGN AND PERFORMANCE .................................................... 5
12.2.1
12.2.2
12.2.3
12.2.4
12.2.5
General
Design of the System
Design of Vacuum Station
Design of Collection Chambers
Design of Vacuum Pipelines
12.3
PRINCIPAL SYSTEM COMPONENTS ......................................................... 8
12.4
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12.3.1 General
12.3.2 Vacuum Pipelines
12.3.3 Collection Chamber
12.3.4 Interface valves
12.3.5 Controller
12.3.6 Sensor
12.3.7 Vacuum Vessel
12.3.8 Vacuum Pumps
12.3.9 Forwarding Sewage Pumps
12.3.10 Motor Control Centre
12.3.11 Telemetry Outstation
12.3.12 Discharge Pipelines
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12.2
5
5
6
7
7
8
8
9
9
10
10
10
11
11
11
12
12
INSTALLATION OF THE SYSTEM ............................................................. 12
12.4.1 Pipelines
12.4.2 Pipe Joints for Vacuum Pipelines
12.4.3 Pumps, Motors and Instrumentation
12
12
13
12.5
TESTING ..................................................................................................... 13
12.5.1
12.5.2
12.5.3
12.5.4
General
Testing of Interface Valves, Controllers and Sensors
Testing of Pipelines
Testing of Pumps, Motors and Instrumentation
12.6
TRAINING OF EMPLOYERS PERSONNEL............................................... 14
13
13
13
14
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Page 2
VACUUM SEWERAGE SYSTEM
12.1
GENERAL
12.1.1
Scope
This Part includes the specifications for the design and provision of vacuum sewerage
systems.
12.1.2
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This Section
Part 1
General
Part 2
Earthworks
Part 3
Part 4
Pipe Installation
Part 5
Part 6
Miscellaneous Metalwork
Part 8
Section 1, General
Section 9, Mechanical and Electrical Equipment
Section 10, Instrumentation, Control and Automation
Section 21, Electrical Works
Section 22, Air Conditioning, Refrigeration and Ventilation.
12
References
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BS 5500, welded pressure vessels
European Standard CEN/TC 165, Vacuum sewerage system outside buildings.

Definitions
The following definitions of vacuum sewerage system apply to this Part:

Batch Volume: volume discharged from a collection sump during one normal cycle of
the interface valve and is equivalent to the volume of the sump within the operating
range of the sensor.
(a)
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12.1.3
(b)
Collection Chamber: interface between the vacuum sewerage system and the
collection sewers consisting of a collection sump and interface valve pit.
(c)
Collection Sump: storage capacity provided to store flows of sewage until sufficient
volume has accumulated to activate the interface valve. Storage may also be provided
to reduce the risk of flooding if there is a system failure.
(d)
Controller: device which, when activated by the sensor, opens the interface valve and,
after the passage of sewage and air, closes the valve.
(e)
Forwarding Pumps: pumps installed at the vacuum station to pump the sewage from
the vacuum system to the trunk sewer.
(f)
Interface Valve: valve which admits the flow of sewage and air into the vacuum sewer
through the service connection.
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Isolation Valve: valve installed to isolate a particular section in the vacuum sewer
network.
(h)
Lift: up-grade section between two down-grade sections of a vacuum pipeline. The lift
height is the difference in sewer invert levels between two successive down-grade
sections. The static lift is the increase in the hydraulic grade line at a lift and is
generally the increase in invert level minus the internal diameter.
(i)
Sensor: device which senses the presence of sewage in the collection sump and
activates the controller to open the interface valve.
(j)
Service Connection: that part of the vacuum pipeline which connects a single collection
chamber to the vacuum sewer.
(k)
Vacuum Generator: equipment installed at the vacuum station to generate a vacuum.
(l)
Vacuum Pipeline: pipeline under negative pressure.
(m)
Vacuum Pump: pump that creates the vacuum in the vacuum pipeline.
(n)
Vacuum Recovery Time: time taken after the operation of an interface valve for the
negative pressure at the valve to be restored to its original value.
(o)
Vacuum Sewer: the major part of the vacuum pipeline into which the service
connections discharge.
(p)
Vacuum Station: vacuum generators, vacuum vessel (or sewage sump), forwarding
pumps and system controls.
(q)
Vacuum Vessel: negative pressure vessel connected to the vacuum pump. The
vacuum sewer discharges into the vacuum vessel and the forwarding pumps pump
sewage from the vessel. The vacuum pumps maintain a negative pressure in the
vessel. When the vacuum generator is an ejector pump, the vacuum vessel is
replaced by a sewage sump at atmospheric pressure.
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(g)
System Description
The Contractor shall be solely responsible for the design and construction of the system to
meet the specified requirements.
The design of the system shall conform generally with European Standard CEN/TC 165,
except as otherwise specified in this Part.
The vacuum sewerage system shall be required to operate under very low flows but it shall
provide effective transfer of sewage to the sewers under all conditions and not cause flooding
or overflow of sewage from the collection vessels.
The maximum noise level at the vacuum station and elsewhere in the system shall not
exceed 65 dbA.
12.1.5
Submittals
The Contractor shall submit complete data and details of vacuum sewerage systems for the
Engineers approval as follows:
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12.1.4
(a)
method statement which shall include :

(i)
name and experience of specialist
(ii)
detailed procedure for the works
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Part
(iii)
list of all construction plant and tools
(iv)
safety procedures
Page 4
hydraulic, structural, mechanical and electrical calculations used in the preparation of

the shop drawings.
(c)
shop drawings for all components and the complete system.
(d)
certificates that all components and equipment to be provided are suitable and made
of such materials to withstand the prevailing climatic conditions of Qatar and the
corrosive environment. Details of proposed corrosion protection systems shall be
provided.
(e)
complete justification for any proposed changes in materials.
(f)
Training program
(g)
operation and maintenance methods manual which shall include:
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(b)
complete information of the system illustrated in detailed drawings
(ii)
detailed procedures for correct operation and maintenance of all system

components.
(iii)
reprogramming manual
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(i)
The Contractor shall not procure materials or commence installation of the Works until the
Engineer has approved his submittals.
12.1.6
Quality Assurance
The vacuum system shall be provided by approved, specialist manufacturers, suppliers and
installers designated in the contract Project Specification.
All supervisors and technicians employed shall be fully competent in the installation methods.
12.1.7
Warranty
The control equipment shall be provided with a satisfactory performance warranty.
In addition to the warranty requirements of Part 1 of this Section, the vacuum sewerage
system supplier shall warrant that the system and its components will meet the performance
for a period of 24 months from the date of startup. The vacuum system supplier shall be
solely responsible for the warranty. The warranty shall be in the form of a letter and report
which shall be submitted to the Engineer, for review. Within the warranty period, any
remedies necessary to bring the vacuum sewerage system into compliance with the
specifications shall be the sole responsibility of the vacuum system supplier.
The Contractor shall furnish the Employer with manufacturers warranty and guarantee
certificates for all equipment.
12.1.8
System Operation
On satisfactory completion, the Contractor shall operate and run the vacuum system for a
period of 400 days during which time he shall be totally responsible for all maintenance
including spares.
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12.1.9
Commissioning
The Contractor shall submit instruction manuals in draft to the Engineer four weeks prior to
the commissioning.
The Contractor shall demonstrate to the Engineer that all equipment functions to meet the
design criteria and specifications.
12.1.10 Maintenance
The Contractor shall provide any special tools and equipment needed to operate and
maintain the system and provide spare parts for two years operation and an additional 400
days for the maintenance, all at his expense.
12.2
SYSTEM DESIGN AND PERFORMANCE
12.2.1
General
The vacuum system shall be supplied by a manufacturer approved by the Engineer.
The general location of the vacuum sewerage system including the locations of collection
chambers, vacuum pipelines, vacuum station and pressure pipeline discharging to the trunk
sewer which forms part of the gravity sewerage system shall be as shown on the Drawings.
The Contractor shall be responsible for carrying out any additional site investigations, for the
design, and for provision of a complete system including supply of all materials and
equipment, testing, startup and commissioning.
12.2.2
Design of the System
The design of the system shall satisfy either of the two conditions:
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outline design of the sewerage system provided by the Engineer
(b)
as an alternative option proposed by the Contractor to avoid deep sewers in the

Contract in which case the design will be based on the Contract Drawings
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(a)
The Contractor shall not procure materials, equipment or begin construction of the Works
until the Engineer has approved the design and all other submittals.
The vacuum sewerage system shall intercept sewage flow and convey the flow to collection
chambers. Collection chambers, interface valves and vacuum pipelines shall be located so
that they do not interfere with or obstruct existing services and access thereto.
Sewage from the collection chambers shall be drawn into the system through interface valves
and conveyed by the vacuum pipelines to a collection vessel located in the vacuum station,
equipped with vacuum pumps.
Sewage from the vacuum station shall be pumped through the pressure pipeline to the
gravity sewerage system. All necessary pipework shall be included from the vacuum station
to the point of discharge to the gravity sewer.
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Design of Vacuum Station
The Contractors design shall optimise the number and locations of the vacuum stations.
Where more than one station is required, the size of the collection vessels, vacuum pumps
and other equipment shall be standardised as far as practicable.
Vacuum stations shall comprise all civil works; mechanical and electrical works including
pipework, vacuum vessel, vacuum pumps, cooling systems, forwarding pumps, odour control
equipment; motor control centre; instrumentation including vacuum data loggers, and valve
telemetry display and telemetry outstation and connection to the control centre; lighting and
all other work necessary in accordance with Sections 9 and 21 to make the vacuum station
complete in all respects.
Forwarding pumps shall be controlled by level probes installed in the collection vessel; two
sets of probes shall be installed, an upper set to run on normal day operation and a lower set
to empty the vessel under extreme low flow conditions. The pump control station shall include
automatic timer, indication and alarm in accordance with Sections 9 and 21.
The vacuum station shall be of cavity wall construction. The Contractor shall design the
station building and submit detailed design drawings for the Engineers approval. The station
building shall incorporate the following minimum requirements:
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12.2.3
minimum internal floor area 12 m
(b)
external cement, sand or concrete blocks
(c)
aluminium doors and window frames
(d)
black PVC-U rainwater drainage connected to surface water drainage conduits if

available, otherwise to a gargoyle and soakaway
(e)
sufficient wall area for telemetry outstation
(f)
QGEWC supply meters to be mounted in external box (QGEWC supply)
(g)
a connection point to the incoming vacuum sewer, fitted with an isolation valve, for
independently testing vacuum valves
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a separate room housing a single water closet and hand basin with both hot and cold
running water
(h)
as
(a)
(i)
water supply to a 200 l GRP header tank above the roof
(j)
external washdown tap with concreted splash area below, draining to the on-site
vacuum collection chamber
(k)
activated carbon type exhaust air filter
(l)
a collection chamber shall be constructed at the site which shall receive the flows
from the water closet, hand basin, external washdown tap, and coolant water from
the liquid ring vacuum pumps.
The vacuum station shall include all pipework necessary for satisfactory performance,
operation and maintenance.
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Design of Collection Chambers
Collection chambers shall be designed such that in each case the lowest invert of the
incoming gravity sewer is above the high operation sewerage level of the interface valve to
avoid surcharging the gravity sewers during normal operation.
Collection chamber sumps shall be sized to give a 4 h retention capacity at average flow
below the level of the incoming sewers. The Contractor shall account for the probability of
power failure and its consequences. Provision shall be made in the control panel and cabling
for connecting mobile standby power generation.
Collection chambers shall be fitted with a level sensing devices and local and remote alarms
as designated, and shall be so located and fitted with access openings to enable clearing of
sewage using pumping or vacuum tankers. In no case will the provision of facilities for
discharge of sewage to the surface water drains be permitted.
Collection chambers shall incorporate an intermediate platform within the chamber to

facilitate easy access to the vacuum interface valve. The area of the platform must be at
least equal to half the plan area of the chamber. Access to the lower part of the chamber
below the intermediate platform shall be provided with a minimum 600 mm diameter clear
opening. Where the intermediate platform is provided by means of a concrete slab, the
access hole into the lower chamber shall be provided with a galvanised open mesh cover as
specified in Clause 6.5.7 of this Section permitting viewing of the lower part of the chamber
from the top of the chamber.
Vacuum interface valves in collection chambers shall incorporate an auxiliary suction pipe
such that if the valve fails the chamber can be emptied into the vacuum pipeline. The
auxiliary suction pipe shall be positioned within 100 mm below the cover level and shall be
operable from ground level outside the chamber.
Interface valve assemblies shall incorporate isolating valves such that the interface valves
can be easily removed without necessitating loss of vacuum in the vacuum pipeline.
Where breathers are used on vacuum interface valves they shall not exceed 5 m in length.
Where the breather head is not against a structure to which it can be securely fixed the
breather head shall be protected by a 50 mm by 50 mm galvanised steel angle cast in
concrete, the head being fixed into the angle with plastic cable ties or similar. Where any
double valve collection chambers are used each valve shall have a dedicated breather.
The sump shall be vented to allow the intake of air. The sump may be vented by the gravity
system provided that the operation of the vacuum system does not unseal the traps on the
internal sewerage system and that the internal sewerage system is vented to atmosphere.
12.2.5
Design of Vacuum Pipelines
Pipeline profiles shall be as follows:
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12.2.4
(a)
the size of individual lifts shall be kept as small as possible to maximise vacuum
transport efficiency and many small lifts shall be provided instead of one large lift.
The minimum horizontal distances between profile changes shall be 6 m for vacuum
sewers and 1.5 m for service connections
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(b)
except at lifts, vacuum sewers shall have a minimum gradient of 1:500 in the
direction of flow. Profile changes shall be made where necessary to ensure that the
pipeline depth does not become excessive
(c)
where the ground surface has a gradient of 1:500 or more in the direction of flow,
vacuum sewers may be laid parallel to the surface. Stagnation of sewage shall be
avoided at locations followed by an uphill section
(d)
lifts shall generally not be more than 1.5 m, but where conditions are such that a lift
exceeds 1.5 m special care shall be taken in the design of pipelines by taking into
consideration the flow capacity and total lengths of the vacuum pipeline.
Air Flow. The total average air/liquid ratio shall not be less than 1.5:1. The Contractor shall
identify in his calculations the average air liquid flows for which the system is designed.
Minimum Negative Pressure. The system design shall achieve a minimum negative pressure
of 25 kPa (gauge) under no flow conditions at each interface valve.
Vacuum Recovery. The system shall be designed so that the vacuum recovery will be fast
enough to ensure that temporary surcharging of collection chambers does not occur under
normal flow conditions.
Length of Vacuum Sewers. Lengths of vacuum sewers shall be such to enable the system to
restart automatically and recover vacuum following rectification any breakdown.
Service Connections. Service connections shall slope away from the interface valve and
shall connect into the top sector of the vacuum sewer contained within the angle of +60
about the vertical axis.
Branch Connections. Branch connections to vacuum sewers shall be by junctions connected

to the sewer above the horizontal axis, and the angle of the junction shall ensure that the flow
towards the vacuum station is generated and backflow is minimised. No connection shall be
made within 2 m of a lift.
Isolating Measures. Adequate means of isolating lengths of vacuum sewer to permit

maintenance shall be provided by isolating valves or appropriate inspecting pipes. Isolating
valves shall be suitable for service under vacuum and pressure and shall be capable of
sustaining a differential vacuum of 80 kPa.. Buried valves shall be provided with extension
spindles and surface boxes.
12.3
PRINCIPAL SYSTEM COMPONENTS
12.3.1
General
All materials used in the manufacture of collection chamber, interface valve and controller
shall be capable of resisting corrosion from soils, groundwater, sewage and sewage gases.
12.3.2
Vacuum Pipelines
Vacuum sewers shall have a minimum diameter of 80 mm and service connections shall
have a minimum diameter of 50 mm.
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All vacuum pipes and fittings shall be of MDPE as specified in Part 3 of this Section. The
minimum pressure rating for plastic pipes shall be 0.6 MPa but higher ratings shall be
employed if the pipe has an initial ovality or if progressive deformation is likely to occur.
Pipelines and components shall be designed to withstand the stresses arising from earth
cover, traffic and cyclic loads, particularly at connections to structures and the range of
negative pressures arising during operation and testing.
12.3.3
Collection Chamber
The chamber shall be watertight and shall be protected against floatation in waterlogged
areas. The internal surface of the sump shall be smooth and the sump shall be designed to
be self-cleansing.
Access to the chamber shall be through a manhole cover and frame as specified in Part 4 of
this section. The size of chamber shall be similar to inspection chamber on the Contract
Drawing.
12.3.4
Interface valves
Interface valves shall be all ABS construction and shall be capable of performing sufficient
cycles to evacuate 3000 m3 without attention. All materials shall be serviceable at 50 C
ambient temperature and 100 % humidity conditions except if the valves are exposed to the
sun where the temperature could reach 80oC. The valve mechanism shall be explosion
proof.
Interface valves shall:
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be minimum of 80 mm diameter and capable of passing solids with a maximum

size of 65 mm diameter with a visual flow through area of not less than 60 %
(b)
be complete with controller, sensor pipework, fittings and telemetry connections
(c)
be vacuum-operated in opening and spring-assisted in closing
(d)
be controlled by sump liquid level and by vacuum
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fail safe in the closed position
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(a)
(f)
prevent backflow to the collection sump
(g)
evacuate the batch volume on each cycle.
Batteries shall not be used in valve actuating or control elements.
Valve opening initiation level and valve opening times shall both be adjustable.
Configurations shall be such that the vacuum ensures positive valve seating.
When the valve is open, the flow stream shall not be obstructed by the valve plunger. The
valve may be protected from obstruction by the installation of constriction in the suction lift
pipework.
The internal diameter of the suction pipe shall not be greater than the internal diameter of the
interface valve which shall not be greater than the internal diameter of the service
connection.
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Valves installed in sumps shall be capable of operating when submerged in sewage.
Valves shall be designed to allow easy access for maintenance. Fixing arrangements shall
enable the valve and control system to be readily replaced.
12.3.5
Controller
Controllers shall
be explosion proof
(b)
open the interface valve only if there is a minimum vacuum of 15 kPa available
(c)
maintain the valve fully open until the sump has been fully emptied
(d)
be adjustable so that a range of air to sewage volume ratios can be obtained.
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(a)
If the introduction of air is allowed after the sewage has been fully emptied, the controller
shall maintain the valve in the open position for a further period.
12.3.6
Sensor
The interface valve shall be provided with a sensor to determine the level of sewage in the
collection sump. The sensor shall be designed to be fouling resistant. Where level sensor
pipes are employed they shall not be less than 45 mm diameter.
12.3.7
Vacuum Vessel
Flows from vacuum pipelines discharged to vacuum stations shall be collected in a vacuum
vessel. The vessel shall be manufactured of steel and be in accordance with the
requirements of BS 5500 or other corrosion resistant material such as GRP. The steel shall
be corrosion protected in accordance with Clause 8.4.2 of this Section.
Vessel capacity shall suit vacuum generator and forwarding pump capacities and the vacuum
rate of inflow and storage volume.
Vessels shall
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(a)
be fabricated and tested for a working vacuum of 70 kPa and rest vacuum of 90 kPa
(b)
be fitted with the required number of correctly sized sewage inlet and outlet
pipes which shall be integral with the vessel. No inlet pipes shall be connected
below the system emergency stop level. The inlet and outlet pipes shall be
located such that solids do not accumulate in the vessel
(c)
be provided with a suitable flanged manhole access cover to permit entry for internal
inspection and maintenance
(d)
be fitted with a level control system which is suitable for operation in vacuum and
easily removed for adjustment or replacement
(e)
be fitted with suitable galvanised mild steel cradles for bolting to the concrete floor
of vacuum station.
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The pump manufacturers advice on the need to install equalising lines connecting the
discharge side of the pumps to the vacuum vessel shall be sought. If required by the pump
manufacturer, a suitably sized and valved equalising line from each pump to the vessel shall
be provided
The steel vessel shall be internally and externally protected from corrosion with a suitable
protection system in accordance with Part 8 of this Section. Details of the proposed
protection method shall be submitted as required by Clause 12.1.5 of this Section. The
protection system shall take account of accessibility for inspection and maintenance.
12.3.8
Vacuum Pumps
Two vacuum generators such as liquid ring or rotary vane pumps or ejector pumps shall be
provided each having sufficient capacity to serve the system.
Vacuum pumps shall be capable of continuous operation and shall be designed for a
minimum of 12 starts per hour. Pumps of equal capacity shall be installed such that one
pump can act as standby.
Vacuum pumps shall be operated by pressure switches attached to the vacuum vessel. The
pumps shall operate on the liquid ring principle and shall exhaust air from the vacuum vessel.
One duty and one standby vacuum pump shall operate in conjunction with a common tank
containing the operating liquid, normally water, and associated pipework connecting the
pumps to the tank so that the water level is maintained at all times. The service liquid shall be
maintained at 30 C by a refrigerated cooling unit, circulating the liquid through the tank.
Ambient air temperatures up to 50 C shall not limit the functioning of this equipment or
cause the vacuum pumps to trip on high circulating water temperature.
Each pump shall be provided with a rotary seal comprising a rubber seal, spring loaded and
rotating against a carbon face. Suitable non-return valves shall be provided to prevent the
exhausted air from returning into the vacuum system. The pressure switches shall control
the operation of the vacuum pumps to maintain the vacuum within the system.
12.3.9
Forwarding Sewage Pumps
Forwarding pumps or pressure vessels used to forward the sewage shall have sufficient
capacity to serve the system. Forwarding pumps shall be as specified in Section 9 except as
modified below.
Forwarding pumps shall be unchokeable sewage pumps suitable for operating under
negative pressure without cavitations. They shall be suitable for a maximum of 12 starts per
hour. The motor speed shall be 1500 rpm.
A 25 mm connection of swept flanged tee shall be provided on each pump delivery, with
hand hole incorporated in the impeller casing or duckfoot bend under the pump and
reversible wear plate fitted under the impeller. Pumps shall be fitted with lip seals to prevent
loss of vacuum from the shaft when pumping from the sewage vessel.
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12.3.10 Motor Control Centre

1
The motor control centre for the operation of all pumps shall be as specified in Sections 9
and 21.
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The operation of pumps shall be controlled by a programmable logic controller and shall
prevent simultaneous starting of the vacuum and sewage pumps to prevent surges.
The controls shall permit the manual or programmed selection of duty and standby pumps
and shall provide for automatic start of the standby pumps in the event of duty pump failure.
The vacuum pumps shall be controlled by monitoring the vacuum in the vacuum vessel with
adjustable pressure switches set to the desired operating range. Additional pressure devices
shall be provided to indicate and record both high and low vacuum.
The level control system shall respond to the following sewage levels in the vacuum vessel or
the sewage sump:
stops vacuum generation

forwarding pumps operate
starts forwarding pumps
stops forwarding pumps.
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Start level
Normal stop level (Low Level)
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Emergency stop level (High Level)
All power, control and instrumentation cabling shall be provided as required for the complete
system.
The following alarms with appropriate remote signalling shall be provided:
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low vacuum alarm indicating that system vacuum is below the minimum preset level
(b)
high sewage alarm indicating that sewage level in the vacuum vessel or sewage sump
is at the high level mark.
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(a)
Telemetry shall be designed and installed in accordance with Section 10.
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12.3.11 Telemetry Outstation
12.3.12 Discharge Pipelines
All pipes, fittings and valves on the discharge side of the forwarding pumps shall be as
specified in Parts 3 and 5 of this Section.
12.4
INSTALLATION OF THE SYSTEM
12.4.1
Pipelines
Vacuum and pressure pipelines shall be installed in accordance with Part 4 of this section
and valves shall be installed as specified in Part 5 of this Section, except where modified
herein.
Vacuum pipelines shall be jointed as specified herein.
12.4.2
Pipe Joints for Vacuum Pipelines
Pipeline components shall be connected in such a way that the pipeline is sealed and
accommodates static and dynamic stresses.
Where mechanical joints are employed they shall comply with the requirements of Part 3 of
this Section and be suitable for vacuum service.
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Pipelines shall be securely anchored or bedded to resist thrust arising from internal vacuum.
Precautions shall be taken against flotation where necessary.
Welded joints shall only be made by suitably trained personnel using approved welding
equipment.
12.4.3
Pumps, Motors and Instrumentation
Pumps shall be installed as specified in Section 9.
Motors shall be installed as specified in Sections 9 and 21.
Instrumentation shall be installed as specified in Section 10.
12.5
TESTING
12.5.1
General
The Contractor shall prepare and submit his proposed testing program for the approval of the
Engineer.
The Engineer shall be notified 24 hours in advance of testing.
Pipelines and equipment shall be adequately restrained before testing.
On satisfactory completion of testing, the Contractor shall submit a report describing the tests
undertaken and the test results.
12.5.2
Testing of Interface Valves, Controllers and Sensors
Interface valves, controllers and sensors shall be tested to demonstrate that they function
correctly to meet specified duties.
Where new valves or controllers are introduced or significant changes are made to proven
valves, laboratory tests shall be undertaken under simulated working conditions and test
certificates provided. The tests, using water and air, shall demonstrate that the complete
valve mechanism can comply with the preceding performance requirements.
12.5.3
Testing of Pipelines
Pipelines shall be pressure and vacuum tested.
Pressure tests shall be carried out in accordance with Clause 4.5.3 of this Section.
Before carrying out a vacuum test, the Contractor shall ensure that the test equipment is
calibrated, is in working order and correctly fitted to the pipe.
The permitted loss of vacuum in pipeline tests shall be corrected to allow for changes in
temperature and atmospheric pressure. Pipe temperatures atmospheric pressure shall be
recorded at the start of the test and at hourly intervals.
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Page 14
Regular vacuum testing and final vacuum testing shall be carried out as specified herein. In
the event of failure under either test, the leaks shall be located and repaired, and the tests
redone.
Regular vacuum testing of all service connections and vacuum sewers shall be carried out on
the pipelines before backfilling and in sections as approved by the Engineer. The test
duration shall be 1 h. Open ends of pipeline shall be capped and a vacuum of 80 kPa applied
and allowed to stabilise for 15 min after which time the fall in vacuum shall not exceed 1.0 %
over the 1 h test.
Final testing of service connections, vacuum sewers and vacuum vessels shall be tested
before the installation of the interface valves. The test duration shall be 4 h. A vacuum of
80 kPa shall be applied using the vacuum pumps in the vacuum station. Instrumentation shall
be provided to record system vacuum during testing. After the vacuum has stabilised, the fall
in vacuum shall not exceed 1.0 %/h for each hour of the test.
12.5.4
Testing of Pumps, Motors and Instrumentation
Testing of pumps shall be in accordance with Section 9.
Testing of motors shall be in accordance with Sections 9 and 21.
Testing of instrumentation shall be in accordance with Section 10.
12.6
TRAINING OF EMPLOYERS PERSONNEL
The Contractor shall prepare and submit a training program and manual for the approval of
the Engineer. The training shall cover system installation, operation and maintenance, and
record keeping and interpretation.
On-site training shall be provided by the system manufacturer specialist staff for a minimum
period of 90 days.
The Contractor shall provide facilities required for implementation of the training program.
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END OF PART
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Part
02: Earthworks
Page 1
EARTHWORKS ............................................................................................. 2
2.1
GENERAL ...................................................................................................... 2
2.1.1
2.1.2
2.1.3
2.1.4
2.1.5
Scope
References
Definitions
Trial Holes
Services Co-ordination
2.2
EXCAVATIONS ............................................................................................. 3
2.2.1
2.2.2
2.2.3
2.2.4
2.2.5
2.2.6
2.2.7
2.2.8
2.2.9
2.2.10
2.2.11
2.2.12
2.2.13
2.2.14
General
Surfaces
Materials
Excavations to be Kept Dry
Access
Trench Excavations
Appurtenant Structures for Pipelines
Excavation in Roads
Excavation in Areas Other Than Road Reserves
Support of Excavations
Slips and Falls and Excess Excavation
Trimming and Levelling
Excavations Not to be Left Open
Dewatering of Excavations
2.3
BACKFILL .................................................................................................... 13
2.3.1
2.3.2
2.3.3
2.3.4
2.3.5
2.3.6
2.3.7
2.3.8
Pipe Bedding
Pipe Surround
Geotextile Filter Membrane
Backfilling Excavation
Backfilling Excavations with Cement-Bound Granular Material
Backfilling Excavation with Flowable Fill (Foamed Concrete)
Backfilling Next to Pipeline Structures
No-Fines Concrete as Trench Backfill
2.4
REINSTATEMENT OF SURFACES ............................................................ 22
2.4.1
2.4.2
Reinstatement within the Highway

Reinstatement of Surfaces Other Than in the Highway
2.5
EXISTING SERVICES ................................................................................. 23
2.6
BLASTING ................................................................................................... 24
2.7
MISCELLANEOUS ...................................................................................... 26
2.7.1
2.7.2
Service Ducts
Formation of Bunds and Embankments
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2
2
2
3
3
3
3
4
5
5
6
8
9
9
10
10
11
11
12
14
16
16
17
19
21
22
22
22
22
26
26
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Part
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Page 2
EARTHWORKS
2.1
GENERAL
2.1.1
Scope
This Part includes earthworks for pipelines including, excavation, granular pipe bedding,
concrete protection of pipe, backfill and compaction, and service protection ducts to protect
existing utilities.
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General
General
Ground Investigation
Concrete
Roadworks
Landscaping.
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This Section
Part 1,
Part 3,
Part 9,
Part 10,
Part 12,
Section 1,
Section 3,
Section 5,
Section 6,
Section 12,
Section 28,
References
The following standards and other documents are referred to in this Part
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2.1.2
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BS 410........................Test sieves
BS 1924......................Stabilised materials for civil engineering purposes
BS 6031......................Code of practice for earthworks
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BS EN 12620..............Aggregates for concrete

BS EN ISO 11058 ......Geotextiles and geotextile-related products

BS EN ISO 12956 ......Geotextiles and geotextile-related products
Ministry of Municipal Affairs & Agriculture, Roads Department, Highway Maintenance
Section, Code of Practice and Specification for Road Openings in the Highway
2.1.3
Definitions
Trench excavation means excavation in all materials of whatever nature encountered for
trenches into which pipes, ducts or cables are to be laid, or manholes, chambers and
appurtenances constructed, and the term pipe shall mean pipe of all kinds and for whatever
purposes.
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02: Earthworks
Page 3
Trial Holes
Trial holes for determining the location of existing services shall be excavated well ahead of
the trench excavation to such depths as necessary to determine and confirm the alignment
for the trench and the soil condition. The Contractor shall arrange for the refilling and
reinstatement of trial holes to be carried out immediately after the required information is
obtained. The reinstatement of trial holes shall be carried out to the approval of the Engineer.
2.1.5
Services Co-ordination
In addition to the requirements of the relevant Parts of Section 1 and Part 1 of this Section,
the following paragraphs shall apply to services co-ordination for pipeline excavations.
Notwithstanding any relevant information furnished by the Engineer, the Contractor shall be
responsible for ascertaining from his own inspection of the Site and the respective Utilities
Service Departments and private landowners the position of all mains, pipes, cables, and
other services and facilities whether underground or overhead within or near the Site.
Except as otherwise specified, the Contractor shall make arrangements necessary for
carrying out the Works with the various Utilities Service Departments and private landowners.
The Contractor shall be responsible for any damage caused as a result of his omission in this
respect, and for any damage caused by his failure to notify the Engineers representative and
the agencies concerned immediately any service is encountered in the excavations.
Work on existing services is specified in Subparts 2.4, 2.5 and 2.7 of this Part.
2.2
EXCAVATIONS
2.2.1
General
The Contractor shall be deemed to have obtained additional site information in accordance
with Clause 1.3.1 of this Section.
2.2.2
Surfaces
Before the surface of the area to be excavated is disturbed the Contractor shall take and
record levels of the area in the presence of the Engineer. At least two days notice shall be
provided to the Engineer.
The demolition of existing works shall be in accordance with Section 2.
Except as otherwise designated in the Project Specification or directed by the Engineer,

breaking out and restoration of existing surfaces and works shall be done in accordance with
the Code of Practice and Specification for Road Openings in the Highway published by the
Highway Maintenance Section, Civil Engineering Department, Ministry of Municipal Affairs
and Agriculture.
Surface materials shall be carefully stripped or otherwise removed and set aside for reuse,
restoration, or replacement as directed by the Engineer.
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2.1.4
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02: Earthworks
Page 4
Where the trench excavation crosses surface barriers such as fences and walls the
Contractor shall
(a)
obtain the written approval of the Engineer before breaching the barrier
(b)
minimise the size of the opening, where possible using a short heading
(c)
carefully dismantle the barrier as necessary for reuse, replacement, or reinstatement
(d)
provide temporary fencing for any removed parts of such barriers as directed by the
Engineer.
Materials
Selected excavated material shall be the most suitable portions of the excavated material
free from matter harmful to other materials in the works and which is capable of being
compacted to the specified density to form stable fill. The material shall also conform to the
requirements mentioned in Clauses 3.3.2, 3.3.3 and 3.3.5 of Section 6.
It shall be the responsibility of the Contractor to locate suitable borrowed or imported fill
material which may be necessary and to carry out such tests as the Engineer may require to
demonstrate the suitability of the fill to be supplied. Imported fill shall be from a source
approved by the Engineer. Imported fill shall have the following properties
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2.2.3
maximum stone size of 150 mm except as specified in Clause 2.3.2 of this Part
(b)
liquid limit less than 35 %
(c)
plasticity index of not more than 10.
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(a)
Excavated material unsuitable for use in the Works shall not be stockpiled on the Site.
Disposal of excavated material not used in the Works shall be the responsibility of the
Contractor and shall be at a location approved by the relevant government agency.
Excavated material shall not be stockpiled on road reservations nor at other locations
designated in the Project Specification. The Contractor shall confine his operations to the
working areas available to him for the construction of the Works particularly where this is
located in roads or in other places to which the public has free access.
Stockpiling materials on the Site or off the Site, as necessary, shall be the responsibility of
the Contractor. The stockpiling of surplus excavated material or other debris on site is not
permitted. All surplus excavated material shall be removed from site to approved disposal
sites. All dump trucks transporting waste shall be fully covered to prevent discharge of the
contents.
Any temporary storage alongside the trench excavation shall be to stable slopes and heights
and deposited in such a manner that no damage and as little inconvenience as possible is
caused. Backfilling materials shall be fenced off and continuously irrigated with water to avoid
dust and pollution.
Where the nature of the excavated material is suitable, the Contractors temporary storage
as aforesaid shall include for separate storage as the Engineer may direct of the various
grades of materials hereinafter specified for the refilling and surface reinstatement of trench
or structure excavation, namely, soft material, coarse material, hard material and topsoil. The
Contractor is to agree a screening location with the concerned municipality.
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02: Earthworks
Page 5
The screening of trench excavated material will not be permitted on site without the written
10
The Contractor shall post signs indicating proposed use of material stockpiled. Post signs
shall be readable from all directions of approach to each stockpile. Signs should be clearly
worded and readable by equipment operators from their normal seated position.
11
The Contractor shall not stockpile excavated materials near or over existing facilities,
adjacent property, or completed work, if weight of stockpiled material could induce excessive
settlement.
12
The Contractor shall obtain all necessary approvals for the sites of borrow pits and quarries.
All borrow pits shall be left in a tidy and regular state. The Contractor shall ensure that pits
are self-draining at all times and do not constitute a nuisance and danger to the public.
2.2.4
Excavations to be Kept Dry
The Contractor shall keep excavations free of water, sewage, and other liquids whether
affected by tides, floods, storms, or otherwise so that the Works shall be constructed in dry
conditions.
The Contractor shall keep the subsoil or accumulated water or sewage at a level lower than
the bottom of the permanent work until trench backfilling is complete or for such other period
Measures taken by the Contractor for the control of water shall conform with the
specifications of this Part.
2.2.5
Access
A minimum clear carriageway width of 3 m shall be maintained for vehicular traffic unless
otherwise approved by the Engineer.
Excavations in roads shall be organised to reduce to a minimum the interval between

opening up and backfilling excavations.
The Contractor shall supply, post and display at all entrances to all properties a Notice of
Excavation before any excavation is undertaken in front of or in the vicinity of the property.
The notice shall be in the form of a self- adhesive glossy sticker which shall be easily
removable. A typical sample is shown in Section E of the Contract Documents. The
Contractor shall remove the label after all the excavation has been backfilled.
Should cess-pits of other artificial obstructions be encountered in the excavation either above
or below ground level the Contractor shall forthwith advise the Engineers Representative
thereof and execute at his own cost such work as may be ordered.
The Contractor shall allow for laying pipes through any cess pits or septic tanks encountered
along the route. Pipes shall be laid such that joints occur either side of the structure or in a
manner approved by the Engineers Representative.
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Trench Excavations
The Contractor shall provide the necessary support of excavations. Details of excavation
support systems shall be submitted to the Engineer for review and approval at least sixty (60)
days before any excavation work commences.
Support of excavations shall be provided in accordance with BS 6031, except as otherwise

specified in this Part.
The term necessary support of excavations covers all normal methods of temporary
support including timber, concrete, steel sheet piling, steel trench sheeting or other materials
as may be approved by the Engineer. Where excavation is carried out near or under an
existing structure or any portion of the Work, the Contractor shall prevent damage due to
subsidence with methods approved by the Engineer.
The maximum trench width shall be as given in Table 2.1 unless otherwise shown on the
drawings. The width of the excavation shall be increased if necessary to provide space for
the trench support system; undercutting of the trench sides will not be permitted.
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2.2.6
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Table 2.1 Maximum pipe trench width at 300mm above pipe crown
Nominal Bore
Maximum Trench
Nominal Bore
Maximum Trench
mm
Width mm
mm
Width mm
550
150
600
200
800
300
900
400
1000
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100
600
1350
800
1550
1000
2000
1200
2300
1400
2500
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500
1250
1500
2700
If the Contractor exceeds these trench widths he shall provide plain or reinforced concrete
cradles and /or reinforced concrete arches to the requirements shown on the drawings and to
the approval of the Engineer at no additional cost. When directed by the Engineer, supply
and install strong and sufficient shoring to support excavations at no additional cost.
No additional payment will be made to the Contractor for working in a confined space or if the
position of the Works precludes the use of mechanical excavators or the storage of
excavated materials next to the excavations.
The Contractor shall submit shop drawings of all temporary works and trench support
systems or proprietary manufacturers catalogues detailing his proposed methods of
construction at least one month prior to starting excavations. The shop drawings shall be
complete with all details, design calculations, and description of construction methods. The
Engineers approval of the Contractors submittal shall not relieve the Contractor from
obligations under the Contract.
Except as otherwise precluded by the Project Specification, the Contractor may propose to
excavate with battered side slopes. If required by the Engineer, the Contractor shall provide
three copies of a report which shall include relevant calculations and method statement
demonstrating the adequacy of the proposals.
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Part
02: Earthworks
Page 7
In the event of any trench being excavated with battered or stepped sides, that portion of the
trench which extends from the formation to a point not less than 300 mm above the crown of
the pipe when laid in its correct position shall be formed with vertical sides. Support shall be
provided to the vertical trench sides to prevent ground movement. Where temporary trench
supports are provided they shall be such that no ground movement occurs on removal.
Where battered sides are proposed, no excavation work shall begin until the Engineers
approval has been obtained. The Engineers approval shall not relieve the Contractor from
his obligations under the Contract.
10
The line and level of trenches shall be as shown on the Drawings and shall be maintained in
accordance with the following procedure:
before beginning trench excavations, the route of the pipeline shall be surveyed and
set out accurately and the existing ground level shall be agreed with the Engineer
(b)
sight rails shall then be fixed and maintained at each change of gradient, and at as
many intermediate points as may be necessary. The centreline and the level to which
the excavation is to be carried out shall be marked on the site rails and the rails shall
not be more than 20 m apart
(c)
alternate methods to maintain line and level of excavations shall be subject to the
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Trench excavation shall be carried out as follows:
trench excavation shall be carried out by such methods and to such lines, dimensions
and depths as shall allow for the proper construction of the Works
(b)
trench widths shall conform with the limits shown on the Drawings, or ,in the case of
flexible pipes, to the widths stated in the Contractors approved methods statement.
Where trench widths do not conform to the limits shown on the Drawings, the Engineer
will direct the Contractor as to the measures to be taken to remedy the situation. Such
remedial works shall be carried out by the Contractor as an obligation under the
Contract at no additional cost to the Employer
(c)
rock encountered in trench excavations shall be so excavated that the clearance

between the pipe, when laid, and the rock sides and bottom of the trench is kept to
the minimum limits necessary to provide for the specified thickness of bedding and
where provided the concrete protection of the pipe
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(a)
12
(d)
bell holes and holes and depressions for couplings, valves and the like shall be
excavated the same distance below these installations as specified for the pipe.
(e)
When the trench width measured 300mm above the crown of the pipe exceeds the
maximum allowable shown on the drawings for granular surround the Contractor shall
proceed as Clause 4.3.2 of this Section.
Limitations on the lengths of opened trenches shall be as follows:

(a)
no length of trench excavation shall begin until the pipes and fittings to be laid in the
length of excavation are available at the Site.
(b)
the Engineer reserves the right to direct the Contractor on the lengths of trench
which shall be excavated at any one time
(c)
the Contractor shall not be permitted to excavate trenches in more than one location
in any road at a given time without the Engineers approval
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(d)

Part
02: Earthworks
Page 8
in areas accessible by the public, the maximum length of open trench in any one
section shall not exceed 100 m. In other areas the trench shall be dug only so far in
advance of pipe laying as the Engineer shall permit.
The Contractor shall at his own expense remove from the Site all unsuitable and excess
material resulting from excavations beyond that required for the foundation, lining or bedding
and shall make good the same with concrete or suitable fill material as may be required by
the Engineer.
14
The Engineer will inspect ground condition, or trench formation level and may direct the
Contractor to remove additional material and to refill the excavation with concrete or other
approved material. Should any acceptable native material at the foundation level
subsequently become unsuitable the Contractor shall remove it and replace it with concrete
or other suitable material as directed by the Engineer at no additional cost to the Employer.
15
If utility obstructions are encountered during excavation and cannot be diverted, the
Contractor shall make the necessary changes to the design drawings and submit to the
Engineer for approval. The Contractor shall not make any deviation from the specified lines
or grade of the tunnel without written approval from the Engineer.
16
Excavation shall be carried out to the dimensions, depths or levels in such a manner as to
avoid excavation of or disturbance of material below grade.
17
Pipes of greater strength or the use of superior pipe bedding may be used in lieu of
maintaining the maximum trench widths shown in Table 2.1 or specified for various pipe
diameters, subject to the Engineers prior written approval.
18
The Contractor shall excavate trenches to the levels that will allow for the pipe wall thickness
and bedding thickness.
19
The Contractor shall leave a clear space as approved by the Engineer, between the edge of
the excavation and the inner toes of the spoil banks.
20
The Contractor shall grade the trench bottom with hand tools, remove loose and disturbed
material, and trim off high areas and ridges left by excavating bucket teeth. Allow space for
bedding material if shown on the design drawings or as specified.
21
The Contractor shall remove soft sub-grade that may cause pipe settlement and replace with
suitable backfill compacted in layers not exceeding 150 mm.
22
The bottom of excavations for permanent structural works shall be free from mud and water,
trimmed clean, protected from the effects of the weather and consolidated to achieve the
required bearing capacity prior to the placement of structural work or construction materials
within the excavation.
2.2.7
Appurtenant Structures for Pipelines
The Contractor shall carry out the necessary excavations to accommodate appurtenant
structures such as manholes, chambers and thrust blocks. The requirements for the
completion of excavations and handling of excavated material shall be as specified above for
trench excavations shall apply.
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02: Earthworks
Page 9
Excavation in Roads
In addition to the foregoing and the provisions of Section 1, pipeline excavation in roads and
highway reserves including the provision of public safety facilities including barriers and
enclosures shall be in accordance with the Code of Practice and Specification for Road
Openings in the Highway published by the Highway Maintenance Section, Roads
Department, Ministry of Municipal Affairs and Agriculture (MMAA).
Where trenches are excavated open cut in roads, the asphalt shall be saw cut along the
edges of the trench, prior to excavation.
In the lanes of the road that remain open to traffic, road drains and channels shall be kept
free from construction materials, debris and obstruction at all times.
Normally trench excavation along roads shall be located in the service reserves or verges
adjacent to the road rather than in the carriageway itself. Trench excavation shall wherever
practicable be carried out in such a way that every part of the excavation is at least 1 m clear
of the existing edge of the carriageway. The Contractor shall obtain information regarding
utilities reservations from the Planning Department of the Ministry of Municipal Affairs &
Agriculture and refer to their publication entitled Road Hierarchy: General Guidance for Road
Cross-Sections and Utilities Disposition.
The Contractor shall take special precautions, which includes the continuous support of the
sides of the excavation, from the start of excavation until the refilling and compaction of the
trench backfill material is completed.
The Engineer may direct the trench excavation to be realigned from that shown on the
Drawings to facilitate the flow of traffic.
Where trench excavation or any other part of the Works obstructs any footpath or right-ofway, or property access, the Contractor shall provide, at his own cost, a temporary access
around the obstruction to the satisfaction of the Engineer. Where applicable, this temporary
access shall include stout wooden bridges with hand rails and kick boards or other approved
construction across any open trench. Suitable steel road plates shall be provided and
maintained where vehicle access is deemed necessary.
No excavated material shall be permitted to be deposited or stockpiled in grassed or planted

areas. The Contractor shall immediately remove excavated material to a temporary storage
area and import selected approved materials for the trench filling operations.
Where excavated material has temporarily been deposited on a verge, the verge shall on
completion of backfill be restored to its original condition and left free from debris.
2.2.9
Excavation in Areas Other Than Road Reserves
Areas other than road reserves shall include but not be limited to cultivated areas,
undeveloped areas, footpaths, verges, non-asphalt roads, lanes, alleys, and all private lands.
The Contractor shall take measures to prevent access of unauthorised persons, the general
public and animals to areas in which there are open excavations, access routes and steep or
loose slopes arising from the Contractors operations.
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2.2.8
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Page 10
The Contractor shall provide adequate temporary barriers and fencing. When necessary,
barriers and fencing shall be illuminated.
Temporary barriers and fencing shall not be removed without the Engineers written
permission, which will not normally be given until the trench excavation has been refilled and
reinstated.
2.2.10
Support of Excavations
The Engineer reserves the right to direct the Contractor to take measures to augment the
Contractors proposals for the support of excavated surfaces. If, in the opinion of the
Engineer, the support proposed by the Contractor is insufficient, the Contractor shall modify
his proposals and provide trench support as directed by the Engineer. The absence of the
Engineers direction, or action by the Contractor in accordance with the direction of the
Engineer shall not relieve the Contractor of his obligations under the Contract.
Shoring shall be properly maintained until in the opinion of the Engineer the permanent work
is sufficiently advanced to permit the shoring to be removed. The removal of shoring shall be
carried out only under the personal supervision of a competent foreman. If the Contractor
proposes not to remove the shoring on completion of the permanent work he shall obtain the
Engineers prior written approval.
All temporary works supporting the faces of excavations shall be removed during backfilling
with the approval of the Engineer. Where removal is impracticable and with the approval of
the Engineer, temporary works shall be left in place. Temporary works left in place shall be at
no additional cost to the Employer.
When, in the opinion of the Engineer, temporary supports need to be left in excavations to
support existing structures or the permanent Works, the Engineer may direct that temporary
supports be left in place. Temporary supports left in place shall be at no additional cost to the
Employer.
Underpinning, supports and other protective measures that are required for buildings,
structures and apparatus in or adjoining excavations shall be provided by the Contractor.
Such permanent or temporary works shall be of adequate design and construction. When
directed by the Engineer, the Contractor shall submit his methods statement for such work
for the approval of the Engineer. The Engineers approval shall not relieve the Contractor
from his obligations under the Contract.
Damage to the Works and any consequential damages caused by the removal of shoring are
the responsibility of the Contractor. Permission or approval by the Engineer to remove
shoring shall not relieve the Contractor from this responsibility.
2.2.11
Slips and Falls and Excess Excavation
Slips and falls in trenches shall be prevented as follows:
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(a)
the Contractor shall effectively support the sides of all trench excavation to prevent
slips and falls of material in the excavation. Support may include the use of closed
sheeting or steel sheet piles, where necessary, to prevent any fall or run from any
portion of the ground outside the excavation into the trench and to prevent settlement
of or damage to existing services and structures next to the excavation
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Part
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(b)
any excavation carried out by the Contractor to prevent slips and fall, or should
portions of trench walls slip or fall away, the Contractor shall at his own expense take
all necessary remedial measures including the excavation removal and reinstatement
of all the ground thereby disturbed
(c)
in all cases where the voids so formed when backfilled would provide support for the
permanent Works or adjacent structures and services, such voids shall be filled
with Grade 20 SRC concrete at the Contractors expense. In all other cases the voids
shall be filled with selected excavated material compacted as specified in this Part.
Trimming and Levelling
No excavation shall be filled in or covered with concrete until it has been inspected by the
Engineer.
Where shown on the Drawings or instructed by the Engineer, a layer of blinding concrete
shall be placed to the required thickness to protect the formation and provide a clean working
surface.
The Contractor shall compact the formation before placing the blinding concrete, when in the
opinion of the Engineer the formation density can be improved by compaction.
When excavating to specified levels for trench excavation for pipelines, or to specified limits
for the face of any thrust block or other structure required to abut or to rest upon undisturbed
ground, excavations shall be trimmed as follows:
the Contractor shall not excavate the last 150 mm until immediately before beginning
construction work except where the Engineer permits otherwise. Should the
Contractor have excavated to within 150 mm above these specified levels or to within
150 mm of these specified limits before he is ready or able to commence the
construction work he shall where required by the Engineer excavate further so as to
remove not less than 150 mm of material immediately before commencing the
construction work and any such further excavation and additional foundation material
ordered by the Engineer shall be at the cost of the Contractor. The last 150 mm shall
be hand excavated
the bottom of excavations shall be carefully boned in and trimmed true to grade with
the aid of a straight-edge.
(b)
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2.2.12
2.2.13
Excavations Not to be Left Open
Trench excavation shall be carried out expeditiously in the following manner:

(a)
the refilling and surface reinstatement of trench excavations shall begin and be
completed as soon as reasonably practicable after the pipes have been laid and
jointed
(b)
the Contractor shall take precautions to prevent flotation of pipes in locations where
open trench excavations become flooded, and these precautions shall include the
partial refilling of the trench leaving pipe joints exposed for tests of the joints
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Part
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Page 12
if the Engineer considers that the Contractor is not complying with the foregoing
requirements, The Engineer will not permit further trench excavation until he is
satisfied with the progress of laying and testing of pipes and refilling of trench
excavation.
Dewatering of Excavations
For construction dewatering refer to Section 1 Part 24 Construction Dewatering.
The Contractor shall submit methods statements including drawings and data showing the
intended plan for dewatering operations. Details of locations and capacities of dewatering
wells, well points, pumps, sumps, collection and discharge lines, standby units, water
disposal methods, monitoring and settlement shall be included. The methods statement shall
be submitted to the Engineer for approval not less than 30 days before the start of
dewatering operations. The Engineer reserves the right to reject the proposal if he is not
satisfied with measures.
The Contractor shall satisfy himself on the scope of dewatering necessary for the
construction of the Works and shall make the necessary investigations to obtain the required
data and information.
Where necessary, the Contractor shall divert natural and artificial waterways encountered at
the Site until the Works are completed.
The Contractor shall perform dewatering as necessary to ensure that
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2.2.14
the Works are installed on dry areas and excavations, including without limitation the
construction of all structures and underground piping
(b)
dewatering is carried out only to a depth sufficient for the required excavation
(c)
during construction, no groundwater shall come into contact with any concrete surface
or reinforcement
(d)
structures shall be capable of withstanding any hydrostatic pressure to which it may

be subjected during construction and until completed.
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(a)
The Contractors dewatering operations shall be conducted so as not to endanger the

foundations or stability of the Works or any adjacent structures. Damage caused by the
Contractors operations shall be made good by the Contractor at no additional cost to the
Employer.
Discharge of groundwater from excavations to the sea, into surface storage ponds or deep
well recharge shall require the approval of the Ministry of Environment.
Water removed from excavations shall first pass through settlement tanks and on-site
treatment prior to discharge.
Unless otherwise approved by the Engineer, wellpoint dewatering systems shall be provided
on both sides of trenches.
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The static water level shall be drawn down a minimum of 300 mm below the bottom of the
excavation so as to maintain the undisturbed state of the foundation soils and allow the
placement of any fill or backfill to the required density. The dewatering system shall be
installed and operated so that the groundwater level outside the excavation is not reduced to
the extent that would damage or endanger adjacent structures or property.
11
The Contractor shall, where extensive dewatering is required, be fully qualified to perform the
dewatering operations or shall furnish the services of an experienced, qualified, and
equipped dewatering subcontractor to design and operate the dewatering and groundwater
recharging system required for the work, all subject to the Engineers approval.
12
When directed by the Engineer, the Contractor shall establish a specified number of
groundwater level monitoring stations at each site which shall be observed during the work.
These shall be located as directed by the Engineer and consist of acceptable open tube
piezometers. When directed by the Engineer, the Contractor shall provide settlement gauges
to the approval of the Engineer and monitor settlement of new and existing facilities.
13
Dewatering shall not result in the flow of water along the pipe zone material. Full
consideration should be given to the use of cut-off walls to reduce the potential for
groundwater flow along pipe trenches. The Contractor shall submit for the Engineers
approval, details of his proposed method of working and temporary works installations to
achieve this.
14
If the use of drainage conduits, channels or subdrains is approved by the Engineer and are to
be left in place below the level and within the width limits of permanent Works they shall be
structural capable of providing support. Ballast filled subdrains to be left in place under
concrete shall be covered with a geotextile membrane. Subdrains left in place shall be filled
with Grade 20 SRC concrete or an approved cementitious grout.
15
The release of groundwater to its natural static level shall be performed so as to maintain the
undisturbed state of the natural foundation soils, prevent disturbance of compacted fill or
backfill and prevent floatation or movement of structures, pipelines and sewers.
16
No dewatering system shall be removed until infiltration testing is completed nor without the
approval of the Engineer. Monitoring and settlement measurement systems shall be
maintained in operation until removal is approved by the Engineer. With the approval of the
Engineer, wellpoints and like items may be abandoned in place.
17
Partially completed permanent works shall not be allowed to become flooded and the
Contractor shall allow for additional standby pumps and equipment required to ensure this. A
pump operator shall be on site 24 hours per day to supervise pumping equipment.
18
In the event of partially completed trenches becoming flooded, the Contractor shall reexcavate to formation level and re-lay the pipes.
19
The Contractor shall provide a silt-trap in any temporary drain which he may construct and
prior to discharge into any permanent drain which he may wish to use for the removal of
water during the construction period. The Contractor shall keep both temporary and
permanent drains clear of silt to the satisfaction of the Engineer until the completion of the
Contract. Any silting up of the watercourses arising from the Contractors failure to comply
with this Clause shall be remedied at his expense whether within the Site or not.
2.3
BACKFILL
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2.3.1
Pipe Bedding
Pipe bedding shall be provided as shown on the Drawings or stated in the Contractors
approved methods statement.
Pipe bedding shall be well compacted to a minimum void ratio to provide a high load-bearing
capacity and a stable base below the pipe and shall completely fill the whole width of the
trench excavated. Compaction requirements equivalent to at least 90 percent of the Standard
Proctor Maximum Dry Density shall be achieved. Additional bedding necessary to fill voids
created by over excavation shall be provided entirely at the Contractors expense.
Pipe bedding shall consist of granular material and shall shall conform with the following
requirements:
shall be free of organic and deleterious matter and shall consist of strong durable
crushed un-weathered rock or stones having roughly cubical or pyramidal shaped
fragments, graded and tested from a source approved by the Engineer. No reactive
carbonate rock or sources with indication of local groundwater contamination shall be
used.
(b)
pipe bedding material for rigid pipes shall be according to the following grading limits
giving in Table 2.2.
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(a)
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Table 2.2 Gradation Requirements for Pipe Bedding, Rigid Pipes
se
300 - 800
% by Mass
Passing
100
80 - 100
60 - 85
20 - 55
10 - 30
0 - 10
>800
% by Mass
Passing
100
90 - 100
50 80
40 70
25 60
10 40
0 - 15
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Sieve Size
25mm
20mm
14mm
10mm
5mm
2.36mm
0.300
<300
% by Mass
Passing
90 - 100
50 - 85
10 - 40
0 - 10
-
(c)
(d)
The minimum thickness of pipe bedding material below the barrel of the pipe is given
in Table 2.3.
Table 2.3 Minimum thickness of bedding material below barrel of pipe
Uniform Soil
Nominal Bore
Rock
Hand Finished
Machine Dug
(mm)
Trench Bottom
Trench Bottom
100 & 150
100
150
200
200 - 500
150
200
250
600 - 800
175
225
275
1000 & above
200
250
300
Pipe bedding and backfill to French drains shall be in accordance with Section 6, Part
14, Clause 14.9.5.
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(e)
The total loss factor for the granular material used in French drains using the ten
minute rotational test shall not exceed 10%.
(f)
Chloride and sulphate levels for bedding materials shall conform to BS EN 10319.
Pipe bedding material for flexible pipes be accoding to the following grading limits given in
Table 2.4.
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Table 2.4 Gradation Requirements for Pipe Bedding, Flexible Pipes

Pipe Diameter (mm)
<300
300
Sieve Size
% by Mass Passing % by Mass Passing
14mm
90 - 100
10mm
50 - 85
50 - 85
5mm
10 - 40
0 - 10
2.36mm
0 - 10
0 - 10
ta
The minimum thickness of granular bedding material around the barrel of the pipes shall be
100mm. Should the Contractor exceed the trench widths given in Table 2.1 he shall precede
as Clause 4.3.2 of this Section.
The design of GRP and PE pipes and bedding is specified in Parts 3 and 4 of this Section.
Granular bedding materials for GRP pipe shall be 10mm nominal size according to the
grading limits given in Table 2.4 and also meet the manufacturers requirements.
After trimming and compaction of the formation, granular bedding material shall be spread in
the trench bottom.
Cut-off walls shall be formed in granular bedding and surround to pipes to prevent the
bedding acting as a subsoil drain. Cut-off walls shall be provided at a maximum spacing of
40 m with one at each manhole and structure and at least one cut-off wall between two
adjacent manholes and structures.
Cut-off walls shall be made from an impervious fine grained clay mixture, prepared with
addition of water where necessary, to suitable trench spoil if available, or imported. Concrete
cut-off walls shall be Grade 20 SRC concrete. Cut-off walls shall be installed across the full
cross-section of the granular bedding material and shall be at least 300 mm wide along the
axis of the pipeline.
Concreting to the pipeline shall be either bed or bed and surround or encasement or backfill
as shown on the Drawings or directed by the Engineer and shall be of Grade 20 SRC
concrete placed as follows:
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(a)
concrete shall not be placed until the joints at each end of the pipe have been
completed
(b)
each pipe to be encased shall be supported on at least two purpose made precast
concrete blocks, which shall be left in place
(c)
concrete encasement shall be placed to the required depth in one operation and pipes
shall be prevented from floating or otherwise moving during concreting
(d)
continuity of concrete backfill or encasement to pipe with flexible joints shall be

broken at each joint, unless otherwise approved by the Engineer
QCS 2014
Page 16
(e)
flexible joints in concrete beds and surrounds to pipes shall be formed as shown on
the Drawings with suitable compressible fibrous board or other similar approved
material
(f)
compaction shall be carried out with approved mechanical vibrators. The maximum
period of time between mixing of the materials and final compaction of any given
material shall be kept to a minimum.
Where unstable ground conditions are met which are likely to cause undue settlement in the
pipeline, the Contractor shall submit a report including site data and the Contractors proposal
for remedial works including structural calculations for the approval of the Engineer. The
Contractor shall carry out the following remedial works as directed by the Engineer.
(a)
improvement of mechanical properties of the soil
(b)
replacement of soil by other soil or blinding concrete
(c)
pile foundations
(d)
reinforced concrete slab foundation.
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Part
02: Earthworks
Pipe Surround
Pipe surround shall be provided as shown on the Drawings or stated in the Contractors
approved method statements.
When concrete cradles are used, all concrete shall have attained adequate strength before
backfilling of the excavation commences between the completed structure and sides of
excavations.
Material for pipe surround and to the first 300mm above the top of the pipe, shall be granular
material as specified in Clause 2.3.1. The material shall be free from sharped edged stones
or other material which may cause damage to the permanent Works.
Material for pipe surround shall be placed in layers of not greater than 150mm compacted
thickness and thoroughly rammed with suitably shaped rammers working alternatively on
either side of the pipe until the fill has been carried up at least 300mm above the top of the
pipe. Care shall be taken to avoid damage to the pipe, coating or sheathing.
Compaction requirements equivavlent to at least 90 percent of the Standard Proctor

Maximum Dry Density shall be achieved.
2.3.3
Geotextile Filter Membrane
Geotextile filter membrane for surround to granular material for ground water drainage shall
conform with the requirements of Section 6 Part 15 Clause 15.1 and shall be used in the
zone extending downwards from 1.5m above the long term water table. The long term water
table is to be determined on the basis of observations made on site of the initially
encountered water table in the excavations. The placement of Geotextile is then to be
directed by the Engineer. Geotextile membrane for structural support to pipe surround in soft
ground shall be wrapped round the granular bedding as shown on the Contract drawings.
For both of the above applications the geotextile properties shall be:
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2.3.2
(a)
mean peak strength BS EN ISO 10319
(b)
elongation at peak strength BS EN ISO 10319
(c)
CBR puncture resistance EN ISO 12236
8kN/m
28%
1500N
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Page 17
(d)
pore size (O90) EN ISO 12956
0.15mm
(e)
permeability (50cm head) EN ISO 11058
100l/m .s
The fabric shall be woven or non-woven consisting of long chain polymeric filaments or yarns
formed into a stable network such that the filaments or yarns retain their relative position to
each other.
The fabric shall be inert to commonly encountered chemicals and chemical properties of the
soil and water. Geotextile fabric shall surround the granular bedding as follows:
the surface to receive the fabric shall be formed to a relatively smooth condition free
of obstruction, depressions, and debris. The geotextile fabric shall be laid loosely.
(b)
if the proposed area for fabric requires more than one panel width of fabric, the
panels shall be overlapped a minimum of 15 percent of the panel width
(c)
to prevent slippage of the overlapping fabric, the areas of overlap shall be stabilised,
as approved by the Engineer, with pins, anchor blocks, or piles of aggregate
(d)
fabric damaged or displaced before or during installation or during placement of

backfill material shall be repaired or replaced
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(a)
Backfilling Excavation
All concrete shall have attained adequate strength before backfilling of the excavation
commences between the completed structure and sides of excavations.
Selected fill material for trench backfill in open areas, shall be suitable material selected from
the excavated material as specified in Clause 2.2 of this Part. Stones larger than 150 mm in
size may be allowed, provided in the opinion of the Engineer, the required densities can be
achieved.
Selected fill material for trench backfill under paved areas, shall be suitable material selected
from excavated materials meeting the following requirements:
(a)
maximum stone size of 75m
(b)
(c)
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2.3.4
(d)
the uniformity coefficient shall not be less than 10
(e)
the total water soluble / acid soluble salt content (for sulphate and chloride) shall not
exceed 2%
(f)
organic content shall not exceed 2%
(g)
the CBR value shall not be less that 15% at 95% maximum dry density at the formation
level. The test procedure shall be as Section 6, Clause 3.10 of the specification.
the material passing the 0.063 sieve shall be less than 15%
the liquid limit shall not exceed 35% and the plasticity index shall not exceed 6%
The trench backfill material shall be placed in layers of not greater depth than 200mm
thickness and be thoroughly compacted to 95 percent of the Standard Proctor Maximum Dry
Density by approved mechanical compaction equipment. In roads and footpaths, the coarse
filling is to be carried up to the level at which surface reinstatement is to begin; elsewhere, to
such level as with the surface reinstatement of the whole of the topsoil will leave the finished
work sufficient to allow for future settlement to the original ground level.
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The moisture content of the material before compaction shall not vary by more than 2% of
the optimum moisture content (BS 1377 Part 2:1990, Test 3.2). If in the opinion of the
Engineer, the fill is too dry, it shall be watered at the expense of the Contractor in an
approved manner during refilling as may be directed by the Engineer.
Any nuclear density measurement (NDM) tests undertaken shall be performed only by
persons or companies holding a valid Authorised User Certificate issued by the Materials
Central Laboratory. Each NDM device shall have a valid Calibration Certificate, also issued
by the Central Materials Laboratory.
The Contractor shall provide the necessary testing apparatus for monitoring soil properties
and shall maintain the apparatus in good working order. A daily log of tests carried out shall
be provided to the Engineer. Testing of soil properties shall be carried out by an approval
laboratory.
Tests to determine the optimum dry density of the fill material shall be carried out as directed
on site, the frequency depending on consistency of material and test results.
Unless directed otherwise, testing for density and moisture content shall be at the rate of:
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one test per backfill layer for each structure such as manholes, chambers, and thrust
blocks
(b)
one test per backfill layer for every 30 m of pipeline trench.
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(a)
Should the backfilling material being placed become unacceptable to the Engineer due to
exposure to weather
(b)
flooding
(c)
having become puddled, soft, segregated
(d)
otherwise unacceptable during the progress of work
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the Contractor shall at his own expense remove such damaged, softened or
segregated material and replace it with fresh approved material.
To permit the proper consolidation of backfill into the voids behind trench sheeting and
supports, trench sheeting shall be withdrawn gradually as backfill progresses in depth and
along the trench.
12
On no account shall any excavated material be dozed back when filling trenches in roads and
no filling shall be carried out unless in the opinion of the Engineer, sufficient mechanical
compactors are in operation on that portion of the work.
13
Where in the opinion of the Engineer sufficient supplies of the suitable material for trench
backfilling cannot reasonably be obtained from excavations the Engineer may order the
Contractor to:
11
(a)
carry out such work as may be necessary to screen out stones
(b)
borrow excavate material from suitable borrow areas on the Site or off the Site and
transport it to the length of trench to be filled to the approval of the Engineer.
All costs for borrow material shall be borne by the Contractor.
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14
Trench backfilling shall be carried out expeditiously as soon as practicable after the pipeline
has been laid, tested and approved.
15
Trench bottom shall be free of any foreign material or backfill contaminated with foreign
material from the trench bottom.
16
Check grade and correct irregularities in bedding material. Loosen top 25-50 mm of
compacted bedding material with a rake or by other means to provide a cushion before laying
each section of pipe, conduit, direct-buried cable, or duct bank.
17
Place backfill material simultaneously in lifts on both sides of pipe and, if applicable, between
pipes, conduit, cables, and duct banks installed in the same trench.
Pipes up to and including 250 mm in diameter: First lift of backfill less than or equal to
1/2 pipe diameter.
(b)
Pipe over 250 mm in diameter: Maximum 150 mm lifts.
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(a)
Thoroughly tamp each lift, including the area under haunches, with handheld tamping bars
supplemented by walking in and slicing material under haunches with a shovel to ensure
that voids are completely filled before placing each succeeding lift.
19
After the full depth of the pipe zone material has been placed as specified, compact the
material by a minimum of three passes with a vibratory plate compactor only over the area
between the sides of the pipe and the trench walls.
20
Do not use power-driven impact compactors to compact pipe zone material.
21
Backfill used above pipe zone shall be processed to meet specified gradation requirements.
Adjust moisture content as necessary to obtain specified compaction.
22
Do not allow backfill to free fall into the trench or allow heavy, sharp pieces of material to be
placed as backfill until after at least 600 mm of backfill has been provided over the top of the
pipe.
23
Do not use power driven impact type compactors for compaction until at least 1.2 m of
backfill is placed over top of pipe.
2.3.5
Backfilling Excavations with Cement-Bound Granular Material
Backfilling excavations with cement-bound granular material shall be used for filling
excavations at manholes, access shafts, pipe line structures in roadways, underneath
exposed existing pipelines or as approved by the Engineer.
Cement-bound granular material shall consist of crushed, hard, clean, durable rock or
washed sand or a combination thereof. The material shall be sufficiently well-graded to
ensure a well-closed surface finish and have a grading within the range shown in Table 2.4
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Table 2.4 Grading for cement-bound granular material

BS 410 sieve size
50 mm
37.5 mm
100
95 - 100
20 mm
45 - 100
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10 mm
5 mm
600 m
300 m
75 m
35 - 100
25 - 100
8 - 65
5 - 40
0 - 10
The granular material shall be mixed with sufficient cement to provide the crushing strength
specified in Paragraph 12 of this Clause. The material shall be mixed in a paddle or pan type
mixer which may be batch or continuous type. Where a batch mixer is used, the mixing times
shall not be less than one minute unless the Engineer approves a shorter time subject to the
results of preliminary trials. Where a continuous mixer is used, the paddles, baffles and rate
of feed of materials shall be adjusted to provide a uniformly mixed material. Where a spray
is used for distributing water into the mixer, it shall be adjusted to provide a uniform moisture
content throughout the mix.
The moisture content of the mixed material shall not exceed 2 % above the optimum as
determined in accordance with the Vibrating Hammer Test of BS 1924.
The Contractor shall carry out preliminary tests on trial mixes to attain the specified crushing
strength.
Plant-mixed material shall be transported to the site by vehicles which shall have capacities
suited to the output of the mixing plant and site conditions, and be capable of clean
discharge. Mixed material shall be immediately transported to its required location and shall
be suitably protected from the prevailing climatic conditions during transportation and the
period before tipping.
All mixed material shall be placed and immediately spread evenly in one layer such that after
compaction the thickness does not exceed 150 mm.
Compaction in trenches shall be carried out immediately after the material has been spread
and completed within two hours of the addition of cement.
Compaction shall be carried out to achieve a density equivalent to 95 % of the average

density of the set of five cubes required for testing in paragraph 12 of this Clause.
10
Any layer of cement-bound granular material not covered within two hours shall, immediately
on completion, be cured for a minimum period of 7 day unless otherwise approved by the
Engineer or the surface is covered by permanent works. Surface curing shall be achieved by
covering with impermeable plastic sheeting until the next permanent layer is laid. The plastic
sheeting shall be adequately secured to the surface and joints shall be have a minimum
300 mm overlap, set to prevent egress of moisture.
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Samples of the mixed material shall be taken from the site immediately before compaction of
the material. A batch of five random samples shall be taken from each layer or such other
area as decided by the Engineer. From each sample a cube test specimen shall be
prepared, cured and tested using the procedure in BS 1924. The specimens shall be
compacted to be within 95 % of the cube density when compacted by vibratory hammer. The
specimens shall then be cured at constant moisture content within the range of curing
temperatures stated in BS 1924 for a period of 7 days. The specimen shall then be weighed,
the dimensions checked and tested in unconfined compression. A representative portion of
the crushed material from each specimen shall then be retained for a moisture content
determination in accordance with BS 1924 and the dry density of each specimen determined
using mass, dimensions and the moisture content of the material.
12
The average 7 days crushing strength for each batch of five test specimens made and tested
in accordance with the method described herein shall be not less than 3.5 MPa for cubes. In
addition to complying with the minimum strength requirements, the root mean square of the
coefficient of variation of the crushing strength of five successive batches of five test
specimens of the cement-bound granular material shall not exceed 25 %. If an area or layer
of cement-bound granular material represented by these specimens fails these tests, the
defective material shall be removed and replaced with new material at the Contractors
expense.
13
The cement-bound granular material shall in no case be less than 150 mm thick from the
outside barrel of the pipe to the nearest point of the shoring, and the greatest care shall be
exercised to ensure complete filling of all voids and thorough consolidation of the concrete.
The Contractor shall allow in his prices for the additional concrete used in excess of the net
requirement.
14
Cement Bound Granular Material discharged from truck mounted drum type mixer into
trench shall:
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11
Placed in lifts as necessary to prevent uplift (flotation) of new and existing facilities.
(b)
In travelled areas, fill entire trench section to pavement finish grade for a temporary
driving surface, and screed off excess and finish with a float.
(c)
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(a)
In other areas, fill the trench section as shown on the Contract Drawings.
Backfilling Excavation with Flowable Fill (Foamed Concrete)
Backfilling excavations with flowable fill shall be used for filling excavations at manholes,
trenches, access shafts, pipeline structures in roadways, underneath exposed existing
pipelines or as approved by the Engineer.
Flowable fill may be placed by chutes, conveyors, buckets or pumps depending upon the
application and accessibility.
For trench backfill, flowable fill shall be placed continuously. To contain the flowable fill along
long open trenches or open ended structures in stages, the end points shall be adequately
bulkheaded to prevent movement.
Flowable fill shall be placed in a manner to prevent flotation or displacement of the

embedded item.
2.3.6
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The 28-day compressive strength of the flowable fill shall be 5 MPa with a unit density of
3
between 1600 2000 kg/m . Accelerators may be used subject to the approval of the
Engineer.
2.3.7
Backfilling Next to Pipeline Structures
Fill materials adjacent to structures such as manholes and chambers shall be placed in
accordance with Clause 2.3.4 above.
Fill material next to structures other than pipeline structures shall be carried out as Specified
in Section 12.
2.3.8
No-Fines Concrete as Trench Backfill
Except where otherwise noted in this Clause, the design, manufacture, use and testing of nofines concrete shall comply with the requirements of Section 5 Part 6.
All material shall be placed and spread evenly. The full width of the excavated trench shall be
filled; formwork other than that required for temporary constructions joints will not be
permitted. The Contractor shall be responsible for the use of any extra material required to fill
the trench beyond the maximum trench widths detailed on the drawings. The no-fines
concrete shall generally be brought up to a height no higher than the level of undisturbed rock
on either side of the trench.
Compaction shall be carried out with approved mechanical vibrators. The maximum period of
time between mixing of the materials and final compaction of any given material shall be kept
to a minimum.
Any layer not covered within 2 hours by another layer of no-fines concrete shall, immediately
on completion of compaction, be cured for a period which shall not be less than 7 days
unless the Engineer agrees otherwise. Curing shall be achieved by covering until the next
layer is laid with impermeable plastic sheeting, adequately secured from being blown off the
surface and with joints overlapped at least 300mm and set to prohibit egress of moisture.
2.4
REINSTATEMENT OF SURFACES
2.4.1
Reinstatement within the Highway
All reinstatement of roadworks to be carried out in the public highway shall be carried out in
accordance with the latest Code of Practice and Specification of Road Openings in the
Highways.
2.4.2
Reinstatement of Surfaces Other Than in the Highway
Unless provided in the Project Specification, surfaces shall be restored to a condition

conforming to the requirements for the particular surface described in the relevant section of
this Specification. Where no specification exists, restoration shall be to the satisfaction of the
Engineer.
All surfaces, gardens or lawns shall be restored to a condition equal to the original surface to
the satisfaction of all Authority requirements, the Engineer and the owners/occupiers.
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Any reinstatement shall be fully maintained by the Contractor until such time that a TakingOver Certificate has been issued for the Works or for the Part of the Works containing the
reinstatement.
2.5
EXISTING SERVICES
The requirements of this Subpart are in addition to the general requirements specified in
Clause 2.1.5 of this Part.
The Contractor shall be required to submit in advance to the various Utilities Services
Departments and to the relevant Municipality where the Works affect the trees and plants
and a weekly programme of the pipelines he intends to lay in order that the various
departments can expose or advise on the location of their respective services.
Except as otherwise designated in the Project Specification, the Contractor shall be

responsible for maintaining all services and utilities including but not limited to waterways,
sewers, drains, gas and oil mains, water mains electricity and telecommunication cables and
all other services, structures, trees, and plants encountered during the construction of the
Works and for any remedial measures necessary to make good any damage caused thereto.
Where designated in the Project Specification, work on services shall be carried out by the
relevant Utility Service Department. The Contractor shall co-ordinate his work with the work
of the Utility Service Department, and carry out his work so as not to interfere with or damage
their services.
Where work is carried out close to or across the line of existing services, the Contractor shall
where necessary provide temporary supports or slings. Where service is interfered with or
damaged, the Contractor shall immediately notify the relevant Utilities Service Department
and shall not undertake repairs without their authorisation and approval. Unless otherwise
authorised and approved, repairs shall be undertaken by the Utilities Service Department and
the cost of such work shall be borne by the Contractor, and the Contractor shall reimburse
the Utilities Service Department its account for performing such work.
Where specified on the Drawings or by the relevant Utility Service Departments split ducts,
conforming with the requirements of Clause 2.7.1 of this Part shall be provided for the
permanent support and protection of services.
The Utility Service Department and the Engineer shall determine whether or not a service
requires to be permanently diverted, temporarily diverted or supported.
Where existing services have to be permanently or temporarily diverted as the unavoidable

result of the construction of the Works, such diversions shall be carried out either by the
Contractor or the Utilities Service Department as directed by Engineer.
Safety shall always be maintained in all work in the vicinity of existing services in accordance
with particular requirements of Utilities Service Department and the requirements of Section
1 and Part 1 of this Section.
10
In addition to the provisions of the above paragraphs, when carrying out pipelaying
operations in the vicinity of existing gas or oil pipelines, the following requirements shall
apply:
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QCS 2014

Part
02: Earthworks
Page 24
(a)
the minimum clearance between the bottom of the oil or gas line and the top of the
pipeline being constructed is to be 600 mm
(b)
a hand excavated pilot hole shall be dug to determine the gas or oil line invert level
and position prior to any trench excavation in gas or oil pipeline reservation
(c)
the excavation for the pipeline under construction must be carried out by hand up to
(d)
2.0 m either side of the existing gas or oil pipeline

manually operated jack hammers may be used within 5.0 m of the buried pipeline
only after completion of item (c) above
(f)
the use of mechanical or hydraulic rock-breakers shall not be allowed within 5.0 m of
the buried pipeline
(g)
before the exposure of live pipeline the Contractor is to erect a suitable substantial
barrier to prevent damage to the exposed pipeline.
(h)
on completion of the concrete surround to the pipelines under construction, the

existing gas or oil pipeline shall be rebedded with a minimum of 150 mm of naturally
occurring soft dune sand bed and surround. The remaining backfill and bund shall be
made up of selected desert fill with a particle size not exceeding 150 mm which shall
be free from organic matter. The Qatar Petroleum (QP) (onshore) Engineer shall be
notified a minimum of 24 h in advance, to witness the backfilling operation
(i)
damage to the external protective wrapping to the gas or oil pipeline shall be reported
promptly to the QP who will arrange for the damage to be inspected and repaired
in strict accordance with QP (onshore) procedures at the Contractors cost
(j)
the Contractor is to provide constant competent supervision whilst work is carried out
next to the existing gas or oil pipelines
(k)
when the works reach 15 m from the existing gas or oil pipeline, the Contractor shall
contact the QP (onshore) Engineering Superintendent, who will arrange the necessary
permit to work. QP (onshore) will require a minimum of 48 h notice before work begins
(l)
a QP (onshore) permit to work does not in any way make QP (onshore)

responsible for any of the Contractors work, nor does it absolve the Contractor from
his responsibilities for complying with the above, but only allows the Works to be
carried out in accordance with the agreed working methods and practices. QP
(onshore) reserve the right to visit the site regularly to observe that the agreed
methods and practices are being adhered to and to stop the work and withdraw the
permits to work should they consider there is adequate justification to do so
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(e)
(m)
the requirements of QP (onshore) may vary from and are not necessarily limited
to the foregoing.
2.6
BLASTING
The Contractor shall not use any explosives in the construction of the works without the prior
written approval of the Engineer and such approval shall be contingent upon the Contractor
being authorised by the Civil Defence Department and the Police.
QCS 2014

Part
02: Earthworks
Page 25
The Contractor shall inform the Engineer in advance about the types and quantities of
explosives needed. Explosives shall be obtained and used in accordance with the regulations
and procedures of the relevant Government Department. The Contractor shall be deemed to
have copies of relevant documentation and to be knowledgeable of relevant practices. The
Contractor shall provide copies of relevant documentation to the Engineer for the Engineers
inspection.
Notwithstanding the requirements of this Clause, the Contractor is responsible for the safe
and correct transport, handling and use of explosives.
Except as otherwise provided in the relevant regulations and procedures the handling of
explosives shall be carried out to conform with the requirements stated in the following
paragraphs.
Except as otherwise permitted by the Government, all unused explosives, or explosive

accessories shall be destroyed at the end of each days work.
Explosives and detonators shall be carried in separate vehicles during transport. The
vehicles must be clean and in a good state of repair and be of sufficient capacity to convey
the explosives safely. The Police may refuse to issue explosives if vehicles do not meet
those standards. A red flag must be clearly displayed by all vehicles when carrying
explosives.
The Contractor must appoint in writing at least one shotfirer who is in possession of a Qatar
Shotfirers Certificate of Competence to carry out all work with explosives on behalf of the
Contractor. The Contractor shall present and provide copies of such certification to the
Engineer for inspection.
The Contractor must establish simple safety rules covering the handling and use of
explosives. A copy of these rules will be given to the concerned shotfirer, who will sign a
receipt book kept for this purpose by the Contractor.
The safety rules shall specify:

(a)
the places where explosives are to be used

times of blasting
(b)
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10
(c)
measures to be taken to contain the products of blasting
(d)
method of initiation
(e)
posting of warning notices, yellow blasting flags and sentries; and audible warning, if
applicable
(f)
actions to be taken in the event of any unusual occurrence or accident
(g)
any other safety aspects relating to the use of explosives
(h)
any special instructions concerning transport
(i)
instructions relating to the limitation of blast vibrations, where appropriate.
The Contractor shall submit a copy of the safety rules to the Engineer.
QCS 2014

Part
02: Earthworks
Page 26
Shotfirers shall be responsible to the Contractor for ensuring that all explosives and
accessories are safely and carefully handled and used, in accordance with the regulations
and procedures of the Government, and his own knowledge of correct shotfiring procedure.
12
Where so directed by the Engineer, the Contractor shall provide and operate suitable
instruments to monitor and record the blast vibrations at no additional cost to the Employer.
13
Where blasting vibration could cause nuisance; e.g., in close proximity to buildings, pipelines
or other structures, the Contractor shall ensure that careful attention is given to the vibration
levels to minimise nuisance.
2.7
MISCELLANEOUS
2.7.1
Service Ducts
The Contractor shall furnish and install new protection ducts of split PVC-U pipes, concrete
encased, to protect existing utility mains or cables where new pipelines are to cross such
utility mains or cables.
After the split PVC-U pipe has been placed around the existing utility mains or cables, the
pipe shall be wrapped twice with polyethylene film, 150 m thick, to prevent fresh concrete
from entering the duct. The protection ducts shall be supported on suitable non-corrosive
spacers before placing the concrete encasement.
All concrete work shall be in accordance with the requirements of Section 5 and concrete
encasement shall be with Grade 20 SRC concrete.
2.7.2
Formation of Bunds and Embankments
The material used in the formation of embankments bunds and other areas of fill shall be
obtained by the Contractor from sources approved by the Engineer. The material shall
equate to selected excavated material or similar.
Bund and embankment material at the optimum moisture content shall be built up evenly
over the full width and compacted in layers not exceeding 300 mm in compacted depth. The
moisture content of material may require adjustment to that required to attain maximum
density. Material which contains insufficient moisture to obtain the desired compaction will
require the incorporation of additional water by the use of approved sprinklers and mixing.
Layers more than 300 mm below road formation levels shall be compacted to 90 % of the
maximum dry density. Layers less than 300 mm below road formation level shall be
compacted to 95 % of the maximum dry density. Maximum dry density shall be determined in
accordance with CML 12-97
The Contractor shall ensure that material laid immediately next to a structure, concrete wall
or thrust block is well compacted. Hand operated vibrating plate compactors vibro-tampers
or power rammers shall be used. In other cases, compaction shall be carried out by vibrating
compactors smooth wheel or pneumatic tire rollers of types approved by the Engineer.
In forming bunds and embankments, the Contractor shall make allowance for consolidation
and shrinkage in attaining the dimensions of bunds and embankments shown on the
Drawings.
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QCS 2014

Part
02: Earthworks
Page 27
The Contractor shall make due allowance for consolidation and settlement of embankments
and bunds both in width and height. Any subsidence that may occur during the period of
maintenance shall be corrected by the Contractor at no additional cost and to the satisfaction
of the Engineer.
Round tops of cut slopes in soil to not less than a 1.8 m radius, provided such rounding does
not extend offsite or outside easements and rights-of-way, or adversely impacts existing
facilities, adjacent property, or completed Work.
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END OF PART
QCS 2014

Part
03: Pipes and Fittings Materials
Page 1
PIPES AND FITTINGS MATERIALS ....................................................................... 3
3.1
GENERAL .................................................................................................................................3
3.1.1
3.1.2
3.1.3
3.1.4
3.1.5
3.1.6
Scope
References
System Description
Submittals
Delivery, Handling and Storage
Pipe Materials
3.2
VITRIFIED CLAY PIPES AND FITTINGS ..............................................................................10
3.2.1
3.2.2
3.2.3
3.2.4
Standards
Manufacture
Repair Couplings for VC Pipes
3.3
CONCRETE PIPES AND FITTINGS ......................................................................................11
3.3.1
3.3.2
3.3.3
3.3.4
3.3.5
3.3.6
Standards
Pipe Materials
Manufacture
Plastic Lining
Epoxy Coating
3.4
GLASS REINFORCED PLASTIC (GRP) PIPES AND FITTINGS ..........................................14
3.4.1
3.4.2
3.4.3
3.4.4
3.4.5
3.4.6
3.4.7
Standards
Design
Pipes and Fittings Manufacture
General
Buried GRP
Exposed GRP
3.5
PVC-U PIPES AND FITTINGS ...............................................................................................25
1.1.1
3.5.2
3.5.3
3.5.4
3.5.5
Standards
Manufacture
Joints
3.6
ACRYLONITRILE BUTADIENE-STYRENE (ABS) PIPES AND FITTINGS ..........................28
3.6.1
3.6.2
3.6.3
3.6.4
Standards
Manufacture
Joints
3.7
DUCTILE IRON PIPES AND FITTINGS .................................................................................28
3.7.1
3.7.2
3.7.3
3.7.4
3.7.5
Standards
Exposed Joints
Buried Joints
Internal Lining
External Coating and Wrapping, Use and Materials
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3
3
5
5
6
9
10
10
11
11
11
11
12
13
13
13
14
16
17
17
17
23
24
25
26
27
27
27
28
28
28
28
28
28
29
29
29
QCS 2014

Part
Page 2
3.7.6
3.7.7
3.7.8
Factory Application of Tape Wrapping

Factory Applied Extruded Polyethylene Coating
3.8
FLANGE ADAPTERS AND FLEXIBLE COUPLINGS ...........................................................32
3.8.1
3.8.2
3.8.3
General
Flange Adapters
Flexible Couplings
3.9
PIPES FOR OTHER USE .......................................................................................................33
3.9.1
3.9.2
3.9.3
3.9.4
Copper Tubes and Fittings

Hose and Appurtenances
Stainless Steel Pipes, Tubes and Fittings
Carbon Steel Pipes and Fittings
3.10
MEDIUM AND HIGH DENSITY POLYETHYLENE (HDPE) PIPES .......................................34
3.10.1
3.10.2
3.10.3
3.10.4
3.10.5
Applicable Standards
Manufacture
Fittings
Pipes and Fittings for Gravity Applications
Testing of MDPE and HDPE Pressure Pipes and Fittings
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33
33
33
34
34
35
37
38
38
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General
Resin
Minimum strength
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3.11.1
3.11.2
3.11.3
32
32
33
POLYESTER RESIN CONCRETE (PRC)-PIPING SYSTEMS FOR NON-PRESSURE

DRAINAGE AND SEWERAGE ...............................................................................................41
3.11
31
31
31
41
41
41
QCS 2014

Part
Page 3
PIPES AND FITTINGS MATERIALS
3.1
GENERAL
3.1.1
Scope
This Part includes the manufacture, factory testing and supply of pipes and appurtenances of
different materials for use in pipelines.
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Concrete
Plumbing Works
Drainage Works to Buildings.
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Section 5
Section19
Section 20
General
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This Section
........................ Part 1
........................ Part 4
........................ Part 5
........................ Part 6
........................ Part 7
........................ Part 8
........................ Part 11
........................ Part 12
References
The following standards or revised/updated versions are referred to in this Part:
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3.1.2
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ANSI B16.3.................Malleable Iron Threaded Fittings

ANSI B16.5.................Steel Pipe Flanges and Flanged Fittings
ANSI B16.9.................Factory-Made Wrought Steel Butt Welding Fittings
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ANSI B16.11...............Forged Steel Fittings, Socket Welded and Threaded

ANSI B16.28...............Wrought Steel Butt Welding, Short Radius Elbows and Returns
ANSI B 36.19..............Stainless Steel Pipe

ASTM A53 ..................Standard specifications for Pipe, Steel, Black and Hot-dipped, Zinccoated Welded and Seamless
ASTM A105 ................Standard specifications for Forging, Carbon Steel, for Piping
Components
ASTM A182 ................Standard specifications for Forged or Rolled Alloy-steel Pipe Flanges,
Forged Fittings, Valves and Parts for High Temperature Service
ASTM A234 ................Standard specifications for Piping Fittings of Wrought Carbon Steel
and Alloy Steel for Moderate and Elevated Temperatures
ASTM A240 ................Standard specifications for Heat-Resisting Chromium and ChromiumNickel Stainless Steel Plated, Sheet and Strip for Pressure Vessels
ASTM A312 ................Standard specifications for Seamless and Welded Austenitic Stainless
Steel Pipes
QCS 2014

Part
Page 4
ASTM A403 ................Standard specifications for Wrought Austenitic Stainless Steel Piping
Fittings
ASTM A774 ................Standard specifications for As-Welded, Wrought Austenitic Stainless
Steel Fittings for General Corrosive Service at Low and Moderate
Temperature
ASTM A778 ................Standard specifications for Welded Unannealed Austenitic Stainless
Steel Tubular Products
ASTM D1000 ..............Standard Test Methods for Pressure-Sensitive Adhesive-Coated
Tapes Used for Electrical and Electronic Applications
ASTM D1004 ..............Standard Test Method for Initial Tear Resistance of Plastic Film and
Sheeting
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ASTM D2412 ..............Standard Test Methods for External Loading Characteristics of Plastic
Pipe by Parallel Plate Loading
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ASTM D2584 ..............Standard Test Method for Ignition Loss of Cured Reinforced Resins
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ASTM D3681 ..............Standard Test Method for Chemical Resistance of Fiberglass (GlassFiber-Reinforced Thermosetting Resin) Pipe in a Deflected Condition
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AWWA C209 ..............Cold-Applied Tape Coatings for the Exterior of Special Sections,
Connections, and Fittings for Steel Water Pipelines
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BS 65:1991.................Vitrified clay pipes, fittings and ducts, also flexible mechanical joints for
use solely with surface water pipes and fittings
BS 864........................Capillary and compression tube fittings of copper and copper alloy
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BS 2494......................Elastomeric seals for joints in pipework and pipelines
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BS 2782......................Methods of testing plastics

BS 3063......................Dimensions of gaskets for pipe flanges
BS 3396......................Woven glass fibre fabrics for plastics reinforcement
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BS 3532......................Method of specifying unsaturated polyester resin systems
BS 3749......................E Glass fibre woven rovings for the reinforcement of polyester and
epoxy resin systems
BS 4027......................Specification for Sulphate-resisting Portland cement
BS 4346......................Joints and fittings for use with unplasticised PVC pressure pipe
BS 5391...................... Acrylonitrile butadiene-styrene (ABS) pressure pipe
BS 5392...................... Acrylonitrile butadiene-styrene (ABS) fittings for use with ABS
pressure pipe.
BS 5556......................General requirements for dimensions and pressure ratings for pipe of
thermoplastic materials
BS 5911......................Concrete pipes and ancillary concrete products
BS 5955......................Code of practice for plastic pipework (thermoplastic materials)
BS 6076......................Tubular Polyethylene film for use as protective sleeving or buried iron
pipes and fittings
BS EN 197..................Cement
BS EN 295..................Vitrified clay pipes and fittings and pipe joints for drains and sewers
QCS 2014

Part
Page 5
BS EN 545..................Ductile iron pipes, fittings, accessories and their joints for water
pipelines - Requirements and test methods
BS EN 598 ----------- ...Ductile iron pipes, fittings, accessories and their joints for sewer
pipelines - Requirements and test methods
BS EN 639..................Common requirements for concrete pressure pipes including joints
and fittings
BS EN 642..................Prestressed concrete pressure pipes
BS EN 1057................Copper and copper alloys
BS EN 1092................Flanges and their joints
BS EN 1401................Plastic piping systems
BS EN 12620..............Aggregates for Concrete
BS EN 13244..............Plastic piping systems
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BS EN 14020..............Reinforcements. Specification for textile glass rovings
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BS EN 14118..............Reinforcement. Specifications for textile glass mats
BS EN 14364 & BS EN 1796 ---- Glass-reinforced thermosetting plastics (GRP)
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BS EN ISO 1456 ........Metallic and other inorganic coatings
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DIN 30674-3 ...............Coating of ductile cast iron pipes; zinc coating with protective covering
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ISO 4179 ....................Ductile Iron Pipes for Pressure and Non-Pressure Pipelines,
Centrifugal Cement Mortar Lining, General Requirements
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ISO 4633 ....................Rubber Seals - Joint Rings for Water Supply, Drainage and Sewage
Pipelines - Specification for Materials.
System Description
Pipes and fittings, except for those used in treated sewage effluent pipelines, shall be
suitable for carrying sewage at temperatures of up to 45C with hydrogen sulphide
concentrations up to 400 mg/l.
Treated sewage effluent pipelines shall be suitable for chlorine concentration up to 15 mg/l.
Pipes shall be suitable for immersion in corrosive groundwater conditions typically exhibiting
the following characteristics unless otherwise specified:
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3.1.3
SO3 Content
Cl Content
pH
Conductivity
:
:
:
:
1.7 g/l
1.07 g/l
8.6
4000 s/cm
The Contractor's attention is drawn to the stringent limits on infiltration detailed in Clause
4.5.2 of this section.
The Contractor shall be responsible for providing a jointing system as recommended by the
pipe manufacturer that enables the installation and use of the designated pipeline systems.
3.1.4
Submittals
The Contractor shall order materials to suit the construction programme and obtain the
Engineers approval of submittals before placing orders. The Contractor shall submit two
copies of the following documents for the approval of the Engineer:
QCS 2014
(a)

Part
Page 6
product data
(i)
originals of catalogues and engineering data sheets for manufactured items.

Each item and option to be provided shall be clearly marked and each item not
to be provided shall be deleted
(ii)
literature to show that products provided meet the requirements for material,
construction, operation, and tests
(iii)
information on the following items as a minimum:

pipes
flexible couplings
gaskets
isolating joints
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sealant systems
manufacturers installation instructions for all items
(v)
certified reports for all tests and inspections designated herein, signed and
sealed, showing full compliance with referenced standards
(vi)
maintenance requirements and procedures
(vii)
period of guarantee for products
(viii)
Manufacturers test reports for hydrostatic proof testing, sustained pressure

testing and burst strength testing.
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shop drawings
Piping material, class, grade and joint type, thickness or schedule, seam or
seamless, coating information if applicable.
(ii)
fittings, couplings, and joints
(iii)
for concrete pipes, details of reinforcement, concrete and joints for straight
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(i)
(iv)
pipes, specials and connections
design data
(c)
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(iv)
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(b)
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linings and protective coatings
(i)
If glass reinforced plastic (GRP) pipes with a stiffness exceeding designated

values by more than 30 percent are proposed, the Contractor shall include in his
submittal complete structural design calculations indicating the effect of the
proposed variation in pipe stiffness of the deformation modulus of the bedding
material or any other related aspect
3.1.5
Delivery, Handling and Storage
Each pipe, fitting and special appurtenance shall be marked with permanent identification
which shall include but not necessarily limited to the following:
(a)
nominal diameter
(b)
name or trade mark of manufacturer
(c)
serial number
(d)
class of pipe, pressure rating in compliance with referenced standards
QCS 2014
Page 7
(e)
date of manufacture
(f)
type of service
(g)
details on fittings such as angle of change and taper
(h)
circular concrete pipes with asymmetrical reinforcement shall have the letter "T" clearly
marked on the inside and outside to indicate the top of the pipe when laid.
The acceptability of the pipes and fittings on delivery to the Site will be based on the results of
tests carried out by one or more of the following:
(a)
the manufacturer at the place of manufacturer
(b)
the Engineer
(c)
a third party on behalf of the Engineer

Part
The Engineer shall be permitted at all reasonable times to visit places of manufacture to
witness tests.
The Engineer may require checking of the dimensional accuracy of GRP pipes and fittings at
the place of manufacture, the cost of such verification shall be borne by the Contractor.
Transport, handling and storage of pipes and fittings shall be carried out as follows:
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in accordance with the manufacturers recommendations subject to the approval of the

Engineer
(b)
effective precautions shall be taken to prevent damage to the pipe and fittings.
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During transport
pipes and fittings shall be well secured and adequately supported along their length
(b)
bolsters and binding of approved type shall be used
(c)
nesting of pipes (placing a smaller pipe inside a larger) may be permitted for pipes of
certain materials and size provided that methods statements demonstrate that
effective precautions will be taken to protect all pipe surfaces and coatings from
damage
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(a)
(d)
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(e)
pipes and fittings of plastic materials shall be covered.
no pipe shall overhang the end of a vehicle
Handling shall be carried out as follows:

(a)
pipes should be lifted singly and not handled as bunches
(b)
pipes shall be handled only by means of

(i)
approved hooks, of the type having a plate curved to fit the curvature of the
inside of the pipe, on ends of sections
(ii)
fabric slings not less than 250 mm wide
(iii)
other methods approved for the pipe used
(c)
use of wire rope, chains and fork lift trucks will not be permitted
(d)
for strings of pipe longer than the standard length precautions shall be taken to avoid
curvature and longitudinal stress in excess of allowable limits
QCS 2014
(e)
Page 8
pipes and fittings of plastic materials

(i)
smaller than 300 mm diameter may be handled manually, larger than 300 mm
diameter and greater than 4 metres in length shall be lifted using fabric lifting
straps or large diameter rope slings positioned at a quarter of the pipe length
from each end
(ii)
there should be enough slack in the slings to keep the hook approximately
600 mm over the pipe
(iii)
steel chain or hooks shall not come into contact with the pipe
VC pipes and fittings shall be transported in pallets and handled only with suitable
equipment
(g)
pipes and fittings shall not be dropped or bumped
(h)
pipes shall not be dragged over the ground
(i)
if rolled, pipes shall be rolled only over adequate timber bearers to prevent damage
(j)
where necessary, chocks shall be used to prevent lateral movement of pipes.
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(f)
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All pipes, fittings and materials shall be stored in accordance with the manufacturer's
recommendations and the following:
pipes may be stored in the open on a flat level area and raised above the ground on
timber bearers so that the lowest point of any pipe or fitting is not less than 150 mm
above the ground
(b)
timber bearers not less than 200 mm wide and 75 mm thick to be provided at 4 m
intervals maximum
(c)
if on pallets or crated, on the pallets or in their crates until required
(d)
if not on pallets or not crated, stacked one above the other as follows:
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Part
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in accordance with the manufacturers recommendations but not to a greater number

of tiers than the following:
........................ pipes 900 mm diameter

........................ < 900 mm 600 mm diameter
........................ < 600 mm diameter
(i)
2 tiers
3 tiers
4 tiers
suitable protective packing shall be placed between tiers to the approval of the
Engineer
(ii)
wrapped pipes shall not be stacked
(e)
if spigot and socket, stacked so that successive pipe layers have sockets protruding
at opposite ends of the stack
(f)
with pipes of different sizes and thickness stacked separately
(g)
with maximum height of stacked pipes not exceeding 2 m, or that recommended by

the supplier if less than 2 m.
Pipes and fittings of plastic materials including GRP shall be:

(a)
stored under cover and out of direct sunlight
(b)
adequately supported along their length
QCS 2014
(c)
10

Part
Page 9
provided with a free flow of air around the pipe.
Storage of jointing materials shall be as follows:

(a)
under cover
(b)
rubber ring gaskets shall
(c)
(i)
be stored in their original packing
(ii)
not be exposed to sunlight
(iii)
protected from exposure to greases and oils
gasket lubricants shall be stored so as to prevent damage to the container.
Pipes and fittings shall be protected in storage to the approval of the Engineer by means of
an impermeable membrane which shall cover the pipes and fittings and separate them from
the ground on which they are supported. The membrane shall be strong and durable in the
prevailing climate conditions.
12
Pipes and fittings shall be subject to visual inspections after off-loading at site and before
installation.
13
The following procedures shall be followed for dealing with damaged pipes and fittings:
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11
pipes and fittings damaged during transportation handling and storage shall be set
aside and the damage brought to the attention of the Engineer
(b)
pipes or fittings that show signs of corrosion or deterioration during storage shall
immediately be treated to arrest and prevent the corrosion or deterioration or
removed from Site, as the Engineer directs
(c)
proposals for repair shall be submitted in writing for the Engineers approval
(d)
no attempt shall be made to repair damage without the Engineers approval
(e)
if in the Engineers opinion the nature of any damage is such that the condition of a
pipe has been impaired and cannot be repaired the pipe concerned shall not be
incorporated in the Works
all rejected pipes shall be immediately removed from the Site
(f)
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it
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as
(a)
(g)
damaged pipe shall be replaced or repaired by the Contractor at his expense and such
repairs shall be to the approval of the Engineer
(h)
the Engineer may require that any GRP pipe or fittings found to be damaged to be
subjected to a further hydraulic test which shall be carried out by the Contractor, at the
Contractors expense, in accordance with the requirements of Subpart 4.5 of this
Section.
3.1.6
Pipe Materials
For the purposes of this specification the following shall apply:

(a)
Pipes of steel, glass reinforced plastic (GRP), PVC-U and polyethylene shall be
deemed to be flexible pipes.
(b)
Pipes of concrete, vitrified clay and ductile iron shall be deemed to be rigid pipes.
QCS 2014

Part
Page 10
VITRIFIED CLAY PIPES AND FITTINGS
3.2.1
Standards
Pipes and fittings for foul sewerage and surface water applications shall be manufactured to
BS EN 295.
Pipes and fittings for land drainage applications shall be manufactured to BS 65.
Sealing rings shall be to BS 2494 or ISO 4633.
3.2.2
Manufacture
Pipes and fittings shall comply with the following:
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3.2
pipes shall have spigot and socket type joints.
(b)
pipes shall be glazed both internally and externally.
(c)
all pipes shall be free of cracks, blisters, broken ends and other imperfections.
(d)
vitrified clay pipes shall have the minimum strength requirements shown on Table 3.2
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(a)
Table 3.2 Minimum Strength Requirements
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28
28
28
200
40
28
300
60
34
400
64
44
500
80
60
600
96
800
96
1000
95
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o
et
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m
Land Drains
(Perforated)
28
150
Foul / SW
(Non-Perforated)
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100
as
Min. Crushing Strength (FN) kN/m

Nominal Bore
(mm)
Joints shall be as follows:

(a)
Pipes and fittings shall be supplied with flexible mechanical joints of the spigot and
socket type joints.
(b)
Sealing rings shall be of elastomeric material suitable for foul sewerage and
surfacewater drainage works, as the case maybe, conforming to BS 2494 or ISO 4633.
(c)
Acceptance of VC pipes on delivery is dependent upon the Contractor demonstrating

that the joints are capable of meeting the water test requirement of Clause 4.5.2 of this
Section.
(d)
Polypropylene sleeve couplings shall not be used.
QCS 2014

Part
Page 11
Fittings shall be capable of withstanding the same load as the adjacent pipes or shall be
provided with concrete surround.
3.2.3
Barrel impermeability, straightness, crushing strength and bending moment resistance and
chemical resistances tests shall be carried out in accordance with BS EN 295 at the
frequency designated for the crushing strength test.
3.2.4
Repair Couplings for VC Pipes
Repair couplings shall be obtained from an approved manufacturer and shall consist of a
moulded synthetic elastomeric sleeve which is fastened over the pipe ends by stainless steel
clamping bands and be complete with a stainless steel shear ring. The repair coupling shall
be suitable for use with vitrified clay pipes and shall include a bushing adapter when joining to
a pipe of the same nominal bore but of a different outside diameter.
Repair couplings shall comply with the joint performance requirements of BS 65 and be
capable of withstanding an external water pressure of 60 kPa without leaking.
Sleeves and bushes shall comply with the requirements of BS EN 681-1. Clamping bands
and shear ring shall be made from 300 series austenitic stainless steel.
3.3
CONCRETE PIPES AND FITTINGS
3.3.1
Standards
Except as otherwise designated, concrete pipes and fittings shall conform to the
requirements of this Subpart following standard specifications:
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reinforced and unreinforced, BS 5911
(b)
prestressed non-pressure concrete pipes, BS 5911.
(a)
The strength requirement and other features of particular application shall be as specified in
this Subpart or designated in the contract specific documentation.
3.3.2
Pipe Materials
Cement used for manufacturing pipes and fittings shall be Ordinary Portland cement
conforming to BS EN 197-1.
Aggregate shall conform to BS 882.
Reinforcement shall conform to BS 4449 or BS 4483 as appropriate.
Admixture shall be used only with the written permission of the Engineer. The methods of use
and the quantities of admixtures used shall be subject to the approval of the Engineer.
Admixture containing calcium chloride will not be permitted.
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QCS 2014

Part
3.3.3
Manufacture
Pipes and Fittings:
Page 12
Storage of concrete materials, mixing, curing and testing of concrete shall be in

accordance with the appropriate Clauses in Section 5. Any deviation from these
clauses shall be made only with the approval of the Engineer
(b)
unless stated otherwise crushing strengths of pipes shall not be less than those
designated in BS 5911 for the designated classes of pipes.
(c)
Reinforced concrete pipes shall have a minimum effective length of 2.5 m except as
otherwise designated or required for special purposes such as curves, closures or
built in pipes.
(d)
Steel reinforcement shall be accurately placed in the concrete wall. The placement of
all steel shall not vary from the designated position in the pipe wall by more than
6 mm from the nominal position. In no case shall the cover to the reinforcement be
less than 25 mm.
(e)
The planes of the ends of the pipes shall be perpendicular to their longitudinal axis.
ta
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Joints
except as specified in other Parts of this Section, pipe joints shall be supplied with
flexible mechanical joints of the spigot and socket type in accordance with BS 5911,
double collar or sleeve type
(b)
gasket stock shall
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as
(a)
comply with BS 2494.
(ii)
be a synthetic rubber compound in which the elastomer is exclusively neoprene.
(iii)
solid compound shall contain not less than 50 % by volume of neoprene and
ov
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(i)
shall not contain reclaimed rubber or deleterious substances.
stock shall be extruded or moulded and cured in such a manner that
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(iv)
cross-sections are dense, homogeneous and free from porosity, blisters, pitting
and other imperfections.
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(a)
(v)
stock shall be extruded or moulded with smooth surfaces to the designated size
within a tolerance of 6 % measured on joint cross-section dimensions.
(c)
the sealing ring shall be confined in a contained groove on the spigot face of each
pipe section to properly position and confine the rubber gaskets in the annular space
(d)
each joint shall contain a neoprene ring gasket as follows:

(i)
the gasket shall be the sole element depended upon for watertightness of the
joint.
(ii)
the gasket shall be of circular cross-section unless otherwise approved by the

Engineer.
(iii)
the length and cross-sectional diameter of the gasket, the annular space
QCS 2014

Part
(iv)
Page 13
provided for the gasket, and all other joint details shall be such as to produce a
watertight joint which shall not leak when pulled 13 mm over and above the
initial jointing allowance.
(e)
the initial jointing allowance is the gap between the spigot and the shoulder of
the socket measured parallel to the centre of the pipeline and shall not be less than
6 mm or greater than 12 mm.
(f)
Joints shall be capable of maintaining water tightness up to an angular deflection of 2

from true, in any direction.
Plastic Lining
Where designated concrete pipes shall be lined with polyvinyl chloride plastic (PVC) liner
plate. The PVC liner plate material shall be as specified in Section 5 Part 14.6. The liner plate
shall be securely fixed to the formwork before pouring concrete and all in-situ welding of the
liner plate shall be carried out by skilled labour using the methods specified by the
manufacturer. Purpose made units shall be used where required; e.g., at junctions.
The installation of liner plates in concrete pipes or structures, and the sealing and welding of
joints, shall be carried out in strict compliance with all applicable specifications, instructions
and recommendations of the plastic liner plate manufacturer. All welding of liner plate shall
be carried out by properly trained and approved workmen.
Once cast into the pipe, the liner shall be permanently and physically attached to the concrete
by the locking mechanism and shall not rely on an adhesive bond.
The lining shall withstand a 100 kPa hydrostatic back pressure applied to the under surface
of the lining without losing anchorage or without rupture.
Damaged liner plate shall be repaired in accordance

recommendation and to the approval of the Engineer.
3.3.5
Epoxy Coating
All exterior surfaces of concrete pipes shall be coated by the pipe manufacturer with a heavy
duty, solvent free epoxy suitable for application to fresh concrete as specified in Section 5. A
minimum of two coats shall be applied to attain a minimum total dry film thickness of 400 m.
3.3.6
Inspection procedures and tests shall be carried out at the place of manufacture. Pipes and
joints shall be hydrostatically tested in accordance with BS 5911.
The performance of pipes shall be verified by the testing of random sample pipes in
accordance with the type of inspection and batch size mentioned. The pipes shall be subject
to rejection on account of non-compliance with the following:
with
the
manufacturers
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3.3.4
(a)
failure to pass hydrostatic test
(b)
failure of the longitudinal concrete surfaces of joints to meet dimensional tolerances
(c)
fractures or cracks
(i)
passing through the shell, except that a single end crack that does not exceed
the depth of the joint shall not be cause for rejection; however
QCS 2014

Part
(ii)
Page 14
if a single end crack that does not exceed the depth of the joint exists in more
than 10 % of the pipes inspected, the defective pipes shall be rejected
(d)
defects that indicate defective mixing and moulding
(e)
surface defects indicating honeycomb or open texture
(f)
spalls
deeper than one half the depth of the joint
(ii)
extending more than 100 mm around the circumference
(iii)
smaller than one half the depth of the joint or less than 100 mm around the
circumference exist in more than ten percent of the pipes
insufficient cover to the reinforcement.
(g)
(i)
GLASS REINFORCED PLASTIC (GRP) PIPES AND FITTINGS
3.4.1
Standards
All activities relating to this section of the particular specification shall comply with the
following or approved equal standard. The latest version of the standard indicated shall
apply.
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3.4
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Statutory provisions shall always apply as amended from time to time.
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Generally applicable standards:

BS EN 681 .................Elastomeric seals. Material requirements for pipe joint seals used in
water and drainage applications.
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er
BS EN 14364 .............Plastic piping systems for drainage and sewerage with or without
pressure. Glass reinforced-thermosetting plastics (GRP) based on
unsaturated polyester resin (UP). Specification for pipes, fittings and
joints
et
it
BS EN 1796................Plastic piping systems for water supply with or without pressure

Glass-reinforced thermosetting plastics (GRP) based on unsaturated
polyester resin (UP)
CEN TS 14632 ...........Plastics piping systems for drainage, sewerage and water supply,
pressure and non-pressure - Glass-reinforced thermosetting plastics
(GRP) based on unsaturated polyester resin (UP) - Guidance for the
assessment of conformity
ISO 25780 ..................Plastic piping systems for pressure and non-pressure water supply,
irrigation, drainage or sewerage Glass-reinforced thermosetting
plastics (GRP) systems based on unsaturated polyester (UP) resin
Pipes with flexible joints intended to be installed using jacking
techniques
ISO 3126 ...................Plastic pipes. Measurement of dimensions wall thickness table.
ISO 4633 ...................Joint rings for water supply, drainage and sewerage pipelines:
Specification for materials
ISO 1172 ....................Textile-glass-reinforced plastics, prepregs, moulding compounds and
laminates - Determination of the textile-glass and mineral-filler content
- Calcination methods
DIN 16 869 - Part 1 ...Centrifugally cast and filled glass fibre reinforced polyester resin pipes
- dimensions.
QCS 2014

Part
Page 15
DIN 16 869 - Part 2 ...Glass-fibre reinforced polyester resin pipes (UP-GF) Centrifugally
cast filled Part 2: General quality requirements, testing.
DIN EN ISO 178 ........Plastics Determination of flexural properties (ISO 178:1993)
DIN EN ISO 527-1 .....Plastics Determination of tensile properties Part 1: General
principles
DIN EN ISO 527-2 .....Plastics - Determination of tensile properties - Part 2: Test conditions
for moulding and extrusion plastics
ISO 15306 ..................Glass-reinforced thermosetting plastics (GRP) pipes Determination
of the resistance to cyclic internal pressure
ISO 10952 .................Plastics piping systems Glass-reinforced thermosetting plastics
(GRP) pipes and fittings Determination of the resistance to
chemical attack for the inside of a section in a deflected condition
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ISO 10928 ..................Plastics piping systems - Glass-reinforced thermosetting plastics

(GRP) pipes and fittings - Methods for regression analysis and their
use
DIN 16966 -6 ..............Glass fibre reinforced polyester resin (UP-GF) pipe fittings and joint
assemblies; collars, flanges, joint rings, dimensions
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DIN-16945 .................Testing of Resins, Hardeners and Accelerators, and Catalyzed Resins
qa
DIN-16946 - Part 1 ....Cured casting Resins - Testing DIN-16946- Part 2 Cured casting
Resins - Types
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DIN EN ISO 75 ..........Plastics Determination of temperature of deflection under load
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DIN EN ISO 527-4 .....Plastics Determination of tensile properties Part 4: Test conditions
for isotropic and orthotropic fibre-reinforced plastic composites
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DIN EN ISO 10468 ....Glass-reinforced thermosetting plastics (GRP) pipes Determination

of the long-term specific ring creep stiffness under wet conditions and
calculation of the wet creep factor (ISO/DIS 10468:1999)
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DIN EN ISO 14828 ....Glass-reinforced thermosetting plastics (GRP) pipes Determination

of the long-term specific ring relaxation stiffness under wet conditions
and calculation of the wet relaxation factor (ISO/DIS 14828:1999)
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DIN EN 681-1 ............Elastomeric seals Material requirements for pipe joint seals used in
water and drainage applications Part 1: Vulcanized rubber
DIN EN 1119 .............Plastics piping systems Joints for glass-reinforced thermosetting

plastics (GRP) pipes and fittings Test methods for leak tightness and
resistance to damage of flexible and reduced articulation joints
ISO 10466 .................Plastics piping systems Glass-reinforced thermosetting plastics
(GRP) pipes Test method to prove the resistance to initial ring
deflection
ISO 7685 .................... Plastics piping systems Glass-reinforced thermosetting plastics
(GRP) pipes Determination of initial specific ring stiffness
ISO 8513 ....................Plastics piping systems Glass-reinforced thermosetting plastics
(GRP) pipes Determination of longitudinal tensile properties
ISO 8521 ....................Plastic piping systems Glass-reinforced thermosetting plastics
(GRP) pipes Test methods for the determination of the apparent
initial circumferential tensile strength
DIN EN 1447 .............Plastics piping systems Glass-reinforced thermosetting plastics
(GRP) pipes Determination of long-term resistance to internal
pressure
QCS 2014

Part
Page 16
ISO 7509 ....................Plastics piping systems Glass-reinforced thermosetting plastics

(GRP) pipes Determination of time to failure under sustained
internal pressure
ASTM D2997 .............Standard Specification for Centrifugally cast Fiberglass (Glass-FiberReinforced Thermosetting-Resin) Pipe.
EN ISO 2078 ..............Textile glass Yarns Designation (ISO 2078)
ASTM D 3517-01 .......Standard Specification for Fiberglass(Glass-Fiber-Reinforced
Thermosetting-Resin) Pressure Pipe
Design
The design of GRP pipes, fittings and bedding shall be carried out by the pipe manufacturer
to enable the pipe to meet the requirements of the Works. The following general
requirements shall prevail for pipes and fittings:
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3.4.2
they shall be designed to achieve a minimum working life of 60 years under all
applicable standard loadings, environmental and installation conditions
(b)
they shall have a minimum stiffness of 10,000 N/m
(c)
Non-pressure pipes and fittings shall be designed for a nominal pressure rating of PN
01 (1 bar)
(d)
Pressure pipes and fittings shall be designed for a normal operating pressure rating of
PN16 (16 bar) to pressure ratings in ISO 25780, EN 14364 or EN 1796.
(e)
they shall convey a liquid with a temperature up to 45C
(f)
they shall be designed to withstand up to 5% long term deflection in their installed

conditions.
(g)
all bends shall be long radius bends unless otherwise approved by the Engineer.
(h)
they shall be capable of withstanding a 95% lower confidence strain of 0.85% over 60
years without failure or cracking when tested in accordance with the strain corrosion
type test requirements specified herein.
(i)
sewerage and drainage pipelines and fittings shall be designed to carry septic sewage
having a maximum hydrogen sulphide concentration of 50mg/l at a temperature of
45C
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(a)
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(j)
irrigation pipelines and fittings shall conform to the water supply standards
(k)
The manufacturer shall provide a valid Certificate of Conformity to EN 1796, EN 14364

or ISO 25780 as applicable. The certificate shall be issued by an independent
certification body or authority.
(l)
For direct jack GRP pipes, the allowable jacking force shall be based on the minimum
wall thickness measured at the bottom of the spigot gasket groove where the wall
cross section has been reduced, and the mean longitudinal compressive strength of
the pipe. A minimum factor of safety of 3.5 in accordance with ISO 25780 shall be
used for the jacking force on a straight alignment. A reduced jacking force shall be
used when jacking to a curvature.
(m)
Direct jack GRP pipes can be used for pressure and non-pressure applications.
QCS 2014

Part
Page 17
Pipes and Fittings Manufacture
The pipes and fitting shall conform to either EN 14364 or EN 1796 for sewage or water
supply pipes. Jacking pipes shall comply with ISO 25780. The referenced test standards
therein have to be fulfilled.
3.4.4
General
All GRP components shall be designed and fabricated by one manufacturer.
GRP pipes and fittings shall be manufactured by an approved process utilising a mandrel or
rotating mould incorporating equipment to accurately control the quantities and placement of
all resins, glass and aggregates.
Use resins, reinforcement and aggregates to produce pipes and fittings, which when
combined as a composite structure will satisfy the performance requirements of this section
of the specification.
Internal and external surfaces shall be free from irregularities, which would impair the ability
of the component to conform to the requirements of EN 14364, EN 1796 or ISO 25780.
3.4.5
Buried GRP
The pipes and fittings shall be constructed using chopped and /or continuous glass filaments,
strands or roving, mats, synthetic veils or fabric, and polyester / vinyl ester resin, aggregate
and fillers. If applicable, additives necessary to impart specific properties to the resin may be
used, subject to the approval of the Engineer.
Filament Wound (FW) GRP Pipes and Fittings

Resins
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(a)
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3.4.3
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Vinyl ester shall be used in the internal resin rich liner of the pipes and fittings.
Isophthalic or vinyl ester shall be used in the structural layer of the pipes and fittings.
Vinyl ester or isophthalic resin shall be used in the outer layer of the pipes and fittings.
Resins shall be cured to achieve a minimum of 90% of the manufacturers

recommended Barcol hardness value.
(b)
Additives
The use of additives such as fire retardants, UV inhibitors or coloured pigments or
dyes shall only be used for specific project based applications and their use shall be
subject to the approval of the Engineer.
(c)
Glass reinforcement
The glass used for the manufacture of the reinforcement shall be type E (aluminacalcosilicate glass), type C (alkali-calcium glass) or type ECR (alumina-borosilicate
glass).
The reinforcement shall be made from continuous drawn filaments of glass and shall
have a surface treatment compatible with the resin to be used. It may be used in any
form, e.g. as continuous or chopped filaments, strands or rovings, mat or fabric.
(d)
Aggregates
Aggregates shall be clean, graded silica sand containing no impurities and a maximum
moisture content of 2%. The maximum particles size of the sand aggregate shall not
exceed 0.8mm.
QCS 2014

Part
Page 18
The overall sand content of the pressure pipes and fittings shall not exceed 30% by
weight.
The overall sand content of the non-pressure pipes and fittings shall not exceed 60%
by weight.
(e)
Fillers
Fillers (other than silica sand aggregate) shall only be permitted if required for a
particular project application and be subject to the approval of the Engineer following
satisfactory long term type tests (ISO 10952, ISO 10466), for a minimum of 10,000
hours.
(f)
Wall construction
Lining Layer
The inner lining layer shall comprise a minimum 2.0mm thick rich vinyl ester
layer suitably reinforced with C glass veil with a glass content not exceeding
10% by weight. The remainder of the lining shall consist of layers of vinyl ester
resin and powder bound ECR acid resistant glass chopped strand mat or roving,
depending on the method of manufacture, with a glass content of between 25%
and 35% by weight.
(ii)
Sand aggregate shall not be used in the lining layer.
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(i)
Structural Layer
The structural layer shall comprise Type E or ECR glass reinforcement and a
thermosetting isophthalic polyester resin with or without sand aggregate.
(iv)
The layer shall be built up in layers of Type E or ECR acid resistant glass chop
roving or continuous roving.
(v)
The manufacturing process shall ensure that no aggregate becomes embedded

in the internal resin rich liner layer.
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(iii)
Outer Layer
Pipes shall be provided with a resin rich layer with C glass veil reinforcement.
(vii)
The resin used in the outer layer shall have a Glass Transition temperature of at
least 75C.
(viii)
The use of special finishes is permitted when the pipe or fitting is expected to be
exposed to extreme climatic, environmental or ground conditions. These may
include the provision of a sand layer, pigments or inhibitors for UV protection or
fire retardation, subject to the approval of the Engineer.
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(vi)
(g)
Bends and Fittings

Bends and fittings shall be equal or superior in quality and performance to the
corresponding pipes. Mitred bends and fittings shall be fabricated from pipes which
have been hydraulically tested successfully.
Centrifugally Cast (CC) GRP Pipes and Fittings

(a)
Resins
Vinyl ester shall be used in the internal pure resin liner of the pipes and fittings.
Isophthalic or vinyl ester shall be used in the structural layer of the pipes and fittings.
Vinyl ester or isophthalic resin shall be used in the outer layer of the pipes and fittings.
QCS 2014
(b)

Part
Page 19
Additives
(c)
Glass reinforcement
The glass used for the manufacture of the reinforcement shall be Type E or ECR
glass.
The reinforcement shall be made from chopped glass filament in long and short fibres
and shall have a surface treatment compatible with the resin to be used.
(d)
Aggregates
(e)
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exceed the lesser of 1/5 the total wall thickness of the pipe or fitting, or 2.5mm.
Fillers
Wall construction
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(f)
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hours.
Lining Layer
The inner lining layer shall comprise a minimum 2.0mm thick pure vinyl ester
resin without glass reinforcement and sand aggregates.
(ii)
The barrier and transition layers between the pure resin lining layer and the
structural layer shall be to suit the manufacturing process.
ov
Structural Layer
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(i)
The structural layer shall comprise glass reinforcement and a thermosetting

isophthalic polyester or vinyl ester resin with or without sand aggregate.
(iv)
The layer shall be built up in layers of ECR acid resistant glass chopped fibres.
(v)

in the inner pure resin liner layer.
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(iii)
Outer Layer
(vi)
Pipes shall be provided with an outer layer formed of a mortar of resin and sand
aggregates with no glass reinforcement.
(vii)
least 75C.
(viii)
An outer protection layer shall be provided which has a minimum of 60% sand
for corrosion protection.
(ix)
The use of special finishes is permitted when the pipe or fitting is expected to be
(x)
The transition layers between the structural layer and the outer layer shall be to
suit the manufacturing process.
QCS 2014
(g)

Part
Page 20
Bends and Fittings

Bends and fittings shall be equal or superior in quality and performance to the
corresponding pipes. Mitred bends and fittings shall be fabricated from pipes which
have been successfully pressure tested.
Direct Jack GRP Pipes

(a)
Resins
Vinyl ester resin shall be used in the internal pure resin liner of the pipes. Isophthalic
or vinyl ester resin shall be used in the structural layer of the pipes. Vinyl ester or
isophthalic resin shall be used in the outer layer of the pipes.
Additives
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(b)
Glass reinforcement
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(c)
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The glass used for the manufacture of the reinforcement shall be Type E or ECR acid
resistant glass.
Aggregates
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(d)
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The reinforcement shall be made from chopped glass filament in long and short fibres
and /or continuous glass filaments, strands or roving, mats, synthetic veils or fabric
and shall have a surface treatment compatible with the resin to be used.
Fillers
(e)
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exceed the lesser of 1/5 the total wall thickness of the pipe or fitting, or 2.5mm.
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it
hours.
(f)
Wall construction
Lining Layer
(i)
The inner lining layer shall comprise a minimum 2.0mm thick rich vinyl ester
layer suitably reinforced with C glass veil with a glass content not exceeding
10% by weight. The remainder of the lining shall consist of layers of vinyl ester
resin and powder bound ECR acid resistant glass chopped strand mat or roving,
depending on the method of manufacture, with a glass content of between 25%
and 35% by weight, when the filament wound manufacturing process is used.
(ii)
The inner lining layer shall comprise a minimum 2.0mm thick pure vinyl ester
resin without glass reinforcement and sand aggregates when the centrifugal
manufacturing process is used.
(iii)
The barrier and transition layers between the pure resin lining layer and the
structural layer shall be to suit the manufacturing process.
QCS 2014

Part
Page 21
Structural Layer
(iv)
The structural layer shall comprise glass reinforcement and a thermosetting

isophthalic polyester or vinyl ester resin with or without sand aggregate.
(v)
The layer shall be built up in layers of Type E or ECR acid resistant glass
chopped fibres.
(vi)

in the inner pure resin liner layer.
Outer Layer
Pipes shall be provided with an outer layer formed of a mortar of resin and sand
aggregates with no glass reinforcement.
(viii)
least 75C.
(ix)
An outer protection layer shall be provided which has a minimum of 60% of sand
for corrosion protection.
(x)
The use of special finishes is permitted when the pipe is expected to be

(xi)
The transition layers between the structural layer and the outer layer shall be to
suit the manufacturing process.
(xii)
The outer surface of the pipes shall be smooth with a resin rich topcoat 0.3mm
thick.
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Longitudinal Compressive Strength
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(g)
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(vii)
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Proof of compression strength shall be supplied by testing all pipe types using the
procedure set out in Annex A of ISO 25780.
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The test results of compressive properties obtained from coupon or spool test
specimens may be used. As described in ISO 25780, the manufacturer shall show the
correlation of the results obtained from coupons or full spools by means of initial type
tests. The pipes shall meet the following requirements for the initial longitudinal
compression properties:
Table 3.4.1 : Longitudinal compressive strength for direct jack GRP pipes
Specimen
Pipe quality
Minimum compressive
strength (single value)
Mean
compressive
strength
Rebated and grooved

specimen
with filler
80 MPa
90 MPa
Coupon specimen
with filler
90 MPa
100 MPa
Rebated and grooved

specimen
without filler
70 MPa
80 MPa
Coupon specimen
without filler
80 MPa
90 MPa
QCS 2014
(h)

Part
Page 22
Dimensions
The manufacturer shall confirm that the outside diameter of the pipe conforms to ISO
25780.
The outside diameter of the jacking pipe shall be compatible with the jacking machine.
The nominal length of the pipe shall preferably be 1m, 1.5m, 2m, 3m or 6m. Other
lengths shall be permitted to suit a particular project requirement.
The jacking force shall be transmitted face to face on the pipe joint without the use of
packer rings, unless required for a specific project application. The permitted deviation
from squareness across the joints external diameter shall be as tabled below:
Manufacturers declared outside

diameter dOD mm
dOD 300
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0.5
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Deviation of
squareness mm
Table 3.4.2 : Permissible deviation from squareness across a joints external diameter
1.0
(i)
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300 < dOD
Marking of jacking pipes
Wall thickness
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Markings shall meet the requirements for the application and conform to ISO 25780.
Designations to meet special quality requirements as item 6 below are permissible.
The marking of the pipe shall be visible on the external and internal surfaces of the
jacking pipe.
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The minimum total wall thickness, including the liner and outer protective layer shall be
declared by the manufacturer, which shall be complying with the standard performance
criteria.
The wall thickness at any point on the pipe and the spigot shall not be less than the
manufacturers declared values.
Abrasion resistance
The pipes shall be resistant to abrasion when tested according to CEN TR 15729 over
100,000 cycles. There shall be no evidence of free glass fibres on the inner surface of the
pipe.
7
Markings
All pipes including cut lengths and all fittings before dispatch from the pipe manufacturers
works shall be indelibly marked as follows on the external and internal surfaces.
(a)
The manufacturer's name, initials, or identification mark.
(b)
The nominal internal diameter in millimetres.
(c)
The length in metres.
(d)
The classification i.e. pressure rating, stiffness.
QCS 2014

Part
Page 23
(e)
The date of manufacture and batch number.
(f)
A stamp to show that they meet the required inspection requirements and hydraulic
tests at the point of manufacturer.
(g)
Identification number stencilled on the inside and outside at each end. The same
number shall appear on all record sheets and documents relating to the manufacture
delivery and testing of that pipe.
(h)
The manufacturing standard.
(i)
Joints
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Except where otherwise detailed on the Drawings, all buried pipes and fittings shall have nonend-load-bearing flexible joints of spigot type or GRP sleeved couplers with EPDM rubber in
full faced elements or rings in accordance with BS / DIN EN 681; manufactured according to
the individual manufacturing technique and supplied as an integral part of the pipe or as
separate fittings. The elastomeric sealing gaskets shall provide the sole means of
maintaining joint watertightness. The sealing gaskets shall be supplied by the pipe
manufacturer.
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Joints in direct jack applications (non-pressure application) can also be of stainless steel
Grade 316 Ti (EN 1.4571) couplers with approximately the same outside diameter as the
pipe so that the joints are essentially flush with the pipe outer surface.
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The manufacturer shall declare the maximum draw for which each flexible joint type is
designed.
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The manufacturer shall declare the maximum allowable angular deflection and the maximum
draw for which each locked joint type and flexible joint type are designed.
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All joints shall remain watertight for all combinations of angular deflection and draw up to the
maximum allowable values. In addition, pipe joints for pipelines laid in open cut trenches
shall be capable of withstanding an external pressure differential equivalent to +10m head of
water without leakage in the straight, deflected and drawn positions.
When a pipe is cut or turned down in order to form a joint, the exposed faces shall be fully
sealed with a continuous coating of vinyl ester resin with a minimum of 1.5mm thick.
Wrapped or cemented joints shall only be used subject to the approval of the Engineer.
3.4.6
Exposed GRP
The use of GRP pipes and fittings for exposed service shall be subject to the approval of the
Engineer. The exposed pipes and fittings shall be designed to resist all bending stresses,
thrust forces, surge pressures, negative pressures, thermal and vibratory forces.
Exposed pipe and fittings shall be manufactured in the same manner and with the same
materials as buried pipe, along with the following requirements unless otherwise approved by
the Engineer.
QCS 2014
(a)
Page 24
An outer protective surface layer shall be provided consisting of a topcoat of UV

inhibitor and resin with or without glass reinforcement to form a resin rich layer with a
minimum thickness of 0.3mm. The outer protective surface layer shall be designed to
resist other project specific extraneous causes (atmospheric conditions, mechanical
damage and chemical stress etc.) as described in the project specification.
Exposed pipes and fittings inside treatment plant buildings, process structures, pumping
stations, and valve chambers shall use PN 16 flanged joints:
Flanges shall be filament wound, tape wound, contact moulded, hot or cold pressed
with epoxy or vinyl ester resins only.
(b)
All bolts shall be stainless steel grade 316.
(c)
Flanges shall be drilled to BS EN 1092 (metric units) resp. DIN 16966-1 type PN16.
(d)
Flanged pipe joints shall incorporate an annular gasket covering the full face of the
flange. Gaskets to be 3mm thick self-energised EPDM or nitrile rubber (NBR) with
embedded stainless steel inlay O rings. The gaskets shall have a shore hardness of
605.
(e)
When flanged joints are to be made, secure the bolts and the nuts initially to finger
tightness. Thereafter the final tightening of the nuts shall be effected by torque
spanners in such sequence that diametrically opposite nuts are tightened together to
achieve the manufacturers recommended torque.
(a)
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Part
External exposed pipes and fittings shall use fixed laminated joints with expansion bellows
and be supported in accordance with the manufacturers requirements.
The exposed pipeline shall be protected by bollards, lateral sand bunds etc. where there is a
risk of physical impact.
3.4.7
A pipe type test group consists of a range or family of products made such that the results of
the long-term type tests are applicable to all products in the group. A pipe type test group
shall be made of products:
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a) manufactured by the same process;
b) with the same material specifications;

c) with the same pipe wall construction (i.e. the sequence of layers, layer
compositions, material properties and design method for using the results of the
long-term type tests in determining the pipe wall for all combinations of DN, PN
and SN);
d) tested with the same loading condition (i.e. uniaxial or biaxial load).
The pipe manufacturer shall submit type test results according to EN 14364 or ISO 25780 for
each product group.
Strain corrosion tests shall be carried for each class and diameter range, where applicable,
according to ISO 25780 and ISO 10467, as a type test generally in accordance with ASTM
D3262 resp. ISO 10952. The strains shall be at levels at which failure can be predicted from
the strain corrosion type test results to occur at 100 hours and 1,000 hours. No failures shall
be below the lower 95% confidence limit of the type test regression line.
The calculated failure strain at 60 years from the results of the quality control test using the
least squares method shall not be less than 0.85%. In the event that a specimen fails the
strain corrosion test all pipes in that class and diameter range, where applicable, pertaining to
that batch which has been manufactured or installed shall be rejected.
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The pipe manufacturer shall carry out the following Inspection Tests. The results of these
tests shall be made available to the Engineer who shall also be allowed to witness some or
all of the tests.
(a) One pipe in every 100 of each type and size of manufactured item shall be tested for
loss of ignition in accordance with ASTM D2584 resp. ISO 1172.
(b) The liner thickness of pipes, fittings and couplings shall be measured in accordance with
Section 6 of ASTM D3567 resp EN 3126. A liner check shall be carried out for one in
every 100 of each type and size of manufactured item. A minimum of one item of each
type and size shall be tested. The liner thickness shall not be less than 1mm at any
pitted point.
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Checks will be carried out by the Engineer at Site. The Contractor shall destroy or indelibly
mark as rejected and remove from Site any pipes or fittings found at any time failing to meet
dimensional criteria or any of the following quality criteria:
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(c) Data for the above tests shall be submitted to the Engineer. The data shall be traceable
to the supplied pipes with a unique number as "Batch no", the test data shall hold all the
above mentioned tests samples results under this batch no. The batch no. shall be
clearly marked as ID on each length of produced pipes.
(a) scratches shall be no deeper than 0.3 mm and no reinforcing fibres shall be exposed
(c) no delaminations shall be evident
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(b) no cracks shall be present on the inside of pipes. Hair cracks on the outside may be
permitted with repair if not longer than 200 mm circumferentially or 6 mm longitudinally.
Impact cracks shall not affect more than 3 % of surface area
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(d) no impact or other damage to pipe ends shall be evident. The end surface of pipe or
fitting shall be completely covered with resin and free from cracks, porosity, bubbles,
voids, exposed reinforcement or extraneous matter
(e) no protruding fibres permitted on jointing surfaces
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no other protuberances. Small globules or resin projections permissible if not more than
25 % of area is affected. Jointing surfaces shall be completely free of any such flaws.
Ridges formed by resin shall not exceed 1.5 mm in depth
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(f)
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(g) air voids, blisters, bubbles are not acceptable if greater than 5 mm diameter or 1 mm
depth. Subject to the approval of the Engineer, if less than 0.5% of internal areas are
affected, such defects may be ground out and repaired
(h) not more than 5 % of the internal or 10 % of the external surface shall be affected by
pitting. No individual pit shall be more than 1 mm diameter or 0.5mm depth
(i)
wrinkles and indentations shall not be more than 2mm deep and not more than 3 % of
surface area affected. Subject to the approval of the Engineer, if not more than 5 mm
deep and 0.5 percent of surface area is affected, such defects may be repaired
(j)
any pipe which when resting freely on the ground and not subjected to any loads other
than its own weight exhibits a deflection of more than 2%, measured along the diameter,
shall be rejected and removed from the Site.
3.5
PVC-U PIPES AND FITTINGS
1.1.1
Standards
Except as otherwise indicated, materials and workmanship described in this section shall
conform to the latest editions of the following standards:
ASTM D1599 ..............Test Method for Short-Time Hydraulic Failure Pressure of Plastic Pipe,
Tubing and Fittings
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Page 26
AWWA M23 PVC Pipe - Design and Installation

BS 3505/3506 - Polyvinyl Chloride Pressure Pipe
BS EN 1401 - Plastic piping for non-pressurised underground drainage & sewerage
BS EN 1452................Plastic piping systems for water supply (UPVC)
DIN 8061 ....................Unplasticised polyvinyl chloride pipes - general quality requirements &
testing
DIN 8062: 1988 ..........Unplasticised polyvinyl chloride (PVC-U, PVC-HI) pipes dimensions
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DIN 8063: 1986 ..........Pipe joint assemblies & fittings for unplasticised polyvinyl chloride
(PVC-U) pressure pipelines
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ISO 1452 ....................Pipes and fittings in PVC U pipes for water supply
The strength requirement and other features of particular application shall be as specified in
this Subpart or designated in the contract specific documentation.
3.5.2
Manufacture
UPVC pipe shall be provided in standard 6 metre lengths, unless otherwise specified,
detailed or required on the approved plans. Shorter lengths, up to 3 metres, will be permitted
when authorised by the Engineer. Field cut lengths of pipe used as closures may not be
shorter than 0.75 metre in length and must be approved by the Engineer. Solvent welded
pipes may be permitted in sizes of 100mm and less.
For sewerage service, PVC-U pipes 200 mm in diameter may be supplied in lengths up to
4 m. PVC-U pipes 150 mm in diameter and less shall be supplied 50 percent in lengths not
exceeding 2 m and 50 percent in lengths not exceeding 4 m.
UPVC Pipes shall be SDR17 as a maximum and shall have be designed to withstand a
0
0
nominal operating pressure of PN16 at 25 C (equivalent to PN10 at 45 C) unless otherwise
specified in the Contract Documents.
All joints for UPVC Pressure Pipe shall be integrally cast, spigot and socket joints, or plain
end with EPDM rubber ring couplings. Joints shall be of the same pressure rating as the pipe.
Solvent weld joints are not permitted for TSE Mains. Gaskets and lubricants shall be made
from materials that are compatible with the plastic material and with each other when used
together. They shall not support the growth of bacteria and shall not adversely affect the
potable qualities of the water that is to be transported. One elastomeric gasket shall be
furnished with each length of socket-end pipe.
Pipe shall have a minimum internal diameter equal to or greater than the pipe size shown on
the Drawings and Bills of Quantities. SDR shall be defined as outside diameter divided by
wall thickness. Acceptable PVC pipe shall have common profiles for interchangeability
between rough barrel dimensions, couplings, ends and elastomeric gaskets so as to facilitate
future repairs. When assembled, the pipe shall have only one gasket per socket and spigot
end.
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Pipes delivered to site shall be no more than 12 months old. The Engineer reserves the right
to reject the pipes older than 12 months old.
3.5.3
Joints
Solvent welded joints shall not be permitted for sewerage pipelines and all jointing shall be by
socket and spigots with sealing rings which shall conform to BS 2494.
Unless otherwise designated, irrigation pipework up to 100 mm in diameter shall be solvent

welded in accordance with BS 4346 Part 1.
3.5.4
Inspection and testing for sewer pipes shall be in accordance with an approved inspection
and test plan.
Inspection and testing for irrigation pipes shall be in accordance with an approved inspection
and test plan.
Test certificates shall be provided by the manufacturer.
All pipes may be subject to inspection at the place of manufacture in accordance with the
provisions of the referenced standards as supplemented by the requirements herein. The
Contractor shall notify the Engineer in writing of the manufacturing starting date not less than
14 calendar days prior to the start of any phase of the pipe manufacture.
During the manufacture of the pipe, the Engineer shall be given access to all areas where
manufacturing is in process and shall be permitted to make all inspections necessary to
confirm compliance with the Specifications.
The Contractor shall perform said material tests in accordance with the requirements of the
Contract Documents. The Engineer shall have the right to witness all testing conducted by
the Contractor, provided that the Contractors schedule will not be delayed for the
convenience of the Engineer.
In addition to those tests specifically required, the Engineer may request additional samples
of any material for testing by the Engineer.
All expenses incurred in obtaining samples for testing shall be borne by the Contractor at no
additional cost to the Contract.
3.5.5
All fittings shall be push-on joint with mechanical fittings. Fittings shall be in uPVC material
compatible with the above specified pipe and having the same minimum Class and Pressure
Rating. The fittings when connected to the main pipe shall provide an integral system
capable of withstanding the working and test pressure.
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ACRYLONITRILE BUTADIENE-STYRENE (ABS) PIPES AND FITTINGS
3.6.1
Standards
Acrylonitrile butadiene-styrene (ABS) pipes and fittings for pressure pipes shall conform to
BS 5391 and BS 5392.
3.6.2
Manufacture
Unless otherwise designated, ABS pipes and fittings shall be class E and manufactured in
accordance with BS 5391 and BS 5392.
3.6.3
Joints
ABS pipes shall be provided with socket and spigot joints, sealed with elastomeric sealing
rings conforming to BS 2494.
3.6.4
Inspection and testing for pipes and fittings shall be in accordance with BS 5391 and
BS 5392.
3.7
DUCTILE IRON PIPES AND FITTINGS
3.7.1
Standards
Unless otherwise stated in the Contract Documents ductile iron pipes and fittings for pipes
shall comply with BS EN 545 and shall be suitable for an allowable operating pressure (PFA)
of 16 Bar and an allowable maximum operating pressure (PMA) of 20 bar.
Unless otherwise stated in the Contract Documents, flanges on ductile iron pipework and
fittings shall comply with BS EN 1092-2 and shall be PN16.
All puddle flanges shall be cast integrally with the wall piece.
3.7.2
Exposed Joints
Ductile iron flanged pipes shall be furnished with integrally cast flanges or screwed on flanges
faced and drilled to class designation. Steel bolts and nuts shall be supplied with two
washers per bolt. Bolt length shall be such that after the joints are made up, the bolts shall
protrude through the nut, but not more than 12 mm. Bolts shall be stainless steel grade to
BS 970 Grade 316 S31.
Gaskets shall be compatible with the fluid to be conveyed. For treated sewage effluent
pipelines, EPDM gaskets shall be used. Gaskets shall be able to withstand a pressure of
PN 16 for a 24 h test period. Thickness of gaskets shall be such that, when jointed in
accordance with manufacturers instructions, the joint shall provide a positive seal for the
range of pressures likely to occur in the pipeline under the maximum joint deflection
permitted.
Pipes and fittings in chambers and pumping stations shall have flanged joints unless detailed
otherwise. Flanges shall comply with BS EN 1092-2 and shall be PN16 unless a higher
pressure rating is detailed elsewhere.
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3.6
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3.7.3
Buried Joints
Pipes and fittings to be buried shall have flexible joints unless detailed otherwise.
3.7.4
Internal Lining
Pipes and fittings shall be lined internally with one of the following linings:
(a)
Polyurethane lining minimum thickness 1,000 micron
(b)
Fusion bonded epoxy powder lining minimum thickness 500 microns
(c)
Ceramic epoxy lining minimum thickness 1,000 micron
All coatings shall be factory applied in strict accordance with the lining manufacturers
specification. Pipes shall be blast cleaned or ground to the equivalent of BS EN ISO 8501-1,
BS 7079:A1, SA 2.5 prior to application of the products.
All liners shall comply with the following standards:
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adhesion to pipe (ASTM D4541) Min 10 MPa
(b)
impact resistance (ASTM2794) Min 10 J
(c)
abrasion resistance (AST D4060, 1kg x 1000cycles) Max 100 mg
(d)
vapour permeability (ASTM D1653, Wet cup method) 1.0g/m2/24hr
(e)
immersion test 20% sulphuric acid (ASTM D-714-87) No effect after 2 years
(f)
salt spray test (ASTM B117 1,000 hours) pass
(g)
spark holiday test voltage V = 248T0.5, where T = thickness of lining in microns
(h)
any defect found in the lining shall be repaired at the manufacturers plant before
shipment.
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(a)
Internal socket end of pipes shall be protected with a minimum thickness of 300m of epoxy.
All pipes shall be clearly marked to indicate the type of lining as follows:
PU Polyurethane
(a)
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(b)
FBE Fusion bonded epoxy
(c)
CE Ceramic epoxy
3.7.5
External Coating and Wrapping, Use and Materials
External coatings for ductile iron pipes shall be factory applied to the approved pipe
manufacturers standards and conform to one of the following specifications.

Part
Inner coat
External DI Pipe Coating Systems
Middle Coat
Final Coat
150m epoxy
Black fusion or hot melt

adhesive bonded
polyethylene sleeving
of nominal thickness
1000m
200g/m2 zinc
150m epoxy
Black tape self

adhesive bituminous
resin on PVC backing
layer complying with
AWWA C2009 Section
24 Type 1. 55%
overlap.
Nil
Nil
Polyurethane as Part 3
3.7.4 minimum
thickness 2000m
BS EN 598, ISO 817,

AWWA C2009
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200g/m2 zinc
Applicable
Standards
BS EN 598, BS 6076
and ISO 8179-1
Table 3.2
Page 30
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QCS 2014
Laminate Tape Properties
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Table 3.3
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Laminate tape shall have the following characteristics:
Applicable
Standard
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Parameter
ASTM D 1000
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Overall thickness
PVC backing thickness
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PVC backing thickness if

fabric reinforcement in
bituminous layer
Tensile Strength
ASTM D 1000
ASTM D 1000
Pipes
600mm dia
Pipes
600mm dia
1.1mm
1.6mm
0.3mm
0.7mm
0.5mm
0.5mm
BS 2782
7.5N/mm
12.0N/mm
Elongation
BS 2782
200%
200%
Tear Resistance
ASTM D 1004
19N/mm
50N/mm
Adhesion to steel
ASTM D 1000
1.0N/mm
2.0N/mm
Adhesion to self
ASTM D 1000
1.8N/mm
1.8N/mm
Impact resistance (single

layer)
Dielectric strength
DIN 30672
8.0Nm
10.0Nm
BS 2872
25,000V
30,000V
Insulation resistance
BS 2782
Water vapour
permeability
BS 2782
1,000,000
megohms
0.65
2
g/m /day
1,000,000
megohms
0.65
2
g/m /day
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NF A48-851
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Spigot ends of pipes that are tape or polyethylene wrapped shall not be wrapped over the
depth of engagement of the spigot with the socket or mechanical coupling but shall be coated
with a minimum thickness of 300m of epoxy.
3.7.6
Factory Application of Tape Wrapping
Before primer application, all oil and grease shall be removed with an approved solvent.
Surfaces to be coated shall be cleaned by mechanical brushing to remove loose corrosion
products, welding slag, loose factory applied bituminous paint or any other foreign matter and
achieve a surface finish equivalent to mechanical scraping and wire brushing as specified in
Clause 8.3.5 of this Section. All surfaces shall be solvent wiped after blast cleaning.
Primer shall be applied to all surfaces to be wrapped immediately following completion of

surface preparation.
Primer shall be allowed to dry before wrapping. Primer application shall be limited to the
amount that can be wrapped during the working day.
Tape shall be applied spirally to provide a 55 % overlap and with sufficient tension to result in
constant adherence without voids or wrinkles. On completion of the wrapping the surface
shall be smoothed to ensure completely sealed overlaps and the absence of air pockets
under the tape. The width of the tape shall be suitable to conform to the size and shape of
the pipeline being wrapped.
On completion of the wrapping, all tape wrapping shall be checked for continuity by a
Holiday detection unit. Any Holidays detected shall be repaired by over-wrapping with tape
and the wrapping retested.
Bond/adhesion tests shall be carried out on all tape wrappings not more than 24 hours after
completion of wrapping.
Test certificates shall be provided by the manufacturer.
3.7.7
Factory Applied Extruded Polyethylene Coating
Extruded polyethylene coating shall be factory applied to preheated epoxy primed pipes and
fittings to provide a minimum finished thickness of 2.0 mm. The coating shall be resistant to
peeling, free from imperfections, and shall be tested for continuity using a minimum 10 kV
spark tester. The polyethylene coating shall be stabilised to prevent ultraviolet and thermal
degradation.
3.7.8
Inspection procedures and tests for DI pipes and fittings shall be carried out in accordance
with BS 4772.
The Contractor shall provide Manufacturers type and quality control test certificates to be
traced to the pipe cast number, heat number or lot number.
Manufacturers certificates shall state the relevant British or ISO standards to which the pipes
and fittings supplied comply.
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The repairs to cement mortar linings, if permitted by the Engineer, shall comply with the
requirements of the designated thickness, minimum bore and surface conditions.
In addition to the prescribed testing, the pipes and fittings shall be subjected to visual
inspection at the place of manufacturer and at Site and will be rejected if the pipes are
incorrectly marked or have defects outside the ranges permitted.
3.8
FLANGE ADAPTERS AND FLEXIBLE COUPLINGS
3.8.1
General
In addition to the types of joints typically designated for each type of pipe, flange adaptors
and flexible couplings may be designated particularly for pressure pipelines.
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Flange adaptors and flexible couplings shall:

be manufactured from rolled steel or other approved materials
(b)
be capable of withstanding the pressure test of the pipeline in which they are
incorporated
(c)
permit minimum angular deflection as shown below:
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(a)
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Table 3.3 Minimum Angular Deflection
450
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Pipe diameter (mm)
750 1200
1200 -1800
>1800
0
0
0
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600 750
be capable of accommodating a movement of 10 mm between ends of pipes they

connect.
(d)
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450 600
Deflection
Adaptors and couplings shall be joined as recommended by the manufacturer.
Where necessary to restrain movement at joints tied flange adaptors shall be used and the
deflection criteria shall not apply.
All fasteners shall be stainless steel to BS970 Grade 316S31.
3.8.2
Flange Adapters
Flange adapters shall be used on PVC-U, GRP, cast and ductile iron, and joints between
each of the materials as designated. Flanges shall be PN 16 rating and gaskets shall be to
BS 3063.
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Flexible Couplings
Flexible couplings shall be used with PVC-U, GRP, cast and ductile iron, and between joints
between pipes manufactured from each of the materials.
3.9
PIPES FOR OTHER USE
3.9.1
Copper Tubes and Fittings
All tubes shall be clean, round, smooth and free from harmful defects and from deleterious
films in the bore. Copper tubing shall conform to BS EN 1057 and shall be half hard, light
gauge copper. Tubing shall be supplied in straight lengths by an approved manufacturer
whose identification mark shall appear on each tube at about 0.5 m intervals. Approved
dielectric isolation fittings or attachments shall be furnished where copper fittings, piping or
tubing are connected to ferrous fittings or connections.
Copper tubes for internal use shall be in accordance with Table X of BS EN 1057. Chromium
plated copper tube shall be of plating quality in accordance with BS 1224, free of defects
such as blisters, pits, roughness, cracks or unplated areas. Fittings shall be of the
compression type complying with BS 864 Part 2 and shall be resistant to dezincification.
Copper tubes for external use shall be in accordance with Table Y of BS 2871 Part 1. Tubing
shall have a factory applied green coloured polythene sheath with a minimum thickness of
1.0 mm. Fittings shall be of the compression or capillary type complying with BS 864 Part 2
and shall be resistant to dezincification. Joints shall be adequately protected with tape to the
3.9.2
Hose and Appurtenances
Hose and hose reel shall be furnished for designated hose bibbs. Hose shall be 25 mm
diameter minimum and provided with an adjustable nozzle. Hose pipes for wash water shall
be matched to the operating head of the supply system, be constructed for heavy duty and be
50m long. Hose pipes shall have a certified test pressure of 1.5 times the maximum
operating pressure. Hose pipes for fire fighting shall be in accordance with Section 23.
Couplings shall be furnished for each size hose, one for each 25 m length of hose provided;
they shall be of cast brass quick fix type and shall have standard threads.
3.9.3
Stainless Steel Pipes, Tubes and Fittings
All stainless steel for pipes, tubes and fittings shall be Type 316L.
Stainless steel pipes and tubes shall conform to ASTM A312 and ASTM A688. Plate shall
conform to ASTM A240; diameters and wall thickness to ANSI B36.19.
Stainless steel fittings and specials shall be compression type conforming to ASTM A234.
Plate shall conform to ASTM A240; diameters, wall thickness and dimensions to ANSI
B36.19, ANSI B16.9.
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3.8.3
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Pipe sizes 50 mm and smaller shall be of Schedule 40 and above seamless stainless steel
with threaded ends, and shall conform to material specifications ASTM A312 and
dimensional specifications ANSI B36.19. Fittings shall be threaded, 2,000 pound forged
stainless steel, and shall conform to material specification ASTM A182 and dimensional
requirements of ANSI B16.11.
Unless otherwise designated, pipe sizes over 50 mm shall be Schedule 10 and above,
seamless stainless steel with bevelled ends for welding conforming to material specification
ASTM A312 and dimensional specification ANSI B36.19. Unless otherwise designated,
fittings shall be Schedule 10, seamless stainless steel with bevelled ends for welding and
conform to material specification ASTM A403 and to the dimensional requirements of
ANSI B16.9 and ANSI B16.28. Flanges shall be ANSI slip-on or welding neck type, with
150 pounds rating conforming to material specification ASTM A182 and to the dimensional
specifications ANSI B16.5.
3.9.4
Carbon Steel Pipes and Fittings
Carbon steel pipes shall conform to :
ASTM A53, ASTM A106 for pipes, and ASTM A105 for fittings and flanges
Carbon steel fittings and flanges shall conform to ASTM A105.
3.10
MEDIUM AND HIGH DENSITY POLYETHYLENE (HDPE) PIPES
3.10.1
Applicable Standards
MDPE and HDPE pipes shall conform to the latest editions of the following standards.
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EN ISO 527 ................Plastics -- Determination of tensile properties
EN ISO 1133-1 ...........Plastics. Determination of the melt mass-flow rate (MFR) and melt
volume-flow rate (MVR) of thermoplastics.
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EN 1519 .....................Plastic piping systems for soil and waste discharge (low and high
temperature) within the building structure Polyethylene (PE)
EN ISO 1167 ..............Thermoplastic pipes, fittings and assemblies for the conveyance of
fluids Determination of the resistance to internal pressure
EN ISO 1183-2 ...........Plastics Methods for determining the density of non-cellular plastics
Part 2: Density gradient column method
EN ISO 2505 ..............Thermoplastics pipes Longitudinal reversion Test method and
parameters
EN ISO 3126 ..............Plastics piping systems Plastic components Determination of
dimensions
EN ISO 6259 ..............Thermoplastic pipes - Determination of tensile properties
EN ISO 9080 ..............Plastic piping and ducting systems determination of the long term
hydrostatic strength of thermoplastics materials in pipe form by
extrapolation
EN 12099 ...................Plastics piping systems Polyethylene piping materials and
components Determination of volatile content
EN ISO 12162 ............Thermoplastic materials for pipes and fittings for pressure applications
- Classification and designation Overall service (design) coefficient
QCS 2014

Part
Page 35
EN 12201 ...................Plastic piping systems for water supply and for drainage and sewerage
under pressure Polyethylene (PE)
EN 12666 ...................Plastic piping systems for non-pressure underground drainage and
sewerage Polyethylene (PE)
EN ISO 13479 ............Polyolefin pipes for the conveyance of fluids. Determination of
resistance to crack propagation.
EN ISO 15512 ............Plastics Determination of water content
EN ISO 16871 ............Plastics piping and ducting systems Plastics pipes and fittings
Method for exposure to direct (natural) weathering
ISO 18553 ..................Method for the assessment of the degree of pigment or carbon black
dispersion in polyolefin pipes, fittings and compounds.
ISO 4065 ....................Thermoplastic pipes Universal wall thickness table
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ISO 4427 ....................Plastics piping systems - Polyethylene (PE) pipes and fittings for water
supply
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ISO 6964 ....................Polyolefin pipes and fittings Determination of carbon black content
by calcination and pyrolysis Test method and basic specification
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ISO 9624 ....................Thermoplastic pipes for fluids under pressure mating dimensions of
flange adaptors and loose backing flanges
qa
ISO 11357-6 ...............Plastics Differential scanning calorimetry (DSC) Part 6:

Determination of oxidation induction time (OIT)
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ISO 11922-1 ...............Thermoplastic pipes for the conveyance of fluids Dimensions and
tolerances - Part: 1: Metric series
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ISO 13761 ..................Plastics pipes and fittings Pressure reduction factors for polyethylene
pipeline systems for use at temperatures above 20C
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ISO 13953 ..................PE pipes and fittings Determination of tensile strength and failure
mode of test pieces from a butt-fused joint
ov
ISO 14236 ..................Plastics pipes and fittings Mechanical joint compression fittings for
use with polyethylene pressure pipes in water supply systems
ASTM D638-10...........Standard test method for tensile properties of plastics
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AWWA C224 ..............Standard for nylon-11 based polyamide coating system for the interior
and exterior of steel water pipe, connections, fittings and special
sections
WIS 4-24-01 ...............Specification for mechanical fittings and joints for polyethylene pipes
for nominal sizes 90 to 1000 mm OD
WIS 4-52-01 ...............Specification for polymeric anti-corrosion (barrier) coatings
WIS 4-52-03 ...............Specification for anti-corrosion coatings on threaded fasteners
3.10.2
Manufacture
MDPE and HDPE (PE) pipes and fittings shall be manufactured from virgin materials only.
Recycled, re-ground or re-generated materials shall not be used.
HDPE pressure pipes and fittings shall be manufactured from material conforming to polymer
classification PE100 having a minimum required strength value (MRS) of 10 MPa at 50 years
and 20C in accordance with ISO 4427. Design stress shall be 8 MPa. The pipe
manufacturer shall identify the manufacturer of the resin, the resin type and classification.
QCS 2014

Part
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The HDPE pipe material shall be certified as meeting the requirements of the PE100+
Association.
HDPE pipes to be installed using trenchless technology applications shall be manufactured

from a PE100-RC material. Pipes manufactured from such material shall have undergone the
Notched Pipe Test at an independent 3rd party laboratory in accordance with ISO 13479 and
the time to failure shall have been a minimum of 8,760 hours (1 year). All other
characteristics shall comply with the PE100 requirements of ISO 4427 and this specification.
HDPE pipes shall have a standard dimension ratio (SDR) of 11 unless indicated otherwise by
the Engineer and shall have a pressure rating of 16 bar (PN16) at 20C (de-rated to 11.8 bar
at 40C, in accordance with Annex A of ISO 4427 Part 1) unless indicated otherwise by the
Engineer.
Pipes and fittings shall be designed to achieve a minimum working life of 50 years under all
applicable loads, environmental and installation conditions.
MDPE pressure pipes and fittings shall be manufactured from material conforming to
polymer classification PE80 having a minimum required strength value (MRS) of 8 MPa at 50
years and 20C in accordance with ISO 4427. Design stress shall be 6.4 MPa. The pipe
manufacturer shall identify the manufacturer of the resin, the resin type and classification.
MDPE pipes shall have a standard dimension ratio (SDR) of 11 unless indicated otherwise by
the Engineer and shall have a pressure rating of 12.8 bar (PN12.8) at 20C (de-rated to 9.5
bar at 40C, in accordance with Annex A of ISO 4427 Part 1) unless indicated otherwise by
the Engineer.
Pipes and fittings shall be homogeneous throughout and free of visible cracks, holes, foreign
inclusions, voids and other injurious defects.
10
The resin from which the pipes and fittings are manufactured shall comply with the
requirements of ISO 4427 Part 1 and be protected from UV attack by the addition of carbon
black in accordance with the standard.
11
Straight lengths of PE pipe shall be supplied in standard lengths of 12m (-0/+50 mm)
measured at 23C 2C. Unless otherwise specified, coil length shall not exceed 100m.
Coiled pipes shall be coiled such that localised deformation is avoided and the minimum
internal diameter of the coil shall not be less than 20 x outside diameter. Prior to jointing the
degree of pipe ovality shall not exceed the permissible levels given in Table 1 of ISO 4427,
Part 2 and the Contractor shall, if required, use mechanical re-rounding equipment to meet
these requirements. Field cut lengths of pipe used as closures may not be shorter than 0.75
metre in length and shall be approved by the Engineer.
12
All pipes shall be indelibly marked at intervals of maximum 1m. The colour of the pipe
marking shall always contrast with the colour of the pipe. Markings shall include the following
information:
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(a)
Manufacturers name, trademark
(b)
Material and designation i.e. PE100
(c)
The nominal pressure (PN) of the pipe / fitting
(d)
Dimension of the pipe (nominal outside diameter x nominal wall thickness)
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Part
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(e)
Standard Dimension Ratio (SDR)
(f)
Production period (date / batch code)
(g)
International Standard to which the pipe / fitting has been produced to
(h)
Designation of the medium for which the pipe is produced for (water, gas, sewage)
(i)
Stencilled in legible letters the pipe identification number on the outside at each end.
Ensure that the same number appears on all record sheets and documents relating to
the manufacture, delivery and testing of that pipe.
Pipes shall be delivered in wooden frames or similar arrangement to avoid movement

between pipes. Pipes shall not be stacked higher than 1m in each frame or packing
arrangement.
3.10.3
Fittings
Unless otherwise specifically approved by the Engineer, all PE pressure pipe fittings for use
with pipes of up to 355 mm OD shall be injection moulded with the same polymer
classification, material type and pressure rating as the pipe to which they are to be
connected. All joints between PE pipes and fittings shall whenever possible be by thermal
butt fusion welding or electro-fusion welding process.
Connections of PE pipes and fittings to metallic fittings shall be made with PN16 backing
rings with a stainless steel stiffener insert or as recommended by the pipe or fitting
manufacturer and approved by the Engineer.
Transition fittings used to join the pipe to flanged fittings and pipes made of other materials
shall be certified by an independent third party as being fully compliant with the Type 1 or
Type 2 requirement of WIS 4-24-01 i.e. they shall prevent the pull out of the pipe at their
rated operational and test pressures.
Metallic fittings shall be fully coated to provide protection against corrosion. The coating shall
be a factory applied fusion bonded epoxy or a nylon 11 based polyamide coating system,
have a minimum dry film thickness of 250 microns and comply with the requirements of
either AWWA C224 or WIS 4-52-01. Any bolts, studs or nuts shall be of stainless steel
(grade 304 or better) or else be protected with a coating that complies with the requirements
of WIS 4-53-03. All buried metallic fittings shall be protected by petroleum impregnated
primer, paste and tape prior to back filling.
Where their use is approved by the Engineer, all compression fittings shall be certified by an
independent third party as being fully compliant with the requirements of ISO 14236. They
shall be tested and certified as being class 1 end load bearing fittings i.e. they shall prevent
the pull out of the pipe at their rated operational pressure. Only materials listed in Tables 1
and 2 of ISO 14236 shall be used in the manufacture of the fitting body.
Where the use of fabricated fittings has been specifically approved by the Engineer such
fittings shall be designed and manufactured in accordance with the requirements of ISO
4427, Part 3, in particular Annex B. The pressure derating factors to be employed by the
fittings fabricator shall be in accordance with annex sections B3 and B5 unless they can
demonstrate that higher factors can be applied. The use of any higher factors shall be
approved by the Engineer prior to commencement of fitting fabrication.
All PE fittings shall, as a minimum, be indelibly marked with the following information:
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13
QCS 2014

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(a)
Manufacturers name, trademark
(b)
International Standard to which the pipe / fitting has been produced to
(c)
Material and designation i.e. PE100
(d)
The nominal pressure (PN) of the pipe / fitting
(e)
Outside diameter and Standard Dimension Ratio (SDR)
(f)
Production period (date / batch code)
PE Fittings shall be individually packed in bulk, bag or individual protection against

contamination. Electrofusion fittings shall always be packed in a sealed bag or container. The
packaging shall, as a minimum, be labelled with the manufacturers name, quantity, type and
dimension.
3.10.4
Pipes and Fittings for Gravity Applications
Pipes and fittings for drainage applications shall be suitable for carrying potable water,
treated sewage effluent, raw sewage and surface water at temperatures up to 40C as
dictated by the particular application and they shall comply with the requirements of EN1519
or EN 12666, as appropriate.
3.10.5
Testing of MDPE and HDPE Pressure Pipes and Fittings
The raw material and pipe manufacturers shall document and certify all products and shall
undertake all testing required by ISO 4427 and this specification.
Prior to delivery of any pipes or fittings the pipe manufacturer shall provide the Engineer with
a comprehensive Inspection and Testing Plan (ITP) for their approval. The ITP shall detail all
the certificates and documents that shall be provided by the pipe manufacturer, together with
details of the testing that they shall undertake, its frequency and associated test reports.
Where the pipe manufacturer cannot themselves undertake the required testing they shall
employ an independent third party laboratory to undertake the testing on their behalf.
Definition of material, pipe and fittings batches for the purposes of batch release testing:
A raw material batch shall be considered as a batch of material supplied by the resin
producer having an individual identification number or code. For the purposes of this
specification it shall also be the raw material used to manufacture a particular pipe
batch.
(a)
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(b)
A pipe batch shall be considered as a continuous production run of a particular pipe

OD and wall thickness manufactured from one resin type with no change in the
(c)
A batch of fabricated fittings shall be considered as group of fittings of the same OD

and wall thickness.
The pipe manufacturer shall undertake the following minimum batch release testing.
QCS 2014

Part
Page 39
Table 1 Release tests to be undertaken on each raw material batch

Characteristics
Sampling
Frequency
Reference
No. of Tests or
Inspections
ISO 4427-1 section 4
Once per raw

material batch
Oxidation induction time
Once per raw

material batch
Melt mass-flow rate
Once per raw

material batch
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Compound Density
Reference
Sampling
Frequency
Geometrical
Marking
This specification
Melt mass-flow rate

Elongation at break
Continuously
No. of Tests or
Inspections
Each pipe or coil
Once per pipe batch
Once per pipe batch
ISO 6259 (Tensile

strength to be 19MPa)
Once per pipe batch
Tensile strength at yield on a

sample cut from MDPE pipe
ISO 6259 (Tensile

strength to be 15MPa)
Once per pipe batch
Longitudinal reversion
Once per pipe batch
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Continuously
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Appearance and colour
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Characteristics
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Table 2 Release inspections and tests to be undertaken on each batch of pipes
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Tensile strength at yield on a

sample cut from HDPE pipe
Pipe wall thickness shall be measured and controlled on a continuous basis using and ultrasonic
thickness gauge or similar device that shall be regularly calibrated in accordance with the gauge
5
In accordance with the recommendations of ASTM D 638, the maximum thickness of the
tensile strength test samples cut from the pipe wall shall be 14 mm. In the event of the pipe
wall being thicker than 14 mm the pipe manufacturer shall machine the test samples in
accordance with the Table 3.
QCS 2014

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Page 40
Table 3 Preparation of samples for tensile testing

Pipe Wall Thickness (WT)
(mm)
Test Sample Thickness

(mm)
No. of samples to be
taken from the pipe wall
14
WT
14 < WT 28
WT/2
28 < WT 42
WT/3
42 < WT 56
WT/4
56 < WT 72
WT/5
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All testing shall be undertaken in accordance with ISO 6259 and all HDPE samples shall
achieve a minimum tensile strength at yield of 19 MPa in order for the pipe to successfully
pass the test. MDPE samples shall have achieved minimum tensile yield strength at yield of
15 MPa.
Table 4 Release inspections and tests to be undertaken on each batch of fabricated fittings
Reference
Sampling
Frequency
Geometrical
Marking
No. of Tests or
Inspections
Continuously
Continuously
This specification
Each fitting
ISO 4427-3 Annex B
Once per batch of

HDPE fittings
1 piece only
ISO 4427-3 Annex B
Once per batch of

MDPE fittings
1 piece only
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Hydrostatic strength at 20 C,
100hrs & 10 MPa x
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Hydrostatic strength at 20 C,
100hrs & 12.4MPa x
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Appearance and colour
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Characteristics
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The fabricated fitting to be hydrostatically tested shall be a tee or branch provided the batch
in question contains this type of fitting, otherwise a bend shall be tested.
In the case of injection moulded fittings the manufacturer shall issue a certificate confirming
compliance with ISO 4427 and providing details of the type testing undertaken by an
independent third party in accordance with sections 7 and 8 of ISO 4427 Part 3.
The pipe manufacturer shall provide the Engineer with a copy of the batch release tests i.e.
all those tests listed above, with each batch of pipes or fittings that is delivered to site.
Prior to delivery of pipes the pipe manufacturer shall provide the Engineer with copies of all
the test results and certification required by ISO 4427, this specification and the ITP, but
which are not covered by the above batch testing requirements. These documents shall
comprise the Type Test Report.
The Type Test Report shall include a copy of the raw material manufacturer's "Certificate of
Quality Control Testing" covering each batch of raw material used for manufacturing pipes
produced under this specification.
10
The pipe manufacturer shall ensure that all the applicable codes and standards are available
at their facility for the Engineers reference during any visit or inspection.
QCS 2014

Part
Page 41
The pipe manufacturer shall provide full assistance and co-operation for any inspection,
when required by the Engineer or by an inspector appointed by the Engineer.
12
The Engineer may reject any item that does not successfully pass the required tests or fully
comply with the requirements of this specification. When a pipe or fitting is rejected, the items
manufactured immediately before or after shall be carefully examined and tested at the
direction of the Engineer. If further defects are found, the entire batch shall be rejected.
13
All pipes and fittings shall be visually inspected by the PE Welding Inspector before
incorporation in the Works.
14
In addition to those tests specifically required, the Engineer may request additional samples
of any material for testing by the Engineer and all expenses incurred in obtaining samples for
testing shall be borne by the Contractor at no additional cost to the Contract.
3.11
POLYESTER RESIN CONCRETE (PRC)-PIPING SYSTEMS FOR NONPRESSURE DRAINAGE AND SEWERAGE
3.11.1
General
3.11.2
Resin
D648. The resin content shall not be less than 7% of the weight of the sample as determine
by test method D2584
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11
3.11.3
1
Minimum strength
The minimum strength classes for different pipe shapes are given below
Table 3.11.1
Strength class
Sc
Nominal size
N/mm
DN
PRC-OC
PRC-TC
150 DN 500
180
180
600 DN 1000
145
160
1200 DN 3000
120
145
QCS 2014

Part
Page 42
Table 3.11.2
Strength class
Sc
N/mm
WN/HN
PRC-TE
300/450 WN/HN 600/900
180
180
700/1050 WN/HN 1000/1500
145
160
1200/1800 WN/HN 1400/2100
120
145
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PRC-OE
ta
Table 3.11.3
Strength class
Sc
N/mm
qa
Nominal size
DN
as
PRC-OK
145
160
120
145
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1200 DN 1800
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800 DN 1000
PRC-TK
END OF PART
QCS 2014

Part
04: Pipeline Installation
Page 1
PIPELINE INSTALLATION ............................................................................ 3
4.1
GENERAL ...................................................................................................... 3
4.1.1
4.1.2
4.1.3
4.1.4
4.1.5
4.1.6
4.1.7
4.1.8
4.1.9
4.1.10
4.1.11
4.1.12
4.1.13
4.1.14
4.1.15
4.1.16
4.1.17
4.1.18
4.1.19
Scope of Work
References
Guidelines
Definitions
Submittals
Quality Assurance
Specialists, Inspection and Testing
Soil Corrosivity Study
Setting Out and Pipeline Alignment
Tools for Installation and Testing
Inspection During Installation
Dewatering
Closures and Short Sections
Cutting of Pipes
Stringing of Pipes
Inspection of Trench Formation
Overpumping and Flow Diversions
Other Services
4.2
DUTILE IRON, PVC, CONCRETE, VITREOUS CLAY, ABS AND

GRP PIPELINE JOINTING ............................................................................ 8
4.2.1
4.2.2
4.2.3
4.2.4
Push-fit Joints
Mechanical Joints
Flanged Joints
GRP Joints
4.3
MDPE AND HDPE PIPELINE JOINTING .................................................... 10
4.3.1
4.3.2
4.3.3
4.3.4
4.3.5
4.3.6
4.3.7
4.3.8
4.3.9
4.3.10
4.3.11
General
PE Welding Technicians
PE Welding Inspectors
PE Welding Equipment
Method Statements
Electrofusion Jointing
Electro-fusion Joint Inspection
Butt Fusion Jointing
Butt Fusion Joint Inspection
Testing of Fusion Joints
Anchorage
4.4
PIPE LAYING .............................................................................................. 14
4.4.1
4.4.2
4.4.3
4.4.4
4.4.5
General
Laying of Rigid and Semi-Rigid Pipes
Laying of Flexible MDPE and HDPE Pipes
Laying of GRP Pipes
Corrosion Protection of Ferrous Pipelines
3
3
4
4
4
5
5
5
6
6
6
6
7
7
7
7
8
8
8
8
9
9
9
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10
10
10
11
11
11
12
12
13
13
13
14
15
16
16
18
QCS 2014

Part
Page 2
Concrete Protection to Pipe

Deflection Criteria for Flexible Pipelines
Backfilling
Deflection at Joints
Wadi Crossings
Pipe Supports
Building-in Pipes to Structures
Cleanliness of Pipelines
Marker Tape
Pressure Pipeline Marker Posts
Valve Chamber Marker Posts
Abandonment of Pipelines
Abandonment of Structures
Corrosion Protection of Flexible Couplings and Ferrous Fittings
4.5
PIPELINE STRUCTURES AND APPURTENANCES .................................. 26
4.5.1
4.5.2
4.5.3
4.5.4
4.5.5
4.5.6
4.5.7
Manholes for Foul Sewerage

Manholes for Surface Water Sewerage
Chambers
Connections to Existing Pipelines
Anchor and Thrust Blocks
Property Connections Survey
Future House Connections
4.6
TESTING OF PIPELINES ............................................................................ 30
4.6.1
4.6.2
4.6.3
4.6.4
4.6.5
General
Gravity Sewer Pipelines
Pressure Pipelines
Other Pressure Pipelines
MDPE and HDPE Pressure Pipelines
4.7
MISCELLANEOUS ITEMS .......................................................................... 38
4.7.1
4.1.2
4.7.2
Manhole Covers and Frames

Duct Covers and Frames
Hinged Aluminium Access Covers
4.8
FUTURE SEWER CONNECTION ............................................................... 40
4.8.1
General
4.9
INSITU LINING OF EXISTING MANHOLES ............................................... 41
4.9.1
General
19
20
20
21
21
22
22
23
24
24
24
24
25
25
26
28
28
28
29
29
29
30
31
32
33
34
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4.4.6
4.4.7
4.4.8
4.4.9
4.4.10
4.4.11
4.4.12
4.4.13
4.4.14
4.4.15
4.4.16
4.4.17
4.4.18
4.4.19
38
39
40
40
41
QCS 2014

Part
PIPELINE INSTALLATION
4.1
GENERAL
4.1.1
Scope of Work
This Part includes the installation of pipelines.
Page 3
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General
Demolition and Alterations
Ground Investigation
Concrete.
ta
Section 1,
Section 2,
Section 3,
Section 5,
General
Earthworks
qa
Part 1,
Part 2,
Part 3,
Part 5,
Part 6,
Part 7,
Part 8,
This Section
References
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4.1.2
BS EN 12620..............Aggregates from natural sources for concrete
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BS 4872......................Approval testing of welders when welding procedure approval is not

required
BS 6072......................Tubular polyethylene film for use as a protective sleeving for buried
iron pipes and fittings
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BS EN 752..................Drain and sewer systems outside buildings

BS EN 12007..............Gas supply systems - Pipelines for maximum operating pressure up to

and including 16 bar, Part 2: Specific functional recommendations for
PE
ISO 12176 ..................Plastics pipes and fittings Equipment for fusion jointing polyethylene
systems, Parts 1 and 2
ISO 21307 ..................Plastics pipes and fittings Butt fusion jointing procedures for
polyethylene (PE) pipes and fittings used in the construction of gas
and water distribution systems
ISO 13953 ..................Polyethylene (PE) pipes and fittings - Determination of the tensile
strength and failure mode of test pieces from a butt fused joint
ISO 13954 ..................Plastics pipes and fittings - Peel decohesion test for polyethylene (PE)
electrofusion assemblies of nominal outside diameter greater than or
equal to 90 mm
SFS 3115:E ................Plastics Pipes Water Tightness Test for Pressure Pipelines (English
version of Finnish Standard)
WIS-4-08-02 ...............Specification for bedding and sidefill materials for buried pipelines
QCS 2014

Part
Page 4
AWWA C200 ..............Steel Water Pipe 150 mm and Larger

AWWA C600 ..............Installation of Ductile-Iron Water Mains and Their Appurtenances.
4.1.3
Guidelines
The following Guidelines are applicable to the installation and testing of HDPE pipes and
fittings:
DVGW GW330...........Installation & Welding of High Density Polyethylene (HDPE) Pipes for
Gas & Water Applications
DVGW GW331...........Supervision of Installation & Welding of High Density Polyethylene
(HDPE) Pipes for Gas & Water Applications
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DVS 2202-1 ................Imperfections in thermoplastic welded joints: Features, description,

evaluation
rw
DVS 2203-1 ................Testing of welded joints of thermoplastic sheets and pipes: Test
methods Requirements
DVS 2207-1 ................Welding of thermoplastics: Heated tool welding of pipes, pipeline
components and sheets made of HDPE
qa
ta
DVS 2208-1 ................Welding of thermoplastics: Machines and devises for the heated tool
welding of pipes, pipe parts and panels
Definitions
Pipes: circular tubes through which fluid can flow including manufactured lengths of pipes,
bends, fittings, junctions and other specials, joints and jointing parts.
Valves: manufactured devices for controlling the passage of fluids through pipes including
sluice gates, reflux valves, and air valves including associated joints, jointing parts, operating
gear and fittings.
Installation: material transport and handling, pipelaying including the complete operation of
laying jointing and testing pipes in trenches or elsewhere, and the construction of pipeline
ancillaries
Pipeline: long, continuous line of pipes and fittings including valves and ancillary structures
and equipment used for transporting fluids; specifically, sewers and ancillary works for the
transport of sewage and surface water and similar pipelines for the transport of treated
sewage effluent.
4.1.5
Submittals
The Contractor shall submit the documents described in the following paragraphs.
Working drawings: Before commencing work the Contractor shall prepare working drawings
necessary for the construction and installation of facilities. The drawings shall be prepared to
A1 size or a size and scale as directed by the Engineer. The drawings shall be submitted to
the Engineer in an orderly manner and at periods which will permit adequate time for review
and approval by the Engineer. Five copies of drawings shall be submitted.
Detailed work programme with schedule for the delivery of pipes and fittings
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4.1.4
QCS 2014

Part
Page 5
Methods statements to supplement the working drawings, as follows:

(a)
installation
(i)
joints and couplings
(ii)
measures to ensure integrity of interior pipe lining and exterior protective

coating at joints and couplings
installation and adjustment of pipe bedding and other supports
(iv)
fitting of pipelines to valves.
testing of sewer pipelines and pressure pipelines to the requirements described

in Subpart 4.5
(c)
welding procedures and electrodes with drawings and schedules as may be

necessary
(d)
safety procedures and protective equipment
(b)
(i)
pipe pressure tests
(ii)
dielectric joint tests
ta
certified copies of reports of required tests including:
qa
(a)
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Quality assurance and control documents including
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(b)
copies of certificates relating to welders tests shall be made available to the

Engineers on request
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(iii)
Quality Assurance
A suitably qualified and experienced safety officer shall be employed to ensure that all
Contractors employees follow safety procedures and are provided with appropriate safety
and protective equipment.
Welders employed on the fabrication and site welding shall have passed the welder approval
tests of BS 4872, Part 1 or other standard approved by the Engineer.
4.1.7
Delivery, storage, and handling shall be as specified in Part 3 of this Section.
The Contractor shall replace or repair pipe damaged during handling and installation, to the
4.1.8
Specialists, Inspection and Testing
The Employer may employ the services of a specialist firm to assist the Engineer as he may
require in any matter connected with pipes, and fitting including the inspection of materials
and workmanship and the witnessing of tests at any stage during the execution and
maintenance of the Works.
Such independent tests may be carried out at any stage during the execution and
maintenance of the Works, but they shall not relieve the Contractor of his obligations under
the Contract.
To the extent ordered by the Engineer, the Contractor shall provide labour, plant, tools and
materials (but not special testing equipment) for direct assistance to the specialist firm in their
inspection and independent testing and for any further work, investigations, and repairs which
the Engineer considers necessary as a result of such inspection or testing.
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4.1.6
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The provision of labour, plant and materials as aforesaid shall be an obligation of the
Contractor where in the Engineer's opinion the inspection test or further investigation shows
that materials and workmanship provided by the Contractor do not comply with the
designated requirements.
4.1.9
Soil Corrosivity Study
Where designated in the Project Specification, the Contractor shall carry out a soil corrosivity
study along the route of proposed ferrous pipelines as directed by the Engineer and mark the
results on the pipeline layout plans.
Soil resistivities shall be undertaken using a low resistance, null-balance earth tester and a
four pin array, or any other equipment approved by the Engineer. Readings shall be
recorded in ohm-cm and shall be taken at 1.0 m incremental depths to a depth 1 m below the
pipeline invert levels. Readings shall be taken at a spacing along the route of the proposed
pipelines as required to reflect the changing soil conditions, but in no case shall the spacing
exceed 500 m.
Soil samples shall be taken as directed by the Engineer along the route of the proposed
pipelines at a maximum spacing of 500 m. Soil samples shall be tested for sulphates,
sulphides, chlorides, pH, moisture content, and carbonates.
4.1.10
Setting Out and Pipeline Alignment
All sewers shall be laid accurately to the lines, and levels gradients shown on the approved
drawings so that the pipeline is straight between successive manholes in the vertical and
horizontal planes.
Pressure pipelines shall be laid accurately to the lines levels and depths shown on the
approved drawings. Where changes of direction are required, deflections shall be made in
Manufactured bends shall only be used where shown on the Drawings or where otherwise
permitted by the Engineers Representative.
Where pipelines of constant gradient are to be laid, the Contractor shall provide, fix and
maintain at such points as may be directed by the Engineers Representative properly
painted sight rails and boning rods of pre-determined measurement for the boning in of
individual pipes to correct alignment. The sight rails shall be situated vertically over the line of
pipes or immediately adjacent thereto and there shall at no time be less than three sight rails
in position on each length of pipeline under construction to any one gradient
If the Contractor wishes to propose an alternative method of controlling pipeline alignment,

he shall submit his proposed method to the Engineers Representative for approval
4.1.11
Tools for Installation and Testing
The Contractor shall supply all necessary tools for cutting, chamfering, jointing, testing and
for any other requirement for satisfactory installing the pipelines.
4.1.12
Pipes and fittings including any sheathing, inside linings and outside coatings, shall be
inspected by the Contractor immediately before and after installation, and damage or other
imperfection shall be repaired by the Contractor as directed by the Engineer before
installation and in accordance with the following:
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(a)
Material required for the repair of pipe, sheathing, linings and coatings shall be
obtained by the Contractor and shall be used in accordance with the manufacturers
recommendations.
(b)
Without relieving the Contractor of any of his obligations, the Engineer may inspect
and test the pipe and appurtenances by any appropriate means, and damage
discovered by such inspection shall be repaired by the Contractor.
(c)
The Contractor shall remove from Site any pipe or appurtenance which in the
opinion of the Engineer is so damaged as to be unfit for incorporation in the Works.
The obtaining of replacements for damaged pipes and fittings to the approval of the
Engineer shall be an obligation of the Contractor.
Dewatering
All pipeline installation work shall be carried out in the dry.
Dewatering shall be carried out as specified in Part 2 of this Section.
4.1.14
Closures and Short Sections
For the purpose of reducing the angular deflections at pipe joints, and for closure sections,
the Contractor will be permitted to install pipe sections of less than standard length. Closing
lengths and short sections of pipes of all types shall be fabricated and installed by the
Contractor as found necessary at Site. Where closing pieces are required, the Contractor
shall make all necessary measurements and shall be responsible for the correctness thereof.
The Contractor shall be responsible for taking the measurements required to determine the
lengths of cut portions of pipes for insertion as closing lengths in pipelines.
4.1.15
Cutting of Pipes
Where pipes are required to be cut on the Site the cutting shall be done by the Contractor in
accordance with the manufacturers recommendations and in a manner approved by the
Engineer.
The pipe and methods of jointing shall be such that the locations of fittings and lengths of
pipe can be adjusted to suit Site conditions.
Cutting of reinforced concrete pipes will not be allowed. Special lengths of pipes shall be
manufactured for closures as required. Other pipes such as GRP, ductile iron, vitrified clay,
MDPE, HDPE, PVC-U and cast iron pipes shall only be cut if approved by the Engineer.
The cutting of vitrified clay pipes, MDPE, HDPE, PVC-U, and ductile iron pipes for inserting
specials, fittings or closure pieces shall be carried out as follows:
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4.1.13
(a)
Cutting shall be carried out in a neat and workmanlike manner with an approved
cutting machine without damage to the pipe and so as to leave a smooth end at right
angles to the axis of the pipe.
(b)
Cutting by hacksaw shall not be permitted unless approved by the Engineer.
(c)
Only experienced men shall be employed by the Contractor on this work.
(d)
The Contractor shall take every precaution to ensure that both the measurement
tolerances and the cutting of pipes are to the accuracy required. Should any errors
occur the Contractor shall correct the defects to the approval of the Engineer.
4.1.16
Stringing of Pipes
Pipes shall be distributed to installation site only in such quantities as can be installed in one
working day or as allowed by the Engineer.
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The Contractor shall take pipes from the storage areas, unload and string along the route of
the proposed pipeline. Pipes shall be so strung as to cause the least practicable interference
with the use of the land.
After a pipe has been strung and immediately before being laid, it shall be cleaned out and
inspected for defects. Cast or ductile iron pipes shall be rung with a light hammer while the
pipe is suspended clear of the ground to detect cracks. Other pipes shall be visually
inspected. Any defective, damaged or unsound pipe shall be rejected. Any damage to the
lining or coating of the pipe shall be repaired or the pipe rejected as directed by the Engineer.
Plastic pipes shall not be strung along the pipe route but shall be stored in accordance with
Part 3 of this Section until required for laying and jointing.
4.1.17
Inspection of Trench Formation
After excavations have been completed to the designated levels and, trench formation
compacted, the Contractor shall issue a formal notice to the Engineer that the trench
formation is ready between designated points for inspection. The Engineer will without
unreasonable delay inspect the said trench formation, unless he considers it unnecessary
and advises the Contractor accordingly. Any rejection of trench formation will be confirmed in
writing by the Engineer.
The formation will be re-inspected by the Engineer after replacement of any unsound material
with material as specified under Clause 2.2.3 of Part 2 of Section 8.
No bedding shall be placed until the Engineers Representative has given his approval to the
trench formation.
4.1.18
Overpumping and Flow Diversions
Flow diversions shall be in accordance with Clause 10.4 of the Section.
4.1.19
Other Services
Where the Works requires the seeking, protection, diversion or relocation of existing services
the procedures set out in Section 6 Part 11 shall be followed.
4.2
DUTILE IRON, PVC, CONCRETE, VITREOUS CLAY, ABS AND GRP

PIPELINE JOINTING
4.2.1
Push-fit Joints
Immediately before assembling each joint incorporating a rubber ring seal, the rubber shall
be inspected for cracks, every part of the ring being deformed by hand to about 150 mm
radius. If under this deformation any cracks are either revealed or initiated then the ring shall
be rejected, cut through completely to prevent inadvertent use, and the matter reported
forthwith to the Engineer. If more than three successive rings inspected in this way are
rejected the Contractor shall on the instruction of the Engineer stop all pipe jointing until the
cause of the defect has been proved and remedied to his satisfaction.
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The rubber ring shall be placed in the groove on the socket or spigot ring. The groove shall
be free of deleterious material; e.g., dirt, moisture, oil, and grease. The inside surface of the
socket shall be lubricated with a compound recommended by the manufacturer which will
facilitate the telescoping of the joint. The spigot end of the pipe shall then be inserted into the
socket of the adjoining pipe using a suitable tool to push the spigot into the socket. The
position of the pipe and the gasket in the joint shall then be checked using a feeler gauge to
demonstrate proper jointing. When joints are not properly made, pipes shall be adjusted, or
removed and rejointed as necessary to ensure proper jointing. Care shall be taken to avoid
twisting or cutting the ring when jointing the pipe.
For pipes up to and including 700 millimetres nominal bore the joints shall be capable of
withstanding a deflection of not less than 1.5 degrees in any direction and for pipes over 700
millimetres nominal bore 0.5 degrees in any direction. All pipe joints shall be capable of
withstanding a draw of 13 millimetres over and above the initial jointing allowance. The
initial jointing allowance is the gap between the spigot and the shoulder of socket measured
parallel to the centre line of the pipeline and shall not be less than 6 millimetres or greater
than 13 millimetres.
4.2.2
Mechanical Joints
Where mechanical joints are approved, installation shall be in accordance with the
manufacturers recommendations. The Contractor shall render the end of each pipe perfectly
smooth so as to allow the joint sleeve to slide freely and where necessary shall coat the pipe
ends with two coats of an approved quick drying sealing and protective compound. Buried
joints shall be wrapped using protective tape as specified in Clause 3.8.5 and applied as
clause 4.3.5.
4.2.3
Flanged Joints
Flanged joints for ductile iron and cast iron pipes and specials shall be made with rubber joint
gaskets and steel bolts and nuts which shall include two washers per bolt. The use of jointing
paste or grease shall not be permitted. The gasket may be fastened to the bolts with cotton
thread. The bores of abutting pipes or fittings shall be concentric and no jointing material is
to be left protruding into the bore.
All nuts shall first be tightened by hand and nuts on opposite sides of the joint circumference
shall then be alternately and progressively tightened with a spanner so as to ensure even
pressure all around the joint.
Buried joints shall be wrapped using protective tape as specified in Clause 3.8.5 and applied
as clause 4.3.5.
4.2.4
GRP Joints
Joints shall be of the O ring or rolling type, and shall incorporate a soft or flexible control
register to help to locate the joint.
GRP pipe joints shall be assembled in accordance with manufacturer's instructions for the
type of flexible joint provided.
Joints shall be capable of withstanding the various tests specified for the appropriate class of
pipe. Joints shall withstand, while maintaining the specified test pressure, a deflection of not
less than 1.5 in any direction or for pipes up to and including 600 mm nominal bore, and
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0.5 in any direction for pipes over 600 mm diameter.

4
Rubber joint rings shall be made of EPDM SBR or nitrile rubber (NBR) and shall comply with
the relevant requirements of BS EN 681-1 for Type WG rings.
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Flanged pipes, if required, shall incorporate an annular gasket and these gaskets shall cover
the full face of the flange and shall have holes cut in correspondence to the bolt holes in the
flanges. Flanges shall be drilled to BS EN 1092 type PN 16. Alternatively jointing system for
flanged pipes, incorporating rubber rings, may be approved by the Engineer. Stainless steel
backing rings shall be inserted between the bolt head / nut and the GRP flange to spread the
load.
4.3
MDPE AND HDPE PIPELINE JOINTING
4.3.1
General
The Contractor shall abide by the following guidelines with regards to jointing MDPE and
HDPE (PE) pipes and fittings unless otherwise approved by the Engineer.
PE pipes and fittings of 90 mm OD and above shall joined by butt fusion whenever
possible.
(b)
PE pipes and fittings of less than 90 mm OD shall be joined together using electrofusion couplings and fittings.
(c)
Electro-fusion fittings may also be used to undertake repairs and install off-takes or
connections on existing pipelines. They may also be used for the joining together of
pipe strings where it is not practical to use a butt fusion welding machine.
(d)
To join PE pipes to metal pipes and fittings such as valves, restrained mechanical
transition fittings and stub flanges shall be used.
(e)
Restrained mechanical fittings may, with the permission of the Engineer, to undertake
repairs and install off-takes or connections on existing pipelines.
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(a)
PE Welding Technicians
All PE electro and butt fusion jointing, PE jointing to GRP and metallic valves and fittings shall
only be undertaken by a certified HDPE Welding Technician holding a valid Welder Licence.
The PE Welding Technician shall have attended a comprehensive course on the Installation
and Welding of High Density Polyethylene (HDPE) Pipes. The minimum course length shall
be 5 days and the Technician shall have sat and passed an exam in accordance with the
GW330 standard of the German Technical and Scientific Association for Gas and Water
(DVGW) or an equivalent national body approved by the Engineer.
The PE Welding Technician shall hold a valid GW330 Welder License or equivalent issued
by a national body approved by the Engineer, which shall be subject to annual renewal by
attending a re-examination course.
4.3.3
PE Welding Inspectors
A specialist PE Welding Inspector shall observe and supervise the handling, welding, jointing
to other materials and testing on site of all HDPE pipes and fittings.
The PE Welding Inspector shall have attended a comprehensive course on the Installation
and Welding of High Density Polyethylene (HDPE) Pipes. The minimum course length shall
be 5 days and the Inspector shall have sat and passed an exam in accordance with the
GW331 standard of the German Technical and Scientific Association for Gas and Water
(DVGW) or an equivalent national body approved by the Engineer.
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4.3.2
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PE Welding Equipment
All welding machines and welding equipment shall fulfil the requirements of DVS 2208-1 or
the relevant part of ISO 12176. All welding machines shall be of an automatic or semiautomatic design where the welding machine determines and controls the welding
parameters based on the pipe and fitting details entered by the operator. They shall also be
equipped with a data logging function that measures and records information listed in DVS
2208-1.
All machines shall undergo a yearly calibration and function test, carried out by a service
centre authorised by the machine manufacturer.
4.3.5
Method Statements
A detailed method statement for PE pipe jointing shall be prepared by the Contractor and
submitted to the Engineer for approval. The method statement shall include details of which
equipment shall be used and how the work will be performed to ensure compliance with the
recommendations of the pipe manufacturer and of this specification. It shall include, but not
be limited to:
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4.3.4
Details of the equipment to be employed by the Contractor, together with procedures

for its operation, maintenance, periodic inspection and testing.
(b)
Details of the experience and certification of the pipe and fitting jointers that shall be
employed by the Contractor.
(c)
Procedures for joint preparation, indicating method and degree of cutting, cleaning,
drying, scraping, alignment, support, etc. of the pipe ends to be joined.
(d)
Jointing procedures, specifying the equipment and tools to be employed, together with
all relevant parameters such as voltage, temperature, pressure, heating time and
cooling down time and the means by which jointing operations shall be controlled.
(e)
Inspection and testing procedures together with proposals for the independent and on
site inspection and testing on welds on a regular basis.
(f)
QA/QC procedures
(g)
All safety precautions and procedures.
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(a)
Electrofusion Jointing
All electrofusion jointing shall be undertaken in accordance with this specification and the
guidance given in DVS 2207-1
Only barcode labelled electro-fusion fittings incorporating fusion indicators and complying
with the requirements of ISO4427, Part 3 shall be used. The electrofusion control unit shall
incorporate data input through the use of a bar code reader pen and a data retrieval facility to
allow historical fusion data to be read on the units screen and to be exported to an external
computer or memory stick.
The electro-fusion control box shall deliver the correct fusion parameters to the electro-fusion
fitting. The power generator shall provide the power requirements of the control box, taking
into account the electrical characteristics of the control box.
Positioning tools including suitable alignment clamps shall at all times be used to minimise
misalignment and prevent movement during the fusion and cooling cycle of the joint. A
suitable shelter shall be used in cold, windy, dusty or wet weather conditions.
Prior to commencing the welding process the Contractor shall measure and ensure that the
ovality of the pipe or spigot end is within the limits given in Table 3 of ISO 4427, Part 3.
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4.3.6
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All pipework shall be cleaned with disposable alcohol impregnated wipes prior to undertaking
the pipe scraping, in order to remove any contamination. Prior to scraping the Contractor
shall measure and mark the area of the pipe or spigot end to be scraped in order to remove
the oxidized surface to a depth between 0.2 and 0.4 mm. The length of the pipe or spigot end
to be scraped shall be equivalent to the insertion depth of the electro-fusion joint plus a
distance of between 10 and 20 mm.
Only rotating mechanical scrapers or peelers, which are capable of cutting a continuous strip
or ribbon over the insertion length of the coupler or fitting, shall be used.
Only after preparation and scraping of the pipe end shall the fitting be removed from its
packaging and immediately inserted over the pipe end.
Each pipe or spigot end shall penetrate completely its relevant part of the electro-fusion
socket.
10
Alignment clamps shall not be removed before the appropriate cooling time has elapsed.
Abnormal displacement of the electric wire coils shall not occur. This shall be checked prior
to commencement of the fusion process.
4.3.7
Electro-fusion Joint Inspection
All completed electro-fusion joints shall be inspected in accordance with the requirements of
Appendix B of EN 12007 Part 2. Should the joint contain any of the faults described in the
standard then the electro-fusion fitting shall be cut out and replaced.
After completion of the fusion process, all fusion indicators shall be checked to ensure that
they are in the position indicated in the Manufacturer's instructions. If any fusion indicators
are not in the required position the electro-fusion fitting shall be cut out and replaced.
The Contractor shall, on a regular basis allow the Engineer to download the historical data
relating to the welds made by the unit through the data retrieval facility.
4.3.8
Butt Fusion Jointing
All butt fusion jointing shall be undertaken in accordance with this specification, the single low
pressure jointing procedure given in ISO 21307 and the guidance given in DVS 2207-1.
Assign a unique joint number to each joint and have a data retrieval facility to allow historical
fusion parameters to be read on the units screen and to be exported to an external computer
or memory stick
In the case of large diameter pipes having a high wall thickness in excess of 35 mm the
Contractor may propose to instead follow the single high pressure fusion jointing procedure
described in ISO 21307. Such a deviation from DVS2207-1 shall only be allowed with the
written approval of the Engineer.
Only pipes and fittings of the same size, SDR and material are to be butt fusion jointed.
A dummy joint shall be made at the start of each welding session using pipe off cuts of the
same size, material and SDR as the pipe being installed. The normal trimming, bead up and
full heat soak cycles will be adhered to.
If the pipe size is changed during the day, if the heater plate is allowed to cool below 180C
or if maintenance of the butt fusion equipment is carried out then a new dummy weld shall be
performed.
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4.3.9
Butt Fusion Joint Inspection
All butt fusion joints shall be inspected in accordance with the requirements of Appendix B of
EN 12007 Part 2. Should the joint contain any of the faults described in the standard then the
joint shall be cut out and replaced. The inspection shall include the following points:
The gap between the two single beads shall not be below the fusion surface.
(b)
The displacement between the fused pipes must not exceed 10% of the pipe wall
thickness.
(c)
The difference between two single bead widths shall not exceed 10% of the double
bead width.
(d)
The weld beads shall be free from all contamination and have a smooth even surface
with no evidence of distortion, holes or bubbles
(e)
At the direction of the Engineer external beads shall be removed with an approved tool
and inspected for contamination and defects. They shall also undergo bend back
testing. Beads should be solid and rounded with a broad root as hollow beads with thin
root and curled appearance can be indicative of excessive pressure or no heat soak.
(f)
Each removed bead shall be numbered with its corresponding joint number clearly
displayed and removed beads shall be retained for inspection by the Engineer.
(g)
The width of each external bead width shall be measured using bead gauges and the
width of the bead shall be within the range given by the pipe and / or welding
equipment manufacturer.
(h)
No signs of damage (such as scratches or deep impressions caused by clamps) shall

be visible on either side of the joint.
(i)
Any joints the do not comply with the above requirements shall be cut out and a new
joint made; the failed joint shall be handed over to the Engineer.
(j)
Records of all tests and inspections shall be maintained by the Contractor and made
available for review and approval by the Engineer.
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(a)
Testing of Fusion Joints
A minimum, 1 % of all butt fusion joints shall be cut out and destructively tested under
laboratory conditions in accordance with ISO 13953 by an approved testing organisation. The
joints to be tested shall be selected by the Engineer immediately upon completion of the
welding process, whereupon they shall be cut out and delivered for testing.
A minimum of 1 % of all electro-fusion fittings shall be cut out and destructively tested under
laboratory conditions in accordance with ISO 13954 by an approved testing organisation. The
fittings to be tested shall be selected by the Engineer immediately upon completion of the
welding process, whereupon they shall be cut out and delivered for testing. They shall
comprise at least 1 of each type of electro-fusion fitting even if this requires more than 1 % of
all electro-fusion fittings to be tested. Note that the minimum test requirement is for one fitting
of each type i.e. bend, coupling, tapping saddle, tee etc. not one of each size and type.
All costs associated with the testing, together with any consequent rectification of faults and
retesting shall be borne by the contractor.
4.3.11
Anchorage
Anchorage lugs shall be provided for socket and spigot fittings and socket clamps and tie
rods used where there is a possibility of pulling the joint under pressure. Concrete thrust
blocks shall be used in lieu of the above where socket and spigot pipe is used below ground.
The Contractor shall submit, for the Engineers approval, working drawings and information
demonstrating the adequacy of anchorage systems other than thrust blocks or other systems
shown on the Contract Drawings.
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4.3.10
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PIPE LAYING
4.4.1
General
Except as otherwise specified in this Clause, pipe bedding shall conform with the
requirements specified in Part 2 of this Section.
The Contractor shall, after excavating the trench and preparing the proper bedding, furnish all
necessary facilities for properly lowering and placing sections of the pipe in the trench without
damage and shall properly install the pipe.
Each pipe shall be carefully lowered onto its prepared bed by means of appropriate slings
and tackle. A recess shall be left in the prepared bed to permit the sling to be withdrawn. If
the prepared bed is damaged, the pipe shall be raised and the bed made good before pipe
laying is continued.
No pipe shall be rolled into place for lowering into the trench except over suitable timber
planking free from roughness likely to damage any coatings.
The section of pipe shall be fitted together correctly and shall be laid true to line and grade in
accordance with the bench marks established by the Contractor. The bench marks shall be
The full length of the barrel of the pipe shall have a uniform bearing upon the bedding
material and if the pipe has a projecting socket, suitable excavation shall be made to receive
the socket which shall not bear on the subgrade.
Pipes shall be laid with the class identification marks or the jointing marks shown by the
manufacturer in the uppermost position. Pipe sections shall be so laid and fitted together
that the pipeline will have a smooth and uniform interior. The pipeline shall be clean and
unobstructed at the time of its installation and shall be true to the required line and levels.
Spigot and socket pipes shall generally be laid upgrade without break from structure to
structure and with the socket end upgrade. Backlaying may be permitted as deemed
necessary and approved by the Engineer.
Whenever work ceases on any pipeline the unfinished end of the pipeline shall be securely
closed with tight fitting plug or cover.
10
Before any pipe is lowered into place, the bedding shall be prepared and well compacted so
that each length of pipe shall have a firm and uniform bearing over the entire length of the
barrel.
11
Pipes shall be laid in straight lines, both in the horizontal and vertical planes, between
manholes or, where directed in the case of pressure pipelines and larger diameter sewers to
regular curves. The placement of pipes shall comply with the following requirements:
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4.4
(a)
each pipe shall be plumbed to its correct line and directly and accurately sighted by
means of a laser positioning system or boning rods and sight rails fixed to secure
posts which shall be set up and maintained at each end of the sewer to be laid and
not more than 20 m apart. Sight rails shall be clearly painted in contrasting colours
and be not less than 150 mm deep, straight and level
(b)
boning rods shall be of robust construction clearly painted and accurately made to the
various lengths required, the lower end being provided with a flat edged shoe of
sufficient projection to rest on the invert of the pipes as laid. The boning rod shall be
complete with a vertical spirit level
(c)
boning rods and sight rails shall not be removed until the pipeline has been checked
and approved by the Engineer
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(d)
alternative methods of locating and levelling pipelines may be allowed subject to the
approval of the Engineer
(e)
any pipe which is not in true alignment, both vertically and horizontally, or shows any
undue settlement after laying, shall be taken up and relaid correctly by the Contractor
(f)
all adjustments in line and grade shall be made by scraping away or filling and
tamping in under the barrel of the pipe and not by wedging or blocking
(g)
the trench shall be kept completely dry
(h)
in no case shall pipes be jointed before being lowered into position
(i)
the gasket should be positioned and lubricated.
Pipelines shall be tested in accordance with Subpart 4.5.
4.4.2
Laying of Rigid and Semi-Rigid Pipes
Each pipe immediately before being laid shall be carefully brushed out and inspected for
defects. In trench pipes with flexible joints except where concrete bed, bed and surround or
protection is required shall be laid on a well compacted bed of granular material extending for
the full width of the trench and with sufficient material at the sides to permit the pipes to be
worked into the granular material and firmly supported to true line and level. Sufficient space
should be left to enable the joints to be made tested and inspected but the Contractor shall
ensure that at least three quarters of the pipe length is fully supported. After the pipeline has
been tested and approved by the Engineer the trench shall be carefully filled to 300 mm
above the crown of the pipe with granular material in accordance with the bedding
requirements specified in Part 2 of this Section and as shown on the Drawings.
Vitrified clay pipes shall be installed in trenches which shall not exceed the maximum trench
width at 300mm above crown of pipe as shown in Table 2.1 of Part 3 of this Section.
Should the Contractor exceed the trench widths given in Table 2.1 he shall provide
calculations to show the loading on the pipe and bedding requirements and where required
he shall provide plain or reinforced concrete cradle or surround, to the approval of the
Engineer, at no additional cost. The same type of pipe bedding/surround shall be used for
the full sewer length between adjacent manholes.
Unless otherwise specified, pipe bedding shall be as shown on the Contract Drawings.
Notwithstanding the above, for Vitrified Clay pipe the special pipe bedding requirements as
Table 4.2 are to be provided in all cases whether or not shown on the drawings or indicated
in the bills of quantity.
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Table 4.2 - Special Bedding Requirements for VC Pipes

Nominal bore
mm
Depth to Invert (D)

m
Bedding Type*
700-800
D>9.0
4.1.1.1.1 Plain concrete cradle
>900
4.0<D<5.0
4.1.1.1.2 Plain concrete cradle
>900
5.0<D<9.0
>900
D>9.0
Reinforced concrete cradle with minimum

0.4% transverse steel
Reinforced concrete surround with minimum
of 1% transverse steel.
(* as shown on drawings)
QCS 2014

Part
Page 16
Laying of Flexible MDPE and HDPE Pipes
This clause does not apply to GRP pipes for which laying requirements are given in Clause
4.3.4 of this Section.
All operations involving the laying, bedding, jointing, backfilling etc. of pipes of plastic
materials shall be strictly in accordance with the manufacturers recommendations subject to
The pipeline shall be laid on a well compacted sand or granular material that shall extend
across the full width of the trench bottom. The pipe bed shall have a minimum thickness of
100 mm and be compacted to a minimum modified Proctor (AASHTO) density of 90% prior
to the laying of the pipeline.
After laying of the pipeline the Contractor shall place pipe surround material on both sides of
the pipe, ensuring that no cavities are left between the underside of the pipe and the trench
bottom or pipe bed. The pipe surround material shall be placed in layers of no more than 150
mm thick and compacted with hand tools across the width of the trench to achieve a
minimum Modified Proctor (AASHTO) density of 90%. The pipe surround shall extend to a
minimum of 200 mm above the crown of the pipe.
Where pipes are laid in good quality ground conditions such as those native soils comprising
granular, sandy or rocky materials, the pipe bed and surround shall comprise clean dry sand
free from silty and foreign materials and particles of larger than 10 mm diameter.
The maximum particle size of the granular material shall also not exceed 10% of the pipe
outside diameter.
Should the excavated native soil fail to meet the above requirements it shall be graded on
site in order to do so or be replaced with an imported sand or granular material complying
with the requirements of the UK WIS 4-08-02 or this specification.
Where pipes are laid in poor quality ground conditions such as those native soils comprising
soft or silty materials, the pipe bed and surround shall comprise an imported granular
material complying with one of the grades given in the UK WIS 4-08-02 or this specification.
Single sized aggregate shall not be used for the pipe bed and surround in conditions where
the native soil comprises of sandy, silty or soft material unless it is wrapped in a geotextile
filter fabric to prevent migration of fine material from the surrounding soil in to the bed and
surround
10
When the grade at which the pipeline laid exceeds 10 trench breakers or clay dams shall be
installed to prevent the migration of bed and surround material due to the flow of water along
the trench.
4.4.4
Laying of GRP Pipes
During the mobilisation period the Contractor shall submit for the Engineers approval the
pipe manufacturers complete and detailed specification for the handling and installation of
pipe and fittings in open trench and such other methods of construction of pipeline specified
or proposed by the Contractor. This specification shall be submitted during the mobilisation
period irrespective of whether the data was submitted with the Tender.
The Contractor shall transport, store, handle and lay pipes in accordance with the approved
manufacturers handling and installation specification as approved by the Engineer.
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4.4.3
QCS 2014

Part
Page 17
The manufacturers handling and installation specification shall include details of the
manufacturers technical expert to be assigned to the Contract. The technical expert shall
have extensive experience of handling and installation of GRP and shall be fully familiar with
the manufacturers handling and installation specification.
The manufacturers technical expert shall provide comprehensive technical assistance to the
Contractor throughout the Contract and shall regularly monitor the Contractors handling and
installation operations.
Any instructions or advice given by the manufacturers technical expert to the Contract shall
be copied to the Engineer. In the event that the Contractor deviates from the approved
handling and installation specification, the manufacturers technical expert shall immediately
inform the Contractor and the Engineer.
All costs associated with the provision of a technical expert by the manufacturer shall be
borne by the Contractor.
GRP pipes shall, unless otherwise directed by the Engineer, be laid on a special bedding
material. The space below the barrel of the pipes shall be filled with special bedding material
to the full width of the trench in layers not exceeding 150 mm in thickness. After pipe laying,
further special bedding shall be placed and thoroughly compacted to fill the entire space
between the pipe and the undisturbed sides of the trench up to a depth of 150 mm above the
top of the pipe. The minimum thickness of the special bedding below the barrel of the pipe
shall be 250 mm or as directed by the Engineer. Where a manufacturer requires greater
thickness of special bedding below, around and over the pipes than those specified they shall
be deemed to have been allowed for in the rates for bedding.
Where GRP pipes are built into a rigid structure; e.g., manhole or a pumping station, the first
100 mm of pipe at entry to the structure shall be surrounded by an approved flexible material.
Flexible joints shall be incorporated adjacent to structures, in accordance with Clause 4.2.4.
Where short GRP pipes are detailed these shall be factory made. Cut ends shall be sealed
with two layers of resin, the second layer being paraffin wax filled to ensure full cure.
10
Where GRP pipes are required to be surrounded with concrete, all necessary precautions
shall be taken to ensure that maximum allowable deflections are not exceeded. Adequate
precautions are to be taken to ensure that the pipe does not float during placing of the
concrete surround.
11
At all times, backfilling shall be carefully carried out to ensure no voids or pockets of
unconsolidated material are present. The Contractor shall monitor the vertical deflection of
the pipes throughout the backfilling operation. No pipe shall exhibit more than 1.5% deflection
after placing and compaction of the granular bed and surround. In addition, after completion
of the trench backfilling, the average deflection of a length of pipe shall not exceed 1.5%, and
every pipe shall be demonstrated to exhibit no more than the manufactures calculated
allowable Initial Deflection, or 3.5% deflection, whichever is smaller. If any of these values
are exceeded, the affected pipes shall be exhumed and re-laid.
12
The deflection shall also be checked on each length between manholes or chambers before
commissioning to determine whether longer term deflections are within permissible limits.
The average deflection of a length of pipe shall not exceed 3%, and every pipe shall be
shown to exhibit a deflection no greater than 5%, or the calculated allowable deflection
consistent with the achievement of a long term deflection not exceeding 5%, whichever is
smaller, at any point. Pipes exhibiting greater deflections shall be exhumed and re-laid.
13
Pipes exhibiting a deflection greater than 8% or 1.6 times the calculated allowable long term
deflection, shall be exhumed, indelibly marked REJECTED, removed from the site and not
reused.
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QCS 2014

Part
Page 18
Corrosion Protection of Ferrous Pipelines
Where tape wrapping is wrapped at site it shall be applied by machine under factory
controlled conditions in accordance with Clause 3.7.6 of this Part.
Pipe joints shall be protected by continuing the tape wrapping, or by heat shrink polyethylene
tubes coated internally with thermoplastic adhesive. The profile of the pipe joint shall be
smoothed using bituminous mastic or preformed plastic foam sections taped in position.
Heat shrink sleeves shall be on pipes with extruded polythene coatings, and in all cases shall
be applied in accordance with the sleeve manufacturers and pipe coating manufacturers
instructions.
Joints within in-situ concrete chambers do not require heat shrinkable sleeve protection.
Damaged areas of protective coating or wrapping shall be repaired in a manner to be

approved by the Engineers Representative.
Ferrous pipelines shall be supplied with one of the following corrosion protection systems:
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4.4.5
Cold applied self-adhesive laminate tape wrapping
(b)
Extruded polyethylene coating
(c)
Loose polyethylene coating
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(a)
Extruded polyethylene coating shall be as Clause 3.7.7. Heat shrink sleeves shall be used
over joints in polyethylene coated buried pipes.
Spigot ends of pipes coated in either of the approved manners shall not be coated over the
depth of engagement within the socket or flexible coupling, but shall be coated with epoxy,
polyethylene or polyurethane for pipes internally lined with these materials.
Where ductile iron buried pipe is designated to be encased in loose polythene sleeving,
installation shall be in accordance with BS 6076.
The pipe shall be supported by a central sling and a length of sleeving pulled over the spigot
end and bunched up to the sling.
10
The pipe shall then be rested on blocks placed at its extremities and the sleeving pulled up to
the socket and folded and taped or tied in position. The sling shall then be replaced to
enable jointing to be carried out. A wide sling shall be used to distribute the weight and thus
obviate intense pressure on the sleeving. Care shall be taken to avoid damage when
removing the sling from the trench.
11
The sleeve shall not be drawn up over the pipe joints until the completion of the hydrostatic
testing. Immediately after making the pipe joint, the pipe trench shall be backfilled as
described hereinbefore in readiness for the hydraulic testing and to prevent damage to the
sleeving.
12
After completion of the hydraulic testing, the sleeving shall be drawn up over and fixed
around the pipe joints. A pad of sleeving shall first be placed around the joint to prevent
damage to the joint sleeve by the edges of the socket or by bolts. A length of sleeving shall
then be drawn over joint overlapping itself either side of the joint for a minimum of 300 mm
and this shall be tied or taped tightly in position.
13
Any pipe sleeving perforated during fitting shall be repaired by overlaying with a short sleeve
folded and secured with tape. Torn or damaged sleeving which is considered by the Engineer
as not repairable by this method shall be replaced by the Contractor.
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QCS 2014

Part
Page 19
Immediately after fitting the pipe sleeving the pipe trench shall be partly backfilled to prevent
damage to the sleeving.
4.4.6
Concrete Protection to Pipe
Where concrete protection to pipelines is specified or ordered by the Engineers

Representative a 75 mm thick Grade 20 concrete layer shall be laid over the full width of the
trench and never less than 150mm wider on each side than the barrel of the pipe and with its
top surface positioned as shown on the drawings.
This concrete shall be allowed to set and be thoroughly washed down before pipe laying is
started.
The length of pipeline laid in any one operation before concreting the pipeline shall be that
which in the opinion of the Engineers Representative permits accurate laying of the pipeline
and proper compaction of the fill.
Pipes up to 1200mm diameter shall be firmly supported on precast concrete blocks and
separated from them by 25mm thick saturated softwood packing.
Pipes greater than 1200mm diameter shall be firmly supported on precast concrete blocks
and separated from them by saturated softwood packing 38mm thick.
Alternatively for pipes up to 300mm diameter a layer of concrete Grade 20 of minimum water
content can be laid on the 75mm concrete layer and the pipes worked into this concrete to
true line and level before it sets. Sufficient space shall be left to enable joints to be made,
tested and inspected but the Contractor shall ensure that the barrel of the pipe is fully
supported for at least two thirds of the pipe length.
After the pipeline has been tested, and approved by the Engineers Representative, the
concrete shall be thoroughly washed down and additional concrete Grade 20 shall be
carefully placed and compacted thereon to avoid disturbing the pipes or joints until the
appropriate profile for the type of protection required has been reached.
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14
Minimum thickness of
surround
mm
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Nominal bore of pipe

mm
Up to and including 500
150
500 900
250
1000 1100
300
1200 - 1400
350
>1400
400
Concrete protection to the pipelines shall be concrete cradle or concrete surround as detailed
on the Drawings and shall be of concrete Grade 20. The thickness of the concrete surround
below, to the sides and above pipes shall be as follows:
When support of excavation is provided building paper shall be placed against that support
before concreting to facilitate withdrawal of support.
10
In the case of spigot and socket pipes with flexible joints the concrete protection at each joint
shall be interrupted in a vertical plane at the edge of the socket by a strip of fibreboard or
other material approved by the Engineers Representative and of the following thickness:
Up to 300mm nominal bore
13mm
QCS 2014

Part
Page 20
Over 300 and up to 600mm nominal bore
25mm
Over 600 and up to 1200mm nominal bore
38mm
Over1200 and up to 2000mm nominal bore
50mm
The protection and filling of headings shall be of mass concrete Grade 20 and may be carried
out in one operation.
4.4.7
Deflection Criteria for Flexible Pipelines
All flexible pipelines will be subjected to deflection measurements at Site. Sections of pipe
failing to meet the specified deflection criteria shall be removed from the trench and relaid,
provided the pipe is not damaged. This procedure shall be repeated until the pipeline is
found to be satisfactory. Removal from the trench and relaying shall be an obligation of the
Contractor. If the permanent set or deflection, after removal, exceeds the limits set out
below, the pipes shall be deemed to be damaged and will therefore be condemned. Pipes so
condemned shall be indelibly marked, removed from the Site, and replaced by the
Contractor.
At all times, backfilling shall be carefully carried out to ensure that no voids or pockets of
unconsolidated material are present. The Contractor shall monitor the vertical deflection of
the pipes throughout the backfilling operation. No pipe shall exhibit more than 3.0 %
deflection after placing and compaction of the granular bed and surround. In addition, after
completion of trench backfilling, the average deflection of a length of pipes shall not exceed
3.0 %, and every pipe shall be demonstrated to exhibit no more than the manufacturers
calculated allowable initial deflection, or 5.0 % deflection, whichever is the smaller. If any of
these values is exceeded, the affected pipes shall be dismantled and relaid.
MDPE and HDPE (PE) pipes may be bent or curved on site down to a minimum radius as
recommended by the manufacturer. In the event of the manufacturer providing no
recommendation, the minimum bend radius shall not be less than 25 times the pipe OD,
Where there are space restrictions the bend radius may be reduced down to 20 times the
pipe OD, but only with the written permission of the Engineer.
No electro-fusion or mechanical joints should be incorporated in the sections of PE pipework

which are to be bent. Instead a formed bend or elbow should be welded in the pipeline in
order to prevent excessive stress.
The deflection shall also be checked on each length between manholes before
commissioning to determine whether longer-term deflections are within the specified limits.
The average deflection of a length of pipes shall not exceed 3 %, and every pipe shall be
shown to exhibit a deflection no greater than 5 %, whichever is the smaller, at any point.
Pipes exhibiting greater deflections shall be exhumed and relaid.
Pipes exhibiting a deflection greater than 8 % or 1.6 times the calculated allowable long term
deflection, shall be exhumed, indelibly marked REJECTED, removed from site and not
reused.
4.4.8
Backfilling
The requirements of Part 2 of this Section shall apply, except as otherwise specified in this
Clause.
After the pipeline has been tested and approved by the Engineer, the trench shall be carefully
backfilled to 300 mm above the crown of the pipe for rigid pipes with granular material.
Backfilling of the pipe trench should be carried out as designated, or shown on the Contract
Drawings.
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11
QCS 2014

Part
Page 21
Where concrete bedding or surround is required, the backfill shall not be placed before the
compressive strength of the site concrete has reached 15 MPa.
Where concreting to pipeline is specified, a blinding layer of Grade 20 SRC concrete shall be
placed over the full width of the trench or heading.
Pipes to be bedded on or cradled with concrete shall be supported on precast concrete

setting blocks, the top face of each block being covered with a separation layer.
Concreting to the pipeline shall be either bed or bed and surround as shown on the Drawings
and shall be of Grade 20 SRC concrete along such lengths as are shown on the Drawings or
ordered by the Engineer.
The pipe shall be prevented from moving during concreting.
Where concrete bed and surround is used with GRP and PVC-U pipes the maximum spacing
between pipe joints shall be 3 m. For other pipe materials the maximum spacing shall be as
When support of excavations is provided, building paper shall be placed against that support
before concreting to facilitate withdrawal of the support. Building paper shall comply with BS
1521 Class A2.
10
In the case of pipes with flexible joints, the concrete at each joint shall be interrupted in a
vertical plane at the edge of the socket by a strip of fibreboard or other material approved by
the Engineer and of the following thicknesses:
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13 mm
Over 300 mm and up to 600 mm nominal bore
25 mm
38 mm
50 mm
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Up to 300 mm nominal bore
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The protection and filling of headings shall be of Grade 20 SRC concrete.
12
Where concrete slab protection to GRP and PVC-U pipelines is required such protection
shall extend a minimum of 200 mm either side of the pipe trench. The slab shall be of
reinforced concrete as shown on the Drawings.
4.4.9
Deflection at Joints
Where the Engineer orders or allows a change of direction to deflect pressure pipelines from
a straight line, either in the vertical or horizontal planes to avoid obstruction or where long
radius curves are permitted, the amount of deflection allowed shall not exceed that required
for satisfactory connection of the joint and shall be approved by the Engineer. Where a
change of direction cannot be made by deflection at the joints of ordinary straight pipes,
bends shall be used. The locations of such bends and other specials are shown on the
Contract Drawings and their exact positions will be determined by the Engineer on the Site.
4.4.10
Wadi Crossings
Work at any crossing of a wadi or other waterway shall be carried out as expeditiously as
possible to the satisfaction of the Engineer and any responsible Government agency or other
authority, with minimum interference to the free flow of water. Details of any temporary works
which may affect the flow of the wadi shall be submitted to the Engineer at least 14 days
before starting work.
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QCS 2014

Part
Page 22
Where pipelines passes underneath a wadi, ditch, open surface water channel, or other
waterway, the pipelines shall be encased in concrete. The minimum thickness of encasement
shall be 150 mm. Unless otherwise designated, the depth of cover shall not be less than 600
mm from the bed of the water coarse to the top of the concrete.
The Contractor shall fill the trench in both banks with rock fill or concrete up to the designated
levels. The extent of this work may be varied to suit each individual crossing. Unless
otherwise ordered, the concrete encasement of the pipe shall extend at least to a section
vertically below the tops of the banks. Protection against erosion to the banks shall be
provided by means of stone pitching or riprap.
4.4.11
Pipe Supports
Pipe hangers and saddle supports shall be of standard manufacture as shown on the
Drawings and in compliance with the following general requirements:
piping shall be supported independently from appurtenances to which it is affixed.
(b)
all weight of piping and contained fluids shall be transferred to a structures or

foundation system through stools, brackets, pipe saddle supports, or overhead hanger
systems.
(c)
a support shall be provided for each pipe at or near the point where it is connected to
machinery or valves. A support shall be provided for each valve and special fitting.
(d)
flexible joints shall be required at either ends of the support system.
(e)
where necessary, expansion joints shall also be provided.
(f)
pipe hangers and supports shall generally be fabricated in Mild Steel. These shall be
galvanised and painted with coal tar epoxy.
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(a)
For pipelines to be fixed in culverts, the Contractor shall prepare proposals for thrust and
anchor support and submit them to the Engineer for approval. Such approval shall not relieve
the Contractor from his responsibility for the adequacy of his proposal. Additional
requirements for both location and details of supports may be shown on the Drawings or
directed by the Engineer as the work proceeds to suit the actual conditions encountered.
4.4.12
Building-in Pipes to Structures
Pipes constructed into a concrete wall or structure shall be protected with a concrete
surround integral with the external face of the structure as shown on the Drawings.
All internal and external protection membranes to the concrete shall be sealed around the
pipe openings as recommended by the membrane manufacturer. When the pipe is later
fixed, the remaining hole shall be re-formed and filled with non-shrink grout.
Any over-excavation adjacent to a structure or beneath the formation level of a pipeline,

either to be constructed under the Contract or in a future contract, shall be backfilled with
Grade 20 SRC concrete.
Pipes and pipe specials through concrete walls and floors shall as far as possible be
positioned and built in during construction. They shall be located exactly in the positions
shown in the Contract Drawings and shall be true to line and level. The Contractor shall take
particular care to ensure that fully compacted concrete is in contact with the pipe at all points.
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QCS 2014

Part
Page 23
Where it is impracticable to cast pipes and specials in the concrete, boxouts shall be
provided in the formwork. The box shall have six or eight sides, depending on the pipe
diameter, and shall be no larger in size than will give adequate clearance for the subsequent
positioning and grouting in of the pipe. The sides of the boxout shall be provided with a
tapered central annular recess to provide a positive key. The boxout shall be provided with a
grout hole and, at the top of the central annular recess a vent hole. The boxhole shall be
stripped with the main formwork and the concrete surface thoroughly cleaned and
roughened.
Unless otherwise shown on the Contract Drawings, where pipes pass through a concrete wall
or structure they shall be protected with a surround of Grade 20 SRC concrete integral with
the external face of the structure. For pipes of less than 500 mm diameter, the surround shall
extend from the wall or structure by 300 mm and the width and depth of the surround beyond
the outside face of the pipe at its horizontal and vertical diameters shall be a minimum of
300 mm or as otherwise indicated on the Drawings. For pipes of 500 mm diameter or greater
the surround shall extend from the wall or structure by 500 mm and the width and depth of
the surround beyond the outside face of the pipe at its horizontal and vertical diameters shall
be 500 mm or as otherwise indicated on the Drawings.
On socket and spigot pipelines except those of GRP or other plastic materials the socket end
of the pipe passing through the wall shall be flush with the outside face of the concrete
surround. On socket of spigot pipelines of GRP or other plastic materials the socket end of
the pipe passing through the wall shall protrude 300 mm from the concrete surround. A
protective synthetic rubber strip 6 mm thick and 150 mm wide shall be provided around the
pipe at the limit of the concrete surround as shown on the Contract Drawings.
On all other flexibly jointed pipes the plain end of the pipe shall protrude from the concrete
surround by a maximum of 300 mm or that distance required to properly make the joint.
The first pipe that is clear of concrete surround beyond the external face of a concrete wall or
structure shall be a short length of either spigot and socket or double spigot to suit the flow
direction and pipe material. The effective length of this pipe shall be 1.5 times the nominal
bore or 600 mm whichever is the greater.
10
For mechanically jointed pipes the plain end shall protrude from the surround by a maximum
of 300 mm or that distance required to make a proper joint.
11
Where the structure is tanked, Grade 20 OPC concrete shall be used and the tanking shall
extend to the concrete surround.
4.4.13
Cleanliness of Pipelines
Pipelines and manholes shall at all times be kept free of all silt, mortar, debris and other
obstructions. When work is not in progress the open ends of the pipeline shall be securely
plugged with an approved watertight plug or stopper firmly fixed to resist unauthorised
removal. Claw type plugs or any type liable to damage the pipe shall not be used. All such
stoppers, plugs or caps shall be provided with a vent incorporating a valve for the purpose of
testing whether the pipeline is under pressure or vacuum and to enable pressures to be
equalised before its removal.
The Contractor shall clear the inside of each fitting and pipe length immediately before
jointing and shall swab all fittings and pipe lengths to remove all dirt, sand or other matter that
may clog the pipeline or contaminate the fluid to be transported in the pipeline. After jointing,
the interior of the pipes shall be freed from any dirt, stones or other matter that may have
entered them. For this purpose, a rubber disc, brush, or other suitable implement that will not
harm the internal lining of the pipe shall be pulled through the pipe after jointing.
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QCS 2014

Part
Page 24
Pressure pipelines and treated sewage effluent pipelines shall be flushed and a swab passed
through. Large diameter pipelines shall be visually inspected internally to the approval of
Engineer.
4.4.14
Marker Tape
All trenches for pressure pipelines, shall be marked with a high quality acid and alkaliresistant red non bio-degradable plastic tape with a minimum width of 150 mm placed during
backfilling 300 mm below finished surface or as directed by the Engineer. These tapes shall
2
2
have a minimum strength of 125 kg/cm in the longitudinal direction and 105 kg/cm
transversely with an elongation factor in the longitudinal direction of 350 percent. The text on
the tape shall be permanent black ink bonded to resist prolonged chemical attack by
corrosive acids and alkaline with message repeated at a maximum interval of two metres.
Tapes over non-ferrous pipes shall be detectable by electro-magnetic means using low
output generator equipment.
The tape wording and colour shall be as follows:
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COLOUR
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WORDING
RED
CAUTION TREATED SEWAGE EFFLUENT
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SURFACE WATER
ta
DANGER : FOUL SEWAGE
WATER MAIN
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DANGER : FUEL PIPELINE
GREEN
GREY
BLUE
BROWN
The tape shall be laid continuous over pipelines and at joints there shall be a minimum of one
metre overlapping. Tape shall be terminated inside valve boxes to allow clipping of detector
equipment to the tape.
4.4.15
Pressure Pipeline Marker Posts
Pipeline marker posts shall be provided at all points where the pipeline crosses boundaries
or changes direction and elsewhere at maximum intervals of 100m. Each marker post shall
be set over the centreline of the pipelines with concrete Grade 20 SRC concrete base
surround in accordance with the Contract Drawings. Marker posts shall incorporate a
description of the pipeline and its service in Arabic and English to the approval of the
Engineer. Offset marker posts may also be used in areas where the post could not be
installed over the centreline of the pipelines.
Coloured marker plates shall be made from multi-layered plastic, green for TSE and orange
for foul sewage.
4.4.16
Valve Chamber Marker Posts
Valve chamber marker posts shall be installed at all chambers, indicating the type of
chamber, its reference number and distance from the marker post in Arabic and English to
Where the pipeline is in a footpath or verge, the marker post shall be installed against the
wall or property boundary and facing the chamber cover, with Grade 20 SRC concrete base
surround.
4.4.17
Abandonment of Pipelines
Pipelines and service connections to be abandoned shall first be emptied completely.
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Part
Page 25
Pipelines and service connections to be abandoned shall be filled completely with a cement
slurry or concrete using a grout pan or an alternative method approved by the Engineer such
that the discharge slurry or concrete can be forced into the pipeline under pressure.
The Contractor shall ensure that all existing connections to the sewer to be abandoned have
been plugged or disconnected before beginning filling.
The Contractor shall inform the Engineer of his intention to begin this operation and shall
obtain the Engineers approval in writing for the abandonment of each particular length before
beginning filling.
Upon completion of the above procedure, the Contractor shall undertake abandonment of
manholes inspection chambers and other structures. Where a pipeline or service connection
to be abandoned connects into a manhole or chamber to be retained, the connection shall be
plugged at the chamber wall and the associated channel in the benching of the manhole or
chamber shall be cleaned and filled with concrete Grade 20 SRC. The benching shall then
be covered with the appropriate protective lining to match the existing manhole lining.
Unless otherwise designated, existing pressure pipelines to be abandoned shall be emptied

and sealed at each end of the pipeline with a removable expanding stopper to the Engineers
approval. The stopper shall include a valve for the purpose of venting and for the equalising
internal and external pressures removal. Any chambers located along the pipeline to be
abandoned shall be demolished and the pipeline ends sealed as specified.
4.4.18
Abandonment of Structures
Where manholes, septic tanks, cesspits, soakpits and other structures are to be abandoned,
they shall be emptied of their contents to the approval of the Engineer. The contents
including sludge from these structures, whether undiluted or mixed with sand, shall be
disposed of off the Site by the Contractor to a location approved by the Engineer. The
Contractor shall submit in writing his proposals for emptying the contents and disposal. No
work shall begin on demolition until the structure has been completely emptied.
After desludging, the roof slabs and tops of walls of the structure shall be demolished to an
elevation not less than 500 mm below existing ground level. The fragments of demolished
structures may be used to partially fill the void. Voids shall be filled up with sand, watered and
well compacted up to the elevation of the underside of the cover slab. The frames and
covers of manholes and chambers shall be removed by the Contractor and delivered to the
designated Employers stores and placed into storage.
If an existing service is found within a structure to be abandoned, the Contractor shall inform
the Engineer and carry out the Engineers instructions for ensuring that the service pipeline is
retained or restored. If a sleeve is to be provided, the sleeve shall extend for 100 mm on
either side of the structure. When backfilling or working around an existing service or sleeve,
the Contractor shall take all precautions to ensure that no damage occurs and that there is
no interruption of service.
4.4.19
Corrosion Protection of Flexible Couplings and Ferrous Fittings
Buried flexible couplings, including flange adaptors shall be protected as follows:
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(a)
Mastic paste filling (Denso paste or similar)
(b)
Mastic tape wrapping (Denso tape or similar)
(c)
and finished with cold applied self-adhesive laminate tape wrapping (or heat shrink
sleeving) in accordance with Clause 8.4.3.5
Couplings, including all associated nuts and bolts, within chambers or pumping stations shall
be polyamide powder coated (Rilsan or similar).
QCS 2014

Part
Page 26
PIPELINE STRUCTURES AND APPURTENANCES
4.5.1
Manholes for Foul Sewerage
The Contractor shall prepare a standard record sheet for every manhole and structure and
shall submit to the Engineer for information only.
Manholes shall be constructed as shown on the Contract Drawings and at the locations
indicated thereon or at other locations directed by the Engineer.
The blinding concrete shall be mass concrete Grade 25 SRC concrete and the manhole base
slab, benching and insitu concrete walls shall be Grade C40 SRC concrete.
Precast concrete manhole rings shall be manufactured using Grade C50 SRC concrete. The
joint surfaces and outer face of the precast concrete rings shall have factory applied epoxy
coating in accordance with Part 8 Clause 8.3.15. The inner face of the precast manhole ring
shall be a prefabricated GRP liner at least 6mm thick bonded by lugs to the concrete. The
completed joints between precast concrete rings shall have an insitu applied sealing strip at
least 6mm thick overlapping the GRP liner by a minimum of 150mm each side. The sealing
strip shall be capable of withstanding the full hydrostatic head of external ground water to
ground level and the maximum internal hydrostatic head, whichever is the greater.
The underside of the base and the external faces of insitu concrete bases and walls shall be
protected with a membrane tanking system. The necessary period for setting, as
recommended by the manufacturer, shall be allowed before beginning other works to
complete the construction of the manhole.
The cover slab shall be surmounted by ductile-iron manhole cover and frame of the quality
specified. The covers in road and paved areas shall be accurately set on precast concrete
segments to the level and slopes of the roads or pavements.
In the case of shallow manholes, the cover and frame may be cast directly monolithic with the
reinforced concrete cover slab and projecting up by 50 mm as shown on the Contract
Drawings.
The interior face of manholes and access shafts shall be prefabricated GRP liners at least
6 mm thick permanent lining.
Prefabricated GRP benchings and channels shall be preformed, inverted and filled with
Grade C40 SRC concrete. Alternatively, the GRP lining may be applied to the in-situ
concrete benching after constructing the benching.
10
GRP lining to walls shall incorporate 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 handling, and shall not buckle or distort during pouring of the concrete surround.
Internal bracing may be used during pouring of the concrete surround. Internal bracing may
be used during pouring to maintain circularity and verticality.
11
Cover slabs shall be precast using Grade C50 SRC concrete and shall incorporate a
preformed flat sheet of GRP on the soffit, bonded to a GRP tube to form the access opening.
Both linings shall incorporate lugs moulded onto the surface to allow bonding to the concrete.
The overall size of the lining to the soffit of the slab shall be 150mm greater than the internal
diameter of the manhole onto which the slab is to be placed.
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4.5
QCS 2014

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Page 27
In all cases, the outer surface of the GRP, exposed to the sewage 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 2mm 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. Fillers, such as silica sand and calcium
carbonate shall not be used. Loss of Ignition Test to BS 2782 (method 1002) shall be
conducted on random samples of GRP manhole liner to detect percentage of glass and the
presence of any silica sand filler.
13
Joints in the lining tubes of insitu concrete manholes shall not normally be permitted.
14
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 prior to casting the insitu concrete walls. 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.
15
If GRP linings to benchings 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
then 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
than 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. After a period to allow pre-gel 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.
16
Top surfaces of benchings shall incorporate silica sand to form a non-slip surface.
17
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.
18
Ladders in structures where shown on the drawings shall be fabricated in stainless steel
Grade S31 or GRP. All ladders shall comply with BS 5395: Part 3. All fixings shall be
stainless steel.
19
Intermediate the Contractor shall provide the Engineer with a 10 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 Final Completion Certificate.
20
All manholes shall be watertight on completion and where leakage is discovered the
Contractor shall perform such work and provide all materials as are necessary to render such
faulty work watertight. The Contractor is warned that he should expect rubbish and debris to
be deposited in the manholes during the course of construction and he should take the
necessary measures to ensure that the manholes clean.
21
Backfilling around manholes in roads shall be carried out using granular material as
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12
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Manholes for Surface Water Sewerage
Bases and mass concrete manholes shall be cast using Grade 40 SRC concrete. Where
reinforced concrete manholes are specified they shall be constructed in accordance with the
drawings and have a GRP liner complying to Clause 4.4.1. The GRP liner shall extend to
300mm above the soffit of the outlet pipe of the manhole. The inner surface above the GRP
liner shall have an epoxy protective coating.
The benching and channels shall be GRP lined as Clause 4.4.1.
The underside of the base and the sides of insitu concrete bases and walls shall be protected
with a membrane tanking system as Clause 4.4.1.
Precast Grade C50 SRC concrete manhole rings may be used above the level of the GRP
inner liner. The precast rings shall have a factory applied epoxy protective coating to all
surfaces.
Cover slabs shall be precast using Grade 50 SRC concrete and shall have a factory applied
epoxy coating to all surfaces.
The Contractor shall provide the Engineer with a 10 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
over to the Engineer before the issue of the Final Completion Certificate.
Ladders in structures where shown on the drawings shall be fabricated in stainless steel
Grade S31 or GRP. All ladders shall comply with BS 5395: Part 3. All fixings shall be
stainless steel.
4.5.3
Chambers
The Contractor shall prepare a standard record sheet for every chamber for valves, meters,
inspection, washouts and other similar purposes for the approval of the Engineer.
Chambers shall be constructed in accordance with the Contract Drawings and at the
locations or at other locations directed by the Engineer.
The Contractor shall ensure that there is a minimum clearance of 300mm around all flanges
and parts of valves built into chambers, including the handwheel.
4.5.4
Connections to Existing Pipelines
At locations shown on the Contract Drawings or as instructed by the Engineer, the Contractor
shall connect the new pipelines to the existing pipelines or structures but not until the said
pipelines have passed the final tests.
The Contractor shall co-ordinate with Drainage Affairs, Maintenance Department staff to
make connections onto existing foul sewers and other drainage pipelines.
The Contractor shall be responsible for dealing with all flows while making connections to
existing sewers or drainage pipework by over-pumping the entire flow between manholes or
other approved bypassing methods. The Contractor shall retain a standby pump and fulltime
operator on site during pumping operations.
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4.5.2
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Page 29
Anchor and Thrust Blocks
The Contractor shall construct anchor and thrust blocks at every bend and junction on
pressure pipelines and where otherwise shown on the Contract Drawings or instructed by the
Engineer. Each thrust block shall to have a sufficient bearing area and shall be placed to
safely transmit thrust to the surrounding original ground. If soft, spongy, unstable or similar
material is encountered upon which the thrust block is to bear this unsuitable material shall
be removed and replaced with Grade 20 SRC mass concrete as directed by the Engineer.
The excavation for the thrust block shall be carried out prior to laying the pipes except that a
trimming margin of not less than 150mm shall be left to be removed by hand excavation in
order to obtain a firm thrust face against undisturbed ground. This trimming margin shall only
be removed after laying and jointing of the pipes and the concrete for the thrust block shall be
placed on the same day as the removal of the trimming margin.
No pressure shall be applied to thrust blocks until the concrete has matured for at least
seven days.
"Rocker" pipes shall be installed adjacent to all concrete thrust blocks.
4.5.6
Property Connections Survey
The Contractor shall complete and submit to the Engineer for approval a standard record
sheet of every property connection. The information shall be recorded on forms provided by
the Engineer.
The Contractor shall survey and prepare individual plans for each property at a scale of 1:500
(or such other scale as may be agreed by the Engineers Representative). These shall show
existing plot boundaries, location of all buildings, location of all visible services and location
and level of all drainage services, including septic tanks. The plans shall indicate the nature
of each building, clearly identifying kitchen, mess areas, toilets, washrooms and the drains
serving these areas and gullies elsewhere. The plans shall identify the drains serving. The
plan shall be submitted on paper and AutoCAD compatible .dwg file. As a separate layer on
the dwg file the Contractor shall mark his proposals for the property connection, including a
cross-section and this shall be submitted to the Engineers Representative for approval. No
property connection work shall commence before approval to the proposed layout has been
received in writing from the Engineers Representative.
In special cases only, an inspection chamber may serve more than one service connection.
Locations of inspection chambers and the layout of service connections shall be as approved
by the Engineer.
Service connections shall be laid at sufficient depths to allow for adequate gradient being
continued throughout the properly drainage system without the pipelines becoming too
shallow for adequate cover to be provided over the pipe.
4.5.7
Future House Connections
During the course of the Contract the Engineers Representative and the Contractor shall
agree on a programme regarding the positions and other details of the junctions to be left for
future house connections. Such branches and junctions shall in all cases terminate in an
approved stopper obtained from the pipe manufacturer.
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4.5.5
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The Contractor shall survey and prepare individual plans for each plot at a scale of 1:500 (or
such other scale as may be agreed by the Engineers Representative). These shall show
existing boundary walls or fences and ground level at each corner of the plot. The plan shall
be submitted on paper and AutoCAD compatible dwg file. As a separate layer on the dwg file
the Contractor shall mark his proposals for the property connection and this shall be
submitted to the Engineers Representative for approval. No property connection work shall
commence before approval to the proposed layout has been received in writing from the
Engineers Representative.
The Contractor shall produce accurate records of the exact location of all service connections
and shall include for these in his rates.
4.6
TESTING OF PIPELINES
4.6.1
General
The Contractor shall submit for the Engineer's approval details of his proposed methods and
programme for testing (including details of test equipment) and shall arrange for all test to be
witnessed by the Engineer or other person appointed by the Engineer. Test equipment shall
be approved by the Engineer and calibration certificates when requested by the Engineer
shall be submitted. The Contractor shall provide all equipment necessary for carrying out
testing and cleaning including pumps, gauges, piped connections, stop ends, and all other
temporary works. All water required for testing and cleaning the pipelines shall be from a
source approved by the Engineer.
Pipelines shall be adequately restrained before being put under test except as hereinafter
detailed. No testing will be permitted until seven days after thrust blocks and other holding
down works have been completed. Trenches may not be left open at joints before testing
pipelines except as permitted by the Engineer who may lay down certain restricting
conditions. In addition to any tests of individual joints or other interim tests which may be
designated elsewhere, the Contractor shall submit all parts of the pipelines to a final test.
This and the following Clauses on testing pipelines do not apply to GRP pipes for which
testing requirements are given in the Project Specification where appropriate.
Pipelines shall be tested in lengths between manholes or valve pits with lengths not
exceeding 400 metres except by agreement with the Engineers Representative. Testing
shall not be against closed valves, and pipes of different diameters shall not be tested
together in the same test. The arrangements for testing a pipeline shall include provision for
purging the air from the pipeline during the test.
In all pipelines which are constructed with mechanical joints or with joints which permit axial
movement, the joints shall be left open so that they may be inspected during hydraulic
testing. In such cases only the barrels of the pipes shall be backfilled prior to hydraulic testing
taking great care to avoid the joints and leaving sufficient space all round the joints to permit
inspection and to undertake remedial measures should the joint be found to leak under
hydraulic testing. After the successful completion of hydraulic testing, the joints shall, if
specified, be wrapped, coated or sleeved as appropriate, and then backfilled in the manner
specified elsewhere in this specification.
The final test shall be applied in the presence of the Engineers Representative.
The Contractor shall keep a record of all tests in a book which shall be available for
inspection and handed over to the Engineers Representative on demand. The Contractor
shall complete standard test record sheets as provided by the Engineer.
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The section under test shall be properly sealed off with blank flanges or special stop end
caps held securely in position by adequate temporary anchorages, and filled with water. All
peak points of the pipeline shall be adequately vented during the filling operation using
temporary bleed valves. All air valves shall be removed and all other valves shall be set in the
open position.
Pipe joints, valves and fittings shall be checked carefully for loose bolts or connections which
might cause leakage and delay the execution of the tests.
10
Should any section fail to pass the tests, the Contractor shall determine the cause of the
failure and shall locate, excavate and repair any damage or leakage sustained by the pipeline
before or during the tests and retest the section. The cost of such repair work, additional
backfilling and reinstatement and abortive tests shall be borne by the Contractor.
11
Water for the test shall be disposed of in a manner to be approved by the Engineer.
Pumping water onto the site shall not be permitted.
12
The Contractor shall be responsible for ensuring that all test methods and procedures comply
with his Health and Safety Plan.
13
The Contractor shall provide detailed method statements for his methods of testing access
shafts, manholes and pipelines.
4.6.2
Gravity Sewer Pipelines
Each pipeline 600 mm or less in diameter shall be tested by air test. Should any pipe fail the
air test, the Engineer may order a water test to be carried out. Acceptance of the pipeline will
then be based on the results of the water test. All pipelines up to and including 1200 mm
shall be tested by air test in accordance with the requirements of BS EN 752.
The Contractor shall, at his own expense, furnish all equipment and materials for making the
tests. Each pipeline shall be tested before backfilling and also after backfilling before carrying
out road reinstatement or laying new road surfacing. Where the pipeline is located under a
new road alignment, the pipeline will be tested after sub-base compaction in complete. All
pipelines shall be subjected to pass infiltration tests as specified herein. All pipes are to be
clean and empty at the time of testing. Tests shall be performed in the presence of the
Engineer.
(a)
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Air Test:
(i)
(b)
the Contractor shall plug all pipe outlets with suitable plugs, and brace each plug
securely where needed
(ii)
air shall be pumped in slowly to the pipe until a pressure of 100 mm water gauge
is indicated on a manometer connected to the system. After the internal
pressure of 100 mm water gauge is obtained, 5 min shall be allowed for the air
temperature to stabilise within the pipe.
(iii)
Air may be added to restore the pressure to 100 mm water gauge. During a
further period of 5 min, the pressure shall not fall below 75 mm water gauge
without further pumping.
Water Test
(i)
all the joints of the pipeline shall be able to withstand a pressure of a minimum
5m head of water, above the crown of pipe at the highest point of pipeline
without leakage. A layer of embedding soil equal to the diameter of pipe shall
be laid over the pipe to prevent the lifting of pipe while applying test pressure.
However, all the joints shall be left open for the purpose of inspection for
leakage if any. All branches and open ends shall be closed with stoppers,
secured with longitudinal braces/thrust block, before testing begins
QCS 2014
Page 32
(ii)
water shall be filled from the lowest point and air allowed to escape through an
air vent fixed for the purpose at the high points of the pipeline section under test.
The diameter of air vent shall be about one and half times the diameter of water
inlet pipe to allow easy escape of air. No entrapped air shall remain in the
pipeline while testing
(iii)
a pressure of 5 m head of water shall be maintained for one hour to allow initial
absorption of water. After that the test pressure shall be maintained for 15 min
and water added shall be measured. If water consumption in 15 min does not
exceed 0.1 l/m2 of wetted inner pipe surface and if there are no visible leakage
through joints, the pipeline shall be treated as passed.
Infiltration Test
(i)
the upper ends of the sewer and service connections shall be closed sufficiently
to prevent the entry of water and pumping of groundwater shall be discontinued
until the groundwater surface reaches its natural level before beginning the
infiltration test the dewatering system shall be stopped, but not be removed until
the infiltration test has been successfully completed or as otherwise permitted by
the Engineer the infiltration shall not exceed 6 litres per millimetre diameter per
kilometre per day of the portion of sewer being tested, including the length of
service connection entering that section.
(ii)
the total length tested in one section shall not exceed 400 m in length. This
length is dependent upon the type of deflection measuring equipment proposed
by the Contractor if flexible pipes are used.
(iii)
no gravity pipeline will be accepted if the total infiltration exceeds the above
mentioned limit and joints will not be accepted if during an internal inspection,
any infiltration is visible.
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(c)

Part
Prior to issue of a Certificate of Completion a CCTV survey shall, on the instruction of the
Engineers Representative, be carried out on a representative sample of no more than 12%
of the length of constructed pipelines. Should this survey indicate sections of pipeline which
fail to meet the specification requirements, the Contractor will be required to carry out
remedial works and undertake additional CCTV surveys at his expense.
4.6.3
Pressure Pipelines
The pipeline shall be tested between valve chambers or into sections not exceeding 400 m in
length unless approved otherwise by the Engineer. The section tests shall be carried out as
follows:
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(a)
each pipeline or section thereof shall be filled with water and all air removed as far as
possible
(b)
the pressure shall then be raised by pumping in water until the test pressure is
reached and shall be maintained at this level by further pumping until it is steady
(c)
pumping shall then be stopped and the time taken for the observed pressure to fall by
1.0 m shall be recorded
(d)
pumping shall then be resumed and the quantity of water pumped in order to restore
the test pressure shall be recorded
(e)
if after three hours the test pressure has not fallen by 1.0 m, pumping shall be
resumed at that stage, the time being recorded as three hours
(f)
the rates of loss shall then be calculated as the recorded quantity divided by the
recorded time
(g)
the test pump and gauge shall be connected to the pipeline at a location other than
the highest point in the pipeline to facilitate release of air from the highest point
QCS 2014
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(h)
the test pressure shall be such that the entire pipeline or section being tested is
subjected to 1.5 times the working pressure, 1.25 times the maximum surge pressure
or 800 kPa, whichever is the greatest
(i)
the loss shall not exceed 0.02 litres per mm diameter per kilometre per 24 hours for
each 0.1 MPa of head applied
(j)
if the pipeline fails to pass the test, the faults shall be located and repaired and the
pipeline retested until it passes the pressure test. All exposed pipe, fittings, valves
and joints shall be visually inspected during the tests.
When all sections have been joined together after completion of section testing, unless
otherwise directed by the Engineer, the entire pipeline shall than be subjected to final test as
follows:
all joints between individual test sections shall be left uncovered during this final test
(b)
the final test shall be carried out using the same procedure as the section test
(c)
in all cases of water tests, where the measured leakage rate exceeds the allowable,
the Contractor shall, at his own expense, make all necessary repairs and carryout
additional testing until a satisfactory result is obtained
(d)
before pressure testing is started the Contractor shall recheck pipes and valves for
cleanliness and shall recheck the operation of all valves. The "open" ends of the
pipeline or sections thereof) shall normally be stopped off by blank flanges or cap
ends additionally secured where necessary by temporary struts and wedges. All
anchor and thrust blocks shall have been completed and all pipe straps and other
devices intended to prevent the movement of pipes shall have been securely
fastened
(e)
since valves cannot be guaranteed to be perfectly drop-tight, testing against closed

valves which are connected to an existing system shall be prohibited; testing against
other closed valves (including air valves) not so connected, may be attempted if
desired, provided the valves are suitably anchored against thrust. No claims
whatsoever will be entertained on account of leaking valves, or any other difficulties
in closing off lengths of pipework for testing, which shall be entirely an obligation of
the Contractor
(f)
on successful completion of the final test, the exposed joints shall be covered and the
trench backfilled as specified in the appropriate Clause 2.3 of this Section.
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(a)
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Part
The pipeline shall be tested for a period of at least 24 hours after which the test pressure
shall be restored by pumping and the quantity of water lost during the test measured.
Plastic irrigation drip pipe work shall be completely filled with water and visually inspected for
leakage. No section showing signs of leakage will be accepted. In addition, any length of pipe
which in the opinion of the Engineer or his designated representative is showing signs of
degradation through contact with sunlight shall be cut out and replaced.
4.6.4
Other Pressure Pipelines
Water Pipelines and Other Pressure Piping Carrying Liquids
(a)
water pipelines and other pressure piping carrying surface water ground water and
treated sewage effluent excluding raw sewage pressure pipelines having socket and
spigot gasket joints shall be given a pressure and leakage test. Ductile iron or
PVC-U pipe shall be tested to AWWA C066 ; steel pipe to AWWA C066
(b)
PVC-U treated sewage effluent pipework shall completely filled with water and
visually inspected for leakage. No section showing signs of leakage shall be
accepted.
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Page 34
Pressure Pipe, Flanged or Welded Joints

(a)
PVC-U, steel, cast iron, ductile iron or other pipe material, with solvent welded,
welded, threaded, flanged, grooved end or flexible couplings and joints shall be
pressure tested. No leakage shall be permitted.
Pressure Air and Gas Piping:

(a)
All piping carrying air or other gasses under pressure shall be given a pressure test.
No leakage is permitted. Low pressure air piping shall be tested pneumatically. Air
pressure of 140 kPa shall be applied to piping and fittings. High pressure air piping
shall be tested to 1400 kPa. There shall be no drop in pressure in a 24-hour period
(b)
Leaks shall be located and repaired to the satisfaction of the Engineer. Pressure
drops due to thermal contraction are acceptable if the pressure returns to the original
test pressure after 24 hours.

Part
All piping, including valves, shall be field tested at the specified pressure with duration of two
hours minimum, for each pressure test. Piping conveying liquids between process tankage,
not subject to pumping, shall be tested to the maximum possible pressure that can be
obtained under static conditions. Air piping shall be tested using air or nitrogen.
All exposed pipe, fittings, valves, hydrants, and joints shall be carefully inspected before
either being cast in concrete or during the open trench tests, or both. All defects discovered
shall be corrected by removal and replacement, as approved by the Engineer, and the work
then retested to demonstrate satisfactory performance.
Where practical, no concrete encasement or backfilling of pipe joints will be permitted before
the satisfactory completion of the tests in any given section.
4.6.5
MDPE and HDPE Pressure Pipelines
Upon substantial completion of the pipeline or major sections, the line shall be cleaned and
hydrostatically tested to prove integrity of the pipeline section and to detect any leakage prior
to commissioning. Testing shall be performed in accordance with the Finnish Standard SFS
3115:E and the procedure described below. The Contractor shall supply all necessary fittings,
equipment and facilities required to undertake the testing.
The Contractor shall prepare a detailed Method Statement for the pressure test that shall
follow the outline test procedure described below and be subject to the approval of the
Engineer.
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(a)
Seal the pipeline. Fix all blank flanges. Remove air valves. Remove all on line
equipment that may be damaged by high pressure.
(b)
Only test against blank flanges, do not attempt to test against closed valves.
(c)
Cover the pipe with sufficient backfill to protect it from direct sunlight, leaving joints
exposed where practical.
(d)
If backfilling is not practicable schedule the tests for early morning or evening.
(e)
Fill the pipeline from the lowest point. Bleed the air from all high points and flange
points where it is possible and tighten once water begins to spill.
(f)
When the line is full, close off the filling valve and check all flanges and the small
diameter test pipework for leaks.
(g)
Phase1
Commence raising the pressure at the filling point to the operating pressure or a
pressure of 5 bar, whichever is higher. Hold this pressure for a period of 2 hours and
add water whenever the pressure drops by 0.2 bar in order to maintain a steady
pressure.
QCS 2014

Part
Page 35
Visually inspect the pipe length for leakage.
(i)
Phase2
After two hours raise the pressure to 1.3 times the operating pressure or 6.5 bar,
whichever is higher, as quickly as is practical. Again maintain this pressure for two
hours by adding water whenever the pressure drops by 0.2 bar.
(j)
Visually inspect the pipe length for leakage.
(k)
Phase3
At the end of the second two hours release the pressure back down to the phase I
level i.e. the operating pressure or 5 bar, within a period of no more than 30 minutes
and as quickly as is practical, in a controlled manner.
(l)
Phase3Case1
If after one hour the pressure in the pipelines remains at or above the operational
pressure, the test is considered to be completed with the pipeline passing the
hydrostatic test.
(m)
Phase3Case2
If after one hour the pressure in the pipeline has fallen below the operational pressure,
water shall be added to raise the pressure back to the operating pressure level, having
first noted the low pressure before adding any water.
(n)
Phase3Case2
Measure the added water by draining it off into a measuring cylinder. (i.e. reduce
pressure to the previously recorded low value and save the water bled off). The
measured quantity is then compared against the allowable quantity to determine if the
pipeline passes the hydrostatic pressure test.
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(h)
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Page 36
Graphical Representation of the Hydrostatic Test Process

Case 1 Pipeline passes test without adding any make up water
Figure 2
Graphical Representation of the Hydrostatic Test Process

Case 2 Water to be added to determine if the pipeline passes or fails
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Figure 1
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Part
Page 37
If during Phase 3 the pressure within the pipeline remains at or above the operational
pressure of the pipeline for a period of at least one hour, the pipeline is considered to have
passed the hydrostatic test.
If water needs to be added the pipeline is considered to have passed the hydrostatic test if
the quantity of water added in terms of litres of water per km of pipeline length per hour of the
phase 3 period is less than that given in the following expression and in Figure 3.
Q Di/50 1 (litres / km/ hour)
Q = added water in litres.
Di = internal diameter for the pipeline in mm.
Hydrostatic Test
Pass
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Figure 3. Hydrostatic Test Allowable Quantities of Make Up Water
The pressure gauge shall be calibrated, certified and to accurate to 0.1 bar. It shall be
connected to the feed pipework.
The small diameter test pipework shall include a bleed valve at upper end of the pipeline and
at all high points together with feed pipework and valve at the lower end of the pipeline. The
feed pipework shall include a means of draining off the water in to a measuring cylinder that
shall have a capacity of at least 2 litres capacity, graduated to 100 mls.
The Contractor shall also have a thermometer for air and water temperature measurement.
Care should be taken not to over pressure the lower end of the system during testing.
Gauges should always be placed at the lower end of the length under test. As far as possible
the difference between the lower and upper end should be kept to one bar. It is recognized
that this may not always be possible when longer lengths are being tested, or where the
slope of the pipeline makes it impractical.
Where the phase II pressure is within the pressure rating of the pipe and test temperatures
O
are 30 C or less no adjustment of test pressure is necessary.
QCS 2014
When ambient temperatures at the time of test are over 30C and test pressures are over the
pressure rating of the pipe then it may be necessary to modify the test pressure according to
the table below or as agreed with the pipe manufacturer.
Test Temp.
O
( C)
32
38
43
49
54
60
Multiplier
0.9
0.8
0.75
0.65
0.6
0.5
When undertaking the testing the Contractor shall also take in to account the following points.
(a)
Care should be taken that any mechanical elements on the system are protected from
elevated pressure or completely removed from the pipeline.
(b)
Do not subject the line to prolonged over-pressure.

procedure within one working day.
(c)
During the summer make sure that the pipe is not subject to direct sunlight during
testing.
(d)
During pressure testing pay full attention to the HSE aspects of the procedure. In
particular keep the general public away from high pressure test areas.
(e)
The test equipment must be capable of pressurizing the test length within a reasonable
time. If the procedure becomes protracted (beyond one working day) the test length
may be modified or reviewed. Extremely long test lengths may be subject to special
procedures.
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Always aim to complete the
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10

Part
MISCELLANEOUS ITEMS
4.7.1
Manhole Covers and Frames
Manhole covers shall be made from ductile iron and comply with BS EN 124 which shall
include:
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4.7
Documentation confirming EN 29002 certification; or
(b)
Documentation identified under Annex A to BS EN 124, concerning Independent Third

Party Inspection.
(c)
Independent random sample testing at an approved testing facility to demonstrate full

compliance with all aspects of the code i.e. load testing and dimensional tolerances.
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Production facilities shall be quality assessed in accordance with ISO 9000 or EN

29002 (BS 5750).
(d)
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(a)
Where manholes are located in road carriageway, the covers shall be non-rock double
triangular Class D400 unless otherwise designated. The double triangular cover shall be
loosely coupled with stainless steel bolts. The frames for sewer and surface / ground water
manholes shall provide a minimum access opening of 750mm square. The frames for TSE
chambers shall provide a minimum access opening of 675mm square.
Manhole covers in paved areas, car parks, verges, roads within property boundaries, and
other areas accessible to pedestrians and light vehicles, shall be non-rock double triangular
Class B125 unless otherwise designated. The double triangular covers shall be loosely
coupled with stainless steel bolts plate. The frames for sewer and surface / ground water
manholes shall provide a minimum access opening of 750mm square. The frames for TSE
chambers shall provide a minimum access opening of 675mm square.
All castings shall be grit blasted and coated on all exposed faces with a zinc primer and coaltar epoxy paint finish in accordance with Part 8 of this Section which shall result in a smooth
coating, tough and tenacious when cold, and neither tacky nor brittle.
QCS 2014

Part
Page 39
The covers and frames on foul sewers shall incorporate a removable self-sealing GRP or
similar corrosion resistant plate meeting the requirements of Part 7 of this Section. The plate
shall fit between the cover and the frame such that no surface area of the frame shall be
exposed to the atmosphere within the manhole. This shall be achieved by the inclusion of a
neoprene sealing ring or by a similar approved method. The plate shall be complete with a
lifting handle on the upper surface. The design of the frame and cover and plate shall be
subject to the approval of the Engineer. A heavy grease seal is to be formed in all cases
between the cover and frame to prevent the ingress of sand.
Manhole covers for sewerage, surface water and treated sewage effluent systems shall have
the following words embossed in both English and Arabic, respectively:
(a)
Sewerage:
Drainage
Foul Sewer
Surface water:
Drainage
(b)
Treated sewage effluent:
Drainage
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(c)
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Surface Water
Treated Sewage Effluent.

The size of lettering shall be approved by the Engineer.
The Contractor shall supply one pair of manhole keys or prying and lifting bar, as appropriate
with each 30 covers provided with a minimum of one tool for each type cover. Keys and
prying and lifting bars shall be of approved appropriate design to match the different cover
configurations. Keyways in manhole covers shall be of the closed type.
Any manhole covers and frames on sewer or surface / ground water manholes that are
damaged or otherwise disturbed during the execution of the Works shall be replaced with
covers and frames with a minimum clear opening of 750mm square and incorporate a GRP
sealing plate. If the opening through the concrete cover slab is less than 750mm square, then
the concrete slab shall also be replaced.
10
Manhole covers for foul sewerage, surface water and treated sewerage effluent shall be
provided with inscriptions both in Arabic and English cast into the top surface of the cover.
The lettering shall conform to the details given elsewhere in these documents or to the
current details available from Drainage Affairs.
4.1.2
Duct Covers and Frames
11
Duct covers and frames shall be of cast iron, galvanised mild steel or aluminium as shown on
the Drawings, and shall be waterproof, non-rocking and recessed for filling with concrete.
12
Cast iron duct covers and frames shall be obtained from an approved experienced
manufacturer, shall have machined seating faces and sloping mating faces to facilitate sliding
out of covers. The covers shall be capable of withstanding a 5 tonne wheel load when the
recesses are filled with Grade SRC 25 concrete, or such other load as may be shown
elsewhere in the Contract Document.
13
Galvanised steel covers and frames shall be obtained from an approved experienced
manufacturer. Covers shall have solid bases fitted with reinforcing rods and where detailed
on the drawings shall incorporate locking bolts. Covers shall be capable of withstanding a 5
tonne wheel load when filled with Grade SCR 25 concrete, or such other load as may be
shown elsewhere in the Contract Document. Covers shall generally be filled with concrete,
but finished with tiling to match the surrounding floor finish.
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Part
Page 40
Aluminium duct covers and frames shall be fabricated from aluminium alloy Grade 6063-T6
or other such chemically resistant alloy which the manufacturer can demonstrate will
withstand aggressive atmospheres likely to be encountered. Covers shall have solid bases,
and shall incorporate reinforcing bars held in place in plastic clips. Those faces of the frame
which will come into contract with cement mortar or concrete shall be painted with two coats
of bituminous paint before installation of the frame.
15
All covers shall be installed strictly in accordance with the manufacturers instructions.
16
Two complete sets of lifting keys including any necessary spanners shall be provided in each
room in which ducts covers are installed.
17
A heavy grease seal is to be formed between the cover and frame to prevent the ingress of
sand.
18
Multiple covers shall have removable intermediate beams.
4.7.2
Hinged Aluminium Access Covers
Hinged aluminium access covers shall be fabricated from chequer or ribbed plate. The
2
covers shall be designed to carry a uniformly distributed load of 7.5 kN/m , and deflection
under this loading shall not exceed one percent of the span.
The frame shall be made from aluminium alloy complying with BS 1474 Grades 6063-T6 or
6082-T6.
Where a cover is to be located within tiled areas, the frame shall be made from channel
sections. The outer vertical arm of the channel frame shall be set flush with the top of the
adjacent floor finishes. The inner vertical arm shall be shorter to allow the chequer plate to sit
the inner arm, while allowing the chequer plate cover to be flush with adjacent floor finishes.
The edges of the chequer plate cover shall be turned down into the channel section. Hinges
shall not stand proud of the cover and sealed lifting eyes shall be provided complete with two
lifting keys for each cover.
Where a cover is to be located on concrete upstands or flat concrete surfaces, the frame
shall be made from angle sections. The edges of the chequer plate cover shall be turned
down over the angle frame to provide a weatherproof cover. A lifting handle shall be provided
on the edge opposite the hinges and a hasp provided for locking the cover with a padlock.
The frame shall be bolted down to the concrete below using a minimum of four 10 mm
diameter stainless steel acrylic resin anchors.
Fixings shall be of stainless steel. Gaskets shall be provided to isolate aluminium alloy from
other material.
4.8
FUTURE SEWER CONNECTION
4.8.1
General
All stub pipes and pipes built into manholes for future connections are to be sealed with an
approved stopper, obtained from the same manufacturer as the pipe.
Marker posts shall be provided at the ends of all pipes left for future connection except where
a single stub pipe is built into a manhole and are to be located as directed by the Engineers
Representative.
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QCS 2014

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Page 41
INSITU LINING OF EXISTING MANHOLES
4.9.1
General
Where directed by the Engineer, the Contractor shall apply a GRP lining to all internal
surfaces of an existing manhole. The lining shall generally comply with the requirements of
Specification Clause 4.4.1.
The cover slab and manhole cover shall be removed. The slab shall be disposed to an
approved tip. The manhole cover and frame shall be thoroughly cleaned, treated with two
coats of bituminous paint and submitted to Drainage Affairs Store.
All surfaces to be lined shall be clean and dry, step irons and any unsound materials shall be
removed to the satisfaction of the Engineer prior to the commencement of any lining or
sealing work.
For walls a preformed liner sized to fit in the existing manhole may be used. The joint
between the base of the liners and existing benching shall be sealed into a chase cut into the
existing benching by a heavy duty epoxy resin based sealant approved by the Engineer,
which must be applied strictly in accordance with the manufacturer's instructions. The space
between the existing internal concrete wall of the manhole and the liner shall be filled using
an approved non-shrink cementitious grout.
Alternatively an in situ wall lining may be used. The walls shall first be made good with 3:1
sand cement mortar and the surfaces to be lined shall be lightly abraded. An in-situ lining
6mm deep in compliance with Specification Clause 4.4.1.9 shall then be formed.
On completion of the lining a new GRP ladder shall be installed in accordance with
Specification Clause 4.4.1.15, if shown on the Contract Drawings.
A new cover slab and manhole cover shall be provided. The cover slab shall comply with
Specification Clause 4.4.1.9. The manhole cover and frame shall comply with Specification
Clause 4.6.1.
The Contractor shall provide the Employer 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.
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4.9
END OF PART
QCS 2014

Part
05: Valves, Penstocks and Appurtenances
Page 1
VALVES, PENSTOCKS AND APPURTENANCES ....................................... 3
5.1
GENERAL ...................................................................................................... 3
5.1.1
5.1.2
5.1.3
5.1.4
5.1.5
Scope
References
Submittals
Quality Assurance
5.2
MATERIALS .................................................................................................. 6
5.3
SLUICE VALVES ........................................................................................... 7
5.4
BUTTERFLY VALVES ................................................................................... 8
5.5
REFLUX VALVES .......................................................................................... 9
5.6
PLUG VALVES ............................................................................................ 10
5.7
SURFACE BOXES ...................................................................................... 10
5.8
VALVE OPERATING TEE KEYS................................................................. 11
5.9
AIR VALVES ................................................................................................ 11
5.10
PRESSURE CONTROL AND RELIEF VALVES.......................................... 11
5.10.1
5.10.2
5.10.3
5.10.4
General
Pressure Reducing Valves
Pressure Relief Valves
Pressure Regulating and Sustaining Valves
5.11
PENSTOCKS ............................................................................................... 12
5.11.1
5.11.2
5.11.3
5.11.4
5.11.5
General
Cast Iron Penstocks
Stainless Steel Penstock
Plastic Penstocks
Stoplogs
5.12
OPERATING DEVICES ............................................................................... 15
5.12.1
5.12.2
5.12.3
5.12.4
5.12.5
5.12.6
Lifts
Liftnut
Gear Lift
Handwheel
Stem Covers
Actuators
5.13
FLAP VALVES ............................................................................................. 17
12
12
12
12
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3
3
4
6
6
5.13.1 Flap Valves (General Purpose)

5.13.2 Flap Valves for Sea Water Applications
12
12
14
14
15
15
16
16
16
16
16
17
17
QCS 2014

Part
Page 2
5.14
MISCELLANEOUS VALVES AND APPURTENANCES .............................. 17
5.14.1
5.14.2
5.14.3
5.14.4
Ball Float Valves

Globe Valves
Quick Coupling Valves
Emitters
5.15
FITTINGS .................................................................................................... 18
17
18
18
18
5.15.2 Flanges, Gaskets, and Bolts

5.16
18
MECHANICAL COUPLINGS ....................................................................... 18
5.16.1 Grooved End Couplings

5.16.2 Flexible Couplings
FLOW CONTROL ........................................................................................ 19
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5.17
19
19
5.17.1 Vortex Flow Control Devices
INSTALLATION AND TESTING .................................................................. 20
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5.18
19
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5.18.1 Installation
5.18.2 Testing
20
20
QCS 2014

Part
Page 3
VALVES, PENSTOCKS AND APPURTENANCES
5.1
GENERAL
5.1.1
Scope
This part includes the specification for the manufacture, testing and supply and installation of
valves, penstocks and appurtenances complete with frames, supports, anchor bolts, stems,
stem guides and other appurtenances.

General
Pipe Installation
Section 1,
Section 9,
Section 10,
General
Instrumentation Control and Automation.
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This Section
Part 1,
Part 3,
Part 4,
Part 6,
Part 8,
All valves are to be fixed to the pipelines with adaptor flanges for easy removal or installation.
5.1.2
References
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ANSI B18.2.1..............Square and Hex Bolts and Screws
ANSI B18.2.2..............Square and Hex Nuts
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ASTM B62 ..................Composition Bronze or Ounce Metal Castings
ASTM D256 ................Test Methods for Impact Resistance of Plastics and Electrical
Insulating
Materials
ASTM D638 ................Test for Tensile Properties of Plastics
ASTM D648 ................Test Method for Deflection Temperature of Plastics Under Flexural
Load
ASTM D695 ................Test Method for Compressive Properties of Rigid Plastics
ASTM D696 ................Test Method for Coefficient Linear Thermal Expansion of Plastics
ASTM D790 ................Standard Test Methods For Flexural Properties of Unreinforced and
Reinforced Plastics and Electrical Insulating Materials
ASTM D1784 ..............Specification for Rigid Polyvinylchloride) (PVC) Compounds and
Chlorinated Polyvinylchloride (CPVC) Compounds
ASTM D2000 ..............Classification System for Rubber Products in Automotive Applications
AWWA C500 ..............Metal-Seated Gate Valves
QCS 2014

Part
Page 4
AWWA C501 ..............Cast-Iron Sluice Gates

AWWA C507 ..............Ball Valves 150 mm Through 1200 mm
AWWA C510 ..............Double Check Valve Backflow-Prevention Assembly.
BS 4772......................Ductile iron pipes and fittings
BS 5163......................Predominantly key-operated cast iron gate valves for water works
purposes
BS 970 Part 1 .............General inspection and testing procedures and specific requirements
for carbon, carbon manganese alloy and stainless steel
BS 2872......................Copper and copper alloy forging stock and forgings
BS 2874......................Copper and copper alloy rods and sections (other than forging stock)
BS 3416......................Specification for bitumen based coatings for cold application
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BS 4164......................Specification for coal-tar-based hot-applied coating materials

BS EN 593..................Butterfly valves
BS EN 1171................Cast iron gate valves
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BS EN 598 ------- Face-to-face valve dimensions
BS EN 1561................Flake graphite cast iron
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BS EN 1563................Founding. Spheroidal graphite cast iron
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BS EN 1982................Copper alloy ingots and copper alloy and high conductivity copper
castings
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BS EN 3196................Nuts, hexagonal, self-locking in heat resisting steel
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BS EN 12334..............Cast iron check valves for general purposes
ISO 9000 ....................Quality Systems

Submittals
The Contractor shall obtain Engineers approval of submittals before placing order for the
following items.
Valves. Complete data for the supply and installation of all valves and appurtenances shall
be submitted as follows:
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5.1.3
(a)
Product data:
(i)
for each type and model of valve, provide
(ii)
assembly instructions,
preventative/corrective maintenance instructions
for each actuator, provide
(iii)
currents at the specified voltage corresponding to locked rotor,

maximum seating torque,
average running load, and speed and full information concerning actuator
dimensions and weights shall be provided
identification of valves and accessories by tag numbers, where applicable.
QCS 2014
(b)

Part
Page 5
The following detailed written procedures shall be submitted to supplement the above
data:
(i)
installation procedures for fixing, supporting, and anchoring valves
(ii)
test procedures for adjusting and testing valve assemblies.
Penstocks:
(a)
Complete fabrication, assembly, foundation, and installation drawings, together with

detailed specifications and information covering performance and materials of
construction, power drive assembly, devices, and other accessories shall be
submitted as follows:
(i)
Shop drawings, data and specifications for the equipment shall include, but not
limited to:
(ii)
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anchor bolt placement in the concrete structure including projections from

concrete or other surfaces
gate size, model numbers, opening sizes, elevations, locations, and
materials of construction
stem sizes including details of connections, thread directions, and stops, and
calculations for stem diameter and operators
stem guide details and locations
gear box types, model numbers, and ratios, including connections furnished
for each type
wall thimbles
motor data, including the motor manufacturer; minimum guaranteed
efficiency and power factor at full load, 3/4 load, and 1/2 load; locked rotor
current in amps; full load current in amps; motor speed in rpm; and mounting
details
Factory Test Reports:
Operations and Maintenance Manuals:
The Contractor shall submit five copies of complete operation and maintenance
manuals for penstocks and valves written in English in accordance with Part 1 of this
Section. Required operation and maintenance data shall include, but not limited to
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(a)
(i)
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Before shipment of any material specified herein, the Contractor shall submit
the results of all test reports for the approval of the Engineer.
complete, detailed written operating instructions for each product or piece of

equipment. Manuals must be specific to the products supplied herein and the
application and operating conditions in Qatar. General manuals will not be
accepted
(ii)
complete, detailed preventative maintenance instructions
(iii)
a complete inventory of all parts and components
(iv)
recommended spare parts lists and sources of supply for the parts
(v)
all safety instructions relating to operation and maintenance procedures
(vi)
name, address and phone number of manufacturer, manufacturer's authorised

service representative
(vii)
troubleshooting instructions.
QCS 2014

Part
Page 6
Quality Assurance
Valves, penstocks and appurtenances shall be supplied by approved manufacturers as

designated in the Project Specification. Production facilities shall be quality assessed in
accordance with ISO 9000 or equivalent.
5.1.5
Packaged items shall be stored in their original packing and wrappers until ready for
inspection by the Engineer. After inspection, all packaged items shall be repacked and
rewrapped such that the items are sealed to the satisfaction of the Engineer, and stored until
ready for use or installation.
Valves and appurtenances shall be stored off the ground, protected from dirt and moisture,
and protected from foreign material entering the ends.
All equipment shall be stored and handled in such a manner to protect equipment, finishes,
and coatings, both internal and external.
During storage, gates for penstocks shall be placed in a position to support and prevent
warping of gates and stems.
5.2
MATERIALS
Cast iron shall conform to BS EN 1561 minimum Grade 250 unless otherwise specified.
Ductile iron shall conform to BS EN 1563 unless otherwise specified.
Aluminium bronze shall conform to BS 2872 Grade CA 104
Bronze shall conform to ASTM B62 Grade 1, except that the maximum zinc allowance shall
be seven percent and the maximum aluminium allowance be two percent, unless otherwise
specified.
Gun metal shall conform to BS EN 1982 Grade LG2
Stainless steel shall conform to BS 970 Grade 316 S 31 unless otherwise specified.
Duplex stainless steel shall conform to BS EN 1.4507 unless otherwise specified.
Manganese steel shall conform to BS 970 Pt 1 Grade ISO M19.
Anchor bolts, assembly bolts, screws, nuts, and washers, including anchor bolts used in the
installation and assembly of each unit shall be stainless steel unless otherwise specified, and
of ample size and strength to safely withstand forces created by operation of the unit while
subject to the hydrostatic heads described herein. The quantity and size of fasteners shall be
as recommended by manufacturer, and as approved by Engineer. All bolt heads and nuts
shall be hexagonal. Anchor bolts shall be furnished with two nuts each to facilitate
installation and alignment.
10
All hand wheels, headstocks, foot brackets, guide brackets and thrust tubes shall be cast
iron. All other materials for valves, penstocks and appurtenances shall be as specified for
each item.
11
Unless otherwise stated Cast iron valves, penstocks and appurtenances shall be prepared
and painted in accordance with part 8 of this Section.
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5.1.4
QCS 2014

Part
Page 7
5.3
SLUICE VALVES
These specifications are applicable to all sizes of sluice valves larger than 80 mm diameter.
Sluice valves shall be of the following types.
(a)
Potable and treated sewage effluent - 80mm diameter up to and including 300mm
diameter, to BS 5163 with resilient seating.
(b)
All other uses other than (a) above, 80mm diameter up to and including 1,000mm
diameter to BS EN 1171metal seated.
Valves shall be of the double flanged cast iron wedge-gate type unless otherwise stated.
Valves shall be cast iron body with renewable gun metal faces on body and wedge and bolton cast iron bonnet. All exposed valves shall be of the rising stem type unless otherwise
specified or shown on the Contract Drawing. Rising stem valves shall also incorporate a
combined yoke. Valves shall close clockwise.
Valves pressure ratings shall equal the class of pipe unless otherwise indicated on the
Drawings.
Valve stems shall be of stainless steel SS316 S31, machined all over, with a machine cut
robust trapezoidal or square form thread, operating in gunmetal.
Stem seals on valves of 350mm diameter and above shall be of the stuffing box and gland
form arranged for easy replacement of packing and seal and shall be accessible for
maintenance without removal of the valve from service. Stem seals on valves below 350mm
diameter may be stuffing box and gland or 'O' ring. If 'O' ring seals are provided they shall be
arranged such that they can be replaced without removal of the valve from service. If 'O' ring
stem seals are provided, the Contractor shall provide with the valve, two replacement sets of
rings labelled with the project number, manufacturer, valve model reference and size of
valve.
Valves shall be provided with suitable handwheels as follows:

diameter shall be adequate for the duty required
(b)
gearing shall be supplied where necessary to ensure that the required operating force
applied by hand to the rim of the wheel does not exceed 250N (25Kgf)
(c)
Handwheels shall have smooth rims and the direction of closing, which shall be
clockwise, shall be cast on them.
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(a)
The following shall apply to spindles :
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(a)
where possible and providing the valve is not subject to submergence, spindles shall
be of the non-rising type and a cast iron bridle piece, or similar, shall be incorporated
on valves of the rising spindle type for this purpose.
(b)
for valves of 300mm bore and above, and for all motorised/actuated valves spindles
shall be of the rising type. Thrust tubes shall be provided between the valve and
headstock in order to absorb the thrust in both direction of operation. Thrust tubes
shall incorporate all necessary fixings brackets and spindle guide plates. Headstocks
shall incorporate a valve position indicator.
(c)
where rising stem valves are subject to submergence the extension spindle shall also
be of the rising type with the threaded portion positioned above top water level.
(d)
extended spindle installations shall include all necessary brackets, intermediate

supports etc.
(e)
where extended spindles require to be operated at open flooring level, spindle guides
or guide brackets shall be provided close to flooring level.
QCS 2014
(f)

Part
Page 8
all spindles shall be of stainless steel Grade 316S31 and shall be compliant with the
requirements for valve stems.
Extension spindle couplings shall be of the muff type and shall be drilled with a nut and bolt
for securing the spindle to the valve stem, which will likewise be drilled to accept the bolt.
Vandal and weatherproof clear polycarbonate tube covers shall be securely fitted to protect
the threads of rising stems and spindles. Tubes shall be clearly and permanently engraved
to indicate the position of the valve.
10
Where valves are required to be operated by tee keys, spindle caps shall be fitted. The caps
shall be drilled and each provided with nut and bolt for securing to the spindle which shall
likewise be drilled to accept the bolt. Where caps are fitted they shall be supplied complete
with operating tee key. The extended spindle shall be such that the tee key will be operated
at 0.9 to 1.2 m above floor level.
11
Where sluice valves above 350 mm bore are mounted with the spindle in the horizontal
plane, valve bodies shall be fitted with renewable gunmetal machined gate slides and the
gates with renewable hard bronze shoes accurately machined to reduce sliding fraction.
12
All sluice valves above 500 mm bore (300 mm if power actuated) shall be provided with
jacking screws. Valves above 350 mm bore where mounted in a horizontal pipeline shall be
provided with feet.
5.4
BUTTERFLY VALVES
Butterfly valves shall comply with BS EN 593 and be of the double flanged, non-wafer,
double eccentric (Offset) type. The valves shall be designed such that the body and disc seat
rings can be easily replaced.
Valves shall be suitably designed to protect the disc edge from the effects of corrosion and
erosion.
The valve body ends shall be double flanged and the flange dimensions shall comply with the
relevant requirements of BS EN 1092. The body shall be manufactured from close grained
cast iron lined with rubber unless otherwise specified. The body parts shall be circular and
the diameter not less than that of the nominal pipe bore. The valve body shall be provided
with suitable lifting lugs.
The disc shall be designed to withstand the maximum pressure differential across the valve
in either direction of flow. The disc shall be contoured to ensure the lowest possible
resistance to flow and shall be suitable for throttling operation. Disc material shall be duplex
stainless steel.
The shaft shall be designed to withstand the maximum torque that will be imposed by the
operator. It may be in one piece or attached as two stub ends on opposite sides of the disc.
The stub end shall be of polygon profile type conforming to P3G or P4C. The means of
attachment of the shaft to the disc shall be by using fixings in a homogeneous corrosionresistant material of a pattern which precludes the assembly becoming loose in operational
service. Grub screws, pins (parallel or taper) or clamps shall not be acceptable. The shaft
material shall be stainless steel SS316 S31. Self-lubricating PTFE faced bearings with O
ring seals shall be provided.
The body seat shall be stainless steel SS316 S31 and the disc seat shall be one piece
moulded nitrile rubber. They shall be designed to be drop tight in either direction at
maximum differential pressure.
Valves shall be provided with suitable stops to prevent movement of the shaft beyond the
limits corresponding to fully open and fully closed position of the disc.
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QCS 2014

Part
Page 9
A suitable external locking device shall be provided on the non-drive shaft end, to enable the
geared unit to be removed with the valve remaining in service in the open or closed position.
Fasteners like nuts, bolts and washers of stainless steel shall be provided.
10
Unless otherwise specified each valve shall be provided with a suitable handwheel of
adequate diameter for the duty required and gearing shall be supplied where necessary to
ensure that the required operating force applied by hand to the rim of the wheel does not
exceed 25 kgf.
11
Extension spindles, headstocks and foot brackets shall be provided where specified.
Headstocks shall incorporate a valve position indicator.
12
The valve shall be closed by clockwise movement of an actuator or handwheel. Direction

arrows clearly indicating 'open' and 'closed' positions shall be provided on the actuator or cast
on the handwheel.
13
Valves shall be provided with a position indicator to show the positions of the disc, mounted
on the driven shaft end.
14
All Valves above 350 mm diameter shall be provided with lifting lugs or eye-bolts
5.5
REFLUX VALVES
Unless otherwise specified Reflux valves shall be swing type, double flanged cast iron
conforming to BS EN 12334. Flange dimensions shall comply with the relevant requirements
on BS EN 1092 PN16. Reflux valve shall have face-to-face dimensions in accordance with
BS EN 558.
The valves shall be of the quick acting single door type designed to minimise slam on closure
by means of heavy gunmetal-faced doors weighted as necessary. The valves shall be fitted
with renewable gunmetal door sealing faces which shall be positively fixed. The door hinge
pin/shaft shall extend through a sealing gland on the side of the body and be fitted with an
external lever to permit back flushing.
Glands shall be of the stuffing-box type with the exception that for valves below 450 mm bore
they shall be of the O ring type.
The valve door shall be weighted to suit the application and the lever shall be of the heavy
duty type designed for the additional of external weights should these be required at some
future date.
Where there is a likelihood of surge pressures being generated reflux valves shall be of the
low loss non-slam wafer type. They shall feature a spring action giving drip tight shut-off.
The movement of the sealing plate shall not lead to scuffing of the seat material.
All reflux valves shall be suitable for operating in the horizontal plane unless otherwise
specified.
Cover plates shall be of sufficient size to allow easy hand access for cleaning and service
and shall be supplied complete with tapped bosses fitted with air release cocks.
Valves above 350 mm bore shall be provided with feet.
The design of the valve body shall be such that there is adequate clearance around and at
the back of the door to minimise jamming by rags and debris. Stops shall be provided to limit
the back lift of the door and shall be positioned to prevent fouling.
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Page 10
The hinge pin/shaft shall be stainless steel SS316 S31 and preferably square in section to
ensure positive location of the door. If circular shafts are utilised the back flushing lever shall
be located on a squared section, the diagonal dimensions of which shall be equivalent to the
full diameter of the shaft. Both door and lever shall be positively and securely fixed to the
hinge pin/shaft. Grub screws, pins (parallel to taper) or clamps will not be acceptable. All
internal fixing devices shall be of stainless steel SS316 S31.
11
Reflux valves fitted to the delivery side of pumps shall be fitted with balance weights to
minimise slam. If specified, they shall be provided with a totally enclosed proximity switch
operated by an external cam fitted to the extended spindle. The proximity switch shall be of
the metal clad type with sealed actuator and cable entry. Cam operated micro-switches will
not be acceptable.
5.6
PLUG VALVES
Plug valves shall be eccentric and equipped with resilient faced plugs and be of nonlubricated type capable of handling abrasive and raw sewage. The plug valves shall have
PN 16 flanged ends. Valves shall be furnished with manual operators as a unit. Each valve
plug shall rotate 90 degrees from the fully open to the tightly shut position and shall seat at an
angle of 90 degrees from the pipe axis in which the valve is installed.
Valves shall be satisfactory for applications involving throttling service and for frequent
operation after long periods of inactivity. Valves with operators shall be suitable for operation
with flow in either direction.
Valves shall be non-lubricated, with non-shock pressure differential acting in either direction;
at 175 kPa differential across the valve, the valve will provide drip-tight shut-off. Valves
75 mm diameter and above shall have bolted bonnet design. Bodies shall be of high carbon
cast iron or nickel iron having 1 % to 1.5 % nickel content. Valves shall have raised seats
and all surfaces in contact with the plug face shall have 90 % pure nickel or coating. Valves
shall have an average tensile strength of 240 MPa. Port areas of valves sizes greater than
100 mm shall be at least 75 % of full pipe area. Flanged valves shall be faced and drilled
minimum PN 16 standard and shall have face-to-face dimensions of standard sluice valves.
Valves shall have balanced plugs to assure low torque and drip-tight shut-off.
Valves shall be equipped with resilient plug facing to provide drip-tight shut-off without use of
sealing lubricants. Even if small solids are trapped between the plug and seat, the resilient
facing shall provide tight shut-off and prevent seat damage. Resilient plug facings shall be
neoprene, ethylene propylene terpolymer, or other suitable materials capable of handling
abrasives and raw sewage.
Valves shall have heavy-duty upper and lower guide bearings capable of resisting corrosion
and lubricated by the liquid being handled.
Valves shall be actuated by means of lever for valves under 80 mm in size and by enclosed
gear and handwheel operator for valves 100 mm and longer. All valves shall be supplied with
operators which required less than 10 N/m torque for operation. Chain wheels with guides
shall be furnished on all valves located 2 m or more above floor levels with stainless steel.
Valves operating devices shall be as specified in Clause 5.12 herein.
5.7
SURFACE BOXES
Surface boxes and covers shall be adjustable cast iron of the slip type and fitted to the sizes
and depths of valves as shown on the Drawings. Covers and frames shall be heavy duty and
be suitable for wheel loads up to 11.43 tonnes.
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Part
Page 11
Surface boxes shall be coated by dipping or other equivalent means using a hot applied coal
tar based material complying with BS 4164 or cold applied bitumen material complying with
BS 3416. No coating shall be applied to any casting until its surfaces are clean dry and free
from rust oil and deleterious material.
5.8
VALVE OPERATING TEE KEYS
Valve operating keys shall have a 50mm square socket. The length of the key shall enable
the valve to be operated with hands at waist height. Unless otherwise stated in the Contract
Documents one tee key per ten valves that are to be tee key operated, shall be provided for
each site.
5.9
AIR VALVES
Air and gas relief valves shall be of the double orifice pattern with grey or ductile cast iron
bodies. The inlet flange shall be faced and drilled in accordance with BS EN 1092 PN16. Air
valves for TSE or potable water shall be of the water type. Air valves for all other waste
water work shall be of the sewage type.
The valve shall be adequately sized for the release of gas from the pipeline (or other
container) without restriction of rate of filling or flow due to back pressure and also to allow
admission of air during pipeline emptying at a rate sufficient to prevent excessive depression
of pressure in the pipe.
Valves shall be designed to prevent the operating elements being in contact with the pipeline
liquid by approved means such as the provision of an auxiliary float and chamber sufficiently
large to isolate the orifice valves and seats throughout the rated operational range.
In applications where the pipeline characteristics may lead to liquid column separation with
consequent possibility of surge a vented non-return valve shall be provided which allows air
to enter freely on separation but controls explosion of air/gas as the liquid column re-joins.
In applications where the hydraulic conditions are such that pressures fall below atmospheric
pressure during normal operation and where air inflow at that time could induce surge
conditions, an air inflow check valve shall be incorporated.
All air and gas relief valves and associated isolating valves shall be works tested and capable
of withstanding the same test pressures as the pipeline or vessel on which they operate.
Air valves and operating linkages that are not made stainless steel shall be pure epoxy resin
coated in accordance with Part 8 of this Section.
Air valves shall be vented wherever possible directly into the wet well. In cases where this is
not possible the Contractor shall provide suitable odour removal for the air expelled from the
valve.
Where air may be drawn into the valve that contains dust, sand etc. means shall be provided
for trapping/filtering this.
10
Air valves shall be installed in such a manner that routine maintenance can be carried out.
11
Air valves shall be fitted with an isolating sluice valves and gearing shall be provided where
necessary to facilitate operation.
5.10
PRESSURE CONTROL AND RELIEF VALVES
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General
The valve body shall be of cast iron conforming to BS EN 1561 with flanges conforming to
BS EN 1092 PN16 or BS 10. The valve shall be extra heavy construction throughout. The
valve interior trim shall be bronze as well as the main valve operation. All working parts shall
be easily removed from the valve body for ease of maintenance. All controls and piping shall
be of non-corrosive construction.
5.10.2
Pressure Reducing Valves
Pressure reducing valves shall maintain any desired downstream-delivery pressure for which
the reducing pilot valve is adjusted provided the upstream head does not drop below a
determined head. During low flow conditions, a resilient rubber valve seat shall ensure drop
tight sealing. The valve shall be completely piped ready for installation.
5.10.3
Pressure Relief Valves
Pressure relief valves shall maintain constant upstream pressure by bypassing or relieving
excess pressure, and shall maintain close pressure limits without causing surges. The main
valve shall be a hydraulically operated, diaphragm-actuated, globe or angle pattern valve. It
shall contain a resilient, synthetic rubber disc. The downstream pressure setting shall be
adjusted by compression of the spring via the adjusted screw.
5.10.4
Pressure Regulating and Sustaining Valves
Pressure sustaining valves shall open and close in modulating action as required to maintain
constant system pressure. On pressure reversal valve shall close tightly. Operation shall be
completely automatic with only one adjustment required to change the pressure setting.
Adjustable pressure range from 1.0 bar to 8.5 bar. The valve shall be "Y" pattern globe
diaphragm actuated with pilot control. The diaphragm shall be made of reinforced neoprene
and the pilot shall be bronze and all tubing copper.
5.11
PENSTOCKS
5.11.1
General
Each item of equipment shall be furnished and installed complete with all supports, anchor
bolts, stems, stem guides, and appurtenances ready for operation. All mechanisms and parts
shall be amply proportioned for the stresses which may occur during operation or for any
other stresses which may occur during fabrication and erection. Individual parts furnished
which are alike in all units shall be alike in workmanship, design, and materials and shall be
interchangeable. Penstock in sewage pumping stations shall be stainless steel/cast iron with
gun metal seating suitable for corrosive environment.
5.11.2
Cast Iron Penstocks
Penstocks shall be suitable for their application, and shall be installed and positioned in such
a manner as to allow ease of operation and maintenance.
Penstocks shall carry identification marks and brass name plates in accordance with BS EN
12334, which identify the penstock number and function.
Penstocks shall be clockwise closing.
Penstocks shall be watertight under the conditions stated for head and direction of flow.
All materials used in manufacture of the penstocks shall conform to the following minimum
standards unless otherwise specified:
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5.10.1
QCS 2014

Part
Cast Iron
Gunmetal
Aluminium Bronze
Stainless Steel
High Tensile Brass
(Manganese Bronze)
Manganese Steel
Phosphor Bronze
BS EN 1561
BS 1400
BS 2872
BS 970 Pt. 1
BS 2874
Grade 250
Grade LG2
Grade CA104
Grade 316 S31
Grade CZ114
BS 970 Pt. 1
BS 2574
Grade ISOM19
Grade P13
Page 13
Fixing nuts and bolts supplied by the manufacturer shall be of stainless steel.
Each penstock shall be provided with a suitable handwheel of adequate diameter for the duty
required. Gearing shall be supplied where necessary:
to ensure that the required operating force applied by hand to the rim of the wheel
does not exceed 250N (25Kgf)
(b)
if the handwheel cannot be readily accessed, extension spindles, headstocks and foot
brackets shall be provided where specified
(c)
where possible, the extension spindle shall be of the rising type with the threaded
portion position above top water level
(d)
headstocks for non-rising spindle installations shall incorporate a position indicator.
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(a)
Handwheels shall have smooth rims and the direction of closing which shall be clockwise
shall be cast on them. Vandal and weather proof clear polycarbonate tube covers shall be
securely fitted to protect the threads of rising stems and spindles. Tubes shall be clearly and
permanently engraved to indicate the position of the valve.
The frames and doors of cast iron penstocks shall be made from close grained grey iron.
The penstocks shall be designed so as to ensure tight closure while maintaining freedom of
door movement during operation and minimising sliding wear of the sealing faces. They shall
incorporate adjustable wedges or swivelling cams and actuating pegs manufactured from a
non-corrodible material.
10
Headstocks and foot brackets shall be provided for non-rising spindle penstocks where the
latter are specifically called for. Guide brackets shall however be provided where necessary.
Non-rising spindles shall be fitted with thrust collars and arranged so as to transmit the thrust
arising due to the operation of the penstock directly to the penstock frame. Where
headstocks are required on non-rising spindle installations they shall incorporate a penstock
position indicator.
11
Penstock spindles shall be of forged stainless steel SS316 S31 , machined all over, with a
machine cut robust trapezoidal or square form thread, operating in a gunmetal nut.
12
Extension spindles shall be of stainless steel SS316 S31and shall be compliant with the
requirements for penstock spindles. Extension spindle couplings shall be of the muff type
and shall be drilled and provided with a nut and bolt for securing the spindle to the penstock
spindle, which shall likewise be drilled to accept the bolt.
13
Extended spindle installations of the rising type shall be provided for valves of 300 mm bore
and above, and for all motorised/actuated penstocks. These shall be of stainless or
manganese steel or manganese bronze. Thrust tubes shall be provided between the
penstock from and headstock in order to absorb the thrust in both directions of operation.
Thrust tubes shall incorporate all necessary fixing brackets and spindle guide plates. All
handwheels, headstocks, foot brackets and guide brackets shall be of cast iron.
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Part
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Where penstocks are required to be operated by tee keys, spindle caps shall be fitted. The
caps shall be drilled and each provided with nut and bolt for securing to the spindle which
shall likewise be drilled to accept the bolt. Where caps are fitted they shall be supplied
complete with operating tee key. The extended spindle shall be such that the tee key will be
operated at 0.9-1.2 metres above floor level.
15
Where penstocks are provided with greasing nipples, these shall be fitted with extension
tubes to facilitate lubrication from a nearby walkway or other readily accessible location.
16
Non-ferrous metal sealing faces shall comprise accurately machined gunmetal or bronze
strips bedded and fixed to machined recesses in the frame and door. The strips shall be
secured by non-corrodible countersunk screws. The faces of the strips shall then be brought
together in the operation position and hand scraped to a watertight finish.
17
Handwheels, headstocks, foot brackets and thrust tubes shall be of cast iron.
18
Cast iron penstocks and headstocks shall be coal tar epoxy coated in accordance with Part 8
of this Section.
5.11.3
Stainless Steel Penstock
Where indicated on the drawings or elsewhere in the Contract Documents, penstocks for use
in aggressive environments shall be manufactured from corrosion resistant materials as
follows:
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14
Metal parts exposed to the atmosphere shall be manufactured from stainless steel to
BS 970 Part 1, Grade 316 S31.
(b)
The frame shall be fixed to the wall using nuts and bolts Grade 316 S31 stainless
steel.
(c)
The door of the penstock shall be manufactured from corrosion resistant plastic or
stainless steel (Grade 316 S31). Plastic shall also be totally resistant to ultra-violet
light. Asbestos shall not be used in any filling materials within plastic gates.
(d)
The seals used on corrosion resistant penstocks shall be suitable for the medium in
which the penstock is immersed. Flexible rubber seals shall not be used on penstocks
immersed in raw sewage for example, where sharp objects and grit may destroy the
seal at the high velocities experienced when opening and closing the doors.
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(a)
All other requirements shall be as specified in Clause 5.11.2 herein.
5.11.4
Plastic Penstocks
Plastic penstocks shall be of the flush invert type and the underside sealing face shall consist
of high resilient material securely bonded into a channel or similar section forming the invert
of the frame into which the bottom of the door shall effect a watertight seal.
The door of plastic penstocks shall be made from sheets of approved rigid cellular polymer
sandwiched between sheets of approved rigid compressed composite plastics. The linear
PVC or GRP materials shall be used. The doors thus formed shall have sufficient strength to
withstand the required working pressure without deflection or distortion that would affect the
operation of water-tightness of the penstock. Totally enclosed steel matrix shall be
incorporated in the door construction to ensure adequate rigidity.
The sealing faces and side guides shall be EPDM having a high resistance to sliding wear
and shall be to the approval of the Engineer. The sealing strips shall be securely fixed to the
inner faces of the frames and adjusting devices or other means of ensuring freedom of
movement without loss of seal shall be provided. The adjusting devices and fasteners shall
be of stainless steel conforming to BS 970 Part 1 Grade SS 316 S31.
QCS 2014

Part
Page 15
Spindle operating nuts shall be of gunmetal or manufactured from an approved ultra-high

molecular weight polyethylene material. The operating nuts for the spindle retaining blocks
shall be fixed in a visible position inside a separate gate lifting bracket bolted on to the top of
the door with stainless steel fasteners. The operating nut or spindle retaining block shall not
be contained within the door.
All plastic materials shall be non-toxic ultraviolet stabilised and shall have fire resistance as
specified in BS 475 and be to Class P and Class I of Part 5 and 7 thereof respectively.
All other requirements shall be as specified in Clause 5.1.3 Clause 5.11.2 herein.
Plastic penstocks shall only be used when indicated in the Contract Documents and
5.11.5
Stoplogs
Stoplogs shall be fabricated from reinforced composite plastic material which is non-toxic and
stabilised against ultraviolet light. Asbestos shall not be used in the manufacture of the stoplogs.
Plastic logs of 300 mm and 400 mm depths shall be furnished to provide closure of stoplog
openings. Full depth gates shall not be acceptable.
Each log shall be provided with a stainless steel eye bolt at each end which fits into a recess
in the under surface of the next log. Two lifting poles fitted with hooked ends for engaging
the eye bolts shall be furnished for each facility and shall be mounted locally on a handrail
supported pole rack. Poles and racks shall be constructed of aluminium and bolts of
stainless steel.
Stoplogs shall provide a high degree of sealing with a leakage rate of less than 0.04 l/sqm of
seating perimeter. Stoplog frame shall be for insertion in a wall and invert recess.
Anchor bolts shall be stainless steel.
Frames shall be manufactured from stainless steel BS 970 or BS 1449 Grade 316. All frames
shall be suitably reinforced and include corner gussets where necessary. All fasteners shall
be stainless steel.
Frames shall be fitted with seals which are molecularly incompatible with the closure
material. Where necessary, the seals shall be fixed with corrosion resistant retaining strips
and stainless steel fasteners.
5.12
OPERATING DEVICES
5.12.1
Lifts
Lifts shall be designed to operate the gate of the specified head with a maximum of 25 kg
force applied to the device. The lift shall be a liftnut for tee key operation or gear/handwheel
lift as designated.
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Liftnut
The liftnut shall be hexagonal, gunmetal and internally threaded to fit the stem. The housing
shall be cast iron and suitable for mounting in the head angle, gate frame extension or wall
mounted bracket. The liftnut shall be flanged to maintain position in the housing and to
accommodate the thrust developed during gate operation. Each lift shall be furnished with a
bronze stop nut. The nut lift shall accept a T-bar operator or handwheel. Suitable T-bar
operators shall be furnished.
5.12.3
Gear Lift
The gear lift mechanism if required shall be of the crank operated type with either a single or
double gear ratio, depending on the lift load. Each type shall have a cast bronze liftnut
threaded to fit the operating stem. Ball thrust bearings shall be provided above and below
the flange on the liftnut to take the load developed in opening and closing the gate. Gears
shall be of cast iron or steel, accurately machined with cut teeth, and smooth running with
suitable shafts running in gunmetal sleeve bearings or roller bearings of ample size. All
geared lifts shall be suitable for auxiliary motor operation. All gears and bearings shall be
enclosed in a cast iron housing. Fittings shall be provided so that all gears and bearings can
be periodically lubricated. The removable cast iron crank shall be fitted with a rotating
handle. The lift mechanism shall be supplied with a cast iron pedestal, machined and drilled
to receive the gear housing and suitable for bolting to the thrust tubes, operating floor or wall
bracket. The maximum crank radius shall be 400 mm. The direction of rotation to open the
gate shall be indicated on the lift mechanism. A cast iron stop nut shall be provided for each
lift. All exposed cast iron shall be coated according to Part 8 of this section.
5.12.4
Handwheel
The housing shall be cast iron and shall be suitable for mounting on the head angle or pipe
frame extension. The lift nut shall be flanged to maintain position in the housing and to
accommodate maximum thrust developed during gate or valve operation. The lift nut shall
be bronze and internally threaded to mate the stem. Each lift shall be furnished with a bronze
stop nut. The steel or cast iron handwheel shall have a solid rim and shall be smooth and
free of sharp edges and an arrow and the work "OPEN" shall be cast in the rim or attached to
the handwheel. Handwheels generally shall be positioned on a headstock 750 mm above
operating level.
5.12.5
Stem Covers
Stem covers shall be provided on all valves or gates with rising stems. Stem covers shall be
clear butyrate with Mylar decals indicating open and close gate position and of sufficient
length to totally enclose the stem when the gate is fully open. The top shall be closed and
the bottom shall screw into a cast iron housing mounted on top of the gate operator. The
inside of this housing shall be bored to the exact diameter of the stem cover to assure
accurate alignment of the cover.
5.12.6
Actuators
Actuators are specified in Section 21.
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5.12.2
QCS 2014

Part
Page 17
FLAP VALVES
5.13.1
Flap Valves (General Purpose)
The seat shall be one-piece cast iron conforming to BS EN 1561 Grade 250 with a raised
section around the perimeter of the waterway opening to provide the seat. The raised
section shall provide a seating plane diverging, top to bottom, from the plane of the mounting
flange to assist in positive closure of the cover. The seat shall be shaped to provide two
bosses extending above the top of the waterway opening for mounting the top pivot lugs.
Pivot lug bosses shall be drilled and tapped for mounting studs. The flap shall be designed
to be either butted to the face of a wall or to the outlet flange of a discharge pipe. The flaps
shall be operable at a head of 10 m.
The cover shall be one-piece cast iron conforming to BS EN 1561 Grade 250 with
necessary reinforcing ribs, with a lifting eye for manual operation, and with bosses to provide
a pivot point connection with the links. Bosses shall be designed to place the hinge bolts in
double shear when gate is assembled.
Each pivot lug shall be one-piece cast iron. Lugs shall have double bosses to place the top
hinge bolts in double shear when they are assembled through the links. The lugs shall be
adjustable in the horizontal plane without removal of the cover from the gate links. The
adjustment shall allow the top pivots to be moved toward the gate seat for reduced sensitivity
of the cover, or moved away from the gate seat to provide opening with a minimum
differential head. Two studs shall be used to connect each pivot to the gate seat.
The links connecting the cover and pivot lugs shall be one-piece heavy duty cast iron. Each
link shall be provided with bronze bushings at each pivot point. The bottom of the links shall
be provided with an adjusting screw to properly align seating faces on the cover with respect
to the seat. The links shall be designed to limit the double hinge action, preventing the cover
from rotating sufficiently to become wedged in the open position.
Cast iron work shall be coated before delivery with a bituminous compound as specified in
Clause 8.5.16.2 of QCS.
5.13.2
Flap Valves for Sea Water Applications
Flap valves frames including fixings for sea water and other aggressive applications shall be
of stainless steel conforming to BS 970 Part 1. Sealing faces shall be phosphor bronze
conforming to BS 2874.
Flap valves manufactured from corrosion resistant materials will also be acceptable for
general purpose applications.
Flap valves above 1500 mm square shall be of the double door type.
Doors shall be of reinforced natural rubber compound of sufficient flexibility to maintain an

efficient seal under minimal seating head conditions.
Door hinges shall be continuous across the full width of the door and manufactured from
homogeneous polypropylenes, polyurethane or similar non-ageing material.
5.14
MISCELLANEOUS VALVES AND APPURTENANCES
5.14.1
Ball Float Valves
Ball float valves shall comply with BS 1212. Flanges shall conform to BS EN 1092.
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5.13
QCS 2014

Part
Page 18
PVC ball valves 50 mm and smaller shall be of the true union socket weld type, and valves
75 mm and larger shall be of the flanged type. Valves shall be rated at 1000 kPa at 50 C
unless otherwise specified.
Metal ball valves 60 mm and larger shall have brass balls with carbon steel bodies, and
valves 50 mm and smaller shall have brass bodies. Valves shall have a Teflon seal and
seat. Valves shall be rated at 1000 kPa at 100 C unless otherwise specified.
Stainless steel ball valves shall be flanged with stainless steel body, ball and stem. Valves
shall be rated at 1000 kPa at 100 C unless otherwise specified.
5.14.2
Globe Valves
Globe valves shall be low-zinc bronze body type with tapered discs permitting close
regulation of flow. Valves 75 mm and larger shall be flanged, Class 125 conforming to ANSI
B16.1 in drilling and dimensions. Valves 60 mm and smaller shall be 1,000 kPa, and shall
have screwed joints.
5.14.3
Quick Coupling Valves
Quick coupling valves shall be of robust construction consisting of a cast bronze body and
dust cap with machined bronze valve cage and seat. The valve washer shall be neoprene
rubber with stainless steel packing washer and fixing screw. The stem seal ring shall be
neoprene rubber.
Double lug keys with swivel hose ells and standard 20 mm diameter hose connectors of the
same manufacturer shall be supplied to the Employers stores at the rate of one key for every
five hose points. Each part shall be cast or machined bronze with neoprene rubber seals.
The cost of supplying these keys complete shall be included in the rates for valves.
5.14.4
Emitters
Bubble emitters shall be brass with 12 mm BSP thread designed for adjustable flows.
5.15
FITTINGS
All flanges, fittings, coupling, valves, and appurtenances shall be rated for the pipeline
pressure, except as noted on the Drawings.
5.15.2
Flanges, Gaskets, and Bolts
Flanges shall be PN 16 rating or as otherwise designated. Flange gaskets shall be ring type.
Thickness shall be 1.5 mm for pipes 250 mm and smaller, and 3 mm for larger pipes.
Flange assembly bolts shall be standard hexagon head machine bolts with heavy hot
pressed, hexagon nuts and shall conform to BS EN 1092. Bolt length shall be such that after
the joints are made up, the bolts shall protrude through the nut, but not more than 12 mm. All
anchor bolts shall be stainless steel.
5.16
MECHANICAL COUPLINGS
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Part
Page 19
Grooved End Couplings
Couplings shall engage and lock the grooved or shouldered pipe ends allowing some degree
of contraction, expansion, and angular deflections. Coupling housing shall be of ductile iron
or malleable iron and shall consist of two or more segments held securely together by at least
two steel bolts. Sealing gasket shall be of such design that internal pressure in the pipe
increases the tightness of the seal and shall be of materials suitable for the intended service.
The coupling shall have a rated working pressure not less than the pressure rating of the
pipe.
Corrosion protection shall be applied in accordance with the requirements specified in Clause
5.16.2 herein.
5.16.2
Flexible Couplings
Flexible (sleeve) couplings of the full sleeve type, split sleeve type, or flanged adapter type
shall provide the requisite pipe flexibility without jeopardising pipe joint integrity due to
hydraulic thrust, and shall have the same pressure rating as the pipe. Couplings shall have
all metal bearing surfaces and shall be provided with galvanised steel bolts and nuts.
Flexible couplings shall be restrained unless the Engineer has given his approval to omit this
feature for specific cases. Specific requirements for each type are as follows:
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5.16.1
full sleeve type couplings shall be properly gasketed and shall be of a diameter to
fit the pipe. Each coupling shall consist of a steel middle ring, two steel followers, two
gaskets, and the necessary steel bolts and nuts to compress the gaskets. Stepped
couplings of this general type shall be used when stepping from one pipe material to
another of the same nominal diameter
(b)
split sleeve type couplings shall consist of one gasket, two housing clamps, and two
bolts and nuts to obtain the flexibility for connecting the piping. Steel shoulders shall
be provided and welded to the pipe ends to accommodate the couplings
(c)
flexible flanged coupling adapters shall be of the sleeve type, consisting of steel
middle ring, steel followers, gaskets, and steel bolts and nuts to compress the
gaskets. The couplings shall contain anchor studs of strength adequate to hold the
pipes together under a pull equal to the longitudinal strength of the pipes.
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(a)
Couplings to be installed underground shall, in addition to any factory applied paint coating,
site have one of the following corrosion protection systems:
hot pour moulding with enamel complying with BS 4164 type IV Grade 105/8, to give
a minimum of 20 mm thickness around all parts of the fittings
(a)
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(b)
laminate tape coating after priming and profiling with mastic
(c)
paint coating with high build coal tar mastic to give a minimum dry film thickness of
500 m in at least three coats.
Step couplings used in force mains with flexible pipes shall be provided with a restraint
system where necessary to prevent longitudinal movement between the flexible pipe and the
coupling. The restraint system shall be as shown on the Drawings or approved by the
Engineer.
No joints shall be coated until hydrostatic testing of the joints is successfully completed.
5.17
FLOW CONTROL
5.17.1
Vortex Flow Control Devices
Where indicated on the drawings or elsewhere in the Contract Documents, Vortex Flow
Control Devices shall be manufactured from corrosion resistant materials as follows:
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Page 20
(a)
stainless steel to BS 970 Part 1, Grade 316 S31.
(b)
the device shall be fixed using nuts and bolts of Grade 316 S31 stainless steel.
INSTALLATION AND TESTING
5.18.1
Installation
The Contractor shall obtain the necessary installation drawings from the manufacturer and
shall store, transport, handle and install the valves, penstocks, stoplogs, and appurtenances
in strict accord with the manufacturers drawings and recommendations. Care shall be taken
during mounting of gates and logs to avoid warping the frames and to maintain clearance
between seating faces.
All ferrous surfaces shall be finish coated in accordance with Part 8 of this Section.
5.18.2
Testing
Factory Testing. Penstocks shall be factory-tested for a seat clearance check in accordance
with the applicable provisions of AWWA C501. Penstocks that do not conform with the
testing requirements of AWWA C501 shall be made satisfactory or rejected and replaced.
Before shipment of the gates, the Contractor shall submit certified copies of test reports to
the Engineer for review.
Site Testing. Following completion of the installation of the penstock, the Contractor shall
furnish the services of the authorised representative of the manufacturer to adjust and
operate the gates of directed by the Engineer. Adjustment shall be made so that the gates
operate smoothly, seat properly, and are installed to the tolerances recommended by the
manufacturer. After the equipment has been tested and adjusted, the Contractor shall
perform a field leakage test on each gate in the presence of the Engineer in accordance with
the applicable provisions of AWWA C501. Both seating and unseating heads shall be tested
as applicable. If any of the equipment fails to meet the above test, it shall be modified as
required and retested to conform with specifications, until the maximum allowable leakage,
per AWWA C501, is not exceeded. Modifications or adjustments required to meet the test
shall not impair the smooth operation of the equipment.
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5.18
END OF PART
QCS 2014
Section 08: Drainage works

Part
06: Miscellaneous Metal Works
Page 1
MISCELLANEOUS METAL WORKS ............................................................. 2
6.1
GENERAL ...................................................................................................... 2
6.1.1
6.1.2
6.1.3
6.1.4
6.1.5
Scope
Reference
Submittals
Quality Assurance
6.2
MATERIALS .................................................................................................. 4
6.2.1
6.2.2
6.2.3
6.2.4
6.2.5
6.2.6
6.2.7
Steel
Stainless Steel
Aluminium
Iron
Welded Anchor Studs
U Channel Concrete Inserts
Concrete Anchors
6.3
COATINGS .................................................................................................... 5
6.3.1
6.3.2
6.3.3
Galvanising
Anodising
Factory Painting
6.4
FABRICATION AND ERECTION ................................................................... 7
6.4.1
6.4.2
6.4.3
6.4.4
6.4.5
6.4.6
6.4.7
General
Staircases
Ladders
Step Irons
Handrails and Railings
Chequer Plate
Gratings and Open Mesh Flooring
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2
2
3
3
4
4
4
4
4
4
5
5
6
6
7
8
9
10
10
11
12
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Page 2
MISCELLANEOUS METAL WORKS
6.1
GENERAL
6.1.1
Scope
This part includes the specifications for the design, fabrication and erection of ladders,
staircase assemblies, open mesh flooring, chequer plate, gratings, handrailing, step irons,
supports, anchors, and other appurtenances.
Related Sections and Parts are as follows
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This Section
Part 1, General
Part 3, Pipes and Fittings Materials
Part 7, Miscellaneous GRP Works
Part 8, Protective Coatings and Painting
Section 1, General
Section 16, Structural Metalwork
Section 17, Metalwork.
Reference
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6.1.2
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BS 970........... Wrought steels for mechanical and allied engineering purposes

BS 1470......... Wrought aluminium and aluminium alloys for general engineering purposes;
plate, sheet and strips
Drawn Tube
forging stock
BS 1474......... Wrought aluminium and aluminium alloys for general engineering purposes bars, extruded round tube and sections
BS 4211......... Specifications for permanent fixed ladders
BS 4592......... Industrial type metal flooring, walkways and stair treads.
BS 5395......... Stairs, ladders and walkways
BS 5493......... Code of practice for protective coating of iron and steel structures against
corrosion
BS EN 1561... Founding Gray Cast Iron
BS EN 1563... Found spheroidal graphite cast iron
BS EN 1993... EURO code 3, Design of steel structures
BS EN 13101. Manhole steps
BS EN ISO 2560 Welding consumables - Covered electrodes for manual metal arc welding
of non-alloy and fine grained steels
EN 124 .......... Gully tops and manhole tops for vehicular and pedestrian areas Design
requirements, type testing, marking, quality control
ISO 9000 ....... Quality System
6.1.3
Submittals
The Contractor shall submit complete data as described below.
QCS 2014
Page 3
Product Data:
(a)
the Contractor shall provide manufacturers specifications, load tables, dimension

diagrams, anchor details and installation instructions for products to be used in the
manufacture of metal fabrications.
Design Calculations and Shop Drawings:

(a)
the Contractor shall provide design calculations and shop drawings for the
fabrication and erection of all assemblies of metal fabrication work which are not
completely shown by manufacturers data sheets, including anchorage and accessory
items. Plans and elevations at metric scales not less than 1:10 scale, and details of
sections and connections at not less than 1:5 scale shall be included
(b)
detailed drawings shall show material type, thickness grade/class dimensions, and
construction scheme. The submittal shall include catalogue pages, erection
description, manufacturers data/instructions and templates.
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Where structural steelwork is to be provided the Contractor shall submit duplicate copies of
dimensioned shop drawings for approval by the Engineers Representative. If drawings are
not approved, one copy shall be returned to the Contractor marked up indicating the
alterations required. Upon final approval one copy of the drawing, stamped Approved by the
Engineers Representative, shall be returned to the Contractor. Four further copies of the
approved drawings shall then be submitted to the Engineers Representative. No shop
fabrication may commence before receipt of the relevant shop drawings.
The shop drawings shall become record drawings on the completion of steelwork erection
and the original drawing and one ISO size A2 (495 & 420) negative of each shall be supplied
to the Engineer. If there were any changes to the steelwork during erection these should be
supplied together with the original and the size A2 signed negative.
WPS and PQR
6.1.4
Quality Assurance
Fabricated metal products and materials shall be provided by experienced and approved
manufacturers and fabricators as designated in the Contract document to the written
Where welding/brazing is required the Contractor shall:
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(a)
submit for approval welding procedure specification (WPS) and procedure qualification
record (PQR) in conformance with AWS D1.1(steel structures), ASME IX (piping and
pressure vessels) and BS EN 288 part 4 (Aluminium) and BS EN ISO 1101-8 (Iron) as
appropriate;
(b)
submit for approval welder qualifications which shall be in conformance with the above
codes and or BS EN ISO 9606-2 (aluminium alloys),
(c)
assign a CSWIP 3.1 or AWS QC qualified welding inspector, who shall be subject to
the Engineers approval, to witness all welding.
6.1.5
Metal works shall be stored off the ground, protected from moisture, until ready for use or
installation.
Metal works shall be stored and handled in such a manner to protect finishes.
Metal works shall be stored and handled to prevent bending under its own weight and
superimposed loads.
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6.2
MATERIALS
6.2.1
Steel
Steel rolled shapes, plates and bars shall conform to the requirements of Section 16 unless
otherwise specified in this Part.
Bolts and nuts shall be of standard commercial quality steel conforming to Section 16, and
shall be galvanised when used with galvanised work.
AWS D 1.1 - Steel Structure Welding Code
ASME VIII Div. 1 - Pressure Vessel welding
ASME IX - Boiler & Pressure Vessel Code - Section IX Welding & Brazing
ASME B31.3 - Process Pipe
Stainless Steel
Stainless steel shall conform to BS 970 and shall be Grade 316 S31 unless otherwise
designated.
Stainless steel bolts, hexagonal cap screws, and studs shall be BS 970 Grade 316 S31
All stainless steel to be welded shall be BS 970 Grade 316L.
6.2.3
Aluminium
All aluminium plate, pipe and structural shapes shall conform to BS EN 12020, and BS 1472
with BS EN 485 Grades 6036-T6 or 6082-T6 or such other chemically resistant alloy that the
manufacturer can demonstrate to be suitable for use in aggressive atmospheres likely to be
encountered in sewage pumping stations. All aluminium items embedded in concrete shall
have two coats of bituminous paint. Where aluminium surfaces are in contact with concrete
surfaces or with dissimilar metals, PVC-U gaskets shall be used to isolate the aluminium.
6.2.4
Iron
Ductile Iron. Ductile iron shall be in accordance with BS EN 1563.
Grey Cast Iron. Cast iron shall be in accordance with BS EN 1561.
Malleable Iron. Malleable iron shall be in accordance with BS EN 13101.
6.2.5
Welded Anchor Studs
Headed anchor studs (HAS) or threaded anchor studs (TAS), as indicated on the Contract
Drawings:
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6.2.2
(a)
Carbon Steel: BS EN ISO 898, either semi-killed or killed aluminium or silicon

dioxidation, unless indicated otherwise.
(b)
Stainless Steel: BS EN ISO 3506, Grade SS 316, Condition CW, where indicated.
6.2.6
U Channel Concrete Inserts
Rolled: BS EN ISO 9445 Type 316 stainless steel, 2.7 mm thickness, 40 mm width by 35
millimetres depth, with stainless steel anchors at 250 mm maximum spacing, Styrofoam
fillers, and end cap.
QCS 2014

Part
Page 5
Nut and Bolt Hardware: Type 316 stainless steel, 16 mm minimum diameter, unless
indicated otherwise. Manufacturers standard to match insert.
6.2.7
Concrete Anchors
For concrete anchor spacing less than 12 anchor diameters and edge distances less than
six anchor diameters, make reduction in allowable pullout and shear values.
Allow for thermal movement resulting from the maximum range in ambient temperature in
design, fabrication, and installation of handrails to prevent buckling, opening up of joints, over
stressing of components, connections and other detrimental effects. Base design calculation
on actual surface temperatures of materials due to both solar heat gain and night time sky
heat loss. Temperature change is difference between high or low temperature and
installation temperature.
Use approved service load allowable values for size, length, embedment, spacing, and edge
distance to match required loads shown in calculations.
6.3
COATINGS
6.3.1
Galvanising
Galvanising shall be executed after all fabrication has been completed and shall be carried
out in accordance with BS 5493:1977. The articles shall be pickled in dilute sulphuric or
hydrochloric acid followed by rinsing in water and pickling in phosphoric acid. They shall be
thoroughly washed, stoved and dipped in molten zinc and brushed so that the whole of the
metal shall be evenly covered and the coating thickness after dipping shall not be less than
the BS 5493 System Reference Number recommended for the particular conditions and in
any case not less than 85 microns.
Unless otherwise specified, all ferrous metals shall be galvanised in conformance with
reference standards according to the nature of the work. Factory fabrication shall be
complete before galvanising. Galvanised coatings that have been marred or damaged
during erection or fabrication shall be repaired using designated touch-up material.
Surfaces of exterior units which have been galvanised after fabrication and are intended for
bolted or screwed field connections shall not be welded, cut or abraded.
Galvanised coatings marred or damaged during erection or fabrication shall be repaired

conforming to BS 5493 and in accordance with the coating manufacturer's instructions.
Unpainted galvanized surfaces shall not be used in an immersed condition within three
months of hot dip galvanizing and/or before an adequate protective patina has formed.
All mild steel parts unless otherwise stated, are to be heavily galvanised by the "hot dip"
process, or other methods as agreed by the Engineer, after fabrication. Where large units are
concerned, an approved metal spraying process to BS specifications may be used subject to
the approval of the Engineer. With the exception of the metal flooring to be supplied
unpainted, the whole of the galvanised mild steel parts and metal sprayed parts are to be
treated with a zinc phosphate primer before leaving the place of manufacture. (No lead oxide
or iron may be used in priming the galvanised parts.) Painting shall be in accordance with
the Schedule A [Work Requirements], Part 5 [Warranted Project Data], 5.1 [Drawings] or as
selected by the Engineer.
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All steel and ironwork of whatever kind to be galvanised shall be thoroughly de-scaled by shot
blasting to clear metal to BS 4232 second quality, to clean the surfaces of all dirt, weld
spelter, grease, slag, oil-paint or other deleterious materials, and immediately after is to be
galvanised by a hot dip process, followed by quenching in water. The molten zinc in the
galvanising bath shall contain not less than 98.5 percent of zinc by weight. All articles are to
be immersed in the bath only for a time sufficient for them to attain the temperature of the
bath and they are to be withdrawn at such a speed that a coating of 90 microns thickness is
achieved, or such other practicable maximum thickness for the article defined in BS 729, Part
"Hot dip galvanised coating on iron and steel." The galvanising is to be done in all cases after
machine work, chipping, trimming, filling, fitting, drilling or bending is completed. Every article
is to be covered evenly on all sides.
The zinc coating shall consist of a uniform layer of zinc free from abrasions, creeks, blisters,
chemical spots or other imperfections, and so applied that it will adhere firmly to the surface
of the steel.
The galvanising shall be applied in such a manner that the spelter will not peel off. The
coating of the finished product shall be even, smooth and uniform throughout. Machine work,
dye work, cutting, punching, bending, welding, drilling, thread cutting and other fabrication
shall all be done, as far as practicable, before galvanising.
10
The galvanising shall have no adverse effect on the mechanical properties of the articles so
treated. Variations in dimensional properties shall be kept to a minimum.
11
The work of surface preparation and galvanising shall be carried out, for any one article, on
the same working day.
12
Galvanising on steelwork where required is to be carried out after fabrication and assembly.
13
Light gauge metal work is to be galvanised by the hot dip process as specified in BS 3083 or
BS 2989.
14
Contact between galvanised steel members and aluminium surface is to be prevented by

means of a layer of "Densochrome" or similar approved tape.
15
All necessary care and precautions are to be taken in shipping and transporting the
galvanised or metal sprayed units to avoid damage to the coating. Where damage proves to
be extensive in the opinion of the Engineer, the whole unit shall be recoated.
16
Where galvanised parts are to be bolted or riveted together, the joint shall be made with an
approved barium or zinc chromate paste.
17
Where the metal parts are too big to be hot dip galvanised, approval of the Engineer shall be
sought for the steel parts to be shot blasted to BS 4232 second quality and then immediately
zinc sprayed to a minimum thickness of 0.1 mm in accordance with BS 2569 Part 1.
6.3.2
Anodising
All aluminium members shall be anodised after fabrication in accordance with Sections 16
and 17.
All aluminium and aluminium alloy materials shall be anodised after fabrication to a thickness
of grade AA 20 and subsequently sealed against corrosion. After anodising, the aluminium
surfaces shall not be painted but left self-finish. Anodising of aluminium shall comply with the
6.3.3
Factory Painting
All protective coatings and painting shall be carried out as specified in Part 8 of this Section.
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Before leaving the factory, ferrous metals not designated to be galvanised shall be given one
coat of primer as specified in Clause 8.2 of Part 8. Portions to be embedded in concrete or
masonry shall not be painted.
6.4
FABRICATION AND ERECTION
6.4.1
General
Stairs, ladders and walkways provided shall conform to BS 4211 and BS 5395.
Fabrication and erection shall be performed by approved specialist subcontractors

experienced in work of equivalent magnitude. Shop drawings shall be prepared by the
Contractor based on the details shown on the Drawings. The Contractor shall
verify all measurements and shall take all site measurements necessary before
fabrication
(b)
be responsible for correctness of detailing, fabrication, and for the correct fitting of
structural members
(c)
not substitute sections
(d)
not modify connections.
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Members and connections, for any part of the structure, not shown on the Drawings shall be
the Contractors responsibility.
The Contractor shall use materials of the size and thickness shown on the Drawings, or if not
shown, of the required size and thickness to produce adequate strength and durability in the
finished product for the intended use.
All work at the factory shall be preassembled to the greatest extent possible to minimise field
splicing and assembly of units at the Site. Units shall be disassembled only to the extent
necessary to comply with transportation limitations and shall be clearly marked for
reassembly and proper installation. Ladders shall be supplied as preassembled units.
For the manufacture of metal fabrications which will be exposed to view, only materials which
are smooth and free of surface blemishes including pitting, seam marks, roller marks, rolled
trade names and roughness shall be used. Any such blemishes shall be removed by
grinding, or by welding and grinding, before cleaning, treating and application of finishes
including anodising and galvanising. Smoothness shall be required all round for handrails
and ladders.
Exposed work shall be formed true to line and level with accurate angles and surfaces and
straight sharp edges. Exposed edges shall be rounded to a radius of approximately 1 mm
Exposed connections with hairline joints which are flush and smooth shall be formed using
concealed fasteners wherever possible. Exposed fasteners shall be flat-head (countersunk)
screws or bolts. Bolt and screw holes shall be predrilled for attachment of metal fabrication
work and for the attachment of adjacent materials.
Welding shall be carried out by experienced tradesmen, and made with designated
electrodes or submerged arc conforming to BS EN ISO 2560. The following procedures shall
be carried out:
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(a)
before fabrication, all steel shall be thoroughly wire brushed, clean of all scale and
rust, and thoroughly straightened by approved methods that will not injure the
materials being worked on
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welding shall be continuous along the entire line of contact except where tack or
intermittent welding is permitted
(c)
where exposed, welds shall be cleaned of slag and ground smooth.
(d)
All stainless steel welding shall be gas tungsten arc welding (GTAW)or shield metal
arc welding (SMAW) processes using stainless steel type 316L consumables
conforming to the requirements of the under-mentioned codes / AWS A5.9 (GTAW) or
AWS A5.4 (SMAW).
(e)
All aluminium welding shall be undertaken using GTAW process using consumables
under 5356 classification of AWS A5.10.
(f)
Welding to be undertaken in accordance with the applicable code as follows:

General guidance for arc welding
BS EN ISO 1101 1
Arc welding of ferritic steels
BS EN ISO 1101 2
Arc welding of stainless steels
BS EN ISO 1101 3
Arc welding of aluminium
BS EN ISO 1101-4
Welding of cast iron
BS EN ISO 1101 -8
Steel Structures
AWS D1.1
Pressure vessels
ASME VIII Div 1
Piping
ASME B31.3
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Fixing shall be carried out as follows:
the Contractor shall fabricate and install anchoring devices with spacing as required
to provide adequate support for the intended use of the work
(b)
fastenings to wooden plugs will not be permitted
(c)
All nuts and bolts shall be threaded in accordance with BS 3643 Isometric series
threads part 2 Limits and tolerances for coarse pitch threads and fitted with 3mm
thick washers beneath bolt and nut.
(d)
Regardless of the materials being fixed all bolts, nuts, washers and anchor plates shall
be of stainless steel Grade 316 S31 to BS 970 and shall remain unpainted. PTFE
washers shall be fitted beneath stainless steel washers for both bolthead and nut.
(e)
Drilled anchor fixings for use on concrete structure shall be of a type approved by the
Engineers Representative. The positions of all drilled anchors shall be approved by
the Engineers Representative and any Contractor proposing to use such fixings shall
be deemed to have undertaken to supply, mark off, drill and fit.
as
(a)
All exposed bolt heads and nuts shall be hexagonal and the length of all bolts shall be
such that when fitted with a nut and tightened down, the threaded portion shall fill the
nut and not protrude from the face thereof by more then half the diameter of the bolt.
(f)
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(b)
(g)
All jointing material shall be provided by the Contractor.
10
Dissimilar materials shall be separated by gaskets.
6.4.2
Staircases
Metal staircases shall be constructed to the overall dimensions detailed on the Drawings and
shall be prefabricated in marine quality mill finished aluminium alloy or galvanised steel.
Staircases shall be designed to span longitudinally from wall to wall and shall be designed to
carry a live load of 5 kPa. Stringers shall be of adequate size to support dead and live loads.
Treads shall be of non-slip surface and shall have adequate stiffness to carry a point load of
1.8 kN at the centre.
Landings shall not exceed 3 m.
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Kicker plates shall extend to a minimum of 100 mm above flooring and open sides. The
risers shall not exceed 200 mm.
Chequer plates shall be as specified in Clause 6.4.6 wherein.
Unless otherwise shown on the Contract Drawings, furnish flush type abrasive nosing on
stairs.
Nosing Components:
Homogeneous epoxy abrasive, with minimum 50 percent aluminium oxide content,
formed and cured upon an extruded aluminium base.
(b)
Epoxy abrasive shall extend over and form curved front edge of nosing.
(c)
Base of Nosing: Extruded aluminium alloy, 6063-T5, heat-treated complying with BS

EN 12020.
(d)
Anchoring System: Double-set anchors consisting of two rows of integrally extruded

anchors.
(e)
Size: 75 mm wide by 6 mm to 10 mm thick by length as shown.
(f)
Colour: Selected by Engineer from manufacturers standard colour range.
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(a)
Ladders
Galvanised steel ladders shall be to the form and dimensions shown on the Drawings, and as
specified below:
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6.4.3
ladders shall comply with BS 5395, Part 3.
(b)
ladders greater than 6000 m shall be provided with an intermediate platform
(c)
stringers shall be solid flat sections of minimum size 65 mm by 13 mm where extended

stringers are provided they shall be radiused over the top for walk-through access and
shall be not less than 600mm apart.
(d)
fixing brackets shall be at maximum 2500 mm centres
(e)
rungs shall be
solid sections of minimum 20 mm diameter
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at 300 mm centres
(iii)
minimum 380 mm wide between stringers
(iv)
minimum 200 mm from adjacent walls
(v)
capable of withstanding a point load of 5000 N applied at the centre of the rung
(ii)
and close to one end

(f)
when supported horizontally over a span of 1.0 m with the climbing face uppermost
and with a load of 1000 N applied at the centre of the span, the ladder shall not
deflect more than 15 mm at the point of application of the load and shall show no
permanent deflection after removal of the load. Each ladder fixing shall be capable of
withstanding shear and pull-out loads of 5000 N
(g)
safety cages shall be provided where indicated and where the distance between
landings exceeds 3500 mm. These shall be constructed of three vertical flat sections,
minimum size 50 mm by 8 mm supported by flat hoops with a diameter of 750 mm.
The hoops shall be at a maximum of 900 mm centres and the first hoop shall be
2400 mm above lowest platform level. No single hoop shall be used
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all welds shall be ground flush and smoothed and ladders hot-dip galvanised after
fabrication. Connections to concrete or masonry walls shall be secure with accurately
positioned stainless steel anchor bolts. Ladders shall be mounted to produce a
finished appearance that is plumb, straight and true to dimensions.
Stainless steel ladders shall generally be of dimensions as designated for galvanised steel
ladders except that all materials shall be of stainless steel.
Aluminium ladders shall be to the form and specified dimensions shown on the Drawings,
and as specified below:
the spacing of stringers, rungs and safety hoops shall be as galvanised steel ladders.
(b)
material shall be aluminium alloy to BS EN 573 grade EN AW-6082.
(c)
ladders shall be of all welded construction. Stringers shall be drilled to receive rungs
which shall be welded into position from the outside of the stringers. Welds shall not
be proud of the outside of the stringers
(d)
rungs shall be of substantial section serrated tube to enable sure hand and foot holds
(e)
fixings shall be of stainless steel. Gaskets shall be provided to isolate aluminium alloy
from other materials
(f)
all other requirements shall be as specified for galvanised steel ladders
(g)
ladders shall be obtained from approved suppliers.
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(a)
Step Irons
Step ironing rising main valve chambers shall be galvanised malleable cast iron, shall
conform to BS EN 13101, and shall be of general purpose type. The tail length shall be 230
mm unless the well into which the tail is to be cast is less than 290 mm thick.
Step irons in house connection chambers shall comply with BS EN 13101 and be the
general-purpose type manufactured of galvanised malleable cast iron. The tail length shall be
115mm. The step irons shall be epoxy coated with a material compatible with a galvanised
surface and finished with a two part, acrylic polyurethane topcoat as detailed below and
applied in accordance with the manufacturers instructions.
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6.4.4
50 DFT
Epoxy Coating
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50 DFT
Two Part Acrylic Finish
Handrails and Railings
Handrailing shall be obtained from an approved experienced manufacturer and shall be

GRP, circular hollow section, marine quality mill finished aluminium alloy (BS EN 573 grade
EN AW-6082) in pre-fabricated lengths complete with fixings or shall be stainless steel
circular hollow section (BS970 Grade316S31). Site welding will not be accepted. All welded
parts to be completed during manufacturing fabrication with approved WPS by Engineer in
accordance with Clause 6.1.4 of this Part. Handrails and railings fabricated from mild steel,
stainless steel, or aluminium as shown on the Drawings and meet the following requirements:
6.4.5
(a)
brackets, bolts and

complete installation
fastening
devices
shall
be
provided
as
required
for
(b)
handrailing and railings shall be provided with smooth bends and welded joints
ground smooth and flush
(c)
installed railings and supports shall withstand a 1100 N load applied at any point,
downward or horizontally or 740 N/m along the top rail, whichever is greater
(d)
the deflection of both rails and standards shall to exceed 2 % of the span/height under
a horizontal load of 360 N/m on the top rail.
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Galvanised steel handrailing shall be provided in accordance with the following requirements:
(a)
stanchions shall have a nominal bore of 40 mm and a minimum wall thickness of

3.25 mm
(b)
stanchions on steel stringers shall have base plates or angles welded to bottom of
pipe and bolted to stringer
(c)
rails shall have a nominal bore of 32 mm and minimum wall thickness of 4 mm
(d)
horizontal handrails shall be 1,100 mm high with an intermediate rail 550 mm high
(e)
railings shall be
(i)
mounted so as to produce a finished appearance that is plumb, straight, and

true to dimension, free from kinks, twists, and abrasions
curves, where indicated on the Drawings or necessary, shall be bent to a radius
(ii)
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of not less than 100 mm. Where shown on the Drawings, or directed by the
Engineer, removable sections shall be provided
toe plates shall be provided where railings are not mounted on stanchions
(g)
welds shall be ground flush and smooth and handrailing hot-dip galvanised after
fabrication
(h)
sleeves shall be provided for setting by other trades where embedded
(i)
connections to concrete or masonry wall surfaces shall be secure with accurately

positioned stainless steel anchor bolts, or with cinch anchors and bolts
(j)
where expanding anchor bolts are used on concrete surfaces, the bases shall be
bedded on a mastic sealant as approved by the Engineer to prevent ingress of water
(k)
at ladders and other openings, 12 mm minimum galvanised steel safety chains with
eyebolt and harness type snap attachments shall be installed.
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(f)
Stainless steel handrailing shall generally be as designated for galvanised steel handrailing
except that all materials shall be of stainless steel Grade 316 S 31, including stainless steel
safety chains and attachments.
Aluminium handrailing shall generally be as designated for galvanised steel handrailing

except as modified below:
handrailing shall comprise double line handrails made from minimum 43 mm
outside diameter 9 SWG tube to BS 1474 Grades 6036-T6, 6082-T6 unless otherwise
designated
(a)
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(b)
fixings shall be of stainless steel
(c)
at ladders and other openings, two stainless chains shall be installed which shall be
fixed to hand rail standards or ladder stringers using suitable aluminium alloy hooks.
All joints shall be made within standards and shall consist of a dowel to provide rigidity fixed
within the handrailing using countersunk stainless steel grub screws. Where removable
lengths of handrails are detailed half lap joints shall be used.
Make provisions for handrails in the exterior and interior installations subject to high humidity
to drain water from railing system.
Posts mounted handrails in concrete, bends and elbows occurring at low points, drill weep
holes of 6 mm diameter at lowest possible elevations, one hole per post or rail. Drill hole in
the plane of the rail.
6.4.6
Chequer Plate
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Part
Page 12
General
2
(a)
all chequer plate shall be designed to support uniformly distributed loads of 7.5 kN/m .
The loading shall be considered a minimum requirement. Where an item of
equipment demands larger loading, the loading shall be increased accordingly.
(b)
maximum deflection shall be 0.2 % of the span under maximum loading

conditions for steel flooring and one per cent for Aluminium
(c)
plate sections shall

(i)
have a minimum thickness of 6 mm, excluding the raised pattern
(ii)
Plates shall be reinforced with angle sections of the same material to meet the
above loading and deflection requirements.
(iii)
be of diamond shaped pattern at the top and have an angled and opposed
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pattern which shall be non-slip type
joints shall be provided at the centre of all openings unless otherwise shown on the
Drawings
(e)
joints and openings shall be reinforced with additional stiffeners where necessary
to provide the required load carrying capacity and deflection criterion.
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(d)
Galvanised steel chequer plate and frames shall be hot dip galvanised after fabrication, and
all fasteners shall be stainless steel. Where specified on the drawings galvanised chequer
plate flooring shall in addition be epoxy coated.
Aluminium chequer plate and frames shall be fabricated from aluminium alloy to BS EN 7559, Grade 6082-T6, and all fasteners shall be stainless steel A4. Gaskets shall be provided to
isolate aluminium alloy from other materials.
Flooring shall be provided in sizes suitable for removal by one man and with the appropriate
cutouts to permit its removal without disturbing or dismantling spindles, supporting brackets
or pipe work. Intermediate supporting members shall be provided and fixed, the cost of which
shall be deemed to be included in the cost of the flooring.
Chequer plate flooring covering openings in concrete or brickwork shall be set flush in frames
of the same material fixed as shown on the drawings.
6.4.7
Gratings and Open Mesh Flooring
General
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(a)
all flooring and walkways shall be designed to support uniformly distributed loads of 7.5
2
kN/m
(b)
gratings and open mesh flooring shall be welded, rectangular opening type, bar
gratings with seat angles, anchors and supports of the same material
(c)
grating up to and including 1.0 m shall be furnished in pieces approximately 1.0 m in

width and all gratings for pans greater than 1 m shall be furnished in pieces 0.8 m in
width
(d)
openings required in gratings shall be banded where openings are provided and shall
be strengthened as necessary
(e)
installed units shall be true to plane and free of warps and irregularities
(f)
units shall be divided for ease of installation and removal
(g)
bearing bars shall be serrated and have a minimum size of 45 mm deep by 5 mm

thick
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the edges of all flooring and platforms shall be finished with approved kerbs, which
shall be provided by the flooring supplier and shall be fitted with fish tail lugs for
building into the concrete work
(i)
the pattern, design thickness and finish shall be approved by the Engineer. The
pattern of open type flooring shall be rectangular and shall match between adjacent
panels
(j)
flooring and walkway supports shall be independent of bearing supports to prevent the
setting up of oscillations and noisy vibrations
(k)
all clips and bolts shall be stainless steel
(l)
all supporting metal work shall be provided on large area openings to provide
support for the flooring
(m)
the faces of flooring which come into contact with cement mortar concrete shall have
two coats of bituminous paint before installation of the frame.
(h)
Galvanised steel gratings and open mesh flooring shall be hot dipped galvanised after
fabrication.
Aluminium gratings and open mesh flooring shall be manufactured in approved structural
aluminium BS 1471, BS 1472 or BS 1474, Grade 6063-T6 or 6082-T6 unless otherwise
designated and all fastens shall be stainless steel. Gaskets shall be provided to isolate
aluminium alloy from other materials.
Stainless steel gratings and open mesh flooring shall be manufactured of Grade 316S31 to
BS 970.
Flooring shall be removable and set flush in frames of the same material. Frames shall be
fixed as shown on the drawings.
The deflection under maximum load shall not exceed 0.2 per cent of the span for steel
flooring and one per cent for aluminium.
Flooring shall be provided in sizes suitable for removal by one man and with the appropriate
cut-outs to permit its removal without disturbing or dismantling spindles, supporting brackets
or pipe work. Intermediate supporting members shall be provided and fixed, the cost of which
shall be deemed to be included in the cost of the flooring.
Steel angle support frames to be embedded in concrete shall be stainless steel,

BS EN 10272:2000 Type 316, unless indicated otherwise.
Welded anchors for stainless steel support frames shall also be stainless steel.
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END OF PART
QCS 2014

Part
07: Glass Reinforced Plastics
Page 1
GLASS REINFORCED PLASTICS ................................................................ 2
7.1
GENERAL ...................................................................................................... 2
7.1.1
7.1.2
7.1.3
7.1.4
7.1.5
7.1.6
Scope
References
Submittals
Quality Assurance
Warranty
7.2
MATERIALS .................................................................................................. 3
7.2.1
GRP
7.3
FABRICATION AND ERECTION ................................................................... 3
7.3.1
7.3.2
7.3.3
7.3.4
GRP Ladder
GRP Handrails and Balustrades
GRP Gratings and Open-Mesh Flooring
GRP Lining for Pump Station Wet Wells
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2
2
2
3
3
3
4
4
4
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Page 2
GLASS REINFORCED PLASTICS
7.1
GENERAL
7.1.1
Scope
This part includes the specifications for all work in connection with glass reinforced plastics
(GRP) ladders, safety cages, handrails, balustrades, gratings, open-mesh flooring, and
linings for pump station wet wells.
7.1.2
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Section 1 - General
This Section
Part 1
General
Part 3
Part 4
Pipe Installation
Part 6
Metal Works
References
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ASTM E84 ..................Test Method for Surface Burning Characteristics of Building Materials
BS 3532......................Method for specifying unsaturated polyester resin systems
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BS 3749......................E glass fibre woven roving fabrics for the reinforcement of polyester
and epoxy resin systems.
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BS EN 14118..............Reinforcement. Specifications for textile glass mats
Submittals
Manufacturers Literature:
7.1.4
(a)
the Contractor shall provide manufacturers specifications, load tables, dimension

diagrams, anchor details and installation instructions for products to be used in
GRP works.
Design Calculations and Shop Drawings:

(a)
the Contractor shall provide design calculations and shop drawings for the
fabrication and erection of all assemblies of GRP which are not completely shown in
manufacturers data sheets, including anchorage and accessory items
(b)
plans and elevations in metric dimensions not less than 1:20 scale, and details of
sections and connections at not less than 1:10 scale shall be included. Detailed
drawings shall show material type, thickness grade/class dimensions, and construction
scheme
(c)
the submittal shall include catalogue pages, erection description, manufacturers data
and instructions and templates where appropriate.
QCS 2014

Part
Page 3
Quality Assurance
Fabricated GRP products and materials shall be provided by experienced approved

manufacturers and fabricators as designated in the contract specific documents and
manufactured to approved patterns.
7.1.6
Warranty
The Contractor shall provide the Employer with a 7-year unconditional guarantee against
failure of all GRP products 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.
7.2
MATERIALS
7.2.1
GRP
GRP material for ladders, safety cages, handrails, balustrades, grating and open-mesh
flooring shall be fabricated from structural quality fibreglass shapes with chemical and
ultraviolet resistance.
Resin shall be all vinyl ester. Glass shall be all ECR and GRP
thickness shall be a minimum 5 mm. The top surface shall be provided with a non-slip silica
sand finish. The structural components shall have Class I fire retardance, with an ASTM E84
flame spread rating of 25 maximum. Fibreglass components shall have an ultimate tensile
strength of 207 MPa, an ultimate compressive strength of 207 MPa, a modulus of elasticity of
20.7 GPa, and a Barcol hardness of 50.
All cut or trimmed edges of the GRP ladder and braces shall be flow coated with an approved
vinyl ester resin. Glass fibres shall not be exposed.
7.3
FABRICATION AND ERECTION
7.3.1
GRP Ladder
GRP ladders shall be obtained from an approved experienced manufacturer and shall be
purpose made to suit the depth of each installation as shown on the drawings. The ladders
shall be drilled for wall fixing at both ends and additional intermediate fixing connections shall
be provided at centres not greater than 1.5 metres. Rungs shall be at 300mm centres and at
a distance of not less than 200mm from the wall. Rungs if tubular shall be no less than
30mm outer diameter, and stringers shall be of a rectangular or channel section no less than
70mm x 25mm in size.
The wall thickness of the laminate shall be not less than 5 mm at any point and there shall be
no sharp edges. The support fixing brackets shall be GRP continuously moulded with the
main lamination and they shall be not more than 500 mm apart (every 2 steps/rungs). The
rungs shall be 250 mm apart with the upper face finished with a non-slip surface.
The support fixing brackets shall be put through the liner wall, and be designed to be totally
encapsulated by concrete. The ladder brackets shall be laminated to the outside of the liner.
Each rung shall be able to withstand a point load of 5000 N.
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7.1.5
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Page 4
When supported horizontally over a span of 1.0 m with the climbing face uppermost and with
a load of 1000 N applied at the centre of the span the ladder shall not deflect more than 15
mm at the point of application of the load and shall show no permanent deflection after
removal of the load. Each ladder fixing shall be capable of withstanding shear and pull-out
loads of 5000 N.
7.3.2
GRP Handrails and Balustrades
GRP handrails and balustrades shall be white (or near white) in colour and shall be obtained
from an approved experienced manufacturer.
The resin, glass and synthetic fibres used in the manufacture of handrails shall be chosen to
produce a chemically resistant product with a resin-rich surface layer suitable for use in
aggressive atmospheres likely to be encountered in sewers and sewage pumping stations.
Standards shall be no smaller than 45 mm square, and shall be 1100 mm high. Base fixing
shall be as shown on the drawings. Where installed on concrete surfaces using expanding
anchor bolts, the bases shall be bedded on an approved mastic sealant to prevent ingress of
water to the bolt holes.
Handrails shall be no smaller than 50 mm square, and shall be located 550 and 1100 mm
above finished floor level on standards spaced no more than 1500 mm apart. Deflection
under vertical loads shall be no greater than deflection under the same horizontal load.
The complete installation shall be capable of withstanding a horizontal force at top rail level of
740 N/m. The deflection of both rails and standards shall not exceed 2 % of the span/height
under a horizontal load of 360 N/m on the top rail.
At ladders and other openings, two removable stainless steel chains, shall be installed which
shall be fixed to handrail standards or ladder stringers using stainless steel (316 S31) hook
bolts.
7.3.3
GRP Gratings and Open-Mesh Flooring
GRP grating and open-mesh flooring shall have the same overall dimensions and design
criteria as designated for steel grating and open-mesh flooring in Part 6 of this Section except
as modified below.
The grating shall be of one piece compression moulded continuous fibreglass strand bar type
grating and other requirements shall be as designated for GRP ladders. The colour and
pattern of the grating and open-mesh flooring will be selected from the available
manufacturers standards and to the approval of the Engineer.
7.3.4
GRP Lining for Pump Station Wet Wells
GRP linings to pumping station 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 6 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 ECR glass chopped strand mat. The lining
shall be at least 6 mm thick and shall be white (or near white) in colour.
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Part
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All linings shall consist of preformed sheets and tubes with moulded on lugs to allow bonding
to concrete. Joints between sheets shall be bandaged on the hidden face, with the
bandaging extending 150 mm either side of the joint. On the inside (exposed) face the joint
shall be filled with vinyl ester paste to produce a smooth finish. Where joints form angles, a
50 mm radius fillet shall be formed using vinyl ester paste prior to bandaging.
Where the Engineer permits the use of GRP lining to upper surfaces, and other areas where
casting in of preformed sheets in inappropriate, lapping of in-situ work onto preformed work,
and application of in-situ lining shall be carried out as follows:
at the junction between preformed linings and in-situ linings, the preformed lining shall
be lightly abraded to a distance of 150 mm from the junction
(b)
a vinylester paste fillet of 50 mm radius shall be formed at internal angles which are
to receive an in-situ lining
(c)
the in-situ lining shall be built up by applying isophthalic or vinyl ester resin to the
whole of the surface to be lined, the fillet and the abraded strip of the preformed lining
(d)
a layer of E or ECR mat shall be rolled into the resin using a suitable steel roller to
exclude all air and provide complete immersion of glass fibre in the resin
(e)
after a period to allow pre-gel 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 the lining is approximately 4 mm
(f)
vinylester resin and ECR glass or synthetic tissue veil shall than be applied in layers
to complete the lining
(g)
where linings are applied to inverts of channels subject to high fluid velocities of 5 m/s,
the GRP lining shall be mechanically fixed to the substrate using stainless steel screws
and washers. After building up approximately 60 % of the required thickness of lining,
stainless steel round headed screws 50 mm long and stainless steel washers 25 mm
diameter shall be used at 500 mm centres (by drilling and plugging) to fix the lining to
the concrete. Particular attention shall be paid to edges of sheets where the flow of
sewage will tend to lift the lining. The remaining layers of GRP shall then be built up
over the screw heads and washers.
The top surface of benchings and platforms shall incorporate silica sand to form a non-slip
surface.
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(a)
END OF PART
QCS 2014

Part
08: Painting and Protective Coatings
Page 1
PAINTING AND PROTECTIVE COATINGS .................................................. 2
8.1
GENERAL ...................................................................................................... 2
8.1.1
8.1.2
8.1.3
8.1.4
8.1.5
8.1.6
8.1.7
8.1.8
8.1.9
Scope
References
Definitions
System Description
Submittals
Quality Assurance
Warranty
Safety
8.2
MATERIALS .................................................................................................. 6
8.2.1
8.2.2
8.2.3
Coating and Painting Materials

Coating and Painting Systems
Abrasive Blasting Materials
8.3
WORKMANSHIP ......................................................................................... 13
8.3.1
8.3.2
8.3.3
8.3.4
8.3.5
8.3.6
8.3.7
8.3.8
8.3.9
8.3.10
8.3.11
8.3.12
8.3.13
8.3.14
8.3.15
8.3.16
8.3.17
General
Manufacturers Recommendations
Mixing and Thinning
Items Not to be Painted During Coating and Painting Operations
Surface Preparation
Application of Protective Coatings and Paint
Maintenance of Prepared Surfaces
Environmental Conditions
Spray Application
Brush Application
Shop Coatings
Site Painting of Manufactured Items
Site Application
Epoxy Coating Work
Epoxy Coatings for Concrete and Rendered Surfaces
Galvanising and Other Finishes of Metals
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2
3
3
4
4
5
5
6
6
7
13
13
14
14
14
14
18
19
19
20
20
20
20
21
21
22
22
23
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Part
Page 2
PAINTING AND PROTECTIVE COATINGS
8.1
GENERAL
8.1.1
Scope
This part includes the specification for the Provision of protective coatings and painting to
protect the surfaces of structures, materials and equipment in interior, exterior, process,
operating, and maintenance service environments as classified in this Part.

General
Miscellaneous Metal Work
Section 1,
Section 5,
Section 6,
Section 9,
Section 10,
Section 16,
Section 17,
Section 21,
Section 26,
General
Concrete
Road works
Structural Metalwork
Metalwork
Electrical Works
Painting and Decorating.
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This Section
Part 1,
Part 3,
Part 5,
Part 6,
References
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8.1.2
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ASTM C97 ..................Standard Test Methods for Absorption and Bulk Specific Gravity of
Dimension Stone
BS 245........................Mineral solvents (white spirit and related hydrocarbon solvents) for

paints and other purposes
BS 1336......................Knotting
BS 1710......................Identification of pipelines and services
BS 4232......................Surface finish of blast-cleaned steel for painting
BS 4652......................Zinc-rich priming paint (organic media)
BS 4756......................Ready mixed aluminium priming paints for woodwork
BS 4800......................Paint colours for building purposes
BS 5493......................Code of practice for protective coating of iron and steel structures
against corrosion
BS 6150......................Code of practice for painting of buildings
BS 7079......................Preparation of steel substrates before application of paints and related
products
BS 7956......................Specification for primers for woodwork
QCS 2014

Part
Page 3
BS EN 10300..............Bitumen-based hot-applied coating material for protecting iron and

steel, including suitable primers where required
BS EN ISO 1461 ........Hot dipped galvanised coatings on iron and steel articles
SIS 055900.................Rust grades for steel surfaces and preparation grades prior to
protective
coating
Definitions
Paints, protective coatings, and coatings: paints, enamels, stains, varnishes, lacquers,
sealers, fillers and other types of coatings whether used as primers, intermediate or finish
coats.
8.1.4
System Description
For purposes of identifying protective coating and painting systems to be applied as specified
in this Part, service environments are classified in Table 8.2.
The classification of areas and surfaces to be coated or painted shall be as designated in the
Project Specification.
Painting in unclassified areas shall be carried out as specified in Section 26.
Surfaces to be Coated or Painted. In general, the following surfaces are to be coated or

painted:
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8.1.3
all exposed piping and other metal surfaces, interior and exterior
(b)
all submerged metal surfaces
(c)
all structural and miscellaneous steel work, including tanks
(d)
interior of tanks, chambers and wet wells that are not protected with GRP or PVC
liners
(e)
exterior above ground concrete as Table 8.5 unless otherwise designated in the
Project Specification
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exterior above ground brick masonry as designated in the Project Specification

interior of structures as designated in the Project Specification.
(g)
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(h)
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equipment furnished with and without shop finished surfaces, except as specified in
Clause 8.1.8
Surfaces Not to be Painted or Coated. The following surfaces in general shall not be coated
or painted unless otherwise designated:
(a)
plastic surfaces
(b)
non-ferrous metal (Galvanised metal shall not be considered a non-ferrous metal)
(c)
mechanical equipment with approved, designated shop finish
(d)
electrical equipment with shop finishes designated in the contract specific

documentation
(e)
piping to be galvanised as designated in the Project Specification
(f)
chain link fencing.
QCS 2014

Part
Page 4
In no case shall any concrete, wood, metal, or any other surface requiring protection be left
unpainted unless otherwise directed by the Engineer or designated in the Project
Specification.
8.1.5
Submittals
Manufacturers Data. The manufacturers specifications and application instructions for paint
materials and systems, including certifications, verification of specified thickness and other
data to show compliance with these specifications shall be submitted to the Engineer.
Painting Programme. A detailed painting programme including method statements shall be

submitted for the Engineers approval. This programme shall be prepared on the basis of
service environments, surfaces, surface preparation, types of paint materials, types of
primers and sealers, and number of coats. The brand name of the product of the
manufacturer for each use shall be listed.
Samples. When required by the Engineer, samples for colour and texture as hereinafter
listed shall be submitted for the Engineers approval. The Contractor shall be responsible for
compliance with all other requirements.
Letter of guarantee required under Clause 8.1.8 of this Part.
8.1.6
Quality Assurance
Protective painting shall be carried out only by approved prequalified subcontractors as

designated in the Project Specification. Protective coating shall be carried out by specialist
subcontractor as designated in the Project Specification.
Applicator Qualifications: The Contractor shall provide information demonstrating that

applicators have successfully completed coating system applications similar in material and
extent to those included in the Works. Only applicators for which such information has been
provided shall be employed.
Single-Source Responsibility: The Contractor shall provide primers and undercoat material
produce by the same manufacturer as the finish coats for each type of coating. Only thinners
recommended by the manufacturer shall be used, and only within the manufacturers
recommended limits.
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Field Samples: Where required by the Engineer field samples shall be provided as follows:
Sample Boards. The Engineers colour chips on 300 mm by 300 mm hardboard shall
be matched with colour, texture and sheen duplicated to simulate actual conditions.
Sample boards shall be resubmitted as necessary for selection by the Engineer.
(a)
(b)
Sample Areas. Where required by the Engineer, partial areas shall be prepared and
finished as directed by the Engineer, using selected 300 mm by 300 mm sample
boards as a guide for final approval of colour, texture and sheen. After approval, the
sample areas shall serve as the standard for workmanship, appearance and materials
for similar areas throughout the project.
All epoxy coating work shall be carried out by a specialist firm or contractor approved by the
Engineer. The specialist firm shall be required to submit a letter of guarantee that the
product it proposes to supply when applied in accordance with this specification and any
additional specifications which shall be quoted by the firm will withstand the environmental
service conditions to be encountered. The Contractor shall provide a guarantee of at least
three years in relation to this coating from the time of application of the coating.
QCS 2014

Part
Page 5
Except as otherwise specified in this Part, delivery storage and handling of coating and paint
material shall be carried out as specified for paint material in Section 26.
Coating and painting materials and apparatus shall be stored in areas approved by the
Engineer. When not in use, storage areas shall be kept locked and inaccessible to those not
employed in protective coatings and painting work. Each storage space shall be provided
with fire extinguishers.
Coating and paint containers shall be opened only when required for use. Unless otherwise
specified in this Part, no materials shall be reduced, changed, or used except in accordance
with the manufacturers label or tag on container.
All coating materials and thinners shall be furnished by the Contractor in original, unopened
containers bearing the manufacturers label and instructions. For materials having a limited
shelf life, the date of manufacture and the length of life shall be shown. The oldest paint of
each kind shall be used first.
All coating materials shall be stirred in a container with a power mixer before use to
thoroughly remix the pigments and vehicles. Only thinners specified by the manufacturer
shall be used. Mixing and thinning directions as furnished by the manufacturer shall be
followed unless modified by the Engineers Representative.
Mixing in open containers shall be done in a well ventilated area. When use of thinner is
permitted, thinner shall be added during the mixing process.
If a coating material requires the addition of a curing agent, the pot life under application
conditions stated on the container label shall not be exceeded. When the pot life limit is
reached, the spray equipment shall be emptied, remaining material discarded, the equipment
cleaned and the new material prepared.
For paints and thinners, records shall be kept of:
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8.1.7
Date of manufacture.
(b)
Shelf life.
(c)
Date of use.
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(d)
(a)
Daily usage of thinners.
Preparation of the paint for application shall be as BS 5493 and the Manufacturers
recommendations.
10
Coating materials, other than thixotropic materials, which have livered, gelled or otherwise
deteriorated shall not be used.
11
No paint shall be used on expiry of the manufactures recommended shelf life nor when the
paint solids cannot be dispersed by mixing after a maximum of 5% thinners has been added.
8.1.8
Warranty
Before beginning coating and specialist paint work, the Contractor shall provide the Engineer
with a letter of guarantee from the specialist subcontractor that the products proposed for use
when applied in accordance with the specifications of this Part and the manufacturers
instructions will withstand the environmental service conditions to be encountered for a
period of 10 years.
QCS 2014

Part
Page 6
Safety
The implementation of manufacturers recommendations concerning health and safety

aspects of paints approved by the Engineer for use on the works shall be mandatory.
Respirators shall be worn by all persons engaged in, and assisting in, spray painting. In
addition, workers engaged in or near the work during sandblasting shall wear eye and face
protection devices meeting the Engineers approval for sandblasting operations and
approved air-purifying, half-mask or mouthpiece respirator with appropriate filter.
Where ventilation is used to control potential exposure to workers, ventilation shall be

adequate to reduce the concentration of the air contaminant to such safe limits that a hazard
to the worker does not exist. Methods of ventilation shall meet with the approval of the
Engineer.
Cloths and cotton waste that may constitute a fire hazard shall be placed in closed metal
containers or destroyed at the end of each work day.
8.2
MATERIALS
8.2.1
Coating and Painting Materials
Epoxy coating and painting materials shall be as follows:

Primer
solvent-free low viscosity
(ii)
(ii two or three pack
(iii)
compatible with and have complete intercoat adhesion with the first coat of high
ov
Protective coats
high build straight aromatic amine cured epoxy
(ii)
two or three pack
(iii)
solvent free type
(i)
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(b)
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build epoxy paint
as
(i)
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(a)
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.l.
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8.1.9
(iv)
completely resistant to the corrosion conditions to be encountered.
Certain types of coal tar epoxy may also be approved by the Engineer for this purpose
in which case the Contractor shall state the type of coal tar and the curing agent to be
used and the percentage content of coal tar.
Stone Paint. Stone paint to be used on exposed external concrete surfaces shall be single
component silane siloxane based water repellent system with not more than 1% water
absorption when tested in accordance with ASTM C97.
Fungus and Mould Resistant Finishes. Where a fungus and mould resistant surface is
designated, the surface shall be treated with a fungicide paint in accordance with the
Varnish: Varnish shall comply with the relevant provisions of BS EN ISO 150.
Where a surface is to receive more than one type of coating or painting material, each
different material used on that particular surface shall have a different colour in order to
facilitate inspection. Colour schedules for coating and painting materials shall be prepared by
the Contractor and submitted to the Engineer for approval.
QCS 2014

Part
Page 7
The list of manufacturers of all paints/coatings/corrosion control systems shall be submitted

for approval by the Engineer.
All materials for lining/multiple coat work, e.g., priming, undercoat and finishing coat shall be
obtained from the same manufacturer and shall be suitable for using together and for the
surface concerned.
All materials shall be used strictly in accordance with manufacturers instructions.
Manufacturer's samples of all paints, varnishes, etc., shall be submitted, free of cost, in
sealed containers to the Engineer for approval before bulk deliveries are made and before
any paintwork is started.
8.2.2
Coating and Painting Systems
The materials, application and use of coating and painting systems are specified in
Tables 8.1 to 8.5. Surfaces in Location A shall receive a total paint thickness of not less than
200 micron and the surfaces in Location B, C and D shall receive a total paint thickness of
not less than 300 micron. The first coat of paint to be applied not more than 4 hours after
substrate preparation. Subsequent coats of paint to be applied within 48 hours of previous
coat. Approval to factory application of this final coat to be sought from the Engineer where
delay in application is liable to cause adhesion problems.
Formulate paints with colorants free of lead, lead compounds, or other materials that might
be affected by presence of hydrogen sulfide or other gas likely to be present at Site.
Identification of pipelines shall be generally in accordance with the Contract Drawings or

Specification or as selected by the Engineer.
Pipelines shall be identified by the colours in Table 8.6. These shall be applied as follows:
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Painting the basic identification colour on the pipe or duct over the whole length and
super-imposing the colour code identifications at intervals; or
(b)
Painting the pipe or duct in bands.
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er
(a)
Where banding is adopted, the decorative or protective colour along the rest of the pipe or
duct shall not be any of the basic identification colours.
The basic identification colours shall be placed at all junctions at both sides of valves, service
appliances, bulkheads, wall penetrations and any other place where identification is
necessary.
Any information regarding the fluid such as pressure, temperature, etc., shall be placed on
the basic identification colour or next to the basic identification colour band. The names,
abbreviations or chemicals symbols shall be either in black or white in order to contrast
clearly with the colour of the pipe or with the basic identification colour. The direction of flow
of the fluid shall be indicated by an arrow situated in the proximity of the basic identification
colour and painted black or white in order to contrast clearly with basic identification colour.
For closed circuits, the flow and return pipes shall be indicated by the use of the word "Flow"
on the one pipe and the word "Return" on the other.
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QCS 2014

Part
Page 8
Table 8.1
Schedule of Paints and Film Thickness per Coat (DFT)
Ref.
DFT
microns
Description
P2
Zinc phosphate epoxy corrosion resistant primer

Two pack polyamide cured.
Zinc Chromate ditto
P3
Zinc phosphate epoxy prefabrication primer. Two pack
50
P4
50
U2
Zinc chromate ditto

T-wash pretreatment for galvanised
surfaces as described in BS 5493
Epoxy micaceous iron oxide. Two pack.
Polyamide cured.
Pure epoxy resin. Two pack. Amine adduct cured.
U3
Coal tar epoxy. Two pack. Polyamide cured
U4
Epoxy tie coat
F1
Silicone alkyd enamel
F2
Urethane. Two pack.
Hot dip bitumen solution to BS 4147, Type 1 Grade D*
Aluminium sealer. Single pack
50
.l.
l
125
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U1
50
ta
50
qa
P1
125
125
25
-
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Table 8.2
Key to Preparation and Painting Schedule
Item
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Item
GB
Z
G
Surfaces above process liquid level and not liable to splashing. Non-aggressive
atmospheres.
Surfaces in contact with untreated or treated water for potable use.
Surfaces below process liquid level or liable to splashing. Non aggressive
solutions and/or atmospheres.
Surfaces in contact with aggressive solutions and/or atmospheres.
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Locations
Table 8.3
Preparation Standards for substrates
Preparation Standards for substrates
Grit blast to Swedish Standards Sa 2 1/2
Clean and degrease
Pickle and hot dip galvanise to BS 729 (applied to items which may be pieced
sufficiently small and excludes stainless steel).
QCS 2014

Part
Page 9
Table 8.4
Preparation and Painting Schedule for Metal Surfaces (Not Buried Pipes)
Item
Item
Item
Factory Operations
Location
Assembly
Prep.
Coatings
1st
2nd
GB
P1 (a) or P2 (a)
U1 (b)
or G
Site
GB
P3 (a) or P4 (a)
Factory
GB
P1 (a)
U2 (b)
or G
Site
GB
P3 (a)
Factory
GB
P1 (a) or P2 (a)
U3 (b)
GB
P3 (a) or P4 (a)
T and P1
GB
P1 (a) or P2 (a)
U1 (b)
GB
P1 (a)
U2 (b)
GB
P1 (a) or P2 (a)
U3 (b)
P1 (a) or P2 (a)
U1 (b)
P1 (a)
U2 (b)
P1 (a) or P2 (a)
U3 (b)
A/C/D
GB
P1 (a)
U2 (b)
A/C/D
GB
P1 (a)
U2 (b)
A/B/C/D
GB
P1 (a)
U1 (b)
Factory
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or G
Site
including headstocks
qa
Cast iron and cast steel
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copper)
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Non-ferrous metal (except
as
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A/B/C/D
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Steel pipes
Iron and steel
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Penstocks and valves of

cast iron
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Steel and Ferrous metal parts
Completed at
Steel stairways and

supporting
Structures
Bridge rail and pin rack rail

Water Towers (Exterior)
Site
QCS 2014

Part
Page 10
Table 8.4 (Contd)

Preparation and Painting Schedule for Metal Surfaces (Not Buried Pipes)
Item
1st
2nd
3rd
4th
F1
F1
Site
P1 (f) or P2 (f)
U1 (b)
F1
F1
Factory
U2 (c)
Site
P1 (f)
U2 (b)
U2 (b)
Factory
U3 (c)
rw
Steel and Ferrous metal parts
Assembly
P1 (f) or P2 (f)
U3
U3 (b)
P1 (f)
U3
U3 (b)
F1
F1
U2 (c)
U3 (c)
F1
F1
U2 (c)
U3 (c)
er
Location
Site Operations and Coatings
Item
Item
A/C/D
F1
F1
U2 (b)
A/C/D
U2 (c)
A/B/C/D
U4
F2
Completed at
Factory
Site
including Headstocks
qa
Cast iron and cast steel
ta
copper)
B
C
A/B/C/D
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Steel pipes
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Non-ferrous metal (except
as
Iron and steel
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Penstocks and valves of

cast iron
.l.
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Structures
Steel stairways and supporting
Bridge rail and pin rack rail

Water Towers (Exterior)
Site
Qualifying Notes:
(a)
To be applied not more than 4 hours after substrate preparation.
(b)
To be applied within 48 hours of previous coat.
(c)
Approval to factory application of this final coat to be sought from the Engineers
Representative where delay in application is liable to cause adhesion problems.
(d)
Refer to Clause 8.3.5.35
QCS 2014

Part
Page 11
Table 8.5
Preparation and Painting Schedules for Surfaces Other Than Metal
Surface
Location
Finish
Particular
Primer
Final Treatment
Preparation
Hard Wood and
Interior
Gloss
Soft Wood
Sand down
Q.D. Acrylic
Alkyd undercoat
Treat Knots
Wood primer
Alkyd topcoat
Sand down
Lead free
Alkyd undercoat
Treat Knots
Wood primer
Alkyd topcoat (2 coats)
Degrease
Emulsion thinned to
High opacity acrylic
Sand down
manufacturer's
emulsion (2 coats)
Exterior Gloss
Plaster
Interior
Flat
(including
Plasterboard)
instructions
Gloss
Ditto
Alkali resistant
primer
Multi-
Ditto
Primer
ta
Interior
Interior
Flat
Concrete -
Alkyd undercoat
Alkyd topcoat
Multi-colour wall finish
Emulsion thinned to
manufacturer's
emulsion (2 coats)
as
Rendering,
qa
colour
Cement
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Interior
.l.
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unprimed)
(primed or
instructions
Interior
Gloss
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(fair-faced),
Alkyd undercoat
primer
Alkyd topcoat
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Brickwork
Alkali resistant
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Immersed & splash

zone
(Refer to the clause entitled Epoxy Coatings for Concrete and

Rendered Surfaces)
Aggressive
atmospheres
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Exterior Masonry Stiff brush
Stabilising primer
paint
Hardboard
Interior
Flat
Textured emulsion
masonry
paint (2 coats)
Zinc chromate High opacity acrylic
spot primer to
emulsion
emulsion (2 coats)
Stabilising primer
Alkyd undercoat
screw and nail

heads
Interior
Gloss
Ditto
Alkyd topcoat
QCS 2014

Part
Page 12
Table 8.6
Standard Colours
The following colours to BS 4800 shall be used for mechanical and electrical equipment. For
equipment not listed the colour shall be agreed with the Engineer.
Colour
(a)
External machinery
18
53
Green-Yellow
(b)
Motors and Pumps
14
53
Green Yellow
(c)
Panels
14
53
Green Yellow
(d)
GRP Covers
08
15
Yellow-Red
(e)
Sewage Pipework
00
53
Black
(f)
Airlines
20
51
Properties
(g)
Sewage valves
00
53
Black
(h)
Airline Valves
20
51
Light Blue
(j)
Water Pipework
12
45
Green
(k)
Water Valves
12
45
Green
(l)
Potable Water/Pipes/Valves
qa
Material / Equipment
12
45
Green/18 E 53
Auxiliary Blue
.l.
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Surge Vessels
(n)
Fire Extinguishing Systems
(o)
Bulk Storage Tanks
(p)
Electrical Services
51
Yellow
04
53
Red
ov
08
Aluminium
E
51
Yellow-Red
Cranes
08
53
Yellow
Control Panels, relay

panels, Instrumentation
enclosures, fuse switches,
distribution boards,
marshalling cubicles etc.
14
53
Green-Yellow
(r)
(colour code)
06
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(q)
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(m)
Light Blue
QCS 2014

Part
Page 13
Abrasive Blasting Materials
The abrasive employed in blasting shall be grades steel grit, ball shot, silica safe sand or
similar and shall be such that it will provide a surface roughness complying with the one
specified by the manufacturer for the primer concerned. The abrasive shall be dry, clean and
free from soluble contaminants and shall be selected as specified in BS 4232.
The type and size of abrasive used for blast cleaning shall comply with the requirements of
BS 4323 Table 2. When directed by the Engineer, the Contractor shall carry out a series of
tests using various sizes of abrasives smaller than the maximum defined in BS 4232 Table 2
to determine which gives the best profile. This size of abrasive shall be used for all
subsequent blast cleaning. The grading of abrasives for equipment which uses abrasives
more than once shall be checked at regular intervals and fresh abrasives added to ensure
that the correct grading is maintained.
The roughness of blast cleaned surfaces measured at the amplitude by any of the methods
defined in BS 4232 shall not exceed 75 microns.
The pH value shall not be less than 4 or greater than 10 when mixed in neutral water. The
material shall not contain soluble chloride.
The level of trace toxic contaminants shall meet Government regulations.
Dune sand shall not be used.
8.3
WORKMANSHIP
8.3.1
General
Unless otherwise specified in this Part, the preparation coating and painting of surfaces shall
be carried out as specified in Part 26 and in accordance with the recommendations of
BS 6150 subject to the approval of the Engineer.
All coatings and paint shall be applied in a workmanlike manner to produce a uniform film of
the specified thickness. Edges, corners, crevices, and joints shall receive special attention to
ensure that they have been thoroughly cleaned and that they receive an adequate thickness
of paint. The finished surfaces shall be free from runs, drops, ridges, waves, laps, brush
marks, and variations in colour, texture, and finish.
Before beginning coating and painting work, the Contractor shall take precautions to protect
the Works and existing facilities from damage or disfigurement. Where necessary, the
Contractor shall protect equipment by providing clean cover sheets. If in the opinion of the
Engineer the precautions are inadequate, the Contractor shall at his own expense make such
improvements as the Engineer directs.
The specified film thickness shall be attained. Particular attention shall be paid to the
attainment of specified film thickness on edges. In hot weather, additional precautions shall
be taken as necessary to ensure the attainment of specified film thickness. Film thickness
shall be checked with a paint inspection gauge furnished by the Contractor. The Contractor
shall calibrate the gauge for the thickness range to be checked at least twice a day. When
measured film thickness is less than specified, additional coats shall be applied as necessary
to attain compliance.
Manual grit blasting equipment shall be approved by the Engineer before use. Air
3
compressors shall be capable of supplying a continuous air volume of at least 6 m /min at a
maximum pressure of 7 MPa to each blasting nozzle. The compressed air supply shall be
free of water and oil. Adequate separators and traps shall be provided. Accumulations of oil
and water shall be removed from air receivers by regular purging.
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8.2.3
QCS 2014

Part
Page 14
On completion of the works, which may have become spotted or touched with paint shall be
cleaned down and all left clean to the satisfaction of the Engineer.
8.3.2
Manufacturers Recommendations
Unless otherwise specified, the coating and paint manufacturers written recommendations
and instructions for storage, thinning, mixing, handling, surface preparation, protection of
other surfaces, application and protection of coated and painted surfaces and for all other
procedures for providing protective coatings and painting shall be strictly observed. No
substitution or other deviation will be permitted without the written permission of the Engineer.
8.3.3
Mixing and Thinning
Coating materials and paint shall be mixed only in designated rooms or spaces in the
presence of the Engineer.
Paint and coating materials shall be protected from exposure to extreme weather, and shall
be thoroughly stirred or agitated, strained, and kept at a uniform smooth consistency during
application. Materials shall be prepared and handled in a manner to prevent deterioration and
inclusion of foreign matter.
Paint and coating materials of different manufacturers shall not be mixed together.
Packaged paint and coating materials may be thinned immediately before application in
accordance with the manufacturers directions. Only thinners recommended by the paint and
coating manufacturer shall be used.
8.3.4
Items Not to be Painted During Coating and Painting Operations
Hardware, hardware accessories, name plates, data tags, machined surfaces and similar
items in contact with coated surfaces shall not be coated and shall be removed or masked
before surface preparation and painting operations. Following completion of coating of each
piece, removed items shall be reinstalled. Such removal and reinstallation shall be done by
workmen skilled in the trades involved.
That portion of steel to be embedded in concrete or masonry shall not be painted and shall
be cleaned as designated for steel surfaces before fixing.
8.3.5
Surface Preparation
General
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(a)
The specified standard of surface preparation shall be attained. Surface preparation

shall have no detrimental effect on the material being protected and shall not be
prejudicial to subsequent coating and painting operations.
(b)
In addition to complying with the specifications of this Clause and the manufacturers
instructions the Contractor shall take such other measures needed to ensure that all
surfaces are clean, and free of deleterious material including but not limited to dirt,
grease, and oil, before the application of primer and between coats.
(c)
All surfaces prepared for coating and painting shall be prepared to the specified
standard and approved by the Engineer before coating and painting work begins.
QCS 2014

Part
Page 15
Cleaning and painting shall be so arranged that dust or spray from the cleaning
process will not fall on wet, newly painted surfaces. The sharp edges of steel surfaces
shall be dulled, rough welds made smooth and weld splatter removed. Hardware,
electrical fixtures and similar accessories shall be removed or suitably masked during
preparation and painting, or shall be suitably protected. Equipment adjacent to walls
shall be disconnected and moved to permit cleaning and painting of wall surfaces, and
shall be replaced and reconnected after the painting has been completed.
Notwithstanding anything in this Section, all surfaces shall be prepared in strict
accordance with the approved paint manufacturer's recommendations.
(e)
Do not apply paint in temperatures or moisture conditions outside of manufacturers

recommended maximum or minimum allowable.
(f)
Overcoating intervals recommended by the paint manufacturer must be strictly

adhered to. The manufacturer must be consulted if and when there is a necessity for a
change in overcoating intervals.
(g)
Where a high quality finish is required, the surfaces shall be filled with an approved
filler 24 hours after the final priming coat has been applied. When the surface is hard
the whole shall be rubbed down with wet and dry abrasive paper to a uniform flat
surface and left clean and free of abrasions and powdered filler.
(h)
All surfaces are to be completely dry and above a temperature of 4 degrees C. No

painting shall be carried out during damp or inclement weather.
(i)
When required by equipment specifications, such equipment shall be primed and finish
coated in shop by manufacturer and touched up in field with identical material after
installation.
(j)
Where manufacturers standard coating is not suitable for intended service condition,
Engineer may approve use of a tie-coat to be used between manufacturers standard
coating and specified field finish. In such cases, tie-coat shall be surface tolerant
epoxy as recommended by manufacturer of specified field finish coat. Coordinate
details of equipment manufacturers standard coating with field coating manufacturer.
ov
Metal
Except as otherwise specified in this Clause, preparation of metal surfaces shall be in

accordance with the relevant provisions of BS 4232, BS 5493, BS 7079, and
SIS 055900.
(b)
Steel to be embedded in concrete, other than reinforcing steel, shall be cleaned to SIS
055900 St. 2 and shall not be primed.
et
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(c)
(a)
Surfaces shall be clean and dry before application of coatings and paint. If coating or
painting takes place over a zinc rich shop primer which has been exposed for an
extended period, the entire coated surface shall be sweep blasted to remove white
rust and other contaminants before application of the first coat.
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(d)
(d)
After the surface has been prepared as specified, the surface shall be further cleaned
by vacuum, clean and dry compressed air, or by clean brush to remove accumulated
grit, shot and dust leaving the surface clean, dry and free of scale, rust and other forms
of contamination.
(e)
In the event that rusting occurs after the completion of the surface preparation, the
surface shall again be prepared to the specified standard.
(f)
When items are to be shop primed or shop primed and finish coated in the shop,
surface preparation shall be as specified herein. The Engineer shall have the right to
witness, inspect, and reject any sandblasting or other surface preparation done in the
shop.
(g)
Blast Cleaning. Blast cleaning shall not be carried out

(i)
on surfaces that are wet or damp surfaces, or may become wet or damp before
the application of primer,
QCS 2014

Part
Page 16
(ii)
when metal surface temperatures are less than 3 C above the dew point
(iii)
or the relative humidity exceeds 80 percent.
(iv)
In close proximity to subsequent coating operations or near other surfaces

susceptible to dust or particle contamination.
In the event of shot or grit blasting not being possible due to interference, the steel
surface may, with the prior written approval of the Engineer, be thoroughly cleaned by
mechanical means in accordance with BS EN ISO 8504-3 to remove all loose rust and
mill scales and primed with one coat of an alkyd type zinc phosphate primer to
60 microns dry film thickness.
(i)
Where blast cleaning is to be carried out outdoors at an exposed (not under cover)
location, preliminary blast cleaning may be done at night with the prior approval of the
Engineer, provided that all surfaces so treated shall be reblasted during daylight hours
to the specified standard before coating or painting materials are applied. This
paragraph does not apply where automatic centrifugal or manual grit blasting is carried
out under adequate cover, provided the specified preparation standard is attained.
(j)
Oil or grease contamination shall be removed by solvent wash before blast cleaning. If
necessary, contaminated areas shall be rewashed and reblasted until contamination is
removed.
(k)
When sandblasting is carried out on Site, care shall be taken to prevent damage to
structures and equipment. Pumps, motors, and other equipment shall be shielded,
covered, or otherwise protected to prevent the entrance of sand and dust. No
sandblasting shall commence before the Engineer inspects and approves the
protective measures.
(l)
After sandblasting, dust and spent sand shall be removed from the surfaces by
brushing or vacuum cleaning.
(m)
Blast cleaned surfaces that are later to be joined by welding and where shop primer is
to be applied shall not be primed to a distance of 100 mm from the area to be welded.
After welding, the area shall be reblasted and primed as specified.
(n)
Areas that are blast cleaned and shop primed before fabrication and are later welded
on Site shall be reblasted to remove all weld slag and splatter and any other foreign
elements and reprimed as specified.
(o)
Fabricated metal work shall not be blast cleaned in the shop until machining and
fabrication has been completed, including continuous welds, with all exposed surfaces
accessible for subsequent treatment. All slag and spatter shall be removed from the
area of the welds by chipping hammer before blast cleaning.
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(h)
Concrete and Rendered Surfaces for Epoxy Coatings

(a)
Concrete and rendered surfaces shall be thoroughly cured, thoroughly dry and free
from moisture before the application of epoxy filler, primer or paint.
(b)
Areas of concrete contaminated with substances deleterious to the application of

epoxy coatings including machine oil or grease for example shall be cut out as
necessary to remove all traces of such substances. The voids so created shall be
filled with an approved epoxy mortar. Areas contaminated with form release agent
shall be scrubbed with suitable emulsion cleaners. Mould growth shall be treated
using a water soluble fungicide. All surfaces so treated and any other water soluble
substances on the surface, such as salt, shall be rinsed with potable water until clean.
(c)
Where membranes have been used for the curing of concrete these must be removed
and the surfaces thoroughly cleaned before the application of painting and protective
coatings.
(d)
All concrete and rendered surfaces to be coated shall be lightly blast cleaned to
remove the cement rich surface layer. Grit and detritus shall be removed by vacuum
immediately prior to priming.
QCS 2014
(e)
Page 17
Blow holes and honeycombed areas in the concrete which in the opinion of the
Engineer are not capable of being levelled at the primer stage shall be filled with epoxy
mortar supplied by the coating manufacturer to obtain a smooth uniform surface. Such
mortar shall be knifed into the surface to level the area and leave no excess.
Preparation of Plaster, Brickwork and Concrete Surfaces for Coatings and Paint other than
Epoxy
(a)
Efflorescence present on the surface of plaster, brickwork and concrete shall be

removed by scraping and brushing before any paint is applied. When efflorescence
has been removed surfaces shall be left for at least three days before priming.
Priming shall be deferred repeatedly, if necessary, until three days after any further
efflorescence which has appeared is removed.
(b)
Plaster surfaces to be painted shall be cleaned down smooth as necessary and all
cracks filled in with stopping for plaster. Filling shall be carried out for the entire
surface before paint is applied to the surface.
(c)
Brickwork, blockwork and concrete surfaces shall be cleaned of contaminating matter

before being primed. Subject to the approval of the Engineer, large holes which would
cause a break in the paint film shall be filled with mortar and the surface rubbed down
to match the surrounding areas.
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ta
Wood
Wood surfaces shall not be painted when the moisture content of the wood measured
with an electric moisture meter exceeds 12 % for interior surfaces and 18 % for
exterior surfaces.
(b)
Hardwoods or softwoods shall be rubbed down with abrasive paper to give a smooth
surface free of contaminating substances, scratches and other imperfections.
(c)
Surfaces which are to be painted shall be rubbed down to remove all contaminating
substances and imperfections which would be visible in the finished paint film. The
surfaces of knots and resinous streaks shall be painted with two coats of knotting, the
first being allowed to dry before the second is applied. Knotting shall conform with
BS 1336.
(d)
The surfaces of timber treated with waterborne preservative by an impregnation

process shall be rubbed down and dry-brushed to remove all traces of efflorescence
before the primer is applied.
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(a)
Where surfaces are suspected of being infected with mould, they shall be treated with
a fungicide.
(e)
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Part
Galvanised Surfaces
(a)
Dirt and other adhering contaminating material shall be removed by wire brushing,
brushing with bristle brushes, or by other methods approved by the Engineer. Cleaning
shall not damage the galvanising. Zinc corrosion products remaining shall be removed
by washing with potable water and scrubbing with hard bristle brushes.
(b)
After being cleaned and degreased, galvanised surfaces shall be etched with T-wash
as described in BS 5493. If any surface fails to turn black, the cleaning, degreasing,
etching, and T-wash processes shall be repeated as often as necessary.
Damaged Surfaces
(a)
Factory prepared surfaces, other than galvanised surfaces, during handling, site
fabrication or erection shall be treated as follows:
(i)
all slag and spatter shall be removed from areas of welds by chipping hammer
(ii)
all areas of damaged primer or other coat shall be thoroughly mechanically wire
brushed and given one priming coat as detailed in Table 8.3
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Part
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(iii)
the priming coat shall be applied by brush taking care to completely cover
uneven
surfaces particularly those of welds
(iv)
subsequent coats shall be applied as specified in this Part.
Application of Protective Coatings and Paint
All paint and coating materials shall be applied in accordance with the manufacturers printed
specifications or instructions; where these differ from the specification of this Part, the more
stringent requirements shall apply. The Contractor shall issue copies of appropriate data
sheets and of the relevant parts of this specification shall be issued to all supervisory
personnel. Where such instructions conflict with this specification a ruling shall be sought
from the Engineers Representative.
Unless in conflict with the manufacturers printed instructions or otherwise specified, the
Contractor may use brush, roller or air spray. Application by spray painting shall be with the
prior approval of the Engineer. Rollers for applying enamel shall have a short nap. Areas
inaccessible to spray coating or rolling shall be coated by brushing or other suitable means.
The Contractor shall ensure that edges, corners, crevices, welds, bolts, and other areas, as
determined by the Engineer, receive a film thickness equivalent to that of adjacent coated
surfaces and not less than the specified thickness.
On beams and irregular surfaces, edges shall be stripe coated first and an extra pass made
later.
Application of paint and condition of work shall be in accordance with manufacturer's

recommendations and with BS 6150 and BS EN ISO 12944.
The designated dry film thickness (DFT) shall be attained for each coat.
Each coat shall be applied evenly, at the proper consistency, and be free of brush marks,
sags, runs, and other evidence of poor workmanship. When these occur, they shall be
brushed out immediately or the materials shall be removed and the surface recoated.
Finished coated surfaces shall be free from defects or blemishes.
Care shall be exercised to avoid lapping paint on glass or hardware. Coatings shall be
sharply cut to lines. Whenever two coats of a dark coloured paint are designated, the first
coat shall contain sufficient powdered aluminium to act as an indicator of proper coverage, or
the two coatings shall be of a contrasting colour.
All coatings shall be cleaned as specified by the manufacturer before the next coat is applied.
10
Manufacturers recommended time between coats shall be strictly complied with. Sufficient
time shall be allowed to elapse between successive coats to permit satisfactory application of
subsequent coats. Once begun, the entire coating operation shall be completed without
delay. Without specific permission of the Engineer, no additional coating of any structure,
equipment, or other item designated to be painted shall be undertaken until the previous
coating has been completed for the entire item. Piping shall not be finish coated until it has
been pressure tested and approved. Exposure of intermediate coats of paint for periods in
excess of a few days shall not be permitted except in the case of work delivered to the Site in
a primed condition and suitably protected.
11
Final coats shall not be applied until after other trades whose operations would be detrimental
to finish painting have finished their work in the area to be painted, and the areas have been
released for final painting.
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8.3.6
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All parts such as pipe supports, seatings and cleats, and back-to-back sections which will
become inaccessible after fabrication shall be treated on both surfaces with the full paint
system before final assembly.
13
Touch-up of all surfaces shall be performed after installation, and all surfaces shall be clean
and dry at the time of application.
14
All paints shall be prepared and applied in strict accordance with the manufacture
instructions. Copies of appropriate data sheets and of the relevant parts of this specification
shall be issued to all the supervisors and foremen concerned with surface preparation and
coating. Where such instructions conflict with this specification a ruling shall be sought from
the Engineers Representative.
15
Except where otherwise specified or approved by the Engineers Representative all priming
paints shall be applied by brush. Airless spray application only shall be used for painting pipe
lining and is the preferred method for the application of epoxy resin based paint.
16
The dried films shall be free from bloom, shrinkage, sheeriness, wrinkling, sagging,
curtaining, discolouration and extraneous matter.
17
Any primer coat exposed to freezing, excess humidity, rain, dust etc. before drying, shall be
permitted to dry and the damaged area of primer shall be removed and surface again
prepared and primed.
18
Bolted site connections other than facing surfaces of Grip Bolts shall be brought together wet.
8.3.7
Maintenance of Prepared Surfaces
Primer or other initial coat shall be applied to all prepared surfaces before deterioration or
oxidation of the surface. In the case of metals, primer or other initial coat shall be applied
within one hour or such shorter period of time which may be recommended by the
manufacturer, but always before the metal temperature drops to less than 3 C above the
dewpoint and before any rusting occurs. Unless otherwise approved by the Engineer for
surfaces other than metal, primer or other initial coat shall be applied within 4h of completion
of surface preparation. No prepared surfaces shall be allowed to remain uncoated overnight.
8.3.8
Environmental Conditions
Coatings and paint shall be applied in a dry and dust-free environment. Coatings and paint
shall not be applied to wet or damp surfaces or when, in the opinion of the Engineer,
application or drying of paint is likely to be adversely affected.
No exterior or exposed paint work shall be carried out under adverse weather conditions; i.e.,
during rain, mist, windstorms, sandstorms, or when the relative humidity exceeds 80 %. Paint
and coatings shall not be applied when it is expected that the relative humidity will exceed
80 % within 18 hours after the application of the coating or paint. Dew or moisture
condensation should be anticipated and if such conditions are prevalent, application of paint
and coatings shall be delayed to be certain that the surfaces are dry. The paint or coating
shall be completed well in advance of the probable time of day when condensation is
expected to occur.
During application, painting shall insofar as practicable be shaded from direct sunlight to
prevent wrinkling and blistering. Exterior painting shall be carried out in shade during the
day.
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Spray Application
All equipment for spray application shall be inspected and approved by the Engineer before
application begins. Spray guns hoses and pumps shall be clean before new material is
added. Adequate moisture and oil traps shall be installed between the air supply and each
application unit.
Suitable pressure regulators and gauges shall be provided for the air supply to the application
units. Spray equipment and operating pressures shall comply with the manufacturers
recommendations.
Heavy pigments which are likely to settle shall be kept in suspension during application by the
use of power driven, continuous agitator.
The spray gun shall be held at right angles to the surface. Each pass shall overlap the
previous one by approximately 50 %.
8.3.10
Brush Application
When coatings are applied by brush, brushes shall be pure hair bristles and shall be of a
style and quality that will permit proper application of the material. Flat brushes shall not be
more that 100 mm wide. Brushes shall be approved by the Engineer. Extending handles
shall not be used.
Brushing shall be affected so that a smooth coat, as nearly uniform in thickness is obtained.
There shall be no deep or detrimental brush marks.
Paint shall be worked into all corners and crevices. When applying solvent type coating, care
shall be taken to prevent lifting of previous coats.
8.3.11
Shop Coatings
Electrical and mechanical equipment shall be coated and painted as specified in this Part and
in Section 9. The location of coating and painting; i.e., in the shop or on Site, shall be as
specified in Section 9.
8.3.12
Site Painting of Manufactured Items
Steel pipework or fabrication shall be works cleaned and painted in accordance with
Tables 8.1 through 8.4. Total dry film thickness shall be in accordance with the location of
surfaces of painted as specified in Table 8.2
Steel, cast or ductile iron encased in concrete (chamber walls and anchor blocks) shall be
prepared and coated as specified under Tables 8.1 through 8.4.
Non-ferrous parts shall be protected using the same finishing system as that specified in
Tables 8.1 through 8.4 for the adjacent ferrous metal structure.
When any coating which has been applied at a manufacturers works is considered by the
Engineer to be unsound or incompatible with the specified system, it shall be rejected. The
surfaces shall be recoated to a finish satisfactory to the Engineer.
When the Engineers Representative does not require the removal of the manufacturers
coating the equipment shall be solvent cleaned.
Hard baked finishes shall be abraded or softened by application of a strong solvent.
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8.3.9
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Page 21
All polished and bright parts shall be coated with an approved rust preventative before
despatch and during erection, and this coating shall be cleaned off and the parts polished
before being handed over.
Manufactured items such as pumps motors, compressors, air vessels, conduits, etc. shall be
coated at works to the specification laid down for the environment in which they are to
operate. If this is impractical they may be paint coated to the manufacturers standard but
when on site the Contractor shall apply a sealing paint and top coats specified in Table 8.1 to
Table 8.4. Final site painting shall be in accordance with Table 8.1 to Table 8.4. The site
coating shall be 150 microns minimum dry film thickness (DFT).
Pre-treatment and primers shall be suitable for the metal concerned and to BS 5493. Dry
film thickness shall be a minimum of 200 microns for all conditions.
8.3.13
Site Application
Protective coverings shall be used to protect surfaces, fixtures, and equipment. Care shall be
exercised to prevent paint from being spattered onto surfaces from which such paint cannot
be removed satisfactorily. Surfaces from which paint cannot be removed satisfactorily shall
be painted or repainted as required to produce a finish satisfactory to the Engineer.
Upon completion of the work, staging, scaffolding and containers shall be removed from the
site in an approved manner. Paint spots, oil or stains upon adjacent surfaces shall be
removed to the satisfaction of the Engineer. No paint, solvents, rags or other materials used
by the Contractor shall be disposed of in any manner or location except as approved by the
Engineer. The Contractor is specifically cautioned to prevent paint of solvents to be in
contact with plants or liquid streams.
8.3.14
Epoxy Coating Work
In addition to the general requirements of this specification the following shall apply to epoxy
coating works:
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illumination at work site the satisfaction of the Engineers Representative
(b)
forced draught ventilation to the approval of the Engineer shall be used wherever
required for the needs of personnel or for drying out surfaces
(c)
operatives shall work in pairs.
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(a)
The Contractor shall demonstrate his methods equipment and materials before any work
commences. Samples areas of substrate shall be prepared and coated as required by the
Engineer and for his approval.
There shall be strict control of surface cleanliness between primer and epoxy coating and
between coats of the same type. Vacuum removal of dust and sand shall be employed and
contamination shall be removed as specified in appropriate surface preparation clauses
herein. Dirt or dust trapped in the painted surface shall be removed with suitable abrasive
paper. The surface being painted shall be completely dry and free of visible moisture
throughout the operations.
The paint shall be applied only to clean dry primed or previously coated surfaces. Any thick
runs or collections of paint shall be removed before they harden.
Not less than two coats shall be applied over the primer by airless spray; not less than three
by brush.
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Each coat shall be distinctly different in colour from the primer or previous coat. The colour
of the final coat shall be as required by the Engineer. Each coat shall be seen to have
completely covered the preceding coat without misses or pinholes or any areas visibly low
in thickness. A high voltage pinhole detector shall also be used to determine the integrity of
the coats.
The manufacturer of the coating shall stipulate primer and epoxy recoat intervals for all
curing temperatures likely to be encountered and these shall be adopted with a maximum
tolerance of +4 h. Where this is exceeded, the surfaces to be recoated shall first be suitably
abraded to remove gloss and provide a key.
Wet thickness gauges shall be used by the coating operators continually to check that
sufficient paint is being applied to achieve the desired dry film thickness.
8.3.15
Epoxy Coatings for Concrete and Rendered Surfaces
No priming shall commence until the moisture content of the cementitious surface is less
than 5 % measured by instruments approved by the Engineer.
Similarly moisture measurements over the primer or any epoxy intercoat shall not exceed
1 % on the concrete scale of the instrument when the probe tips are held against such
painted surfaces just prior to recoating.
The primer shall be applied by suitable nylon bristle brush or spray over the whole area to be
coated at such thickness that it may then be squeezed into the pores of the concrete.
Excess shall be removed by the most suitable means before application of the high build
epoxy.
The Engineer may approve an alternative application method where the Contractor can
demonstrate a suitable technique.
The total dry film thickness of the paint layer shall have a minimum value of 0.75 mm.
Whenever the Paint Inspection Gauge has been used and wherever the coating has been
otherwise damaged for 50 mm around such damage the surface shall be abraded and the
area touched in with not less than two thick applications to restore the coating integrity and
thickness to that specified.
Adhesion tests will be carried out on the cured coating surface using the test equipment
supplied under the Contract in accordance with the best practice. The resulting test
specimens shall show no indication of poor adhesion to the substrate, residual laitance or
intercoat adhesion weakness.
Where required in the Project Specification or on a written request by the Engineer, the
following instruments shall be provided for the Engineer sole use for the duration of the
Contract:
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(a)
one adhesion tester (0-35 kg/cm )
(b)
one DC high voltage Holiday detector No. 105
(c)
one paint inspection gauge
(d)
one moisture meter.
8.3.16
Galvanising and Other Finishes of Metals
Galvanising and other finishes of metals shall be carried out as specified in Parts 3 and 6 of
Section 8.
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Part
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8.3.17
The Contractor shall conduct dry film thickness (DFT) measurements and other inspections
of all painted work, on completion of which the Engineer will make his own measurements,
examinations and inspections. If painted works are found unsatisfactory, the contractor shall
carryout remedial works as necessary at his expense and the works shall be retested by the
Engineer until such time the works are found satisfactory.
The Contractor shall provide and maintain two sets of the following inspection devices in
good working condition until final acceptance of painting and coating. One set shall be for
the Contractors use and the other for the sole use of the Engineer. On final acceptance of
painting and coating, the inspection devices will be handed back to the Contractor.
Svensk Photographic Standard in accordance with SIS 055900
(b)
non-destructive magnetic-type DFT gauge
(c)
wet fill thickness combs
(d)
surface profile meter
(e)
non-destructive type electrical holiday detector
(f)
low-voltage detector of the wet-sponge type and a non-sudsing type wetting agent, for
testing discontinuities and voids in epoxy and thin film coatings
(g)
high-voltage, low-current, spark type detector for electrical inspection of coal-tar

enamel only
(h)
maximum and minimum thermometer
(i)
hygrometer
(j)
flow cup type B No. 4 and timer.
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(a)
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END OF PART
QCS 2014

Part
09: Trenchless Pipeline Construction
Page 1
TRENCHLESS PIPELINE CONSTRUCTION ................................................ 3
9.1
GENERAL ...................................................................................................... 3
9.1.1
9.1.2
9.1.3
9.1.4
9.1.5
9.1.6
9.1.7
9.1.8
9.1.9
Scope
References
Definitions
System Description
Submittals
Quality Assurance
Site Conditions
9.2
TRENCHLESS PIPELINE CONSTRUCTION GENERALLY ......................... 5
9.2.1
9.2.2
9.2.3
9.2.4
9.2.5
Scope
Surveys and Setting Out
Monitoring Lines and Levels
Temporary Site Facilities
Safety Requirements
9.3
MATERIALS .................................................................................................. 7
9.3.1
9.3.2
9.3.3
9.3.4
9.3.5
Pipes
Joint Packing
Lubricant
Joint Sealant
Grout
9.4
THRUST AND RECEPTION SHAFTS ......................................................... 11
9.5
PIPEJACKING ............................................................................................. 12
9.5.1
9.5.2
General
Tunnelling Shields for Pipejacking
9.6
MICROTUNNELLING .................................................................................. 12
9.6.1
9.6.2
9.6.3
9.6.4
9.6.5
9.6.6
9.6.7
9.6.8
9.6.9
9.6.10
9.6.11
9.6.12
9.6.13
9.6.14
9.6.15
General
Contractor Responsibilities
Safety and Environment
Micro-tunnel Design Elements
Design Checking
Finite Element (FE) and Finite Difference (FD) Models
Verification of Results
Design Parameters for the Calculations
Design Loadings
Design Submissions
Certification Procedure
Contractors Documents
Construction Responsibilities
Quality Assurance/Control
5
5
6
7
7
7
10
10
10
10
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3
3
3
3
3
3
5
5
5
12
12
12
13
13
14
15
17
17
18
18
18
19
20
20
21
21
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Part
Page 2
Materials
Temporary Works
Construction Preparation
Construction Execution
Working in Compressed Air
Ground Pre-treatment
Drainage During Construction
Disposal of Tunnel Seepage and Waste Water
Testing
Grouting
Surface and Building Settlement Monitoring
Contractors Obligations
Microtunnelling Machine
9.7
THRUST SYSTEM ...................................................................................... 28
9.8
LUBRICATION HOLES................................................................................ 29
9.9
RECORDS ................................................................................................... 29
9.10
TESTING ..................................................................................................... 29
22
22
22
23
24
24
25
25
26
26
26
27
28
28
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9.6.16
9.6.17
9.6.18
9.6.19
9.6.20
9.6.21
9.6.22
9.6.23
9.6.24
9.6.25
9.6.26
9.6.27
9.6.28
9.6.29
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9.10.1 General
9.10.2 Watertightness
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30
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Part
Page 3
TRENCHLESS PIPELINE CONSTRUCTION
9.1
GENERAL
9.1.1
Scope
This part includes the specification for the construction of pipelines by microtunnelling,
pipejacking or other trenchless methods approved by the Engineer.
9.1.2
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General
Concrete
Ground Investigation.
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Section 1,
Section 5,
Section 23,
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General
Earthworks
Pipe Installation
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This Section
Part 1,
Part 2,
Part 3,
Part 4,
References
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9.1.3
BS 2494,.....................Materials for elastomeric seals for joints in pipework and pipelines
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BS 5228,.....................Code of practice for noise control on construction and demolition sites
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BS 6164,.....................Code of practice for safety in tunnelling in the construction industry.

Definitions
Pipejacking: technique for constructing pipeline by thrusting pipes or other permanent lining
of preformed units progressively into the ground by means of jacks or similar equipment
while excavation proceeds at the leading end.
Microtunnelling: small diameter tunnelling technique employing mechanical excavation

methods usually within a non-man entry guided tunnel boring machine with primary lining
inserted behind by jacking.
Shaft: excavated thrust and reception pits used for tunnelling operations.
9.1.5
System Description
The Contractor shall be responsible for the design of the pipes including joints to meet the
requirements of the method of construction.
9.1.6
Submittals
The Contractor shall submit complete data and details for the trenchless pipeline construction
for the Engineer's approvals follows:
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9.1.4
(a)
Structural design calculations for the trenchless pipeline and temporary works:
(i)
the description and specification of pipes and design calculations.
(ii)
details of the permitted angular deflection and draw for the proposed pipes.
QCS 2014

Part
Page 4
(iii)
the Contractor shall submit full details of the pipes together with details of
previous works undertaken using similar pipes.
(iv)
details of proposed manufacturer of pipes with relevant literature and details of

manufacturer's Quality Control system.
(v)
anticipated jacking loads.
(vi)
structural design of thrust walls.
(b)
Shop drawings.
(c)
Materials Specifications.
(d)
Method statements which shall include:

details of the specialist sub-contractor's qualifications and experience in microtunnelling together with project references including previous employers' names
and current contact details and a curriculum vitae of the proposed tunnelling
machine operator including details of relevant experience in Qatar and the
Middle East.
(ii)
detailed procedure for the Works.
(iii)
a description of tunnelling equipment with relevant literature and a statement

from the tunnelling machine manufacturer detailing a delivery schedule for spare
parts and consumables for the proposed tunnelling machines.
(iv)
preconstruction activities (geotechnical investigations including test pits).
(v)
safety procedures.
(vi)
handling and fixing of the inner pipe in the case of pipe jacking with larger
diameter pipes.
(vii)
programme of work, including proposed production rates.
(viii)
bentonite injection system details.
(ix)
detailed method statements for all other aspects of micro-tunnelling work.
(x)
where appropriate for the size of machine proposed, details of man access into
the tunnel and tunnel boring machine.
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(i)
Designs of thrust and reception shafts and detailed drawings.
(f)
Dewatering arrangements and disposal of groundwater.

Methods for dealing with different ground conditions.
Equipment layout at the thrust and reception shafts.
(h)
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(g)
(e)
(i)
Details of sleeving system.
(j)
Ventilation.
(k)
Lighting and communications.
(l)
Disposal of surplus excavated material:

(i)
details of the spoil separation process to produce clean slurry for recirculation to
the tunnel boring machine.
(ii)
details of the containment of the excavated material to prevent water and slurry
draining from the Contractor's designated working area or wagons. Lagoons for
storage and settlement of slurry from the micro-tunnelling process will not be
permitted.
(iii)
details of the purpose made tanks for settlement of slurry shall be provided.
(iv)
details of the solid waste disposal procedure to an approved tip in a manner

which does not cause spillage of slurry, mud or any other solid or liquid waste on
the carriageway.
QCS 2014

Part
(v)
Page 5
disposal of surplus water, once all solids have been removed, to an approved
surface/ground water outfall, if locally available, or removed by tanker to an
approved point of disposal.
(m)
Pilot bore.
(n)
Plan at 1:50 scale showing working plant positions, spoil removal faculties, materials
storage facilities, launch and reception shafts, fencing, offices, discharge lines, ground
water removal facilities, etc.
The Contractor shall not procure materials or begin construction of the Works until the
Engineer has approved all submittals. The Engineers approval shall not relieve the
Contractor of his obligations under the Contract.
9.1.7
The Contractor shall employ an approved specialist subcontractor experienced in trenchless

methods for the pipeline construction.
9.1.8
Quality Assurance
The Contractor shall employ an approved prequalified specialist subcontractor as designated

in the contract specific documentation. All personnel in the employment of the subcontractor
shall be experienced and competent in their respective tasks and shall work only under the
control of a qualified supervisor.
9.1.9
Site Conditions
The Contractor shall carry out additional geotechnical site investigations which he considers
necessary. The results of such investigations and laboratory testing together with the factual
and interpretive reports shall be submitted to the Engineer for approval. The Engineers
approval shall not relieve the Contractor of his obligations under the Contract.
9.2
TRENCHLESS PIPELINE CONSTRUCTION GENERALLY
9.2.1
Scope
Where a pipeline is designated in the Contract documents to be constructed by a trenchless

method, the Contractor shall not be permitted to adopt open trench methods and shall
confine his surface operations to working shafts and the area immediately adjacent to such
shafts. In locations where construction of pipelines is not indicated to be by trenchless
method, the Contractor may elect to construct additional lengths of pipelines by a trenchless
method in accordance with this specification, subject to the Engineers approval.
9.2.2
Surveys and Setting Out
Before commencing the excavation of any shafts for pipejacking or microtunnelling, the
Contractor shall
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(a)
establish at least four adequately protected bench marks comprising steel pins
embedded in a block of concrete adjacent to the shaft to facilitate the setting out of
the underground works
(b)
record the initial levels for pipelines beneath or across roads and submit a copy of
these to the Engineer
(c)
record and report with supporting photographs of the condition of structures, roads,
footpaths and other paved areas that are located over and beside all jacking or
microtunnelling routes.
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Part
Page 6
During construction of a drive between any two working shafts, the Contractor shall observe
levels on predetermined cross-section points at regular intervals to determine if there is any
subsidence.
Temporary benchmarks shall be set up along the centre of the pipe at 15 metre intervals
between the shafts and at 5 and 10 metres offsets. Levels shall be taken along the centre of
the pipeline and at offsets of 5 metres and 10 metres each side of the pipeline at 15 metre
intervals between shafts. Levels shall be taken and recorded on all of the above points at
daily intervals during micro-tunnelling works, again one week before issue of a Completion
Certificate, and finally at the end of the 400 day period of maintenance.
Immediately following completion of the drive between any two working shafts, the Contractor
shall
repeat the level survey of the ground surface along the centreline of the drive as
described above
(b)
record and report to the Engineer with supporting photographs any changes to the
condition of roads, footpaths and other paved areas.
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(a)
Before the completion of the whole of the Works and again before the expiry of Period of
Maintenance, the Contractor shall repeat the surveys and inspections as described above for
all of the trenchless pipeline construction.
The Contractor shall determine the location of all working shafts having due regard to
existing services, minimising disruption to traffic and pedestrian movements and achieving
the required system layouts, as approved by the Engineer. The Contractor shall prepare
suitably scaled working drawings for the setting out of the Works, including the location of
existing services and all other relevant details and submit these for the Engineers approval.
As-built surveys of each micro-tunnel drive shall be undertaken. For all micro-tunnel drives
of internal diameter 800 mm or more, including any permitted sleeves of this size, the
Contractor shall employ an approved independent survey company to undertake an as-built
survey of the drive. Coordinates and levels shall be provided for every pipe joint. For steel
sleeves, coordinates and levels shall be provided at 5 metre intervals. Each completed drive
shall be surveyed immediately after completion of the drive. No further micro-tunnel drives
may be commenced until the survey results have been submitted to and approved by the
Engineer. No pipes may be installed within sleeves until the survey results have been
submitted to and approved by the Engineer.
9.2.3
Monitoring Lines and Levels
A laser guidance system shall be used for the control of the pipe alignment. The shield/tunnel
machine shall be fitted with a calibrated laser target, robustly constructed and rigidly secured
to the shield/tunnel machine.
The setting of the laser and target and the alignment of the tunnel relative to the laser beam
shall be checked frequently at intervals as directed by the Engineer. In addition, the
Contractor shall verify the accuracy of the laser guidance system by conventional theodolite
and level control methods to the approval of the Engineer.
The invert level of the finished pipeline at the drive shaft shall be within 10mm of the
required level shown on, or interpolated from, the Contract drawings.
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The invert level and line of the pipeline shall at no point deviate from the design by more than
the following:
QCS 2014

Part
Page 7
Pipe Bore
Vertical
Horizontal
D mm
mm
mm
D < 600
20
25
600 D 1000
25
40
1000 < D 1400
30
100
D > 1400
50
200
The pipe manufacturers stated permitted draw or angular deflection shall not be exceeded at
any individual joint.
If the line and levels of any section of pipeline deviates from the design alignment within the
tolerances the shield/tunnel machine shall be steered in a manner that ensures a gradual
return to the correct alignment.
If the deviation in the lines and levels exceeds the tolerance specified above, the Contractor
shall stop work and immediately inform the Engineer. The Contractor shall submit proposals
to rectify the deviation. Work shall be resumed only on the written instruction of the Engineer.
Where micro-tunnelled sewers are required to connect into existing pipelines or pipelines
previously completed under this project, due allowance for the tolerance shall be made prior
to commencing the drive to ensure that the finished pipeline profile does not require the pipe
contents to flow uphill.
9.2.4
Temporary Site Facilities
In addition to the provisions of Section 1, the Contractor shall provide the following at each
thrust shaft as a minimum:
air-conditioned mobile office
(b)
telecommunication between the mobile office and the work crews
(c)
adequate ventilation
approved gas detectors and oxygen meters
(d)
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(e)
first aid kit.
9.2.5
Safety Requirements
The Contractor shall adopt safe working practices for tunnelling in accordance with BS 6164.
Only authorised personnel shall be allowed access to the Site.
The Contractor shall ensure that a suitably qualified safety officer is present during tunnelling
operations.
9.3
MATERIALS
9.3.1
Pipes
Pipe material and the lining and coating shall be as designated in the Project Specification. If
the use of other pipe material or lining and coating is proposed, technical details and
justification shall be submitted for the Engineers approval.
QCS 2014

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Pipes shall be designed to withstand the maximum axial thrust with a factor of safety of four
based on the full effective area of the pipe and the ultimate compressive strength of the pipe
material. For reinforced concrete pipes the full effective area at the joint shall be used. The
pipe design shall take into account both permanent service loads and temporary loads
encountered during installation.
Where GRP or similar material pipes with concrete surround are proposed the concrete shall
be regarded as sacrificial. The concrete surround shall be designed to withstand the
maximum jacking force. The design shall also ensure that the GRP or similar material pipe
is not subjected to forces during installation. Vitrified clay pipes shall be in accordance with
Clause 3.2 of this Section.
The Contractors submittals shall describe the measures to be taken to avoid the
development and transfer of grout shrinkage and expansion stresses to the pipe and to avoid
any adverse chemical reaction between the pipe and the concrete, grout or other materials
comprising the pipeline. The pipe manufacturer shall guarantee that the crushing and beam
strength of the pipe are sufficient for their intended use.
Joints in pipes shall be designed to avoid projections which could obstruct the travel of the
pipe. Joints shall be watertight under axial loading and at the permissible deflection of the
pipes. Quality control tests at the factory shall include subjecting the pipe joints, at maximum
permissible deflection, to a hydrostatic pressure of 0.2 MPa.
Standard pipes shall generally be of 2.0 m in length. Where required, pipes shall incorporate
lubricant injection holes spaced equally around the circumference. Concrete pipes with a
liner shall only be permitted to have lubricant injection holes in the concrete. Lubrication
holes shall be clear of joints and shall be plugged on completion of the work. Pipes may
incorporate lifting holes and fixing holes for securing temporary apparatus; all such holes
shall be threaded to enable plugs to be screwed into the sockets to withstand external water
pressures.
Joints which shall be used in conjunction with a resilient packing and shall be capable of
accepting repeated angular deflections as recommended by the pipe manufacturer without
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damage to pipe or loss of structural integrity
(b)
the ingress or egress of water or lubricant under the maximum test pressures
(c)
the ingress of either or both soil or groundwater onto the bearing surfaces.
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(a)
Unless otherwise directed by the Engineer the joint design for concrete pipes shall be such
that areas available for transmitting the maximum permitted thrust force will be sufficient to
ensure that with an angular deflection of 1 and with resilient packing material in place, the
maximum pressure applied to the joint bearing surface will not exceed 23.5 MPa for drives up
to 100 m in length and 21.0 MPa for drives in excess of 100 m in length.
Unless Authenticated independent test results acceptable to the Engineer are available, two
consecutive axial load tests incorporating a 1 angular deflection with the application of
double the maximum permissible thrust force (or, if greater, of the greatest thrust force that
the proposed thrust equipment can apply) shall have been successfully conducted without
visible crushing, cracking or spalling of the pipe being evident, before pipes will be accepted
for use. The tests shall be extended to record the loading at which visible signs of failure
become evident, and shall be carried out in an approved manner to simulate actual working
conditions. Pipes which have been submitted to the proof load test will not be permitted in
the Works.
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Where the Contractor elects to construct certain sections within larger diameter pipes and
grout the annular space, the external pipe may be of steel. The difference between the
external face of the inner pipe and the internal face of the outer pipe shall not be less than
150 mm. The steel pipe and the grout shall be regarded as sacrificial and the inner pipe shall
be designed as a stand alone pipe, capable of withstanding installation forces and soil, traffic
and groundwater loads.
11
Where the Contractor elects to construct certain sections not within larger diameter pipes,
pipe installation by trenchless methods shall continue until at least one additional length of
pipe beyond the limit of trenchless construction is exposed. The condition of the exposed
pipe and its exterior coating will be inspected by the Engineer. Where in the opinion of the
Engineer the pipe or coating has been excessively damaged during installation, the
Contractor shall submit a proposal for review by the Engineer, for demonstrating the
adequacy of the pipeline installed by trenchless methods and for rectifying defects. The
proposal shall also include jacking out of defective pipes.
12
Concrete jacking pipes shall comply with the provisions of BS EN 1916 and BS 5911-1.
13
Collars shall be manufactured from weldable stainless steel plate Grade 316 Ti (EN 1.4571).
They shall be provided with suitable stainless steel lugs or anchors to enable them to be cast
into the body of the pipe, if applicable.
14
Joints in concrete jacking pipes shall be in-wall flexible joints of the fixed collar type. They
shall be designed to include one or more joint seals. All joint surfaces which will transmit
load during installation shall be plane and free from irregularities that could cause high local
concentrations of stress.
15
The nominal internal bore of the micro-tunnelling pipes shall be as indicated on the Drawings
or as specified by the Engineer. The Contractor shall select an appropriate external diameter
for the pipe which shall be submitted to the Engineer for approval.
16
The design of the jacking pipes and determination of acceptable pipe fabrication tolerances
shall be the responsibility of the Contractor. Maximum compressive stresses applied to the
pipe shall not exceed 33% of the design compressive strength of the pipe and shall not
exceed the pipe manufacturers recommended allowable stresses.
17
Pipes for installation by micro-tunnelling shall be fit for purpose and shall be one of the
following:
Concrete designed specifically for jacking to BS EN 1916:2002 and BS 59111:2002+A2:2010 with a GRP pipe lining in accordance with Section 8 Part 3 Clause
3.4. . The GRP lining pipe shall incorporate watertight joints between adjacent pipes
and shall accept no longitudinal load during jacking. The joint between adjacent pipes
shall be designed to ensure concentricity of adjacent pipes and shall prevent
application of any lateral forces to the GRP pipe. The coarse aggregate used in the
manufacture of the pipes shall be crushed Gabbro rock. The external surface of the
pipe shall be coated with at least 300 DFT abrasion resistant epoxy. Pipes shall be
factory manufactured by an approved experienced manufacturer. Pipes shall not be
manufactured on-site.
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10
(b)
Concrete designed specifically for jacking to BS EN 1916:2002 and BS 59111:2002+A2:2010 with a polymer lining as described in Section 5 Part 14 Clause 14.6.
The coarse aggregate used in the manufacture of the pipes shall be crushed Gabbro
rock. The external surface of the pipe shall be coated with at least 300 DFT abrasion
resistant epoxy. Pipes shall be factory manufactured by an approved experienced
manufacturer. Pipes shall not be manufactured on-site.
(c)
Direct jack GRP pipes to BS ISO 25780:2011 shall be in accordance with Clause 3.4
of this Section.
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(d)

Part
Page 10
The joint between adjacent jacking pipes shall be designed to ensure concentric
alignment of adjacent pipes and uniform transfer of jacking forces from one pipe to the
next. The pipe joint shall consist of a substantial external stainless steel guide ring to
achieve this requirement. The joint shall also incorporate one or more EPDM or other
approved elastomeric sealing gaskets.
Joint Packing
Packers shall be incorporated into each joint in concrete jacking pipes in order to distribute
the jacking pressure and avoid point loads and to prevent damage to the ends of the pipes
during the jacking process. The packers shall not extend over the full joint width, a gap to the
inside surface should be left to prevent localised spalling, in accordance with the
The material used for packing shall withstand all imposed loadings applied during the
installation of pipes for each completed length without showing signs of deterioration or
distress. The initial thickness of the packing shall be such that the final joint gaps achieved
upon completion of the pipeline are a normal width of 8 mm.
The material proposed for the joint packing and its mechanical properties shall form part of
the pipe design submission from the Contractor.
9.3.3
Lubricant
Lubricant shall always be used. Lubricant shall be polymer or bentonite-based slurry

approved by the Engineer. It shall be stored and mixed in a manner recommended by the
supplier and tested before use. Sufficient quantity of the lubricant material shall be kept
available at Site.
9.3.4
Joint Sealant
The joint sealant for the jacking pipe shall be of the elastomeric ring type complying with
BS 2494. Joint sealants shall be stored in a manner recommended by the supplier.
9.3.5
Grout
Grout used for slurry replacement shall

consist of either ordinary or sulphate-resisting cement and water as determined by
geotechnical data and directed by the Engineer
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9.3.2
(b)
have nominal strength at least equivalent to the requirement for Grade 20 concrete.
(c)
have admixtures only if tests have shown to the satisfaction of the Engineer that their
use improves the properties of the grout, such as by increasing workability or slightly
expanding the grout.
Full details of the proposed grout mix including admixtures shall be submitted to the Engineer
for approval.
2
Grout used for annular space filling shall

(a)
be a low-strength foam concrete placed at low pressures.
(b)
have a mix density in the range 900-1200 kg/m
(c)
have free water/cement ratio not greater than 0.6.
QCS 2014

Part
Page 11
The internal pipe shall be filled with water to avoid floatation forces, hydration temperatures
and to resist forces during grouting. A 5 m high free vented standpipe shall be used. A free
venting standpipe of not less than 100 mm diameter shall be installed on the grout injection
feed to restrict grouting pressures to a maximum of 0.1 MPa. GRP carrier pipe and joints
shall be protected from the possible adverse physical or chemical effect of grout, and
compressible material shall be wrapped around the pipe.
THRUST AND RECEPTION SHAFTS
The dimensions of thrust and reception shafts shall be the minimum necessary to construct
the Works.
Excavations shall comply with the requirements in Part 2 of this Section. Dewatering, if
necessary, shall be conducted at a rate which will minimise the inducement of settlements at
the ground surface. The shafts shall be kept dry at all times.
The thrust wall of the thrust shaft shall be normal to the proposed line of thrust. The thrust
wall shall be sufficient to accept repeatedly the maximum permitted thrust force without
movement. The Contractor shall not thrust directly from permanent parts of any shaft, or
walls of other structures. The thrust wall shall not be joined to the jacking rig base concrete.
Shaft base slabs shall be capable of withstanding external uplift pressure from groundwater,
if any, in addition to other imposed loads.
Any tail tunnel which has been used as a reaction surface shall pass the designated
watertightness test at a time not less than 14 days after the load has been removed.
The design of the thrust wall and any other associated temporary works shall be such as to
prevent damage to any part of the permanent works.
Any void between the soil face used to provide a reaction to the thrust force and the thrust
wall shall be grouted up.
Where the excavation is in water-bearing ground, the Contractor shall provide means of
checking whether any solids are being removed with the water from excavation. Regular
checks shall be made to compare the volume of solids removed with the calculated volume
as a safeguard against excessive loosening or loss of material beyond the shaft dimensions.
The Contractor shall select the location of the drive and reception shafts. These locations
shall be submitted to the Engineer for approval. These shafts may be incorporated as part of
the permanent works. All modifications to the shafts converting them into access manholes
shall be completed at the Contractor's own expense. Details of the modifications shall be
submitted to the Engineer for approval and shall conform to those shown on the Contract
drawings.
10
Prior to commencing work at a shaft, the Contractor shall provide details of the shaft support
system, working plant position, spoil facilities, material storage facilities, dewatering
arrangements, etc. The details shall include a sketch of all the working facilities at the head
of the shaft.
11
Access down into the shaft for personnel and equipment shall be approved by the Engineer.
Hand railing set at a height of 1 100 mm above ground level together with toe boards and
protective netting to prevent equipment falling into the shaft shall be provided at each shaft.
Fencing shall be erected around each shaft site establishment to prevent the entry of
unauthorised persons.
12
The dimensions of shafts shall be the minimum necessary to safely construct the Works.
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9.4
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Backfilling of shafts shall be undertaken in accordance with Section 8 Part 2 Sub-Clause

2.3.3.
9.5
PIPEJACKING
9.5.1
General
The maximum lipping between edges of adjacent jacked pipes shall not exceed the
maximum tolerance given in Clause 9.2.3 of this Part.
The horizontal drive rate shall be maintained equal to the excavation rate throughout the
operation.
Where dewatering is required it shall incorporate standby facilities and shall have been in
operation sufficiently in advance to attain stable groundwater levels before beginning
tunnelling. If, during the course of the work, the shaft face becomes unstable through water
ingress, it shall be immediately sealed and made safe.
Damaged pipes shall be replaced either by pushing through to the end of the line or broken
out and replaced by pushing up adjacent pipes.
The Contractor shall ensure that oil and lubricant spillage is minimised. Any spillage of oil or
lubricant shall be cleared as soon as is practicable and the inside of the pipes shall be
cleaned on completion of the pipejacking.
9.5.2
Tunnelling Shields for Pipejacking
Where considered necessary, the Contractor shall provide and maintain a shield suitable for
excavating in the ground conditions as envisaged by him and in accordance with his chosen
method of excavation. In determining the type of shield and method of excavation to be
used, the Contractor shall take account of the need to ensure that the face of the excavation
is adequately secured at all times such that ground loss is kept to a minimum and is
controlled to prevent excessive ground loss. The shield shall be removed on completion of
the tunnelling operation.
Rotating excavating heads fitted to shields shall be capable of rotating clockwise and
counter-clockwise.
The shield shall be equipped with steering jacks and such beads, ploughs and copy cutters
as may be required for adjusting the alignment of the pipes.
Multiple lubricant injection points shall be provided within the shield in order to provide
immediate ground support when necessary.
9.6
MICROTUNNELLING
9.6.1
General
Micro-tunnelling shall be defined as a method of installing pipe or casing by jacking the pipe
or casing behind a remotely controlled, laser guided, steerable, guided tunnel boring machine
which fully supports the excavated face with fluid and/or earth pressure balance at all times.
Micro-tunnelling pipe is defined as pipe or casing capable of withstanding installation jacking

and any other construction loads in addition to permanent live and dead loads.
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The method to be employed for micro-tunnelling shall be selected by the Contractor to suit
ground conditions and ground water pressure. The Contractor shall submit a detailed
method statement which shall be approved by the Engineer prior to commencing microtunnelling.
9.6.2
Contractor Responsibilities
The Contractor shall carry out, and be responsible for, the detailed design of:
(a)
The micro-tunnel;
(b)
All associated works (including shafts, connections, etc.).
The design shall be prepared by qualified design engineers or other professionals who
comply with the criteria stated in the Specifications. The Contractor warrants that he, his
designers and design sub-contractors have the experience and capability necessary for the
design. The Contractor undertakes to ensure that the designers shall be available to attend
discussions with the Engineer at all reasonable times.
The Contractor shall satisfy himself that he has sufficient geotechnical details before
commencing the detailed design. If available, a copy of existing geotechnical investigation
reports shall be provided to the Contractor. These reports are provided for information only
and the Contractor is advised to corroborate the details provided and commission any
additional site investigation works he deems to be necessary.
The Contractor shall be responsible for ensuring that he avails himself of all necessary
utilities information, existing and proposed, prior to commencement. Where available, a copy
of existing utilities information shall be provided by the Engineer. These reports are provided
for information only and the Contractor shall be responsible for ensuring that the information
collected is the most recent and factual record of existing and proposed services in the
project area. The Contractor shall utilise appropriate equipment and methods to aid him in
the determination of the line and level of existing utilities apparatus. This may be undertaken
either by the Contractors own staff or by specialist sub-contractors.
The Contractor shall be responsible for obtaining all approvals/consents required for the
disposal of excavated material/spoil that is surplus or unsuitable for incorporation in the
permanent works. The Contractor may propose, subject to the approval of the Engineer,
remedial measures to be taken for the improvement of earthwork arisings, which are not
suitable in the as-dug condition, for use in the permanent works.
The Contractor shall allow the Engineer full access to real time micro-tunnelling data any time
during construction.
9.6.3
Safety and Environment
The Contractor shall carry out all works to the requirements outlined in all current appropriate
Regulations, Codes of Practice. The following recognised documents shall form the basis for
guidance and development of the safety plan and site procedures:
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(a)
UK Health and Safety at Work Act including the provisions of BS 5228, Parts 1 and 2;
(b)
BS 6164: Safety in Tunnelling (Code of Practice);
(c)
Guide to Best Practice for the Installation of Pipe-jacks and Micro tunnels.
The Contractor shall develop a safety plan to encompass all aspects of safety and
environmental requirements prior to commencement of the work. This plan shall be a
working document and be subject to continuous review throughout the period of the contract.
All machinery, including hoists shall be suitable for quiet and efficient operation and shall be
installed and maintained to an acceptable safety standard.
QCS 2014

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Page 14
A site safety culture shall be instigated on-site prior to work commencing and be developed
throughout the course of construction. The culture will comprise of the use of key
management tools by the site management (and outlined in the site safety plan) in educating
the site operatives in all aspects of best safety practice and awareness in their work. An
induction session shall be given to all operatives and staff irrespective of their discipline and
experience. This should, in particular outline all local requirements relating to the contract,
actions to be taken in event of emergencies, and an overview of the Site and its personnel.
The content of the induction may be varied to suit the recipients. Each operative shall
receive training, together with any appropriate examination or documentation, to ensure he is
completely aware of the requirements of each aspect of his job and the hazards which are
inherent in its execution.
The Contractor shall produce a risk/hazard analysis of the key elements of the pipe-jacking
operation and utilise the results of the analysis in reducing such risks that remain to a
minimum. Such hazards shall be communicated to workers through induction, tool box talks
and the like.
The Contractor shall develop and implement a plan for immediate underground evacuation in
the event that the presence of toxic/inflammable gas is identified in the excavation. In such
case the Contractor shall identify and take appropriate action to rectify such hazard prior to
allowing work to recommence.
Appropriate training and certification shall be given to all operators of plant. This shall be
carried out only by engineering staff competent in the use and hazards associated with the
particular item of plant concerned.
9.6.4
The micro-tunnelling system shall be selected by the Contractor to suit local ground and
groundwater conditions. The Contractor shall submit a detailed method statement for
approval by the Engineer prior to starting micro-tunnelling work.
Micro-tunnelling operations shall be carried out in a manner that minimizes ground

movement in front of and surrounding the pipeline. Settlement of the ground surface shall be
minimized. Damage to structures and utilities above and in the vicinity of the underground
operations shall be prevented.
The ground shall be continuously supported in a manner that prevents loss of ground and
maintains the stability of the tunnel face and perimeter at all times.
A full work force shall be maintained on a continuous basis (24 hours per day) during any
emergency or work stoppage that could endanger the tunnel excavation, sub-surface
infrastructure and surface facilities.
Dust, noxious gasses or other atmospheric impurities shall be actively controlled in

accordance with the relevant Qatar occupational health and safety legislation. Approved
instrumentation for monitoring air quality in work areas and pipelines accessed by personnel
shall be provided. This environmental control and associated procedures to be followed in
monitoring shall be fully documented in the Contractors Safety Plan.
All micro-tunnelling and underground construction work shall be performed in accordance

with the relevant Qatar occupational health and safety legislation and the approved
Contractors Safety Plan. This Plan shall include safe procedures to mitigate risks associated
with the work, including identification and logging of any and all visitors into and out of the
underground works and prevention of unauthorized entry. Safe procedures shall also be
established for personnel entering the tunnel to carry out maintenance or for other purposes.
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QCS 2014

Part
9.6.5
Micro-tunnel Design Elements
Tunnel Pipe Design
Page 15
The watertight lining pipe shall be installed by single pass pipe jacking using a remote
controlled tunnelling operation to the alignments and grades shown on the drawings.
Remote controlled tunnelling operations apply to trenchless pipe installation by microtunnelling where the carrier pipe is installed directly behind the tunnelling machine and
the machine provides support to the excavation face at all times.
(b)
All jacking pipes, including special designs, shall be sufficiently reinforced with steel to
withstand all stresses induced by handling, jacking, earth and water pressures and all
working loads at the depths at which they are to be used without cracking, spalling or
distortion. A load factor of not less than 1.5 shall be used in the calculations to
determine the strength of the pipes required. The clear cover to any steel
reinforcement shall not be less than nominal 50 mm. The pipes are designed and
calculated in according ATV 161 (Technical Standard of pipe jacking).
(c)
The strength of the pipes shall be tested by a three edge bearing test. When
subjected to the design load in such a test, the maximum crack developed on the pipe
shall not exceed 0.25 mm. If this test not possible an equivalent quality control and
security system has to be developed.
(d)
All pipes shall be manufactured by a supplier approved by the Engineer. The process
of manufacture may be by centrifugal or vertical casting subject to submission and
approval by the Engineer. All pipes shall be cast with a minimum of 3 grout holes
equally spaced around the pipe wall. A steel threaded insert ( to 1 BSP minimum
dimension) shall be cast in each hole. All pipes shall be of spigot and socket design
with an integral steel collar cast on the socket or trailing end. The collar shall be
suitably and securely fixed to the reinforcing cage of the pipe prior to the pipe being
cast. Each pipe shall have a 75 mm dia lifting hole or lifting anchor cast in the top
centre to facilitate a lifting device. All pipes shall have their date of manufacture clearly
and indelibly marked on them. All pipes shall be fully cured and have reached the
designed concrete strength prior to delivery.
(e)
The Contractor shall submit full details of his proposals for the pipes, giving detailed
drawings showing sizes, reinforcement and jointing arrangements, all cast in items and
concrete design including specifications for all component materials. A full set of
design calculations including the parameters adopted for the design shall also be
submitted.
The name of the manufacturer, place of manufacture and manufacturing process shall
be identified at an early stage and provision made for inspection of such facilities by
the Engineer for his approval.
(f)
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(a)
(g)
The jacking equipment including any required intermediate jacking stations shall have
a capacity of not less than 20 per cent greater than the calculated theoretical
maximum jacking load.
(h)
The design of the tunnel shall take into account the required life span, the proposed
use, the ground conditions, the sequence and timing of construction and the local
existence of adjacent structures. Relaxation of stresses in front of boring machine and
excavation, installation and water-tightness of lining pipe should be considered. The
required life span is 100 years. 100-year durability design shall meet the requirements
of BS 8110.
(i)
Numerical methods shall be used to evaluate the loading on the lining pipe. Results of
the numerical calculations shall be used to assess surface settlements. The
Contractor shall specify, justify and explain the model he intends to use. The
Contractor shall also submit two licensed English versions of the software including all
manuals, to the Engineer.
QCS 2014
(j)
Page 16
The Contractor shall be solely responsible for the accuracy of the numerical model and
the assumptions necessary to fully simulate the anticipated ground and the tunnel
excavation within it, the installation of any support measures and the construction of
the permanent tunnel lining system. The Contractor shall provide in his Design
Submission numerical simulations which are applicable to and reflect the work and
construction stages proposed by him. State of the art modelling techniques, material
properties, simulation procedures and material definition, shall be applied. In addition
the Contractor shall at least consider the requirements as outlined below for the
modelling process:
Tunnel Access Shaft

The positions of the micro-tunnel shafts and tunnel are shown on the Contract
Drawings. The Contractor may suggest alternative positions to suit his equipment and
works programme. The final depth and position of the shafts and tunnel however shall
be subject to the approval of the Engineer.
(b)
The working shaft shall be designed to withstand the force applied by the main jacking
station and of adequate dimensions to fully cater for the underground installation of all
necessary pipe-jacking equipment. This will include the jacking frame and thrust ring
assembly, slurry pumping equipment, electrical isolation box and guidance system.
Consideration must also be given to safe access and working space for the pit bottom
crew. The design of the shaft base shall incorporate the requirements of a thrust block
for the jacking frame to bear upon and a tunnel launching eye and sealing ring through
which the TBM is launched. The design of these structures will depend on the type of
ground and jacking pressures envisaged. They are normally considered to be
temporary structures, being removed on completion of the drive, but consideration may
be given to incorporating them in the permanent works wherever possible.
(c)
Requirements for launching the TBM assembly, which may comprise multiple units of
varying length, shall also be taken into consideration when deciding upon the overall
size of the shaft base.
(d)
Micro-tunnel shafts shall be placed at main road intersections to take drainage from
the surrounding areas.
(e)
Micro-tunnel shafts shall be built to Employers standards and requirements. The

Contractor may propose alternative designs subject to the approval of the Engineer.
(f)
Shaft openings shall be located within the central reservation or footway areas. No
openings shall be accepted within the highway carriageway.
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(a)
The design of the tunnel shafts shall take due account of the following:
(i)
Need to provide a structurally sound and stable reinforced concrete shaft wall
and superstructure that shall comply with all relevant BSI standards. Design
calculations and materials shall be submitted for approval to the Engineer prior
to any construction work being undertaken.
(ii)
All shafts shall be watertight.
(iii)
All shafts for sewerage applications shall be full lined internally with GRP in
accordance with Part 4, Clause 4.4.1.
(iv)
All shafts for surface water / ground water applications shall have a combination
of GRP lining and epoxy protective coating internally in accordance with Part 4,
Clause 4.4.2. .
(v)
Where practical, the underside of the base slab and external faces of the walls
shall be protected by a membrane tanking system. Where this is not possible,
the Contractor shall propose a protection system for approval by the Engineer.
(vi)
All ladders, platforms and handrails, where shown on the Contract Drawings,
shall be to QCS Section 8, Part 6, Clauses 6.4.1 to 6.4.7. Platforms shall be
provided at maximum distances of 6 metres and shall be positioned to allow

Part
QCS 2014

Part
Page 17
maintenance equipment to be lowered unhindered to the base of the shaft.

Ladders shall terminate at platforms and be staggered between platforms.
(vii)
Down-pipes shall be secured by stainless steel brackets to the inside of walls.
9.6.6
Design Checking
All drawings and calculations intended for incorporation into the design package shall be
checked by an approved Independent Checker. Evidence of the extent and scope of
checking carried out on each set or subset of calculations shall be provided either in the form
of parallel calculations or by marking up the calculation sheets or by providing a summary on
the cover sheet.
All drawings shall be checked with due consideration for the following:
completeness;
(b)
compliance with the relevant requirements of the Contract Documents;
(c)
consistency between calculations, schedules, reports, drawings, specifications;
(d)
compliance with standards, codes, regulations and statutory requirements;
(e)
dimensional accuracy and presentation.
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(a)
With his approval the Independent Checker confirms that the relevant documents are in
compliance with the Employers requirements, relevant local and international standards and
designed correctly.
9.6.7
Finite Element (FE) and Finite Difference (FD) Models
A numerical analysis shall be carried out and fulfil the following geometrical requirements:
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Notwithstanding the requirements as listed below the mesh layout shall be such that
numerical accuracy is guaranteed. If required, the Contractor shall perform sensitivity
studies with different levels of mesh refinement.
(b)
Width of mesh shall extend at least two tunnel diameters beyond the limits of the
tunnel lining.
(c)
The model used for the design at the ground sections of the tunnel shall be capable of
considering the joint system and joint properties of the ground strata, by either explicitly
modelling joint systems or applying suitable models with equivalent properties.
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(a)
Element size around excavation contours shall not be larger than those elements that
correspond to an angle of 10 degrees along the arch. Infinite elements shall be used along
the border of the mesh or a suitably large mesh shall be proposed so that the influence of
boundary of mesh is negligible for FE models: The practical limit of the aspect ratio of zones
should be kept to approximately 1:4 or less in order to achieve reasonable solution accuracy.
The practical limit for FD models of the aspect ratio of zones should be kept to approximately
1:1 or less in order to achieve reasonable solution accuracy.
Each computation shall be accompanied by a report that shall at least include a description
and interpretation of:
(a)
definition of the mesh;
(b)
selection of design sections;
(c)
definition of geological strata;
(d)
selected input parameters;
(e)
material models used;
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(f)
results including surface settlements and expected deformations in the tunnel;
(g)
dimensioning of the tunnel lining.
Verification of Results
Numerical calculations for the design of the lining shall be verified using different analytical
methods.
9.6.9
Design Parameters for the Calculations
Parameters required for the design and not defined in this document shall be established by
the Contractor. All details on these parameters shall be provided by the Contractor in his
Design Basis Report subject to the consent of the Engineer.
The results of site investigations carried out are to be summarised in the Data Reports and
the Contractor shall conduct supplementary site investigations within the project area as
designated and/or where considered appropriate. The interpretation of all site investigation
data, including the interpretation of the Data Reports and of the bore logs shall be the
responsibility of the Contractor. The Contractor shall justify and explain the derivation of all
his geotechnical parameters in his geotechnical interpretative report. The geotechnical
parameters used for the design require the consent of the Engineer. The worst credible
ground parameters as identified in the site investigation data shall be used to check the
micro-tunnel lining (at the ultimate limit state).
9.6.10
Design Loadings
The Contractor shall include for the following loads in his calculation of the stresses and
strains induced in the installed pipeline:
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9.6.8
Ground/Rock Loads;
(b)
Water Loads: Groundwater levels with sufficient safety margins for the design shall be
determined from groundwater observations. The design calculations shall be carried
out both for an upper bound and a lower bound of the ground water level subject to the
consent of the Engineer;
(c)
Live Loads: For underground structures under a roadway, a live load as defined in BS
5400, Part 2 for highway bridges considering type HA loading combined with 45 units
HB loading shall be allowed for in the design;
Surcharge Loads: For all underground structures and in locations where live loads as
specified above do not apply, a surcharge load of 22.5 kN/m applied at ground level
shall be allowed for in the design;
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(e)
All other loads.
The Contractor shall take into account any other loading criteria which may be applicable to
achieve the full performance of the micro-tunnel, including water pressures under operational
conditions within the lined tunnel.
In addition to the design sections as defined above the Contractor shall carry out case
studies of all relevant and possible combinations of geological, hydrogeological and
geometrical conditions as necessary for his design and construction. The Contractor shall
also provide calculations in accordance with the soil /rock classification proposed by the
Contractor and based on the Contractors geotechnical interpretation. The Contractors
calculations shall cover all possible geotechnical conditions anticipated over the entire tunnel
length. Notwithstanding the calculations as requested above, the Contractor shall consider
within his design submissions one numerical simulation of the tunnel construction of at least
every 400 m of the bored tunnel section. Within the Preliminary Design Submission the
Contractor shall propose these calculation sections which shall be subject to the consent of
the Engineer.
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9.6.11
Design Submissions
The Contractor shall submit his proposed detailed design report to the Engineer for approval,
not less than four weeks prior to his intended construction start date for this element of work,
or as specified by the Engineer. The submission should include, but not be limited to, the
following :
Summary of all subjects addressed in the design stages;
(b)
Summary of the design criteria adopted in the design stages;
(c)
Final hydraulic model for overall drainage system including all input and output data;
(d)
Final hydraulic design and calculations for overall drainage system including
connections;
(e)
Final hydraulic design and calculations for the temporary pumping station if required.
4 no. complete sets of detail drawings-paper prints (A1) to include:
The modified positive surface water drainage system and micro-tunnel plans at
1:1000 scale based on survey sheets and incorporating coordinate grid,
proposed sewers connections, access and maintenance shafts, invert, cover
and ground levels. Key plan of the proposed system plans including coordinate
grid, contract area, sewer connections, main building and road/street names,
and layout plan of the temporary pumping station sites at 1:100 or 1:50 scale if
required.
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(a)
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For the purpose of obtaining all necessary approvals on completion of the detail design
stage, the Contractor shall submit to the Engineer the following:
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Sections of micro-tunnel and the modified positive surface water drainage system at
1:1000 horizontal and 1:100 vertical scales. Sections are to be related to each the
system plan and include chainages, access and maintenance shafts number, invert,
cover and ground level, tunnel diameter, gradient, terrain crossed, major service
crossings and any connecting branch sewer details.
(b)
(c)
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Standard drawings for the modified positive surface water drainage system, microtunnel cross section, access and maintenance shafts and miscellaneous details to
appropriate scales based on Employers standards.
4 no. complete sets of the detailed construction specification;
4 no. Bills of Quantities, containing the principal items;
(a)
(d)
The submittal of the detail design for approval shall also be accompanied by 4 copies
of a comprehensive Engineering Report including the design calculations, which will
detail revisions and amendments to the design subsequent to the approvals given for
design. The report shall include copies of the comments made on the design and
corresponding actions taken;
(e)
Drawings, designs, documents and reports submitted for approval will not be accepted
if there is no evidence of internal, qualified, checking; or if the quality of the contents of
the Drawings and documents clearly indicate that they have not been checked
thoroughly;
(f)
Partial submittals will not be accepted.
If significant changes are required to the above original document submissions, the
Contractor shall re-submit to the Engineer.
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Certification Procedure
The entire design of the Bored and any Cut and Cover Tunnels (layout design, structural
design and geotechnical design) shall be checked by the Accredited Checker. On
completion of the design and check the respective certificates shall be submitted to the
Engineer in accordance with the UK DMRB BD 2/02.
The Contractor shall provide a certificate of assurance from a reputable TBM manufacturer
or refurbisher to warranty that the proposed TBM is fit for purpose to carry out the intended
works.
At least four weeks before the commencement of any tunnel excavation works, the
Contractor shall submit to the Engineer test certificates concerning all material properties and
characteristics as defined in the relevant sections herein and/or used for tunnel design
purposes from an independent and acknowledged source.
9.6.13
Contractors Documents
The Contractors Documents shall comprise, but not be limited to the following:
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Safety Procedure Manual (Project Specific Safety Plan);
(b)
Risk mitigation plan;
(c)
Contingency plan;
(d)
Pre-construction inspection reports of adjacent properties and utilities;
(e)
List of drilling team (Names, qualifications, experience, training, etc.) and management
control.
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Full details of the micro-tunnelling system shall be supplied with the above submittals,
including:
Type(s), number(s) and model reference of proposed micro-tunnelling system.
If not from single source, detail main elements of the system.
(b)
Written confirmation from manufacturer (with company seal) that the machine
configuration is suitable for the external diameter of pipe proposed.
(c)
Cutter face details, including tooling and face port opening dimensions.
(d)
System of alignment control and steering control and activation.

Full details and justification for excavation and spoil disposal method(s).
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9.6.12
(f)
Hydraulic jacking system maximum capacity and method of limiting to maximum

jacking pipe capacity.
(g)
Details of any intermediate jacking stations.
(h)
Electrical system and on-site power supply.
(i)
Proposed communication system between the MTBM (Micro-Tunnel Boring Machine)

and operating personnel on the surface.
Full and comprehensive details of the procedures and resources that will be used to perform
the work shall be provided, including;
(a)
Machine launch and reception;
(b)
Pipe handling and connections;
(c)
Supplementary alignment surveying;
(d)
Excavation and spoil disposal;
(e)
Closure of any intermediate jacking stations;
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(f)
Emergency procedures;
(g)
Ventilation of tunnel, including gas monitoring.
(h)
All materials, including slurry, lubricants;
(i)
Location of approved spoil disposal facility;
(j)
Drawings showing layout, temporary equipment locations and complete jacking set-up
in typical jacking shaft.
Daily logs shall be used to record the micro-tunnelling work and any associated delays. The
log shall be submitted to the Engineer for record purposes on a weekly basis. The basis of
the log shall be the electronic data recorder that operates with the micro-tunnelling system.
The log shall include:
MTBM alignment deviation data and applied jacking load shall be recorded at intervals;
(b)
Alignment deviation shall not exceed 0.3 m in 5 minutes;
(c)
The commencement and completion of jacking of each pipe section;
(d)
The operating pressure if pressure balanced system is used;
(e)
Quantities of lubricant injected;
(f)
Air quality monitoring results;
(g)
Unusual events.
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Part
Construction Responsibilities
During construction, the Contractor shall be responsible for:
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9.6.14
Providing a temporary and secured drainage system for the Works (N.B. restricted
access, safe and dry working environment, etc.);
(b)
Taking all necessary precautions to protect the tunnel and/or adjacent properties from
flooding (e.g. groundwater may be problematic in the area);
(c)
Provision of a temporary wall, if required, to enable the executed tunnel section to

serve as temporary storage.
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The Contractor shall provide temporary pumping facilities to the extent required to avoid
delays to the construction programme and quality of the work. The Contractor shall also
indicate any EFA sites (Emergency Flood Area) if required for flood alleviation works during
the construction works and confirm the availability of the land. The Contractor shall be
responsible for the fencing, safety and security of any temporary EFA areas. Any fuel and/or
power sources shall be provided as appropriate. All facilities/connections in this respect shall
comply with standard regulations regarding their storage and/or use.
The Contractor however shall be responsible at his cost for providing temporary submersible
pumps to evacuate any flooded tunnel sections and discharge to an acceptable outfall point.
9.6.15
Quality Assurance/Control
All pipes delivered to site shall be the subject of inspection and approval by the Engineer
before they can be incorporated in the Works. Any and all rejected pipes shall be immediately
removed from site and replaced with pipes acceptable to the Engineer. Pipes and pipe
gaskets shall be stored or stacked on-site in accordance with the manufacturers
recommendations.
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Every jacking shift shall be supervised by at least one person with previous experience of
micro-tunnelling work. Operators of the micro-tunnelling system shall have prior knowledge
and ability in its proper operation and shall run test the system after set-up and before
starting the drive. The Contractor shall follow manufacturers instructions when operating the
complete system and operational manuals shall be available to site operational personnel at
all times.
The installed pipeline shall be subject to visual inspection. Visible leaks (flowing or dripping
water) in pipes, pipe joints, manholes and structures shall be repaired even if leakage test
requirements are satisfied.
9.6.16
Materials
Pipe repair materials shall be supplied by the pipe manufacturer as suitable for the intended
purpose and applied strictly in accordance with the pipe manufacturers instructions. Water
used for lubricant or grout shall be of neutral pH and shall be clean, fresh and free from oil,
organic or other deleterious matter. Polymers shall be non-toxic and grout for filling voids
outside the installed micro-tunnel pipeline shall be designed by the Contractor and submitted
for approval. The pipe material shall be reinforced concrete (RC) or GRP subject to the
The Contractor shall also submit a sample of the pipe wall section, joint band and gasket
seal. This wall section shall be completely fitted with the proposed grout bush and flush
fitting plug to be watertight.
The Contractor shall obtain the pipe manufacturers warranty that the pipe conforms to the
specifications and shall be free from defects in materials and workmanship.
9.6.17
Temporary Works
The Contractor shall develop his temporary works design taking into account all site
constraints identified elsewhere in the Contract Documents. The Contractor shall provide
clear method statements detailing all stages of the temporary works including supporting
calculations for the temporary works. These method statements shall be issued to the
Engineer before works can commence. Calculations shall be included where relevant, e.g.
as part of settlement checks on adjacent structures. A Detailed Safety Plan identifying
hazards and mitigating measures shall also be included in the Temporary Works Method
Statements.
9.6.18
Construction Preparation
The Contractor shall be responsible for:
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the means and methods of micro-tunnelling and pipe jacking operations and shall be
solely responsible for and shall ensure the safety of the work, his site personnel, the
public and adjacent property (public and private);
(b)
maintenance of clean working conditions at all locations at all times;
(c)
control and implementation of safety precautions for personnel entering pipeline;
(d)
organizing equipment in all areas to ensure safe operation at all times;
(e)
providing safeguards to prevent leakage of fuel or lubrication oils from micro-tunnelling

system equipment. Hydraulic oils used by the Contractors plant shall be biodegradable and non-flammable.
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The pipeline shall be placed within 50 mm of the vertical and 200 mm of the horizontal
alignment shown on the Drawings. Steering corrections shall be made to the pipeline so that
the joint to joint angle of any two adjacent pipes does not exceed 0.5 degrees. The
Contractor shall submit daily records of deviations.
Each section of pipe shall be jacked forward as the excavation progresses in such a manner
that complete and adequate ground support is provided at all times and such that joints
maintain their integrity and the pipe train continuity is maintained.
The Contractor shall ensure that jacking loads do not exceed the manufacturers safe jacking
capacity by effective management of the pipe jacking alignment and pipe lubrication controls
(intermediate jacking stations).
No damaged pipes shall be permitted to be used in the permanent works. Pipes damaged in
the casting and handling process in the factory shall not be permitted on-site. Repairs to cast
pipes, either in the factory or on-site shall be confined to minor cosmetic repairs only. All
repairs shall be subject to the approval of the Engineer and carried out to an approved
procedure. Any pipes identified as being unfit for use in the tunnel shall either be removed
from site and destroyed or clearly marked and quarantined for later inspection and possible
repair.
A proprietary seal of rubber or EPDM shall be incorporated in each pipe joint, including joints
between pipes and inter-jacks / TBM. The design of the seal shall be commensurate with the
detailing of the pipe joint. Seals may be fitted either at the place of manufacture or on-site
prior to placing of the pipe below ground. In either case the seals shall be fitted in accordance
with the manufacturers instructions. Seals shall be inspected for damage by the surface
crew immediately prior to pipe use and any damaged seals replaced. Pipe seals shall be
suitably lubricated with a soap solution or other such compound in the pit bottom immediately
prior to closing the joint with the jacking frame.
A minimum of 30 mm thick Medium Density Fibreboard (MDF) packer shall be fitted to the
socket face of each pipe prior to the pipe being used in the tunnel. The packer, comprising
several segments to form the 360% annulus, shall be firmly glued to the socket end and in
such manner as to be 25 mm inset from the intrados of the pipe. These packers may be
fitted on either at the factory or on-site, however it should be noted that in wet weather
conditions suitable protection may be required in cases of lengthy exposures.
Pipes shall only be lifted on-site using the cast in lifting hole or lifting anchor and a purpose
made lifting device. Such device shall be fully tested and carry relevant certification. Pipes
shall be stored in an orderly fashion in a designated area, not more than two pipes high and
on purpose made timber supports.
Pipes shall be power lowered by crane or gantry down the working shaft and set on a
purpose made cradle comprising the base of the jacking frame assembly. The cradle shall
have been set true to line and level prior to commencement of the jacking and secured to the
shaft bottom. The thrust wall assembly behind the jacking frame shall also be set at right
angles to the line of drive to ensure that no misalignment occurs at the pipe joint on closure.
The lifting device shall be removed from the pipe prior to the joint being closed and jacking of
the pipeline recommenced. The lifting hole shall be sealed with a precast concrete plug and
rapid setting mortar prior to the hole location passing through the eye seal. Jacking of the
pipeline shall be carried out in such manner as to limit any deflection at a joint to the
manufacturer's recommended maximum. Pipe loadings shall normally be limited to 50% of
the design load (or similar as agreed) whereupon an inter-jack assembly shall be installed.
On completion of a drive the line shall be fully inspected for damage or leaking joints. The
Contractor shall propose remedial works in such cases. Holes used for injection of lubricants
shall be filled with an approved mortar to a smooth finish at the intrados of the pipe.
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9.6.19
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Construction Execution
All excavation works shall be properly set out to the line, level, curve or slope required within
accepted tolerances. Survey stations, centre lines, bench marks and grade lines shall be
clearly marked in paint on the tunnel walls. Chainages at 10 metre intervals shall also be
clearly marked by appropriate permanent means.
Internal tunnel marking shall be done prior to jacking any lining pipes. This method can be
used to mark the exact location of any problem areas during the jacking operation.
The Contractor shall establish and maintain reference control lines and grades for the Works,
which shall be used to exactly locate the pipeline and structures. The primary control for the
micro-tunnelling system shall be checked at least once per week or not more than 60 metre
intervals of constructed pipeline.
9.6.21
Working in Compressed Air
Provisions shall be made on the tunnelling machine to facilitate entry into the face of the
machine under compressed air for inspections and maintenance. These provisions shall
comply in all respects with all relevant statutory regulations governing work in compressed
air. The airlocks and other equipment fitted to the machine shall comply with the
requirements of CENprEN12110.
All equipment and personnel necessary to perform such interventions for inspection or
maintenance shall be available throughout the pipe-jacking operations.
The Contractor shall submit details of the compressed air installation for the Engineers
approval, along with details of the qualification and previous experience of lock attendants,
medical lock attendants, compressor attendants and supervisory staff.
In highly permeable ground where air losses might be excessive, arrangements shall be
made to inject thick bentonite slurry into the face prior to an intervention to form a cake on
the exposed face in order to limit air loss.
Air compressors shall have a standby capacity of at least 50% and be powered by an
independent power source.
All essential parts of the compressed air system, including pipelines carrying compressed air
to the face, shall be duplicated. All pipework, valves, gauges, etc. must be protected from
impact damage. Where flexible hoses are used to carry the compressed air through the pit
bottom jacking arrangement they shall also be protected from entrapment. In the event of
failure of one part of the system it should be possible to isolate that part without interrupting
the air supply.
A safety valve shall be fitted to free air side of the pressure bulkhead of the tunnelling
machine. This safety valve shall be set to relieve at marginally above the working pressure
and shall be of adequate size to match the installed capacity of the air compressors. Prior to
any work in compressed air the system should be tested to working pressure.
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9.6.20
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Any airlock fitted to the tunnelling machine shall be at least 1.5 meters diameter. The air lock
should be designed as a pressure vessel, subjected to a hydraulic test and issued with an
appropriate test certificate. Air lock doors should be at least 500 millimetres by 400
millimetres. Doors should normally be kept closed by the air pressure but the door opening
to the front of the tunnelling machine should also be able to be locked shut whilst persons are
being decompressed in the lock. The airlock should be comprised of two chambers to allow
access into the working chamber in case of emergency. For use at pressures above one bar
the lock should be fitted with seating for the persons being decompressed. Where the
working pressure is above 0.7 bar a medical lock shall be provided which shall be manned by
a medical lock attendant whenever work in compressed air is in progress and for twenty four
hours afterwards. If necessary the quality of the compressed air supplied to the working
chamber shall be improved by coolers and filters to ensure compliance with the specified
requirements. The supply of compressed air to the working chamber shall be sufficient to
ensure that the level of any contaminant shall not exceed 10% of the short term exposure
level when measured at atmospheric pressure. Air quality should be monitored at least once
per day.
The Contractor shall appoint a registered medical practitioner experienced in compressed air
work to advise on decompression methods to be adopted and on all other aspects of health
relating to the work in compressed air. All employees will be medically examined prior to
working in compressed air. Records will kept of all medical examinations and details of each
compressed air exposure including working pressure, working time, decompression
procedures, etc. No person shall be allowed to work in compressed air if the Contractor has
reason to suspect that person is under the influence of drink or drugs such that his capacity
is impaired. No one shall be allowed to enter the compressed air working chamber alone.
10
An experienced lock attendant shall be on duty at the free air side of the air lock at all times
when there are persons in the compressed air working chamber. All valves gauges and
controls at the lock attendants station shall be clearly marked with their function and method
of operation.
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Smoking shall be banned in compressed air and no person shall take smoking materials into
compressed air. As far as is practicable no combustible material shall be taken into the air
locks and or the working chamber. The use of burning or welding equipment should be
strictly limited and shall be subject to a permit to work system. Fire extinguishers shall be
provided in the air locks and the working chamber whenever work in compressed air is in
progress.
9.6.22
Ground Pre-treatment
Pre-treatment of the ground, where applicable, shall be applied in advance of the tunnel
excavation to provide sufficient stability of the excavated area. Execution of such works shall
not commence before consent has been given to the design of such works by the Engineer.
The surface settlement monitoring shall be installed, initialised and baselined prior to any
ground modification work.
9.6.23
Drainage During Construction
The Contractor shall supply, install, operate and maintain sufficient pumps and pipe work to
control and remove water from any part of the underground works. Standing water shall not
be allowed. The capacity of pumps installed where required, including at launch/reception
pits, shall always be at least twice the normal volume of the inflow of water plus the volume of
flushing water if drilling equipment is used. The minimum capacity of the pumps shall be 20
l/s.
The Contractor shall store or immediately have available standby pumps in good working
conditions of the same capacity. This equipment shall be maintained properly and tested
frequently.
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The Contractor shall provide settlement tanks or other decontamination facilities before the
water is discharged. The Contractor shall submit his design for these facilities as part of his
method statement. The Contractor shall remove all accumulated slurry, silt or other debris
from the Works on an ongoing basis.
9.6.24
Disposal of Tunnel Seepage and Waste Water
Tunnel seepage and wastewater arising from the Works shall be collected and discharged
via a settlement tank. Seepage and wastewater shall not be discharged into the public
drainage system unless it meets the standards listed below. Where necessary, the water
shall be treated to achieve these standards.
The Contractor shall comply with BS 6031:1981 Code of Practice for Earthworks or
equivalent, regarding the general control of site drainage and the requirements of the
Relevant Authority. The Contractor shall ensure that water which may have come into contact
with contaminated material shall be disposed of in an appropriate manner. The Contractor
shall have to apply for consents and approvals as follows:
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obtain and complete standard permit application form for proposed discharge into a
PWA system.
(b)
before any discharges can be permitted into a PWA pipeline, written approval shall be
obtained from the relevant department of the PWA. Failure to obtain the permit can
result in immediate closure of the Works.
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(a)
The Contractor shall make provisions that all hazardous substances including oil drums or
containers on-site are controlled in accordance with the relevant legislation and are properly
stored so that no oil or their contaminants are allowed to reach watercourses or groundwater.
9.6.25
Testing
The Contractor shall provide all apparatus, assistance, documents and other information,
electricity, equipment, fuel, consumable, instruments, labour, materials, and suitably qualified
and experienced staff, as are necessary to carry out the specified tests efficiently. The
Contractor shall agree, with the Engineer, the time and place for the specified testing of any
plant, materials and other parts of the Works.
The Engineer may vary the locations of details of specified tests, or instruct the Contractor to
carry out additional tests. If these varied or additional tests show that the tested Materials or
workmanship is not in accordance with the Contract, the cost of carrying out this Variation
shall be borne by the Contractor, notwithstanding other provisions of the Contract.
The Contractor shall promptly forward to the Engineer duly certified reports of the tests.
When the specified tests have been passed, the Engineer shall endorse the Contractors test
certificate, or issue a certificate to him to that effect.
9.6.26
Grouting
As soon as each section of pipeline has been installed, its periphery shall be grouted using a
cement based grout with a minimum 48 hour compressive strength of 345 kPa (50psi) and
minimum 28 days compressive strength of 1380 kPa (200psi). Every effort shall be made by
the Contractor to place the grout even when it is known that the periphery contains polymer
or other lubricant and shall demonstrate that grout is not being taken before the grouting
operation is terminated.
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The grouting pressure shall be sufficient to move the grout to fill the annulus along the pipe
but shall not be greater at the injection nozzle than the pressure limit set by the pipe
manufacturer. The injection points shall be placed at not more than 6 metre intervals along
the pipeline. Grouting shall be carried out around pipelines at launch and reception shafts as
soon as the pipeline is placed at these locations to prevent water and soil from entering the
shafts. Additional grouting shall be carried out at the Contractors expense, if required to
ensure that the joints are watertight.
The micro-tunnel shall be adequately lit and ventilated for safe access, egress and for
working. If open flames are to be used where combustible gasses may enter the air, tests for
combustible gas shall be conducted continuously during the work. The tunnel workers shall
carry a gas meter that automatically records the level of combustible gas. Particular care
shall be taken that pipe repairs are carried out in accordance with approved ventilation and
safety procedures.
Infiltration Acceptance Test of the installed pipe, which shall be witnessed by the Engineer,
shall be in accordance with ASTM C969. The internal inspection of the completed pipeline
shall be the subject of approval by the Engineer.
9.6.27
Surface and Building Settlement Monitoring
The Contractor shall submit, for the consent of the Engineer, the detailed proposal for
positioning of ground and building monitoring points and other instruments and the frequency
of the measurements. Excavation works shall not start until the consent of the Engineer to
that submission has been obtained. During construction the Contractor shall review
monitoring frequencies depending on settlement trends, the extent of construction activity in
an area and the behaviour of the structures.
The monitoring data shall be copied to the Engineer on the same day that the readings are
taken, followed by hard copies with analysis within 24 hours. In addition to carrying out all the
normal surveying requirements for carrying out a pipe-jack the Contractor shall set-up
surface settlement monitoring points at suitable intervals along the projected pipeline. The
spacing of such points may be as close as 10 metres in sensitive areas however may vary
according to the depth and location of the jack.
In addition to monitoring over the centre line of the drive readings shall be taken at suitable
lateral distances to the centreline at each monitoring chainage. In roads these cross sections
shall extend the full width of the road corridor.
Settlement monitoring points shall also be installed at the corner of each building or structure
within a recognised distance from the tunnel centreline. The distance shall normally be
equivalent to the depth to invert of the proposed pipeline with a minimum of 20 metres.
A full record of existing ground and structure levels shall be taken and agreed prior to
commencement of pipe-jacking operations.
A photographic record of existing damage and faults to all adjacent surface structures shall
be made by the Contractor and agreed prior to commencement of pipe-jacking operations.
During the jacking operation between any two shafts the Contractor shall survey the levels of
the appropriate monitoring points on a daily basis.
Monitoring shall be carried out on any particular section of points when the tunnel face is
within 20-50 metres of that section dependent on the tunnel depth and ground conditions.
Monitoring shall continue at each section until the tunnel drive has been completed or in the
case of excessive settlement until the settlement has ceased or the rate of settlement
becomes acceptable.
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QCS 2014

Part
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If during jacking operations the actual movement of the ground reaches 90% of the predicted
value the Contractor shall immediately review his predictions and if appropriate revise his
operational procedures accordingly. Where such movement occurs suddenly and adjacent
to the tunnel face the Contractor shall not proceed with the jacking operation until a revised
method has been agreed with the Engineer.
9.6.28
Contractors Obligations
The Contractor shall carry out the Tests on Completion in accordance with this Clause after
providing the As-Built documents for the part to be tested.
Unless otherwise stated in the Particular Conditions, the Tests on Completion shall be carried
out in the following sequence:
Pre-commissioning tests per stage, which shall include the appropriate inspections
and pressure tests to demonstrate that each item of the stage is acceptable and that
the Works can safely proceed to the next stage
(b)
Commissioning tests, which shall include the specified operational tests to

demonstrate that the Works or Section can be operated safely and as specified, under
all available operating conditions.
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(a)
For all tests described in sub-paragraph (a) and (b) the pipe and joints shall be considered
watertight if water infiltration is so low that it can only be detected as damp patches without
flowing or dripping water. Likewise, the tests described in sub-paragraph (a) and (b) shall be
used to confirm that the pipeline remains equally watertight throughout the leak testing.
As soon as the Works, or a Section, have passed each of the Tests on Completion described
in sub-paragraph (a) and/or (b), the Contractor shall submit a certified report of the results of
these tests to the Engineer.
9.6.29
Microtunnelling Machine
A remote control tunnelling machine shall be used and it shall include a closed circuit
television (CCTV) camera which transmits a picture of the laser beam on the target together
with other machine information (such as jacking force, face pressure, length, roll, pitch,
steering attitude, temperature valves open or closed) to a microprocessor console on the
surface from where the system is operated.
The tunnelling machine shall be steerable, incorporating hydraulic rams to move the
articulated cutting head. The line and level control shall be achieved by a laser beam
transmitted from the jacking shaft to a target mounted in the tunnelling machine
The design of the tunnelling machine shall ensure no rotation or rolling during installation.
The tunnelling machine shall be capable of operating under groundwater conditions where
encountered. The hydrostatic balance shall be not less than 3 m head of water.
9.7
THRUST SYSTEM
The thrust system shall distribute the force to the pipes through a thrust ring and packing.
The jacks shall be capable of applying the thrust symmetrically to the thrust ring. Intermediate
jacking stations may be used at the discretion of the Contractor where frictional resistance or
obstructions result in unacceptable thrust forces.
A purpose made compressible packer of hard board or other approved material shall be
included between the thrusting surfaces. Pushing blocks shall not be in direct contact with
the pipe or preformed unit, which shall be protected by means of a steel ring, template or
other approved method. Damaged pushing blocks shall not be used.
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Page 29
Spacer blocks, if used, shall be true and free of distortion.
Thrust rings shall be free from distortions and sufficiently stiff so as to transfer the load from
the jacks uniformly to the packing.
Except at the shield, each group of jacks shall be interconnected hydraulically to ensure that
the load is evenly distributed to the thrust ring. Each jack shall incorporate a load cell.
At the rig and at intermediate station, automatic thrust recording equipment monitoring load
cells incorporated in each jack shall be provided together with a pressure metering device.
Other continuous records, including cutter torque, rate of progress, slurry pressure, slurry
flow, pitch, roll, and earth face pressure shall be provided. Copies of these records shall be
submitted daily to the Engineer.
The thrusting force shall not exceed the maximum permissible force stated in the method
statement. Thrust pressure shall be monitored and controlled to ensure that the pipe joint
deflection does not exceed the maximum permitted angular deflection of 1 .
9.8
LUBRICATION HOLES
Lubrication holes shall be threaded to enable plugs to be screwed into the socket and to
withstand external pressure. A non-return valve shall be fitted where opening a lubrication
hole would permit ground loss. Upon completion of grouting, the plugs shall be covered with
material similar to that of the pipes. The pressure of the lubricant shall be maintained until it
is replaced by grout.
9.9
RECORDS
The Contractor shall maintain and submit to the Engineer after each day a log which records
the following information:
location of drive, between manholes
(b)
strata encountered
(c)
position and orientation of the pipes
(d)
thrusting pressure used on both main and interjack rams during driving of each pipe
(e)
line and levels of pipeline constructed including details of angular deflection at joints
roll of pipejacking shield
(f)
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(g)
average length of pipeline constructed per shift
(h)
thrust from ground on face of machine
(i)
readings of oxygen, methane and hydrogen sulphide gas at the excavating face
(j)
volume of excavated materials removed
(k)
volume of grout used, the points of injection and pressure at the points of injection
(l)
Contractors operating personnel.
9.10
TESTING
9.10.1
General
Upon completion of the permanent construction of the pipeline, it shall be tested for
watertightness, alignment, condition and soundness, and all other designated requirements.
QCS 2014

Part
Page 30
In the event of the Works failing a test, the Contractor shall take such remedial action as is
necessary, subject to the Engineers approval of the methods proposed. The Works shall
then be retested until such time as the Works pass the test.
9.10.2
Watertightness
Leakage tests shall be carried out in accordance with Clause 4.5.4 of this Section.
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END OF PART
QCS 2014
Section 09: Mechanical and Electrical Equipment

Part
01: General
Page 1
GENERAL ...................................................................................................... 2
1.1.1
1.1.2
1.1.3
1.1.4
1.1.5
1.1.6
1.1.7
1.1.8
1.1.9
1.1.10
1.1.11
1.1.12
1.1.13
1.1.14
1.1.15
1.2.1
1.2.2
1.2.3
1.2.4
1.2.5
1.2.6
1.2.7
1.2.8
1.2.9
1.2.10
1.2.11
1.2.12
1.2.13
1.2.14
1.2.15
1.2.16
1.2.17
1.2.18
Scope
Related Works
References
Submittals
Quality Standards
Manufacturers Experience
Factory Inspection
Factory Tests and Test Certificates
Shipment, Storage and Handling
Adaptation of Equipment
Guarantee
Job Conditions
Approved Manufacturers and Subcontractors
Hydraulic Sump Model Testing
Sewage Characteristics
Materials
Workmanship
Tropicalisation
De-rating Due to Climate Conditions
Steel
Equipment Bases and Bedplates
Anchors and Sleeves
Safety Guards
Drive Units
Bearings
Lubrication
Electric Motors
Pressure Gauges
Nameplates and Data Plates
Noise Levels and Vibration
Metal Plating
1.1
INSTALLATION AND COMMISSIONING .................................................... 20
1.2.19
1.2.20
1.2.21
1.2.22
1.2.23
1.2.24
1.2.25
1.2.26
1.2.27
Co-ordination
Preparation of Installation Areas
Manufacturers Installation Supervision
Installation
Instruction and Training of the Employers Personnel
In-Service Checks
Specialised Training Programme for Employers Personnel
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2
2
2
3
10
11
11
11
11
12
12
12
12
13
13
14
15
15
15
15
16
16
16
16
17
17
18
18
18
19
19
19
20
20
20
20
20
21
21
23
23
24
QCS 2014

Part
01: General
Page 2
GENERAL
1.1
GENERAL MECHANICAL AND ELECTRICAL REQUIREMENTS
1.1.1
Scope
This Part specifies the General Mechanical and Electrical Equipment Requirements, which
apply to all mechanical, and electrical systems and equipment and are a part of each and all
of the separate Sections of the Specification. The Contractor shall direct the attention of all
manufacturers and suppliers of mechanical and electrical equipment and related
appurtenances for the works to the provisions in the Contract Documents and this Section
and also to the extreme climatic conditions.
1.1.2
Related Works
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General
Sewerage
Structural Metal work
Metal work
Electrical Works
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Section 1,
Section 8,
Section 10,
Section 16
Section 17
Section 21,
References
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1.1.3
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BS 88,.........................Cartridge fuses for voltages up to and including 1000 Va.c. and 1500
Vd.c
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BS 89,.........................(IEC 51) Direct acting indicating analogue electrical measuring

instruments and their accessories
BS 142,.......................Electrical protection relays
BS 159,.......................High voltage busbars and connections
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BS 162,.......................Electrical power switchgear and associated apparatus

BS 381C, ....................Colours for identification, coding and special purposes
BS 449,.......................The use of structural steel in building

BS 729, ......................(ISO 1459,1460,1461) Hot dip galvanised coatings
BS 970, ......................(ISO 683) Wrought steels for mechanical and allied engineering
purposes
BS EN 1561, .............(ISO 185) Flake graphite cast iron
BS 1780,.....................Bourdon tube pressure and vacuum gauges
BS 2048,.....................Dimensions of fractional horse power motors
BS EN 1563, .............(ISO 1083) Spheroidal graphite or nodular graphite cast iron
BS 3643,.....................
ISO metric screw threads. Principles and basic data
BS 3790, ....................(ISO 155, 254, 1813, 4183, 4184, 5292) Endless wedge belt drives
and
endless
V-belt drives
QCS 2014

Part
01: General
Page 3
BS 4142, ....................(ISO 1996/2/3) Method of rating industrial noise affecting mixed

residential
and
industrial areas
BS 4196, ....................(ISO 3740-3745) Sound power levels of noise sources
BS 4794, ....................Pt. 2 (IEC 337-2), Control switches
BS 4800, ....................Paint colours for building purposes
BS 4884,.....................Technical manuals
BS 4921,.....................Sheradised coatings on iron and steel
BS 4999,.....................
General requirements for rotating machines
BS 5000,.....................Rotating electrical machines of particular types or for particular

applications
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BS 5472,.....................Low voltage switchgear and control-gear
BS 5304,.....................Code of practice for the safety of machinery
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BS 5685,.....................(IEC 521), Electricity meters

BS 5950,.....................Structural use of steel work in building
BS 6231,.....................PVC insulated cables for switchgear
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BS 7626,.....................(IEC 185), Current transformers
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BS 7671,.....................Requirements for electrical installations
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BS 8233,.....................Sound insulation and noise reduction for buildings

BS EN ISO 9000, ......Quality management and quality assurance standards
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BS EN 60439, ............Low voltage switchgear and control gear assemblies
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BS EN 60947, ............Low voltage switchgear and control gear

BS EN 10084, ............Case hardening steels. Technical delivery conditions
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BS ISO 10816, Part 1,
Part 3 and Part 7, ......Mechanical vibration in rotating and reciprocating machinery.
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AWS D1.1, ................Steel structure welding code
List of Approved Suppliers prepared by the Public Works Authority

1.1.4
Submittals
General
(a)
in addition to the requirements of Sections 1, 8, 10 and 21 the Contractor shall submit

the following information as described in the below paragraphs
(b)
the Contractor shall note that submittals will not be approved unless submitted in
order. All submittals shall be clearly marked with the name of the manufacturers, subcontractors and Contractors contract number such that they can be clearly identified
and are unique to the Contract
(c)
all drawings shall be on ISO standard sized paper A1 unless specified otherwise.
Each drawing shall be marked with the Contractors and manufacturers names and
references, project title drawing number, drawing title, scale, the date of completion
and a full description and date of all amendments. A clear space 100m x 160 mm shall
be left at the bottom right hand corner of each drawing for the Engineers approval and
disclaim stamps
QCS 2014
(d)
Page 4
any work commenced or materials ordered before receipt of the Engineers approval
shall be entirely at the Contractors risk. Modifications required to comply with
approved submittals shall be at the Contractors expense.
Submittal Schedule
general. The Contractor shall submit a programme for all the submittals, with dates, for
the Engineers approval. Adequate time shall be left in this programme for approval
(b)
submittal times. Table 1.1 shows a Table of times for submittals and approvals. These
times may be varied in the Project Specification depending on the scope and
complexity of the Works. The Contractor should also note that the times for approval
are dependent on the above, and drawings being submitted in an orderly fashion.
Submittals of many drawings and information at any one time will delay the approval
process. If the Engineer has to extend the approval time he will notify the Contractor
within 7 calendar days of receipt of the submittal of the date on which he will grant
approval or otherwise.
(c)
copies: numbers of submittals are as required in Table 1.1 below. In addition to the
requirements of Table 1.1 the Contractor shall submit all record drawings,
photographic records, test records and operation and maintenance manuals in
electronic format on the latest form of digital record such as a CD.
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(a)
Programme
(4)
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Design data
(4)
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Manufacturing programme
(4)
Shipping and delivery
schedules
(4)
Materials and product data
(4)
Fabrication and assembly
drawings
(4)
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Material and
products data
Shop drawings
Records
Testing and
commissioning
Time to be submitted
(calendar days)
as
Submittal stage
Submittal type
Number of copies in
brackets
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Table 1.1
Submittals and Approvals

Part
01: General
Working drawings
(4)
Co-ordination drawings
(4)
Record drawings
(4)
Photographic records
(3)
Plan and procedures
(4)
Test records
(4)
Time for
comments/approva
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(calendar days)
14 days after Contract

start
start
30 days before start of
manufacture
21 days
30 days before shipping
21 days

start
21 days

start
21 days
30 days after approval

of materials and product
submittals
30 days after approval
of working drawings
14 days after notification
of change
7 days after date of
photograph
30 days before
commencement of
testing
7 days after tests
7 days
21 days
21 days
21 days
21 days
14 days
14 days
21 days
QCS 2014

Part
01: General
Submittal stage
Operation and
maintenance
Submittal type
Number of copies in
brackets
Time to be submitted
(calendar days)
Time for
comments/approva
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(calendar days)
Operation and
maintenance manuals and
instructions
(5)
60 days before *
commencement of
testing
30 days
As-built drawings
(5)
As erection progresses,
but all drawings within
90 days of Practical
Completion Certificate
40 days
Draft only. Final version to be submitted before issue of Practical Completion Certificate (PCC) or
similar.
Design Data
justification for the overall design, sizing of process units, levels and layout
(ii)
to show compliance with standards used. This may include quality manuals and
procedures
(iii)
as required in the particular and general project specification
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(i)
design data shall be derived from standard methods of calculations. Computer

generated data will only be accepted if it is produced by software with a proven record
of use in the field in which it is supplied
(c)
any calculations which do not follow recognised standards or norms shall have full
supporting justifications, with technical references.
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Material and Product Data
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(b)
programme. When required by the Engineer a critical path type programme shall be
submitted showing all the manufacturing activities with the critical path clearly
identified.
(b)
shipping and delivery schedules. These shall include the following:
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(a)
date of shipping, arrival at port and on site
(ii)
details of packing methods. Any unique packing, shipping, handling and

unloading requirements shall be stated.
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(i)
this shall include data and supporting calculations which is required for the following:
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(c)
materials and product data

(i)
approval of materials and equipment shall be based on latest manufacturers

published data
(ii)
complete and detailed information of all materials and equipment to be

incorporated in the Works shall be submitted. Detailed descriptions and
specifications, catalogue cut outs, installation data, diagrams, dimensions,
controls, and any other data required to demonstrate compliance with the
Project Specification shall be submitted. Each item submitted shall be
referenced to the applicable paragraph in the specification.
(iii)
materials of construction of materials, equipment or components shall be stated.

At the request of the Engineer, a sample of these shall be submitted for further
study before approval. Where samples are required by the Engineer, the period
required to obtain the sample will be taken into account when scheduling
approvals.
QCS 2014

Part
01: General
Page 6
materials and product specification data forms shall be submitted for each item of
equipment. These shall summarise the specification features as called for in these
specifications, and including such other necessary data, as would provide a complete
and adequate specification, for reordering an exact duplicate of the original item from
the manufacturer at some future date. The assigned tag numbers and manufacturers
part numbers shall be included, but will not be considered as a substitute for any of the
required statement of specifications. More than one tag numbered item may be
included on a sheet.
(e)
fabrication and assembly drawings. These shall be supplied for any fabrication or
assembly of equipment which is to be carried out in the factory or on site. Sectional
drawings shall be provided for equipment such as pumps, clearly showing the
materials and individual components.
(f)
test certificates. Manufacturers test certificates, type test certificates, third party test
certificates and quality control test certificates shall be submitted as required in the
general and particular Project Specification. Certificates shall be originals or
certificated copies.
Shop Drawings
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These shall include the following:

(a)
working drawings. These shall include layout drawings. They are drawings, diagrams,
illustrations and schedules specifically prepared by the Contractor for each part or area
of the works. They shall include general arrangements of the equipment and
appurtenances in relation to the buildings and structures. Standard or specialised
procedures for installation work recommended by the manufacturers of materials or
equipment and method statements for installation work shall be submitted. They shall
include drawings of any templates required for the installation work.
co-ordination drawings. These shall be prepared by the Contractor to show how
multiple system and interdisciplinary work will be co-ordinated. The location, size and
details of fixings, box-outs, apertures, ducts, holes, cable routes, access doors/covers
and plinths shall be shown on detailed layout drawings which are coordinated with the
building and civil structural drawings. Drawings shall illustrate clearances for lifting
equipment, maintenance, access requirements and loadings due to equipment
heights.
(c)
electrical drawings. These shall include single line diagrams, load schedules, cable
schedules, cable schedules, loop diagrams, piping and instrumentation diagrams,
panel layouts and circuit diagrams
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Record Submittals
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(b)
(a)
record drawings. These shall be prepared as work proceeds. They shall provide a
record of any modifications to materials and equipment, and to the layout,
arrangement and installation of the works.
(b)
photographic records shall also be made, as specified in Section 8, and as required in

Testing and Commissioning Submittals

(a)
test procedures plan. At least 30 days before testing and commissioning is to be

performed, a detailed and comprehensive procedure plan shall be submitted for the
performance of each separate test. Each procedure plan shall describe and itemise
the involved system including associated electrical equipment, and shall include
evidence of an organised step-by-step procedure, properly co-ordinating the efforts of
the various trades and manufacturers representatives involved, and of the operations
of the facilities. Procedures shall include an estimated duration and date for each
procedure and the personnel and equipment required.
(b)
procedure plan information. Each procedure plan shall include the following
information, as applicable:
QCS 2014

Part
01: General
Page 7
(i)
description of temporary procedure facilities, including drawings and sketches

as required to fully illustrate the facilities
(ii)
list of test materials and estimated quantities
(iii)
list of instruments, measuring and recording devices, and other test equipment,
whether a part of the equipment or furnished separately for temporary use.
Copies of calibration certificates shall be submitted for any test equipment.
(iv)
names of supervising and inspecting manufacturers, where applicable
(v)
complete listing of all functional parameters to be served and recorded
(vi)
recording intervals.
record materials. Samples shall be submitted of the forms, charts, and other materials
to be used in recording demonstration and validation test results. Wherever possible,
standard forms shall be used.
(d)
test recording. Neat and comprehensive records of each test shall be maintained by
the Contractor. Each portion of the test procedure shall be described with all
components itemised. Records shall be prepared on forms in a step-by-step fashion
paralleling the approved procedure plans. Forms shall list for each test or check the
following:
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(c)
check/list taken
(ii)
result anticipated
(iii)
result obtained
(iv)
if incorrect, corrective action taken
(v)
re-test/check result
(vi)
step (iv) and (v) shall be repeated until all systems operate as required.
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(i)
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Instruments, gauges, and other sensors and display devices forming a part of
the various systems shall be employed for data acquisition where applicable.
The Contractor shall furnish all other instruments, gauges, recorders, and test
devices as required, types conforming to the approved procedure plans. All
applicable data such as, but not limited to, water and other liquid levels, flows,
pressures, head differentials, duration of runs, instrument readings, voltage
settings, drive speeds, motor running currents, torque, voltages and related
information, as applicable, and in accordance with approved test procedures
shall be recorded at the start and finish of each operational demonstration and
at 30 minute intervals during system validation tests, unless other intervals are
specified or agreed with the Engineer.
(e)
when a repeat of the same demonstration or validation test is required to verify the
results, the repeat procedure shall be indicated on the recorded data by numerical
indication, data and time.
Operation and Maintenance Manuals and Instructions - General

(a)
the Contractor shall provide fully detailed manuals covering all mechanical, electrical
and electronic equipment. The manuals shall be in English
(b)
two copies of the draft manuals shall be submitted to the Engineer for review and
approval, before the programmed commencement of commissioning works
(c)
the remaining three copies of the manuals shall be provided to the Engineer, before
the commencement of the maintenance period. They shall include all revisions and
comments made by the Engineer and any revisions or corrections necessitated by
changes made during installation and testing
(d)
manuals shall be contract specific, and be fully indexed and sectioned, for allocation
and distribution to the specialist staff involved on the particular plant and equipment
QCS 2014

Part
01: General
Page 8
(e)
where several sub-contractors and manufacturers have supplied equipment the

Contractor shall, if required by the Engineer provide a complete integrated manual
which clearly demonstrates the inter-relation of the equipment
(f)
manuals shall be provided in durable hard cover backed A4 sized loose-leaf four ring
binders. Lever arch binders are not acceptable. The full project title shall appear on the
cover and spine
(g)
the manuals shall enable the client to safely operate, maintain, dismantle, reassemble
and adjust all parts of the works
(h)
Original copies of leaflets and instructions provided by the specialist manufacturers

shall be provided. Superfluous information shall be clearly deleted and relevant
information referred to separately in the text
(i)
all instructions and manuals shall be written in accordance with BS 4884, IEC 278, and
in accordance with other recognised guidelines on technical manual writing.
Operation and Maintenance Instructions and Manuals shall confirm to Section 1, Clause
7.12.2.
10
Operation and Maintenance Instructions and Manuals Contents shall also confirm to the
following listed items or otherwise agreed with the Engineer.
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these shall comprise a number of volumes, dependent on the amount and technical
content of the equipment installed. The operating instructions shall always form a
separate volume. Manuals shall include sections containing information as described
in the following paragraphs
(b)
introduction. The names, addresses, telephone and fax numbers of the Site, Employer,
Consultant, Contractor, sub-contractors, manufacturers and agents. The date the
Contract commenced, and the date of the Practical Completion Certificate. This item is
to be completed when the date is established. A brief description of the equipment
provided and the contractual scope of the work, with descriptions of any work
subcontracted
(c)
general equipment description
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(a)
general process description. This shall provide a general description of the

treatment processes based on process P&I drawings included with the manual
(ii)
process design parameters. This shall provide information on the performance

of the process systems
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(i)
(iii)
(iv)
(d)
general description of the mechanical equipment. This shall provide a brief

description of all mechanical equipment provided
general description of the electrical equipment. This shall provide a brief
description of the equipment provided, listing individual control panel
compartments and the remote controls
detailed equipment description

(i)
mechanical equipment. This shall provide details of all the mechanical
equipment including type, rating, duties, characteristic curves and
manufacturers, and full component schedules, with serial numbers
(ii)
electrical equipment. This shall provide details of all electrical equipment and
cables including detailed information on the control panel(s), listing the display
and controls available for each compartment and stating the rating,
manufacturer and supplier of main components, and full component schedules
with serial numbers. This section shall include a schedule of input and output
signals, detailing number, signal type, polarity, digital open or closed state and
analogue range, and detailed calibration routine
QCS 2014

Part
01: General
Page 9
(e)
operating instructions. These shall provide details of how each component of

equipment is controlled and operated in both automatic and hand modes, including the
control philosophy and its interrelationship with other interdependent equipment.
Details of equipment operation under non-routine conditions and details of start-up and
shut-down procedures with any associated safety checks shall be provided. (see note
below)
(f)
inspection and maintenance instructions. This shall provide schedules and time
intervals for routine inspection, maintenance and lubrication tasks, referring to
individual manufacturers instruction manuals for full details. They shall describe briefly
to more complex tasks that will be needed from time to time (see note below)
(g)
fault finding and correction. This shall provide a guide to first line checks that can be
undertaken in the event of equipment failure, without the need for reference to the
detailed instructions. A detailed guide of more complex checks shall be provided as
below
more complex tasks, involved with plant shut-downs, fault rectification to

component level, fault diagnostics, overhauls, etc.
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Note: section (f), (g) and (h) should, in addition to the routine operating and
maintenance tasks, identify the following:
highlight any particular complex or critical tasks over the above normal
requirements
(iii)
measurements and guidance on limits of acceptable wear for all items subject to
wear.
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spare parts
(i)
The Contractor shall assess and recommend the consumable and strategic
spares requirements of all equipment supplied under the Contract. They shall be
listed in the manuals. These and any other recommended spares shall also be
identified in sufficient detail for the Employer to select and purchase spares, and
shall be provided with drawings or annotated diagrams showing the spare parts
(ii)
consumable spares are for those components which are scheduled for routine
replacement during annual or more frequent service
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specific hazards associated with operating and maintaining the equipment, e.g. auto
starting, high voltage, noise levels
(iii)
strategic spares are for those components or items of equipment (e.g. gear box)
not duplicated by standby equipment, which are expected to operate for not less
than 5 years under normal operating conditions, but whose premature failure
would cause the process to fail
(iv)
the Contractor shall indicate which spares are available ex-stock.
(v)
the Contractor shall provide all the above necessary spares during the
maintenance period and in addition shall provide sufficient spares for 2 years of
operation on issue of the PCC.
(i)
special tools. A list of the special tools supplied for the maintenance of all equipment
included in the Contract shall be provided
(j)
test certificates. Certificates and documents of equipment tests shall be provided (e.g.
pressure vessels, lifting equipment, etc.). Performance test certificates and
characteristic details shall be provided. Set points for timers, overloads, pressure
switches, relief valves, etc. shall be provided
(k)
inventory of as-fitted equipment. A schedule of this shall be provided
(l)
drawings list. A list of the as-built drawings shall be provided
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As built drawings
after erection has been completed, the Contractor shall submit to the Engineer copies
of the following As-built drawings for approval, including:piping and instrumentation diagrams
(ii)
site layouts showing main works operational features
(iii)
equipment layout
(iv)
general arrangement drawings
(v)
mechanical details
(vi)
electrical power circuit diagrams
(vii)
control schematic diagrams
(viii)
HV and LV distribution single line diagrams
(ix)
HV and LV cable routes
(x)
PLC or computer programs
(i)
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one master copy of the proprietary software package shall be provided to the
Engineer within one week of the issue of the PCC. All software licences and/or
registration requirements must be forwarded promptly to the Engineer for
subsequent registration with the manufacturer. Sole rights to all software
developed and written on all schemes financed by Employer will be retained by
the Employer
assembly drawings shall clearly show the construction details and be in
sufficient detail to facilitate dismantling and re-assembly
(xii)
parts lists shall be included for identification of replacement items
(xiii)
cable schedules shall include cable reference numbers and core reference
numbers relating to power circuit diagrams
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(xi)
the above are to be supplied to the approval of the Engineer. The Contractor shall
provide the Employer prints of each on thick paper and one ISO size A1 (594 x 420)
negative of each. All drawings shall be prepared on a CAD system and printed on ISO
standard sized paper A3 unless specifically requested otherwise. One set of drawings
shall also be submitted in Windows based AutoCAD System, software version and
storage media shall be as approved by the Engineer. Each drawing shall be marked
with the Employers, Consultants, Contractors and manufacturers names and
references, drawing number, title, scales, date of completion and a full description and
date of all amendments, and shall be certified as-built. The project title shall be
included in a box at the bottom right hand corner of each drawing.
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(xiv) diagrams where necessary shall be in colour to identify different components,

networks, systems etc.
1.1.5
Quality Standards
All equipment furnished shall be new, and where feasible, shall be a standard product of an
approved or experienced manufacturer, and assembled from standard components readily
available.
Equipment shall conform to the requirements of the Project Specifications and reference
standards.
Manufacturers shall operate an ISO 9000 approved quality system, or equivalent in-house
quality system. If requested, details of the quality system shall be submitted to the Engineer.
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Manufacturers shall be from the approved list in the Project Specification and shall have
furnished equipment of the type and equal or larger size than specified, which has been
installed, and demonstrated successful operation for at least 5 years and at least 5
installations in the Gulf countries, or in countries with similar weather conditions. User
certificates will be required to be submitted.
1.1.7
Factory Inspection
The Engineer or his representative may inspect the equipment at the factory. The Contractor
shall notify the Engineer of the manufacturing schedule 30 days before commencement in
order that the factory inspection can be arranged. Factory inspections will be made at any
reasonable time during manufacturing, testing or after the completion of testing and prior to
shipment. Approval of equipment at the factory only allows the manufacturer to ship the
equipment to the Site and does not constitute final acceptance. Where specified, the
Contractor shall include in the Contract Price for all the costs of the Engineer or his
representative.
1.1.8
Factory tests shall be carried out as specified in the Project Specification, and as required by
international standards and industry norms.
The Contractor shall ensure that the manufacturer provides all labour, materials, electricity,
fuel, stores, apparatus and all instruments as are requisite and as may reasonably be
required to carry out the test efficiently. The Engineer or his representative may witness the
tests. Where specified the Contractor shall include in the Contract Price for all the costs of
the Engineer or his representative.
The Contractor shall submit from the equipment manufacturer, or his authorised
representative, a certified written test certificate in accordance with the requirements of the
relevant test procedure.
If after examining or testing any equipment the Engineer, or his representative, shall decide
that such equipment or any part thereof is defective or, not in accordance with the
specification, he may reject the said equipment or part thereof. He shall notify the Contractor
in writing within 7 calendar days of the rejection, stating the grounds on which the rejection is
based.
Wherever possible Site conditions shall be simulated, or the tests shall be extended to allow
for Site conditions.
1.1.9
Shipment, Storage and Handling
All equipment shall be boxed, crated or otherwise enclosed and protected for shipment,
handling, and storage. Electrical materials shall be delivered in manufacturers original
cartons or containers with seals intact as applicable. Large multicomponent assemblies shall
be delivered in sections that facilitate site handling and installation.
All equipment shall be kept dry, off the ground and covered from exposure to weather prior to
installation. Pumps, motors, electrical equipment and equipment having anti-friction or sleeve
bearings shall be stored in weather proof storage facilities. Where possible, heaters provided
in equipment shall be connected and operated until the equipment is placed in operation. The
Contractor shall prevent corrosion, contamination or deterioration of stored equipment.
Storage shall be covered and the temperature and humidity maintained according to the
manufacturers requirements.
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1.1.6
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Equipment and materials shall be handled in accordance with manufacturers

recommendations. Large or heavy items shall only be lifted by the designated points.
Padded slings and hooks shall be used for lifting to prevent damage.
All equipment shall be fully protected until final acceptance and all factory surfaces shall be
protected from impact, abrasion, discoloration and other damage. All damaged equipment
shall be repaired or replaced before final acceptance.
1.1.10
Adaptation of Equipment
Any alteration of the structure or building shown on the Contract Drawings to accommodate
substitute equipment shall be the responsibility of the Contractor. Equipment which requires
alteration of the structures or buildings will be considered only if the Contractor assumes all
responsibility for making and co-ordinating all necessary alterations, at no additional cost to
the Employer. All modifications to structures, mechanical, electrical, or other work made
necessary by such substitution shall require the approval of the Engineer. The cost of this
work shall be made at the Contractors expense.
Following approval of the mechanical and electrical drawings the Contractor shall prepare
and submit to the Engineer the revised drawings showing any necessary modifications to the
proposed buildings and civil structures. The location, size and details of box-outs and fixings
for mechanical and electrical and other equipment shall be shown on the revised Drawings
and the Contractor shall be responsible for providing in the civil structures the correct location
and size of the box-outs and fixings shown on the approved mechanical and electrical
drawings. The Contractor shall prepare at his own cost the necessary revised civil drawings
and detailed structural and other design calculations and submit them to the Engineer for
approval. The Contractor shall not be entitled to an extension of time for completion for any
delays from the preparation of such revised drawings.
1.1.11
Guarantee
The Contractor shall provide a guarantee during the maintenance period for all the equipment
in accordance with the General Conditions of Contract. In addition to the general guarantee
requirements, equipment warranty shall cover:
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faulty or inadequate design
(b)
improper assembly or erection
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(a)
defective workmanship or materials
Job Conditions
The Contract Drawings indicate the general arrangement, layout and locations of equipment,
valves, inserts, anchors, motors, panels, pull boxes, cables, conduits, stub-ups, lighting
fixtures, power and convenience outlets, and exterior lighting units, and may not be exact.
The Contractor shall conform to the Drawings as closely as possible, exercising care to
secure approved headroom and clearances, to overcome structural interference and to verify
scaled dimensions, field dimensions and conditions at the place of work.
1.1.13
Approved Manufacturers and Subcontractors
The Contractor shall ensure that all equipment shall be supplied, installed, tested and
commissioned by subcontractors recommended by the equipment manufacturer and
approved by Engineer. Large complex units, shall be installed, tested and commissioned by
the manufacturers representatives as specified. Installation procedures shall be supplied
and authorised by the equipment manufacturer.
1.1.12
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1.1.14
Hydraulic Sump Model Testing
Unless otherwise specified in the Project Specification hydraulic sump model tests shall be
performed by the pump manufacturer or an approved specialist hydraulic testing laboratory.
Physical hydraulic model tests shall be carried out to study the hydraulic performance of the
sump and behaviour of flows in the wet well for all possible combinations of pump operation.
Models shall be designed and constructed to a scale approved by the Engineer as necessary
to properly assess the wet well performance.
The model tests shall investigate the effects of the pump performance on sump operation
and provide information on the following as a minimum:
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(b)
(c)
(d)
(e)
hydraulic conditions in the pumping station inlet and wet wells under varying flows and
pump combinations
formation of air entraining vortices in the sumps
formation of swirl at the suction pipework of the pumps
velocity distribution in the suction pipework of each pump
hydraulic surge effects in the pumping station inlet and wet wells caused by starting or
stopping of one or more pumps
start/stop levels for the pumps
grit and solids deposition in the wet well.
videos and coloured photographs with time and date stamping shall be produced to
show the model test and important features. Commentaries shall be added to videos
to describe the events recorded.
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(a)
The model tests and study shall make recommendations on any modifications to the
pumping station inlet and wet wells considered necessary to overcome adverse hydraulic
conditions, and the provision of any flow splitters, diverters and benching required to improve
the hydraulic conditions.
Model Requirements:
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the model shall be constructed to an approved scale based on an appropriate Froude

number and the pumping station general arrangement drawings
(b)
the walls of the wet well and inlet arrangement shall be constructed from transparent
material to allow the flows to be viewed. The top of the model shall be open to allow
viewing of the flows. A viewing platform above the model shall be provided for
inspection and measurement
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the method of construction shall be such that the dimensions of the wet well may be
adjusted to vary the hydraulic distribution and identify the optimum shape
(c)
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(d)
the Contractor shall submit four copies of drawings showing the general arrangement
and details of the models for approval by the Engineer. The drawings shall also show
details of all ancillary equipment forming part of the testing
(e)
after completion of the testing the Contractor shall submit to the Engineer 4 copies of
the Model Test report, including all documentation, photographs and videos.
1.1.15
Sewage Characteristics
Sewage characteristics are typical of an arid climate municipal area with a sewerage system
comprising gravity sewers and rising mains. Hydrogen Sulphide is present in varying levels
throughout the sewerage system and the levels given in the Project Specification must be
used for materials selection.
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Unless otherwise specified in the Contract documents, typical Qatar sewage characteristic
shall be taken as:
(a)
Temp C
25 - 45
(b)
PH
(c)
BOD mg/l
200 - 220
(d)
SS mg/l
150 - 200
(e)
Alkalinity (caco3)
225 - 245
(f)
Chloride mg/l
400 - 500
(g)
Sulphide mg/l
10 16
(h)
TDS
1500 - 2000
7.0 - 7.5
PRODUCTS
1.2.1
Materials
All materials used in the manufacture of equipment shall be new, and guaranteed free from
defects, and shall be capable of resisting corrosion from sewage. The Contractor shall
ensure that the manufacturer ascertains the conditions and service under which materials
and equipment are to operate and warrants that operation under those conditions shall be
successful. Equipment and materials provided shall be suitable for the service conditions and
for meeting the specifications. All structural members shall be considered as subject to shock
or vibratory loads.
All equipment and materials shall be designed to sustain all stresses that are likely to occur
during fabrication, handling, transportation, erection, and intermittent or continuous operation.
Iron castings shall be tough, close-grained grey iron free from blow-holes, flaws, or excessive
shrinkage and shall conform to BS EN 1561 Grade 250 and to BS EN 1563 Grade 250 for
ductile iron unless otherwise specified.
Structural steel shall be as specified in Section 8, 16 and 17.
Stainless steel shall be BS 970 Grade 316 S31 unless otherwise specified. All references to
BS 970 Grade 316 shall include the statement (partially replaced by BS EN 10084) after
Grade 316.
Bolts, nuts, washers and anchor plates, shall be of stainless steel Grade 316 S31, to BS 9701, and shall remain unpainted. At lest two washers shall be provided with each nut and bolt
set. PTFE or nylon washers and spacers shall be fitted beneath stainless steel washers for
both bolt head and nut when used to fix dissimilar metals.
All nuts and bolts shall be threaded in accordance with BS 3643 "ISO metric screw threads"
Part 2 "Specification for selected limits of size" and fitted with 3mm thick washers beneath
bolt and nut.
All exposed bolt heads and nuts shall be hexagonal and the length of all bolts shall be such
that when fitted with a nut and washers and tightened down, the threaded portion shall fill the
nut and not protrude from the face thereof by more than half the diameter of the bolt.
However, two complete threads must be visible as a minimum.
Safety guards shall be of stainless steel of Grade 316S31 to BS 970-1.
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1.2
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Workmanship
All equipment shall be designed, fabricated, and assembled in accordance with the best
modern engineering practice. Individual parts shall be manufactured to standard sizes and
gauges so that repair parts, are readily available and where practicable can be replaced on
site. Corresponding parts of duplicate units shall be interchangeable.
1.2.3
Tropicalisation
The equipment shall be suitable for installation in tropical areas. Tropical grade materials
shall be used wherever practicable. Some relaxation of these provisions may be permitted
where equipment is hermetically sealed.
Iron and steel are to be painted or galvanised unless specified otherwise. Indoor parts may
alternatively be chromium or copper-nickel plated or other approved protective finish. Small
iron and steel parts (other than stainless steel) of all instruments and electrical equipment,
the cores of electro-magnets, and the metal parts of relays and mechanisms shall be treated
in an approved manner to prevent rusting. Cores which are built up of laminations or cannot
be anti-rust treated shall have all exposed parts thoroughly cleaned and heavily enamelled,
lacquered or compounded.
Iron and steel shall not be used in instruments and relays. Where used, steel screws shall
be zinc, cadmium or chrome plated or, where plating is not possible due to tolerance
limitations, shall be dull nickel plated brass or be of other approved finish. Instrument screws
except those forming part of a magnetic circuit shall be brass or bronze. Springs shall be of
non-rusting material. Pivots and other parts for which non-ferrous material is unsuitable shall
be of an approved stainless steel.
Fabrics, corks, paper and similar materials, which are not subsequently to be treated by
impregnation, shall be adequately treated with an approved fungicide. Sleeving and fabrics
treated with linseed oil varnishes shall not be used.
Wood shall not be used in equipment unless absolutely necessary. Where used, woodwork
shall be of thoroughly seasoned teak or other approved wood which is resistant to fungal
decay and free from shakes and warp, sap and wane, knots, faults and other blemishes. All
woodwork shall be suitably treated to protect it from the ingress of moisture and the growth of
fungus and termite attack. All joints in woodwork shall be dove-tailed or tongued and pinned.
Where used, metal fittings shall be of non-ferrous material.
Adhesives shall be impervious to moisture, resistant to mould growth and not subject to the
ravages of insects. For jointing woodwork only synthetic resin cement shall be used.
1.2.4
De-rating Due to Climate Conditions
The De-rating requirements for the climate conditions for all materials and equipments shall
be in accordance with Section 21 unless otherwise agreed with the Engineer.
1.2.5
Steel
Fabrication of structural steel shall conform to BS 449 and BS 5950 AWS D1.1 unless
otherwise indicated or specified. All fabrications shall be designed for dynamic and vibratory
loadings. Welding shall conform to Sections 16 and 17. All steelworks shall be galvanised
after fabrication unless otherwise specified. Galvanised bolts and fasteners shall be used
with galvanised assemblies.
If practicable, steel plate and members shall have a minimum nominal thickness of 6 mm
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1.2.2
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Wrought steels shall be selected from the appropriate steel grade of BS 970 and shall be
free from blemishes, shot or hammer marks. The steel grade used shall be subject to the
Engineers approval.
Cast molybdenum steel shall be to BS 3100 Grade B unless otherwise specified.
1.2.6
Equipment Bases and Bedplates
Equipment assemblies shall be mounted on a single heavy cast iron or welded steel bedplate
unless otherwise shown or specified. Bases and bedplates shall be provided with machined
support pads, tapered dowels for alignment or mating of adjacent items, adequate openings
to facilitate grouting, and openings for electrical conduits. Seams and contact edges between
steel plates and shapes shall be continuously welded, and welds ground smooth. Machinery
or piping shall not be supported on bedplates other than that which is factory installed.
Jacking screws shall be provided in equipment bases and bedplates to aid in levelling prior to
grouting. Plates of minimum thickness of 6 mm shall be provided. Pump bedplates shall
include a drip lip and provisions for directing gland leakage to a single disposal point.
1.2.7
Anchors and Sleeves
Each equipment manufacturer shall supply the required anchor bolts, nuts, washers, and
sleeves of adequate design for securing the bases and bedplates to concrete plinths. They
shall be stainless steel or, hot-dip galvanised as specified. Sleeves shall be at least
1.5 times anchor bolt diameter. Anchor bolts shall be provided of sufficient length to allow for
maximum of 40 mm of grout under baseplates and adequate anchorage into structural
concrete.
All anchors used in wet areas or areas containing sewage or sewage gases shall be resin
anchors of BS 970 grade 316 S31 approved stainless steel. Fixing anchors shall be sealed
with material appropriate to and recommended by the manufacturers of the concrete
protection material.
Steel work shall normally be bolted to the concrete, with grout added as necessary. G.R.P.
lamination or other lining material shall be terminated on the equipment secured.
Consideration shall be given to subsequent removal of equipment, using additional brackets
or bolts which can be demounted without affecting the lining material.
1.2.8
Safety Guards
Belt or chain drives, fan blades, couplings, exposed shafts and other moving or rotating parts
shall be covered on all sides with safety guards to BS 5304. Safety guards shall be free of all
sharp edges and corners. Safety guards shall be fabricated from a minimum of either 2 mm
thick, galvanised or aluminium-clad steel, or 12 mm mesh galvanised expanded metal.
Guards shall also be of sufficient strength to contain rotating parts in the event of a
catastrophic failure. Guards shall be designed for easy installation and removal. Necessary
supports, accessories, and fasteners shall be provided, of hot-dip galvanised steel or
stainless steel. Guards in outdoor locations shall be designed to prevent entrance of sand.
Hinged access doors shall be provided for routine maintenance. Microswitches shall be
provided on guards to prevent the main drive from starting, if specified.
1.2.9
Drive Units
The requirements for the design, manufacture, construction installation, testing and
commissioning of drive units shall be in accordance with Section 21 unless otherwise agreed
with the Engineer.
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Bearings
The Contractor shall select the most appropriate type of bearing for the equipment being
supplied.
Equipment with vertical shafts shall have thrust and guide bearings.
Sealed for life units are to subject the Engineers approval and shall have a minimum design
life of 50,000 hours operation at maximum loading.
Bearings fitted to gearboxes shall have a minimum design life of 100,000 hours at maximum
loading.
Plant which may be subject to vibration whilst stationary shall be provided with bearings
designed to withstand damage from such a cause.
Single journal plain bearings shall have phosphor bronze or synthetic lubrication impregnated
bushes with carbon or stainless steel journals respectively. Synthetic bearings shall only be
used where bearing conditions can readily be inspected.
Plain type bearings shall be self-lubricating by either grease, forced oil or impregnation.
Ball and Roller type bearings shall be adequately lubricated by oil or grease and sealed to
prevent leakage of lubricant along the shaft or the ingress of dust and water.
Bearings not integral with a casting shall be mounted in substantial Plummer blocks.
10
Bearings shall be sized and rated for the temperatures encountered in service conditions.
Additional cooling shall be provided if necessary.
1.2.11
Lubrication
Suitable lubrication shall be provided to ensure smooth operation, heat removal and freedom
from undue wear. Plant selected shall require minimum lubrication attendance and down
time for lubricant change.
The Contractor shall supply the first fill of oil and grease from approved lubricant suppliers
prior to completion, testing, and final acceptance. In addition sufficient approved lubricants
for two years normal operation shall be provided.
All grease nipples, oil cups and dip sticks shall be readily accessible, being piped to a point
as near as practicable to the lubrication point.
Gearboxes and oil baths shall be provided with adequately sized filling and draining plugs
and suitable means of oil level indication.
Roller chain drives shall have a constant feed of lubricant, when in operation (viz oil bath or
autolube system).
Drain points shall be located or piped to a position such that an adequately sized container
can be placed beneath them. Where a large quantity of oil is involved or drainage to a
container difficult, a drain valve and plug shall be provided at the point of discharge.
Bearings equipped with forced fed oil lubrication shall be automatically charged prior to
machinery starting up, and pressure monitored during operation, with automatic shutdown of
machinery and alarm on low oil pressure.
Access, without the use of portable ladders, to lubrication systems shall be such as to permit
maintenance, draining and re-filling, without contamination of the charged lubricant.
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1.2.10
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The design of breathers shall take into account the humidity and atmospheric contamination
at the vent point and measures shall be incorporated to prevent contamination of the
lubricant.
10
Grease application shall be by steel lubrication nipples manufactured in accordance with B.S.
1486, Part 1 and 4.
11
Anti friction bearings requiring infrequent charging shall be fitted with hydraulic type nipples.
12
Plain bearings requiring frequent charging shall be fitted with button head pattern nipples.
13
A separate nipple shall be provided to serve each lubrication point. Where a number of
nipples supply remote lubricating points they shall be grouped together on a conveniently
placed battery plate, with spacing in accordance with the recommendations of B.S. 1486,
Part I, Table 9 and 10.
14
The type, grade and amount of lubricant shall be clearly marked on a label adjacent to the
equipment.
15
Lubricants shall be suitable for the temperatures encountered in service conditions.

Additional cooling of lubricant shall be provided if necessary.
16
Lubrication of equipment shall ensure constant presence of lubricant on all wearing surfaces.
Lubricant fill and drain openings shall be readily accessible. Easy means for checking the
lubricant level shall be provided. Prior to testing and/or operation, the equipment shall
receive the prescribed amount and type of lubricant as required by the equipment
manufacturer. Equipment lubrication systems shall require no more than weekly attention
during continuous operation, shall not require attention during start-up or shut down, and
shall not waste lubricants.
1.2.12
Electric Motors
The requirements for the design, manufacture, construction installation, testing and
commissioning of motors shall be in accordance with Section 21 unless otherwise agreed
with the Engineer.
1.2.13
Pressure Gauges
Gauges shall be connected to the suction (where applicable) and discharge pipework of each
pump, compressor and blower. The gauges shall be 150 mm diameter and in accordance
with BS 1780 and Section 10 and shall include a petcock between the pump/blower and the
gauge. A non-corrosive diaphragm gauge isolator shall be provided for solids-bearing or
corrosive fluids. Suction gauges shall be of the compound type and shall have a range of + 1
bar. Discharge gauge ranges shall be a standard commercially available range with the
maximum reading 1.2 times greater than the pumps rated shut-off pressure. Discharge
gauges shall also read to 1.0 bar. All gauge mountings shall be free of vibration.
The pressure readings shall be recorded on the MCC/SCADA system using pressure
transmitters.
Pressure gauges shall be always kept calibrated as QCS Section 10 requirements.
1.2.14
Nameplates and Data Plates
Nameplates and data plates shall be stainless steel of ample size with embossed, stamped
or etched lettering in English, fastened to the equipment in a prominent place with corrosionresisting pins. The manufacturer, serial number, date of manufacture, model number and
essential operating characteristics shall be displayed on nameplates, which shall be to the
approval of the Engineer. Data plates shall be inscribed with specific or directed information.
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Protection of Finish. The Contractor shall provide adequate means for fully protecting all
finished parts of the materials and equipment against damage, from whatever cause, during
the progress of the work, and until final completion. All materials and equipment in storage
and during erection shall be protected in such a manner that no finished surfaces shall be
damaged or marred, and all moving parts shall be kept perfectly clean and dry. Painting and
protective coatings shall conform to applicable requirements of colours. They shall be to the
approval of the Engineer, and the following requirements, unless modified or otherwise
specified elsewhere. Painting systems shall be as specified in Section 8 Part 8.
Factory Painting. On mechanical equipment, drives, starters, control panels and other similar
self-contained or enclosed components, a factory primer and high-quality oil-resistant baked
industrial enamel finish shall be applied. Surfaces that are inaccessible after assembly shall
be painted or otherwise protected by a method which provides protection for the life of the
equipment.
Shop Priming. Two shop coats of metal primer shall be applied on surfaces to be finish
painted at the site, the coating thickness to protect surfaces until finished. Primers specified
for the required field applied paint systems as in Section 8 shall be used. The Contractor
shall submit for approval the coating systems intended for use. Shop primers for affected
items of equipment shall consist of only those approved for the intended protective coating
system. Working drawings indicating compliance with this requirement shall be submitted.
Rust Prevention. Machined, polished, other ferrous surfaces, and non-ferrous surfaces which
are not to be painted shall be coated with an approved rust preventive compound, and, in the
case of aluminium be anodised. Structural galvanised steel and stainless steel need not be
coated.
1.2.16
Noise levels: With the envisaged maximum number of items of equipment operating on load
(including existing equipment), the sound level outside an envelope of 1 metre radius from
any items of equipment, shall not exceed 85 dB (A). The Contractor shall include for suitable
sound attenuation to achieve this level, generally in accordance with BS 8233. This will apply
in the audible frequency range 20 Hz - 20k Hz. Above 20k Hz, the Contractor must state
whether any fundamental frequencies are generated in the ultrasonic region. Noise levels
shall be assessed in accordance with BS 4196, taking into account the actual or proposed
site conditions. Noise levels shall be limited to the values specified for designated
equipment.
Vibration Levels : The Contractor shall ensure that the stiffness of the floors/buildings and
supporting structures must be meet the requirements of vibration and resonance respect to
frequencies. Vibration levels shall be within the limits and comply with BS ISO 10816, Part 1,
3 and 7.
1.2.17
Metal Plating
Chromium plating shall be to BS 1224.
Sheradising shall only be used in internal air conditioned environments, and shall be to
BS 4921.
Galvanising shall be hot-dip, to BS 729.

environment shall be galvanised.
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1.2.15
Whenever possible steel in a wet or external
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The requirements for the design, manufacture, construction, installation testing and
commissioning of all labour, materials and accessories for the MV Cubicle Switchboards,
Main Switchboards, Submain Switchboards, Motor Control Centres, MCCB panel boards,
distribution boards etc shall be in accordance with Section 21 unless otherwise agreed with
the Engineer.
1.1
INSTALLATION AND COMMISSIONING
1.2.19
Co-ordination
The Contract Drawings show in a general arrangement form the arrangements desired for
the principal equipment, piping, and similar appurtenances, and shall be followed as closely
as possible. Proper judgement shall be exercised in carrying out the work to secure the best
possible headroom and space conditions throughout, to secure neat arrangement of all
equipment, and accessories, and to overcome local difficulties and interference of structural
conditions wherever encountered.
The Contractor shall take all measurements for his work at the installation sites, verify all
dimensions and conditions at the place of installation, verify the Sub-contractors drawings
and be responsible for the proper installation, within the available space of the equipment
specified and shown on the Drawings. Written details and reasons for proposed deviations
from Drawing and Specifications shall be submitted. The Engineers approval for any
variations shall be obtained before making any changes.
1.2.20
For the tests on the Site the Contractor shall provide at his own expense unless specified
otherwise, such labour, materials, electricity, fuel, stores and apparatus and instruments as
may be requisite and as may be reasonably demanded to carry out such tests efficiently.
If after inspecting, examining, or testing any equipment the Engineer shall decide that such
equipment or any part thereof is defective, or not in accordance with the Contract, he may
reject the said equipment or part thereof, by giving the Contractor written notice within 7
calendar days of such rejection, stating therein the grounds upon which the decision is
based.
1.2.21
Prior to installing the equipment, the Contractor shall ensure that installation areas are clean,
free of dust intrusion and that concrete or masonry operations are completed. The
installation areas shall be maintained in broom-clean condition during installation operations.
All buildings where permanent doors and windows have not been installed shall be provided
with temporary protection to prevent dust ingress and any other damage to equipment, all to
1.2.22
Manufacturers Installation Supervision
Where specified in the Project Specification, the Contractor shall ensure that each equipment
manufacturer furnishes the services of an authorised representative especially trained and
experienced in the installation of his equipment to:
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1.2.18
(a)
supervise the equipment installation in accordance with the approved instruction

manual
(b)
be present when the equipment is first put into operation
(c)
inspect, check and adjust until all trouble or defects are corrected and the equipment
installation and operation are acceptable
QCS 2014

Part
01: General
Page 21
(d)
witness and supervise operational demonstrations and system validation tests to the
extent specified.
(e)
prepare and submit certified test report.
All costs for manufacturers representatives services shall be included in the Contract Price.
1.2.23
Installation
General. Prior to installation the equipment shall be cleaned, conditioned, and serviced in
accordance with the approved instruction manuals.
Equipment. Equipment shall be installed in accordance with approved instruction manuals by

an approved specialist sub-contractor. The Contractor shall employ skilled craftsmen
experienced in installation of the types of equipment specified, and shall use specialised tools
and equipment, such as precision machinist levels, dial indicators, gauges, and micrometers,
as applicable.
Anchor Bolts. The Contractor shall provide bolts with templates or setting drawings and
verify that bolts are correctly located before structural concrete is placed.
Base and Bedplate Grouting. Grouting shall not be carried out until initial fitting and
alignment of connected piping is completed and approved by the Engineer. The Contractor
shall level and align equipment on concrete foundations using suitable steel and brass
shimming, then entirely fill the space under base or bedplates with non shrink grout.
Exposed grout shall be bevelled at a 45 angle, except that exposed grout at horizontal
surfaces shall be rounded for drainage. Exposed grout shall be trowelled or pointed to a
smooth dense finish and damp cured with burlap for three days. After the grout has fully
hardened, the Contractor shall remove jacking screws and tighten nuts on anchor bolts. The
Contractor shall check the installation for alignment and level, and perform approved
corrective work as required to conform to the tolerances given in the instruction manual.
1.2.24
General
operational demonstrations and system validation tests are required for all mechanical
and electrical equipment, and systems specified including all associated and related
electrical systems and control devices specified in this Section, Sections 10 and 21,
and the Project Specification
all costs for these shall be included in the Contract Price
(b)
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(c)
materials, potable water, chemicals and electrical power for testing and commissioning
and validation shall be supplied by the Contractor. Temporary facilities, storage, and
similar facilities necessary for these shall be supplied by the Contractor. Testing and
commissioning shall be performed under continuous inspection by the Engineer. The
Contractor shall provide sufficient experienced skilled staff to carry out the testing and
commissioning. Various equipment manufacturers shall be present, if specified.
(d)
all defects and malfunctions found by testing and commissioning shall be corrected
immediately, using approved methods and new materials for repairs as required.
Interruption time necessary for corrective work may, at the Engineers discretion, be
added to the specified testing and commissioning periods
(e)
satisfactory completion and approval of required commissioning and testing is one of

the conditions precedent to the Engineers acceptance of the work, but does not
constitute final acceptance
(f)
testing and commissioning shall be in accordance with the Project Specification, the
QCS, the relevant International Standards, QGEWC requirements, industry norms and
to the Engineers approval.
QCS 2014
Test Procedures
(a)
(i)
primary tests and checks
(ii)
unit testing
(iii)
system validation tests
(iv)
commissioning and setting to work
(b)
the Contractor shall not proceed from one stage to the next without the Engineers
written approval
(c)
consolidation of demonstration, testing, and instruction requirements. Unit and system

validation testing, commissioning and instruction of the Employers personnel may be
performed simultaneously.
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Primary Checks and Tests
all component units and complete systems shall conform to the Specifications,
Drawings and the approved working drawings, samples, construction manuals,
material lists, and other approved submittals
(b)
all specified components and complete systems shall have been installed satisfactorily
and are operable
(c)
all installations shall be safe to use.

permitted if approved by the Engineer
(d)
all cleaning work shall be completed
(e)
equipment shall be free from physical damage due to mechanical force, exposure to
the elements, incorrect connection, etc.
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(a)
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Temporary access, covers etc. will only be
Unit Testing
(a)
unit testing is defined as tests on individual equipment such as pumps, compressors,

blowers, fans conveyors and all similar equipment item. Tests may be performed
simultaneously on groups of identical equipment, items, and groups of items supplied
by one manufacturer, if practicable
(b)
potable water shall be used to fill tanks, wells piping and systems that contain water,
sewage, or sludge in normal operation. Where necessary specified chemicals shall be
used for chemical systems but shall not exceed in-service concentrations
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tests shall show that all component units operate with the quantities, efficiency,
repeatability, and accuracy specified
(c)
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testing shall be carried out in stages as follows:-
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Part
01: General
(d)
5
tests shall be carried out continuously for a minimum period of 8 hours, unless other
periods are specified.
System validation tests

(a)
system validation tests shall not commence until unit tests have been satisfactorily
completed
(b)
this is defined as testing of complete systems that perform a discrete process function
such as pumping systems, emergency power systems and similar systems. Each
system shall include associated structures, tanks, piping, utilities, instrumentation and
controls, and like related items. Two or more separate systems shall be validation
tested simultaneously when necessary to validate an entire specific function
(c)
potable water shall be used for system validation tests if it is possible to carry them out
satisfactorily with this medium. If the tests require use of the medium used in service,
then this shall be used
QCS 2014
(d)
Page 23
each system validation tests shall be carried out for minimum of 24 hours, unless
longer is needed to prove the performance of the system.
Commissioning and Setting to Work

commissioning is defined as testing all the equipment and systems together under
actual operating conditions using all the mediums used in actual operating conditions.
Setting to work follows consecutively from this. Once the equipment and systems are
operating satisfactory they are left to work
(b)
each system shall be tested, including standby equipment, by continuous operation

under the in-service condition for not less than 7 consecutive days unless required
otherwise by the Engineer, with no interruptions except for normal maintenance or
corrective work. Where the in-service condition is an automatically controlled repeat
cycle with on/off intervals, it shall be so operated
(c)
systems shall be operated continuously under constant inspection of trained operators.

System operation shall be cycled from full load to light load and back to full load each
24 h. Variable speed equipment shall cycle through the applicable speed range at a
steady rate of change. Simulated alarm and failure operating conditions shall be
induced. Test controls and protective devices shall be tested for correct operation in
adjusting system functions or causing system shutdown
(d)
failure of an item of equipment or a system during the stated periods will result in
termination of the test. The test will only recommence when the Engineer is satisfied
with the remedial work. The test shall then recommence for a further 24 hours
(e)
subject to Contractors request and Engineers approval in each specific case, the
Contractor may be permitted to simulate certain operating conditions relating to flow
rates, water levels, and malfunctions. Permission for simulations will be granted only
where it is unwise or impossible to obtain the conditions covered by the capability of
ranges or equipment. The simulation methods shall reflect reasonable anticipated
operating conditions.
(a)
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Part
01: General
Instruction and Training of the Employers Personnel
After the equipment has been installed, tested, adjusted and placed in satisfactory operation
the Contractor shall provide the services of qualified staff approved by the Engineer, or if
specified in the Project Specification, of the manufacturers representatives, to instruct and
train the Employers operating personnel in the use and maintenance of the key items of
equipment as specified. An instruction and training programme shall be conducted for up to
six operators designated by the Employer. The Contractor shall give the Employer at least
one months written notice of the proposed instruction and training programme. Instruction
and training covering basic system operation theory, routine maintenance and repair, and
hands on operation of equipment shall be included. The duration of the programme shall
be based on the complexity of equipment involved, and the Engineers approval of instruction
adequacy obtained before terminating the programme. Instruction and training periods shall
be acceptable to the Engineer and Employer.
1.2.26
In-Service Checks
General. In-service checks of all systems and equipment shall be carried out by the
Contractor twice during the Contract maintenance period by the Contractor with qualified
technical representatives of the various system manufacturers, including manufacturers of
equipment components within systems, if specified. Checks shall be detailed and complete
and shall be performed under the observation and to the satisfaction of the Employer. All
costs for in-service checks shall be included in the Contract Price.
Notification. The Employer shall be notified in writing at least 10 days before carrying out of
in-service checks and the Employers approval shall be obtained prior to commencing work.
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1.2.25
QCS 2014

Part
01: General
Page 24
Consultation. During the in-service checks, the manufacturers technical representatives shall
consult with the Employer to review the instruction manuals and the pertinent operational and
maintenance problems encountered, and shall furnish technical advice and
recommendations to the Employer.
Programme. Initial in-service checks shall be performed approximately 6 months after final
acceptance. The last in-service checks shall be performed 30 days prior to the end of the
Contract maintenance period.
Reports. A written report on each in-service check, signed by the appropriate manufacturer
or his representative, shall be delivered to the Employer within 10 days following the checks.
The report shall describe the checking procedures in detail, and shall state all advice and
recommendations given to the Employer.
Operation and Maintenance Manuals. These shall be altered to take into account any
modifications to equipment, drawings or operating procedures. Replacement drawings and
pages, marked as revisions, shall be supplied with sufficient copies to allow all the operation
and maintenance manuals to be updated.
1.2.27
Specialised Training Programme for Employers Personnel
Where designated in the Project Specification the Contractor shall provide a specialised
training programme and manual for the Employers key personnel in the equipment, electrical
systems and instrumentation systems, to be conducted by the supplier/manufacturer and
held at locations outside Qatar. The training programme and manual shall be submitted to
the Employer for approval and shall be designed to:
provide in depth information and familiarisation of the equipment installed in the
Project
(b)
receive specialised training in the design, proper operation, maintenance and

replacement of the equipment and components
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(a)
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The Contractor shall provide whatever assistance is requested by the Employer to develop
meaningful itineraries for the training programme. The Contractor shall provide hotel
accommodation, travelling expenses by air, land transport and per diem allowance as per the
Ministry of Education guidelines.
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END OF PART
QCS 2014

Part
10: Odour Control Equipment - Scrubber Type
Page 1
10
ODOUR CONTROL EQUIPMENT-SCRUBBER TYPE ................................. 2
10.1
GENERAL ...................................................................................................... 2
10.1.1
10.1.2
10.1.3
10.1.4
10.1.5
Scope
References
System Description
Submittals
Warranty
10.2
PRODUCTS ................................................................................................... 4
10.3
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10.2.1 General
10.2.2 Scrubbers
10.2.3 Fans
10.2.4 Recirculation Pumps
10.2.5 Chemical Feed Pumps
10.2.6 Chemical Storage Tanks
10.2.7 Rotameters
10.2.8 WYE Strainer
10.2.9 Sump Overflow Trap
10.2.10 Acid Supply Connection
10.2.11 Pressure And Vacuum Gauges
10.2.12 Pressure Switches
10.2.13 Drench Showers
10.2.14 Water Softener
10.2.15 Control Panel
10.2.16 Factory Inspection and Testing
10.2.17 Spare Parts and Tools
2
2
2
3
4
4
5
7
8
9
10
11
11
11
12
12
12
12
12
13
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10.3.1 Installation
10.3.2 Site Inspection and Testing
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QCS 2014

Part
Page 2
ODOUR CONTROL EQUIPMENT-SCRUBBER TYPE
10.1
GENERAL
10.1.1
Scope
This Part specifies the requirements for the design, manufacture, construction, installation
testing and commissioning of odour scrubber systems and related auxiliary equipment.
Section 8,
Section 10,
Section 21,
Drainage Works
Instrumentation Control and Automation
Electrical Works
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General
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This Section
Part 1,
10
References
The following standards or revised/updated versions and other documents are referred to in
this Part:
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10.1.2
BS 848,.......................Fans for general purposes
BS 970 (ISO 683) .......Wrought steels for mechanical and allied engineering purposes
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BS 1646 (ISO 3511) ...Symbolic representation for process measurement control functions
and instrumentation
BS 2782 (ISO 181, 174, 307, 8618) Methods of testing plastics
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BS 3496 (ISO 1888) E glass fibre chopped strand mat for the reinforcement of polyester and
epoxy resin systems
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and epoxy resin systems
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BS EN 1092...............Circular flanges for pipes valves and fittings

BS 4994......................Design and construction of tanks and vessels in reinforced plastics
BS 5000 (IEC 34,72) Rotating electrical machines of particular types or for particular
applications
BS 5345 (IEC 79) .......Code of practice for selection, installation and maintenance of
electrical apparatus for use in potentially explosive atmosphere
BS 5512 (ISO 281) .....Methods of calculating dynamic load ratings and rating life of rolling
bearings
BS 6105 (ISO 3506) ...Corrosion resistant stainless steel fasteners
BS 6339 (ISO 6580) ...Dimensions of circular flanges for general purpose industrial fans
10.1.3
System Description
Performance requirements:
concentration of hydrogen sulphide (unless specified otherwise)
other contaminants:
: 500 ppm
QCS 2014

Part
Page 3
Mercapatans
Amines (mono (di/tri)
Ammonia
Sulphide concentration in solution
Number of air changes per hour in ventilated
volume
:
:
:
:
trace only
10ppm
50ppm
50 mgl
Removal of hydrosulphide gas and ammonia

Removal of amines
Removal of mercapatans
:
:
:
4 minimum. More if Contractor deems

necessary.
99.8%
95%
No requirement
The above criteria are for domestic sewage of a quality normally encountered in Qatar.
Highly septic sewage or sewage from industrial sources will need special analysis and the
possible addition of a sulphuric acid stage or a separate sodium hydroxide stage.
The scrubber shall be the counterflow, packed bed tower type.
Sodium hydroxide 20 % w/w (NaOH) and sodium hypochlorite 12 % w/w (NaOCl) are to be
used as the scrubbing reagents for removing hydrogen sulphide from the odour source. For
some installations with ammonia levels above 30 ppm or other industrial chemicals, addition
of a sulphuric acid 20 % w/w (H2SO4) stage will be necessary. Operation of the scrubber
shall be automatically controlled (with manual override capability) as follows. A single speed
fan activated by a manual start/stop push-button switch, draws odorous air through the
packed beds of the scrubber. The selected recirculation pump (a standby is to be provided),
also activated by a manual start/stop pushbutton switch, circulates scrubber liquors through
the packed beds. Sulphuric acid (if used), Sodium hydroxide and sodium hypochlorite are
added to the scrubber liquor via metering pumps. Sulphuric acid must be added separately
in another stage. These pumps are controlled through set points on analysers for pH for
H2SO4 and NaOH and Redox (oxidation reduction potential) for NaOCl. Chemical is added
until the highest set point on the analyser is reached. The recirculation pumps shall be
interlocked with the metering pumps so that in automatic mode, recirculation pump failure will
cause shut down of metering pumps. Pressure switches shall initiate change over to the
standby Flow switches (rotameters) shall initiate change over to standby on low flow fan.
The final control involved in the scrubber is water makeup to replace both bleed scrubber
liquor and evaporative losses. This is to be achieved with a capacitance type liquid level
element and a solenoid valve on the supply line fed from the water softener.
Scrubber liquid is bled off continuously so that the potable water added is sufficient to
maintain the salts in solution.
The odour scrubber system shall be designed for indoor or outdoor installation as shown on
the drawings and specified.
The chemical storage and feed system shall be designed for outdoor installation.
A duplex ion exchange water softener shall be fitted on the potable water supply line, with
booster pumps if necessary.
10.1.4
Submittals
In addition to the requirements of Part 1 of this Section, the Contractor shall provide data and
information as described in the following paragraphs.
Design Data providing the following information:
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(a)
calculations to justify the sizing of the fans, packed bed, pumps and chemical storage
tanks
QCS 2014
(b)
calculations as required by BS 4994 category III pertaining to the construction of the

scrubber and chemical storage tanks
(c)
structural calculations for foundations and guy wires or any other external means of
support, taking into account wind loadings
(d)
user certificates.
Shop Drawings providing the following information:

(a)
fibreglass resin and plastic liner manufacturers technical data on composition.

Characteristics of resin and liner including hydrostatic and burn test
(ii)
manufacturers technical data on other equipment used
dimensional layout of stack and all equipment used
(c)
fan test data as BS 848 Parts 1 and 2.
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Instrumentation:
complete layout and wiring diagrams of unit control panels.
(b)
complete process and instrumentation diagrams drawn in accordance with BS 1646
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(a)
Samples
(a)
(i)
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product data
vessel and duct GRP and liner, packed media.
Operation and maintenance and instruction manuals including:
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(a)
odour reduction field test report(s) as specified in Part 10.3
(b)
the documentation in Clauses 2, 3 and 4 above in Part 10.1.4.
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Part
Warranty
In addition to the guarantee requirements of Part 1 of this Section, the Contractor shall
ensure that the odour control scrubber equipment manufacturer be responsible for the proper
performance and warranty of the odour control system. The system shall be designed and
guaranteed to meet the odour removal requirement as outlined in this specification.
Warranties and guarantees by the suppliers of various components in lieu of single-source

responsibility by the scrubber manufacturer will not be accepted. The Contractor shall ensure
that the scrubber manufacturer is solely responsible for the warranty.
The scrubber manufacturer must state in his proposal the guaranteed removal efficiency of
the scrubber, based on the gas inlet concentration.
10.2
PRODUCTS
10.2.1
General
Those items of the scrubbers and fans specified to be constructed of fibre glass reinforced
polyester resin shall have approximately 25 % glass reinforcement with a 75 % resin content
and conform to the following:
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10.1.5
(a)
the polyester resin shall be ortho and isophtalic polyester vinylester resin to BS
3532
(b)
reinforcing material shall be a commercial grade of glass fibre water resistant type E
chopped strand mat or woven glass fabric to BS 3496 and BS 3749
QCS 2014

Part
Page 5
(c)
surface finish shall be a gelcoat flow coat isophtalic resin to BS 3532. All drilled, cut
or otherwise exposed edges shall be sealed with polyester resin
(d)
all materials, fabrication procedures, manufacturing tolerances, workmanship, tests,

and product quality shall conform to BS 4994
(e)
the scrubbing towers and chemical storage tanks shall include conductive resin strips
behind weld lines, and nozzle fitting joints, to enable a full spark test to be carried out,
both in the factory and subsequently on site
(f)
Each scrubbing tower and chemical storage tank shall have a corrosion resistant
welded thermoplastic liner of either PVC-u or polypropylene. If PVC-u is used it shall
be annealed after fabrication and welding.
Scrubbers
The scrubber shall be single or dual stage vertical, counter-current design, packed tower
type.
The scrubber shall contain in the main packed bed a minimum depth of 3 m of nominal
50 mm size filamentous toroidal helix shaped or spherical type packing, having a free volume
2
3
of 95 %, with 28 m of surface area per m of packing. Packing is to be randomly dumped
into the scrubber; structured type packing is not acceptable. Material of construction is to be
polypropylene. Pressure drop per metre of packing shall not exceed 15 mm water column.
The scrubber shall include an entrainment separator/demister, internal spray piping or liquid
distribution as recommended by the specialist scrubber packing manufacturer, packing,
packing supports, lifting and hold down lugs.
All liquid handling nozzles, external to the vessel, shall be flanged to NP16. Gas handling
nozzles shall be of the dimensions as outlined in BS 6339. Couplings shall be fully flanged,
NP16. Minimum projection of nozzles shall be 150 mm.
Scrubber nozzles and appurtenances shall include:

make-up water inlet
(b)
hydrochloric acid supply connection
(c)
overflow
(d)
sump drain
scrubber liquor recirculation inlet (to spray header)
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10.2.2
(f)
scrubber liquor recirculation outlet (to pump suction)
(g)
pH probe mounting
(h)
Redox probe mounting
(i)
level sensor mounting connections with stilling well
(j)
a minimum of three manholes with neoprene gaskets (for servicing spray nozzles,
packed bed, and scrubber sump)
(k)
four GRP tie down lugs or base flange
(l)
mounting brackets for scrubber recirculation piping
(m)
stainless steel guy wires as necessary
(n)
gas sampling points on inlet and outlet to the scrubber. If necessary, both shall be
piped using 12 mm piping to a convenient point for use of a hand held hydrogen
sulphide monitor.
QCS 2014

Part
Page 6
The scrubber tower shall be capable of operating at the design flow rate with a maximum
static pressure loss of 75 mm water column. The packing depth, recirculation rate, and
recirculation solution shall be designed to meet the required efficiency.
The scrubber housing and internal structural members shall be fabricated of GRP, and shall
be not less than 5 mm thickness. External reinforcing ribs, if required for pressure or vacuum
conditions or wind load, shall be suitably designed and installed not more than 1 m apart.
Colour shall be white.
An internal moisture entrainment separator section shall be furnished with each unit which is
to consist of 300 mm deep packed bed. The demister shall be capable of removing not less
than 99 % of the entrained moisture of the air exiting the scrubber, consisting of droplets
10 m and larger.
Packing support plates for the main bed shall be manufactured from polypropylene having
40 mm by 40 mm square openings and being 40 mm deep. Packing support plates for the
entrainment separator section shall be manufactured from polypropylene, having a minimum
84 percent open area , or same as above. Any internal supports required shall be of the
same material as the shell. Support plates are not required for chevron blades.
10
The scrubbing liquid distribution system shall be the spray type of manufacturers standard
design, sized for the flowrates required and taking into varying air delivery rates of +10 %.
No liquid distributors shall be permitted. Spray headers shall be placed at the manufacturers
recommended distance above the packing. Material of construction shall be chlorinated
polyvinyl chloride (PVC-C), NP16. Spray nozzles shall be spiral design, full cone type,
constructed of PVC
11
The scrubber shall be designed with a minimum of 600 mm of shell height between the gas
inlet and bottom to act as an integral sump. The sump shall hold a minimum of two minutes
supply of scrubbing liquid. The sump shall be furnished with a level sensor as specified
herein.
12
No internal wetted metal bolts, or components are permitted. All external bolts and fasteners
including anchor bolts and flanged bolts shall be BS 970 316 stainless steel. Stainless steel
anchor bolts guy wires and clips shall be provided by the manufacturer.
13
The scrubber shall be supplied with integral mounting lugs and pipe supports for the (PVC-C)
scrubber liquor recirculation piping. Mountings shall be designed with consideration for pipe
inlet and outlet connections. Pipe supports shall be non-metallic channels and straps.
14
The scrubber shall be equipped with a differential pressure gauge on the inlet and outlet
ductwork which shall be installed so that abnormalities that may occur in the scrubber can be
visually detected. The scrubber shall have pressure taps located below the main packed bed
and above the entrainment separator, and the gauge shall be mounted on a scrubber shell.
The differential pressure gauge shall include instrument traps, and valve manifolds to permit
testing and zero setting of the gauge. Plastic tubing equipment with PVC condensate traps
shall connect the high and low pressure taps. The gauge shall have a 100 mm round face.
15
Redox and pH probes for analysing the contents shall be located in the scrubber sumps. The
probes and analysers shall provide the chemical feed control as described herein. The
probes shall meet the following specifications:
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(a)
range : pH probe
(b)
stability :
01.% per 24 hours, non-cumulative
(c)
wetted materials sensor
Liquid crystal polymer body
(d)
accuracy/ sensitivity
(e)
temp. limits
0-14 pH : Redox probe; 0-1000 mV
0.1 pH unit : Redox probe : 1 mV

0
65 C
QCS 2014

Part
Page 7
(f)
pressure rating
0-350 kPa
(g)
interconnect cable
(h)
each probe shall be supplied with a two wire transmitter and analyser
(i)
the analyser shall be microprocessor based with a 4 digit display, with dual
programmable high/low set points, contacts. Alarm conditions shall be indicated on
the instrument by front panel LEDs with auxiliary alarm contacts. Automatic or
manual temperature compensation shall be selectable, with the option to display the
process temperature. A data logging system for high/low signals shall be
incorporated. Set-up, alarm and control functions shall be accessible on the front
panel
(j)
each probe shall be provided with a protector or well as recommended by the

manufacturer
(k)
the manufacturer shall supply all necessary hardware and wiring for installation of
probe and analyser.
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manufacturers standard
The sump liquid level sensor shall be a capacitance type liquid level probe with a Teflon
coated probe element and integrally mounted cast iron or epoxy coated enclosure. The probe
shall be a dual-point sensor, for high and low liquid levels. On low liquid level, an electrically
operated solenoid valve shall open and allow scrubber make-up water to flow into sump. The
valve shall close when high set point is reached. Low-low level shall simultaneously sound an
alarm in the control panel and shut off the recirculation pumps. Probe shall be inserted in
type 316 stainless steel stilling wells mounted externally of the scrubber.
17
All instrumentation mounted inside the scrubber tower or tanks shall be intrinsically safe.
10.2.3
Fans
Duty/standby fans shall be provided for each scrubber unit. Each fan shall have a single
speed motor with the capacity and power to deliver the required volume of air against the
total pressure losses in the air intake, duct collection systems, packed bed, mist eliminator
and ductwork to the fan and exiting out of the stack.
The fan shall be centrifugal, belt-driven type constructed from corrosion resistant fibre glass
reinforced plastic or stainless steel, with vibration free mountings. The fan shall be capable
of the performance specifications as shown below:
(b)
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16
(c)
operating temperature : 0 -70 C
(d)
Motor : high efficiency, 415 V, 3 phase, 50 Hz IP 55; 1500 rpm power as required,
rated for zone 2 use with methane gas (BS 5345), to BS 5000, 1500 rpm.
unit capacity
static pressure :
(a)
as required
3000 Pa, or as required
0
Exhaust fans shall be suitable for continuous 24-hour operation and shall be nonoverloading. Each fan shall operate such that no point on the fan curve requires more than
the rated motor power.
The fan housing, flanges and backward curved impellers shall be constructed of flame
retardant GRP laminate or stainless steel, capable of resisting continuous fume temperature
0
of 70 C. The manufacturer shall state the type of resin used and confirm that it will perform
satisfactorily under the operating conditions. All interior surfaces exposed to the corrosive air
stream shall be resin rich.
Wheel and shaft assemblies shall be statically and dynamically balanced to a maximum of
0.5 m displacement prior to assembly and every fan test run prior to shipment.
QCS 2014
Fans shall comply with BS 848 and be provided with the following standard features:
(a)
drive assembly: belts shall be oil, heat and static resistant type, sized for continuous
duty. Shafts shall be constructed of heavy duty steel turned, ground and polished,
keyed at both ends
(b)
bearings: heavy duty, self-aligning, pillow block bearings, with grease fittings
(c)
shaft seal: a fibreglass and neoprene shaft seal shall be placed where the shaft
leaves the housing, along with a viton shaft slinger between the seal and wheel on
belt drive units
(d)
bases: heavy gauge hot rolled steel, epoxy coated
(e)
the fan shall be provided with the following accessories:

flanged and drilled inlet and outlet to BS 6339
(ii)
drain
(iii)
access door
(iv)
vibration isolation system
(v)
belt and shaft guard as Part 1
(vi)
earthing as QGEWC requirements and BS 7671
(b)
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flexible connectors:
flexible connectors shall be installed on the fan inlet and outlet to dampen
axial, lateral, and vibrational duct movement. Flexible connectors shall be
installed at each fan inlet and outlet
(ii)
the flexible connector shall be resistant to the corrosive gases being processed
and shall be able to withstand 3750 Pa. The flexible connector shall be
minimum 30 mm long.
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Dampers:
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suitable sized dampers shall be provided as follows:

(i)
balancing damper between the fan outlet and the scrubber inlet
(ii)
isolation dampers at each fan inlet and outlet
(a)
(i)
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(f)
Page 8
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Part
the dampers shall be provided in accordance with the following specifications:
(i)
the damper shall be flanged and drilled to withstand 3000 Pa
(ii)
the blade thickness shall be as required by the damper manufacturer
(iii)
the bearings shall be moulded plastic material
(iv)
fibreglass axles shall extend full length of blade and 150 mm beyond frame
(v)
the unit shall be equipped with a full circumference blade seal to limit leakage
3
2
to less than 1 m /m min at 3000 Pa.
10.2.4
Recirculation Pumps
Pumps shall be of the direct coupled, single stage, end suction, horizontal, back pullout
corrosion resistant, centrifugal type.
Impellers with integral shaft sleeves shall be balanced semi-open fibre glass reinforced resin
polyester or PVC-C.
The pump casing shall be a resin injected hot press moulded fibre glass reinforced polyester
or PVC-C. The casing shall be free standing supported by heavy duty non-metallic feet.
Suction and discharge nozzles shall be NP16 flanges.
QCS 2014

Part
Page 9
The shaft shall be constructed of 316 stainless steel of sufficient diameter to assure rigid
support of the impeller to prevent excessive vibration.
The bearing housing shall be constructed of cast iron, machined with precision pins of
tongue-and-groove construction to ensure permanent alignment.
Bearings shall be of the anti-friction, oil lubricated, ball type and enclosed in a cast iron, oiltight bearing frame. Bearings shall have a minimum L-10 rating of 20,000 hours under full
load continuous 24-hour duty. Bearings shall be oil lubricated. The pump shall be equipped
with constant level oiler.
The shaft seal shall be mechanical, EPDM/carbon/ceramic. Seal water shall be provided if
necessary.
Pumps and motors shall be bolted to a common GRP baseplate. Pumps shall be grouted in
place with epoxy grout.
Pumps shall be directly coupled to the motor with a suitable spacer type coupling and guard.
10
Duty/standby change over shall be by means of a low flow switch mounted in the liquor feed.
11
Motor:
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each pump shall be provided with a horizontal squirrel cage induction, totally
enclosed fan cooled motor, of sufficient power such that no point on the pump
curve requires more than the rated power of the motor furnished
(b)
each motor shall be suitable for 415 V, 3 phase, 50 Hz continuous 24-hour operation
and shall conform to the requirements of Part 1 of this Section and Section 21.
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(a)
Chemical Feed Pumps
The pumps shall be of the hydraulically balanced double diaphragm type, wherein a
measuring piston reciprocates within a cylinder and causes hydraulic oil to deflect a flat
diaphragm. The diaphragm shall be supported throughout the entire pumping stroke. The
hydraulic oil system shall include a means to automatically relieve excess hydraulic pressure,
makeup oil and bleed-off vapours. Mechanically operated devices are not acceptable. The
chemical metering head shall include a diaphragm cavity moulded into the head material, or
have other intrinsic design features to prevent diaphragm damage during restricted inlet
conditions. The pump shall have a flow-through liquid path from bottom to top. The
diaphragm shall be capable of sealing under full head bolt torque limits without stressing the
diaphragm. Pump heads shall be polyproylene and diaphragms PTFE.
The metered liquid shall enter the metering head at the bottom and exit at the top through
alumina-ceramic disk or ball type check valves. These may be gravity seating or spring
loaded to meet service conditions. Valve assemblies shall be replaceable without threading.
Valve seats, shall be of Viton, gaskets shall be PTFE.
The pump mechanism shall have flooded lubrication using a common oil with the hydraulic
system. It shall not contain auxiliary lubricator mechanisms. The pump mechanism shall be
sealed from direct contact with the outside atmosphere and shall be suitable for operation in
ambient conditions of 55 C without the use of heating or cooling devices. Manual capacity
adjustments between 0 and 100 % shall be accomplished while the pump is idle, or
operating, by simply changing the piston stroke length. A minimum of 400 adjustment
increments shall be available. Stroke adjustments shall provide positive, repeatable settings
within 0.25 % over the entire pumping range. Pump delivery shall be repeatable within
1 % accuracy over a 10 to 1 range.
Pump bearings shall be heavy duty ball or tapered roller type designed for an L10 life of at
least 50,000 hours in accordance with BS 5512.
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10.2.5
QCS 2014

Part
Page 10
Each pump shall have an integral pressure relief valve to prevent damage to the pump or
piping in the event of a downstream pipe blockage.
Pumps shall be capable of operating continuously with liquids at 40 C.
Each pump specified herein shall be driven by a squirrel cage induction motor suitable for
operation on a 240 V, single phase, 50 Hz power supply, and meeting the requirements for
electrical motors as specified in Part 1 of this Section and Section 21. Motors shall be direct
coupled to the pumps, with flexible couplings.
Each pump discharge shall include a back pressure valve designed to create a constant back
pressure without chatter or cycling. Parts in contact with the pumped liquid shall be suitable
for use with H2SO4, NaOH and NaOCl as specified herein. A PTFE diaphragm shall seal
the spring and bonnet from the product. The diaphragm shall seal on a replaceable seat and
shall ensure tight shutoff at zero flow.
10.2.6
Chemical Storage Tanks
The storage tanks shall be of lined laminated construction, designed and fabricated in
accordance with BS 4994 category III, and shall provide safe, sound, and leak-proof storage
at atmospheric pressure for the specified liquids. Lamination thickness specified in the
standards shall be considered minimum thicknesses.
Tanks shall be constructed of a welded PVDF, PVC-u or polypropylene liner and contactmoulded translucent reinforced plastic resin. As a minimum, tank construction shall consist of
a 50 m resin-rich exterior mat, a middle layer mat to develop the necessary strength, and a
250 to 300 m resin-rich nexus veil interior and a minimum 3 mm thick plastic liner.
Tanks, anchors, and supports shall be designed for exterior installation that shall withstand a
horizontal wind load without movement or damage. Tanks shall also be designed for a
concentrated dead load at the top of the tank of 500 kg. Tanks shall include hold-down
anchors. Anchors shall be designed to hold the tank against an uplift pressure of 2 m of
water column. Tanks shall be designed for pneumatic tanker loading.
Factory-applied insulation shall be provided for all storage tanks. Insulation shall be 50 mm
thick and shall provide a maximum coefficient of thermal conductivity (K Value) of 0.4
2
kg.cal/h/m /C. Insulation shall be protected by an additional fibreglass laminate built up to a
minimum thickness of 0.4 mm. This protective laminate shall include expansion joints
spaced to preclude damage due to thermal expansion. A lip shall be provided at each joint to
prevent moisture from entering. The exterior laminate shall also include a pigmented
protective gel coat in a colour to be selected by the Engineer. Loose insulation shall be
packed into the gusset around the pipe neck at each tank nozzle, and shall be taped to
provide a weatherproof seal.
A permanently attached encapsulated paper or stainless steel tag shall be affixed to the
outside laminate covering the insulation. This label shall contain the following information:
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(a)
manufacturer
(b)
corrosion-resistant liner
(c)
type of liner reinforcement
(d)
chemical to be stored
(e)
(i)
concentration
(ii)
maximum specific gravity
(iii)
maximum temperature
exterior resin
QCS 2014
(f)
tank capacity
(g)
date of manufacture.
Page 11
The tanks shall include the fittings and appurtenances shown on the drawings and described
herein:
(a)
hinged, top-mounted access manway (800 mm diameter) with non-slip walkway and
316 stainless steel ladder cage, and handrailing
(b)
conical gusseted, flanged connections for fill, inlet, outlet, drain, vent and
overflow. All shall be minimum 75 mm diameter. The overflow shall be piped into
the tank bund to prevent splashing. Connections shall be located as shown on the
Drawings. Flange face and bolting shall be in accordance with NP 16
(c)
low level probes shall be fitted in each tank to stop the dosing pumps in the event of
low level being detected. Suitable gasketed covers shall be provided for these
probes
(d)
screened vent. The vent shall be sized for release of air during tanker offloading
(e)
anchor and lifting lugs
(f)
A visual cat and mouse type liquid level gauge shall be provided on each tank, or
alternatively a hand operated pneumatic bubbler.
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Tanks shall be segregated in bunds. Bunds shall have individual capacities equal to 1.1
times the tank full volume. Alternatively tanks of a proprietary design with integral bunds may
be provided.
10.2.7
Rotameters
General. Rotameters shall be provided as shown on the drawings and specified herein.
Rotameters shall include a plastic housing or frame. Rotameters shall include a flow indicator
suitable for indoor installations. All wetted parts and fittings shall be 316 stainless steel,
except O-rings. Meters shall have a minimum rangeability of 10:1.
Make-up Water. Rotameters shall include a dial flow indicator, 316L or plastic, suitable for
high pressure, high temperature flow indication. The metering float shall be magnetically
coupled to an indicator housed in a fully gasketed, reinforced fibreglass case. Accuracy shall
be plus or minus 5 % of full scale. A stainless steel control valve shall be provided for
precise regulation of liquid flow rate.
Seal Water (if used) and recirculation pump rotameters shall be armoured purge meter type
with magnetically coupled indicator used for low flow, high pressure, and high temperature.
Accuracy shall be plus or minus 10 % of measuring flow rate. Rotameter shall include a
12 mm stainless steel needle valve.
10.2.8
WYE Strainer
Wye strainer shall be installed on the potable water, recirculation and dosing pump feeds,.
Strainers shall have a PVC body with type 316 stainless or PVC strainers with 0.8 mm
perforations.
10.2.9
Sump Overflow Trap
A trap shall be provided on the scrubber sump overflow line to prevent air inflow through the
scrubber.
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QCS 2014

Part
Page 12
10.2.10 Acid Supply Connection

1
The scrubber shall be equipped with a nozzle for addition of a dilute acid solution to the
sump. A 50 mm PVC ball valve and 50 by 100 mm funnel shall be installed for this.
10.2.11 Pressure And Vacuum Gauges

General. Pressure gauges shall be of the stem-mounting type.
Construction. Gauges shall be of the bourdon tube or bellows type with 270 clockwise
pointer travel. Dials shall be white with black numerals. Dial size shall be 100 mm. Panel
mounted gauges shall have round bezels for flush mounting and rear connection, others shall
have a stem-mounting bottom connection. Connections for all gauges shall be male 12 mm
threaded with square wrench flats. Wetted parts shall be compatible with the process fluid.
Cases shall be impact resistant plastic. Accuracy shall be 0.5 % of span.
Chemical Seal. The gauge shall be furnished with a diaphragm seal. The diaphragm seal
shall have a 316 stainless steel (minimum) top and bottom housing and a 316 stainless steel
diaphragm welded to the top housing. When the process fluid is not compatible with 316
stainless steel, the manufacturer shall provide a diaphragm seal compatible with the process
fluid. The process connection shall be a 20 mm threaded connection with a flushing
connection. The fill fluid shall be silicone.
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10.2.12 Pressure Switches
Pressure switches shall be operated by a brass bourdon tube actuating a switch. Switches
shall be single pole double throw, rated at 4 A, 240 V a.c., 50 Hz, and have deadband
adjustable up to 100 % of switch range. The adjustable operating range shall be 1 mPa, with
calibrated dials and two pointers indicating set and reset points. Enclosures shall be IP 65.
Pressure switches shall be fitted in the dosing and potable water booster pump lines to effect
changeover from duty to standby pumps.
A pressure drop transmitter shall be fitted in the ducting to effect changeover from duty to
standby fans.
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10.2.13 Drench Showers
One or more drench showers shall be provided by the chemical storage tanks, as specified.
Showers shall be operated by a walk-on platform with stainless steel operating linkages and
a stainless steel stay open valve which locks open.
The shower deluge shall be provided by gravity from a tank mounted above the shower with
an in-line or tank mounted thermostatically operated heater, fitted with 30 mA RCD
protection.
The shower shall incorporate an emergency eye/face wash fountain with a flexible hose
The shower shall be complete with a light and emergency shower/eye wash signs.
10.2.14 Water Softener

1
These shall be dual cylinder water softeners, rated for continuous output with an integral
meter initiated water power regeneration. The softener shall use a fine bead resin bed in
conjunction with a brine solution. The softener shall be rated for 28 days use without the salt
storage being replenished.
QCS 2014

Part
Page 13
A water storage break tank shall be provided to feed the softeners via duty/standby water
booster pumps.

1
A prewired, preassembled electrical control panel shall be provided for the odour control
system, as specified in the particular Project Specification
The panel shall be supplied complete with all equipment and accessories, including the
following:
motor control switches and indicating lights for the fans, recirculating pumps chemical
metering pumps, pH and Redox analyser/controllers
(b)
interlocks between recirculating pumps, chemical metering pumps, and sump level
control. Interlocks between pH and Redox analyser/controllers, chemical metering
pumps, and the make-up water solenoid valve and level controls
(c)
selector switches for manual or automatic operation
(d)
an annunciator with volt-free contacts for remote signalling, as required in the Project
Specification.
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Additionally the panel construction and components shall meet the requirements of Part 1 of
this Section, Section 21 and shall be suitable for connection to 415V 3 phase 50Hz.
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(a)
10.2.16 Factory Inspection and Testing
The Contractor shall secure from the equipment manufacturers certification that the following
factory tests have been carried out, and submit to the Engineer prior to shipment.
Fibreglass vessels shall be tested as follows:
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hydrostatically tested prior to shipment, with water to the top of the vessel for a
minimum of 24 hours
(b)
the water must be contained with no leaks or excessive wall deflection.
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(a)
Fans shall be tested as required by BS 848, Parts 1 and 2
One pump of each size supplied shall be factory tested. Where multiple units are provided,
only one of each size and type shall be tested. Dosing pumps shall be tested in accordance
with BS 5316 Part 2, recirculation pumps to BS 5316 Part 1.
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10.2.17 Spare Parts and Tools

1
The Contractor shall provide from the equipment manufacturers all the spare parts and tools
required during the commissioning and maintenance periods as specified in Part 1, including
those below:
In addition, sufficient chemicals shall be provided for the complete operation of the odour
removal system for 2 years of operation.
QCS 2014
Page 14
(1)
(2)
(2)
(2) (if fitted)
Scrubber
main packing
spray nozzles
moisture separator packing
(100 %) (for 1 bed)

(1) (set)
(5%) (of total)
Dosing pumps
diaphragms
Disk check valves and sets
Pump gaskets and O rings
Pumps and motors
(8)
(8)
(8) (complete sets)
(2)
Recirculation Pumps
Impeller
Seals
Pump and motor
(2)
(8)
(1)
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Fan
Complete Centrifugal Fan
Sets of V- belts
Sets of bearing
Shaft seals
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Item
The following spare parts shall be furnished as a minimum requirement, in addition to any
additional spare parts required for two years of operation.
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Part
10.3.1
Installation
The Contractor shall ensure the supplier of the odour control system furnishes the services
on site of a factory trained service technician or engineer. He shall inspect the equipment
installation, advise and assist with commissioning, and train the Employers operations and
maintenance personnel.
The odour control system shall be installed in accordance with manufacturers written
instructions, by suitably qualified and experienced personnel.
10.3.2
Site Inspection and Testing
Vessel and tank tests. The above water tests shall be repeated on site after installation.
Fans shall be tested as required by BS 848 Part 1 and shall be installed in accordance with
BS 848 Part 5.
Odour System Test: The Contractor shall test as follows:
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10.3
(a)
the odour control system to certify that it meets requirements after completion of the
installation
(b)
all odour shall be testing conducted by the Contractor in the presence of the
Engineer
(c)
the odour control system test shall be conducted after all the air systems are tested
and balanced. Separate H2S tests shall be conducted on each odour control system
(d)
the H2S tests shall be repeated at the end of the maintenance period
with the plant in full operation during the time of year determined by the Employer to
have greatest odour problems, using the actual gas levels generated by the pumping
stations
QCS 2014
(e)
Page 15
the hydrogen sulphide test shall comprise as follows:

(i)
hydrogen sulphide (H2S) concentrations shall be measured using a calibrated

portable H2S analyser
(ii)
if instructed by the Engineer, bottled H2S gas shall be used to determine if the
specified H2S performance requirements are met
(iii)
each test: three sets of samples shall be taken over an 8 h period:
each test shall consist of an inlet and outlet H2S test

the supplier shall be responsible for supplying the H2S for the bottled H2S
testing
the three H2S levels to be tested shall be selected by the Engineer.
if the odour control system fails to meet the performance criteria, it shall be the
Contractors responsibility to make all the modifications necessary to improve
performance at no cost to the Employer. The Contractor shall pay for all additional
testing required to verify that performance criteria are being met
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(f)

Part
final acceptance of the system will only be possible after successful completion of
this testing
(h)
documentation for all the testing shall be submitted to the Engineer.
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END OF PART
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QCS 2014

Part
11: Screening Equipment
Page 1
11
SCREENING EQUIPMENT ........................................................................... 2
11.1
GENERAL ...................................................................................................... 2
11.1.1 Scope
11.1.2 References
11.1.3 Submittals
2
2
2
PRODUCTS ................................................................................................... 2
11.2.1
11.2.2
11.2.3
11.2.4
11.2.5
11.2.6
11.2.7
11.2.8
General
Brush Screen
Band / Escalator Screen
Rotary Raked Bar Screen
Semi Rotary Raked Bar Screen
11.2.6 Step Screen
Straight Bar Screen
Covered Skip Containers
11.3
SCREENINGS TRANSFER SYSTEMS ......................................................... 6
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11.3.1 Screening Trough

11.3.2 Conveyor Belt
2
3
3
4
4
5
5
6
6
6
SCREENING WASHER/COMPACTORS ...................................................... 7
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11.4
11.2
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11.4.1 Screening Washer/Compactor

11.4.2 Washer/Dewaterer
7
7
GEAR REDUCER .......................................................................................... 8
11.6
MOTORS ....................................................................................................... 8
11.7
CONTROLS ................................................................................................... 8
11.8
INSTALLATION AND COMMISSIONING ...................................................... 8
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11.5
11.8.1 Installation and Commissioning

11.8.2 Testing
8
8
QCS 2014

Part
Page 2
SCREENING EQUIPMENT
11.1
GENERAL
11.1.1
Scope
This part specifies the requirement for the design, manufacture, construction, installation,
testing and commissioning of screening equipment.
11.1.2
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General
Sewerage
Building Electrical Works
Electrical Works
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Section 1
Section 8
Section 10
Section 13
Section 21
11
References
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BS EN 10084, ...........Case hardening steels
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Submittals
In addition to the requirements of Part 1 of this Section, the Contractor shall reconfirm the
information provided in the Technical Submission Schedules submitted with his Tender.
11.2
PRODUCTS
11.2.1
General
Screens shall be complete with all the necessary ancillary equipment and with screenings
washing and compacting facilities.
The screens shall be fitted with an automatic cleaning mechanism, which shall remove the
screenings adequately and positively into a screenings transfer system to the screenings
washing equipment without risk of spillage. The transfer system shall be totally enclosed and
be fitted with bolted removable access cover sections.
Unless otherwise stated in the Contract Documents the Contractor shall make his own
assessment of the amount of screenings that will be produced by his equipment and the
design of the screenings handling system shall be sized accordingly.
In all cases the screens shall be protected by a torque limiting device in addition to the motor
overload protection. Rake parking switches shall also be provided and in each case the
electrical circuit information for each device shall be provided with drawings for approval.
The screening equipment shall not immediately restart on removal of the obstruction but
shall be manually reset at the control panel.
The screen aperture shall be as stated in the Contract Documents.
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11.1.3
QCS 2014

Part
Page 3
All moving parts of the screen shall have oil impregnated, sintered bronze or grease
lubricated bearings. In the case of the latter, individual stainless steel feed pipes and flexible
polyurethane tubes to the bearings shall be fed from a manifold that shall be located in a
convenient position outside any guards on the screen. A manual grease feed pumping
system shall be incorporated.
The screen framework and components shall be designed to resist both hydraulic and drive
mechanism loads during normal running and all modes of failure. Screen rake mechanism
shall be arranged such that the minimum number of moving parts will remain immersed
when the screen is in the parked position.
The complete headgear shall be enclosed within a removable glass reinforced plastic splash
hood and a hinged door shall be provided to give visual inspection of the screens. The hood
shall incorporate air admittance valves.
The plant shall be controlled by PLC suitable for SCADA and telemetry connection and shall
incorporate a Human Machine Interface (HMI) within a dedicated Motor Control Centre
(MCC).
10
The screen shall be manufactured from stainless steel Grade 316 S31 to BS 970-1(partially
replaced by BS EN 10084), unless otherwise stated.
11
Limit of position indication shall be incorporated into the drive mechanism by means of
proximity switches protected to IP68.
11.2.2
Brush Screen
The screen shall comprise perforated stainless steel Grade 316 S31 to BS 970-1 (partially
replaced by BS EN 10084), or moulded polyurethane panels with 6mm apertures. .
The rotating brush shall incorporate adjustment arrangements to optimise brush

effectiveness and reduce brush wear. Brush adjusters shall be fitted with either locknuts,
stiff nuts or stop retainers to prevent disengagement of the brush resulting in consequent
damage of the screen plates.
The screening panels shall be bolted to the framework using stainless countersunk bolts.
Edge clearances shall not be capable of trapping screenings and in any event shall not
exceed 5mm.
The screen shall be provided with a brush wiper mechanism to ensure the complete removal
of screenings from the brush.
11.2.3
Band / Escalator Screen
Travelling Band / Escalator Screens shall not be permanently secured to the screen
chamber walls. Location fixings shall be positioned at coping level for ease of access.
Screens to be housed in enclosed structures shall be manufactured in sections to facilitate

removal from the chamber making due allowance for the maximum height available.
Where the size of the screen permits, the screen may be hinged such that it can be tilted out
of the chamber for maintenance purposes.
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QCS 2014

Part
Page 4
The screen shall consist of a moving band of screening panels supported above coping level
on two cast iron sprockets mounted on a horizontal headshaft supported in self aligning roller
bearings. The headshaft shall be mounted on machined guides to allow for adjustment to
compensate for chain wear. Tension screws shall be provided and shall be manufactured
from stainless steel.
The main chain shall comprise links, bushes, pins and rollers and shall be self-lubricating by
immersion in the flow. The links shall carry the mesh panel support frame and shall be fixed
with stainless steel set screws. The chain shall run in curved guides at the bottom of the
channel. Sprockets shall not be used to return the chain at the bottom of the channel.
The mesh panels shall be constructed of perforated stainless steel Grade 316 S31 to BS
970-1 (partially replaced by BS EN 10084), or moulded polyurethane, and provided with
elevators to raise the screened material to the cleaning point. Woven panels shall not be
used for screening sewage. The panels shall be designed to withstand full differential head
across a fully blinded panel.
A sealing plate shall be provided between the outer edge of the mesh panels and a sealing
angle bolted to the walls of the screening chamber. The plate shall enclose the chain guide
on the upstream side of the screen to prevent debris fouling the chain. Sealing strips shall
be provided between adjacent mesh panels to maintain the screening aperture when panels
articulate around the bottom curve of the chain guide.
Spray jets shall be provided within the head section to remove the screenings from the mesh
into a debris collecting trough. The spray pipe feeding the jets shall be provided with a
washout valve fitted with a hose connection to facilitate flushing of the system. A rotating
brush shall be provided immediately after the spray jets to remove fibrous material that has
interwoven between the mesh apertures. The brush shall be easily renewable and fixed by
stainless steel set screws.
The spray jet water shall be applied at the correct quality and pressure to efficiently remove
all screenings during one pass of the panels.
10
Chain driven screens shall be provided with chain tensioners and have provision for manual
adjustment in the event of chain stretching.
11
Tracked carriages shall also be provided with wheel adjustment so that engagement in the
channels of the track can be optimised.
11.2.4
Rotary Raked Bar Screen
Rotary curved bar screens shall be raked by a shaft mounted rake mechanism revolving
continuously through 360o. The rotation of the cleaning rake shall clean the radius of the
stationary bar rack and elevate screenings to a discharge point at the top of the rack. At this
point a wiper mechanism shall ensure that the rake is cleared of all screenings before
continuing its cycle.
11.2.5
Semi Rotary Raked Bar Screen
Semi rotary curved raked bar screens shall comprise a single cleaning rake which by means
of a pivoting linkage describes a rotary path along the stationary curved rack, disengages at
the top of the screen rake and re-engages at the bottom of the rack.
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At the top of the rack a wiper mechanism shall ensure that the rake is positively cleared of all
screenings before continuing its cycle.
This type of screen may also be hydraulically operated.
11.2.6
11.2.6
Step screens shall not be permanently secured to the screen chamber walls.
fixings shall be positioned at coping level for ease of access.
Screens to be housed in enclosed structures shall be manufactured in sections to facilitate

removal from the chamber making due allowance for the maximum height available.
Where the size of the screen permits, the screen may be hinged such that it can be tilted out
of the chamber for maintenance purposes.
The screen shall consist of a series of self cleaning screening bars in a staircase
configuration. Every other bar shall be fixed in a rigid structure and the remaining bars shall
form a robust moveable framework that shall revolve in a reciprocating motion to lift the
screenings step by step to the top for discharge.
A sealing plate shall be provided between the outer edge of the screen and the walls of the
screening chamber. The plate shall enclose the drive mechanism on the upstream side of
the screen to prevent fouling by debris. Chain drives, if used, shall incorporate means of
adjustment to compensate for chain wear. Tension screws shall be provided and shall be
manufactured from stainless steel.
The screen shall be designed to prevent blockage at the base by grit or stones and shall be
constructed of stainless steel Grade 316 S31 to BS 970-1 (partially replaced by BS EN
10084).
11.2.7
Straight Bar Screen
The straight bar screen may be vertical or inclined and shall comprise a stationary bar rack
or grid which is automatically cleaned by one or more power operated rakes.
The screen bars shall be at the centres as specified in the Contract and fabricated from
stainless steel to BS 970, Grade 316 S31 (partially replaced by BS EN 10084).
The screen may be front or back raked. In the case of reciprocating rake machines, the
rakes shall clear the bars on the down stroke and engage positively with screen bars prior to
the upward stroke. A wiper mechanism shall ensure that the rake is cleared of all screenings
before continuing its cycle.
The cleaning rake shall be jam proof type, chain driven, suitable for either front or back
cleaning, and shall be formed of stainless steel with teeth of adequate length and section
bolted on for easy replacement.
Chain driven screens shall be provided with chain tensioners and have provision for manual
adjustment in the event of chain stretching.
Tracked rake carriages shall also be provided with wheel adjustment so that engagement in
the channels of the track can be optimised.
Step Screen
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Covered Skip Containers
Covered skips shall be suitably sized and fabricated from steel sheets of sufficient thickness
to withstand full volume of screenings or grit loading and the stresses of movement and
dumping of the screenings and grit.
The shape and dimensions of the skip containers shall be compatible with the configuration
of the screenings and grit dewaterers so that discharge to the skip containers occurs without
spillage. The skips shall have a nominal length of 3.6m, nominal width of 1.8m and nominal
liquids capacity of 3.6m3 and shall be suitable for use with Government of Qatar standard
skip transporting vehicles.
Skip containers shall have rubberised castor wheels, with a minimum wheel diameter
150mm.
Skip containers shall be epoxy coated in accordance with Section 8, with a minimum of at
least 3 epoxy coats.
Covered skips shall be interchangeable between the screens and grit removal applications.
Skips shall be subject to a 5 year replacement guarantee under regular use by the Client,
provided that the skips are not subjected to misuse.
11.3
SCREENINGS TRANSFER SYSTEMS
11.3.1
Screening Trough
Screenings shall be discharged from the screens into a screening trough for water borne
transfer to the washer/compactors. The trough shall be made of minimum 6 mm thickness
stainless steel Grade 316 S31 to BS 970-1 (partially replaced by BS EN 10084) plate with
bolted removable access cover sections.
Water for flushing the screenings from the screen discharge collection point to the
washer/compactor shall be 6mm screened sewage, treated sewage effluent or potable water
as specified in the Contract. Screened sewage shall only be used with the approval of the
Engineer and the Contractor shall take all necessary measures to eliminate odour release
and to treat any odours that are released.
The trough shall be supplied with two inspection ports having dimensions of approximately
100 mm by 500mm. A 25 mm pipe flushing connections shall be provided at each end of the
drainage collecting trough to allow washing/cleaning of the trough.
11.3.2
Conveyor Belt
Conveyor belts shall be of 3-ply standard endless conveyor belting (joints to be vulcanised),
reinforced with fabric between plies of width 800mm and a thickness of 20mm (upper plycontact surface 7mm, middle ply 8mm and bottom ply 5mm thickness). This conveyor shall
be incorporated with SS side plates, doctor blades, troughing and stainless steel return
idlers, adjustable tail pulley and a motorized head pulley permitting rotation in both
directions. The conveyor shall be mounted on stainless steel frame work.
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SCREENING WASHER/COMPACTORS
11.4.1
Screening Washer/Compactor
Screenings compactors shall consist of an inlet hopper, high energy washing zone, screw
compactor, electric motors and reduction gear drive unit, discharge pipe, drain connections
and water spray system. The whole unit shall be factory assembled and tested prior to
shipment. The unit shall be designed to wash faecal and organic matter from the screenings
before compaction and discharge through a chute suitable for use with a standard skip.
The washing impeller and its drive unit shall be hinged from the tank for ease of
maintenance.
A drain shall be installed at the lowest point of the wash tank, be fitted with a knife valve and
shall be piped, together with the wash water overflow, to a local drain point.
The dewatering compartment shall be a screw compactor operating in a trough with

maximum 6mm diameter perforations for drainage. The compactor screw shall be fitted with
a hard wearing brush on the periphery of the screw blades to ensure free drainage is
maintained. The brush shall be arranged to allow adjustment for wear.
The compactor will have a minimum capacity as required by the volume of screenings
expected to be produced by the contractors proposed screens and will be designed to
provide compacted screenings with a maximum moisture content of 50% and a maximum
faecal content of 5%.
The compactor screw shall be constructed of stainless steel flights welded to a stainless
steel solid shaft. The screw shall extend a minimum of 600mm beyond the end of the
dewatering zone. The pressing zone shall be a cylindrical stainless steel pipe rising towards
the discharge chute. Stainless steel shall be Grade 316 S31 to BS 970-1 (partially replaced
by BS EN 10084).
The discharge pipe shall be made of stainless steel and shall use long-radius fittings
designed to avoid any jamming of the partially dewatered/compacted screenings. The
discharge pipe shall be easily disassembled to clear blockages and shall terminate in a
position or manner such that a standard skip can be easily removed from below it.
11.4.2
Washer/Dewaterer
Washer/dewaterers shall be of the two stage brush and perforated plate type and fabricated
from stainless steel with removable GRP access covers.
The first stage, (washing stage) shall contain the rotating brush assembly fitted with four
polypropylene brushes, and the second stage, (dewatering stage) shall contain a rotating
rubber roller assembly fitted with four tensioned rollers.
The screening panels shall be manufactured from stainless steel with 3mm perforations.
The machine shall be complete with integral inspection walkway, access ladder and
handrailing, the walkway width being 900mm minimum. Where duty and standby machines
are specified a common walkway may be sited between the machines, however the
machines must be of sufficient height to allow discharge of the screenings into a common
skip.
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The filtrate shall collect in the bottom of the machine and discharge through a NP16 flanged
outlet of 100mm n.b. A 100mm n.b. overflow outlet, flanged to NP16 shall also be provided
above the centre line of the machine. Pipework shall be of stainless steel.
11.5
GEAR REDUCER
The screens and washer/compactors shall be powered by an electric motor and gear
reducer.
The gear reducer shall include anti-friction bearings with high overhung load properties and
oil-seal, double-lip, high temperature synthetic riding on precision ground shaft, to minimise
leakage possibilities. The speed reducer shall be enclosed in a cast iron weatherproof
casing. Gears shall be made of hardened and heat treated forged steel. The gear reducer
shall not be overloaded under any normal operating conditions and shall be designed for
heavy-duty service. The gearing shall be oil lubricated.
11.6
MOTORS
Motors shall have Class F insulation and be rated for continuous duty operation. They shall
conform to the requirements of Section 21 of the specification and the recommendations of
the manufacturer.
Motors shall be sized so that under maximum continuous loading the motor rated power is a
minimum of 50 % greater than the driven load.
11.7
CONTROLS
All necessary controls shall be incorporated in an FBA as described in Section 21.
The controls shall include all the necessary relays, starters, timers, indicators, breakers,
switches and fuses and all other electrical accessories required to make the system
complete and perfect in every way.
11.8
11.8.1
Installation and Commissioning
The equipment delivered to Site shall be examined by the Engineer to determine that it is in
good condition and in conformance with the approved working drawings and certification. All
equipment shall be installed in strict accordance with Part 1 of this Section 9.
11.8.2
Testing
Test Procedures shall be in accordance with Part 1 of this Section 9 and the particulars of
the Contract.
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END OF PART
QCS 2014

Part
12: Grit Removal Equipment
Page 1
12
GRIT REMOVAL EQUIPMENT...................................................................... 2
12.1
GENERAL ...................................................................................................... 2
12.1.1 Scope
12.1.2 References
12.1.3 Submittals
2
2
2
PRODUCTS ................................................................................................... 2
12.2.1
12.2.2
12.2.3
12.2.4
12.2.5
12.2.6
General
Hydro Dynamic Separator
Vortex Grit Separator
Cross Flow Grit Removal
Screw Grit Classifier
Reciprocating Rake Grit Classifier
12.3
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12.2
2
3
3
4
5
6
6
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GRIT REMOVAL EQUIPMENT
12.1
GENERAL
12.1.1
Scope
testing and commissioning of grit removal equipment.
12.1.2
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General
Drainage Works
Electrical Works
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Section 1
Section 8
Section 10
Section 13
Section 21
12
References
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BS EN 10084 .............Case hardening Steels
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BS 970 (ISO 683) .......Wrought steels for mechanical and allied engineering purposes.
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Submittals
12.2
PRODUCTS
12.2.1
General
Grit removal equipment shall comprise vortex grit separators, sized to achieve the specified
operating criteria and each shall operate in conjunction with a grit classifier.
The Contractor shall make his own assessment of the amount of grit which will be produced
by his equipment and the design of the grit handling systems shall be sized accordingly.
Grit separators shall be complete with all necessary ancillary equipment and controls.
(MCC).
An interlock shall be provided between the grit removal device and the grit classifier.
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Hydro Dynamic Separator
The grit separator shall be designed to efficiently remove grit from waste water inflows to
protect downstream components of the Treatment Plant. They shall utilise the special
characteristics of controlled hydro dynamic flow, to separate settleable solids and operate at
high hydraulic loadings to minimise facility space requirements.
The separator shall have no moving parts and require no maintenance. Grit separation shall
be accomplished entirely by the unit geometry and hydraulic flow regime. The tangential
inlet and overflow design shall ensure that vortex flow develops and that no short circuiting
through the unit can take place.
The flow shall enter through the tangential bottom inlet pipe, spiral and rise through the
separator, flows through the annular opening created by the conical section and the overflow
floor, over the overflow weir and out through the de-gritted overflow pipe or channel.
Grit and other settleable solids shall drop to the sloped bottom and be concentrated into the
unit sump. The concentrated grit shall be removed from the sump using a grit pump or airlift
pump.
A tangential inlet shall induce a vortex flow pattern within the separator hence creating ideal
conditions for the potential currents of a vortex funnel. The resulting flow patterns shall be
well defined and low in turbulence leading to favourable conditions for grit settling.
A conical section extending into the interior of the vessel shall be used to stabilise the
secondary currents and increased the boundary surfaces to induce further grit settling.
The collected and concentrated grit in the sump shall be pumped to a screw classifier which
shall be used to wash and classify the grit in order to minimise organic solids concentrations
in the grit discharge.
All internal parts and weirs shall be stainless steel Grade 316 S31 to BS 970-1 (partially
replaced by BS EN 10084).
12.2.3
Vortex Grit Separator
The circular tank grit trap shall be supplied complete with geared motor, gearhead assembly,
impeller drive tube, impeller, air blower and airwash/airlift assemblies.
The grit trap shall be designed such that the headloss is less than 7mm. The design shall be
capable of removing grit from screened sewage and depositing grit into the grit classifier.
The grit removal chamber shall have inlet and outlet separated by greater than 270o of the
tank periphery. There shall be a sloping floor connecting the upper and lower sections.
The grit removal device shall be fitted with a rotating impeller. The impeller shall be
manufactured in two halves and shall be clamped to the drive tube when fully assembled.
The stub shaft should not have any supporting bearings under the water and should be
hanging from the gear head assembly.
The impeller shall be fitted with four fixed blades set at an angle of 30o and provide sufficient
washing action to prevent lighter solids entering the classification gap between impeller and
grit hopper whilst allowing settled grits through for collection.
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12.2.2
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The impeller blades shall create a slight upward flow in the central zone of the upper
chamber whilst leaving the outer annulus of the upper chamber quiescent to allow grit
settlement.
The impeller shall be driven by a helical geared motor with a service factor of 2.0 or greater.
The geared motor shall be fully weatherproofed and shall be oil lubricated and the drive shall
incorporate a slewing ring bearing and helical spur gearing transmission. Torque limiter to
be provided for protecting the drive unit.
An airwash/airlift assembly shall be provided to facilitate grit washing and removal. The
assembly shall consist of an airlift pump discharge pipe, minimum 100mm diameter, with
airwash and airlift headers. Separate air supply lines consisting of minimum 38mm diameter
pipe shall connect to the airwash and airlift header. The airwash header shall discharge an
adequate quantity of air for air washing of the collected grit. Each air delivery line shall
terminate above the drive gear head and connected to a three way ball valve, minimum
38mm diameter, with automatic operation.
The Contractor shall supply a displacement blower and pipework to provide air for the
airwash/airlift operation. The blower shall have the capacity to provide sufficient quantities of
air at the required pressure to ensure efficient operation of the airwash/airlift system.
10
All internal parts and weirs shall be stainless steel Grade 316 S31 to BS 970-1 (partially
replaced by BS EN 10084).
12.2.4
Cross Flow Grit Removal
Cross Flow Grit Removal Equipment shall be designed to achieve an optimum sewage
velocity to enable the complete satisfactory settlement of the specified fine grit particles.
Each arm assembly shall be equipped with a sufficient number of scraper flights such that
they will be capable of removing up to 50 mm of grit from the floor of the grit settlement tank
into a grit sump.
The Contractor shall supply and install all the equipment necessary for its operation inclusive
of bridge, scraper arms, drive assembly, inlet guide vanes, tubes, pipes, grit pump and
fixings etc.
The plant shall be designed for installation in a circular flat-bottomed tank.
The approach velocity into the detritor shall be 1.2m/s with a maximum horizontal velocity
across the tank not exceeding 0.3m/s unless stated otherwise in the Contract Documents.
The inlet shall span the diameter of the tank and be equipped with inlet deflectors which shall
evenly distribute the flow across the whole width of the tank. The deflector support
channels, spindles and sleeves complete with concrete guide vanes shall be supplied and
installed by the Contractor.
The bridge structure shall be constructed from stainless steel section braced together. The
beams shall be designed to withstand the total loadings imposed by the bridge and its
associated equipment plus a super-imposed load of 250kg/m2 (equivalent to two men)
without exceeding a total deflection of 1/360 of the bridge span.
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The access walkway shall comprise stainless steel non-slip floor plates fixed to the bridge
structure and supporting double row handrailing which shall comply with Section 8 Part 6.
The centre bearing assembly shall be designed to withstand the total loading of the rotating
scraper arms and other forces associated with the plant in operation.
10
The scrapers shall be driven by a motor/gearbox unit, directly or via a chain drive. In both
cases a torque limiting device shall be supplied to initiate safe plant shut down should a
blockage occur.
11
The peripheral speed of the scraper arm shall not exceed 5m/min.
12
The scraper arms, blades and shaft shall be fabricated from stainless steel and shall
incorporate a scoop at the extreme end to assist in the sweeping of the deposited grit into a
grit sump, or into the classifier hopper, depending on the system design.
13
Duty and standby grit pumps shall lift the grit into the classifier hopper.
12.2.5
Screw Grit Classifier
Each grit separator shall have an individual grit classifier. However, the grit delivery
pipework shall be arranged such that if one classifier is out of operation, e.g. for
maintenance, its associated separator can be connected to another classifier.
The grit classifiers shall be capable of handling the water and grit removed from the grit
separators at the rate discharged by the grit air lift or grit pump.
The grit classifiers shall be a free standing units of the helical screw type which shall
efficiently deposit dry organic free grit to a skip positioned beneath the discharge chute.
A wash water supply shall be connected into the classifier to assist with washing the grit.
The units shall be provided with a valved washout drain at the lowest point which shall be
piped, together with the wash water overflow, to a local drain point.
The screw drive unit shall be mounted at the upper end of the screw trough. The whole of
the unit shall be guarded over its whole length.
The screw conveyor shall use a shaft-less screw resting on wearing surfaces. The screw
device shall not have a submerged end bearing.
The screw shall be formed in stainless steel Grade 316 S31 to BS 970-1 (partially replaced
by BS EN 10084) plate of 8mm minimum thickness and the trough of a similar metal in 6mm
plate.
The wearing surfaces in the screw trough shall be easily replaceable and formed of high
density polyethylene (HDPE).
The screw shall be fitted on one bearing placed in the drive unit. The bearing shall be a
combined thrust and radial type sufficient to accommodate the total axial and thrust loading.
10
The screw conveyor shall have adequate accessibility for maintenance.
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Reciprocating Rake Grit Classifier
Reciprocating rake grit classifiers and cleaning mechanisms shall comprise a multiple-rake
reciprocating mechanism mounted within the cleaning channel constructed parallel to the
direction of flow and integral with one side of the cross flow grit settlement tank. The
mechanism shall be inclined and deposit clean grit into the collecting skip positioned below
the grit discharge. The discharge point shall be above Top Water Level. The grit shall be
separated from the organic matter by the washing action of the reciprocating rake and
suitable means of returning organic matter to the collecting tank shall be provided, together
with the necessary built in pipework, screen and washwater pump.
The rake and blades shall be fabricated from stainless steel section and shall be suspended
from the drive unit by connecting rods and bell cranks.
The classifier shall be driven by a motor/gearbox unit with torque unit switch via a crank
mounted on the output shaft; balance weight arms, secondary output shaft; bellcrank and
rake hangers.
The entire reciprocating mechanism shall be totally enclosed to prevent accidental contact
and release of odours.
12.3
12.3.1
12.3.2
Testing
the Contract.
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12.2.6
END OF PART
QCS 2014

Part
13: Aeration Equipment
Page 1
13
AERATION EQUIPMENT .............................................................................. 2
13.1
GENERAL ...................................................................................................... 2
13.1.1 Scope
13.1.2 References
13.1.3 Submittals
13.2
2
2
2
PRODUCTS ................................................................................................... 2
13.2.1 General
SHAFT ROTOR AERATORS ........................................................................ 3
13.3.1
13.3.2
13.3.3
13.3.4
Rotor Aerators
Aeration Tank Baffle
Vertical Shaft Surface Aerators
Floating Aeration Devices
13.4
SUBMERSIBLE AERATION DEVICES ......................................................... 5
13.5
AIR BLOWERS OR COMPRESSORS .......................................................... 5
3
4
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13.3
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13.5.1 General
AIR PIPEWORK............................................................................................. 5
13.6.1
13.6.2
13.6.3
13.6.4
13.6.5
13.6.6
Intake Ducting
Discharge Pipework
Blower Manifold
Air Supply Main
Distribution Pipework
Flow Control and Isolation
13.7
AIR DIFFUSERS............................................................................................ 8
13.7.1
13.7.2
13.7.3
13.7.4
13.7.5
General
Fine Bubble Air Diffusers
Tubular Membrane Diffusers
Plate Membrane Diffusers
Coarse Bubble Air Diffusers
13.8
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13.6

13.8.2 Testing
5
6
6
7
7
7
8
8
8
9
9
10
10
QCS 2014

Part
Page 2
AERATION EQUIPMENT
13.1
GENERAL
13.1.1
Scope
testing and commissioning of equipment to dissolve oxygen into liquids using air.
References
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13.1.2
General
Sewerage
Electrical Works
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Section 8
Section 10
Section 13
Section 21
13
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BS EN 10084 .............Case hardening steels
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BS 3170 .....................Specification for flexible couplings for power transmission

BS EN 779 .................Particulate air filters for general ventilation
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Submittals
13.2
PRODUCTS
13.2.1
General
The works shall be complete with the appropriate number of air blowers, pipework, fittings,
valves, diffusers, control equipment and all the necessary ancillaries to make the plant
complete.
The aeration devices selected by the Contractor shall be based on achieving maximum
oxygen transfer efficiency for the design liquid depth. The minimum oxygenation rate in clean
water shall be 2.0 kgO2/kW.h at 20C
Upon selection of a particular aeration device the Contractor shall provide sufficient test data
demonstrating the oxygen transfer efficiency of the aeration device at the design liquid
depth. Tests shall have been carried out in accordance with the requirements of the
American Civil Association standard Measurement of Oxygen Transfer in Clean Water test.
If the contractor is unable to provide evidence that their equipment has been tested in this
way the Contractor shall undertake an oxygen transfer test in clean water in accordance with
the American Civil Association standard at an approved testing laboratory.
The sizing and number of aeration devices shall be dependent upon the oxygenation
requirements of the process.
The Contractor shall supply the Engineer with all supporting design calculations and criteria
used to determine the type and size/no. of aeration devices selected for approval.
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(FBA).
The Contractor shall design, supply and install the optimum number and configuration of air
blowers to give the best whole life cost and maintain the integrity of the process.
The Contractor shall provide standby facility at all control valves and shall, insofar as is
possible, design and select the valves to be identical to rationalise maintenance.
Stainless steel shall be Grade 316 S31 to BS 970-1 (partially replaced by BS EN 10084)
unless otherwise stated.
13.3
SHAFT ROTOR AERATORS
13.3.1
Rotor Aerators
The rotor shall be suitably sized for the process requirements up to a maximum of 9 metres
in length. The rotor shall be suitable for immersion at depths of 0-300mm
The rotor shaft shall be of stainless steel sealed at both ends and suitably strengthened
along its length to minimise the effects of torsion.
The shaft shall be supported at the drive end and non-drive end by cylindrical roller bearings.
Stainless steel aeration blade elements shall be equi-spaced around the circumference and
along the length of the drive shaft.
In order to minimise the effects of clogging of the aerator, the aeration blades shall be fixed
by bolting to the drive shaft only.
The aeration blades should be positioned such that pulsating torque transferred to the drive
shaft, caused by the action of their immersion in the process liquid, is prevented.
The drive unit shall comprise a helical geared reduction gearbox. Design of the rotor/drive
unit shall prevent contamination of the drive unit from sludge thrown by the rotor.
Splash type lubrication of the gears shall be facilitated by means of an oil bath.
Shaft bearings shall be protected against water ingress by the provision of rubber lip seals.
10
Bearings shall be roller or angular contact type, designed for a B10 life expectancy in excess
of 100,000 hours.
11
Steel foundation plates shall be provided beneath the drive mechanism suitable for fixing by
anchor bolts.
12
Power transmission from the reduction gearbox to the rotor shall be via a flexible coupling.
The coupling shall be designed to minimise the transmission of vibration from the rotor to the
drive unit. The flexible coupling shall be in accordance with B.S.3170.
13
The end of the rotor shaft shall be fitted with a split pattern self aligning bearing assembly.
14
The bearing unit shall consist of a cast iron housing and grease lubricated heavy duty double
row roller bearing with lip seals. Locking collars shall be provided.
15
The rotor unit shall be fitted with GRP splash guards which shall be positioned along the full
length of the rotor between the top of the rotor and the underside of the walkway.
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GRP covers shall be provided for the drive unit, bearings and end bearing assembly.
13.3.2
Aeration Tank Baffle
An aeration tank baffle shall be provided to direct surface velocities downwards thus
maintaining the necessary flow velocities for the depth of tank specified in the contract.
The baffle shall cover the full width of the tank and be fabricated from stainless steel.
The baffle shall be provided complete with all necessary fixing bolts and brackets.
13.3.3
Vertical Shaft Surface Aerators
The aerator shall comprise a central deflector/cone complete with profiled blades. The aerator
shall be of all-welded construction. Alternatively the impeller shall be the centrifugal screw type
comprising a central shaft to which a spiral vane is fully welded along its length
The aerator impeller shall be fabricated from stainless steel.
Cross baffles for use with the aerator impeller shall be fabricated from stainless steel and shall
be of all-welded construction suitable for bolting to the aeration tank floor.
In order to promote mixing of the process liquid and to avoid short circuiting, up-draught tubes
shall be fitted below the aerator impeller.
Up-draught tubes shall be manufactured from stainless steel or GRP and be suitable for bolting
to the tank floor via adjustable mounting brackets.
Stainless steel tie rods suitable for bolting to the tank structure shall be provided complete with
adjustable turn buckles for alignment of the up draught tube.
The drive shaft shall be fully welded construction manufactured from steel tube and plate.
The drive shaft shall be connected to the reduction gearbox via a fixed coupling.
The drive unit shall comprise a helical geared reduction gearbox.
10
The drive unit shall be fitted with a 3 phase high efficiency motor complying with the
requirements of Section 21.
11
Where specified by the contract the drive motors shall be suitable for variable speeds via
frequency invertors.
13.3.4
Floating Aeration Devices
Where specified vertical shaft type aerators shall be mounted on a floating raft.
The raft shall be manufactured from stainless steel box section. The structure shall be suitably
braced for rigidity and interconnections between cross members shall be demountable
The raft shall be supported in the process media by use of suitably sized Polyethelene drum
buoyancy aids, or equal approved by the Engineer, which shall be bolted to the raft framework.
The raft assembly shall be restrained within the tank structure by means of a minimum of three
stainless steel guy ropes complete with turnbuckles.
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QCS 2014

Part
13.4
SUBMERSIBLE AERATION DEVICES
The aerator shall comprise the following:

(a)
Submersible Motor
(b)
Impeller
(c)
Venturi and / or Diffuser
(d)
Air Inlet pipe
(e)
Base Support
Page 5
The submersible motor shall be in accordance with Section 21 of this specification.
The impeller shall be a turbine type manufactured from stainless steel and suitably profiled to
promote agitation of the media.
Where specified by the Contract agitation of the process media shall be by use of a submersible
centrifugal pump which shall be in accordance with Part 3 of this Section 9.
The diffuser assembly shall be manufactured from corrosion resistant materials and be rigidly
secured to the drive assembly frame.
The diffuser profile shall ensure uniform distribution of the aerated liquid.
13.5
AIR BLOWERS OR COMPRESSORS
13.5.1
General
Air blowers or compressors shall comply with Section 14 of this Part 9.
13.6
AIR PIPEWORK
13.6.1
Intake Ducting
The air supply to the blowers will be provided from the air inside the blower room. Individual
air intake ducting shall be supplied for each blower for this purpose.
The ducting shall be of stainless steel Grade 316 S31 to BS 970-1 (Partially replaced by BS
EN 10084) supported from the blower room floor and shall include two filters (1 No.coarse
and 1No.fine), silencer and air intake.
The combined efficiency for particle removal by the two filters shall suit the requirements of
the blowers and the aeration diffusers selected, but shall not be less than EU4. The filters
shall be of the pad or dry pocket type. The filter enclosures shall be fabricated from stainless
steel and shall be designed for ease of access to the filter elements for
inspection/replacement without dismantling the ductwork.
The silencer shall ensure that the noise level described for the blowers shall not exceed
75dBA at one metre. It can be a separately mounted unit or mounted on the common
baseplate with the blower assembly. The casing shall be fabricated from stainless steel
Grade 316 S31 to BS 970-1 (partially replaced by BS EN 10084), and shall be approved by the
Engineer. Only reflective or reactive type silencers are to be used. Absorptive or dissipative
silencers shall not be used.
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The blower room air intakes shall be mounted directly to the wall and shall comprise a fixed
blade weather and sand trap louvre complete with bird screen. The louvre shall be designed
to exclude rain and sand from entering the building. The intake shall be fabricated from
stainless steel Grade 316 S31 to BS 970-1 (partially replaced by BS EN 10084), or a suitable
non-corroding material as approved by the Engineer.
Filters shall be tested in accordance with BS EN 779 at the manufacturer's works.
13.6.2
Discharge Pipework
Each blower shall be provided with individual discharge pipework, which shall be connected
to a common manifold. The discharge pipes shall be supported from the blower plant room
floor.
Discharge pipework shall be stainless steel Grade 316 S31 to BS 970-1 (partially replaced by
BS EN 10084). The supports shall be of steel galvanised after fabrication.
Each discharge pipe shall be provided with a suitably sized blow-off valve, non-return valve
and isolation valve.
The blow-off valve shall be an actuated butterfly valve and shall be fitted with an exhaust
silencer. The discharge from the silencer shall be at least 2 metres above floor level and
shall be directed vertically upward or mounted in the horizontal plane. The silencer shall
ensure that the noise level of the exhaust does not exceed the level described for the
blowers.
The non-return valve shall be of the wafer check type.
Butterfly valves shall be provided for isolation of the individual pipelines. They shall be
gearbox driven to suitably limit the rate at which the operator can shut off the valve. The
valves shall be capable of being operated with the operator standing at floor level.
13.6.3
Blower Manifold
The blower discharge pipework shall tee into the manifold. The manifold shall be installed in
the blower plant room and shall be supported from the floor. The manifold shall be sized for
the duty blowers operating simultaneously delivering air at their maximum output.
A valved tapping shall be provided for the fitting of a pressure transducer for monitoring the
pressure within the manifold.
If necessary, a silencer shall be installed within the manifold to ensure that the noise level
outside the building, transmitted via the pipework, does not exceed 75dB(A). This shall be
based on the duty blowers delivering at their normal rated output.
The manifold shall be fabricated from stainless steel Grade 316 S31 to BS 970-1 (partially
replaced by BS EN 10084). The supports shall be of steel, galvanised after fabrication.
Automatic condensate drain traps shall be installed at any location where water can collect in
the discharge pipework/manifold assemblies.
The blower manifold and any other above ground air pipework that exceeds 60 C surface
temperature shall be insulated.
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Air Supply Main
A supply main shall be provided and shall connect the blower house manifold to the
distribution pipework. The main shall extend from the blower house to the treatment process
units.
The supply main shall be sized for the duty blowers operating simultaneously delivering air at
their maximum output and the velocity shall not exceed 20 m/s.
A dirt pocket with an automatic condensate drain trap shall be installed to collect and drain
water at the lowest position on the main. A chamber for access to this condensate drain trap
shall be provided.
The main shall be laid to an even grade sloping back to the condensate trap.
13.6.5
Distribution Pipework
Distribution pipework shall be made from stainless steel Grade 316 S31 to BS 970-1
(partially replaced by BS EN 10084).
Additionally, the gauge of the pipes to which the diffusers are to be fitted shall be sufficient to
allow the use of screw fit aeration disc base plates and to withstand local forces generated at
the joints by the flow of effluent over the discs.
The pipework grid shall be broken down into sections, which shall be indicated on the
Contractor's drawings.
Coupling seals shall be manufactured from a rubber compound suitable for long-term
immersion in aerated effluent. If push-fit connections are used they shall be of a design that
inhibits the removal of the spigot piece once inserted into the socket.
Pipework shall be fixed to the concrete floor of the process units by means of stainless steel
pipe supports fixed by means of stainless steel anchor bolts. Pipe supports shall provide a
means of fine adjustment of the level of the aeration grid.
Pipework supports shall be sufficiently numerous to support the grids without sagging and to
allow the pipework to resist mechanical, hydrodynamic and hydrostatic loads without
generating excessive loading in the pipework.
The maximum air velocity in any portion of the air distribution pipework shall not exceed 20
m/s. When selecting connections, consideration shall be given to heat, internal and external
corrosion, expansion and contraction and resistance to all normal and abnormal forces.
Each diffuser array shall be provided with condensate drains and purge pipes which shall be
taken above TWL and be accessible from walkways. Protection against siphoning of effluent
into the air main shall be provided. Self-sealing diffusers shall not be considered to meet this
specific requirement.
13.6.6
Flow Control and Isolation
Each aeration zone shall be provided with a flow modulation valve to control the flow of air
into each zone as required by the process. The valves shall be of an eccentric plug or iris
type with a linear characteristic across their design flow range.
Each aeration zone shall be provided with an isolation valve. Valves shall be of a gate or
butterfly type.
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13.6.4
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Each aeration zone shall be aerated by a series of arrays of diffusers via a dropper. Each
dropper shall have provision for measuring and adjusting the air flow rate to balance the air
flows in the correct proportions over the area of the pocket to maintain adequate mixing.
The provisions for measuring and adjusting the air flow rate on each dropper shall be linked
to the SCADA system to achieve remote monitoring and adjustment of each individual
dropper.
13.7
AIR DIFFUSERS
13.7.1
General
The size and number of diffusers selected shall provide the necessary oxygen required by the
process.
Particular attention should be paid to the number of diffusers selected in order to avoid "dead"
areas within the aeration zone.
The diffusers shall be evenly spaced along the floor of each tank and shall provide an air
3
2
flow rate of not less than 2.2 m /hr per m of tank surface area
Manufacturers test certificates shall be provided clearly stating the required air flow rate
necessary to achieve even flow distribution through the diffuser.
13.7.2
Fine Bubble Air Diffusers
Diffusers shall be installed on the distribution pipework. Diffuser holders shall be

manufactured from materials compatible with the distribution pipework. The diffusers shall
be selected for long service with a minimum replacement period of 10 years. Diffusers that
can be cleaned in situ will be preferred.
The materials of the diffuser shall be non-biological and resistant to sewage and its byproducts and the membrane shall be manufactured from EPDM.
The membrane
perforations shall be formed such that tearing of the material is minimised. The diffusers
shall be fitted with either integral non-return valves, or similar system, which are capable of
automatically sealing and preventing water ingress into the air piping if the air pressure falls.
The maximum air flow rate through each diffuser shall not exceed the rated design flow for
3
2
the diffuser or 175m /hr of air at standard conditions per m of effective membrane area,
whichever is the lower.
13.7.3
Tubular Membrane Diffusers
The aerator shall consist of the following:
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(a)
Membrane holder complete with air distribution holes.
(b)
Membrane
(c)
Clamping rings
The membrane holder shall be manufactured from stainless steel.
The membrane properties shall be as 13.7.2.2 above.
The membrane holder shall incorporate an integral check valve to prevent backflow of process
media into the diffuser grid pipework.
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Part
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The membrane holder shall be fixed to the distribution pipework via a threaded nipple or via
threaded pipe adaptors and stainless steel tie rods complete with stainless steel nuts bolts and
washers.
The membrane shall be retained to the holder via stainless steel clamping rings.
The diffuser shall be suitable for operating at flow rates of 1.0 to 15.0 m /hr.
13.7.4
Plate Membrane Diffusers
The size and number of aeration devices selected shall provide the necessary oxygen required
by the process.
The aerator shall consist of the following:
Diffuser trough
(b)
Membrane
(c)
Stiffening plate
(d)
Seal
(e)
Retaining Clamps
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(a)
The diffuser trough shall be fabricated from stainless steel plate. The trough shall comprise
suitable brackets for bolting the diffuser assembly to the delivery pipework.
The membrane properties shall be as 13.7.2.2 above.
The membrane shall be supported by means of a stainless steel stiffening plate which shall
contain air distribution holes to uniformly distribute the air across the area of the membrane.
The distribution holes shall be positioned relative to the membrane perforations such that
backflow of the process media during loss of air supply is inhibited.
The membrane assembly shall be sealed into the diffuser trough by means of a profiled rubber
gasket.
The membrane assembly shall be retained in the diffuser trough by means of stainless steel
clamps. The number of clamps shall be dependent upon the length of the diffuser. The clamps
shall be equi-spaced along the length of the diffuser.
The diffuser shall be suitable for operating at flow rates from 1.0 to 25.0m /hr.
13.7.5
Coarse Bubble Air Diffusers
The air diffuser consists of two simple parts, the diffuser body assembly and the flexible
check diaphragm. Both parts are molded together so no separation can occur. During
aeration, the diaphragm rises allowing the air to exit through the orifice of the disk body.
When the air stops, the diaphragm is instantly seated against the diffuser body by the
pressure of the liquid, preventing backflow and clogging. The formation of the air check
diaphragm will allow double shear of the discharged air from the orifice, along with assisting
in reducing the requirements of maintaining each diffuser level for proper air distribution.
The air diffuser material shall be adequate to prevent plugging and resist brittleness or
growing of the diaphragm through absorption of chemical components in the liquids.
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13.8.1
13.8.2
Testing
the Contract.
Where specified in the Contract the aeration system shall be tested as follows:
The aeration tank shall be cleaned of any contaminants which may inhibit successful testing.
The use of synthetic detergents for this purpose is not permitted.
The aeration tank shall be filled with the required test volume of potable water/final effluent.
The dissolved oxygen monitoring equipment shall be calibrated: at zero D.O. using water deaerated with sodium sulphite solution; at saturation, with aerated water after prolonged and
vigorous aeration; and at 50 % saturation, achieved by vigorously aerating water with a gas
containing 10.5% oxygen in nitrogen.
Calibration results should show a linear relation between D.O. meter and concentration of D.O.
Deviations shall require recalibration, checking of the probe including necessary refurbishment,
checking of any temperature compensation. Calibration shall be undertaken under the same
temperature conditions as those envisaged within the tank.
Multiple probes shall be utilised and distributed evenly throughout the tank.
Once the necessary equipment is positioned and the required volume of potable water/final
effluent is added to the tank the air saturation equilibrium concentration of D.O. shall be
checked. The water temperature shall also be measured.
A strong solution of sodium sulphite shall be made in warm water, if possible. The required
quantity shall be sufficient to provide 20% excess over the stoichiometric amount required for
deoxygenation. The mass of anhydrous sodium sulphite in Kg is therefore: -
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13.8
Volume of tank x D.O concentration in mg/l (prior to addition of sulphite) x 7.88 x 1.5
1000
Note: excessive sodium sulphite addition will result in a longer oxygen uptake.
10
A strong solution of cobalt chloride, to act as a catalyst, should be added to the tank sufficient to
give a concentration of 0.5mg/l. The mass required is therefore:
Mass CoCl2 (g) = 2 x tank volume
11
The chemical solutions shall be distributed evenly through the aeration tank. Rapid addition at a
single point is not permitted.
12
At the start and end of each test the temperature of the water shall be measured to the nearest
o
0.1 C and the barometric pressure to the nearest mm of mercury.
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Part
Page 11
The aeration equipment shall be activated and the airflow rate, temperature and pressure
shall be closely monitored. In the case of mechanical aeration equipment the power drawn
shall be monitored.
14
The dissolved oxygen probes shall be connected to a multi channel potentiometer recorder. The
increase in dissolved oxygen levels shall be monitored until the air saturation is reached (after
approx 6/kLa hours). At 90% saturation a sample of liquid shall be taken to examine the quantity
of residual cobalt.
15
When the test liquid has reached air saturation level a sample shall be taken and the
concentration of dissolved oxygen shall be determined using the modified Winkler method.
16
The recorded concentrations of D.O. and calculated or measured values of saturation

concentrations results shall be plotted as graphs of loge of D.O. deficit against time for D.O.
values from 20 to 80% of the saturation value for each probe. The slopes of these graphs shall
be used to calculate separate values of KLa as described by the equation:
-
Cs - Ct =-KLa t(min 1)
Cs - Co
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13
The average of the KLa values plotted shall be used to determine the KLa of the aeration
system.
18
Cs shall be calculated using the following equation:
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Cs =
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17
Following the determination of KLa and by applying the correction factor the oxygenation
capacity of the system shall be calculated using Oc = KLa.V.Cs
20
The aerator shall be + or - 10 % of the contractors stated values for oxygenation capacity. If this
tolerance is exceeded the Contractor shall provide rectification at his own expense.
21
Where the aeration equipment is a mechanical device the Contractor shall also demonstrate
that the minimum velocity across the aeration tank floor of 60mm/s is achieved. If this velocity is
not achieved the Contractor shall provide rectification at his own expense
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END OF PART
QCS 201

Part
14: Air Blowers & Compressors
Page 1
14
AIR BLOWERS AND COMPRESSORS ........................................................ 2
14.1
GENERAL ...................................................................................................... 2
14.1.1 Scope
14.1.2 References
14.1.3 Submittals
2
2
2
14.2
PRODUCTS ................................................................................................... 2
14.3
AIR BLOWERS .............................................................................................. 3
14.3.1 Centrifugal Blowers

14.3.2 Positive Displacement Blowers
3
4
AIR COMPRESSORS.................................................................................... 5
14.4.1
14.4.2
14.4.3
14.4.4
14.4.5
14.4.6
14.4.7
General
Reciprocating Compressors
Rotary Compressors
After Cooler
Air Receivers
Fabrication Requirements
Booster Compressor
14.5
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14.4
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5
5
5
6
6
7
7
8
8
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Part
Page 2
AIR BLOWERS AND COMPRESSORS
14.1
GENERAL
14.1.1
Scope
testing and commissioning of air blowers and compressors.

General
Drainage Works
Electrical Works
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Section 1
Section 8
Section 10
Section 13
Section 21
14
References
The following standards or revised/updated versions are referred to in this part:
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BS ISO 10816 ...........Part 1 and Part 3, Mechanical vibration in rotating and reciprocating
machinery
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BS 1123 ....................Safety valves, gauges and fusible plugs for compressed air or inert
gas installation
BS 5169 ....................Specification for fusion welded steel air receivers
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BS 5493 .....................Code of Practice for protective coating of iron and steel structures
against corrosion
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BS EN ISO .................Paints and varnishes. Corrosion protection of steel structures by

protective paint systems
BS ISO 1217 ..............Displacement compressors. Acceptance tests
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BS1042 ......................Measurement of fluid in closed conduits
ISO 10474 .................Steel & Steel Products Inspection Documents

PD 5500 .....................Specification for unfired fusion welded pressure vessels
British Compressed Air Society's Code of Practice and the Pressure Systems and
Transportable Gas Containers Regulations 1989
14.1.3
Submittals
14.2
PRODUCTS
The Contractor shall assess which type and configuration of blowers or compressors that will
offer the best whole life cost benefit for use on the plant to supply the process air
requirements.
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Part
Page 3
The number of blower/compressor sets provided shall be sufficient to ensure the full range of
process air requirements can be met and that a minimum of one standby unit for each
application is available at maximum process airflow. Blower/compressor sets shall be the
same model with the same rated capacity for each separate application.
The motor rating shall be rated at least 10% greater than the maximum power required
under all climatic and operating conditions.
Each blower/compressor set shall be provided with an acoustic enclosure and a surge
protection system. The acoustic enclosure shall limit the noise level to not more than
75Db(A) when measured at 1 metre distance from any point at the enclosure surface at any
time. The enclosure ventilation shall be designed to ensure that adequate cooling of the
blower set is maintained. Consideration should be given to ducting the enclosure exhaust
direct to atmosphere to limit the temperature rise within the blower house to a maximum of
5C above ambient. The enclosure shall be designed to allow for ease of access to the
blower set, without the necessity to lift the complete enclosure, to allow for routine inspection
and maintenance procedures.
The level of vibration in each blower / compressor shall be within the limits and comply with
BS ISO 10816, Part 1 and Part 3.
The blower/compressor sets shall be of a proven design with at least five years operational
experience in similar applications. Where multiple units are required to meet the duty in
addition to single duty applications, the design shall be proven in applications where two or
more units are automatically controlled to meet the varying air demand.
14.3
AIR BLOWERS
14.3.1
Centrifugal Blowers
Blower sets shall comprise of single stage centrifugal air blowers with modulating powered
inlet and outlet guide vanes, gearbox, lubrication system, electric drive motor, and suction
and discharge flexible stainless steel connection compensators, all mounted on a common
baseplate. The sets shall be installed on flexible machine mounts.
The volume flow rate from the blowers shall be modulated control on the inlet and outlet
guide vanes which shall be capable of varying the delivery rate down to 45% of the rated
output without causing the blower to go into surge when operating either singly or in parallel.
A high operating efficiency shall be maintained throughout the flow range.
Materials and equipments of construction shall give a design running life of at least 100,000
hours before major maintenance is necessary.
The impeller shall be statically balanced and the whole rotor shall be dynamically balanced.
The first responsive critical speed of the rotating assembly shall be at least 10% above the
maximum operating speed.
The gearboxes shall be of the parallel shaft high speed helical type. The gears shall have a
minimum AGMA service factor of 1.5. A labyrinth oil seal shall be fitted to each shaft to
prevent oil seepage from the casing under operating and static conditions. The seals shall be
designed to ensure there is no contamination of the process air.
Each gearbox shall be fitted with an oil level sight glass and a drain plug which shall be
readily accessible in operation.
The baseplate shall be provided with lifting points to allow the complete set to be handled
using chain slings.
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Instrumentation for the safety monitoring of air blowers shall include oil temperature, oil level,
air temperature at inlet and outlet from the blower, outlet air pressure, surge conditions,
bearing temperature and vibration and motor running current. The instruments shall provide
signals for the shutting down of air blowers if unsafe conditions arise and for visual indication
of the fault. Additionally, the contractor shall provide all necessary instrumentation for
measuring the airflow from each blower.
Each blower shall be equipped with an inlet air filter, automatic unloading device, pressure
relief valve, pressure switch and under load (no flow) detection device to trip the blower in
case of drive/flow failure.
10
Each blower shall be performance tested at the manufacturers works, using the control
motors, to BS ISO 1217:1996. Air flow measurement for these tests shall be carried out in
accordance with BS 1042. Blower casings shall be works hydro-statically tested to 1.5 times
the maximum working pressure.
14.3.2
Positive Displacement Blowers
The blowers shall be complete with all ancillary equipment which may be required to enable
the units to operate correctly.
Blowers shall be air-cooled and of the double rotor positive displacement rotary type with
cast iron casings delivering oil-free air.
Each blower shall be complete with an automatic unloading device, dead-weight pressure
relief valve, spring type pressure relief valve, pressure gauge, pressure switch and non
return valve of the wafer or nozzle ring check pattern.
The blower speed shall not exceed 70% of the maximum designed speed or 2300 rpm
whichever is the lower.
Each blower shall have an under load detection relay or other similar device to trip the
blower in the event of a drive or flow failure.
The blower casing shall be high-grade cast iron adequately ribbed to assist cooling and
avoid distortion. The rotors shall be spheroidal graphite iron with integral shafting. Timing
gears shall be of nickel cast iron positively keyed to the rotor shafts, they shall be accurately
ground with close clearances to prevent interference between rotors.
The blower shall be fitted with an oil lubrication system for the bearings and timing gears.
The blower shall be fitted with mechanical seals to prevent the ingress of oil into the rotor
chamber.
The lubrication system shall include filling and drain plugs and oil level indicators visible from
outside the acoustic cover.
The drive between the blower and motor shall be of the vee belt or flat toothed belt type and
of approved design.
10
The complete blower assembly shall be mounted on steel section frame which shall
incorporate a blower mounting plate, motor adjustment slides and guard support brackets,
the frame is to be supported on anti vibration mounts.
11
An inlet silencer complete with replaceable filter element shall be fitted to each blower, the
silencer shall be fitted with a visual indicator to warn of filter blockage.
12
Outlet silencer shall be fitted to maintain noise levels as low as possible. A flexible coupling
shall be fitted to prevent vibration transmission to the air supply system.
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Silencers are to be of the reactive type, absorptive type silencers will not be permitted.
14
Components likely to wear in the course of normal operation shall be capable of replacement
with readily available replacement components.
14.4
AIR COMPRESSORS
14.4.1
General
The design and installation of the compressed air system shall be in accordance with the
requirements of the British Compressed Air Society's Code of Practice and the Pressure
Systems and Transportable Gas Containers Regulations 1989.
Compressors shall be rated to achieve the duty at optimum efficiency and may be selected
from one of the following types unless otherwise specified in the particular specifications:-
(b)
(b) Reciprocating Multi Stage
(c)
(c) Rotary Screw
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Reciprocating Compressors
Reciprocating Single Stage Compressors shall be of inherently oil free design. The
compressor shall be of cast iron construction with aluminium cylinder heads and shall be air
cooled. The unit, complete with electric motor, shall be mounted on a rigid bedplate
incorporating anti vibration mountings. The drive arrangement shall be belt or shaft driven
and shall be fully guarded. A suitable means of achieving alignment shall be provided and
where appropriate flexible couplings shall be used.
Reciprocating Multi-Stage Compressors shall be as above but incorporate interstage cooling

and be of the short stroke design for low piston speeds.
Both single and multistage units shall be provided with the following:-
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14.4.2
Low oil level cut out switch.
(b)
Crank case oil sight glass.

Air inlet filter.
Silencer complete with pressure gauge and low pressure cut out (filter blockage
protection).
(d)
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(c)
(a)
(e)
Pressure gauge tappings after each stage for compressors up to 15kW, and gauges
and safety valves on compressors over 15kW.
(f)
Oil pressure indicator on compressors over 100kW.
(g)
Final air temperature indicator on compressors over 100kW.
(h)
Unloader valve unit.
(i)
Air dryer system (Dehumidifier) where dry air is required.
14.4.3
Rotary Compressors
Rotary Screw Compressors shall be of the inherently oil free design and shall be either the
single stage or multi-stage type depending on the duty.
The separate stages shall be enclosed in individual housings, the male rotor being gearbox
driven whilst the female rotor is driven via a timing gear.
QCS 201

Part
Page 6
The rotor shafts shall be supported by precision made ball and roller bearings
Lubrication to the driving gear, bearings and timing gear shall be via an oil pump driven by
the main shaft. The lubrication system shall be complete with oil filter and cooler, pressure
gauge and fail-safe pressure switch.
On multi stage units air cooling shall be undertaken by an intercooler.
The compressor shall be motor driven via a flexible coupling and gearbox common to both
stages. A suitable means of alignment shall be provided.
The complete compressor set ie. compressor, motor, gearbox and associated cooling
equipment shall be supplied on a rigid bed plate suitable for floor mounting via anti vibration
mountings.
14.4.4
After Cooler
All types of compressor shall be fitted with an aftercooler. These shall be of the air cooled
type comprising an air to air heat exchanger. The aftercooler shall cool the process air to a
o
temperature of 10 C above ambient. The aftercooler shall be fitted with an automatic
condensation drain which shall be provided with a manual bypass.
Delivery lines from the Compressor Sets shall be fitted with the following equipment:-
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Oil trap/filter prior to entry into the air receiver. The filter shall be fitted with an auto
drain and manual by pass.
(b)
Adjustable safety valve (lockable).
(c)
A solenoid valve for unloading (dependant upon compressor size) for applications
where the compressor is directly coupled to a surge vessel.
(d)
A non return valve.
(e)
A high efficiency coalescing oil filter (0.001 micron filtration).
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(a)
Air Receivers
Unless otherwise stated, one air receiver shall be provided, normally being online, but with
the capacity to be isolated from the system.
These shall be manufactured from fusion welded steel and shall comply with BS 5169 or
equivalent for the appropriate pressure class.
Air receivers greater than 1000 litres capacity shall be designed and manufactured in
accordance with PD 5500 or equivalent.
Each integral air receiver shall have sufficient capacity to damp out air pulses from the
compressor and to prevent pressure drops on process valve actuations.
The air receivers shall be connected such that the duty compressor delivers into either or, if
two air receivers are specified, both of the air receivers. Diaphragm isolation valves shall be
provided for isolating either of the receivers from the system.
The air receivers shall be suitable for floor mounting and shall be supplied with two
inspection ports. The inspection ports shall be of the elliptical type and pressure sealed.
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14.4.5
QCS 201

Part
Page 7
Fabrication Requirements
The air compressors shall be air-cooled. The cooling air shall be drawn directly from the
ambient air, routed through the enclosure and exhausted upward through the enclosure box.
The cooling air for the motor shall be drawn directly from the ambient air.
The drive motors shall be directly coupled to the air end by flexible coupling.
The compressors shall be suitable for indoor installation.
Each air compressor shall have an efficient filter for cleaning intake air and micro filter after
the discharge. Each compressor shall be fitted with a silencer, which shall be sized to
prevent excessive pressure drop.
All instrument tappings shall be via suitable bosses welded to the tank structure. The vessel
shall be supplied with:
(b)
Pressure relief valve.
(c)
Drain valve.
(d)
Lifting lugs.
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Pressure gauge.
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(a)
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14.4.6
The vessel shall be corrosion protected to give maintenance free service for a period of 20
years minimum, as defined in BS 5493 (partially replaced by BS EN ISO 12944) or
equivalent and as specified in Section 8 part 8
Full certification in triplicate shall be supplied with the air vessel. The vessel shall also
feature a stainless steel nameplate containing the following details.
The manufacturers name.
(b)
The date of manufacture.
(c)
The standard to which the vessel was built.
(d)
The maximum design pressure.
(e)
The minimum design pressure where it is other than atmospheric.
(f)
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The design temperature

The test pressure
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(a)
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14.4.7
Booster Compressor
In case discharge pressure in excess of 15 bar is required, then booster compressors will be
required. Alternatively multistage piston type air compressor can also be proposed. The
booster compressor package shall comprise the following items:
(a)
Booster compressor and motor mounted on common base plate.
(b)
V-belt drive with guard.
(c)
Oil/water separator or after cooler with automatic drainage and associated unloaded
start.
(d)
Solenoid valve to close the inlet at standstill.
(e)
Safety valve on the oil/water separator or after cooler.
(f)
Anti vibration floor mounts.
(g)
Suitably sized air receiver.
QCS 201

Part
Page 8
14.5
14.5.1
1 The equipment delivered to Site shall be examined by the Engineer to determine that it is
in good condition and in conformance with the approved working drawings and certification.
All equipment shall be installed in strict accordance with Part 1 of this Section 9.
14.5.2
Testing
the Contract.
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END OF PART
QCS 2014

Part
15: Settlement Tank Equipment
Page 1
15
SETTLEMENT TANK EQUIPMENT .............................................................. 2
15.1
GENERAL ...................................................................................................... 2
15.1.1 Scope
15.1.2 References
15.1.3 Submittals
2
2
2
MATERIALS .................................................................................................. 2
15.3
BRIDGES AND SCRAPERS .......................................................................... 3
15.3.1
15.3.2
15.3.3
15.3.4
15.3.5
Scrapers
Bridges
Walkways
Bearings
Drive Units
15.4
ELECTRICAL EQUIPMENT ........................................................................... 5
15.4.1
15.4.2
15.4.3
15.4.4
15.4.5
15.4.6
General
Slip-Ring Current Collectors
Emergency Isolator Limit Switch
Motor Decontactor Plug and Socket
Parking Switch
Cabling
15.5
ANCILLARY EQUIPMENT ............................................................................. 6
15.5.1
15.5.2
15.5.3
15.5.4
15.5.5
Diffusion Drum
Weir plates and scum boards
Scum Skimmer
Scum Collection
Effluent Channel Cleaning
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15.2
3
3
4
4
4
5
5
5
5
6
6
6
6
7
7
7
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Part
Page 2
SETTLEMENT TANK EQUIPMENT
15.1
GENERAL
15.1.1
Scope
This part specifies the requirement for the design, manufacture, construction, testing and
commissioning of equipment for primary and secondary settlement tanks.

General
Drainage Works
Electrical Works
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Section 1
Section 8
Section 10
Section 13
Section 21
15
References
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BS 4 Part 1 .................Structural steel sections
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15.1.2
BS 449 Part 2 .............Specification for the use of structural steel in building
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BS 970 ......................Wrought steels for mechanical and allied engineering purposes
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BS 7671 .....................Requirements for electrical installations. IEE Wiring Regulations.

Sixteenth edition
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BS EN 10029 .............Specification for tolerances on dimensions, shape and mass for hot
rolled steel plates 3 mm thick or above
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BS EN 10084 .............Case Hardening Steels

BS EN 10113 .............Hot-rolled products in weldable fine grain structural steels
BS EN 10155 .............Structural steels with improved atmospheric corrosion resistance
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BS EN 10210 .............Hot finished structural hollow sections of non-alloy and fine grain
structural steels
BS EN 12020 .............Aluminium and aluminium alloys
BS EN 60947-1 ..........Specification for low-voltage switchgear and controlgear

15.1.3
Submittals
15.2
MATERIALS
All reference to stainless steel shall mean stainless steel to BS970 Grade 316 S31 (partially
replaced by BS EN 10084) unless otherwise stated.
All reference to aluminium shall mean marine grade aluminium milled finished 6063TF alloy
to BS EN 12020.
All materials shall be protected against corrosion in accordance with Section 8 Part 8.
QCS 2014

Part
Page 3
BRIDGES AND SCRAPERS
15.3.1
Scrapers
The tank scrapers shall be of the half-bridge rotating type or fixed bridge type as specified in
the Contract Documents.
Non retractable tubular steel arms shall connect the scraper blades to the drive. The
stainless steel scraper blades shall be fitted with removable heavy duty neoprene rubber or
synthetic material hard wearing strips having a minimum shore hardness of 70. They shall
be not less than 20mm thick and shall be fastened to the mechanism in such a way that the
blades may be reversed. The minimum blade life shall be 2 years. Blades shall be arranged
to form a continuous spiral across the floor and vertically up the side wall of the tank. Either
the arms or blades shall be hinged to compensate for minor variations in the tank floor and
side wall. Slotted holes shall be provided on the scraper rubber blades for adjustment
against wear.
The two arms of fixed bridge scrapers with any appendages shall be equally balanced
statically and be supported for rigidity using stay rods and turn buckles.
The scraper and its driving mechanisms shall be designed to allow for longitudinal and
vertical movements of the bridge.
15.3.2
Bridges
The bridge shall be fabricated from structural steelwork to BS4 Part 1: BS449 Part 2: BS
EN10029: BS EN10113: BS EN10155 and BS EN10210.
Primary tanks bridges shall be fabricated from stainless steel or from marine grade
aluminium. Secondary bridges may be fabricated from mild steel, galvanised and painted in
accordance with Section 8.
Fixed bridges shall span the full width of the tank.
Rotating half bridges shall be supported at the centre of the tank using a tripod manufactured
from the same material of the bridge. The structure shall be designed to withstand the total
loadings induced by the bridge and other forces associated with the bridge and scraper
when in operation. The top plate of the support structure shall accommodate the centre
bearing assembly and diffuser drum supports.
The bridge shall be designed to take a uniform distribution load of 250 kg/m2 in addition to
the weight of the scraper assembly and shall be capable of satisfactory operation under wind
loads, acting horizontally and normal to the total area of exposed surfaces.
The maximum permissible deflection with this superimposed load shall not be greater than
1/360 of the bridge span. On removal of the load the bridge deflection shall fully recover and
return to its original mid span position on either side of the bridge.
The bridge design shall include provisions to adequately cope with all torsional moments that
it may reasonably be expected to encounter, with a safety factor of 2.0.
Fixed bridges shall be constructed with equal mass on both sides of the centre of the tank.
At each end provision shall be made in the design of the supports to allow for expansion and
contraction resulting from temperature differentials of not less than 10C beyond the
recorded maximum and minimum ambient temperatures in the region.
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15.3
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Part
Page 4
Walkways
The bridge structure shall have suitably rated open stainless steel or aluminium walkway the
full length of the structure and the width shall be 850mm, between handrailing.
Handrailing shall be manufactured from stainless steel to BS970 Grade 316 S31 (partially
replaced by BS EN 10084) or marine grade aluminium tubes with standards 1100mm above
the walkway, top rail and an intermediate rail 550mm above the walkway.
Toeboards 150mm high shall be fitted along both sides of the walkway.
Insulation shall be provided as necessary to prevent electrolytic action between dissimilar

metals.
15.3.4
Bearings
Fixed Bridges:
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15.3.3
Rotating Bridges:
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Where the feed pipe rises from the centre of the hopper the scrapers shall be supported from
the bridge on a frame around the pipe and shall have at least one steady bearing of
phosphor bronze or stainless steel at the base of the scraper frame. The inner ring of this
bearing shall be bolted to the feed pipe and the outer ring bolted to the scraper frame. All
shafts on the drive system shall have at least two bearings whatever the configuration and
as many guides as are necessary to retain stability.
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The centre bearing assembly shall be designed to permit both horizontal rotation and vertical
undulation of the bridge structure. The slewing and trunnion arrangement shall be designed
to withstand the total loading of the bridge and other forces associated with the bridge and
scraper in operation. Lubrication for the pivot pins, trunnions, etc. shall be provided from a
readily accessible grease nipple battery plate.
Drive Units
For fixed bridges a motor, flange mounted to a reduction gearbox, shall provide the drive.
The motor speed shall not exceed 1500rpm. The motor and gearbox shall be easily
accessible for maintenance.
Rotating bridges shall be driven by a double-wheeled drive unit mounted on the end
carriage. The end carriage shall be fabricated from mild steel and incorporate the trailing
rear-driven wheel and the leading driving wheel and shall incorporate guards covering all
wheels to protect from the possibility of wheel nip. The driving wheel shall be driven by a
motor and gearbox unit. Both wheels shall be polyurethane tyred.
Gearboxes and motors shall have an ingress protection rating conforming to BS EN 609471: IP55 classification. Gearboxes shall have a life of 100,000 hours and be selected in
accordance with the AGMA recommendations for power calculation and service factor
application, shall incorporate filler cap/breather, dipstick or level plug and drain plug, and
have a noise level of not greater than 65 dB(A) at 1 metre distant in any direction.
For fixed bridge drive units the following shall apply:
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15.3.5
(a)
A drip tray, with gunmetal drain tap, shall be located under the motor and gearbox
reduction unit(s). The drip tray shall be manufactured from stainless steel not less
than 2mm thickness.
(b)
Any drive required between the reduction gearbox and the scraper shaft shall be by
pinions and spur wheels or geared slewing rings as appropriate.
QCS 2014

Part
Page 5
(c)
The gearbox may be oil or grease lubricated whilst all other bearings shall be grease
lubricated. All grease lubrication pipes shall be manufactured from stainless steel
tube and be terminated at a common location on the bridge at a point which affords
operational access to enable convenient, safe lubrication and be suitably labelled.
(d)
The speed of the scraper assemblies measured at the tank periphery shall be. as
follows:
Primary tanks 0.75 1.0m/min
Final tanks
0.3 2.5m/min fully variable.
The drive system shall incorporate a loss of rotation monitor and an overload
protection device comprising a torque limiting coupling set at the appropriate cut out
torque. The device shall incorporate a switch and alarm indication system drawing
attention to the fact that the torque limiting device has operated.
(e)
The gearbox output mechanism shall be restrained by a torque arm fitted with a
weatherproof, strain gauge type torque indicator and electro mechanical overload
contacts.
(g)
Guards shall be provided fully enclosing the scraper drive mechanisms.
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(f)
ELECTRICAL EQUIPMENT
15.4.1
General
Electrical equipment and installation shall comply with Section 21 together with the following
supplementary clauses.
15.4.2
Slip-Ring Current Collectors
All power supply, controls and signals to rotating bridges shall be fed to/from the bridge via
an underfeed slip ring collector assembly fixed to the stationary centre bearing base plate.
The unit shall comprise phosphor bronze sliprings fitted with spring loaded brush-holders
complete with copper graphite brushes, housed in an overall enclosure with an IP55 rating.
Current rating shall be adequate for starting and running the size of bridge drive motor
chosen by the bridge manufacturer. The assembly shall also be suitable for the transmission
of control signals.
The minimum voltage shall be 24v current capability, twelve circuits shall be provided as a
minimum.
Cable boxes shall be suitable for accepting cable from below via 25mm cable entry and exit
points.
15.4.3
Emergency Isolator Limit Switch
Each rotating bridge shall have an emergency isolator switch mounted on the leading edge
of the drive carriage.
The switch shall have an enclosure rating of IP55 and shall be operated by a touch bar
located on the leading edge of the drive carriage. The switch/touchbar assembly will
constitute an emergency stop.
15.4.4
Motor Decontactor Plug and Socket
The supply cable to the drive motor shall incorporate a suitably rated weatherproof
decontactor plug and socket.
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15.4
QCS 2014

Part
Page 6
The male section of the unit shall be connected directly to the drive motor using suitably
rated flexible cable. The female socket shall be securely supported in a position to ensure
that the latch button is readily accessible from the bridge.
15.4.5
Parking Switch
Each rotating bridge shall be provided with a magnetic proximity switch protected to at least
IP55 standard arranged to ensure that the bridge is parked at a fixed location on the tank.
On installations with bridge mounted starters, a parking selector switch must be provided
which is accessible from off the bridge.
15.4.6
Cabling
The Contractor shall supply and install all on-bridge cabling from the slipring collector.
Cabling shall be stranded copper 600/1000 volts grade and suitable for the application in
accordance with BS 7671 and specification Section 21.
The main cable from the collector shall be a single multi-core which is to be terminated at the
motor end of the bridge with an IP55 junction box. From the terminal box individual three or
two core cables shall be run to the various items of equipment included in the bridge
contract.
All cables shall be suitably supported along their length with approved cleats. The spacing
centres for the cleats shall not exceed that given in BS 7671. Cleats to be of rigid PVC
secured to the bridge structure using stainless steel nuts and bolts. The bridge structure
must be pre-drilled prior to galvanising to accept the saddle fixings. Crimped terminals shall
be used for all connections.
15.5
ANCILLARY EQUIPMENT
15.5.1
Diffusion Drum
Diffuser drums shall be constructed in glass reinforced plastic suitably strengthened and
supported from the bridge so as to be positioned in the centre of the tank.
The drum shall be sized to be 10% of the total area of the tank and 2m deep. The top of the
diffusion drum shall project 150mm above TWL.
The drum skin and flange thicknesses shall be not less than 4mm and 6mm respectively.
Two 180 opposed square cut outs with internal baffles above TWL shall be installed in each
drum to enable the removal of grease and sludge.
15.5.2
Weir plates and scum boards
'V' notch weir plates shall be supplied for bolting to the tank walls. The weir plate shall have
90o notches equi-spaced around the periphery of the tank and slotted adjustment holes.
The spacing and size of "V" notches should be determined by calculation. The maximum
discharge per notch should be 30-40m3/day to enable uniform outlet conditions.
The weir plate shall be 300mm deep and be fabricated from composite plastic or GRP. The
weir plate shall be pre-curved and of minimum thickness 6mm. Sealing strips shall be
provided for installation between the weir plates and the tank wall to allow for discrepancies
in the structure.
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Part
Page 7
Scum boards and fixing brackets shall be provided on all tanks. The brackets shall be
stainless steel with stainless steel bolts and be so designed that no fixing is required to the
tank wall within 250mm of the weir level.
The brackets shall hold the scum board securely 500mm from the inside face of the weir
wall. The scum boards shall be manufactured from GRP, 305mm deep by 6mm thick precurved and shall be positioned so that 100mm of the scum board is above water level.
15.5.3
Scum Skimmer
A scum skimming arm (trailing scum board) shall be attached to the bridge (for rotary bridge)
or to the scraper arm (for fixed bridge) which must maintain contact with the scum board in
all positions. The scum arm shall sweep the scum to a trumpet at the periphery of the tank
which shall automatically discharge the scum via pipework to a scum/grease trap. The blade
shall be fabricated from GRP or stainless steel and shall protrude 100mm above top water
level.
15.5.4
Scum Collection
Scum shall be collected in a scum box attached to the tank wall. The scum box shall be
fabricated from stainless steel and terminate with a flanged connection. Scum box flush
shall be provided suitable for operation from either the bridge or tank periphery. Not less
than two scum collection boxes shall be provided at final settlement tanks associated with
Activated Sludge Plants.
15.5.5
Effluent Channel Cleaning
Where called for in the Contract Documents a spray jet system shall be mounted on the
travelling bridge (or on an extension to the scraping mechanism in the case of fixed bridges),
to clean the outlet channel. The jets shall be fitted with hooded cover plates to prevent
aerosols being forced upwards. A submersible sewage pump, fitted to the bridge or scraper
extension shall supply tank effluent to the nozzles. A strainer shall be fitted to the pump. To
allow cleaning of the filter, the pump discharge shall be a flexible hose, to allow lifting of the
pump from the bridge without dismantling the pipework.
Spring loaded polypropylene bristle brushes shall be supplied and arranged to assist in
cleaning of the effluent channel and weir walls without restricting effluent flow. The
assembly shall be fabricated from 316L stainless steel. Springs shall be of stainless steel.
Effluent channel cleaning systems shall not be installed in primary tanks unless they are fully
covered and odour controlled.
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END OF PART
QCS 2014

Part
16: Tertiary Treatment Granular Filters
Page 1
16
TERTIARY TREATMENT GRANULAR FILTERS .......................................... 2
16.1
GENERAL ...................................................................................................... 2
16.1.1 Scope
16.1.2 References
16.1.3 Submittals
2
2
2
16.2
PRODUCTS ................................................................................................... 2
16.2.1
16.2.2
16.2.3
16.2.4
General
Filtration Rates
Nozzle Plates
Pressure Filters
16.3
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2
3
4
4
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16.3.2 Testing
6
6
QCS 2014

Part
Page 2
TERTIARY TREATMENT GRANULAR FILTERS
16.1
GENERAL
16.1.1
Scope
testing and commissioning of tertiary treatment granular filters.
16.1.2
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General
Drainage Works
Electrical Works
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Section 1
Section 8
Section 10
Section 13
Section 21
16
References
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BS 970 ......................Wrought steels for mechanical and allied engineering purposes
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BS 1780 .....................Specification for bourdon tube pressure and vacuum gauges

BS 4870 .....................Specification for approval testing of welding procedures
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BS 4871 .....................Specification for approval testing of welders working to approved

welding procedures
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PD 5500 .....................Unfired fusion welded pressure vessels
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Submittals
16.2
PRODUCTS
16.2.1
General
Filters shall be of the downward flow sand type and shall include a minimum of two batteries
operating in parallel. Access to valves and pipework etc shall be constructed such that
operation and maintenance can be carried out safely and without obstruction. The
contractor shall be responsible for providing all access walkways and ladders.
Unless otherwise specified in the Contract Documents the filter material shall have an
effective size of 1.8mm and a uniformity coefficient of 1.5.
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16.1.3
QCS 2014

Part
Page 3
Valving, penstocks and associated pipework shall be provided on each filter for raw water
inlet, filtered water outlet, washwater inlet, washwater outlet, air scour, filter slow drain and
air after back wash. All valves shall be butterfly type and with the exception of the slow drain
valve shall be controlled automatically and shall include provision for manual operation.
Valves shall be in accordance with the valves section of this specification. Actuators shall be
electrically operated, quarter turn type. Valves and penstocks shall be positioned to allow for
manual operation from adjacent walkways. The backwash delivery manifold and air scour
delivery manifold shall be fitted with a pressure gauge to BS 1780 or equivalent.
Pipework shall be stainless steel, uPVC, HDPE or GRP and in accordance with Section 8 of
this Specification.
Filters shall be automatically backwashed using air scour blowers and washwater pumps.
The washwater pumps shall draw filtered water from a backwash tank, which shall
automatically be replenished following a wash cycle. The working volume of the tank shall
be equivalent to the volume of backwash water required for two complete wash cycles.
The backwash pumps shall be controlled to give a gradual increase in wash cycle. Control
will either be by speed control of the pump motor or by a controlled slow opening valve on
the washwater pipe. A non-return valve shall be included in the delivery pipework.
The air scour pipework shall incorporate a non-return valve, which shall rise to a height
above the filter top water level, before dropping down to the filter and d an automatic drain
valve at the lowest point to relieve the system of leakage water through the valve, to prevent
process water passing from the filter to the blower.
The backwash delivery manifold and air scour delivery manifold shall be fitted with a
pressure gauge
10
Pressure filters shall be provided with a pressure gauge mounted on the front of the vessel
visible from the walkway.
11
Loss of media from the filters is not acceptable. The raw water inlet/washwater outlet shall
be designed to prevent the passage of media during the backwash cycle. The level of the
fluidised bed shall be well below the washwater outlet to prevent sand loss.
12
Flow measuring and recording equipment shall be provided to indicate the flow through each
filter, washwater flow and air scour flow.
13
Rapid gravity filters shall be provided with loss of head measuring instrumentation.
14
Sample taps shall be provided on the raw water inlet / washwater outlet and the filtered
water outlet pipework of each filter. The taps shall be accessible from walkways.
16.2.2
Filtration Rates
Filtration rates shall not exceed 7.5 m/hour for single media filtration and 12m/hour for multimedia filtration. Sufficient capacity shall be provided to ensure that these flowrates are not
exceeded with one unit out of service and one unit backwashing.
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QCS 2014

Part
Page 4
The maximum allowable solid loading shall be 1.2 kg/m2 between backwashes unless
otherwise specified in the Contract Documents. Depending on the type of media selected, a
variation to the solid loading of 1.2kg/m2 may be permitted provided that reasons
substantiating the variation are clearly stated in the tender as an alternative option.
The maximum acceptable number of backwashes shall be ONE per filter per day during
"AVERAGE - CONDITIONS".
16.2.3
Nozzle Plates
Where a nozzle plate is incorporated into the design of the filter then the plate shall be
stiffened to withstand sand, surge and backwash pressure loading. Nozzle fixing access
shall be from below. Access through the nozzle plate is not permitted.
Where the design of the filter incorporates a nozzle plate, the underfloor section shall be
vented to prevent air pocket accumulation and subsequent major sand disturbance during
the back wash cycle.
Laterals and headers shall be uPVC with nozzles for water and air distribution. Support
brackets shall be Grade 316S31 Stainless Steel.
16.2.4
Pressure Filters
Pressure filters shall be all steel, designed, manufactured, inspected, tested in accordance
with PD 5500 or equivalent.
Longitudinal seam welds shall not cross at any intersection with circumferential welds but
shall be offset a minimum length corresponding to 90o of shell circumference.
Allowance for a vessel life expectancy of 25 years shall be made and the corrosion
allowance shall be not less than 2.0mm.
Pressure filters shall be fabricated from Carbon Manganese steel, and full fabrication details
shall be submitted for approval by the Contractor. The vessel shall comprise two domed
ends with an intermediate cylindrical section. Not less than two lifting lugs shall be provided
for lifting of the complete vessel. Vessels may be vertically or horizontally mounted.
The inlet and outlet pipework shall be designed to the same criteria as the pressure filter
terminating in flanged connections. A drain line shall be provided complete with isolating
globe valve and flanged hose connection suitable for a flexible hose of 50mm diameter.
Pressure filters shall be supplied complete with associated fittings internal manhole access,
sand door, pressure gauges and air valves.
The sand door shall be located at the lower end of the centre cylindrical section of the filter
shell. The underfloor inspection hatch shall be located on the lower domed end of the
vessel.
The filter shell shall be mounted on fabricated feet for mounting on pre cast concrete plinths
on the filter room floor at a height to enable man entry into the lower inspection access
hatch.
Pressure filters shall be provided with a double acting large orifice air valves.
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QCS 2014

Part
Page 5
A 150 mm nominal diameter pressure gauge shall be surface mounted on the vessel using a
purpose made mild steel bracket welded to the vessel.
11
The man access shall be of the "T-bolt" closure type of not less than 600 mm internal
diameter with the hinge running parallel to the filter diameter and be provided in the
cylindrical section of the vessel to permit access and located such that internal launders and
bellmouths can be visually inspected without entry into the filter.
12
Both the sand door and under floor inspection hatch shall be of the flanged type and be
provided with a lifting swing davit which shall incorporate a lifting screw, so that the whole
flange cover may be lifted up and then swung out from the entry port. The davit shall be
fabricated onto the cylindrical wall of the vessel.
13
A safety/hand rail shall be located adjacent to the man-way with a fixing for a safety rope.
Each man-way access shall incorporate a traffolite warning notice permanently fixed to the
cover in view of an operative intending to access the vessel. The notice shall state
"WARNING Ensure full isolation and permit to work and depressurisation before entry.
14
Welding shall only be carried out by Contractors' staff who are qualified and experienced to
undertake this work in accordance by PD 5500 or equivalent by reference to the following:-
(b)
BS 4871 or equivalent.
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BS 4870 or equivalent.
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10
The Contractor shall mark clearly with their respective safe working pressure in lettering not
less than 80mm in height in gloss paint.
16
A brass plate shall also be fixed to the vessels which will state:Name of manufacturer with address.
(b)
Identification number.
(c)
Client's Order number.

Shell Thickness.
(d)
(a)
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(e)
Corrosion Allowance.
(f)
Shell Diameter.
(g)
Head Diameter.
(h)
Head Thickness.
(i)
Head Corrosion Allowance.
(j)
Degree of X Ray Inspection.
(k)
Tan Length.
(l)
Design Pressure.
(m)
Hydraulic Test Pressure.
(n)
Weight.
(o)
Length.
QCS 2014

Part
(p)
Inspection Date.
(q)
Inspectors Initials.
(r)
S.W.P.
Page 6
The Contractor shall allow for 100% category 1 radiographic testing.
18
The Contractor shall employ an independent testing authority to oversee the design,
fabrication and testing of pressure vessels as defined in BS5500. The independent testing
authority shall report direct to the Engineer.
19
The Contractor shall make provision for all the necessary work associated with carrying out
the Inspecting Authority's recommendations resulting through the use of PD 5500 or
equivalent in assessing design, manufacturing procedure, documentation and testing of the
vessel.
16.3
16.3.1
equipment shall be installed in strict accordance with Part 1 of this Section 9, the relevant
Parts of this Section 9 for ancillary equipment installed and the manufacturers instructions.
16.3.2
Testing
Test Procedures shall be in accordance with Part 1 of this Section 9 and in addition those
listed below.
Unless otherwise stated in the Contract Document the performance of the filter shall be
assessed by samples taken from the following points within the works.
(a)
Raw water - prior to any treatment.
(b)
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17
Final water into storage reservoir
(c)
Individual filters outlet.
Samples are to be collected using automatic composite samplers over a period of 7 days.
Each sample shall comprise 24 No discreet hourly samples. Spot samples may also be
taken for the performance assessment by the Engineer.
The performance of the works will be judged to be acceptable if samples, collected during
the Tests before Completion meet all of the criteria for all the determinants listed in the
Contract Document.
Sample collection and analysis shall be undertaken by an approved independent laboratory

at the Contractors cost.
END OF PART
QCS 2014

Part
17: Sludge Thickening & Dewatering Equipment
Page 1
17
SLUDGE THICKENING AND DEWATERING EQUIPMENT ......................... 2
17.1
GENERAL ...................................................................................................... 2
17.1.1 Scope
17.1.2 References
17.1.3 Submittals
17.2
2
2
2
THICKENING AND DEWATERING ............................................................... 2
17.2.1 General
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17.3.1 General
17.3.2 Polyelectrolyte Mixing System
17.3.3 Conditioning Tank
17.3.4 Drainage Section:
17.3.5 Machine Rollers
17.3.6 Drive Unit
17.3.7 Sludge Scraper and Lift Blades
17.3.8 Washwater System
17.3.9 Hydraulic Power Pack
17.3.10 Machinery Construction and Materials
17.3.11 Ventilation
GRAVITY BELT THICKENER ........................................................................ 3
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17.3
2
3
3
3
4
4
4
4
5
5
5
5
CENTRIFUGE................................................................................................ 6
17.4.1
17.4.2
17.4.3
17.4.4
17.4.5
General
Sludge Feed Pumps
Sludge Discharge Arrangements
Ventilation
Washwater System
17.5
6
7
7
7
8
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17.4

17.5.2 Testing
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Page 2
SLUDGE THICKENING AND DEWATERING EQUIPMENT
17.1
GENERAL
17.1.1
Scope
This part specifies the requirement for the design, manufacture, construction, testing and
commissioning of sludge thickening and dewatering equipment.
References
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17.1.2
General
Drainage Works
Electrical Works
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Section 1
Section 8
Section 10
Section 13
Section 21
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BS 970 ......................Wrought steels for mechanical and allied engineering purposes.
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Submittals
17.2
THICKENING AND DEWATERING
17.2.1
General
The approved methods of mechanical thickening of surplus sludge are:
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Centrifuge
Gravity belt thickener
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(a)
(b)
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17.1.3
The approved method of mechanical dewatering of sludge is by centrifuge.
Sludge feed systems shall comprise feed pumps complete with electro-magnetic flowmeters,
interconnecting pipework and fittings. The number of feed pump sets shall be in accordance
with the Contract documentation but as a minimum one duty and one standby pump shall be
installed.
The feed pumps shall be of the progressive cavity type and shall be fitted with a mechanical
speed variator. Speed shall be automatically and manually adjustable to regulate the flow
into the thickener according to its performance and variations in the incoming sludge quality.
The pumps shall comply with the requirements of this Section 9.
Thickened sludge shall discharge to a thickened sludge pump and be pumped to the
digestion system unless otherwise specified. A minimum of one duty and one standby pump
shall be provided. All necessary pipework and valves shall be provided.
Thickened sludge pumps shall be of the progressive cavity type fitted with motors rated IP65.
The pumps shall be in accordance with the general requirements of this Section 9.
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Part
Page 3
Access platforms and stairways shall be provided to give operators access to all items of
Plant requiring maintenance or operation.
Polymer preparation and dosing systems shall be provided complete with all interconnecting
pipework and fittings. The system shall be in accordance with the general requirements of
Section 22.
The control equipment shall comprise new FBAs that shall incorporate a PLC section
complete with Human Machine Interface (HMI) suitable for connection to SCADA and
telemetry in accordance with Section 21 of this Specification.
10
All plant and equipment shall be housed in an air-conditioned building.
17.3
GRAVITY BELT THICKENER
17.3.1
General
Each gravity belt thickener (GBT) unit shall be a complete package plant and the general
arrangement of each belt thickener system shall include:-
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Belt thickener
Polyelectrolyte mixing system
Conditioning tank
Drive unit
Sludge scraper and lift blades
Washwater system
Hydraulic power pack
Ventilation
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(a)
(b)
(c)
(d)
(e)
(f)
(g)
(h)
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Sludge belt thickeners shall consist of an endless dewatering belt passing around a series of
rollers.
The design of the plant shall permit a controlled feed of sludge to be mixed with a controlled
flow of polyelectrolyte in a mixing drum from which it shall go through a flocculation stage
prior to discharge onto the dewatering belt. The flocculated sludge shall then travel along the
belt before climbing over a ramp and discharging as a thickened sludge from a horizontal
stage of the machine.
The belt shall be washed automatically using final effluent, and be arranged for ease of
threading, alignment and tensioning.
17.3.2
Polyelectrolyte Mixing System
A non-clogging, multiple baffle mixing device shall be incorporated into the inlet of the
machine. The mixing system shall ensure intimate dispersion of conditioning polyelectrolyte
agent with the incoming sludge. The polyelectrolyte dosing position shall be both multiple
and variable to suit the type of sludge being treated.
17.3.3
Conditioning Tank
Mixed sludge and polyelectrolyte shall pass to a bifurcated upwardly diverging conditioning
tank, which shall be suitably sized to enable good floc formation to occur. The outlet of the
tank shall be designed such that the flocculated sludge distributes gently and evenly across
the full width of the filter belt.
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Drainage Section:
The drainage section shall comprise a woven mono-filament polyester filter belt horizontally
supported on a PVC-U perforated support grid to allow rapid drainage of filtrate to a
collection system. The edges of the belt shall be raised by means of guides to prevent
sludge overflow during peak flow rates.
The belt weave selected shall be suitable for the sludge to be dewatered.
The belt shall incorporate a simple quick release to enable belt replacement to be effected
with minimal delay.
Blades shall be located at the entry position to the drainage section to induce drainage
furrows in the sludge blanket.
Drainage shall be connected into the works drainage system.
17.3.5
Machine Rollers
The machine shall be equipped with the following rollers:-
Manually adjustable tension rollers to allow pre-setting of the belt tension. The rollers shall
be mounted on the top frame member in plummer blocks fitted to manually adjustable slides.
A hydraulically sleeved belt alignment roller. The alignment system shall be automatic. The
belt shall be maintained central to the roller system. Should the alignment system fail or lose
pressure, excessive wander shall be detected by limit switches and the drive shall stop.
A drive roller mounted on the top frame member in plummer blocks.
Plummer blocks shall be fitted with heavy-duty bearings. Bearings shall have a guaranteed
life in excess of 100,000 hours. Auxiliary seals shall be fitted to bearings to prevent the
ingress of water.
For maintenance purposes, rollers shall be easily removable from the side of the machine,
without the need to dismantle any other components.
17.3.6
Drive Unit
The drive roller shall be chain-driven through a set of sprockets and manually adjusted
hydraulic speed variator by an induction motor or gear motor unit.
Gear motors shall be suitably rated and protected.
Gear motors bearings shall have a guaranteed life in excess of 50,000 hours. The AGMA
service factor of the gear motor shall not be less than 1.5.
17.3.7
Sludge Scraper and Lift Blades
An easily replaceable sludge blade shall be positioned at an angle to the drive roller to
ensure that sludge is effectively removed from the filter.
An easily replaceable sludge lift blade shall be positioned on the horizontal section of the
filter belt immediately prior to the drive roller. The blade shall be capable of being locked in
or out of position, as the process requires. The blade height shall be adjustable and shall
exert a backpressure on the advancing sludge to cause it to back up over the blade and
dewater by self-weight.
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17.3.4
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Sludge shall fall down a stainless steel Grade 316 S31 to BS 970-1 (partially replaced by BS
EN 10084) chute directly to a thickened sludge pump.
17.3.8
Washwater System
The belt wash system shall consist of a high-pressure spray pipe fitted with an integral
cleaning device for cleaning nozzles without dismantling or interrupting operation. Final
effluent shall be used as washwater. The whole belt wash area shall be totally enclosed to
prevent release of spray to the atmosphere surrounding the thickener.
A break tank and booster pumps shall be incorporated as part of the system, if the supplied
pressure of the final effluent washwater system is not sufficient. The Contractor shall adhere
to the appropriate health and safety guidelines, relating to water borne and air borne bacteria
arising from high-pressure atomising washwater systems utilising final effluent, in his design.
17.3.9
Hydraulic Power Pack
An hydraulic power pack shall be supplied to provide drive and control for each GBT. This
shall be floor mounted adjacent to the thickener.
The hydraulic power pack shall comprise:-
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A hydraulic fluid tank fitted with filler cap, strainer, fluid level gauge and fluid
temperature gauge, bund and lockable drain.
(b)
An electric motor driven hydraulic pump. The pump speed shall not exceed 1500 rpm.
(c)
Hydraulic accumulator, filter, pressure regulators and control valves.
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17.3.10 Machinery Construction and Materials
The machine frame shall comprise structural steel channel and angle sections welded and
bolted to form a rigid framework. The frame shall incorporate fabricated steel stops to allow
operators to view the horizontal section of belt.
Filtrate troughs, filtrate tanks, conditioning tanks, etc., shall be constructed of stainless steel
plate to BS970 Grade 361 S31 or shall be of glass reinforced plastic.
The sides of the machine shall be enclosed within easily removable GRP or PVC-U panels.
Guards and splash plates shall be of steel or PVC-U materials. Guards shall be placed over
moving parts of the machine.
Scraper, thickening and furrow blades shall be of high-density plastic, to avoid damage to
the filter belt.
The equipment shall be self-contained, hydraulic power packs, actuating mechanisms and
drive units shall be mounted on the structural framework.
All steelwork other than stainless steel shall be galvanised.
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17.3.11 Ventilation
1
A ventilation hood and curtain system shall be provided to isolate the thickener from the
surrounding building and ensure that high rate ventilation is concentrated on the machines.
A ventilation system shall be provided to ensure that odour/gasses are contained within the
hood. The ventilation system shall be designed for connection to an odour control unit.
QCS 2014

Part
Page 6
CENTRIFUGE
17.4.1
General
Centrifuges shall be of the horizontal decanter type and consist of a high speed rotating bowl
containing a scroll conveyor. The scroll shall be designed to rotate in the same direction as
the bowl but at different speed. The bowl and the scroll shall be balanced independently.
The speed differential will be provided and controlled by using two motors with variable
speed control system.
The centrifuge shall be designed for use with wastewater sludges. The bowl, scroll and
bearing hub of the centrifuge shall be manufactured in duplex stainless steel SAF 2205 or
higher grade. The bowl shall be centrifugally cast. All other parts in contact with sludge shall
be constructed of stainless steel Grade 316 S31to BS 970-1 (partially replaced by BS EN
10084).
Inlet and outlet parts, rotating parts and wear zones shall be designed with either
replaceable wearing parts or from abrasion resistant materials. Inlet and outlet parts,
rotating parts and wear zones shall be designed such that replacement or adjustment can be
completed easily within a single working day. The edge of the screw conveyor shall be
protected by spray-on tungsten carbide alloy or tungsten carbide tiles.
The centrifugal force at the inner surface of the bowl shall be a minimum of 2500g for
thickening centrifuges and 2900g for dewatering centrifuges. For torque based back drive
systems, the pond depth in the centrifuge bowl shall be adjustable through the use of
replaceable or adjustable dam plates at the liquid discharge end.
The solids discharge shall be fitted with field replaceable stellite bushes.
The differential speed adjustment between the bowl and the scroll conveyor shall be an
energy efficient system driven by an electric motor. Differential speed adjustment of scroll
speed shall be infinite within the range of 1 to 15 rpm with an accuracy of +/- 0.05 rpm via
an electric motor and inverter. The adjustment of the differential speed to accommodate
changes in solids content of the feed shall be fully automatic.
Torque experienced by the back drive shall be monitored continuously. Two stages of high
torque alarm shall be provided. Stage one shall initiate feed shut off. If the torque drops
below the torque alarm, the control system shall automatically open the feed. Stage two
high high torque alarm initiates the centrifuge shut down sequence. The centrifuge scroll
shall be kept running to clear the bowl when the decanter is slowing down under normal
shutdown or a high high alarm shutdown sequence.
The sludge feed tube shall be designed to allow the dosing of polymer directly into the scroll
distribution ports. The sludge inlet zone shall be low shear design to minimise floc
destruction.
The centrifuge shall be balanced and factory tested with a vibration level less than 5mm/s.
The centrifuge shall be equipped with rubber vibration dampers to minimise the transfer of
vibration to structures. The centrifuge shall be continuously monitored for vibration, with a
two stage alarm. Stage one shall initiate a high vibration alarm warning displayed on the
control panel and through the telemetry system. Stage two shall signal a high high vibration
alarm and initiate the automatic centrifuge shutdown sequence.
10
The centrifuge noise level shall not exceed 75 dBA when measured one metre from the
machine in any direction.
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17.4
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Part
Page 7
The bearings shall be designed for a L10 life of 100,000 hours. Bowl bearings shall be
continuously monitored for temperature with a two stage alarm. Stage one shall initiate a
high temperature alarm warning displayed on the control panel and through the telemetry
system. Stage two shall signal a high high temperature alarm and initiate the automatic
centrifuge shutdown sequence.
12
The main bearings on the centrifuge scroll and gears shall be lubricated for life.
13
The centrifugal bowl assembly and drive system shall be mounted on a base frame. The
base frame shall be able to support all the static and dynamic loading. The base frame shall
be fabricated from carbon steel with painting and corrosion protection in accordance with
Section D Part 4
14
Centrate from the centrifuges shall be discharged directly into the site drainage system.
17.4.2
Sludge Feed Pumps
Each centrifuge shall have a dedicated duty and standby feed pump.
17.4.3
Sludge Discharge Arrangements
The thickening centrifuges shall have a thickened sludge pump dedicated to each centrifuge
outlet with standby pumping facilities that can be immediately utilised for any centrifuge
without affecting the flow from any other centrifuge.
Dewatered sludge from the dewatering centrifuges shall be transported by a system of

conveyors to a sludge loading area outside the building.
The Contractor shall size the conveyer system to handle all dewatered sludges from the
centrifuges at up to 25% dry solids.
The conveyor system shall incorporate an adjustable high level cut out which shall inhibit
flow from the centrifuge to prevent overflow.
If any one conveyor fails it must still be possible to operate the necessary number of duty
centrifuges using the remaining conveyors.
Emergency off buttons shall be provided adjacent to each conveyor.
The conveyor system installed under this contract shall permit the installation of further duty
centrifuges in future.
The conveyor system shall be of proprietary manufacture with the detailed arrangements,
including the controls, designed by the supplier or a specialist in such equipment.
The body and helical screw of screw conveyors shall be of stainless steel construction and
the system shall be heavy duty and robust in construction with ample features that will allow
for ease of operation, maintenance and repair
17.4.4
Ventilation
A sealed inlet and outlet arrangement shall be installed to prevent the emission of gasses
from the system into the building. The ventilation system shall be designed for connection to
an odour control unit.
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The Contractor shall assess the need for ventilation for maintenance purposes in
accordance with the centrifuge manufacturers recommendations and provide an appropriate
system to protect personnel and equipment from harmful effects of sewage sludge gasses,
whilst the centrifuge is either not in use or is being maintained.
17.4.5
Washwater System
Each centrifuge shall incorporate a wash system, which shall consist of an automatically
operated injector nozzle designed to displace sludge through the process in preparation for
when the centrifuge is being shut down. A further manual hose shall be provided for manual
washing of the centrifuge during maintenance. Final effluent shall be used as washwater. A
break tank and duty/standby booster pumps shall be incorporated as part of the system.
17.5
17.5.1
equipment shall be installed in strict accordance with Part 1 of this Section 9, the relevant
Parts of this Section 9 for ancillary equipment installed and the manufacturers instructions.
17.5.2
Testing
Test Procedures shall be in accordance with Part 1 of this Section 9 and in addition those
listed below.
Unless otherwise stated in the Contract Documents, performance prior to Taking Over shall
be judged against the following criteria.
Sludge thickening four spot samples shall be collected each day of the feed sludge and the
thickened sludge over a period of 7 days. The quantity of polyelectrolyte used over this
period shall also be recorded. The thickening plant will be considered acceptable if during
this period the thickened sludge has a dry solids content equal to or greater than stated in
the Tender Submission and the quantity of polyelectrolyte used does not exceed the quantity
stated in the Tender Submission.
Sludge Dewatering four spot samples shall be collected each day of the feed sludge and
the dewatered sludge over a period of 7 days. The quantity of polyelectrolyte used over this
period shall also be recorded. The dewatering plant will be considered acceptable if during
this period the dewatered sludge has a dry solids content equal to or greater than stated in
the Tender Submission and the quantity of polyelectrolyte used does not exceed the quantity
stated in the Tender Submission.
Sample collection and analysis shall be undertaken by an approved independent laboratory

at the Contractors cost.
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END OF PART
QCS 2014

Part
18: Mixers and Stirrers
Page 1
18
MIXERS AND STIRRERS ............................................................................. 2
18.1
GENERAL ...................................................................................................... 2
18.1.1 Scope
18.1.2 References
18.1.3 Submittals
2
2
2
COMPONENTS ............................................................................................. 2
18.2.1
18.2.2
18.2.3
18.2.4
18.2.5
18.2.6
18.2.7
18.2.8
18.2.9
General
Bearings (Non Static Mixers)
Sealing (Non-submersible mixers)
Balance
Rating Plate
Couplings
Guarding
Installation and Lifting Equipment
Protection from Corrosion
18.3
SUBMERSIBLE MIXERS ............................................................................... 5
18.4
TANK MIXERS............................................................................................... 6
18.5
STATIC MIXERS ........................................................................................... 6
18.6
2
3
3
4
4
4
4
4
5
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18.2
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Part
Page 2
MIXERS AND STIRRERS
18.1
GENERAL
18.1.1
Scope
This part specifies the requirement for the design, manufacture, testing and commissioning
of mixers and stirrers.
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General
Drainage Works
Electrical Works
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Section 1
Section 8
Section 10
Section 13
Section 21
18
References
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18.1.2
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List of Approved Suppliers prepared by Public Works Authority
BS 970 (ISO 683) .......Wrought steels for mechanical and allied engineering purposes.
Submittals
18.2
COMPONENTS
18.2.1
General
Mixers and stirrers generally fall into the following categories:(a)
Static In-line Mixers

Submersible Shrouded Mixers
(b)
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18.1.3
(c)
Submersible Banana Blade Mixers
(d)
Tank Mixers
(e)
Stirrers/Flocculator Paddles
The mixer performance (excluding static mixers), related to its required duty and installed
media, shall be stable and the unit shall be non-overloading.
Contractors shall select the most economic units given the constraints of the operating
parameters and particular requirements of the specification.
For static mixers the pressure rating of the associated pipework shall be rated to a minimum
of 16 Bar unless otherwise stated.
Mixer propellers, casings and all other external parts shall be of stainless steel construction
minimum Grade316 S31 to BS970-1
QCS 2014

Part
Page 3
Bearings (Non Static Mixers)
The axial thrust generated shall be taken by a thrust bearing arrangement or angular contact
bearings. Thrust bearing arrangements incorporated into the motor housing are not
permitted. The Contractor shall demonstrate that the bearings are suitably rated in his
submittals for approval. Setting of thrust bearings shall account for dynamic loading, albeit
setting is carried out with the machinery stationary.
Rolling element ball or roller bearings shall be sealed for life and shall be rated to give a
minimum life of 75,000 hours at maximum load without replacement. Bearings shall be
protected by water throwers and lip seals where appropriate. The bearing housing shall be
of the cartridge type to allow removal of the bearing without disturbing the units.
Plain/Bush Bearings where utilised, shall be in bronze or equal, split for easy maintenance
and positively locked to prevent rotation.
Bearing housings shall be of the cartridge type to allow removal of the bearing without
disturbing the units.
18.2.3
Sealing (Non-submersible mixers)
For soft-packed gland arrangements, packing shall be graphite impregnated PTFE, of

approved manufacture. Asbestos based packing will not be permitted.
The gland design shall incorporate the following:
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18.2.2
A tapered "lead in" at the mouth of the gland entry to facilitate packing replacement and
obviate the risk of damage on assembly.
(b)
The surface finish of the adjacent metal parts shall be 0.4m CLA on the shaft gland
sleeve and 1.6m CLA on the stuffing box bore.
(c)
Where running clearances are excessive, the packing shall be protected by an

independent ring of robust material which reduces the clearance to a minimum.
(d)
The packing must not be used as a bearing.
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All studs, dowels and adjustable nuts shall be manufactured from stainless steel.
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(f)
Lantern rings shall be of gun metal or bronze and shall be split for ease of removal.
The stuffing box shall be manufactured from cast iron of a heavy section independent of the
mixer body and shall be provided with drain holes.
Mechanical seals shall be employed in submersible or closed tank applications with

differential pressures greater than 17 Bar or where controlled leakage is not permitted.
The Contractor shall specify the type, size and material of the mechanical seal he intends to
supply. It shall be the responsibility of the mixer manufacturer to ensure that the tolerances
required by the seal manufacturer are not exceeded. Checks shall be carried out on the
mixer casing and shafting for:
(a)
Shaft straightness
(b)
Rotational Balance
(c)
Shaft run-out
QCS 2014

Part
(d)
Bearing clearance - lateral and radial movement
(e)
Shaft tolerance and ovality
(f)
Concentricity
(g)
Seat squareness
(h)
Coupling alignment
Page 4
The Contractor shall ensure that the seat, face and component materials of the mechanical
seal are suitable for the media.
18.2.4
Balance
The whole of the rotating assembly, including locking key(s) and mixing element, shall be
dynamically balanced as an integral component. The mixing element shall also be
dynamically balanced separately and then assembled to the shaft, to form without further
adjustment, a dynamically balanced whole.
18.2.5
Rating Plate
Rating plates shall be fitted to all mixers, be manufactured and fixed by corrosion resistant
material (excluding brass), and include full details of the mixer including size, type and serial
number.
The weight of the mixer including motor/mounting brackets etc. shall be marked on the data
plate
18.2.6
Couplings
For large mixers, couplings shall be provided to permit the removal of drive shafts, bearings,
etc. without removing the mixer or motor. Couplings between the thrust bearing and motor
shall be accommodated within motor/support stools.
Couplings shall be of the pin and buffer type unless otherwise specified.
18.2.7
Guarding
All machine enclosures shall be safeguarded with guards fixed to the body or motor as
practical for the application.
Shaft guards shall extend the whole length of the shaft.
18.2.8
Installation and Lifting Equipment
Independent of application, the mixer shall be positively located and secured when
operating. Methods of installation shall be one of the following methods:-
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(a)
Swivel Mounting (for tank mixers/stirrers) - ease of removal of the mixing element from
the media shall be facilitated by means of a swivel mounting arrangement installed on
the top of the tank. This shall incorporate an adjustment to enable off centre mixing.
QCS 2014

Part
Page 5
Guide Rail mounting (for submersible mixers) - the mixer shall be supported by the
lifting chain from a hanging point and have a sliding guide bracket of stainless steel
Grade 316 S31 to BS 970-1 (partially replaced by BS EN 10084) mounted on a vertical
guide rail. It shall be possible to remove and replace the mixer safely without lowering
the level in the sump, or leaning into or entering the sump. The guide rail and hanging
arrangement shall permit full adjustment of the depth and direction of the mixer. The
guide system shall be retained at the lower end and upper end by stainless steel
mounting brackets. Rails shall be installed to within 05mm/m length of the vertical
with no more than +1mm -0mm tolerance between parallel rails.
(c)
Direct flange mounting to a mixing tank shall preferably be from the top. Side entry
3
mounting is acceptable for vessels greater than 4m . The mounting shall be designed
to enable removal through the flanged hole. Alternatively and especially for drum
applications, the impeller can be of the folding type.
(b)
Integral lifting brackets, shackles and lifting eyebolts shall be provided and shall be
manufactured from stainless steel with a minimum U.T.S. of 540 MN/m2, and certified by an
approved testing authority. Both bolt and hole shall be permanently marked, preferably by
punching, with the diameter and thread form used. All eyebolts shall be of the collar type
18.2.9
Protection from Corrosion
The internal & external finishes shall be in accordance with Section 8 Part 8.
18.3
SUBMERSIBLE MIXERS
Submersible shrouded mixers installed in open or closed topped tanks or chambers, should
be considered for the mixing of sewage, slurries, sludges and industrial process solutions
where there is an absence of rags and other large debris.
The mixer shall be easily removable from the installed position and this shall be achieved by
means of a guide rail system which also allows depth adjustment of the unit.
The assembly shall be directly driven from a submersible motor through an oil casing and,
when the specified duty dictates, also via a reduction gearbox. The motor shaft shall extend
to form the drive shaft of the propeller.
The oil casing shall provide lubrication and cooling for the seals and create a barrier between
the motor and the media. Expansion of the oil within the sealed casing shall be contained by
an air volume. Moisture sensor shall be provided for detecting any seal failures.
The propeller shall be designed to deter clogging and produce high efficiency, and the
shroud shall be fitted over the propeller to improve efficiency and direct the flow from the
mixer. The shroud shall be optional and the unit shall be capable of continuous operation
without it.
Motor cooling shall be achieved by the surrounding media.
Submersible banana blade mixers shall be easily removable from the installed position and
the blades shall be manufactured from lightweight glass reinforced plastic
Shafts shall either be sealed from the media in which they are working or shall be
manufactured from grade 316 stainless steel. Coated shafts shall not be permitted.
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Part
Page 6
Submersible mixer motors shall be certified for use in a Zone 1 explosive atmosphere and be
capable of working at 20m liquid depth. All other requirements for motors and shaft seals
shall be to the requirements of Section 9 Part 2 2.4 (submersible pump fabrication).
18.4
Tank Mixers
Tank mixers installed in open topped or closed tanks or chambers should be considered for
the mixing of chemicals, slurries, sludges, industrial process solutions where there is an
absence of rags and other debris.
Tank mixers and stirrers shall be easily removable from the installed position and shall be
achieved by means of a flanged connection at the top or side of the tank or, in the case of
portable mixers, by means of a positioning bracket which shall be universally adjustable as
necessary for the application.
The assembly shall be driven from a totally enclosed fan cooled motor or air motor through a
reduction gear box.
The gear box output shaft shall extend to the propeller shaft via a rigid coupling. Shaft
sealing shall be provided between the mixer and a closed tank. The motor shaft shall extend
to form the drive shaft of the gear box.
Propellers shall be designed to produce high efficiency.
18.5
STATIC MIXERS
Static Mixers installed in line within pipework for the blending of liquid to liquid and gas to
liquid in waste water treatment applications shall be constructed from materials suitable for
use with the chemicals they are associated with and shall be complete with end connections
compatible with the mating pipework. Changes in diameter or shape relative to the adjacent
pipework shall not be permitted.
Mixing shall be achieved by either flow splitting, rotating and recombining, or by vortex
action. The mixer shall incorporate sufficient elements to ensure complete and homogenous
mixing across the pipe section given the specified flow variations.
Assuming complete and homogenous mixing, the mixer shall maximise energy efficiency to
reduce the pressure losses through the unit. A characteristic curve of pressure loss against
flow shall be provided at the tender stage.
Where chemical injection points are integral with the mixer, they shall be designed and
positioned to maximise the mixing efficiency. Injectors shall be manufactured from materials
that tolerate the chemicals being dosed allowing for the design pressures.
18.6
Installation and commissioning shall be in accordance with Part 1 of this Section 9.
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END OF PART
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Part
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Page 1
19
CHLORINATION ............................................................................................ 2
19.1
GENERAL ...................................................................................................... 2
19.1.1 Scope
19.1.2 References
19.1.3 Submittals
CHLORINATION SYSTEMS .......................................................................... 2
19.3
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19.2.1 General
19.2.2 Chlorinators
19.2.3 Ejectors
19.2.4 Motive Water Pumps
19.2.5 Chlorine Gas Cylinders
19.2.6 Chlorine Gas Header
19.2.7 Automatic Cylinder Change-Over Module
19.2.8 Automatic Isolation Valve
19.2.9 Chlorine Gas Header
19.2.10 Gas Feeder
19.2.11 Residual Chlorine Recorders
19.2.12 Chlorine Consumption and Recording Apparatus
19.2.13 Analyser Cells
19.2.14 Gas Leak Detection Equipment
19.2.15 Drum and Cylinders Handling
19.2.16 Pipework
19.2.17 Ventilation
19.2.18 Emergency Breathing Apparatus and Air Compressor
19.2.19 Warning and Safety Notices
19.2
2
2
2
2
3
4
4
4
4
5
5
6
7
8
9
9
9
11
11
11
12
12
ON SITE GENERATION OF CHLORINE ..................................................... 13
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19.3.1 General
19.3.2 Salt Saturators
19.3.3 Brine Feed
19.3.4 Electrolyser
19.3.5 Sodium Hypochlorite Storage
19.3.6 Sodium Hypochlorite Dosing
19.3.7 Pipework
19.3.8 Electrical Installation
19.3.9 Transformer / Rectifier
13
13
13
14
14
14
15
15
15
15
19.4
ANALYSERS ............................................................................................... 16
19.5
NEUTRALISATION SYSTEMS .................................................................... 16
19.5.1
19.5.2
19.5.3
19.5.4
General
Neutralisation Tower
Circulating Pumping Units
Pipework and Electrical Connections
19.6
16
17
17
17
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Page 2
CHLORINATION
19.1
GENERAL
19.1.1
Scope
of gaseous chlorination disinfection plants.
References
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19.1.2
General
Drainage Works
Electrical Works
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Section 1
Section 8
Section 10
Section 13
Section 21
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BS 970 (ISO 683)

Wrought steels for mechanical and allied engineering purposes.
PWA Chlorine Safety Guidelines Liquefied Chlorine Gas
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Submittals
19.2
CHLORINATION SYSTEMS
19.2.1
General
Gaseous dosing systems shall comprise pressurised and liquefied gas drums or cylinders
complete with automatic changeover equipment, gas feeders and solution injection. All gas
dosing systems shall be based upon the full vacuum and remote injection principle.
Unless otherwise stated the system shall comprise the following equipment:
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19.1.3
(a)
Chlorinator
(b)
Ejector complete with diffuser
(c)
Motive water pump
(d)
Chlorine gas cylinders
(e)
Chlorine gas header
(f)
Automatic cylinder change-over module
(g)
Remote vacuum controller for cylinders
(h)
Pipework
(i)
Gas feeder
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19: Chlorination
(j)
Dosing control
(k)
Residual chlorine recorders
(l)
Chlorine consumption recording apparatus
(m)
Analyser cells
(n)
Gas leak detection equipment
(o)
Neutralisation equipment
(p)
Lifting and moving facilities for cylinders
(q)
Safety equipment
(r)
Drench shower linked to SCADA system
Page 3
Chlorinators
The Contractor shall supply and install the chlorinators, one as stand-by. The chlorinators
shall be of the floor mounted vacuum type, and provided with evaporator of suitable capacity.
The chlorinators shall feed ejectors with the adjusted dose of chlorine. A diffuser shall be
connected to each ejector.
All interconnecting pipes between the chlorinators and ejectors shall be under vacuum, and
pressure must be prevented from building up in the system by means of pressure relief
valves.
Chlorinators shall be designed to shut-down automatically the chlorine supply to ejectors

vacuum line at the following cases:
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19.2.2
The water supply to the ejectors fails.
(b)
The ejectors vacuum line breaks.
(c)
The water supply pipeline accidentally shuts down due to the closing of a valve or
valves.
(d)
The electric supply fails.
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(a)
The chlorinators shall be of the compound loop system and suitable for automatic control by
signals received separately from the flowmeter and the chlorine residual controller.
The accurate dosing scale of the apparatus should have a ratio of about 20:1 between the
maximum and minimum dosing rates. The rate will be automatically adjusted by means of
the chlorine residual controller according to the free chlorine residual needed. Provision
shall be made for manual adjustment.
Best chlorine resisting materials shall be used through the whole parts of the system. The
unit shall be of modular design, free standing with all control components protected within a
rigid fibre-glass cabinet or similar.
The components within the cabinet shall be readily accessible from the front for ease of
maintenance and shall be easily removable for examination or changing if required.
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Page 4
Ejectors
The ejectors shall be of the aspirator type to give maximum efficiency in mixing the chlorine
with the water. The ejector water supply must be designed to suit the maximum rated output
of the chlorinators offered.
Each ejector shall be connected to a diffuser for regular distribution of the chlorine solution at
the injection point.
The ejectors shall be separated from the chlorinators to give flexibility of placing the
chlorinators in their rooms and to inject the chlorine solution by the ejectors at the injection
point.
19.2.4
Motive Water Pumps
The Contractor shall supply and erect electrically driven boosting pumps. The pumps shall
be connected in parallel to supply water to the ejectors.
Motive water pumps shall be multi-stage, stainless steel, ring construction and provided on a
duty/standby basis. Pumps shall be provided complete with isolation valves, reflux valves
and delivery pressure gauges. Suction and delivery pressure gauges shall be provided on
each pump and downstream of flow control valves where flow splitting is provided.
A filter shall be fitted to each suction pipeline.
The discharge and manometric head of each pumping sets shall be chosen to suit the
working conditions of the ejectors at their maximum rated output.
The pumps shall be of the centrifugal type with high efficiency. Each pump shall be directly
coupled to a totally enclosed air cooled electric motor, the motor shall be complete with its
starter, rated for continuous running (24 hours) with class (F) insulation.
The pumps impellers, shafts, diffusers (if any), shall be made of stainless steel.
Ammoniator motive water systems shall be provided complete with base exchange water
softeners, complete with local salt saturator for regeneration or from bulk salt saturators if
employed at the site. The water softener shall be dual auto-rotation element units complete
with auto-timers and regeneration controller.
19.2.5
Chlorine Gas Cylinders
Where specified in the Contract the Contractor shall supply chlorine gas cylinders of the
pattern and size specified.
19.2.6
Chlorine Gas Header
The Contractor shall provide a suitable manifold and header system to convey gas from the
cylinders via the changeover panel to the associated gas feeder.
The pipework shall include flexible connectors, isolating valves, interceptor traps, gas filters
and all necessary mild steel pipework.
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19.2.3
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Each header shall be complete with electric heater. The heater shall be of suitable power to
prevent the freezing of chlorine gas when its flow rate through the header is maximum.
On drum chlorine systems, a combined liquid trap and gas filter shall be provided complete
with a self-regulating heater.
Pipework and valves shall be designed and constructed to withstand the pressure and
corrosive nature of the gas. Welding, if used, shall be to the relevant British Standard or
equivalent for pipework conveying corrosive liquids under pressure. Suitable isolating valves
and couplings shall be provided to each major item of plant to facilitate removal for
maintenance. Pressure testing of the pipework and valves shall be carried out by the
contractor to the approval of the Engineer, and shall comply with the relevant British
Standard or equivalent.
Each header shall be suitable for connecting two chlorine drums of capacity one ton each.
19.2.7
Automatic Cylinder Change-Over Module
Where specified in the Contract the Contractor shall supply and erect an automatic
changeover panel which will change from duty gas supply to standby in the event of low
pressure on the duty supply. The changeover panel shall include duty/standby indication,
bottle change required, and the pressure of gas in the duty cylinder.
The changeover panel shall be mechanically operated and be complete with pressure
reducing valves to prevent re-liquification of the gas and changeover valve block heater.
The line between the changeover panel and the gas feeder incorporate individual failsafe
vacuum gas regulator valves.
The automatic change-over module shall not permit a return to the initial source until the
secondary source is exhausted.
The Contractor shall also supply a remote vacuum controller for each cylinder on duty to
shut-down the cylinder on indication of loss of vacuum.
19.2.8
Automatic Isolation Valve
The discharge from drums shall be protected by an automatic isolation valve system. The
system shall either be a proprietary system, or it shall comply with the following Clauses.
The automatic control of the isolation valve system shall be from the gas leak detection
equipment.
For gas leak testing purposes, a remotely mounted manual opening facility shall be provided
for each isolation valve. These shall be spring return push buttons with engraved labels
"Press and Hold to Open Drum No 1 (No 2) Valve" and shall be incorporated into a
shutdown control panel (mounted in a safe area) with the following features.
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(a)
Lamp (Green)-Drum No 1 Valve Open
(b)
Lamp (Green)-Drum No 2 Valve Open
(c)
Hand/Off/Auto Selector-Drum No 1 Valve
(d)
Hand/Off/Auto Selector-Drum No 2 Valve
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Part
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(e)
Push Button-Press and Hold to Open Drum No 1 Valve
(f)
Push Button-Press and Hold to Open Drum No 2 Valve
(g)
Push Button-Reset System
Page 6
The isolation valve shall be a two way PTFE taper plug valve suitable for use with dry
chlorine. The body shall be of LCB carbon steel and plug of monel metal.
The automatic isolation valve shall be a spring return, giving fail safe operation in the event
of loss of air supply.
The Contractor shall be responsible for the air supply to the valve. The supply line shall
incorporate a moisture trap and drain located as near as possible to the electrically operated
solenoid valves to be used for isolation valve control.
The solenoid valves shall operate from a 110 volt 50 Hz electricity supply and shall be
mounted outside the control box. Valve terminal enclosures shall be fully shrouded and
fitted with a propriety cable compression gland. Final connection to these valves shall be via
short lengths of flexible multicore cable from an adjacent termination box.
The air supply to the automatic isolation valves shall be suitably rated nylon tubing supported
in 25mm PVC conduit.
A sufficient length of tubing shall be provided adjacent to the automatic isolation valve in
order to facilitate maintenance and valve height adjustment.
10
The connections to the automatic isolation valves shall be 2 No special elbows with a 3/4"
BSP female rotary union for connection to the existing drum valve and a 3/4" BSP male taper
for connection to the isolation valve are required for this purpose.
11
A 3/4" male/male nipple shall be provided on the upstream side of the isolation valve for
connection to the gas header pipework system.
12
The pneumatically operated isolation valves shall be supported in a manner which facilitates
adjustment in three planes to relieve the pipework connections adjacent to the valve of the
weight of the valve and actuator.
13
The Contractor shall supply and install a robust tubular guard rail to protect the vulnerable
valve and pipework arrangement on the discharge side of the drum from swinging drums.
14
The framework shall be fabricated in mild steel tubular sections and painted in accordance
with Section 8 Part 8 the Specification.
15
The frame floor anchor plates and holding down bolts shall be designed to withstand an
impact from a swinging chlorine drum.
16
The guard railing may be utilised for the support of the automatic isolation valves.
19.2.9
Chlorine Gas Header
The Contractor shall provide a suitable manifold and header system to convey gas from the
cylinders via the changeover panel to the associated gas feeder.
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Page 7
The pipework shall include flexible connectors, isolating valves, interceptor traps, gas filters
and all necessary mild steel pipework.
Each header shall be complete with electric heater. The heater shall be of suitable power to
prevent the freezing of chlorine gas when its flow rate through the header is maximum.
On drum chlorine systems, a combined liquid trap and gas filter shall be provided complete
with a self-regulating heater.
Pipework and valves shall be designed and constructed to withstand the pressure and
corrosive nature of the gas. Welding, if used, shall be to the relevant British Standard or
equivalent for pipework conveying corrosive liquids under pressure. Suitable isolating valves
and couplings shall be provided to each major item of plant to facilitate removal for
maintenance. Pressure testing of the pipework and valves shall be carried out by the
contractor to the approval of the Engineer, and shall comply with the relevant British
Standard or equivalent.
Each header shall be suitable for connecting two chlorine drums of capacity one ton each.
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19.2.10 Gas Feeder
Chlorine shall be dosed via duty/standby gas feeders, of the all vacuum/remote ejector
principle.
The gas feeder shall dose gas automatically in proportion to flow, chlorine levels, super or
residual whichever may be applicable.
Gas feeders shall be located such that access for maintenance is unobstructed. Rear
access is acceptable providing a minimum of 1 metre free space is available for egress in
emergencies.
The gas feeder shall incorporate the following features:
High Level Vent - in the event of gas vent, gas shall be directed to a high level external
non-hazardous area.
(b)
Positive Gas Shut Off - in the event of loss of vacuum, gas shall be prevented from
entering the system.
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(c)
Vacuum Gauge - indicating system vacuum state.
(d)
Flowmeter - indicating as flow thorough feeder.
Microprocessor based process controllers shall provide automatic control, changeover

monitoring and transmission facilities for disinfection control. The unit shall not be
susceptible to memory corruption during normal electrical supply transients and shall be
protected by a stabilised power supply.
The unit shall provide a continuous display of the actual chlorine residual and also indicate
set residual parameters on demand. A separate readout shall also be provided to give
operational data including alarm settings etc.
Each unit shall be provided complete with its own residual signal transmitter.
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Page 8
An integral printer shall provide the following status data on its respective system, on
demand or at pre set intervals.
(a)
Date
(b)
Time
(c)
Residual chlorine levels
(d)
Water Flow
(e)
Gas Flow
(f)
Alarm Conditions (high and low residual)
In addition a 4-20 mA analogue signal shall be provided to drive a pen of a three pen
recorder (the two other pens being driven from the two other controllers associated with its
respective pumping system). The pen recorder shall be a 7 day circular recorder and each
pen shall be arranged to operate at different radii despite have similar residual chlorine
levels. The recorder shall be wall mounted adjacent to the chlorination equipment.
10
The residual chlorine of the effluent shall be measured, indicated and controlled. It is
required to supply and erect two chlorine residual sampling, measuring and controlling units,
one as stand-by. Each unit shall be mounted with the chlorinator in one panel.
11
The residual chlorine measuring unit shall be of the amperometric type with suitable bimetallic electrodes to measure free available residual chlorine.
12
The electrodes shall be continuously cleaned by a suitable mechanical means. The

electrodes shall be stationary and not to be allowed to move during the continuous cleaning
operation.
13
The measuring cell shall be designed to measure free available chlorine. The signal
generated in the measuring cell shall be fed to the recorder for recording. The measuring
cell assembly contain equipment for regulating the pressure, flow and pH of the sample
water before being passed through it.
14
The instrument shall include control components to provide automatic control of residual
chlorine by adjusting the feed rate of chlorinators.
15
The sampling and measuring components shall be complete with all necessary pipe work,
sampling pumps, valves and fittings.
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19.2.11 Residual Chlorine Recorders

1
The measured values of residual chlorine shall be automatically recorded by residual

chlorine recorders. It is required to supply two recorders (one as stand-by).
The recorders shall be of the servo type which receive the residual chlorine signals from the
residual measuring unit.
These signals shall be current proportional to the residual chlorine. The current shall then be
indicated and recorded by the conventional self-balancing amperometric recorder head on a
suitable diameter weekly inkless (pressure sensitive) chart.
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The recorder shall have the same range for residual chlorine as the residual measuring
apparatus, which is from 0 to 2.0 mg/lit.
The reading of residual chlorine shall be transferred to the chlorine apparatus.
19.2.12 Chlorine Consumption and Recording Apparatus

1
Duty and standby continuous measurement and totalising chlorine consumption measuring
and recording apparatus shall be provided.
19.2.13 Analyser Cells

Sampling point shall be selected by the Contractor and agreed with the Engineer. The
Contractor shall include in his supply individual analyser cells. These units shall be supplied
with buffer pump and container together with pressure switches and sample/by pass
facilities.
The filter shall be mounted outside the unit in a convenient location and in a way which does
not require dismantling of the access cover.
Sufficient buffer solution shall be provided for preliminary testing and tests before
completion.
The system shall provide for triple validation of the analyser cells and supply lines.
Residual Chlorine analyzers shall be used to monitor the amount of free residual chlorine in
final effluent/irrigation water. Each residual chlorine analyzer system shall comprise of a
sensor, transmitter, buffer solution and other accessories. The analyzer should be provided
with a flow regulating/isolation valve, sample flow indicator (VA type) Y strainer and
associated pipework, skid mounted and installed in a GRP enclosure. The analyzer shall
have a maximum response time of ten seconds for step change of 90%.
Transmitter shall comprise 3 digits LCD, have a measurement accuracy of 2%. These
shall be fields selectable from 0-0.5 to 0-20 mg/l. complete width. Automatic compensation
for temperature. They shall have an isolated 4-20 mA d.c. output, and be suitable for surface
mounting or digital signal if a data bus is specified. The enclosure shall be protected to IP66.
The sensor shall be of the Amperometric type sensor with flow through installation, and be
complete width with an internal temperature sensor for automatic compensation. The sensor
shall be complete with bottle of buffer solution and interconnecting cable.
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19.2.14 Gas Leak Detection Equipment

1
Drum stores, bottle stores and chlorinator rooms shall be provided with a gas sensing alarm
system.
Each store/room shall be provided with sensors mounted in positions to achieve maximum
effectiveness with chlorine sensors mounted at a low level. Multiple sensors shall be
provided in larger stores/rooms where single sensor may not effectively sense all leaks.
Alarm control panels shall be mounted in a safe area outside the rooms, and shall operate
via an integral battery back up system. Where available, the system may be powered from a
central uninterruptable Power Supply (UPS) system.
QCS 2014
Page 10
(b)
Warning lamps or LED's for each gas sensor to indicate:
(c)
1st stage leak at 3.0 mg/l
(d)
2nd stage leak at 10.0 mg/l
(e)
Alarm/control contacts for:
(f)
Controlling Drum Shutdown Systems (where applicable)
(g)
Controlling Ventilation Fans
(h)
Controlling Door Access Warning Lamps
(i)
Signalling to Central Control Room or SCADA System
(j)
Signalling to a Site Telemetry Outstation
(k)
Instrument fault lamp or LED and warning contact.
(l)
Audible/visual warning device.
(m)
Power 'ON' or instrument 'HEALTHY' lamp or LED.
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Meter displaying the concentration of the gas leak in mg/l.
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(a)
Alarm control panels shall incorporate:
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Part
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The automatic Chlorine drum change-over system shall be arranged to change from the duty
drum to the standby drum when the 1st stage leak level of 3.0 mg/l is reached. Further drum
change-over shall be inhibited until the system is manually reset.
Chlorine drums shall be automatically isolated when the 2nd stage leak level of 10 mg/l is
reached and the evaporators shall continue operating until the gas pressure reduced to zero.
Once isolated, drums shall remain isolated until the system is reset and the drum automatic
isolation valves manually re-opened. Operation of the automatic isolation system shall
initiate a works shut down.
Ventilation fans in the affected room shall automatically be switched ON when the 1st stage
leak level of 3.0 mg/l is reached. Ventilation fans in the affected room shall automatically be
switched OFF when the 2nd stage leak level of 10.0 mg/l is reached. If the leak level falls
below the 1st stage leak level, the ventilation fans shall continue to run on for 10 minutes
before stopping.
Each access door to stores or rooms shall be provided with warning lamps to permit or
prohibit entry. A green lamp shall indicate that it is safe to enter, at leak levels below the 3.0
mg/l threshold: A red lamp shall indicate that a 1st or 2nd stage leak has been detected.
Each lamp box colour shall be provided with a minimum of two lamps so that a single lamp
failure does not render the indication in-operative.
Each building containing a store or room shall be provided with an external flashing/rotating
beacon coloured RED and an audible warning device. The audible device shall produce an
output of 106dB(A) at 1 metre and shall remain sounding until such time as the alarm is
accepted/cancelled, and it shall self cancel after 5 minutes. The flashing/rotating beacon
shall remain operational whilst 1st or 2nd stage leak persists.
10
The location of the external flashing/rotating beacon shall be such that it is readily visible to
persons entering the site via the main access route.
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19.2.15 Drum and Cylinders Handling

The Contractor shall provide a travelling crane complying with Part 7 of this Section 9 as
stated in the Particular Specification.
Drums shall be moved using a roller system. Each roller shall comprise a set of four
trunnions which shall be used as a method of positioning the outlet valves of the drums and
also for spacing and supporting the drums. The trunnions shall be fixed to steel I-beams,
which shall be fixed rigidly to the floor of store.
Cylinders shall be set in racks and provided with positive restraint clamps. These clamps
shall be either profile clamps or chain restraints which prevent movement of the cylinders
from the stored position.
The handling system shall be designed so that it is not possible to pass a hoisted drum over
a drum in use.
The Contractor shall supply one weighing balance for weighing of the chlorine cylinders.
The balance shall be of the spring type with three (3) tons measuring capacity.
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19.2.16 Pipework
The Contractor shall provide and install all pipework and valves etc. necessary for the
complete installation for the chlorination equipment system.
2 Pipework shall be provided with the necessary valves, bends, tees and unions for easy
dismantling. Pipework materials should be provided in accordance with the chlorination
equipment manufacturers recommendations and shall comply with international industry
standards. Typically uPVC pipe will be used for water and chlorinated water and carbon
steel for liquid chlorine.
3 All pipework shall be neatly laid and securely fixed in position. Similarly all valves shall be
securely fixed, clearly numbered and labelled in accordance with the operating instructions.
4 Pipework shall be clean, dry and free from oil and grease and shall not be cleaned with
organic solvents.
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19.2.17 Ventilation
1
Drum stores, bottle stores, and chlorinator rooms shall all be provided with forced ventilation
systems, design to produce at least 6 volume changes of air per hour, and arranged to
provide a negative pressure within the rooms.
Automatic control of the extract fans shall be from the gas leak detection equipment.
Manual control of the fans shall be provided from a safe area outside the rooms. Manual
control shall be available regardless of the action of the gas leak detection equipment. The
manual control shall be arranged so that it is not possible for ventilation fans to be turned off
when the automatic system is calling for the fans to be turned on.
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Extract grills and fans shall be positioned at a low level with the fan exhaust arranged to
discharge the vented gas away from pedestrian walkways and roadways. If necessary,
ducting to a point above building eaves level shall be provided to achieve this, subject to
Intake grills shall be positioned at a high level and arranged so that the entire contents of the
room are fully replenished with fresh air when the extract fans are running.
19.2.18 Emergency Breathing Apparatus and Air Compressor

The Contractor shall supply Masks with air bottles (cylinders) to allow for working in
contaminated air for 30 minutes. Their size shall be according to requirements of personnel
dealing with chlorine gas. They shall be stored in cupboard.
The Contractor shall supply a motor driven portable air compressor. The compressor shall
be mounted on a carriage with 2 pneumatic tyred wheels and handles for trailing. Also it
shall be provided with an air reservoir of ample capacity. The set (air compressor and air
reservoir) shall be complete with safety valves, pressure gauges, valves, piping and
necessary safety devices.
The air intake shall be from the free atmospheric air.
The compressor shall be provided with suitable connection to allow for filling the air bottles
(cylinders) of the masks. The compressed air must be free of any lubricating oil traces.
The capacity of compressor shall be enough to fill the air bottle of the mask-up to its working
pressure in 5 minutes.
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The Contractor shall provide and fix engraved labels with white lettering 20mm high on a
Red background. Externally mounted labels shall be provided with a stainless steel
backplate for added support. The labels shall be:
(a)
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19.2.19 Warning and Safety Notices
External to the gas store:
WARNING:
CHLORINE AND SULPHUR DIOXIDE STORE
DO NOT ENTER WHEN WARNING LIGHT
AND ALARM IS ON
(b)
Internal to the Gas Store, in a prominent location:

WARNING
IF ALARM SOUNDS ALL
PERSONNEL MUST VACATE
THIS DRUM STORE
The Contractor shall display first aid advice in Arabic & English and protective clothing for
personnel who deal with chlorine equipment. As a minimum notices shall say:
Chlorine is a highly irritating gas immediately affecting the eyes, nose, throat and chest.
Anyone so affected must be removed to fresh air and medical treatment sought.
Warning lamps with alarm to be provided at the entry to the evaporator room and chlorinator
room for alerting the personnel in case of a gas leak. Lamps shall indicated
QCS 2014

Part
19: Chlorination
Page 13
Red > 9 ppm chlorine

Yellow >3 - 9 ppm chlorine
Green < 3 ppm chlorine
ON SITE GENERATION OF CHLORINE
19.3.1
General
Sodium hypochlorite generation, batching, dosing and dechlorination shall be automatically

controlled. The Transformer/Rectifier and control panel shall be located in a separate room
from the electrolyser and hypochlorite storage tanks where mounted internally. The location of
plant within the generation room shall take into account local zoning restrictions.
Generation rooms shall be provided with either one full wall free air ventilator or automatic
forced extract air systems. High level ventilators shall be provided.
19.3.2
Salt Saturators
Salt saturators shall be provided for the storage of fully saturated salt solution (brine). The total
storage capacity shall be not less than 1 months consumption at maximum works output. The
salt saturators shall be approved with regard to FDA Regulations for use of non-toxic materials.
The saturators shall be rated for the peak salt consumption requirement of overnight generation
of sodium hypochlorite and incorporate an internal suction discharge limiter to prevent tracking
of partially saturated salt solution. The units shall be supplied and installed complete with the
filter bed gravel and first salt fill on foundations prepared by the Civil Contractor to the
Contractors requirements. The saturators shall be suitable for outdoor use.
The saturators shall include
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19.3
Inlet and Outlet connection manifolds.
(b)
Tanker charging connection and manifold.
(c)
Overflow to drain.
Vent pipe complete with dust arrester
Upper and lower level manway inspection points.
(e)
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(d)
(a)
(f)
Shrouded inlet float valve.
(g)
Surrounding bund of not less than 110% of the Saturator Volume.
(h)
Visual indication of salt level
19.3.3
Brine Feed
Brine feed through the electrolyser to the hypochlorite storage tank shall be provided on a
duty/standby basis. Fixed speed, manually adjustable stroke pumps shall be suitable for this
application.
The feed line shall be fitted with a flow monitor and a sampling point for brine testing. The
contract shall include a brineometer for this purpose.
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Part
19: Chlorination
Page 14
Electrolyser
Rating of the electrolysers shall be dependant on the requirement for generation of sodium
hypochlorite during the off peak period. Multiple electrolysers shall be provided to achieve the
required capacity. Standby shall be provided by either one spare unit or 25% of the capacity
which ever is the greater, held in store at the site.
The anode/cathode is a consumable item within the generation package. Manufacturers offer a
five year guarantee with regard to life consumed during a five year cycle of operation. The
Contractor shall transfer this guarantee to the Purchaser which shall become effective from the
date of the Take-Over. The Contractor shall therefore ensure that the current density value is
commensurate with a five year cycle of operation.
The electrolysers shall be rack mounted such that access to all connections is within view of
maintenance staff. Disconnection and replacement shall be possible without associated
pipework disturbance.
Hydrogen release from the electrolysers shall be manifolded for transportation with the sodium
hypochlorite for high level discharge in the hypochlorite storage tank. The sodium hypochlorite
feed line shall incorporate a flow switch, for process shut-down in the event of low flow, a
temperature switch for over temperature shut down of the process and a sample point for
sodium hypochlorite sampling.
Any equipment which is in the defined Potentially Explosive Atmosphere shall be selected in
The water feed to the electrolyser shall be 'softened' as required via duty/standby water
softeners with automatic changeover.
A heat exchanger shall be included with the electrolyser to transfer heat generated in the
product to the incoming diluted brine solution in order to maximise the overall efficiency of the
unit. Where this may not be sufficient, pre-heating with an electric immersion heater shall be
provided.
19.3.5
Sodium Hypochlorite Storage
The sodium hypochlorite storage tanks shall be provided on a duplicate basis. The capacity
shall be sufficient for 48 hours consumption at the maximum works output. The tank shall be
suitable for external application and shall include forced ventilation for hydrogen dispersion.
The tank(s) shall be installed in bund(s) of not less than 110% of the tank volume.
Duty/Standby ventilation fans shall be provided to supply air into the storage tank for high level
discharge with dispersed hydrogen from the gaseous space above the stored liquid. Flow
sensors shall monitor fan operation and shut down the generation process in the event of low
flow detection.
19.3.6
Sodium Hypochlorite Dosing
Dosing of sodium hypochlorite shall be via duty/standby dosing pumps. Control of the pumps
shall be related to the flowrate through the works chlorine disinfection requirements, and
residual requirements.
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19.3.4
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Part
19: Chlorination
Page 15
Overall control of the whole system shall be by means of a programmable logic controller (PLC)
which shall be configured so that failure of the PLC shall not result in danger to personnel or
equipment.
19.3.7
Pipework
All pipework fittings and valves associated with the generation equipment shall be rigidly fixed
and supported, pipe routes over floor areas shall be adequately protected against accidental
damage.
19.3.8
Electrical Installation
The electrical installation shall be in accordance with Section 21 of this specification.
19.3.9
Transformer / Rectifier
A duty transformer/rectifier shall provide low voltage DC for the electrolyser. The unit shall be
free standing, the input shall be 415V, 3ph, a.c., output should not be greater than 24V dc with
full wave rectification.
The unit be in accordance with the specification Section 21 and be capable of operation in
ambient temperatures up to 500C. Cooling shall be via natural convection ventilation.
The rectifier shall include:A dc voltmeter
(b)
A dc Ammeter
(c)
A dc Centre zero voltmeter
(d)
Lockable input isolator
(e)
Main input contactor
(f)
On/Off push buttons
(g)
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Hand/Off/Auto selector
Current level setting
(h)
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(a)
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(i)
Mains "on" lamp
(j)
DC "live" lamp
(k)
Hours run meter
All status and alarms shall be provided at the signals and alarms marshalling box.

1
A control panel shall be mounted adjacent to the Transformer/Rectifier to provide overall system
control. The panel shall be in accordance with Section 21 - Factory Built Assemblies of
Switchgear and Control Gear.
The Panel shall include indication and control equipment for the process.
In particular the following alarms shall be provided locally and at the signals and alarms
marshalling box:-
QCS 2014

Part
19: Chlorination
(a)
Improper voltage
(b)
Rectifier failure
(c)
Protection voltage failure
(d)
Storage tank low level
(e)
Low/high electrolyte temperature
(f)
Low electrolyte level
(g)
Low air flow
(h)
Bund flood
(i)
Low water flow
Page 16
ANALYSERS
Residual Chlorine analyzers are used to monitor the amount of free residual chlorine in final
effluent/irrigation water. Each residual Chlorine analyzer system comprises of a sensor,
transmitter, buffer solution and other accessories. The analyzer should be provided with a flow
regulating/isolation valve, sample flow indicator (VA type) Y strainer and associated pipework,
skid mounted and installed in a GRP enclosure. The analyzer shall have a maximum response
time of ten seconds for step change of 90%.
Transmitter shall comprise 3 digits LCD, have a measurement accuracy of 2%. These shall
be fields selectable from 0-0.5 to 0-20 mg/l. complete width. Automatic compensation for
temperature. They shall have an isolated 4-20 mA d.c. output, and be suitable for surface
mounting. The enclosure shall be protected to IP66.
The sensor shall be of the Amperometric type sensor with flow through installation, and be
complete width with an internal temperature sensor for automatic compensation. The sensor
shall be complete with bottle of buffer solution and interconnecting cable.
19.5
NEUTRALISATION SYSTEMS
19.5.1
General
The neutralisation system shall include the following:
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19.4
(a)
Neutralisation tower.
(b)
Circulating pumping units.
(c)
Air exhaust system.
(d)
Caustic soda ash enough for two (2) times use.
(e)
Necessary pipes, fittings, valves.
(f)
Necessary electric connections.
When the concentration of the chlorine gas in the air reaches four (4) mg/lit, by volume, the
chlorine leak detectors shall operate the neutralization system.
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Part
19: Chlorination
Page 17
Caustic soda solution prepared at the bottom part of the neutralization tower shall be sucked by
the pumps and delivered to the spraying nozzles at the top of the tower. In the same time
contaminated air shall be delivered to the lower part of the tower by the extraction fans. Contact
shall happen, between the contaminated air and the caustic soda solution, through the contact
rings and the neutralized solution shall be collected back at the bottom of the tank. The process
shall continue until the concentration of the chlorine gas in air becomes normal. The neutralized
solution shall be drained out from the lower part of the tower and another volume shall be
prepared to be ready for emergency cases.
19.5.2
Neutralisation Tower
The tower shall be made from reinforced fibre glass. The neutralizing solution shall be prepared
at the bottom of the tower by using of caustic soda ash. In the upper part of the tank, the
spraying system with its nozzles shall be installed.
Porcelain or P.V.C. rings shall be placed on certain brackets inside the tower for increasing the
contact area between the contaminated air and the sprayed neutralization solution.
19.5.3
Circulating Pumping Units
One duty and one stand-by pump shall be used to circulate, the neutralization solution from the
bottom of the tower to the spraying installations.
The pumps shall be of discharge and head to suit the supplied installations.
The pumps shall be manufactured from suitable materials to withstand the corrosion action of
the handled media.
19.5.4
Pipework and Electrical Connections
The price of neutralization system shall include all air ducts, caustic soda pumps, pipes and
electric connections required. Air ducts shall be of uPVC complete with necessary valves and
fittings.
The caustic soda pump suction and delivery pipes including valves and fittings shall be of PVC.
19.6
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END OF PART
QCS 2014

Part
02: Submersible Pumps
Page 1
SUBMERSIBLE PUMPS................................................................................ 2
2.1
GENERAL ...................................................................................................... 2
2.1.1
2.1.2
2.1.3
Scope
References
Submittals
2.2
PRODUCTS ................................................................................................... 3
2.2.1
2.2.2
2.2.3
2.2.4
2.2.5
2.2.6
2.2.7
General
Design Conditions
Materials
Fabrication
Accessories
Factory Inspection and Testing
Spare Parts and Tools
2.3
2.3.1
2.3.2
General
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2
2
3
4
5
5
8
8
9
9
9
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Part
Page 2
SUBMERSIBLE PUMPS
2.1
GENERAL
2.1.1
Scope
This Part specifies this requirements for the design manufacture, construction, installation,
testing and commissioning of submersible pumps, designed to handle raw unscreened
sewage with a non-clog type impeller, complete and ready for operation as shown on the
Drawings and as specified herein.
Pumps may be used for applications other than sewage, in which case they shall be modified
accordingly.

General
Section 1,
Section 8,
Section 10,
Section 21,
General
Sewerage
Electrical Works
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This Section
Part 1,
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References
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2.1.2
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BS 970, (ISO 683) ......Wrought steels for mechanical and allied engineering purposes
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BS 1400,.....................Copper alloy ingots and copper alloy and high conductivity copper
coatings
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BS 3468, (ISO 2892) ..Austenitic cast iron

BS 4999,.....................General requirements for rotating electrical machines
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BS 5345,.....................Codes of practice for the selection, installation and maintenance of

electrical apparatus for use in potentially explosive atmospheres
BS 5512, (ISO 281) ....Methods of calculating dynamic load ratings and rating life of rolling
bearings
BS 6007, (IEC 245) ....Rubber insulated cables for electric power and lighting
BS 6105, (ISO 3506) ..Corrosion-resistant stainless steel fasteners
BS 6861, (ISO 1940) Balance quality of requirements of rigid rotors
BS 7671,.....................Requirements for electrical installations
BS EN 1092,...............Circular flanges for pipes, valves and fittings
BS EN 1561, (ISO 185) Flake graphite cast iron
BS EN ISO 9906 Grades 1, 2 and 3 Acceptance tests for centrifugal mixed flow and axial
flow centrifugal pumps Part 1 Class C tests
ISO 10816 Part 1 & Part 7, Mechanical vibration in rotating and reciprocating machinery
2.1.3
Submittals
In addition to the requirements of Part 1 of this Section the Contractor shall provide data and
information described in the following paragraphs
Design Data
QCS 2014
(a)
Page 3
the Contractor shall provide manufacturers published pump curves, system curves
and the necessary hydraulic calculations to justify the sizes of any pumps selected.
Shop Drawings
impeller diameter
(ii)
maximum impeller diameter
(iii)
minimum impeller diameter
(iv)
velocity of liquid in pump suction at duty point
(v)
velocity of liquid in pump delivery at duty point
(vi)
velocity of liquid in the pump casing or impeller eye at duty point
(vii)
net positive suction head (dry well submersibles only)
(viii)
the materials of construction shall be specified in detail and itemised against a

sectional drawing of the pump proposed.
(ix)
characteristic curves for the full range of impeller diameters.
(i)
after approval of the pump types the Contractor shall submit the test data as required
under factory inspection and testing
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(b)
the Contractor shall provide the following:
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Part
Operation and Maintenance Manuals and Instructions. The Contractor shall include all the
documentation provided as above and as required in Part 1.
2.2
PRODUCTS
2.2.1
General
Pumps and drives shall be rated for continuous duty and shall be capable of pumping the
flow range specified in the Project Specification without surging, cavitation, or excessive
vibration to the limits specified. All pumps and drives shall be from approved manufacturers.
The pumps shall meet maximum allowable shut-off head, and if dry-mounted submersibles,
the maximum allowable required net positive suction head (NPSH) designated in the Project
Specification.
The pumps shall not overload the motors for any point on the maximum pump speed
performance characteristic curve and the pump operating range, within the limits of stable
pump operation, as recommended by the manufacturer, to prevent surging, cavitation, and
vibration.
To ensure vibration-free operation, all rotative components of each pumping unit shall be
statically and dynamically balanced to BS 6861 and the following requirements shall be met:
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(a)
the mass of the unit and its distribution shall be such that resonance at normal
operating speeds is within acceptable limits
(b)
in any case, the amplitude of vibration as measured at any point on the pumping unit
shall not exceed the below limits
(c)
at any operating speed, the ratio of rotative speed to the critical speed of a unit, or
components thereof, shall be less than 0.8 or more than 1.3.
Vibration outside the limits specified in 2.2.2.8 shall be sufficient cause for rejection of the
equipment.
The completed units, when assembled and operating, shall be free of cavitation, vibration,
noise, and oil or water leaks over the range of operation.
QCS 2014

Part
Page 4
All units shall be so constructed that dismantling and repairing can be accomplished without
difficulty.
The Contractor shall be responsible for proper operation of the complete pumping system,
which includes the pump, motor, variable speed drive unit (if designated), and associated
controls furnished with the pump.
The Contractor shall ensure that the controls and starting equipment are suitable for use with
the pump motor, taking into account all requirements including starting currents and number
of starts per hour.
10
For the performance curve of the selected pump impeller, the head shall continuously rise as
flow decreases throughout the entire curve from run out to shutoff head.
11
The Contractor shall ensure that drive motors, variable speed drive systems (if designated)
and pumps shall be supplied and tested together by the pump manufacturer, who shall
supply full certification for the proper function of the entire pumping system.
12
If variable speed drive systems are specified, motor and drive system shall be fully
compatible, and shall be of sufficient power and torque, and be capable of sufficient heat
transfer for starting, accelerating and continuously operating over the entire range of
head/capacity conditions, from minimum to maximum pump operating speed, as designated.
The motor shall be derated to take into consideration the reduced cooling effect when
running at the lowest speed with the variable speed drive.
2.2.2
Design Conditions
Pumps shall be designed and constructed to satisfactorily operate and perform within the
designated design conditions and the requirements specified herein. They shall be designed
for a life of 100,000 hours with service intervals at 20,000 hours.
Castings, fabrications, machined parts and drives shall conform to the industry standards for
strength and durability and shall be rated for continuous duty over the entire operating range.
Bearings shall be of the anti-friction type designed for an L10 life of at least 50, 000 hours in
Pump maximum operating speed shall not exceed 1500 rpm.
Pumps shall be designed to pass all suspended solids up to 100mm diameter, including
stringy matter, rags, paper, plastics, etc. without choking except in the case of pumps
delivering into a 100mm diameter rising main where the capability shall be 80mm diameter.
Pumps shall be suitable for use in the conditions specified in Section 1.
Renewable impeller wear rings shall be fitted, to the impeller and case, except where not
available on a standard production unit.
Vibration levels shall not exceed the levels given in ISO 10816 Part 1 and Part 7, quality
bands A and B.
Submersible pumps shall have the duckfoot bends flanged to BS EN 1092 PN16. In the
case of dry mounted submersible pump the outlet and inlet shall be flanged to BS EN 1092
PN16.
10
The pump, motor and associated electrical equipment shall be rated for a minimum 10 starts
per hour, unless otherwise designated.
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QCS 2014
11

Part
Page 5
The Contractor shall ensure that the pump manufacturer provides certification which
guarantees the following:
(a)
flow rate
(b)
total head
(c)
power input
(d)
efficiency
2.2.3
Materials
Pumps shall be manufactured of the following materials as a minimum:
(b)
impellers shall be duplex stainless steel
(c)
casing wear rings (where fitted) shall be brass BS 1400 or for abrasive
(d)
applications nitrile-rubber clad steel or to the approved manufacturers standard
(e)
impeller wear rings shall be stainless steel BS 970 316 S31
(f)
bends shall be cast iron, BS 1452 Grade 250
(g)
motor casings shall be cast iron, grade 250 or SS316 S31
(h)
shafts shall be stainless steel, Grade 316 S31 to BS 970 Part 1
(i)
fasteners shall be stainless steel Grade 316S31 to BS970-1.
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volute casings shall be cast iron, BS EN 1561 Grade 250
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The lifting system shall be manufactured of the following materials:

the guide rail system shall be stainless steel, BS 970 Type 316 S31
(b)
lifting chains, rings, hooks and shackles shall be stainless steel BS970 Grade 316
S31.
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(a)
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(a)
Fabrication
General. Pumps shall be fabricated in accordance with the following requirements:

(a)
pump shall be capable of handling raw, unscreened sewage

in the case of submersible installations no portion of the pump shall bear directly on
the floor of the wet well. In the case of dry mounted pumps a substantial purpose
built mounting frame shall be provided by the pump manufacturer
(b)
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2.2.4
(c)
pressure gauge taps and air bleed taps shall be provided as stated under accessories
(d)
all castings shall be produced in accordance with the pump manufacturers

specifications under the manufacturers direct supervision
(e)
pumps shall be designed with dual mechanical seals, as below
Wet well pumps shall incorporate the following features:

(a)
pumps shall utilise a guide system to permit easy removal and reinstallation
without dewatering the pump sump
(b)
discharge connections shall be made automatically with a simple downward

motion without rotation when the pump is lowered into operating position. The pump
shall be capable of being removed without disconnecting any fasteners
QCS 2014
(c)
Page 6
an appropriate length of chain shall be connected to the motor eyebolts to permit

raising and lowering of the pump. The lifting chains shall be fitted with suitable
additional rings in order that the pumps can be lifted in stages from the sump invert
level using the lifting gear. An additional hook and chain permanently fixed to the
bottom of the lifting equipment to support the weight of the pump set during lifting
operations shall be provided.
Impeller. Impellers shall be fabricated according to the rated motor size as follows:
(a)
non-clog type statically and dynamically balanced, keyed to the shaft
(b)
provided with pump-out vanes to prevent material from getting behind the impeller
and into mechanical seal area
(c)
provided with wear ring as necessary to assure efficient sealing between volute
and impeller
(d)
impellers shall not be trimmed unless approved by the Engineer
(e)
single/multi vane or vortex type, with a cutter impeller in the case of small flows.
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Discharge Connection and Guide Rails. Sliding guide bracket and discharge connections
shall be provided which, when bolted to the floor of the sump and to the discharge line, will
receive the pump discharge connecting flange without need of adjustment, fasteners, clamp,
or similar devices. The guide rails shall not support any portion of the weight of the pump.
The pump discharge connections shall incorporate a sealing face and connection yoke to
allow for automatic coupling to fixed discharge connection pipework. The guide rails shall be
fabricated in stainless steel BS 970 Grade 316 S31.
Pump Shafts:
pump shafts shall be of such diameter that they will not deflect more than 0.05 mm
measured at the mechanical seal, whilst operating at full driver output
(b)
the shaft shall be turned, round and polished
(c)
shaft shall be key-seated for securing the impeller.
the drive motor and pump/motor bearings shall be sealed along the shaft with
tandem mechanical seals operating in an oil filled chamber. The seals shall require
neither routine maintenance or adjustment, but shall be capable of being easily
inspected and replaced.
(a)
Shaft Seals:
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(a)
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(b)
two back to back mechanical seals shall seal the motor off from the pump.
(c)
the upper seal shall be oil lubricated with a carbon rotating component and fixed
tungsten carbide component
(d)
the lower seal shall have both parts in tungsten carbide.
(e)
a detector shall indicate when moisture is leaking past the first seal.
Bearings:
(a)
bearings shall be capable of taking the static weight of the rotating parts and any
thrust generated by the operation of the pump
(b)
the upper bearing(s) shall be of the grease lubricated sealed for life type, the lower
bearing(s) shall be lubricated by the internal oil supply
(c)
the bottom bearing(s) shall be of the angular contact ball bearing type in
combinations with roller bearing(s)
QCS 2014
(d)
Page 7
if required in the project specification, remote indication shall be provided for bearing
high temperature, using a thermistor at the lower bearing, to provide a signal at
95 C.
Motors:
(a)
motors shall be 415 V / 690V or as indicated in project requirements, phase, 50 Hz,

rated at 10 % above the maximum power requirement
(b)
motors shall be squirrel cage, induction, air filled, totally sealed to IP 68, suitable
for the maximum immersion depth likely to be encountered, rated for zone 2 use with
group 1 gases, to BS 5345
(c)
motor insulation shall be Class F, limited to a Class B temperature rise
(d)
motor temperature shall be monitored using a thermistor, in each phase of

the winding, set to stop the motor when the monitored absolute temperature reaches
130 C
(e)
a watertight cable junction box sealed from the motor shall be provided for the motor
power and signalling
(f)
cables shall be EPR insulated, Niplas sheathed, flexible 450/750 volts grade, oil and
grease resistant, with tinned annealed copper conductors in accordance with
BS 6007. The cable shall be brought directly out of the submersible motor without
joints, and shall be of sufficient length, minimum 20 m to be terminated in an IP67
junction box outside adjacent to the wet well. They shall be sized in accordance with
QGEWC regulations and BS 7671
(g)
cables shall be supported using a proprietary sock arrangement at the top of the wet
well
(h)
Pumps shall be provided with proprietary monitoring and control units for inclusion
in the motor controls. Analogue inputs shall include the following:
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Part
winding temperature
(ii)
bearing temperature
(iii)
cooling oil temperature
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(i)
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Digital inputs shall include the following:

high winding temperature
(v)
high bearing temperature
(vi)
loss of coolant oil/seal failure
(vii)
over temperature
(viii)
moisture ingress
(iv)
(i)
Motors shall be capable of start up and operation in the event of a completely

flooded wet well. Motors shall be selected to meet the maximum power required for
the selected impeller at all operating conditions
(j)
Motor cooling shall be an efficient system to the manufacturer's design.
(k)
motors shall be derated for dry well and/or variable speed operation
Coatings and Protection

(a)
Cathodic protection with replaceable sacrificial zinc anodes shall be provided if

required in the Project Specification.
(b)
The cooling jacket shall be stainless steel
(c)
all other parts shall be to the approved manufacturer's standard protection
QCS 2014

Part
2.2.5
Accessories
The following accessories shall be provided for each pump:
Page 8
pressure gauges. The discharge pipework of each pump shall be provided with a
19 mm diameter tapped opening and stainless or brass isolating valves and
diaphragm pressure gauges In the case of dry-mounted submersibles a similar
tapping valve and gauge shall also be provided on the suction pipework of each pump
(b)
air bleed offs. In the case of submersible pumps automatic brass air bleed ball
valves shall be provided on the reflux valves, venting via a 40 mm diameter
stainless steel pipe to the wet well. In the case of dry mounted submersible pumps
these valves shall be provided on the highest point of the volute casing
(c)
labels. Each pump shall have a stainless steel label permanently fixed to the pump
and an identical label fixed to the pump starter compartment.
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(a)
The Contractor shall secure from the pump manufacturer certification that the following
internal inspections and tests have been conducted on each pump at the factory, and submit
to the Engineer prior to FAT witness proposed:
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the pump casing has been tested hydrostatically to 1.5 times the maximum closed
valve pressure
(b)
impeller, motor rating and electrical connections checked for compliance with the
Project Specifications
(c)
motor and cable insulation tested for moisture content or insulation defects
(d)
prior to submergence, the pump has been run dry to establish correct rotation and
mechanical integrity
(e)
the pump has been run for 30 minutes submerged under a minimum of 2 m water
(f)
after the operational test (e) above, the insulation tests (b) above has been
performed again, and after the performance test (2) below
(g)
NPSH (dry well mounted pumps only)
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(a)
Each pump shall tested at the factory for performance according to BS EN ISO 9906 Grades
1, 2 and 3, including:
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2.2.6
(a)
flow
(b)
inlet pressure
(c)
outlet pressure
(d)
motor power
(e)
torque
(f)
efficiency
(g)
Net Positive Suction Head (NPSH) (valid for all type of pumps).
The Contractor shall secure from the pump manufacturer the following certification and
submit to the Engineer prior to shipment:
(a)
certified copies of the pump characteristic curves and reports generated by the tests
described above and as required by BS EN ISO 9906 Grades 1,2 and 3
QCS 2014

Part
Page 9
(b)
foundry composition certificates for all major castings (pump case, impeller, motor
housing) showing exact material composition and tests conducted to ensure
compliance with the pump manufacturers material specifications.
(c)
the lifting chains, rings and shackles shall be load tested and Proof tested compare
with one of the below mentioned applicable codes requirements, and clearly and
permanently tagged with the SWL. Test certificates shall be supplied with Authorised
TPA approval.
Chain (sling and hooks): BS 4942 part 1 and 6 / ISO 2903 / ISO 7595
Shackles: BS 3551 / BS 3032 / BS 6994
Ring and Links: BS 2902
The Contractor shall ensure that the pump manufacturer provides all spares and special tools
required during the commissioning and maintenance periods, and as required below.
In addition to the spare parts required in Part 1 the following spare parts for each pump shall
be furnished to the Employer:
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2.2.7
three sets of complete upper and lower bearings
(b)
three sets of wear rings
(c)
three sets of gaskets and three sets of O rings complete
(d)
three sets of upper and lower mechanical seals
(e)
additional spare parts as recommended by pump manufacturer to cover two years of

operation following the maintenance period.
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(a)
2.3.1
General
The equipment delivered to the Site shall be examined by the Contractor to determine that it
is in good condition and in conformance with the approved working drawings and
certifications. All equipment shall be installed in strict conformance with Part 1 of this Section
and the manufacturers instructions.
2.3.2
If required in the Project Specification, or in the case of submersible pumps rated at 50 kW or

greater, the Contractor shall provide the services of the pump manufacturers representative
to supervise the installation, commissioning and start-up of the pumping equipment.
The commissioning tests shall be performance and reliability trials, mainly for the purpose of
satisfying the Engineer that the pumpsets have been correctly assembled and installed and
that their performance matches that obtained during the manufacturers works tests. In the
event of an unwarranted change in the pump performance characteristics or power
consumption, all necessary steps shall be taken as soon as possible to establish the cause
and remove the fault. Similar action shall be taken for an undue increase in bearing or gland
temperature, increased gland leakage rates, unsatisfactory vibration levels or any other fault
or defect in the operation of the pumpset.
The site reliability trials shall include the following:
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2.3
(a)
a record of bearing and coupling clearance and alignments shall be tabulated to

show the as-built condition of each pump
(b)
a record of all overload, timing relay and oil pressure relays shall be tabulated to
show the as-built condition of each motor starter
QCS 2014

Part
Page 10
(c)
all cables shall be megger tested to confirm the integrity of the insulation.
tabulated record of results shall be made
(d)
the control panel shall be statically tested with motors disconnected to confirm the
correct sequence of operation
(e)
each pump shall be operated individually over the range from closed valve to
maximum emergency top water level, on a recirculation basis, using fresh water, and
for a minimum of four hours continuously. During this test the following parameters
will be recorded:motor phase currents
(ii)
pump output
(iii)
ambient and test water temperatures
(iv)
motor/pump casing temperature
(v)
power consumed
(vi)
power factor
(vii)
vibration
(viii)
signs of cavitation noise
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(i)
the commissioning trials shall extend until each pump unit has run continuously for
at least 3 days under all operating conditions. The term continuously shall include
running at various speeds or on a start/stop basis as determined by the control
system
(g)
the Contractors supervisory staff, and the pump manufacturers representative, if

required by the Project Specification or the above, shall be present during the period
of the tests and trials. The Contractor shall be responsible for any failure of the whole
equipment or any part thereof, whether such failure shall be determined by the
methods detailed herein or otherwise. If the pump test or trial is interrupted by the
Contractor, or through negligence on the part of the Contractors staff, it shall be
completely repeated for the pumpset concerned.
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(f)
END OF PART
QCS 2014

Part
20: Washwater Systems
Page 1
20
WASHWATER SYSTEMS ............................................................................. 2
20.1
GENERAL ...................................................................................................... 2
20.1.1 Scope
20.1.2 References
20.1.3 Submittals
20.2
2
2
2
PRODUCTS ................................................................................................... 2
20.2.1 General
20.2.2 Washwater Booster Set
2
2
TESTING ....................................................................................................... 3
20.4
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20.3
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WASHWATER SYSTEMS
20.1
GENERAL
20.1.1
Scope
of washwater systems.

General
Drainage Works
Electrical Works
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Section 1
Section 8
Section 10
Section 13
Section 21
20
References
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20.1.2
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BS 1123 .....................Safety valves, gauges and fusible plugs for compressed air or inert
gas installation
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BS 5169 .....................Specification for fusion welded steel air receivers
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PD 5500 ....................Specification for unfired fusion welded pressure vessels
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ISO 10474 ..................Steel & Steel Products Inspection Documents
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Submittals
20.2
PRODUCTS
20.2.1
General
The wash water system shall be capable of delivering a supply of final effluent wash water to
the plant at the rate recommended by the manufacturers of the proprietary equipment plus a
minimum of 6 l/s at 4 bar(g) with any two hydrants open and all process water requirements
being meet simultaneously.
The design shall ensure that the hydrant pressure does not exceed 5 bar.
reducing valves may be utilised for this purpose.
20.2.2
Washwater Booster Set
The wash water system shall comprise a minimum of one duty pump and a standby pump,
pressure vessel with adjustable differential pressure switches, interconnecting pipework and
valves, and a terminal panel. The motor starters and controls shall be part of a FBA. The
pumps shall be provided with a duplex-strainer in the suction piping to prevent any debris
from entering the system.
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20.1.3
Pressure
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The pressure vessel shall be adequately sized to keep the maximum number of pump starts
under the worst conditions to 15 per hour. The pressure vessel shall incorporate a butylrubber diaphragm to contain the water and shall be charged with nitrogen or another
approved inert gas.
The vessel shall be of welded construction and in accordance with the relevant British
Standards or ASME VII Div 1, and shall be complete with all necessary fixtures and fittings
and shall include the following:Inspection manhole single or double bridged, according to size, which shall seat on
pressure.
(b)
Flanged inlet and outlet connections.
(c)
System compound pressure gauge of the diaphragm type.
(d)
Safety valve, to relieve excess air pressure in tank to atmosphere.
(e)
50mm drain connection with valve.
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(a)
The vessel shall be high quality epoxy coated inside and out after all manufacture has been
completed, and shall be suitable for the maximum working pressure required by the process.
The upper dome of the vessel shall be fitted with a suitable spring loaded pressure relief
valve, which shall be arranged to commence to open at 110% of the maximum system
working pressure, and be fully open at 120% of this pressure.
The pressure vessel, which shall be of vertical or horizontal construction, shall be mounted
on a minimum of four mounting feet, to raise the vessel off the base plate a distance of not
less than 300mm.
The vessel shall be fitted with a 150mm diameter pressure gauge, connected such that it
reads the air pressure in the vessel and thereby indicating the pressure in the system.
There shall be provided for the vessel a manually operated air release valve, to enable the
system to be depressurised to atmosphere before the system is drained and to enable the
vessel to be recharged.
Pressure switches shall be robustly constructed and suitable for the arduous duties involved,
and shall be fully adjustable over their working range, together with adjustable differentials.
20.3
TESTING
1 Testing of the vessel to the recommended Code of Practice shall be carried out at the
manufacturers works, and a test certificate shall be issued. The working and test pressures
shall be stamped onto the outside of the vessel such that they are clearly visible.
20.4
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END OF PART
QCS 2014

Part
21: Miscellaneous Equipment
Page 1
21
MISCELLANEOUS EQUIPMENT .................................................................. 2
21.1
GENERAL ...................................................................................................... 2
21.1.1
21.1.2
21.1.3
21.1.4
Scope
References
Submittals
General
21.2
PROGRESSIVE CAVITY PUMPS.................................................................. 2
2
2
2
2
21.2.1 General
21.2.2 Pump Design
21.2.3 Macerator/Muncher
2
2
3
END SUCTION PUMPS ................................................................................. 3
21.3.1
21.3.2
21.3.3
21.3.4
21.3.5
21.3.6
General
Casing
Shaft and Impeller
Gland Plate
Bearings
Pump Performance
21.4
PRESSURE FILTERS AND STRAINERS ...................................................... 5
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21.4.1 Pressure Filters

21.4.2 Basket Strainers
3
4
4
4
5
5
5
6
POLYMER PREPARATION AND DOSING SYSTEMS .................................. 6
21.5.1
21.5.2
21.5.3
21.5.4
General
Wetting and Dispersing Device
Flocculent Storage Tanks
Dosing Pumps
21.6
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21.5
6
7
7
7
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MISCELLANEOUS EQUIPMENT
21.1
GENERAL
21.1.1
Scope
of miscellaneous items of equipment.
References
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21.1.2
General
Drainage Works
Electrical Works
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Section 1
Section 8
Section 10
Section 13
Section 21
21
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BS 970 (ISO 683) ----- Wrought steels for mechanical and allied engineering purposes
BS 3170 ----------------- Specification for flexible couplings for power transmission
BS EN 10084 ----------- Case hardening steels
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Submittals
21.1.4
General
The plant shall be complete with electric motors, starters and switchboards, cabling,
accessories, valves, piping, holding down bolts, lubricators, appendages and connections to
make the plant complete and perfect in every part and detail.
There shall be included all necessary stairs, ladders, platforms etc. to provide permanent,
fixed safe and easy access for the maintenance of every item of plant.
21.2
PROGRESSIVE CAVITY PUMPS
21.2.1
General
Each pump shall be capable of pumping sludge with a dry solids content 50% greater than
the design percentage of solids.
It should be noted that macerators/munchers might be required in certain applications.
The design of the installation shall allow the pump rotor to be removed from the installed
pump body without the need to remove the pump casing from its installation.
21.2.2
Pump Design
The pumps shall be of the horizontal rotary type, for abrasive service provide hard chrome
plated tool steel, for corrosive service provide hard chrome plated SS316 S31 having an
abrasion resistant helical rotor operating in a resilient, synthetic rubber stator, suitable for the
handling of the sludge.
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21.1.3
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The pumps shall be of robust construction throughout suitable for the arduous conditions
involved when pumping sludge, and shall be capable of working for long periods without
requiring maintenance attention.
The rotor speed shall not exceed 400 rpm and provision shall be made for easy inspection of
the rotor.
The pumps may be direct driven or belt driven and the motors shall be mounted beside the
pumps.
The pumps and motor shall be mounted on a robustly constructed baseplate which shall
incorporate, if belt driven, a positive belt tensioning device and shall be arranged such that
access for inspection and maintenance is not unduly restricted or hindered by pipework
connections etc.
For belt driven pumps, the drive between the pump and motor shall be by Vee Belts and
shall be rated such that with half the number of belts broken the remaining belts can transmit
the full driving power required by the pump at maximum duty.
The belt drive and pulleys shall be completely protected by suitable guards easily removable
for inspection.
Each pump shall be supplied with a spring loaded pressure relief valve, the discharge of
which shall be separately piped back to the suction pipework. To allow an increased head
for main clearing purposes the valves shall be arranged to relieve at 45 metres head or at
the maximum head under which the pumps may operate, whichever is the lower.
The pumps shall be arranged with suction on gland and the suction body shall be fitted with
a flushing connection from the wash water system.
10
The Contractor shall provide and install all necessary pipework and valves from wash water
system to the pumps.
11
Calculations for sizing the pumps shall be supplied with the offer and when tested at the
makers works, the pumps shall give results that conform to the said calculations.
21.2.3
Macerator/Muncher
Macerators if required shall be installed upstream of each pump and shall be able to handle
an equivalent flow.
The macerator/muncher shall comprise a slow speed, high torque, parallel shaft grinder.
The macerator/muncher shall ensure that the progressing cavity pumps are protected from
and can adequately cope with the diverse materials likely to be encountered in the sludge.
21.3
END SUCTION PUMPS
21.3.1
General
End suction pumps may be close horizontally coupled to the motor as a single compact unit
or independent of the motor.
The pumps shall be continuously rated and designed for an operating life of 20 years without
major overhaul. Components likely to wear in the course of normal operation shall be
capable of replacement with readily exchangeable components.
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The pump casing and other parts in contact with the liquid shall be suitable for the duties
involved.
Close coupled pumps shall be directly coupled to the drive motor through a rigid coupling
and end thrusts accommodated in the motor bearings. The motor shall be flanged and
spigotted for correct alignment, it shall be fitted with jacking bolts to ease removal.
Independent pumps shall be coupled to the drive motor through a flexible coupling which
shall not be capable of transmitting end thrust to the motor.
The rotating unit must be removable type from the pump casing without disturbing the
suction and delivery piping and the motor. A spacer type flexible coupling shall be used for
power transmission.
21.3.2
Casing
The pump casing shall be of duplex stainless steel and be abrasion resistant, capable of
taking shock loads and incorporate lifting eyes for removal of the pump. It shall be designed
and correctly formed to provide the highest efficiency and absence of turbulence and shall
be flanged and spigotted for correct location and jointing.
Readily replaceable back and front casing wear rings shall be provided, unless otherwise
specified the casing wear rings shall be stainless steel Grade 316 S31 to BS 970 Part 1 and
the wear rings shall be locked to prevent rotation by dowels or other similar approved
method.
The pump casing shall be complete with integrally cast feet and lifting points.
21.3.3
Shaft and Impeller
The shaft shall be of stainless steel of minimum Grade 316 S31 to BS 970-1 and of ample
diameter to withstand all stresses imposed.
Where shafts are exposed to the process fluid and where they pass through the sealing
gland they shall be fitted with positively driven stainless steel sleeves Grade 316-S31 to BS
970-1, which shall extend through the stuffing box.
The impeller shall be made of duplex stainless steel DIN 1.4517 and be of robust
construction and be machined where possible with the water passages and blades filed and
scraped, to produce smooth surfaces so that rags and stringy matter will not adhere. It shall
be provided with auxiliary back blades to reduce the pressure at the mechanical seal and
prevent the ingress of solids and abrasive matter. Hydraulic balance holes shall not be
provided and the impeller shall be tested and adjusted for static and dynamic balance. The
impeller shall be fitted to the drive shaft by a fitted impeller key and secured by a contoured
nut, provided with a positive locking arrangement. Impellers are to be provided with
renewable wear rings. Impeller wear rings shall be stainless steel Grade 316 S31 to BS 970
Part 1. The shaft shall be fully protected from contact with the pumped liquid.
The pump shall rotate in a clockwise direction when viewed from the suction end. The
rotating element shall be in balance and designed so that the maximum operating speed is
not less than 30 per cent below the first critical speed and there is no tendency for any part
to unlock due to possible reversal of rotation.
21.3.4
Gland Plate
The gland plate shall be flanged and spigotted for correct alignment, it shall be fitted with
jacking bolts to ease removal from the pump casing.
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The gland plate shall be fitted with a cartridge type mechanical seal. The gland stuffing box
shall be designed for soft gland packing as an alternative.
The mechanical seal selected shall be suitable for the pump duty and the media being
pumped, the seal shall be water lubricated and shall not in normal use permit any controlled
leakage from the pump.
21.3.5
Bearings
Independent pumps shall be fitted with an external shaft bearing assembly. It shall positively
locate the shaft so that on reassembly the shaft and impeller are in true alignment within the
rotating unit and it shall be provided with locating dowels and jacking bolts to ease removal.
Bearings shall be generously rated and sized to take all thrust and radial loads and to ensure
satisfactory and stable running under all conditions of operation, they shall be to ISO
standard with SI unit dimensions. Bearings shall be of anti-friction type designed for an L10
life of at least 100,000 hours in accordance with BS 5512. The bearings shall be arranged for
oil or grease lubrication.
21.3.6
Pump Performance
The pump head/flow characteristic curve shall be stable, rising steadily to closed valve head
and non-overloading. The closed valve head shall be a minimum of 110% of the maximum
duty head
Where the maximum duty is met by parallel pump operation, a single pump shall be capable
of operation without run-out or overloading.
The Contractor shall make his own assessment of the friction losses under all operating
conditions.
The pump quantity/power characteristics shall be stable and non-overloading such that the
maximum power absorbed under any condition remains at least 10% less than the rating of
the motor.
Characteristic curves for the pump shall be supplied with the Tender to a large scale which
shall show the capacity of the pumps when pumping singly at minimum and maximum head.
Where two or more pumps are installed discharging through the same pumping main, the
characteristic curves shall include the system curves for all combinations of pumps. Curves
showing pump efficiency and kW loading shall also be included. Where pumps are supplied
with variable speed drives provide pump curves for minimum and maximum speed with
pump efficiency and kW loading at intersections of the system curve.
When tested through their complete range of workable heads at the makers works, the
pumps shall give results which conform to the curves submitted with the Tender
21.4
PRESSURE FILTERS AND STRAINERS
21.4.1
Pressure Filters
Automatic self cleaning filters shall be specifically suitable for use with organic contaminants.
Cleaning shall be by a hydraulically powered suction scanner, automatically activated when
the differential pressure across the filter reaches an adjustable level, nominally 3.5m.
The filter body and all internal parts, including flanges, shall be stainless steel Grade 316S31
to BS 970-1 (partially replaced by BS EN 10084). The screen shall be 150 micron mesh size.
The flushing line shall be connected to the works drainage system.
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The control system shall feature a fail-safe timer to prevent continuous flushing due to
malfunction. The filter shall not flush when the system or pumps are not working.
All the filters shall have isolation valves in the suction and delivery side for easy
maintenance. The controller for the filters shall be equipped with a timer and pressure
differential control unit.
Pressure gauges shall be connected to suction and delivery side of each filter, pressure
switches shall be mounted in the electric control panel in an isolated compartment.
Input and output flanges dimensions shall be in accordance with BS EN 1092 PN 16.
21.4.2
Basket Strainers
The strainer shall be of the duplex in-line basket flanged type, of compact design and shall
incorporate large filtration areas giving low pressure drops.
The body and cover will be of cast iron to BS EN 1561 grade 250 or equivalent, and shall
be fusion bonded epoxy coated internally and externally with a minimum thickness of 300
microns. Flanges shall be PN16 to BS EN 1092.
Internal parts shall be of stainless steel Grade 316S31 to BS 970-1 (partially replaced by BS
EN 10084) or equivalent.
The filter shall be 920 microns mesh inserted into a perforated plate basket.
Strainers shall be suitably rated for all working and test delivery pressures.
A differential pressure switch shall be connected between the inlet and outlet of the filter, and
if the pressure drop across the filter is exceeded by 50% (or other value recommended by
the Manufacturer and agreed with the Engineer) a lamp on the panel shall indicate filter
blocked and operation of the system shall be disabled.
21.5
POLYMER PREPARATION AND DOSING SYSTEMS
21.5.1
General
A polyelectrolyte make-up, storage and dosing system shall be provided. The system shall
be sized to provide the polyelectrolyte requirements of the sludge thickening system as
designed by the Contractor and provide an adequate storage period of the necessary raw
materials
The Contractor shall provide a facility for dosing by direct injection into the pipework, of preprepared polyelectrolyte, upstream of the conditioning tanks. The facility shall be manually
selected via a gate valve and capable of being isolated from the dosing system.
The dry granule storage hopper shall be fabricated of stainless steel and shall have a 25kg
minimum capacity. The hopper shall be mounted on the polyelectrolyte feeder and shall be
provided with supports. The hopper shall be provided with a low-level alarm.
The hopper shall be enclosed by a stainless steel cabinet with a tubular heater fitted inside
to prevent condensation and maintain polyelectrolyte in a dry condition.
The transfer of granules into the hopper shall use a vacuum system designed to operate with
1 tonne bulk bags.
The dry granule transfer equipment for the transfer of dry polymer from hopper to wetting
device shall include the following: -
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(a)
A granule feeder with single screw discharge. The granule feeder outlet shall be fitted
with a heater to prevent condensation.
(b)
A stainless steel funnel to direct the granules from the screw discharge into an air lift
venturi. The funnel shall be fitted with a sieve.
(c)
A centrifugal air blower to provide a high velocity air stream. The motor shall be totally
enclosed with a degree of enclosure protection appropriate to the equipment. The
level of protection shall not be less than IP55.
(d)
An air dehumidifier.
(e)
A venturi granule injector to feed the granules into the air stream.
(f)
An anti-static connecting hose.
All stainless steel parts shall be Grade 316 S31 to BS 970-1 (partially replaced by BS EN
10084)
21.5.2
Wetting and Dispersing Device
Wetting and dispersing devices shall ensure that every granule of polyelectrolyte delivered
by the air stream is wetted and dispersed into the make-up tank. No conglomerates of
polyelectrolyte shall be produced. The spray heads shall be of stainless steel Grade 316 S31
to BS 970-1 (partially replaced by BS EN 10084) and shall be fitted with a water pressure
gauge and a control pressure switch. Potable water shall be used
The Contractor shall provide the Engineer with design calculations to demonstrate that he
has made all reasonable endeavours to optimise the use of water on works processes.
For the polyelectrolyte system, the Contractor must install a break tank of sufficient water
capacity to allow batch polymer to be mixed for one days use.
The Contractor shall design the polyelectrolyte break tank with optimal spare capacity and
shall impose a strict regime of control to suppress any peaks and troughs of the water
demand pattern.
21.5.3
Flocculent Storage Tanks
Flocculent storage tanks shall be fabricated from glass-reinforced plastic or steel reinforced
glass fibre and shall include the following: Slow speed propeller or turbine mixer.
(a)
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(b)
Level electrodes to control solenoid valves, air blower, mixer, screw feeder and dosing
pumps.
(c)
Mounting for wetting and dispersing device.
(d)
Flanged inlet, outlet, drain and overflow connections.
(e)
Removable covers.
(f)
Sight glass.
(g)
Tank contents gauge with analogue output to SCADA system.
21.5.4
Dosing Pumps
Duty and standby chemical metering pumps shall be provided complete with all pipework,
valves and any necessary metering arrangements. The output of the pumps shall be
variable by means of hydraulic variator or adjustable speed drive depending on pump type
selected, so as to get accuracy in the dosing rate.
QCS 2014

Part
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Flow meter (analogue-mechanical type) shall be installed in the delivery line of the pump to
get the chemical flow rate.
21.6
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END OF PART
QCS 2014

Part
22: Ventilation Systems
Page 1
22
VENTILATION SYSTEMS ............................................................................. 2
22.1
GENERAL ...................................................................................................... 2
22.1.1 Scope
22.1.2 Noise Level
22.1.3 Inlets and Outlets
2
2
2
VENTILATION SYSTEMS ............................................................................. 2
22.2.1
22.2.2
22.2.3
22.2.4
22.2.5
22.2.6
22.2.7
Ventilation Rates
Wet Well Ventilation/Process Area Ventilation
Dry Well Ventilation
Motor Room Ventilation
Fans
Fan Motors
Ducting
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2
3
3
4
4
4
4
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VENTILATION SYSTEMS
22.1
GENERAL
22.1.1
Scope
This part specifies the particular requirement for the ventilation systems for sewerage and
sewage treatment installations. This section is to be read in conjunction with Section 22.
Where there is conflict then the requirements of this Section shall prevail.
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General
Drainage Works
Electrical Works
Air Conditioning, Refrigeration and Ventilation
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Section 1
Section 8
Section 10
Section 13
Section 21
Section 22
22
Noise Level
The noise level due to ventilation and air conditioning equipment shall be no greater than
sound power level 65dB(A) at one metre.
The Contractor shall include for sound absorbers and anti-vibration mountings as necessary.
22.1.3
Inlets and Outlets
All inlets and outlets through the roof shall be fitted with approved GRP or Aluminium cowls
and bird screens. All inlets and outlets through walls shall be fitted with demountable
aluminium louvers. All materials used for external fittings shall be highly resistant to ultraviolet light.
All louvers shall be of the sand trap type and shall be fitted with internal sand filters and
mosquito screens.
22.2
VENTILATION SYSTEMS
22.2.1
Ventilation Rates
The minimum number of air changes per hour shall be:
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22.1.2
Toilets
12
Stores
12
Workshops
15
Garages/Car park areas
12
Messes (two speed)
6 20
Motor Room
10 20
Dry Well
20
Covered areas containing untreated sewage
6 when covered rising to 20 prior to and

during man entry
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Part
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Wet Well Ventilation/Process Area Ventilation
Ventilation equipment shall ensure that at all times the wet well area is not hazardous to
operators, during operation or shut down of the pumping plant. It should be noted that the
gases given off by sewage may include methane (marsh gas), carbon dioxide, nitrogen,
oxygen, hydrogen, hydrogen sulphide, water vapour and other constituents. In naturally
ventilated wet wells/process area levels of hydrogen sulphide of up to 100 ppm are common
and concentrations in excess of 400 ppm have been measured. Methane concentrations
above the lower explosive limit are possible. This should be borne in mind when designing
the ventilation system and odour control systems.
The system shall be capable of treating the specified H 2S concentration such that the
operating mean H2S level in the well does not exceed 3 ppm. Removable cell type
deodorisers shall not require filter replacement in a period less than 6 months. Bulk carbon
deodorisers shall not require carbon regeneration in a period less than 2 years. Pelletised
activated caustic or water regenerable carbon shall be used for the bulk type deodorizer
units.
Where H2S levels are likely to exceed 20 ppm, a chemical scrubber of other suitable pre-filter
shall be provided before a carbon filter.
The system shall operate on the principle of forced draught ducted outlet/natural ducted
inlets and account shall be taken of the fact that the gases to be handled have differing
specific gravities. The high and low level ducted inlets and outlets should span the width of
the wet well so that there is a constant sweep of clean air across the wet well.
A complete fan/motor assembly shall be provided as a spare. This shall include the fan
housing on the bulk carbon deodorisers.
On bulk carbon deodoriser systems a flow switch shall be fitted into the extract ductwork to
actuate an alarm on the annunciator in the event of failure of the extract system.
In the event of failure of the wet well ventilation red rotating beacon, high intensity, alarm
lights shall be illuminated adjacent to each wet well access door.
The extract shall be through a Deodoriser unit as specified elsewhere to remove obnoxious
smells.
Warning labels worded as follows in English and Arabic shall be fitted at each alarm light
location.
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22.2.2
WARNING
DO NOT ENTER WHEN RED LIGHT IS ON
NO NAKED LIGHTS AT ANY TIME
10
Two identical systems shall be provided, each capable of providing 60% of the overall design
requirement for ventilation.
11
The treated air shall be discharged into the atmosphere via a stack which shall extend above
the height of the building.
22.2.3
Dry Well Ventilation
The system shall operate on the principle of forced draught outlet/ natural ventilation inlet via
the stairways and other apertures.
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Part
Page 4
Fans shall be of the double motor type having a standby motor which comes into operation
should the duty motor fail. Alternatively two complete fans and motors shall be provided and
installed to act as duty and standby.
22.2.4
Motor Room Ventilation
The system shall operate on the principle of forced draught outlet/ natural ventilation inlet via
inlet louvers. All inlet louvers shall be fitted with 2" thick metallic washable filters. Access
shall be provided for cleaning/changing filters.
Fans shall be of the double motor type having a standby motor which comes into operation
should the duty motor fail. Alternatively two complete fans and motors shall be provided and
installed to act as duty and standby.
22.2.5
Fans
Fans shall be of the axial flow or centrifugal types suitable for handling air of high humidity
and having concentrations of hydrogen sulphide.
They shall be of non ferrous construction or be protected with suitable epoxy resin coatings.
Odour Control fans shall be constructed entirely from stainless steel Grade 316 S31 to BS
970-1 (partially replaced by BS EN 10084) or fibreglass reinforced plastic of vinyl ester resin.
For deodorizer fan units, bearings shall be of the roller or ball type and shall be mounted
using adaptor sleeves and plumber blocks with provision for lubrication. Sealed bearings
shall be used for small fan units in dry well/motor room ventilation system.
22.2.6
Fan Motors
Fan motors shall be suitable for continuous operation in hot, humid atmospheres at an
o
ambient temperature of up to 55 C at 100% humidity.
The degree of protection shall be IP55 and for the wet well a classification of Ex N IIA T3 or
better is required.
All motors shall comply with the section of this Specification headed "Motors" insofar as it
applies.
22.2.7
Ducting
Ventilation ducting shall be of GRP, Reinforced uPVC or Stainless Steel to BS 970, Grade
316 S31. Material thickness, stiffening and joint arrangements shall not be of a standard
lower than those set out in the Chartered Institution of Building Services (C.I.B.S), Guide
(Section B3) 1983 Edition.
Ducting shall be complete with all necessary supports. Galvanised or stainless steel nuts
and bolts shall be used for all ducting joints and all supports and brackets shall be
galvanised. All supports, ducting, brackets and fixings in wet wells shall be stainless steel as
specified elsewhere.
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Ducting shall be sized so that the air velocity within the ducts shall not exceed 5.5 metres per
second.
Flexible connections and anti-vibration mountings shall be provided as necessary between

the ductwork and fans and provision shall be made for thermal expansion.
Where ducts pass through the roof or floor slab the gap shall be sealed with polystyrene or
similar approved material. Wood is not acceptable.
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END OF PART
QCS 2014

Part
03: Centrifugal Pumps (Dry Well)
Page 1
CENTRIFUGAL PUMPS (DRY WELL) .......................................................... 2
3.1
GENERAL ...................................................................................................... 2
3.1.1
3.1.2
3.1.3
Scope
References
Submittals
3.2
PRODUCTS ................................................................................................... 3
3.2.1
3.2.2
3.2.3
3.2.4
3.2.5
3.2.6
3.2.7
General
Design Conditions
Materials
Fabrication
Accessories
3.3
3.3.1
3.3.2

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2
2
3
4
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9
9
10
10
10
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Page 2
CENTRIFUGAL PUMPS (DRY WELL)
3.1
GENERAL
3.1.1
Scope
This Part specifies the requirements for the design, manufacture construction, installation
testing and commissioning of vertical spindle, single-suction, dry-well, non-clog, centrifugal
type pumps, to handle sewage, surface and groundwater as specified.
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General
General
Sewerage
Electrical Works
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This Section
Part 1,
Section 1,
Section 8,
Section 10,
Section 21,
References
The following standards or revised/updated versions and documents of other organisations

are referred to in this Part:
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3.1.2
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BS 4,...........................Structural steel sections

BS 449,.......................The use of structural steel in building
BS 1400,.....................Copper alloy ingots and copper alloy and high conductivity copper
coatings
BS 3170,.....................Flexible couplings for power transmission
BS EN 1092,............... Circular flanges for pipes valves and fittings
(ISO 10816 ) Part 1 and Part 7, Mechanical vibration in rotating and reciprocating machinery
BS 4999,.....................(IEC 34,72) General requirements for rotating electrical machines
BS 5304......................Code of Practice for the safety of machinery
...................................BS EN ISO 9906 Grades 1, 2 and 3 Acceptance tests for centrifugal
mixed flow and axial flow centrifugal pumps
bearings
BS 6861, (ISO 1940) ..Balance quality of requirements of rigid rotors
BS 7613,.....................Hot rolled quenched and weldable steel plates
BS EN 10113..............Hot rolled products in weldable fine grain structural steels
ASME V ......................Boiler and Pressure Vessel Code, Nondestructive Examination
ASME VIII Div. 1 .........Boiler and Pressure Vessel Code, Design and Fabrication of Pressure
Vessels
3.1.3
Submittals
In addition to the requirements of Part 1 of this section the Contractor shall provide data and
QCS 2014
Design Data
(a)
Shop Drawings
duty impeller diameter
(ii)
(iii)
(iv)
(v)
(vi)
(vii)
net positive suction head
(viii)

sectional drawing of the pump motor, drive shafting and flywheel proposed.
(ix)
(i)
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(b)
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Part
documentation provided as above and the results of all the factory and site inspection and
testing in the manuals
3.2
PRODUCTS
3.2.1
General
flow range specified in the Project Specification without surging, cavitation, or vibration.
The pumps shall meet maximum allowable shut-off head and maximum allowable required
net positive suction head (NPSH) specified in the Project Specification.
The pumps shall not overload the motors for any point on the maximum speed pump
performance characteristic curve within the limits of stable pump operation as recommended
by the manufacturer to prevent surging, cavitation, and vibration, as well as throughout the
entire pump operating range.
To ensure vibration-free operation, all rotative components of each pumping unit shall be
statically and dynamically balanced to BS 6861, and the following requirements shall be met:
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(a)
operating speeds is avoided
(b)
in any case, the amplitude of vibration as measured at any point on the pumping unit,
motor or drive shafts shall not exceed the below limits 3.2.2.
(c)
at any operating speed, the ratio of rotative speed to the critical speed of a unit, or
Vibration outside the below limits shall be sufficient cause for rejection of the equipment.
All parts of each pump shall be designed to withstand the stresses that will be imposed upon
them during their handling, shipping, erection, and operation.
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Part
Page 4
difficulty.
The pump supplier shall be responsible for proper operation of the complete pumping
system, which includes the pump, motor, variable speed drive unit (if designated), and
associated controls furnished with the pump.
10
For the performance curve of the selected pump impeller, head shall continuously rise as
flow decreases throughout the entire curve from runout to shutoff head.
11
The Contractor shall ensure that drive motors, variable speed drive or softer starter systems
(if designated) and pumps are furnished and tested together by the pump manufacturer, who
shall supply full certification for the proper function of the entire pumping system, within the
limits of the designated design conditions.
12
If variable speed drive systems are specified, motor and drive system shall be fully
compatible, and shall be of sufficient power and torque, and be capable of sufficient heat
3.2.2
Design Conditions
for a life of 100,000 hours with service intervals at 20,000 hours.
Bearings shall be of the anti-friction type designed for an L10 life of at least 50 000 h in
Pump and motor maximum operating speed shall not exceed 1500 rpm, unless a lower
speed is specified in the Project Specification.
Pumps shall be of non-clog design, capable of passing spheres of a minimum 100 mm

diameter unless other diameters are designated.
Pumps shall be suitable for use in the conditions specified in Section 1. The pumped media
temperature shall be taken as 40 C.
Renewable impeller wear rings shall be fitted, to the impeller and volute case, except where
not available on a standard production unit.
Vibration levels shall not exceed the levels given in ISO 10816 Part 1 and Part 7 quality
bands A and B
The pump, motor and associated electrical equipment shall be rated for a minimum of
10 starts per hour, unless otherwise designated.
10
guarantees the following:-
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(a)
flow rate
(b)
total head
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Part
(c)
power input
(d)
efficiency
(e)
NPSH required
Page 5
3.2.3
Materials

volute casings shall be Ni-resist cast iron, BS EN 1561, Grade 250
(b)
impellers shall be duplex stainless steel DIN 1.4517;
(c)
impeller wear rings shall be of duplex stainless steel DIN 1.4462;
(d)
casing wear rings shall be of non ferrous or stainless steel BS970-1 Grade 316 S31
with good anti- seizure propertied against the rotating element. There shall be a
difference of at least 50 points Brinell hardness of the opposed wear surfaces;
(e)
suction elbows shall be cast or ductile iron, BS EN 1561, Grade 250
(f)
stuffing box covers shall be cast iron, BS 1452, Grade 250
(g)
bearing frames shall be cast iron, BS EN 1561, Grade 250
(h)
pump shafts shall be of Duplex stainless steel conform to DIN 1.4462 or a suitable
duplex ferritic austenitic stainless steel;
(i)
pump shaft sleeves shall be stainless steel Grade 316 S31;
(j)
fasteners shall be stainless steel to BS 970-1 Grade 316 S31.
(k)
fly wheels if fitted shall be steel, BS 3100.
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(a)
Supporting steelwork for bearings, drive shafts, platforms, ladders and stairways shall comply
with BS 4, BS 449, BS 7613 and BS EN 10113 as applicable.
Additional or other requirements for materials of construction may be specified in the Project
Specification
3.2.4
Fabrication
General: The pump shall be fabricated in accordance with the following requirements, and
as described in the following paragraphs.
pumps shall be capable of handling raw, unscreened sewage, effluent, storm or
groundwater as required
(a)
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(b)

(c)
components shall conform with the requirements listed in the following paragraphs.
Volute casings:
(a)
volute casings shall be large enough at all points to pass any size solid which can
pass through the impeller
(b)
wall thickness shall be sufficient to withstand all stresses in service at full operating
pressure
(c)
volute casings and integral discharge nozzle shall be cast in one piece, with smooth
water passage lined with a proprietary corrosion and erosion liner to the
manufacturers recommended specification,
(d)
a hand hole (minimum size 75 mm by 125 mm) shall be provided near discharge
flanges for inspection and cleaning. The inner contour of hand hole covers shall
conform to that of volute casings
QCS 2014
a minimum 12 mm brass or stainless steel tap shall be provided on the top and
bottom of discharge nozzles, next to discharge flanges, for venting and draining
(f)
volute casings shall be so arranged that impellers may be removed without disturbing
either suction or discharge piping.
Impellers:
impellers shall be cast or machined in one piece
(b)
impellers shall be designed with smooth water passages to prevent clogging by string
or fibrous materials
(c)
impellers shall be fitted with a renewable wear ring and the casing shall be fitted with
a matching wear ring
(d)
entire rotating assemblies shall be designed so that they may be withdrawn from
pump assemblies without disturbing the suction or discharge piping connections
(a)
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Suction elbows:
suction elbow shall be supplied by the pump manufacturer as DI flanged long radius
reduced elbow with integral lining to resist cavitation.
(b)
(b) a minimum 25 mm brass or stainless steel pipe tap shall be provided near the
suction flanges for a pressure gauge connection.
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(a)
Stuffing boxes:
(a)
stuffing box covers shall be accurately machined to fit onto the volute casing and
shall be of sufficient thickness to withstand the pressure imposed upon it under
operating conditions. Stuffing box cover and back vanes of the impeller shall allow
water cooling to the gland packing.
(b)
stuffing boxes shall be cast integrally with the stuffing box cover and shall be of
sufficient depth to hold at least 5 rings of packing
(c)
soft-packed glands shall be designed for grease or water lubrication and shall be
provided with large size grease lubricators with indicators
(d)
glands and lantern rings shall be split to facilitate easy repacking and shall have
tapped easy withdrawal holes on the upper face.
Bearing frames, bearing housings, and bearings:

(a)
bearing frames shall be cast in one piece
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(b)
frames shall carry both radial and thrust bearings
(c)
outboard bearings shall be the thrust bearing and the housing shall be designed to
provide an axial clearance adjustment downward between the impeller and suction
cover by use of shims or other suitable means
(d)
bearing housings shall be fitted with suitable grease seals to prevent loss of grease
and to prevent entrance of contaminants
(e)
frames shall be provided with a tapped hole with a minimum diameter of 25 mm,
located as low as practicable to drain the leakage from packing glands
(f)
bearing frames shall be accurately machined, centered, and securely bolted to

volutes and stuffing box cover assemblies
(g)
construction shall be such that entire rotating assemblies may be removed without
disturbing the suction or discharge piping
(h)
large openings shall be provided adjacent to stuffing boxes to facilitate adjustment

and repacking
(i)
upper bearings shall be the thrust type and shall carry the entire pump thrust load
QCS 2014
(j)
bearings shall be grease lubricated with a provision for forcing out the old grease and
limiting back pressure.
Supporting bases:
pumps shall be furnished with a suitable supporting base either cast integrally with the
volute or otherwise attached to the pump casing
(b)
bases shall provide openings large enough to permit access to suction elbows and
cleanout hand holes
(c)
bases shall be designed to support the assembled weight of the pump and shall safely
withstand all stresses imposed thereon by vibration, shock, and all possible direct and
eccentric loads
(d)
pump bases shall be of an adequate horizontal dimension to provide sufficient footing

contact area and anchorage facilities
(e)
the height of pump bases shall be such that the suction flange will clear the floor,
footing surfaces or ducts, with sufficient space allowed for dismantling bolts.
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(a)
Pump shafts:
(a)
pump shafts shall be of such diameter that they will not deflect more than 0.05 mm at
the face of the stuffing box while operating at the maximum design speed, as
determined by calculations from the manufacturer
(b)
the entire length of shafts shall be turned, ground, and polished
(c)
a renewable shaft sleeve shall be provided over shafts through the stuffing box
(d)
shafts shall be key-seated for securing the impeller and coupling
(e)
sleeves shall be secured either by key or suitable locking screw to the Engineers
approval.
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vertical shafting shall be connected to drive motors with a direct, close coupled
connection or of the flexible type, consisting of sections with flanged universal joints
and intermediate bearings and Plummer blocks as designated or required
(b)
splined connections shall be provided adjacent to the pump
(c)
(d)
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Drive shafts:
mating steel flanges for connection to driver and driven units shall be furnished
shafts shall be designed for continuous duty to transmit the maximum output torque
and power of the units
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(e)
components shall be adequately sized and designed for the service intended,
including transient due to power failure
(f)
all shaft sections shall be statically and dynamically balanced individually.

sections shall not exceed 3 m and shall run below their first critical speed
(g)
intermediate shaft support bearings shall be of the anti-friction type, grease

lubricated, mounted in Plummer blocks dowelled to the supporting steel work
(h)
slip splines in drive shafts shall permit removal of the pump rotating assemblies
without removal of any section of intermediate shafting, bearings, or discharge piping
(i)
intermediate bearings shall be supported by steel channel sections either fixed

in position on the dry well walls, or mounted on a substantial frame with support
from the dry well walls. There shall be no transmission of vibration from each
bearing.
Shaft
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Page 8
Ring bases and base plates:

(a)
pump drive units shall be mounted on a suitable cast iron or fabricated steel ring base
with adequate clearance and openings to provide ready access to the upper shaft
coupling
(b)
ring bases shall be a minimum of 250 mm high and shall be rugged enough to
support the full weight of the motor
(c)
base plates shall be square and shall be of sufficient thickness to support the drive
assemblies
(d)
base plates shall be drilled to accommodate the size and number of anchor bolts
required
(e)
where designated, bases shall be mounted on a suitable bolted, removable framing to

cover access openings.
fly wheels shall be fitted where required for surge protection and to achieve smooth
start and smooth stop to avoid NRV slamming
(b)
fly wheels shall be mounted in a housing directly beneath the drive motor and above
the motor room floor, if the motors are mounted in a motor room
(c)
the top bearing housing and drive shaft shall carry the flywheel. Unless agreed by the
Engineer, the fly wheel shall not be mounted on the motor shaft
(d)
fly wheels shall be statically and dynamically balanced to BS 6861 and shall be
positively keyed to the drive shaft
(e)
flywheels shall be designed such that there is an even tangential stress distribution
throughout the flywheel
(f)
flywheel speeds shall not exceed 30ms for cast iron and 50ms for cast steel.
-1
-1
Motors:
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(a)
(a)
motors shall be in accordance Section 21
(b)
motors shall be 3 phase 50 Hz, voltage as specified in the Project Specification

motors shall be squirrel cage, induction air cooled to IP 54, as a minimum, unless
specified otherwise in the Project Specification
(c)
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Fly wheels:
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Part
(d)
motors shall be derated for variable speed operation
(e)
Motors above 75 KW shall be provided with bearing vibration monitoring on 2 axes
(f)
Motors above 75 KW shall be provided with winding temperature monitoring PT100 or

similar subject of Engineers/Client approval.
13
Pump Control Systems: Pump control systems shall be furnished and installed in
accordance with Section 10 and the Project Specification.
14
Coatings:
(a)
all parts of the pump shall be fusion bonded epoxy coated to a minimum thickness of
300 microns. External parts and the motor shall be coated as the paint specification in
Section 8
(b)
Coupling, pump shaft and impeller shall be balanced together to ISO 1940 quality level
G 6.3 prior to final assembly.
(i)
drive motor / flywheel coupling.
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Part
(ii)
flywheel / drive shaft coupling.
(iii)
drive shaft / pump coupling.
3.2.5
Accessories
The following accessories shall be provided for pumps:
Page 9
guards. Substantial galvanised perforated guards shall be provided at all exposed

couplings, drives and shafts, in accordance with Part 1. The guards shall extend the
whole length of the shaft and include hinged access doors at lubrication/inspection
points for all points requiring maintenance
(b)
pressure gauges. The suction and discharge nozzle of each pump shall be provided
with a 19 mm diameter tapped opening, stainless steel or brass isolating valves and
diaphragm gauges as Part 1
(c)
volute bleed-off. Each pump shall be installed with a volute automatic air bleed-off
brass valve from high point of the volute, venting via pipe to the wet well as below.
25mm tee with isolation valve and piping to drain channel, shall be given below the air
bleed-off valve for manual venting of the air in the casing.
(d)
access
ladders,
stair
ways
and
platforms
shall
be
provided
to
all points requiring maintenance, including couplings, bearings and sliding joints,
as Sections 8, 16 and 17.
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(a)
Arrangements shall be made for draining away to the drainage channel or sump any water
which leaks from pump glands or any other source using 50 mm minimum diameter stainless
steel pipe.
Vibration sensors (in both axial and traverse direction) and temperature sensors shall be
fixed on large pumps and motors (i.e. above 75 KW) for condition monitoring. Similarly
vibration sensors (in both axial and traverse direction) shall be provided for the plumber block
bearings of the drive shaft and the data should be made available in the SCADA panel.
3.2.6
inspections and tests have been conducted on each pump at the factory, and submit to the
Engineer prior to shipment:
valve pressure
(a)
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(b)
Specifications
(c)
motor insulation tested for moisture content or insulation defects
(d)
the insulation test (b) above has been performed again after the performance
test (2) below.
Each pump has been factory tested for performance according to BS EN ISO 9906 Grades
1, 2 and 3, including:
(a)
flow
(b)
inlet pressure
(c)
outlet pressure
(d)
motor power
(e)
torque
(f)
efficiency
QCS 2014
Page 10
submit to the Engineer prior to shipment.
(a)
(b)
foundry Composition Certificates for all major castings (pump case, impeller, motor
compliance with the pump manufacturer material specifications
(c)
non destructive test certificates for major parts as "pump shaft" and "impeller" to be
issued under ASME V requirements
(i)
Ultrasound test (UT) method for pump shaft shall satisfy the required criteria of
ASME VIII Div.1 Appendix 12.
(ii)
Magnetic particle inspection (MPI) and/or dye penetration inspection (DPI)

methods for impeller shall satisfy the required criteria of ASME VIII Div. 1
Appendices 6, 8 and/or 7.
driving shaft balancing certificate as ISO 1940 requirements with balancing quality
level G16.
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(d)
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The Contractor shall provide from the pump manufacturer all the spare parts and tools
those below:
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3.2.7
one set of complete bearings
(b)
three sets of stuffing box packing
(c)
one complete coupling
(d)
one set of wear rings
(e)
two sets of rubber coupling buffers
(f)
one set of shaft sleeves
(g)
three lantern rings for packing box.
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(a)
The Contractor shall supply, furnished by the pump manufacturer, a complete set of all
special tools required for maintenance of the pumping equipment, in a lockable tool box,
complete with the list of spares.
3.3
3.3.1
The equipment delivered to the Site shall be examined by the Engineer to determine that it is
All equipment shall be installed in strict conformance with Part 1 of this Section and the
3.3.2
The Contractor shall provide the services of the pump manufacturers representative to
supervise the installation and commissioning of the pumping equipment.
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Part
Page 11
satisfying the Engineer that the pumpsets have been correctly assembled and installed and
and remedy or rectify the fault. Similar action shall be taken for an undue increase in bearing
or gland temperature, increased gland leakage rates, unsatisfactory vibration levels or any
other fault or defect in the operation of the pumpset.

a record of bearing and coupling clearance and alignments shall be tabulated to
show the as-built condition of each pump
(b)
a record of all overload, timing relay and oil pressure relays shall be tabulated to
show the as-built condition of each motor starter
(c)
all cables shall be megger tested to confirm the integrity of the insulation.
tabulated record of results shall be made
(d)
(e)
maximum emergency top water level on a recirculation basis using fresh water and
for a minimum of four hours continuously. During this test the following parameters
will be recorded:-
(ii)
pump output
(iii)
(iv)
(v)
power consumed
(vi)
power factor
(vii)
vibration
(viii)
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motor phase currents and voltages
the commissioning trials shall extend until each pump unit has run continuously for
at least 3 days under all operating conditions. The term continuously shall include
running at various speeds or on a start/stop basis as determined by the control
system
(g)
(i)
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(a)
(h)
the Contractors supervisory staff, and the pump manufacturers staff if required by the
Project Specification, shall be present during the period of the tests and
trials. The Contractor shall be responsible for any failure of the whole equipment or
any part thereof, whether such failure shall be determined by the methods detailed
herein or otherwise. If the pump test or trial is interrupted by the Contractor, or through
negligence on the part of the Contractors staff, it shall be completely repeated for the
pumpset concerned.
The operation, over the entire specified range, shall be free of cavitation, excessive vibration
or noise.
Vibration shall be checked and recorded. The full speed vibration of all pumps shall be within
acceptable limits as 3.2.2.8 Excessive vibration shall constitute sufficient cause for rejection
of the equipment.
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Page 12
Each pump performance shall be documented by obtaining concurrent reading showing

motor voltage and amperage, pump suction head and pump discharge head as follows:
(a)
readings shall be documented for a least four pumping conditions to ascertain the
actual pumping curve
(b)
one test shall be at shutoff head
(c)
each power lead to the motor shall be checked for proper current balance.
Bearing temperatures shall be determined by a contact type thermometer. A running time of

at least two hours shall be maintained at the maximum specified operating head.
In the event any of the pumping equipment fails to meet the above test requirements, it shall
be modified and retested in accordance with the requirements of this Section until it meets
the specified requirements, and approval of the Engineer.
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END OF PART
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Section 09: Mechanical And Electrical Equipment

Part
04: Centrifugal Pumps (Split Casing)
Page 1
CENTRIFUGAL PUMPS (SPLIT CASING) .................................................... 2
4.1
GENERAL ...................................................................................................... 2
4.1.1
4.1.2
4.1.3
Scope
References
Submittals
4.2
PRODUCTS ................................................................................................... 3
4.2.1
4.2.2
4.2.3
4.2.4
4.2.5
4.2.6
4.2.7
General
Design Conditions
Materials
Fabrication
Accessories
4.3
4.3.1
4.3.2

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2
2
3
4
5
5
9
10
10
11
11
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Part
Page 2
CENTRIFUGAL PUMPS (SPLIT CASING)
4.1
GENERAL
4.1.1
Scope
This Part specifies the requirements for the design, manufacture construction, installation
testing and commissioning of single stage centrifugal split casing pumps, to handle treated
sewage effluent, surface and groundwater as specified.
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General
General
Drainage Works
Electrical Works
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This Section
Part 1,
Section 1,
Section 8,
Section 10,
Section 21,
References

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4.1.2
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BS 449........................The use of structural steel in building
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BS 1400......................Copper alloy ingots and copper alloy and high conductivity copper
coatings
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BS 970, (ISO 683) ......Wrought steels for mechanical and allied engineering purposes
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BS 3100......................Steel castings for general engineering purposes

BS 3170......................Flexible couplings for power transmission
BS EN 1092................Circular flanges for pipes valves and fittings
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BS 4999, (IEC 34,72) .General requirements for rotating electrical machines

BS 5304......................Code of Practice for the safety of machinery
bearings
BS 7613......................Hot rolled quenched and weldable steel plates
BS EN ISO 9906 Grades 1, 2 and 3 Acceptance tests for centrifugal mixed flow and axial
flow centrifugal pumps
BS 6861, (ISO 1940) ..Balance quality of requirements of rigid rotors
BS 7854 (ISO 10816) Part 1 and Part 7, Mechanical vibration in rotating and reciprocating
machinery
BS EN 10113..............Hot rolled products in weldable fine grain structural steels
4.1.3
Submittals
In addition to the requirements of Part 1 of this section the Contractor shall provide data and
QCS 2014
Design Data
(a)
Shop Drawings
duty impeller diameter
(ii)
(iii)
(iv)
(v)
(vi)
(vii)
net positive suction head
(viii)

sectional drawing of the pump motor, drive shafting and flywheel proposed.
(ix)
(i)
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(b)
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Part
documentation provided as above and the results of all the factory and site inspection and
testing in the manuals
4.2
PRODUCTS
4.2.1
General
flow range specified in the Project Specification without surging, cavitation, or vibration.
The pumps shall meet maximum allowable shut-off head and maximum allowable required
net positive suction head (NPSH) specified in the Project Specification.
The pumps shall not overload the motors for any point on the maximum speed pump
performance characteristic curve within the limits of stable pump operation as recommended
by the manufacturer to prevent surging, cavitation, and vibration, as well as throughout the
entire pump operating range.
To ensure vibration-free operation, all rotating components of each pumping unit shall be
statically and dynamically balanced to BS 6861, and the following requirements shall be met:
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(a)
operating speeds is avoided
(b)
in any case, the amplitude of vibration as measured at any point on the pumping unit,
motor or drive shafts shall not exceed the below limits 4.2.2.
(c)
at any operating speed, the ratio of rotating speed to the critical speed of a unit, or
Vibration outside the below limits shall be sufficient cause for rejection of the equipment.
All parts of each pump shall be designed to withstand the stresses that will be imposed upon
them during their handling, shipping, erection, and operation.
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Part
Page 4
difficulty.
The pump supplier shall be responsible for proper operation of the complete pumping
system, which includes the pump, motor, variable speed drive unit (if designated), and
associated controls furnished with the pump.
10
For the performance curve of the selected pump impeller, head shall continuously rise as
flow decreases throughout the entire curve from runout to shutoff head.
11
The Contractor shall ensure that drive motors, variable speed drive systems (if designated)
and pumps are furnished and tested together by the pump manufacturer, who shall supply
full certification for the proper function of the entire pumping system, within the limits of the
designated design conditions.
12
If variable speed drive or soft starter systems are specified, motor and drive system shall be
fully compatible, and shall be of sufficient power and torque, and be capable of sufficient heat
Design Conditions
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4.2.2
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for an operating life of 100,000 hours with service intervals at 20,000 hours. Wearing
components shall have a design life of not less than 5 years or 10 years where major
dismantling is required.
Bearings shall be of the anti-friction type designed for an L10 life of at least 100,000 hours in
Pump and motor maximum operating speed shall not exceed 1500 rpm, unless a lower
speed is specified in the Project Specification.
Horizontal shaft pumps installed on plinths at ground level are the preferred arrangement.
Pumps shall be suitable for use in the conditions specified in Section 1. The pumped media
temperature shall be taken as 40 C.
Renewable impeller wear rings shall be fitted, to the impeller and volute case, except where
not available on a standard production unit.
Vibration levels shall not exceed the levels given in ISO 10816 Part 1 and Part 7 quality
bands A and B.
The pump, motor and associated electrical equipment shall be rated for a minimum of 10
starts per hour, unless otherwise designated.
10
guarantees the following:-
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(a)
flow rate
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(b)
Duty Head
(c)
power input
(d)
efficiency
(e)
NPSH required
4.2.3
Page 5
Materials
volute casings shall be Ni-resist cast iron, BS EN 1561, Grade 250.
(b)
impellers for sewage, treated effluent and ground water shall be duplex stainless steel
DIN 1.4517.
(c)
impeller wear rings shall be of duplex stainless steel DIN 1.4462
(d)
casing wear rings shall be of non ferrous or stainless steel BS 970-1 Grade 316 S31
with good anti seizure propertied against the rotating element.. There shall be a
difference of at least 50 points Brinell hardness of the opposed wear surfaces.
(e)
suction elbows shall be cast or ductile iron, BS EN 1561 or BS EN 1563, Grade 250.
(f)
stuffing box covers shall be cast iron, BS EN 1561, Grade 250.
(g)
bearing frames shall be cast iron, BS EN 1561, Grade 250.
(h)
pump shafts shall be duplex stainless steel to DIN 1.4462.
(i)
pump shaft sleeves shall be stainless steel Grade 316 S31.
(j)
fasteners shall be stainless steel to BS 970-1 Grade 316 S31.
(k)
fly wheels if fitted shall be steel, BS 3100.
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Supporting steelwork for bearings, drive shafts, platforms, ladders and stairways shall comply
with BS 4, BS 449, BS 7613 and BS EN 10113 as applicable.
Additional or other requirements for materials of construction may be specified in the Project
Specification
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General: The pump shall be fabricated in accordance with the following requirements, and as
described in the following paragraphs.
Fabrication
4.2.4
(a)
pumps shall be capable of handling treated sewage effluent, stormwater or

groundwater as required
(b)

(c)
components shall conform with the requirements listed in the following paragraphs.
(d)
components that would come in contact with chlorine shall, as far as practically
possible, be resistant to attack by chlorine.
Volute casings:
(a)
volute casings shall be large enough at all points to pass any size solid which can pass
through the impeller
(b)
volute casings shall be of the double volute type split axially with the suction and
delivery branches, bearing housing and feet cast integrally with the same half casing,
thus enabling the whole of the rotating assembly to be removed without opening pipe
joints or disturbing the alignment of the pumpset.
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wall thickness shall be sufficient to withstand all stresses in service at full operating
pressure
(d)
volute casing halves shall be cast in one piece, with smooth water passage lined with a
proprietary corrosion and erosion lining to the Manufacturers recommended
specification,
(e)
two lifting screws eye bolts shall be fitted to the upper casing
(f)
a minimum 12 mm brass or stainless steel tap shall be provided on the top and bottom
of discharge nozzles, next to discharge flanges, for venting and draining
(g)
volute casings shall be so arranged that impellers may be removed without disturbing
either suction or discharge piping.
(h)
the split casing pumps shall be constructed of two half casings fitted with tapered
guide pins to BS EN 22339 to ensure accurate alignment on re-assembly. The casing
joint shall be a metal face to face joint with a non hardening sealing compound, no
jointing gasket shall be used. Metal face to face joints shall be flat and parallel with a
maximum gap of 0.05mm, mating faces shall have a surface finish of 0.8 microns
C.L.A or better.
Impellers:
impellers shall be cast or machined in one piece and fusion bonded epoxy coated with
a minimum 500 micron thickness.
(b)
impellers shall be designed with smooth water passages and finished to smooth
surfaces, they shall be balanced statically and dynamically as a whole assembly
together with the shaft and secured on the shaft by a suitable locking nut
arrangement..
(c)
impellers shall be fitted with a renewable wear ring and the casing shall be fitted with a
matching wear ring
(d)
entire rotating assemblies shall be designed so that they may be withdrawn from pump
assemblies without disturbing the suction or discharge piping connections
(e)
impellers shall be double entry shrouded type, and shall be fully balanced and
supported between bearings.
(f)
impellers shall be supplied from the manufacturers standard range and shall not be
trimmed or cropped to meet the specified duty.
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Impellers shall be selected from middle range for their pump casing and shall be sized
such that a larger impeller (with 10% increase in diameter) capable of supplying an
additional 25% flow can be fitted in the pump casing with no modifications.
(g)
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(c)
Suction elbows:
(a)
suction elbows shall be supplied by the pump manufacturer as DI flanged long radius
reduced elbows with integral lining to resist cavitation.
(b)
a minimum 25 mm brass or stainless steel pipe tap shall be provided near the suction
flanges for a pressure gauge connection.
Stuffing boxes:
(a)
stuffing box covers shall be accurately machined to fit onto the volute casing and shall
be of sufficient thickness to withstand the pressure imposed upon it under operating
conditions. The stuffing box cover and back vanes of the impeller shall allow water
cooling to the gland packing.
(b)
stuffing boxes shall be cast integrally with the stuffing box cover and shall be of
sufficient depth to hold at least 5 rings of packing
(c)
soft-packed glands shall be designed for grease or water lubrication and shall be
provided with large size grease lubricators or water connections with indicators.
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(d)
(d) glands and lantern rings shall be split to facilitate easy repacking and shall have
tapped easy withdrawal holes on the upper face.
Bearing frames, bearing housings, and bearings:

bearing frames shall be cast in one piece
(b)
frames shall carry both radial and thrust bearings
(c)
outboard bearings shall be the thrust bearing and the housing shall be designed to
provide an axial clearance adjustment downward between the impeller and suction
cover by use of shims or other suitable means
(d)
bearing housings shall be fitted with suitable grease seals to prevent loss of grease
and to prevent entrance of contaminants
(e)
frames shall be provided with a tapped hole with a minimum diameter of 25 mm,
located as low as practicable to drain the leakage from packing glands
(f)
bearing frames shall be accurately machined, centred, and securely bolted to volutes
and stuffing box cover assemblies
(g)
construction shall be such that entire rotating assemblies may be removed without
disturbing the suction or discharge piping
(h)
large openings shall be provided adjacent to stuffing boxes to facilitate adjustment and
repacking
(i)
upper bearings shall be the thrust type and shall carry the entire pump thrust load
(j)
bearings shall be grease lubricated with a provision for forcing out the old grease and
limiting back pressure.
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Supporting bases:
pumps shall be furnished with a suitable supporting base either cast integrally with the
volute or otherwise attached to the pump casing
(b)
bases shall provide openings large enough to permit access to suction elbows and
cleanout hand holes
(c)
bases shall be designed to support the assembled weight of the pump and shall safely
withstand all stresses imposed thereon by vibration, shock, and all possible direct and
eccentric loads
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(a)
pump bases shall be of an adequate horizontal dimension to provide sufficient footing

contact area and anchorage facilities
(d)
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(e)
the height of pump bases shall be such that the suction flange will clear the floor,
footing surfaces or ducts, with sufficient space allowed for dismantling bolts.
(f)
Motors of horizontal pumps shall be mounted on an extension of the pump base plate
and shall drive the pump directly through a flexible coupling.
(g)
Motors of close coupled vertical pumps shall be mounted on an extension of the pump
support frame and shall drive the pump directly through a flexible coupling.
(h)
Remotely driven vertical pumps shall have a plummer block bearing mounted on an
extension of the pump support frame and shall drive the pump directly through a
flexible coupling between the plummer block and pump shaft, the drive shaft between
the plummer block and motor shall have flexible couplings at each end.
Pump shafts:
(a)
pump shafts shall be of such diameter that they will not deflect more than 0.05 mm at
the face of the stuffing box while operating at the maximum design speed, as
determined by calculations from the manufacturer
(b)
the entire length of shafts shall be turned, ground, and polished
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Page 8
(c)
a renewable shaft sleeve shall be provided over shafts where exposed to the process
fluid and through the stuffing box
(d)
shafts shall be key-seated for securing the impeller and coupling
(e)
sleeves shall be secured either by key or suitable locking screw to the Engineers
approval.
(f)
shaft sleeves shall be sealed internally to prevent leakage along the shaft.
Drive shafts:
vertical shafting shall be connected to drive motors with a direct, close coupled
connection or of the flexible type, consisting of sections with flanged universal joints
and intermediate bearings and plummer blocks as designated or required
(b)
splined connections shall be provided adjacent to the pump
(c)
mating steel flanges for connection to driver and driven units shall be furnished
(d)
shafts shall be designed for continuous duty to transmit the maximum output torque
and power of the units
(e)
components shall be adequately sized and designed for the service intended, including
transient due to power failure
(f)
all shaft sections shall be statically and dynamically balanced individually. Shaft
sections shall not exceed 3 m and shall run below their first critical speed
(g)
intermediate shaft support bearings shall be of the anti-friction type, grease lubricated,
mounted in plummer blocks dowelled to the supporting steel work
(h)
slip splines in drive shafts shall permit removal of the pump rotating assemblies
without removal of any section of intermediate shafting, bearings, or discharge piping
(i)
intermediate bearings shall be supported by concrete beam, or steel channel sections

either fixed in position on the dry well walls, or mounted on a substantial frame with
support from the dry well walls. There shall be no transmission of vibration from each
bearing.
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(a)
Ring bases and base plates:
ring bases shall be a minimum of 250 mm high and shall be rugged enough to support
the full weight of the motor
(b)
pump drive units shall be mounted on a suitable cast iron or fabricated steel ring base
with adequate clearance and openings to provide ready access to the upper shaft
coupling
(a)
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(c)
base plates shall be square and shall be of sufficient thickness to support the drive
assemblies
(d)
base plates shall be drilled to accommodate the size and number of anchor bolts
required
(e)
where designated, bases shall be mounted on a suitable bolted, removable framing to

cover access openings.
Fly wheels:
(a)
fly wheels shall be fitted where required for surge protection and to achieve smooth
start and smooth stop to avoid NRV slamming.
(b)
fly wheels shall be mounted in a housing directly beneath the drive motor and above
the motor room floor, if the motors are mounted in a motor room
(c)
the top bearing housing and drive shaft shall carry the flywheel. Unless agreed by the
Engineer, the fly wheel shall not be mounted on the motor shaft
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Page 9
(d)
fly wheels shall be statically and dynamically balanced to BS 6861 and shall be
positively keyed to the drive shaft
(e)
flywheels shall be designed such that there is an even tangential stress distribution
throughout the flywheel
(f)
flywheel speeds shall not exceed 30ms-1 for cast iron and 50ms-1 for cast steel.
Motors:
shall be in accordance with Section 21.
(b)
motors shall be 3 phase 50 Hz, voltage as specified in the Project Specification
(c)
motors shall be squirrel cage, induction air cooled to IP 54, as a minimum, unless
specified otherwise in the Project Specification
(d)
motors shall be de-rated for variable speed operation
(e)
motor shall be sized to be able to drive the larger impeller (as per 4.2.4.- 3g) with no
modification.
(a)
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Part
Pump Control Systems: Pump control systems shall be furnished and installed in accordance
with Section 10 and the Project Specification.
14
Coatings:
4.2.5
1
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Coupling, pump shaft and impeller shall be balanced together to ISO 1940 quality level
G 6.3 prior to final assembly.
drive motor / flywheel coupling.
(ii)
flywheel / drive shaft coupling.
(iii)
drive shaft / pump coupling.
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(i)
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Couplings:
Accessories
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all parts of the pump shall be fusion bonded epoxy coated to a minimum thickness of
300 microns unless otherwise stated. External parts and the motor shall be coated as
the paint specification in Section 8
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The following accessories shall be provided for pumps:

guards. Substantial galvanised perforated guards shall be provided at all exposed
couplings, drives and shafts, in accordance with Part 1. The guards shall extend the
whole length of the shaft and include hinged access doors at lubrication/inspection
points for all points requiring maintenance
(a)
(b)
pressure gauges. The suction and discharge nozzle of each pump shall be provided
with a 25 mm diameter tapped opening, stainless steel or brass isolating valves and
diaphragm gauges as Part 1
(c)
volute bleed-off. Each pump shall be installed with a volute automatic air bleed-off
brass valve from high point of the volute, venting via pipe to the drain channel as
below, a 25mm tee with isolation valve and piping to the drain channel, shall be
provided below the air bleed-off valve for manual venting of the air in the casing..
(d)
access ladders, stair ways and platforms shall be provided to all points requiring
maintenance, including couplings, bearings and sliding joints, as Sections 8, 16 and
17.
Arrangements shall be made for draining away to the drainage channel or sump any water
which leaks from pump glands or any other source using 50 mm minimum diameter stainless
steel pipe.
QCS 2014
Vibration sensors (axial and radial) and temperature sensors shall be fixed on large pumps
and motors upper and lower bearings (i.e. above 75 KW) for condition monitoring. Similarly
vibration sensors (axial and radial) shall be provided for the plumber block bearings of the
drive shaft, the data from all sensors should be made available in the SCADA panel.
4.2.6
valve pressure
(b)
Specifications
(c)
motor insulation tested for moisture content or insulation defects
(d)
the Insulation Test (c) above has been performed again after the performance test (2)
below.
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(a)
(b)
inlet pressure
(c)
outlet pressure
(d)
motor power
(e)
torque
(f)
efficiency
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(a)
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Each pump has been factory tested for performance according to BS EN ISO 9906 Grades 1,
2 and 3, including:
submit to the Engineer prior to shipment.
(a)
(b)
inspections and tests have been conducted on each pump at the factory, and submit to the
Engineer prior to shipment:
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foundry Composition Certificates for all major castings (pump case, impeller, motor
compliance with the pump manufacturer material specifications.
(c)
(d)
4.2.7
1
non destructive test certificates for major parts as "pump shaft" and "impeller" to be
issued under ASME V requirements.
(i)
ultrasound test (UT) method for pump shaft shall satisfy the required criteria of
ASME VIII Div.1 Appendix 12.
(ii)
magnetic particle inspection (MPI) and/or dye penetration inspection (DPI)

methods for impeller shall satisfy the required criteria of ASME VIII Div. 1
Appendices 6, 7 and/or 8.
driving shaft balancing certificate as ISO 1940 requirements with balancing quality
level G16
The Contractor shall provide from the pump manufacturer all the spare parts and tools
those below:
(a)
one complete set bearings
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Part
(b)
three sets of stuffing box packing
(c)
one complete coupling
(d)
one set of wear rings
(e)
two sets of rubber coupling buffers
(f)
one set of shaft sleeves
(g)
three lantern rings for packing box.
Page 11
The Contractor shall supply, furnished by the pump manufacturer, a complete set of all
special tools required for maintenance of the pumping equipment, in a lockable tool box,
complete with the list of spares.
4.3
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4.3.1
The equipment delivered to the Site shall be examined by the Engineer to determine that it is
All equipment shall be installed in strict conformance with Part 1 of this Section and the
4.3.2
The Contractor shall provide the services of the pump manufacturers representative to
supervise the installation and commissioning of the pumping equipment.
satisfying the Engineer that the pump sets have been correctly assembled and installed and
and remedy or rectify the fault. Similar action shall be taken for an undue increase in bearing
or gland temperature, increased gland leakage rates, unsatisfactory vibration levels or any
other fault or defect in the operation of the pumpset.

a record of bearing and coupling clearance and alignments shall be tabulated to show
the as-built condition of each pump
(a)
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(b)
a record of all overload, timing relay and oil pressure relays shall be tabulated to show
the as-built condition of each motor starter
(c)
all cables shall be megger tested to confirm the integrity of the insulation. A tabulated
record of results shall be made
(d)
(e)
maximum emergency top water level on a recirculation basis using fresh water and for
a minimum of four hours continuously. During this test the following parameters will be
recorded:(i)
motor phase currents and voltages
(ii)
pump output
(iii)
(iv)
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Part
(v)
power consumed
(vi)
power factor
(vii)
vibration
(viii)
Page 12
the commissioning trials shall extend until each pump unit has run continuously for at
least 3 days under all operating conditions. The term continuously shall include
running at various speeds or on a start/stop basis as determined by the control system
(g)
the Contractors supervisory staff, and the pump manufacturers staff if required by the
Project Specification, shall be present during the period of the tests and trials. The
Contractor shall be responsible for any failure of the whole equipment or any part
thereof, whether such failure shall be determined by the methods detailed herein or
otherwise. If the pump test or trial is interrupted by the Contractor, or through
negligence on the part of the Contractors staff, it shall be completely repeated for the
pumpset concerned.
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(f)
The operation, over the entire specified range, shall be free of cavitation, excessive vibration
or noise.
Vibration shall be checked and recorded. The full speed vibration of all pumps shall be within
acceptable limits as 4.2.2.8 Excessive vibration shall constitute sufficient cause for rejection
of the equipment.
Each pump performance shall be documented by obtaining concurrent reading showing

motor voltage and amperage, pump suction head and pump discharge head as follows:
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readings shall be documented for a least four pumping conditions to ascertain the
actual pumping curve
(b)
one test shall be at shutoff head
(c)
each power lead to the motor shall be checked for proper current balance.
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(a)
Bearing temperatures shall be determined by a contact type thermometer. A running time of

at least two hours shall be maintained at the maximum specified operating head.
In the event any of the pumping equipment fails to meet the above test requirements, it shall
be modified and retested in accordance with the requirements of this Section until it meets
the specified requirements, and approval of the Engineer.
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END OF PART
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Part
05: Archimedian Screw Pumps
Page 1
ARCHIMEDIAN SCREW PUMPS.................................................................. 2
5.1
GENERAL ...................................................................................................... 2
5.1.1
5.1.2
5.1.3
Scope
References
Submittals
5.2
PRODUCTS ................................................................................................... 3
5.2.1
5.2.2
5.2.3
5.2.4
5.2.5
5.2.6
General
Design Conditions
Materials
Fabrication
5.3
5.3.1
5.3.2
Installation
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3
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4
8
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Page 2
ARCHIMEDIAN SCREW PUMPS
5.1
GENERAL
5.1.1
Scope
This Part specifies the requirements for the design, manufacture, construction, installation
testing and commissioning of open type Archimedes screw pumps.

General
Drainage Works
Electrical works
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Section 1,
Section 8
Section 10,
Section 13,
Section 21
References

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5.1.2
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BS 970 (ISO 683) ......Wrought steels for mechanical and allied engineering purposes
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BS 1400......................Copper alloy ingots and copper alloy and high conductivity copper
coatings
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BS 3496 (ISO 1888) ...E glass fibre chopped strand mat for the reinforcement of polyester
and epoxy resin systems.
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BS 3749......................E glass fibre woven roving fabrics the reinforcement of polyester and
epoxy resin systems
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BS 4395......................High strength friction grip bolts and associated nuts and washers for
structural
engineering
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BS 4604 (ISO 225, 272, 885, 887, 888, 4759) The use of high strength friction grip bolts in
structural steel.
BS 4870......................Approval testing of welding procedures
BS 4871......................Approval testing of welders working to approved test procedures

BS 5512......................(ISO 281) Methods of calculating dynamic load ratings and rating life
of rolling bearings
BS 5950......................Structural use of steel work in building
BS 6105 (ISO 3506) ..Corrosion resistant stainless steel fasteners
BS EN 287 .................Approval testing of welders for fusion welding
BS EN 288 .................Approval of welding procedures for metallic materials
AGMA .........................
5.1.3
American Gear Manufacturers Association Standards
Submittals
In addition to the requirements of Part 1 of this Section, the Contractor shall provide data and
Design data providing the following information:
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Part
Page 3
(a)
the calculations justifying the sizing of the screw, speed, flow rate, efficiency, rating of
motor, gearbox and bearings
(b)
User certificates shall be supplied.
Shop Drawings
The Contractor shall provide calculations for the following:
the maximum deflection of the screw
(b)
the maximum static and dynamic stresses on the torque tube, torque tube -to -flight
welded joints and radial welded joints on the tube segment
(c)
the calculations shall demonstrate that, including for cyclic stress, the screw has a life
in excess of 10 years
(d)
Mill certificates for the steel used, welding consumables and procedures.
(a)
Operation and maintenance manuals and instructions. These shall include the
documentation required above and the results of any factory tests, site inspections and
testing.
5.2
PRODUCTS
5.2.1
General
All equipment shall be provided including screw, bearings, gearbox, motor drive, lubrication
system, couplings, guards and appurtenances to provide a fully operational system to
perform the duties specified herein and in the Project Specification.
The Contractor shall be fully responsible for the integrated operation and warranty of all
components supplied.
The screw pumps welding and NDT to meet the AWS D1.1 requirements.
5.2.2
Design Conditions
The pumps shall be designed to handle raw sewage with stringy wastes, rags, paper and
plastics.
The Contractor shall obtain a chemical analysis of the particular sewage to be pumped, and
select the pump materials and coatings accordingly.
The equipment shall be capable of continuous duty unattended, be fully automatic in

operation, and require the minimum of maintenance.
The design criteria for the system are given in the Project Specification. The peripheral
speed of the screw blades shall not exceed 3 m/s and the shaft speed shall not exceed
60 rpm.
The screw pumps shall be designed taking into account the emergency top water level in the
sump. The pumps may operate at this level. The tendency for the rotating assembly of the
pump to float shall be taken into consideration when selecting bearings and other
components, and also in the design of the screw assembly and fixings.
The screw pump and bearings shall be sized for the worst case i.e. the weight of the screw
and water, neglecting any buoyancy effect.
The design of the screw pump must take into account the following:
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Part
(a)
start-up inertia forces
(b)
cyclic forces during operation
(c)
deflection induced stresses
(d)
unbalanced stress effects.
Page 4
Materials
Screws shall be manufactured from mild steel, to BS 970 Part 1.
Screw covers shall be as sub-clause 9
Top and bottom bearing shall use life lubricated ball bearings
Fasteners. These shall be stainless steel, BS 970 type 316S31, except for those securing the
bearing stub shafts to the screws. These shall be to BS 4395 and BS 4604
Coating system. This shall consist as follows for the screw. Alternative coating systems shall
be to the approval of the Engineer.
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5.2.3
two component polyamide cured zinc epoxy primer, dry film thickness (DFT) 40
microns
(b)
two component micaceous iron oxide pigmented polyamide cured epoxy sealer, DFT
50 microns
(c)
two coats of two component high solids polyamine cured epoxy coating, each coat
DFT 200 microns
(d)
the steel shall be blast cleaned to ISO

microns
(e)
the remainder of the components shall be painted as Section 8.
SA 2 with a blasting profile of 40 -70
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(a)
Fabrication
Components shall be fabricated as described in the following paragraphs.
Screw pumps
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screw pumps shall be of fabricated welded construction and consist of a mild steel
screw operating in an inclined steel trough liner which shall be grouted into a concrete
channel.
(a)
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5.2.4
(b)
screws shall be electric motor driven through a heavy duty speed reducing gearbox
(c)
screws shall consist of a robust mild carbon steel tube onto which are welded two or
more cold formed helical mild steel blades to make a continuous spiral, with stub
shaft housings at the ends
(d)
screw pumps deflection shall be limited to the screw length between bearing supports
divided by 360 in accordance with the value given in BS 5950 Part 1 tables, or the
screw manufacturers recommendations
(e)
tubes shall have a minimum wall thickness of 9 mm or greater, if required, to limit the
deflection in accordance with the above
(f)
welds shall be continuous fillets on each side of each blade, except when crossing a
tube weld, which shall be continuous seam welds parallel to the tube axis
(g)
circumferential welds for joining tubes shall not occur at a greater distance than 20%
from the extremities of the finished tube. If possible they shall be at the lower end of
the tube
(h)
blades shall have a minimum thickness of 12 mm
QCS 2014

Part
Page 5
the tips of the blades shall be reinforced by means of a stainless steel strip 60mm wide
and of the same thickness as the screw. This shall be welded onto the side of the
blade, with full penetration weld
(j)
the stub shaft housing at each end of the centre tube shall effect a gradual reduction in
diameter and shall be weldable steel castings, to BS 6460 1979 equal. The stub
shafts shall be steel forging to BS 970 Part 1; 1972 or equal and the fastenings to the
housings shall not under any circumstances be subject to cyclical stressing. The stub
shaft shall be readily removable from the housing prior to transport and readily
replaceable at site. The stub shaft housing at each end should be sealed and equipped
with an accurately machined face to which the stub shaft forgings are bolted
(k)
the whole assembly, with the stub shafts bolted on, shall be placed in a lathe and
machined true after all the welding has been completed, except for the helix edge
reinforcement strips
(l)
pumps shall be equipped with a side rail or splash plate which shall extend the full
0
length of the trough and around 230 of the circumference. The splash plate shall be
fabricated from G.R.P
(m)
sufficient tolerances should be provided throughout screws, associated bearings and

transmissions to permit thermal movement of units due to ambient and operating
temperatures.
(n)
all welding shall be by welders coded to BS 4871 and BS EN 287
(o)
all welding procedures shall confirm to BS 4870 and BS EN 288.
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screws shall be supported at the top by a self aligning double spherical ball or roller
bearing designed to accommodate the required axial and radial loads
(b)
thrust shall be transferred from the shaft to the bearing by means of a thrust ring.
Circlips or locknuts are not acceptable
(c)
facilities should be provided for adjustment of bearings to permit realignment of the

screw if necessary
(d)
bearing supports shall be of fabricated steel or cast iron and shall be of adequate area
to transmit all live and dead loads to the concrete structures supporting them
(e)
a minimum of four holding down bolts shall be provided for each support
(f)
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Bearings
screws shall be supported at the bottom by ball bearings. The bottom bearing housing
and mounting shall be designed to withstand radial and axial forces including any upward
forces due to buoyancy during emergency sump level conditions. A sensing probe for
any water entrainment on the bottom bearing housing shall be provided.
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(i)
(g)
the two halves of the bearing shell shall be identical, so that they can be interchanged
to equalise wear
(h)
seals shall consist of multiple split packing glands and labyrinth arrangement to
protect the seals from any debris in the pumped medium. It shall be possible to
renew the seals without removing the stubshaft, or supporting the screw.
(i)
alternatively the bottom bearing may comprise of an eco-friendly lubricated for life
bearing, fully self aligning in all three axis. No grease lines shall be provided. Te lower
bearing housing shall be suitable for continuous or intermittent operation when
submerged or running in air. The lower bearing housing shall be specifically designed
to exclude the pumped liquid and shall contain not less than two lip seals running in a
hardened section of the shaft. Confirmation that the lip seals are compatible with the
lubricant (pumped liquid) shall be provided.
(j)
an external stationary split cast iron shroud shall be provided to prevent detritus
damaging the bearing and seal
QCS 2014
Page 6
(k)
an external stationary split cast iron shroud shall be provided to prevent detritus
damaging the bearing and seal
(l)
bearings shall be rated for an L10 life of at least 100,000h in accordance with
BS 5512.
Gearbox
(a)
the screws shall be coupled to heavy duty totally enclosed, robust and oiltight speed
reducing gearbox rated for continuous duty, having the output shaft at right angles to
the input shaft
(b)
gearboxes shall be designed to operate continuously at the required angle of

inclination, and shall have adequate oil capacity to avoid frequent attention and shall
be equipped with a level indicator with maximum and minimum levels clearly marked
(c)
backstops shall be fitted to prevent reverse rotation of the screw when the motor is
de-energised. This may be contained within main gearboxes, or be fitted externally in
the form of a suitable brake
(d)
gearmotors in lieu of separate motor and gearbox are not acceptable
(e)
gearboxes shall be rated as AGMA standards, quality class 12 or higher, to handle

the shock loadings appropriate to the prime mover, and shall be suitably derated to
allow for frequency of operation, ambient temperature and running time
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the minimum calculated life

100 000 h as AGMA standards
under
normal
operation
shall
exceed
(ii)
adequate cooling facility for the gear box shall be provided. Cooling system
equipments from the gear box manufacturer shall be procured.
(iii)
cooling fins on the gearbox and/or fans shall not be permitted.
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(i)
transmissions shall be capable of the withstanding maximum torque

generated by the prime movers and shall be rated either 1.5 times the power needed
to drive the gearbox at its specified capacity or 1.1 times the motor Kw rating, which
ever is greater
(g)
gearboxes shall be directly driven through flexible couplings or `V' belt transmissions,
as specified
(h)
pump drives fitted with belt transmissions shall have a means for increasing the
screw speed to achieve a future increase in capacity of not less than 10 %
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belts shall be rated at 1.5 times the Kw rating of the motor, and shall be oil, heat
and static resistant.
(i)
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(f)
(j)
5
access for inspection purposes shall be allowed for in the design of the gearbox
castings.
Drive motors
(a)
the drive motor shall be a totally-enclosed fan-cooled unit as Section 1
(b)
the motor and transmission shall be continuously rated and of adequate capacity to
meet the power requirement of the pump
(c)
the motors shall be foot mounted near the gear box and supplied with slide rails
where necessary for the adjustment of belt tension
(d)
motors shall be designed to operate continuously at the required angle of inclination
(e)
motors shall have power rating 1.15 times greater than the power required to
drive the pump at its specified capacity, or be rated to drive the pump in emergency
conditions, which ever is greater.
QCS 2014

Part
Page 7
Bed Plate
The drive motor and gearbox shall be mounted on a substantial fabricated steel mounting
bed plate. The base of the fabrication shall be suitable for mounting on a horizontal concrete
mounting plinth. The fabrication shall be stress relieved when all welding is complete and
prior to machining. The bed plate shall be provided with Tee slots for bolts to facilitate
removal of the motor without lifting clear of studs or other protrusions.
Couplings
Two types of coupling shall be fitted on the screw pumps, as follows:
not less than six driving pins and bushes. The bushes shall have an inner
sleeve to allow rotation in the pin. The pins shall all be shouldered
(ii)
bosses shall be a tight fit in the shafts and shall be secured with hand fitted
keys
(iii)
couplings shall be machined balanced matching sets.
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(i)
the coupling between the motor and gearbox shall be of the fluid coupling type to
instantaneously protect the motor and gearbox should the screw become suddenly
arrested in rotation. The coupling shall be fully rated to transmit the motor full load
power without exceeding normal working temperature. The fluid coupling shall be
rated to take account of the specified climate conditions and shall be tested and
adjusted for static and dynamic balance. It shall incorporate the following features:
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(b)
coupling between gearbox and screw pump. This shall be a flexible multipin and
bush, rated as the gearbox. It shall include the following features:
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(a)
the weight of the coupling shall only be taken on the motor shaft providing the
motor shaft and bearing are adequate for the load without significant lift
reduction. Alternatively, a separate support bracket shall be provided.
(ii)
a flexible element between the coupling output shaft and the gearbox input shaft
shall be provided. Bosses shall be a tight fit on shafts and secured with hand
fitted keys.
(iii)
the casing shall be fitted with filler plugs and fusible plug for high fluid temperature
protection in event of the screw pump becoming suddenly arrested in rotation.
(iv)
internal bearings shall be adequately lubricated and all seals shall be efficient.
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(i)
the fluid used shall be inhibited against foaming oxidation and rusting and suitable
for operating in the ambient temperature range as specified.
(vi)
the filling of the coupling shall be carefully regulated to suit the torque
characteristics of the Screw and Gearbox Unit during both the starting and running
conditions.
(vii)
the slip of the fluid coupling shall be taken into consideration when sizing the
Screw Pump.
(v)
Screw Channel Covers

(a)
Insulated covers in glass reinforced plastic material shall be provided over all screw
pumps. The manufacturer shall be a specialist firm approved by the Engineer.
(b)
Covers shall be manufactured using unsaturated polyester resin with a corrosion

resistant layer on the underside of an approved resin of the vinyl ester type.
(c)
The top (or main) laminate shall be reinforced in the proportions 35% E glass as
chopped strand mat to 65% resin.
(d)
The first intermediate (or internal) insulating layer shall be of polyurethane foam or
polystyrene 50mm thick.
QCS 2014

Part
Page 8
The second intermediate (or internal) layer shall be reinforced in the proportion of 10%
E glass as chopped strand mat to 70% resin (with 20% filler). This layer shall have a
minimum thickness of 0.1mm and a maximum thickness of 1.25mm.
(f)
The lower, corrosion resistant, layer shall be reinforced in the proportion 10% C
glass veil or polyester tissue of 90% resin, this layer shall have a minimum thickness of
0.75mm and a maximum thickness of 1.00mm.
(g)
The total thickness of the internal and the corrosion resistant layers shall be 2.0mm.
(h)
The lower face of the corrosion resistant layer shall have a smooth surface finish as
produced by contact with a mould.
(i)
The upper surface of the top layer shall be provided with a non-slip finish as produced
by dusting the surface of the laminate with silica sand as soon as the resin has set to a
soft gel and removing surplus sand after 24 hours.
(j)
To prevent weathering the covers shall be treated by painting or the addition of

approved additives to the resin, to provide ultraviolet protection and to give a final
colour to be approved by the Engineer.
(k)
Covers shall consists of individual units not exceeding 30kg in weight. All joints and
fixings shall be made using stainless steel fittings and corrosion resistant gaskets all to
the approval of the Engineer. Fixings shall be such that individual units can be
removed and replaced from above.
(l)
Covers shall be capable of withstanding vertical loads of + 750 kg/m2.
(m)
Lifting handles shall be manufactured from stainless steel to BS 970 Part 1, Grade
316 S31 and the fixing shall pass through the cover such that the handle and/or fixings
can be readily replaced. Handles shall not be part of, or cast into, the covers.
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Trough Liner
Screw pumps shall be mounted in steel troughs supplied and installed by the
Contractor. The Contractor shall provide all necessary brackets and fixings for the
adequate installation of the trough within the channel.
(b)
The Contractor shall be responsible for the final alignment of the trough to provide the
correct clearances, and for the grouting-in of the trough.
(c)
The Screw Pump trough shall be a leak free mild steel fabrication of not less than
5mm thickness formed to give the correct clearances to the Screw Pump.
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The trough shall extend between the pump inlet well and the discharge channel without
distortion.
The Contractor shall provide all necessary end and intermediate
fixing/support brackets.
(d)
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(e)
(e)
The trough shall be so shaped as to avoid wedges between screw and side walls and
to provide for return of any excess liquid or solids without interference with pump
rotation.
(f)
GRP side profiles pieces shall be provided to contain the pumped liquid on the high
water level side of the screw axis. The profiles shall be fixed to the steel trough and the
channel side wall using approved stainless steel fixing bolts, to maintain a small
0
clearance around approximately 230 of the screw circumference.
5.2.5
inspections and tests have been conducted before shipment from the factory
(a)
inspection of all welds and 100% radiographic testing for full penetrated welding/butt
welding and 100% Magnetic Particle Inspection (MPI) or Dye Penetration Inspection
(DPI) for filet welding as AWS D1.1 requirements
(b)
static deflection test (unloaded)
QCS 2014

Part
(c)
measurement of coating system thickness
(d)
testing of motor as required by Section 21.
Page 9
The Contractor shall provide, from the specialist manufacturers of the screw pump
equipment, all the spares and tools required during the commissioning and maintenance
periods as specified in Part 1, including those required below.
Special tools, if required for normal operation and maintenance, shall be furnished with the
equipment.
The following spare parts shall be provided for each pump size:
1 set
Belt drives
1 set
Top bearing
Coupling rubbers
1 set
Torque release coupling
Bearing seals
1 set
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Gearbox bearings and gaskets
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1 set
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Lubricant pump system
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Bottom bearing
5.2.6
2 sets
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Rupture discs
5.3.1
Installation
The Contractor shall arrange to have the manufacturer or supplier of the equipment furnished
under this Part provide the services of competent factory-trained personnel to supervise the
installation and initial operation. Installation of all assemblies and components shall be in
accordance with the details indicated on the approved shop drawings and the printed
instructions of the manufacturer.
5.3.2
The Contractor shall operate each pumping unit over the entire designated operating range.
The operation over the entire range shall be free of vibration and noise.
The screw shall be run dry and the following monitored over a 1 day period:
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5.3
(a)
motor power consumption
(b)
gearbox, top and bottom bearing temperature
(c)
lubricant temperature
(d)
Backstop temperature.
The screw shall be run with water in and the following monitored over a 7 day period
(a)
water flow rate or depth of water the screw is immersed
(b)
motor power consumption
(c)
gearbox and top bearing temperature
QCS 2014

Part
(d)
lubricant temperature
(e)
backstop temperature
Page 10
At the end of the 7 day period the Contractor shall change the lubricants and filter in the
bottom bearing lubricant system and the gearbox. The oils shall be analysed for any
contaminants at an accredited laboratory. After a further 3 months the contractor shall return
and sample the oil in the both systems. These shall be analysed as above. If excessive levels
of contaminants are present in the oil, then the Engineer will instruct the Contractor to take
action accordingly.
The lubricants shall be changed at the end of the guarantee in all the rotating elements of the
screw pumps. These shall be analysed as above for contaminants.
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END OF PART
QCS 2014

Part
06: Surge Control System
Page 1
SURGE CONTROL SYSTEM ........................................................................ 2
6.1
GENERAL ...................................................................................................... 2
6.1.1
6.1.2
6.1.3
6.1.4
6.1.5
6.1.6
Scope
References
System Description
Submittals
Quality Assurance
Warranty
6.2
PRODUCTS ................................................................................................... 4
6.2.1
6.2.2
6.2.3
6.2.4
6.2.5
Design Conditions and Performance Characteristics

Materials
Fabrication
6.3
6.3.1
6.3.2
Installation
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2
2
3
3
4
4
4
5
6
7
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QCS 2014

Part
Page 2
SURGE CONTROL SYSTEM
6.1
GENERAL
6.1.1
Scope
The Part specifies the requirements for the design, manufacture, construction, installation,
testing and commissioning of complete surge protection systems, including flywheels, surge
vessels, compressors, air valves and necessary accessory items.

General
Submersible Pumps
Centrifugal Pumps
Section 1,
Section 8,
Section 10,
Section 21,
General
Drainage Works
Electrical Works
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This Section
Part 1,
Part 2,
Part 3,
References

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BS 449, ......................The use of structural steel in building

BS 729 (ISO 1459, 1460, 1461) Hot dip galvanised coatings on iron and steel articles
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BS 1387 (ISO 65) .......Screwed and socketed steel tubes and tubulars and for plain end
tubes suitable for welding or screwing to BS 21 pipe threads
BS 1571 (ISO 1217) ...Testing of positive displacement compressors and exhausters
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BS 2872,.....................Copper and alloy stock and forgings

BS 3601 (ISO 2604) ...Specification for carbon steel pipes and tubes with specified room
temperature properties for pressure purposes
BS EN 1092,..............Circular flanges for pipe, valves and fittings

BS 5304,.....................Code of practice for the safety of machinery
ASME VIII Div. 1, ........Boiler and Pressure Vessel Code, Design and Fabrication of Pressure
Vessels
6.1.3
System Description
Hydraulic Design. Surge control devices are to be provided where necessary at all pumping
stations. The Contractor shall assume no inertia assistance from any air valves fitted. Air
valves will not be accepted as a primary means of surge suppression. Flywheels may be
used. In the case of multiple pumping mains separate surge suppression systems shall be
provided for each main. The design shall include for the worst case i.e. surge conditions
existing when the system is pumping at maximum rate and a power failure occurs. Surge
analysis shall be based on the friction factor used for new pipelines. Pump manufacturer
shall carry out surge analysis for the whole system including the pipe work within the
pumping station.
QCS 2014
Page 3
System Design. The following types of system may be used for surge protection:
(a)
flywheels. These shall be used where there is sufficient reserve capacity of liquid in
the wet well or surge tower {see (b)} at all times to allow the flywheel to continuously
recharge the main with liquid
(b)
surge towers. Their use is only applicable when the total head developed by the
pump is low
(c)
hydropneumatic atmospheric surge vessels. Their use is only applicable when the
static head in the rising main is low. They shall incorporate a dip tube and a float air
valve which allows air in and out of the vessel depending on the liquid level in the
vessel.
(d)
bladder type pressure vessels. Their use is only applicable when no negative
pressures occur in the main in either a surge condition or normal operation
(e)
hydropneumatic surge vessels with compressors. Their use is only applicable where
there is a substantial static head in the rising main
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Air Valves. Air valves shall be installed on the rising main as specified or required to optimise
the hydraulic efficiency of the main. They shall comply with Section 8 Part 5.
6.1.4
Submittals
In addition to the submittal requirements of Part 1 of this Section, the Contractor shall submit
data and information as the following paragraphs.
Design Data:
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Hydraulic Calculations. The Contractor shall submit a complete computer

based hydraulic transient analysis showing the performance of the surge control
system under various model scenarios. Normal operating modes and the sudden
shut down of the pump following a power failure shall be simulated. The program
shall have the facility to model the characteristic of the different manufacturers air
and reflux valves, and any other proprietary equipment
(b)
structural calculations. Structural calculations for the design of the pressure vessel
and its supports shall be provided.
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(a)
Shop drawings: Shop drawings shall be provided for the fabrication and erection of the whole
system, including air compressors, air valves, surge vessels. Layout drawings, pressure
vessel calculations, schematic drawings and electrical drawings shall be provided.
Catalogue pages, manufacturers detail instructions, templates and installation methods shall
be provided.
documentation required by Part 1 of this Section on the surge protection system in the
operation and maintenance manuals. A copy of the surge analysis and site tests as
described below shall also be included. Documentation for the compressors in accordance
with BS 1571 shall be provided
6.1.5
Quality Assurance
Both the Company carrying out the surge analysis and the software used for the computer
transient analysis shall have a proven record in surge analysis. Software used shall be a
recognised water industry standard.
The Contractor shall employ Third Party Agency (TPA) to oversee the design, fabrication and
testing of pressure vessels as defined in PD5500. The independent testing authority shall
report direct to the Engineer.
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QCS 2014

Part
Page 4
Warranty
In addition to the guarantee requirements of Part 1 of this Section, the Contractor shall
ensure that the Company carrying out the surge analysis provides a warranty of the
performance of the entire surge protection system. This shall not in any way relieve the
Contractor of his contractual obligations.
6.2
PRODUCTS
6.2.1
Design Conditions and Performance Characteristics
Unless specified otherwise in the particular Project Specification, transient surge pressures
shall be limited as the following paragraphs.
Positive (over) pressure - Positive surge pressures shall not exceed the design pressure of
the pipeline, taking into account any de-rating for temperature. The rating of pipeline
restraints and thrust blocks shall be considered in limiting the positive pressure.
Negative (under) pressure - Negative surge pressures shall not exceed the following:
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6.1.6
GRP, asbestos cement, and cement lined ductile/cast iron and steel-limit 1 metre of
vacuum (-1 metre)
(b)
Bitumen lined ductile/cast iron and steel-limit 3 metres of vacuum (-3 metres)
(c)
uPVC, ABS, HDPE, MDPE - limit 3 metres of vacuum (-3 metres).
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(a)
Stress cycling. Certain types of plastic pipeline can fail prematurely due to duty cycling.
Where the pump start/stop cycling is likely to be high this should be considered.
Pipeline Manufacturers Recommendations. In all instances the recommendations of the

pipeline manufacturer with respect to positive and negative pressures and stress cycling
must be followed. Pipeline seals must be included in these recommendations.
Surge Vessels. These must be designed, inspected and tested in accordance with PD 5500
Code 2 with a 2.0 mm corrosion allowance Design pressure ratings shall be 1.25 times the
greatest pressure the vessel will be subject to. Vertical vessels shall be used wherever
possible for sewage. Any supports or plinths shall designed for the vessel to be completely
full of liquid.
Surge protection equipment shall be chosen in the following order of preference:
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(a)
flywheel to be used in all cases where high head is involved to protect against valve
slamming,
(b)
surge vessel
(c)
combination of flywheel and surge vessel
6.2.2
Materials
Surge Towers. If these are constructed in concrete, then Section 8 shall apply. If in the
same material as the pipeline, then the specifications applying to the pipeline shall apply.
Surge vessels. These shall be constructed from steel in accordance with PD 5500.
Coatings. Surge vessels shall be coated internally with an epoxy paint system of minimum
thickness 300 microns. The system shall be proven in use in this application. The external
coating system shall be in accordance with paint system in Section 8 Part 8.
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Part
Page 5
6.2.3
Fabrication
Flywheels. These shall comply with the requirements of Part 3.
Surge Towers (stand pipes). These may be constructed in concrete, G.R.P or steel. The top
of the tower shall be vented back to the wet well or through a suitable de-odouriser. An
emergency overflow shall be provided, routed to a drain. They shall be capable of
withstanding the maximum pressure generated by the pumps or surge transients, assuming
the tower is full of liquid. Means shall be provided for draining the tower and cleaning it out.
Hydropneumatic Atmospheric Surge Vessels. These shall be constructed in steel as

specified above for surge vessels. They shall include the following features:
facility for draining the vessel. If possible, this shall be using the pressure pipeline
(b)
manway access if the vessel is large enough to accommodate this, or inspection

hatch for cleaning the vessel out
(c)
air/float valve on top of the vessel. This shall be readily accessible for cleaning and
maintenance
(d)
vent back to the wet well or a suitable drain for the above valve
(e)
pressure gauge with isolating cock to measure the maximum and minimum pressures
(f)
flanges shall be to BS EN 1092 PN 16.
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food grade iso-butyl rubber bladder. This shall have a guaranteed life of three years
in contact with the liquid pumped and at the specified temperatures
(b)
bladder pressurisation valve and gauge. This is for recharging the bladder. Access
ladders/platforms shall be provided as necessary.
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(a)
(a)
Hydropneumatic Surge Vessels with compressors. The vessel shall be constructed in steel
as specified above. The vessel shall include the features (a) (b) (e) and (f) described in 3
above and in addition the following:
liquid level gauges
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Bladder Type Pressure Vessels. These shall be constructed in steel as specified above for
surge vessels. They shall include the features (a) (b) (e) and (f) described in 3 above and in
addition the following:
(i)
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(a)
(ii)
tubular glass, liquid-level gauges with 20 mm tube outside diameter shall be

provided. The minimum viewing length shall be 600 mm per gauge. Sufficient
gauges shall be provided to view the entire operating range of water levels in
the pressure vessel. Threaded 20 mm connections shall be provided. Isolation
valves with ball checks shall be provided to prevent loss of liquid upon gauge
breakage. Valves shall be of an offset pattern with integral bonnet. Valve
bodies shall be bronze. A drain cock shall be provided on the lower valve.
Valves shall have pressure ratings of 1.5 times the maximum surge pressure
anticipated, or NP 16, whichever is greater
flanges shall be provided, NP 16 for the maximum and minimum level probe
locations, respectively.
(b)
safety relief valves.

These shall comply with the
PD 5500 and shall be
capable of passing air and water. Valves shall have a bottom inlet and side outlet.
The inlet shall incorporate a calibrated spring set to allow the valve to open at the
vessel design pressure.
(c)
air pipework. Air piping shall be galvanised to BS 729 and conform to BS 1387 or
BS 3601, of a minimum of 25 mm diameter.
A brass ball valve shall be
provided as a block valve at the pressure vessel. Brass check valves shall be
provided in the air line. All shall be rated for 16 bar.
QCS 2014
Page 6
air compressor assembly

(i)
the compressor unit shall be self-contained and consist of a single-acting, two-
(ii)
stage, if necessary, air-cooled, reciprocating-type compressor motor with V-belt

drive and regulation, on a fabricated steel skid. Valves shall be of stainless
steel and shall be easily removed or inspected without use of special
tools.
(iii)
the compressor shall be driven by an electric motor which shall comply with
Section 21
(iv)
the air inlet filter silencer shall be of the dry replaceable cartridge type
(v)
the compressor shall shut down at unsafe oil level and shall not restart without
adding oil
(vi)
if necessary, the compressor shall be provided with finned tube, air-cooled

intercooler to remove the heat of compression. The compressor shall have an
automatic centrifugal starting unloader valve which will cause the pressure in
the compressor cylinders to be vented to atmosphere upon compressor
stopping, thereby allowing the compressor to start against minimum load
(vii)
rotating parts shall be guarded in conformance with BS 5304
(viii)
the oil sump on each compressor shall be fitted with a valve and drain
extension pipe of sufficient length to enable the oil to be drained without spilling
over the base. Sumps containing 1.0 or less may be fitted with a capped pipe.
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automatic air volume control system
the automatic air volume control system, in conjunction with pressure vesselmounted sensor probes and the air compressor unit, shall control the air/water
ratio in the hydropneumatic pressure vessel and maintain the air/water ratio
within a range compatible with the surge control system design and established
system static and maximum operating pressures
(ii)
contacts shall be provided for remote indication of excessive high or low water
level in the vessel.
Capacitance type level probes with a probe well
plumbed to the side of the hydropneumatic vessel shall be provided as
Section 10. A control panel with all necessary controls, relays and time delay
circuits to actuate the air add/vent solenoid valves, and signal a high or low
tank water level shall be provided.
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(d)

Part
Solenoid Valves
(i)
solenoid valves of sizes 5 mm through 40 mm for air service shall have forged
bronze bodies to BS 2872 with Teflon seats. Internal plunger, core tube,
plunger spring, and cage assembly shall be stainless steel BS 970 Part 1
316S12. Solenoid enclosures shall be IP 68. Valve actuators shall be 240Va.c.
Seals shall be Teflon. Valves shall have a maximum operating pressure and a
maximum differential pressure of 16 bar. Solenoid valves shall be energised to
open.
6.2.4
inspections and tests have been conducted at the factory and submit to the Engineer prior to
shipment.
Surge Vessels. These shall be inspected and tested in accordance with ASME VIII Div.1
sewer class (Welding, Non Destructive Testing (NDT), Hydro test, etc.)
Compressors. These shall be inspected and tested in accordance with BS 1571.
Motors and control panels. These shall be inspected and tested as described in Section 21.
QCS 2014

Part
Page 7
Control System. This shall be inspected and tested as described in Section 10.
6.2.5
The Contractor shall provide from the specialist manufacturers of the surge equipment all the
spares and tools required during the commissioning and maintenance periods as specified in
Part 1, including those required below.
Special tools, if required for normal operation/or maintenance of any component of the surge
control system, shall be supplied with the equipment.
Air Valves. A complete seal/gasket set shall be provided for each air valve installed.
Control panels and control systems.
Compressors.
6.3
6.3.1
Installation
All equipment shall be installed and commissioning in accordance with the manufacturers
recommendations and under the supervision of the surge control system suppliers factory
trained personnel.
6.3.2
Surge protection system performance shall be verified by field tests at pumping rates
specified for each pressure main and for power failure at the maximum pumping rate. The
surge control system supplier shall provide a chart recorder and pressure transducer system
to develop a permanent record for each pressure main test.
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END OF PART
QCS 2014

Part
07: Lifting Equipment
Page 1
LIFTING EQUIPMENT ................................................................................... 2
7.1
GENERAL ...................................................................................................... 2
7.1.1
7.1.2
7.1.3
7.1.4
Scope
References
System Description
Submittals
7.2
PRODUCTS ................................................................................................... 3
7.2.1
7.2.2
7.2.3
7.1.1
7.2.4
7.2.5
7.2.6
7.2.7
7.2.8
7.2.9
7.2.10
General
Design Conditions
Davits
Monorail Travelling Hoists
Cranes
Manually Operated Chain Blocks
Electrically operated Rope Lifting Hoist
Mechanical Components
Electrical Components
7.3
7.3.1
7.3.2
Installation
Site Tests
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2
3
3
3
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4
4
5
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6
7
8
9
9
10
10
QCS 2014

Part
Page 2
LIFTING EQUIPMENT
7.1
GENERAL
7.1.1
Scope
This Part specifies the requirements for the design, manufacture, construction, installation,
testing and commissioning of hoists, monorails, bridge cranes trolley assemblies, davits and
A frames.

General
Drainage Works
Electrical Works
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Section 1,
Section 8,
Section 10,
Section 21,
References
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ASME B30.9 ------------ Synthetic round sling endless

ASME B30.10 ---------- Cranes, hooks
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7.1.2
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BS 466 (ISO 4301, 8306) -- Power driven overhead travelling cranes, semi-Goliath and
Goliath chain for general use
BS 729 (ISO 1459, 1460, 1461)-- Hot dip galvanised coatings an iron and steel articles
BS 449 ------------------- The use of structural steel in building
BS 466, Power driven overhead travelling cranes.
BS 302 (ISO 2408) ---- Stranded steel wire ropes
BS 2853 ----------------- The design and testing of steel overhead runway beams
BS 2902 ----------------- Higher tensile chain slings
BS 2903 ----------------- Higher tensile steel hooks
BS 2903,----------------- Higher tensile steel hooks for chains, slings, blocks and general
engineering purposes
BS 3032 ----------------- Higher tensile steel shackles
BS 3114,----------------- Alloy steel chain, grade 80. Polished short link calibrated load chain
for pulley blocks
BS 3243 ----------------- Hand-operated chain blocks
BS 3243,----------------- Specification for hand operated chain blocks
BS 3551,----------------- Alloy steel shackles
BS 4942,----------------- Short link chain grade (T) 8
BS 4941 (IEC 292) ---- Specification for motor starters up to and including 1000 V a.c and
1200 V d.c.
BS 5304,----------------- Code of practice for safety of machinery
BS 5714,----------------- Method of measurement of resistivity of metallic materials
BS 5744,----------------- Code of practice for safe use of cranes
BS 6231,----------------- PVC-insulated cable for switchgear and control gear wiring
BS 6346,----------------- PVC-insulated cables for electricity supply
BS 6405,----------------- Non-calibrated short link chain (grade 30) for general engineering
purposes
BS 2573 (ISO 4301) -- Rules for the design of cranes
BS 6994,----------------- Steel shackles
BS 7121,----------------- Code of practice for safe use of cranes
BS 7613,----------------- Hot rolled quenched and tempered weldable structural steel plates
BS 7668,----------------- Weldable structural steels. Hot finished structural hollow sections in
weather resistant steels
BS 7671,----------------- Requirements for electrical installations
BS 4942 (ISO 1834, 1835, 3075-3077) Short link chain for building purposes
BS 6994 (ISO 2415) -- Steel shackles for lifting purposes
QCS 2014

Part
Page 3
BS EN 287 -------------- Approval testing of welders for fusion welding

BS EN 288 -------------- Approval of welding procedures for metallic materials
BS EN 1492-1 ---------- Flat woven webbing slings
BS EN 10113 ----------- Hot-rolled products in weldable fine grain structural steels
BS EN 10155 ----------- Structural steels with improved atmospheric corrosion resistance
BS EN 10210 ----------- Hot finished structural hollow sections of non-alloy and fine grain
structural steels
BS EN 13414-2 -------- Specification for information for use and maintenance to be provided
by the manufacturer
BS EN 13414-1 -------- Slings for general lift services
BS EN 60947 ----------- Low voltage switch gear and control gear.
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ISO 4309/3481 Part 2 Methods of measuring the performance of laboratory electric

resistance furnaces.
ISO 2903 ---------------- ISO metric trapezoidal screw threads tolerances
ISO 7592 ---------------- Calibrated round steel link lifting chains
System Description
General. Lifting equipment shall be provided as required to remove equipment for

replacement and/or maintenance purposes. The design shall ensure safe access is provided
for the operation of the lifting equipment. Overhead cranes may also be required to grant
access for maintenance of roof mounted equipment such as light fittings, fans, and shall be
designed to facilitate this. Davits shall only be used to lift submersible pumpsets and other
equipment from wells. Lifting equipment shall be supplied with all the necessary spacers,
clamps, harnesses, slings, D links and eye bolts to lift any of the installed plant. Guards shall
be provided in accordance with Part 1.
7.1.4
Submittals
Design data. Complete structural calculations of crane and monorail member and
component sizing and design, shall be submitted, as required by BS 2573, BS 2853 and the
building requirements.
Shop Drawings. These shall be submitted as required by Part 1. Lay-out drawings shall
clearly show the lifting height of the equipment and clearances in relation to other equipment
and structures where the largest items are lifted.
Test certificates shall be submitted as required under factory inspection and testing.
Operation and maintenance manuals and instructions. The Contractor shall include all the
documentation required by Section 1 on the lifting equipment in the operation and
maintenance manuals. A copy of the design data, factory and site tests shall be included in
the manuals.
7.2
PRODUCTS
7.2.1
General
Hoist monorails, bridge cranes, davits and A frames shall include all equipment,
appurtenances and auxiliaries to make the lifting equipment fully operational and capable of
performing under the specified load conditions.
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7.1.3
QCS 2014

Part
Page 4
Lifting systems, including hoists, as far as feasible, shall use the standard components of one
manufacturer to simplify maintenance.
Nameplates shall be permanently attached to the monorail hoist and bridge crane hoist
assemblies. The lifting capacity shall be stencilled on in tonnes in both Arabic and English on
each side and shall be clearly legible from the working level.
Warning signs in the Arabic and English languages shall be provided to the approval of the
Engineer and affixed to the bottom lift blocks or pendant controllers.
7.2.2
Design Conditions
Cranes and lifting equipment shall be suitable for indoor or outdoor installation, as
designated.
The high ambient temperature in which lifting equipment and particularly cranes may be
required to operate shall be taken into consideration, particularly with respect to the electrical
load ratings of motors, switchgear, resistors, cables and wiring, as well as mechanical heat
sources such as brakes, bearings and gearing. Due allowance shall be made for possibly
higher temperatures than the maximum recorded shade temperature near the roofs of
buildings, if the lifting equipment is mounted in a building, or for the effect of direct sunlight if
mounted externally.
Design of travelling monorail hoist and bridge crane hoists and incidental accessories shall
be based upon the use of a factor of safety of 5, structural beans shall have a factor of safety
of 2 with capacity load on all mechanical parts of the system. The factors of safety shall be
based upon the ultimate strength of the material used. The equipment shall be of ratings and
sizes designated in the Project Specification.
Lifting equipment shall be rated for the load of the heaviest installed item of plant, and
designed such that one man can operate it without difficulty.
Hooks and load chains shall reach to the floor of the lowest level.
Lifting equipment installations shall comply with BS 5744 and BS 7121.
7.2.3
Davits
Davits and sockets shall be fabricated from fully welded mild steel, to BS 7668, BS 7613, BS
EN 10155, BS EN 10013, galvanised and protected in accordance with BS 729 and Section
8.
Davits too heavy to manhandle shall consist of a davit arm, with removable pillar, and rotating
removable jib arm.
Davits shall have a roller thrust bearing swivel for the upright pillar, with a locking
mechanism.
Sockets shall be cast-in, unless bolted sockets are specified, or it is not possible to fix cast-in
sockets. A rubber socket plug with a stainless steel chain shall be provided to prevent sand
ingress when the davit is not in use.
7.2.4
Monorail Travelling Hoists
Each hoist shall comprise a manually operated geared travelling pulley block complete with
steel runway beams, A frame supports where specified and all accessories including slings
and spreaders.
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QCS 2014

Part
Page 5
Pulley blocks shall be manually operated up to a height of 6 to 8 m. Above 8 m electric

hoists shall be provided.
The runway beams shall be designed, tested and certified in accordance with BS 2853.
The blocks shall run on the lower flange of the runway beam and shall be of the spur geared
close haul type.
The blocks shall be complete with a geared travelling trolley and shall be capable of being
easily removed from the trolley without the necessity for dismantling. The operating chain for
the longitudinal motion of the trolley shall extend to within 600 mm of the floor.
Load chain collection boxes shall be provided.
Monorail systems shall not be used for loads exceeding 2000 kg.
7.2.5
Cranes
Cranes shall comprise end carriages and bridge units to be bolted together on site, during
erection.
Cranes shall be single girder or double girder as designated.
All exposed moving parts of the drive mechanisms shall be fitted with safety guards wherever
possible, in accordance with Part 1.
The bridge girders, end carriages and crab structures of the crane shall be designed and
constructed in accordance with all the relevant requirements of BS 466 and BS 2573. With
the crane operating under maximum service load, the stress in any operating component
shall not exceed the permissible values stipulated in Part 1 of BS 2573. The crane
manufacturer shall supply all the information required in Appendix B of BS 466.
The main bridge girders shall be plate or box girder designed as compound beams with the
rails for the crab track secured on the top flange.
Jacking points and tie downs shall be provided for both bridge and crab.
7.2.6
Manually Operated Chain Blocks
The hoisting wheel shall be grooved and pocketed to receive the load chain. The load chain
shall be stainless steel chain Grade 80 to BS 3114.
Hand chains shall be to Grade 30 BS 6405 or better.
Chain guides shall be provided to ensure effective guidance of the load chain into the load
chain wheel pockets. A stripper shall be provided to ensure effective disengagement of the
load chain from the load chain wheel.
The idler wheel scores shall be so shaped as to avoid twisting the chain as it passes round.
The pitch diameter of the idler wheels shall not be less than 16 times the size of the chain,
unless they are so shaped as to avoid a bending action on the link.
The load chain anchorage, associated fittings and framework at the slack end shall be rated
at 2.5 times the maximum tension in the load chain when the working load limit is being lifted.
Any link used for connecting the load chain to a terminal fitting shall be of the material
specified for the chain and heat treated to provide mechanical properties and strength
equivalent to those of the load chain.
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QCS 2014

Part
Page 6
The hook shall be made from high grade forged stainless steel complying with BS 2903 C
type and provided with a safety catch. The hook shall be supported on a ball thrust bearing
to allow free swivelling under full loads.
The sheaves of the hook block shall be guarded to prevent a hand or fingers being trapped.
The crab hoisting gear shall be such that one man is capable of easily raising the maximum
load.
A galvanised mild steel chain collecting box shall be incorporated.
10
A reliable and effective braking and locking arrangement shall be provided.
11
Lifting blocks supplied for lifting equipment from wet wells shall be of stainless steel and shall
include the facility for obtaining a fresh lift on the equipment lifting chains at 1 metre intervals.
7.2.7
Electrically operated Rope Lifting Hoist
All hoists above a height of 8 m shall be electrically operated.
The hoist rope drum shall be of high quality cast iron with left and right hand spiral grooves to
accommodate the hoist rope in one layer. As far as possible, the drive gearing shall be fixed
directly to the rope drum to obviate high torsional stress in the drum shaft. The rope shall be
securely clamped to the drum.
The hoist drum shall incorporate a wire rope rewind system and guides to prevent the hoist
rope skipping and damaging the lay.
The hoist braking system shall be of the automatic electro-mechanical fail safe type which,
when the current is cut off or fails will automatically arrest the motion and hold at rest any
load up to and including the rated load. The system shall safely control the lowering of the
same load form the highest to the lowest point of lift and shall not allow any slippage of the
suspended load to occur when the Raise motion is initiated.
The hoist rope shall be a flexible wire rope specially designed for usage with cranes and in
accordance with BS 302, with a safety factor of not less than six times the maximum tension
induced by the safe working load.
The crane hook shall be of high grade forged steel trapezoidal section in accordance with BS
2903, C type. The hook shall be supported on a ball thrust bearing to allow free swivelling
under full loads and shall also be fitted with a safety catch. The safe working load shall be
marked in the hook in accordance with BS 2903.
The sheaves of the hook block shall be guarded to prevent a hand or fingers from being
trapped between the sheaves and the in-running rope.
A limit switch shall be fitted to prevent over hoisting. This shall be self-resetting, closing
automatically when the hoist motor is put in reverse.
Brakes shall be well protected from oil and grease leakage or spillage, and from adverse
effects of atmospheric condensation or dust. A simple and easily accessible means of
carrying out adjustment for wear of the shoes or linings shall be provided for all brakes.
10
Automatic brakes, operating when the drive motor stops shall be supplied for the long and
cross travel motions.
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QCS 2014

Part
7.2.8
Mechanical Components
End Carriage
Page 7
both end carriages of electrically operated cranes shall be powered either by a

duplicate geared motor drive, or by a single motor unit and a layshaft system.
Longitudinal and cross traverse motions shall be provided on the crane such that the
operation is speedy without impairing safety in working. The longitudinal and traverse
motions shall be operated by means of hand chains extending to within 600 mm of
the operating floor. The hoisting and lowering chains shall be of the same length.
The hook and load chain shall be such that the hook will reach to the lowest floor
level. The operating chain for the longitudinal motion of the crane shall be suitably
positioned to enable the operator to move the unit easily, without dragging the
operating chains over the control panels or other equipment
(b)
the runner wheels shall be of cast steel, with double flanges, mounted on roller
bearings, or fitted with phosphor-bronze bushes running on hardened steel axles.
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Crab Unit(s)
the crab frame shall be in accordance with BS 466 and shall provide a strong rigid
framework for the hoist and cross-travel machinery mounted thereon. The placement
and layout of mechanical and electrical items shall facilitate easy inspection, service
and maintenance of the motors, reduction gearing and braking system
(b)
the runner wheels shall be of cast steel with double flanges and mounted on roller
bearings. Gearing shall be of totally enclosed type with machine cut gears. Bearings
shall be ball or roller.
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(a)
Endstops. Resilient or spring type buffers shall be provided on all runway/cross beams and
crane rails. Where carriages are equipped with electric travel the endstops shall be provided
with limit switches at the end of each direction of travel.
Crane Rails. These shall comply with BS 449 and BS EN 10155 The line of the rails shall not
vary by more than 3mm throughout the whole length of travel. Whenever possible, rails shall
be one piece. Where rails are to be jointed this shall be by electrical induction welding.
Access Platforms And Ladders
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safe means of access shall be provided for examination and maintenance of the
crane or other equipment only accessible from the crane. Guards shall be fitted
where possible under the crab and long travel motor and gearbox assembly to
prevent persons on the ground being endangered by falling objects during
maintenance
(a)
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(b)
all ladders, platforms and access ways shall comply with Section 8. Open mesh
flooring shall not be used. Access ways shall be not less than 800mm wide. The
platforms and access ways shall be securely fenced with double tiered guard rails and
steel toe boards or kicking plates.
Painting. This shall be in accordance with Section 8.
Materials. Steel used for the fabrication of the lifting equipment shall comply with BS 449, BS
7613, BS 7668, BS EN 10113, BS EN 10155 and BS EN 10210 as applicable. Welding
procedures shall comply with BS EN 287 and BS EN 288
QCS 2014

Part
7.2.9
Electrical Components
Motors
Page 8
motors shall comply with the Part 1 of this Section and Section 21 except they shall be rated
for 150 starts per hour (Duty type S7) for not less than one hour with a shaft
output power at least 15% greater than the maximum power which will be required for
operation and testing of the crane in the ambient temperature specified, at the
maximum rated load.
Control Gear
a triple pole isolating switch with HRC fuses shall be provided at ground level for
each lifting assembly. This switch shall be lockable in the OFF position only and
shall be provided with a Yale type lock and three keys. The switch shall have a label
marked CRANE ISOLATING SWITCH in English and Arabic.
(b)
starters and controllers for the crane motors shall be designed and constructed in
accordance with the requirements of BS 466, BS 4941, BS EN 60947 and
section 21. All control circuits shall operate at 110 volts
(c)
mechanically and electrically interlocked reversing contactors shall be provided for

each motion including speed control of the hoist. Accelerating contactors shall cut out
the rotor circuit resistance of the motor in steps with suitable delays. Contacts shall
be adjustable and renewable
(d)
controller and resistors shall be rated such that temperatures do not exceed the limits
specified in BS 4941 during operation of the crane under maximum temperature
conditions. Starting resistors shall have not less than a ten minute rating. Speed
control resistors shall be one hour rated
(e)
the control gear and cabling shall be suitable for inching i.e. many repeated small
movements at both creep and normal speed, in any direction of motion
(f)
the starters and controllers shall be housed in well constructed sheet steel panel
cabinets of not less than 2mm thick, sprayed and painted with an anti-condensation
paint. The enclosures shall be protected against dust and damp to classifications
IP 54. Starting resistors shall be mounted in a ventilated section of each control
cubicle. The resistors shall all be fitted with terminal bars. The control cubicles shall
be provided with lockable hinged access doors, also interlocked with the main
isolating switch.
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(a)
Controls
(a)
the long-travel, cross-travel and slow and normal speed hoist motions of each crane
shall all be controlled from the lowest level by a pendant push button station. The
controls shall operate on a low voltage system supplied by a double wound isolating
transformer. Both primary and secondary sides of the transformer shall have HRC
fuse protection. One pole of the secondary winding shall be effectively earthed
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(b)
push button controls shall be of the pendant type with hold-on type push buttons
automatically returning to the off state on release of the button. Push buttons shall
be provided for SLOW -UP, SLOW DOWN NORMAL UP, NORMAL DOWN,
LEFT, RIGHT, FORWARD AND REVERSE. A larger size red Emergency Stop
button shall initiate tripping of the control gear main circuit breaker and automatic
application of the brakes on all motions. Re-closure of the main circuit breaker shall
be initiated by a separate Reset button also on the pendant. The pendant shall be oil
tight polyethylene, totally enclosed to IP65, shockproof, and shall be suspended
from the crab unit. The voltage at the pendant shall not exceed 55 volts to earth
(c)
limit switches shall be provided for all motors at the end of each direction of travel
QCS 2014
(d)
Page 9
infrared or radio remote control shall be provided, where specified, or if necessary for
safe operation of the crane. Two battery packs with battery charger, sensors, sensor
connecting cables with clips, receiver and decoder shall be provided. Adequate
sensors shall be provided at each level (minimum three) to ensure continuous control
in all zones of operation. If radio is used then approval shall be obtained by the
Contractor for the frequencies used.
Cables wiring and earthing

(a)
an insulated conductor system shall be provided for electrically powered cranes

supply. The insulated conducted system shall be of the type where each phase is
individually insulated and supported on a metal support. The type where all
conductors are contained within a single extruded or moulded insulation will not be
permitted. A festoon insulated cable system shall be provided for the cross-travel
supply
(b)
the wiring and earthing of the cranes shall conform to BS 466. Cables and wiring
shall be of 600/1,000 volt grade PVC insulated cables in accordance with BS 6231
and BS 6346. Wherever possible, the cables shall be run in screwed heavy gauge
galvanised steel conduit. All cable ends shall be clearly labelled with identification of
the appropriate terminals
(c)
the selection installation and testing of cables and wiring shall be in accordance with
BS
7671
except
that
maximum
current
ratings
shall
be
raised
by a factor of 1.4 times the rating for continuous duty obtained (after applying all
necessary de-rating factors for high
ambient temperature, grouping and
disposition form of installation, etc). The up-rating factor of 1.4 is based on the one
hour motors specified for crane operation
(d)
the crane structure, tracks, motor frames and metal cases of all electrical equipment,
including metal conduit and cable guards, shall be earthed in accordance with
BS7671.
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Part
The Contractor shall secure from the lifting equipment manufacturer certification that the
following inspections and tests have been conducted on each lifting equipment at the factory,
and submit to the Engineer prior to shipment.
Cranes shall be inspected and tested in accordance with the requirements of BS 466 with the
difference that the Tests on Purchasers Premises (Clause 54) shall also be carried out in
the manufacturers works and witnessed by the Engineer.
The works tests shall include overload tests during which a 25% overload shall be lifted by
the hoist at the middle of the crane span and sustained under full control whilst it is moved up
and down at both normal and creep hoist speeds. Whilst still under overload the crab unit of
each crane shall be operated form end to end of its travel.
The mechanism and controls for the long travel motions shall be tested under light running
conditions without moving the crane.
Tests on manually operated cranes and hoists shall comply with the above insofar as they
are applicable.
Control panels, motor and any factory installed wiring shall be inspected tested in accordance
with Part 1 of this Section and Section 21.
7.2.11
Two years supply of spare parts and lubricants shall be supplied for each lifting device
supplied.
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7.2.10
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Part
Page 10
7.3.1
Installation
Lifting equipment shall be installed in accordance with the requirements and instructions of
the manufacturer. If specified in the Project Specification, the lifting equipment manufacturer
shall provide a representative to supervise the installation and testing.
7.3.2
Site Tests
After erection cranes and hoists shall be inspected, tested and certification provided by a
qualified independent crane testing specialist in accordance with the requirements of Clause
54 of BS 466 and the tests witnessed by the Engineer. Hand cranes shall be similarly tested.
Electrical equipment shall be tested in accordance with the requirements of Section 21
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END OF PART
QCS 2014

Part
08: Electric and Pneumatic Actuators
Page 1
ELECTRIC AND PNEUMATIC ACTUATORS ............................................... 2
8.1
GENERAL ...................................................................................................... 2
8.1.1
8.1.2
8.1.3
8.1.4
8.1.5
Scope
References
System Description
Submittals
8.2
PRODUCTS -ELECTRIC ACTUATORS ........................................................ 3
8.2.1
8.2.2
8.2.3
8.2.4
8.2.5
General
Motors
Controls
Actuator Mounting
8.3
PRODUCTS -PNEUMATIC ACTUATORS .................................................... 6
8.3.1
8.3.2
8.3.3
8.3.4
General
Cylinder Actuators
Diaphragm Actuators
Solenoid Valves for Pneumatic Actuators
8.4
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2
2
2
3
3
4
4
5
5
6
6
6
7
QCS 2014

Part
Page 2
ELECTRIC AND PNEUMATIC ACTUATORS
8.1
GENERAL
8.1.1
Scope
This Part specifies the requirements for the design, manufacturer, construction, installation,
testing and commissioning of electric and pneumatic actuators for valves and penstocks.
References
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8.1.2
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This Section
Part 1, General
Section 8, Drainage Works
Part 4, Pipe installation
Part 5, Valves Penstocks and Appurtenances
Part 8, Protective Coatings and Painting
Section 10, Instrumentation, Control and Automation
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BS 5501 (IEC 79) .......Electric apparatus for potentially explosive atmospheres

BS 5793 (IEC 534) .....Industrial process control valves
BS EN 60534..............Industrial control valves
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PNEUROP .................(European Committee of manufacturers of compressors, vacuum

pumps and pneumatic tools) Recommendations
System Description
Actuators shall be capable of extended and continuous operation under conditions specified
in Section 1 and at the specified valve operating pressure. Submersible actuators, if
required, shall operate at the specified temperature.
8.1.4
Submittals
Design Data. This shall include calculations justifying the sizing of valves and actuators for
the hydraulic and system requirements.
Shop Drawings.
including:
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8.1.3
Complete shop drawings for each type of actuator shall be provided,
(a)
specifications for materials of construction of actuators and all appurtenance
(b)
wiring diagrams
(c)
ratings for actuator torque, power input, cylinder or diaphragm pressures, motor
ratings and enclosures, operating speeds, and other information requested by the
Engineer
QCS 2014
(d)
4

Part
Page 3
actuator dimensions.
Operation and maintenance manuals and instructions. These shall be provided for each type
of actuator, including:
(a)
list of lubricants
(b)
lubrication instructions
(c)
complete assembly and wiring diagrams
(d)
results of all tests specified above and carried out on site
One set of manufacturers recommended spare parts for two years shall be provided for each
actuator.
One set of cover screws, gaskets, O rings and ram seals shall be provided for each
actuator.
Two years requirement of consumable supplies shall be provided for operation and
maintenance of all actuators.
8.2
PRODUCTS -ELECTRIC ACTUATORS
8.2.1
General
Electric type actuators shall include the motor, heaters, operators unit gearing, limit switches,
torque switches, declutch lever, auxiliary handwheel, reversing starter, switches, mechanical
position indicator, and accessories as required.
The valve and gate actuator motor and all electrical enclosures shall be waterproof, IP 67, as
a minimum unless explosion proof, to BS 5501, EEXD II BT4, or submersible, IP 68 is
specified.
When specified, a hammer blow mechanism, that travels sufficiently enough to allow the
motor to reach full speed before imparting a hammer blow, to start the valve or gate in motion
in either the closing or opening direction, shall be incorporated.
The power gearing shall consist of helical gears of heat-treated steel, and worm gearing of
hardened alloy steel. All power gearing shall be grease lubricated with high speed parts on
anti-friction bearings.
It shall be possible to remove the motor operator from the valve and gate without taking the
valve or gate out of service.
The valve actuating speed shall be at 300 mm per minute unless specified otherwise.
Pneumatic type actuators shall include the cylinder or diaphragm actuator, solenoid valves,
pneumatic positioners, pressure gauges, manual testing station, and other accessories, as
designated to provide a complete, functional actuator.
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8.1.5
QCS 2014

Part
Page 4
Motors
Motors shall be totally enclosed non-ventilated construction with Class F insulation with
temperature rise limited to Class B, and shall comply with Part 1 of this Section and
Section 21.
Available operating torque shall be at least two times the valve manufacturer's maximum
torque requirements. The motor shall be designed specifically for use on valve operation,
having high torque capacity coupled with low inertia.
The motor shall be of sufficient size to open or close a valve against the maximum specified
differential pressure when the voltage drop at the motor is 10 % of the nominal voltage.
Electrical power to the motor shall be 3 phase, 50 Hz, 415V for 0.4 kW or larger and 1 phase,
240V, 50Hz, for smaller than 0.4 kW.
The motor shall be pre-lubricated and all bearings shall be of the anti-friction type.
Motor rating shall be continuous duty unless otherwise designated.
Heaters and thermostats shall be provided for high humidity conditions.
Electrical and mechanical disconnection of the motor shall be possible without draining the
actuator grease or lubricant
8.2.3
Controls
Each actuator shall be equipped with a reversing starter, control relays, 2-position limit
switches and torque limiting switches.
Additional position, limit switches, hand-off-auto switch, open-auto close hand switch, open,
close, stop push-button switches, position indicating potentiometer, position indicating lights,
electric braking or a position controller, or both, shall be provided for the specified analogue
signal input, unless otherwise specified.
Position limit switches shall be double pole, double throw and provided for both open and
close positions of travel. They shall be connected directly to the valve through continuous
gearing and follow its position at all times. Switches shall be rated 10 amps at 240 V a.c.
The actuating point shall be adjustable over at least 50 % of the travel.
Torque limiting switches shall be provided and be responsive to the mechanical torque
developed in seating, backseating, or by obstruction. The torque switch shall operate a
calibrated dial integrally mounted and directly related to the torque output of the operator.
Torque control accuracy shall be within 5 %. The use of torque wrenches for calibration will
not be required.
Reversing starters shall include a reversing contactor, mechanical and electrical interlocks,
and thermal overload relays as required. The contactor shall break all lines to the motor. All
controls shall operate on 110 V.a.c.
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8.2.2
QCS 2014

Part
Page 5
Push-button switches (open-stop-close) shall be located for ease of accessibility. The

controls shall be arranged for remote operation by isolated momentary or continuous contact
switches rated not less than 2 A at 240 V a.c. Terminals shall be wired such that open and
close operation only is possible by appropriate external connections.
The hand-off-auto switch shall select between local (HAND) and remote (AUTO) control for
open, close, stop operation. In the OFF position both local and remote controls shall have no
effect.
For all modulating duty operations a 4-20 mA convertor shall be provided, powered internally
from a 24 V supply, to transmit the valve position remotely.
Position indicator lights shall be at least 2 W, green lens for open, red lens for close; shall be
interchangeable and located near the push-button switches. Both shall light when the valve
is between open and closed limits.
10
Additional position limit switches shall be fully adjustable, of the same rating, and driven in
the same manner as the other limit switches provided.
11
The position controller shall utilise an independent position feedback potentiometer and shall
accept a 4-20 mA d.c. signal for modulating the valve position, unless otherwise specified.
The final positioning accuracy shall not be less than 1 % of position specified by the signal. A
damping circuit shall prevent overshoot in excess of 2 % for a full-scale step input. The
controller may be separately housed but must be of the same class as the actuator housing.
Power shall be derived from the actuator power supply.
8.2.4
Actuator Mounting
Special mounting requirements, such as shaft and neck extensions, shall be provided as
shown on the Contract Drawings, and as required for safe operation.
8.2.5
The Contractor shall secure from the actuator manufacturer certification that each actuator
has been performance tested at the factory and individual test certificates shall be supplied
for each actuator. The test equipment shall simulate a typical valve load and the following
information shall be recorded, and included with the test certificate.
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(a)
current at maximum torque setting
(b)
torque at maximum torque setting
(c)
test voltage and frequency
(d)
flash test voltage
(e)
actuator output speed or operating time
In addition, the test certificate shall display details of specifications such as gear ratios for
both manual and automatic drive, closing direction, wiring diagram code number, remote
position transmitter resistance and interposing relay voltage, etc.
QCS 2014

Part
Page 6
PRODUCTS -PNEUMATIC ACTUATORS
8.3.1
General
The available instrument and operating air pressures and quality are as specified in the
particular Project Specification. Pressure reducing valves shall be provided where required
for each actuator.
Direct mounted pneumatic positioners shall be provided for each valve, mounted on the
valve, unless specified otherwise. Positioners shall provide 0.1 to 1 bar (gauge) output.
Electronic output of 4 to 20 mA shall be provided
Wrench or handwheel operated manual override shall be provided for each actuator, unless
otherwise specified. The force to operate these shall not exceed 25 Kgf.
Throttling manual override shall be provided for actuators where specified.
Where potentiometers are specified for positioning cylinder actuators they shall be 1000 ,
mounted, enclosed and provided with double pole double throw position indicating switches.
Test points shall be provided at each actuator to allow an external supply of compressed air
to be connected to checked the operation of the actuator and the position indicator.
Where required fail-safe actuators (fail open or fail closed, as required) shall be provided
Pressure gauges for pneumatic signal and operating air supply links shall be provided.
A filter shall be provided for each pneumatic actuator, unless specified otherwise.
10
Special mounting requirements, such as shaft and neck extensions shall be provided as
shown on the Drawings.
8.3.2
Cylinder Actuators
Cylinder actuators shall be as follows:

type: double acting cylinder, unless otherwise specified or shown. In compliance with
BS 5793, BS EN 60534 and PNEUROP recommendations as applicable
(a)
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8.3
(b)
actuator cover : cast iron or steel, complete with gaskets and seals, internally coated
with epoxy
(c)
piston : cast iron or steel, epoxy coated
(d)
piston rod : chrome plated carbon steel
(e)
solenoid control valves shall be provided with mountings and piping
(f)
actuators shall be suitable for operation at 5-7 bar, unless designated otherwise. Test
pressure shall be 10 bar
8.3.3
Diaphragm Actuators
Diaphragm type actuators shall not be provided for valves larger than 150 mm nominal
diameter unless approved by the Engineer. They shall confirm to the standards in Part 8.3.2
1(a).
QCS 2014

Part
Page 7
Diaphragm actuator construction shall be as follows:

(a)
diaphragm case and mounting hardware:

aluminium is not acceptable
(b)
diaphragm : flexible neoprene or Buna N
(c)
spring : enclosed and corrosion resistant.
cast iron, steel, or stainless steel;
8.3.4
Solenoid Valves for Pneumatic Actuators
Solenoid valve actuators shall be as follows, and to the standards in Part 8.3.2. 1(a) above
electrical characteristics : 240 or 110 V a.c., 50 Hz, single phase
(b)
enclosure : IP 68, unless otherwise designated
(c)
rated for continuous operation
(d)
fitted with spring return unless otherwise specified
(e)
the inlet shall be normally open or normally closed as required by the control system.
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(a)
Electric and pneumatic actuators shall be installed and commissioned in accordance with
The tests listed under Part 8.2.5 shall be repeated at site. In addition the actuator
performance shall be tested as part of the control system.
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8.4
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END OF PART
QCS 2014

Part
09: Odour Control Equipment - Carbon Type
Page 1
ODOUR CONTROL EQUIPMENT-CARBON TYPE ...................................... 2
9.1
GENERAL ...................................................................................................... 2
9.1.1
9.1.2
9.1.3
9.1.4
9.1.5
Scope
References
System Description
Submittals
Warranty
9.2
PRODUCTS ................................................................................................... 4
9.2.1
9.2.2
9.2.3
9.2.4
9.2.5
9.2.6
9.2.7
9.2.8
General
Materials
Fabrication
Accessories
Centrifugal Fan
Electrical Control Panel
9.3
9.3.1
9.3.2
General
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2
2
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3
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4
5
6
6
8
8
8
8
9
QCS 2014

Part
Page 2
ODOUR CONTROL EQUIPMENT-CARBON TYPE
9.1
GENERAL
9.1.1
Scope
This Part includes the requirements for the design, manufacture, construction, installation
testing and commissioning of force ventilated and passive odour control equipment.
Section 1,
Section 8,
Section 21,
General
Drainage Works
Electrical Works
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General
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This Section
Part 1,
References
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9.1.2
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ASTM D2862 ..............Test Method for Particle Size Distribution of Granular Activated Carbon
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ASTM D3467 ..............Test Method for Carbon Tetrachloride Activity of Activated Carbon
BS 848,.......................Fans for general purposes
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BS 5000 (IEC 34, 72)Rotating electrical machines of particular types or for particular
applications
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BS 3496 (ISO 1888) ...E glass fibre chopped strand mat for the reinforcement of polyester
BS 5345 (IEC 79) .......Code of practice for selection, installation and maintenance of
electrical apparatus for use in potentially explosive atmosphere
BS 6105 (ISO 3506) ...Corrosion resistant stainless steel fasteners
BS 2782 (ISO 174, 181, 307, 8618) Methods of testing plastics
BS 6339 (ISO 6580) ...Dimensions of circular flanges for general purpose industrial fans
BS EN 779, Particular air filters for general ventilation
9.1.3
System Description
Concentration of hydrogen sulphide
specification
Other Contaminants:
Mercaptans
Amines (mono/di/tri)
Ammonia
500 ppm unless otherwise specified in project
:
:
:
trace only
10 ppm
50 ppm
QCS 2014

Part
Sulphide Concentration in Solution

Removal of hydrogen sulphide gas
and ammonia
Removal of amines
Removal of mercaptans
:
:
50 mg/l
99.8 %
:
:
95 %
No requirement
Page 3
The ventilation for force ventilated systems will operate continuously.
Air shall be supplied into the wet well to dilute the air/gas mixture via a fly screened inlet.
The deodorisation equipment shall operate continuously.
The sizing and design criteria for the system are given in the particular Project Specification.
The odour system shall be designed for indoor or door out installation as shown on the
Contract drawings and as specified.
9.1.4
Submittals
In addition to the requirements of Part 1 of this Section, the Contractor shall provide
information and data as described in the following paragraphs.
Design data providing the following information:
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calculations to justify the sizing and life of the carbon bed(s) at the concentrations
given
(b)
calculations to justify the sizing of the fan(s) if forced ventilated odour control
equipment is used
(c)
user certificates
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(a)
(i)
fibreglass resin manufacturers technical data on composition and

characteristics of resin for fibreglass items including hydrostatic and burn tests
(ii)
manufacturers technical data on other equipment used
(iii)
carbon specification including test reports
dimensional layout of stack and all equipment used
(b)
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product data
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Shop Drawings providing the following information:
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(c)
4
Samples:
(a)
fan test data as BS 848.
vessel and duct GRP, pre-filter mesh, activated carbon.
Operation and maintenance and instruction manuals including:

(a)
odour reduction site test report(s) as specified in Part 9.3.2
(b)
the documentation in 3 and 4 above.
9.1.5
Warranty
The Contractor shall obtain from the Odour Control System manufacturer a warranty that his
system meets the specified odour level reduction criteria, and life for the carbon bed. This
does not in any way alter the Contractors guarantee under the Contract.
QCS 2014

Part
Page 4
9.2
PRODUCTS
9.2.1
General
All units shall be designed to operate continuously in temperatures up to 55 C with 100 %

condensing humidity and to reduce odours to an unobjectionable and unobtrusive level, and
shall consist of one of the following types, as specified.
passive deodoriser. This system will be used for totally enclosed areas without
forced ventilation where positive displacement occurs. The passive deodoriser
system shall operate as a free-standing unit suitable for outside use in the conditions
prevailing at site and shall contain pre-filter cells, activated carbon filter cells or loose
activated carbon and all necessary appurtenances. Access to the filters shall be
quick and easy without the requirements of special tools for replacement of carbon,
cells and pre-filters. The design of the entire unit shall be such as to ensure a
minimum of maintenance time
(b)
forced ventilation deodoriser system. The deodoriser shall contain pre-filter cells,
activated carbon filter cells, or loose activated carbon, fan unit, a vent stack and all
necessary appurtenances. Access to the filters shall be quick and easy without the
requirements of special tools for replacing carbon, cells and pre-filters. The design of
the entire unit shall be such as to ensure a minimum of maintenance and operating
timing.
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Activated Carbon Support System. This shall be one of two types

removable carbon cell type filters. Carbon filters shall be of the rechargeable cell
(b)
type with stainless steel or moulded GRP frames and perforated faces riveted
together. The filter cells shall be arranged to give a counter current multiple pass
system with the lowest filter taking the heavy load. When the lowest filter is spent it
shall be removed and higher filters moved down to replace the one beneath and a new
filter fitted in the highest position. Two additional complete sets of carbon filters shall
be provided as a minimum
(c)
bulk carbon system. The odour control unit forms a receptable for the granular
activated carbon which is placed in, either manually or using a proprietary
mechanical vacuum device.
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(a)
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(a)
Materials
Deodoriser Unit and Ducting: These shall be of chemical and ultraviolet light resistant GRP
using water resistant E glass chopped strand mat or woven glass fabric to BS 3496 and BS
3749. All surfaces and exposed edges shall be gel coat/flow coat covered using resin to
BS 3532. Alternatively the deodoriser unit and ducting may be manufactured in uPVC or
polypropylene/selmar and wrapped externally with G.R.P, generally as above. All fittings
shall be stainless steel and sealing strips shall be neoprene. The units shall have smooth
semi-gloss finish in white and shall be fully weatherproof.
Moisture Eliminator. These shall be incorporated in each duct. They shall be manufactured
from corrosion resistant materials and shall incorporate drain facilities and access panels for
cleaning. They shall incorporate a baffle arrangement with air cooling.
Prefilters. Prefilters shall be of washable urethane or polypropylene knitted wool to BS EN

779 designed as a particle and moisture barrier. The unit shall have an access plate for easy
removal of prefilters. They shall be fabricated such that:
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9.2.2
(a)
maximum efficiency is not less than 95%, based on test dust No. 2
(b)
maximum air velocity is 2.5 m/s at the design airflow
(c)
the clean filter resistance does not exceed 90 Pa
QCS 2014
Page 5
(d)
filters do not sag, flutter or be obstructed by contact with other filters or duct surfaces
(e)
the size shall be not less than 600 mm x 600 mm x 45 mm thick
(f)
corrosion resistant drain valves are provided
(g)
there are no void areas or short-circuiting
Activated carbon. This shall be as follows:

(a)
removable cell type units. Carbon granules shall be coconut based and impregnated
with potassium iodide, size 5-10 BS mesh. The cells shall be adequately filled and
sealed to prevent short circuiting. Cells shall be rechargeable.
(b)
bulk carbon filters. The activated carbon shall be virgin granular, derived from
bituminous coal, vapour-phase type, chemically impregnated with sodium hydroxide,
and suitable for control of sewage odours. Sufficient activated carbon shall be
provided to fill the adsorber to the full bed depth as designed by the odour control
system manufacturer. The carbon shall have the following performance
(c)
specifications:
percentage by weight (ASTM D3467), 60

1000
3.7 mm
8 percent
as determined by ASTM D2862 on a dry basis. The delivered apparent density

shall range from 0.55 to 0.64 g/cu cm
calculated on a total product basis
dense packing as defined by procedure for apparent density determination
where a glass 100 ml graduated cylinder is filled through a funnel with 24 mm
inside diameter stem at a uniform rate not exceeding 1 ml/s. Pressure drop is
measured across a 900 mm deep carbon bed, at least 125 mm in diameter
the determination of H2S breakthrough capacity shall be made by passing a
3
moist (85 % R.H.) air stream containing 1 % H2S at a rate of 1450 m /min
through a 20 mm diameter by 230 mm deep bed of uniformly packed activated
carbon and monitored to 50 mg/l breakthrough. Results are expressed in g H2S
removed per g of carbon
the carbon supplied shall be of a type chemically regenerable in-situ by the use
of up to 48 % sodium hydroxide for a minimum number of five times, or
regenerated by water if appropriate.
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(2)
(3)
1450 Pa/bed of 900 mm

25 g H2S removed/100 g of carbon
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notes:
(1)
0.55 g/cu cm
95
15 percent
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Carbon Substrate
CC1 4 Number
Iodine number, minimum
Mean particle diameter
Percent ash maximum
Impregnated Carbon
(1)
Apparent density minimum
Hardness number, minimum
(2)
Moisture, maximum
Maximum head loss (Pa) at 0.254 m/s linear
(3)
velocity (through a dense packed bed)
(4)
H2S breakthrough capacity, minimum
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Part
(4)
(5)
Fittings and fasteners. Fittings shall be stainless steel BS 970 Grade 316S31, fasteners shall
be stainless steel BS 970 Grade 316 S31 and BS 6105.
9.2.3
Fabrication
Carbon adsorbers shall be fabricated such that the vessel walls are not used to transfer any
vertical loads to the foundations or vertically support any portion of the carbon support
system. The carbon support system shall be removable for vessels of 1 m diameter or less
and shall be constructed of materials resistant to corrosion or deterioration under the service
conditions specified.
QCS 2014

Part
Page 6
Four bed activated carbon units shall be horizontal, cylindrical vessels utilizing vertical media
beds and provided complete with supports and anchoring system, all nozzles, and access
hatches. Units shall be complete with access platform and ladder, support saddles, flanged
inlet and outlet nozzles, grounding rods, carbon bed monitoring system, and manways and
sample ports as specified.
Vessels shall be constructed in accordance with BS 4994 category III or equivalent.
9.2.4
Accessories
Each carbon adsorber vessel shall include the following accessories:

manometer: This shall be provided to continuously monitor the pressure drop
across each carbon bed
(b)
sample probes: each vessel shall have three 40 mm diameter sample probes
per bed which shall extend into the bed a minimum of 300 mm. The sample probes
shall be adequate to provide suitable extraction of carbon samples from the carbon
bed. The sample probes shall extend outside the vessel wall and shall be isolated
with a uPVC ball valve
(c)
grounding rod: a stainless steel rod shall be provided to adequately ground

each carbon bed
(d)
H2S monitor: one portable hydrogen sulphide monitor shall be provided for each
adsorber vessel to detect hydrogen sulphide concentration via a colour coded
detector card. The housing shall be a weatherproof enclosure which also
allows easy replacement of detector cards
(e)
PVC-u drainage valves and 20 mm diameter pipework routed back to the wet well to
drain off any condensate/regeneration liquid from the prefilters
(f)
PVC-u drain valve and 20 mm diameter pipework routed back to wet well to drain off
any condensate/regeneration liquid from the deodoriser unit
(g)
air tight covers with gaskets to facilitate easy removal of carbon cells or loose carbon
(h)
three PVC-u air sample probes which extend outside vessel walls and are fitted with
PVC-u isolating valves
(i)
gaskets: 3 mm thick full face constructed of neoprene or equal
(j)
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(a)
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lifting and holding down lugs
An inlet shall be fitted to the wet well to allow fresh air to be drawn in. This shall be of GRP or
PVC-u construction with an insect screen.
9.2.5
Centrifugal Fan
The fan shall be centrifugal, belt-driven type constructed from corrosion resistant fibreglass
reinforced plastic or stainless steel with vibration free mountings. The fan shall be capable of
the performance specifications as shown below:
(a)
unit capacity : as designated
(b)
static pressure : 3000 Pa, or as required
(c)
operating temperature : 0 - 70 C
(d)
Motor : high efficiency, 415 V, 3 phase, 50 Hz IP 55;1500 rpm, power as required,

rated for zone 2 use with methane gas (BS 5345), to BS 5000.
Exhaust fans shall be suitable for continuous 24-hour operation and shall be nonoverloading. Each fan shall operate such that no point on the fan curve requires more than
the rated motor power.
QCS 2014

Part
Page 7
The fan housing, flanges and backward curved impellers shall be constructed of flame
retardant GRP laminate or stainless steel, capable of resisting continuous fume temperatures
of 70 C. The manufacturer shall state the type of resin used and confirm that it shall
perform satisfactorily under the operating conditions. All interior surfaces exposed to the
corrosive air stream shall be resin rich.
Wheel and shaft assemblies shall be statically and dynamically balanced to a maximum of
0.5 m displacement prior to assembly and every fan test run prior to shipment.
Fans shall comply with BS 848 and be provided with the following standard features:
drive assembly:
belts shall be oil, heat and static resistant type, sized for
continuous duty. Shafts shall be constructed of heavy duty steel turned, ground and
polished, keyed at both ends
(b)
bearings: heavy duty, self-aligning, pillow block bearings, with grease fittings
(c)
shaft seal: a fibreglass and neoprene shaft seal shall be placed where the shaft
leaves the housing along with a viton shaft slinger between the seal and wheel on belt
drive units
(d)
bases: heavy gauge hot rolled steel, epoxy coated.
(e)
the fan shall be provided with the following accessories:
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(ii)
drain
(iii)
access door
(iv)
vibration isolation system
(v)
belt and shaft guard as Part 1
(vi)
earthing as QGEWC requirements and BS 7671
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flanged and drilled inlet and outlet to BS 6339
flexible connectors:
flexible connectors shall be installed on the fan inlet and outlet to dampen
axial, lateral, and vibrational duct movement
(ii)
the flexible connector shall be resistant to the corrosive gases being processed
and shall be able to withstand 3750 Pa. The flexible connector shall be
minimum 30 mm long.
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(i)
Dampers:
(i)
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(f)
(a)
(a)
(b)
(a) suitable sized dampers shall be provided as follows:

(i)
balancing damper between the fan outlet and the carbon adsorber inlet
(ii)
isolation dampers at each carbon adsorber outlet.
(b) the dampers shall be provided in accordance with the following specifications:
(i)
the dampers shall be flanged and drilled to withstand 3000 Pa
(ii)
flange mount channel frame shall be vinylester with reinforced bearing pad
(iii)
the blade thickness shall be as required by the damper manufacturer
(iv)
the bearings shall be moulded plastic material
(v)
fibreglass axles shall extend full length of blade and 150 mm beyond frame
(vi)
the unit shall be equipped with a full circumference blade seal to limit leakage
3
2
to less than 1 m /m min at 3000 Pa
QCS 2014

Part
Page 8
9.2.6
Electrical Control Panel
A prewired, preassembled electrical control panel shall be provided for the odour control
system as specified in the Project Specification. The control panel shall contain pushbuttons,
indicating lights, fan motor starters, alarms, and other controls for a complete automatic
system. The panel shall be wired suitable for connection to 415 V a.c., 3 phase, 50 Hz
source. The panel shall comply with Part 1 of this Section and Section 21.
9.2.7
The Contractor shall secure from the equipment manufacturers certification that the following
factory tests have been carried out, and submit to the Engineer prior to shipment. Fibreglass
vessels shall be tested as follows:
hydrostatically tested prior
vessel for a minimum of 24 h
to
shipment,
with
water
to
the
top
of
the
(b)
the water must be contained with no visible signs of leaks or excessive wall deflection
(c)
a minimum of two burn tests of cutouts, from areas where access doors or piping
cutouts are required, to verify glass resin ratio.
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(a)
Activated carbon shall be tested as Part 9.2.2.4
Fans shall be tested as required by BS 848, Part 1 and 2.
9.2.8
The Contractor shall provide from the equipment manufacturers all the spare parts and tools
those below. In addition, sufficient activated carbon shall be provided for the complete
operation of the odour removal system for two years of operation.
The following tools and shall be provided in addition to any others required:
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sampling tool
(b)
plastic container for shipping carbon samples.
(a)
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The following spare parts shall be furnished as a minimum requirement, in addition to any
additional spare parts required for two years of operation.
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Item
Quantity
Complete Centrifugal Fan (1)
Sets of V-belts
(2)
Sets of bearings
(2)
Shaft seals
(2) (if fitted)
Carbon
(1) Supplies guaranteed for two years operation
Prefilter set
(2)
9.3
9.3.1
General
If required by the Project Specification, the Contractor shall furnish from the odour control
system supplies the services on site of a factory trained service technician or engineer. He
shall inspect the equipment installation, advise and assist with commissioning and train the
Employers operations and maintenance personnel.
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Page 9
The odour control system shall be installed in accordance with manufacturers written
instructions, by suitably qualified and experienced personnel.
9.3.2
Vessel Test. The above water test shall be repeated on site after installation.
Fans shall be tested as required by BS 848 Part 1 and shall be installed in accordance with
BS 848 Part 5.
Odour Vessels Test: The Contractor shall test as follows:

the odour control system to certify that it meets requirements after completion of the
installation
(b)
all odour testing conducted by the Contractor in the presence of the Engineer
(c)
the odour control system test shall be conducted after all the air systems are tested
and balanced. Separate H2S tests shall be conducted on each odour control system
(d)
the H2S tests shall be repeated at the end of the maintenance period
with the equipment in full operation during the time of year determined by the
Employer to have greatest odour problems, using the actual gas levels.
(e)
the hydrogen sulphide test shall comprise as follows:
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(a)
hydrogen sulphide (H2S) concentrations shall be measured using a calibrated

portable H2S analyser
(ii)
if instructed by the Engineer, bottled H2S gas shall be used to determine if the
specified H2S performance requirements are met
(iii)
each test: three sets of samples shall be taken over an 8 h period:
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(i)
final acceptance of the system will only be possible after successful completion of
this testing
(g)
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each test shall consist of an inlet and outlet H2S test

the supplier shall be responsible for supplying the H2S for the bottled H2S
testing
the three H2S levels to be tested shall be selected by the Engineer.
if the odour control system fails to meet the performance criteria, it shall be the
Contractors responsibility to make all the modifications necessary to improve
performance at no cost to the Employer. The Contractor shall pay for all additional
testing required to verify that performance criteria are being met
(h)
documentation for all the testing shall be submitted to the Engineer.
END OF PART
QCS 2014
Section 10: Instrumentation Control

Part
01: General
Page 1
GENERAL ...................................................................................................... 2
1.1
1.1.2
1.1.3
1.1.4
1.1.5
1.1.6
1.1.7
1.1.8
1.1.9
1.1.10
1.1.11
1.1.12
1.1.13
1.1.14
1.1.15
1.1.16
1.1.17
Scope
References Standards
System Responsibility
Presubmittal Meeting
Submittals
Quality Standards
Factory Inspection
Shipment, Storage, and Handling
Guarantee
Job Conditions
Approved Manufacturers
Approved Installation Subcontractors
Software
1.2
PRODUCTS ................................................................................................... 9
1.2.1
1.2.2
1.2.3
1.2.4
1.2.5
1.2.6
1.2.7
1.2.8
1.2.9
1.2.10
1.2.11
1.2.12
1.2.13
1.2.14
1.2.15
1.2.16
Materials
Structural Steel Fabrications
Mountings
Instrument Identification
Electronic Equipment
Equipment Operating Conditions
Power Supplies
Signal Isolators, Converters and Conditioners
Auxiliary Contacts by Others
Air Supply Valves
Instrument Piping
Filter Regulator
Manifolds
Electrical
Process Connections
1.3
INSTALLATION ........................................................................................... 12
1.3.1
1.3.2
1.3.3
1.3.4
1.3.5
1.3.6
1.3.7
1.3.8
1.3.9
1.3.10
Inspection
Installation and Supervision
Instrument Calibration
System Validation
Commissioning
Final Acceptance
Commissioning Assistance
Instruction and Training of The Owner's Personnel
Specialised Training Programme for Owners Personnel
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3
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6
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7
7
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8
8
8
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9
9
9
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10
10
10
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11
11
11
11
11
11
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12
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Page 2
GENERAL
1.1
This Part covers the general requirements for design, supply, installation and commissioning
of all instrumentation, control and automation (ICA) systems complete in every detail as
specified in the other Parts of Section 10.
The complete ICA system, shall be furnished by a single ICA Subcontractor to ensure system
uniformity, subsystem compatibility and co-ordination of all system interfaces. Deviations
shall be as specified in the Project Specification or approved by the Engineer.
1.1.2
Scope
Provide all tools, equipment, materials, and supplies and perform all labour required to
complete the supply and installation, including all instrumentation signal and power conduit
and wiring not specifically shown on the electrical drawings, validation, start-up and
commissioning of a complete and operable ICA system as indicated in the Project
Specification.
Provide all the necessary equipment components and interconnections and the services of
the manufacturers, engineering representatives for the engineering, implementation,
commissioning, operation, and instruction, to ensure that the Owner receives a completely
integrated and operational ICA system as herein specified.
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General Telemetry/SCADA
Primary Elements
Panel Mounted and Miscellaneous Field Instruments
Panel and Control Room Hardware
Section 8,
Section 9,
Section 21,
Sewerage
Electrical Works
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This Section
Part 2,
Part 3,
Part 4,
Part 5,
The standards referred to for Manufacturers quality procedures and documentation are:
1.1.3
ASTM A123, A386......Galvanizing

ASTM A36, A500, A501, A570, A618, Structural steel shapes
BS 970........................Wrought steel for mechanical and allied engineering purposes
BS 5308......................Instrumentation Cable
BS EN 10084..............Case hardening steels. Technical delivery conditions
BS EN 60654..............Operating conditions for industrial process measurement and control
BS ISO 5725 ..............Accuracy of measurement methods and results
BS ISO 9000-2 ...........Quality procedures
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Part
01: General
Page 3
System Responsibility
Contractor's attention is directed to the fact that the ICA system as specified in these ICA
Parts of Section 10 is an integrated system, and therefore shall be provided by a single
competent, qualified instrumentation Subcontractor (hereinafter referred to in these ICA
Sections as the ICA subcontractor) who shall have total responsibility for the ICA work of this
Section. Entire system installation including calibration, validation, commissioning,
operational testing, and training shall be performed by qualified personnel, possessing all the
necessary equipment and who have had experience performing similar installations. The
system shall be integrated using the most modern and proven design and shall, as far as
practical, be of one manufacturer. Overall system performance shall be guaranteed by the
ICA Subcontractor.
The Contractor shall appoint a qualified ICA Subcontractor who shall perform the work under
this ICA Section, the Contractor shall be fully responsible at all times for the conduct and
performance of the appointed ICA Subcontractor. Although many references made herein
are to work requirements and responsibilities of the ICA Subcontractor such references shall
only mean that responsibility shall pass through the ICA Subcontractor but in the final
analysis shall rest with the Contractor.
The ICA Subcontractor shall be responsible for the correct installation of all hardware and
systems specified in this ICA Section. Certain primary elements, final control elements, etc.,
although provided as part of this Section, shall be installed in the process lines under other
Sections of these Specifications; however, this installation shall be under the direct
supervision of the ICA Subcontractor.
The ICA Subcontractor shall be responsible to see that all components of the instrumentation
system, including primary measuring, indicating, transmitting, receiving, recording, totalising,
controlling, and alarming devices and all appurtenances, are completely compatible and shall
function as outlined and he shall furnish and install such additional equipment, accessories,
etc. as are necessary to meet
1.1.5
Presubmittal Meeting
The Contractor shall arrange a meeting between the ICA Subcontractor and the Engineer
within sixty (60) days after award of the Contract for a detailed discussion and verification of
the ICA Subcontractor's system engineering methods and equipment and to generally
provide a framework for communication and co-ordination. This meeting shall be attended
by ICA Subcontractor, Contractor and the Engineer.
1.1.6
Submittals
Submittals and approvals schedule shall generally be as specified under Section 9, Part 1,
Clause 1.1.4. All items proposed for this section shall be listed. Items shall be identified by
tag number, description, function, manufacturer, model number, descriptive literature and
statement as to whether items is as specified or equivalent. Logic diagrams and flow charts
illustrating the process control philosophy, shall be provided.
Shop Drawings. Before proceeding with any manufacturing, submit shop drawings for
approval in complete bound sets indexed by specification number. Describe the items being
submitted. Manufacturer's specification or data sheets shall be clearly marked to delineate
the options or styles to be furnished. Submit only complete systems, not pieces of equipment
from various systems.
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1.1.4
(a)
show dimensions, physical configurations, loop diagrams and cable termination

schedules
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Part
01: General
Page 4
(b)
submit fabrication drawings, nameplate legends, and control panel internal wiring and
piping schematic drawings clearly showing all equipment and tag numbers on all
panels
(c)
submit panel graphic drawings where applicable. Include material specifications lists
where applicable. Include a draft of the theory of operation for all relay or PLC logic
circuits and analogue control loops
(d)
Process and Instrumentation Diagrams. Prepare and submit instrumentation loop

diagrams for all work included in the ICA Sections in accordance with BS 1646.
Within 90 days from the start of the Contract, submit an "Equipment Specification Data" form
for each item of equipment which shall summarise the specification features as called for in
these Specifications and include such other necessary data as would provide a complete and
adequate specification for reordering an exact duplicate of the original item from the
manufacturer at some future date. The assigned tag numbers and manufacturer's part
numbers shall be included but will not be considered as a substitute for any of the required
statement of specifications. More than one tag numbered item may be included on a sheet.
Operation and Maintenance Manuals and Instructions. Furnish instruction manuals and part
lists for instrumentation equipment provided under the ICA sections. Obtain distribution
method instructions from the Engineer.
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schedule. Deliver two (2) copies of manuals 60 days before commencing the Site
Acceptance Tests. After installation is complete, update the manuals to reflect any
changes which occurred during installation and deliver the remaining three copies of
manuals to the Engineer immediately after the Site Acceptance Test. The manuals
shall be in English.
(b)
manuals shall be contract specific, and be fully indexed and sectioned, for allocation
and distribution to the specialist staff involved on the particular plant and equipment
(c)
where several sub-contractors and manufacturers have supplied equipment the

Contractor shall, if required by the Engineer provide a complete integrated manual
which clearly demonstrates the inter-relation of the equipment
(d)
manuals shall be provided in durable hard cover backed A4 sized loose-leaf four ring
binders. Lever arch binders are not acceptable. The full project title shall appear on
the cover and spine
(e)
the manuals shall enable the client to safely operate and maintain all parts of the works
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Original copies of leaflets and instructions provided by the specialist manufacturers

shall be provided. Superfluous information shall be clearly deleted and relevant
information referred to separately in the text
(f)
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(a)
(g)
all instructions and manuals shall be written in accordance with BS 4884, IEC 278, and
in accordance with other recognised guidelines on technical manual writing.
(h)
contents. include, in the manuals, not less than the following information, as
applicable, for each instrument, equipment, subsystem and/or control loop:
(i)
general, introduction and overall description, purpose, functions, simplified

theory of operations, etc
(ii)
specifications (including equipment specification data sheet as described above

under Shop Drawings)
(iii)
installation procedures, commissioning and operational procedures and

precautions
(iv)
shut-down procedures
(v)
suitability based on HAZAN/HAZOP studies
(vi)
maintenance, calibration, and trouble shooting instructions
QCS 2014

Part
01: General
Page 5
(vii)
schematics and wiring diagrams or flow charts
(viii)
detailed circuit operational description including annotated programmable

controller ladder diagrams or flow charts
(ix)
parts list and spare parts recommendations as specified in Section 9.
(x)
material, test and calibration certificates
(xi)
copies of final approved equipment specification data forms.
format. Use drawings and pictorials to illustrate the text to the extent necessary to
ensure a clear, concise presentation. If manuals have been written to cover a family of
similar instruments or equipment, strike out inapplicable information in a neat fashion
or emphasise applicable portion by heavily weighted arrows, circles or boxes;
whichever provides the clearest and neatest presentation.
Where identical
instruments are used in more than one control loop or subsystem, include only one
instruction manual, however, an index by tag number for all instruments shall identify
its location in that manual
(j)
control loop and/or subsystem operational descriptions shall identify the function of
each instrument and its relation to the other instruments in the loop
(k)
binding. Bind each manual in a cover which indicates the system name,
manufacturer's name, local address and telephone number, and year of purchase.
Punch and bind manuals in standard three ring binders and include system name and
ICA Subcontractor's name on binding.
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(i)
Further to the above Clause 1.1.5.4, the Contractor shall ensure that the structure of the
operation and maintenance manual meets the conditions specified in Section 1 Clause
7.12.2 or otherwise agreed with the Engineer.
Record Drawings:
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The Contractor shall submit complete schematics, wiring diagrams and installation
drawings to include all installed field and panel conduit and piping/tubing runs and
routing, tray systems, supports, mounting details, point to point diagrams with a cable,
wire, tube and termination numbers. One copy of applicable schematics and diagrams
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(a)
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shall be placed in each control panel in a protective envelope or binder
the above are to be supplied to the satisfaction of the Engineer. The Contractor
shall provide the Owner prints of each on thick paper and one ISO size A1
negative of each. All drawings shall be prepared on a CAD system
and printed on ISO standard sized paper A3 unless specifically requested
otherwise. One set of drawings shall also be submitted in Windows based
AutoCAD System software version and storage media shall be as approved by the
Engineer. Each drawing shall be marked with the Owners, Consultants,
Contractors and manufacturers names and references, drawing number, title,
scales, date of completion and a full description and date of all amendments, and
shall be certified as-built. The project title shall be included in a box at the bottom right
hand corner of each drawing.
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(b)
ICA Subcontractor's System Validation Report. The ICA Subcontractor, shall submit a report
for each control system, panel and associated field instruments certifying that the equipment:
(a)
had been properly installed under his supervision
(b)
is in accurate calibration
(c)
was placed in operation in his presence
(d)
has been checked, inspected, calibrated and adjusted as necessary
(e)
has been operated under maximum power variation conditions and operated
satisfactorily, and
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(f)

Part
01: General
Page 6
fully covered under the terms of the guarantee
This report shall indicate calculated system tolerances, data verifying that the system meets
these tolerances, and any provisional settings made to devices. Data sheets shall be similar
to those used for Calibration.
Factory Acceptance Test (FAT) and Site Acceptance Test (SAT). Submit for approval at
least 30 days prior to the test demonstration, a written plan for demonstrating that each
system of equipment provided under the ICA Sections meets the specified operational
requirements. The plan shall include procedures to be used in final operation testing of entire
systems including a description for each system of test methods and materials, testing
instruments and recorders, a list of the equipment involved with the functional parameters to
be recorded on each item, and shop drawings of required temporary by-passes and like
facilities.
Final Acceptance Report. Submit three copies of certified test results and records.
1.1.7
Quality Standards
Qualification and Manufacturers. The ICA Subcontractor shall be an approved systems

integrator, a panel fabricator, and installer of field instruments. The ICA Subcontractor shall
have a minimum of 5 years documented experience in providing ICA equipment on a single
system responsibility basis, of which at least 3 years shall be for municipal water and
wastewater pumping stations and sewage treatment works. The personnel employed for
system engineering, supervision, start-up, operational testing and training shall be regular
employees of the ICA Subcontractor. The ICA Subcontractor shall be fully responsible for the
technical supervision of the installation to ensure that it is proper in all respects.
Certification by Single ICA Subcontractor. At the time of quoting to prospective contractors

prior to tender opening, each prospective single ICA Subcontractor shall execute and submit
a written certification of intent to assume full responsibility for the complete requirements of
the ICA Section including deputation of qualified personnel for instructing operating personnel
and preparing technical documentation.
A certificate of compliance with the ICA
specifications shall also be provided.
Standard of Quality. Furnish equipment of the types and sizes specified which has been
demonstrated to operate successfully. Wherever, in the Project Specification and in these
specifications, materials or equipment have been specified by using the name of products or
manufacturers, the term "or equal and approved" is always understood to follow immediately.
Material and equipment, so specified, has been selected as being most suitable and is
regarded as a standard and is not intended to eliminate others of equal quality and
performance. Workmanship for the installation of instruments, wiring, piping, painting and
labelling shall be equal to the best industrial standards for instrumentation and control work.
All equipment shall be suitable for installation and continuous services in the climatic
conditions prevailing in Qatar.
All electrical equipment and materials, including their installation, shall conform to the
standards specified for each equipment, unless specified otherwise in this Section.
All equipment of a similar type shall be supplied from a single manufacturer to ensure
common spares, operation and maintenance procedures.
1.1.8
The ICA manufacturers shall demonstrate a successful track record of having complete
similar ICA installation works. The ICA Subcontractor shall provide a reference list from the
instrumentation manufacturers for having installed and commissioned instruments operating
under process and ambient conditions similar to the specified works.
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Page 7
Factory Inspection
Factory Inspection. The Engineer or his representative may inspect fabricated equipment at
the factory. Notify the Engineer at least 30 days prior to shipment, so that factory inspection
can be arranged. Factory inspection shall be made only after manufacturer has performed
satisfactory checks, adjustments, tests and operations. Tests shall be made using simulated
inputs and output loads. Approval of equipment at the factory only allows the manufacturer to
ship the equipment to the site, and does not constitute final acceptance by the Engineer.
The Engineer reserves the right to inspect the ICA equipment at the factory. The Engineer
will indicate on return of the approved submittal, each item requiring factory inspection.
1.1.10
Factory test carried out for primary elements shall include pressure and calibration tests.
Certificates shall be provided for pressure test, calibration test and conformity to
specifications. Material certificates shall be furnished if it is so specified.
Factory Acceptance Test (FAT) shall be carried out for the control and automation equipment
such as control panels. FAT procedure shall be submitted to the Engineer for approval. FAT
based on the approved test procedure shall be witnessed by the Engineer or his authorized
representative at expense of the Contractor.
If after examining or testing any equipment the Engineer, or his representative, shall decide
that such equipment or any part thereof is defective or, not in accordance with the
specification, he may reject the said equipment or part thereof. He shall notify the Contractor
in writing within 7 calendar days of the rejection, stating the grounds on which the rejection is
based.
1.1.11
Shipment, Storage, and Handling
Box, crate, or otherwise enclose and protect instruments and equipment during shipment,
handling, and storage. Keep all equipment dry and covered from exposure to weather,
moisture, corrosive liquids, and gases or any element which could degrade the equipment.
Protect painted surfaces against impact, abrasion, discoloration, and other damage. Repair
any damage or replace defective equipment, as directed and approved by the Engineer.
1.1.12
Guarantee
The Contractor shall provide a guarantee during the maintenance period for all the equipment
in accordance with the General Conditions of the Contract.
Equipment warranty shall cover defects in materials or workmanship for 400 days from date
of satisfactory completion of Site performance test and issue of Practical Completion
Certificate.
Individual warranties by component manufacturer in lieu of single source responsibility shall

not be acceptable.
Items which fail during the warranty period, excluding expendable items, shall be replaced
without cost to the Owner.
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1.1.9
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Part
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Page 8
Job Conditions
Drawings are diagrammatic and show the intended arrangement for system operation,
piping, and appurtenances. Conform to Drawings as closely as possible and exercise care to
secure neat arrangement of piping, valves, conduit, and like items, and to overcome
structural interferences. Verify dimensions and conditions at the place of work, and install
materials and equipment in the available spaces.
1.1.14
The ICA equipment shall be provided by approved, prequalified system manufacturers and
suppliers designated in the Project Specification.
1.1.15
Approved Installation Subcontractors
Installation Subcontractor shall be approved, prequalified and designated in the Project

Specification.
1.1.16
Furnish the following items as specified herein. Provide the Engineer, with an itemised list in
a letter of transmittal accompanying each shipment.
Special Tools and Accessories. Furnish special tools, instruments, and accessories for
maintaining instruments and equipment requiring periodic repair and adjustment as specified
elsewhere in this Section. Also, furnish special lifting and handling devices for equipment
requiring such devices.
Maintenance Materials and Spare Parts. Deliver in manufacturer's original containers

labelled to completely describe contents and equipment for which it is furnished.
Spare parts shall be sufficient for 2 years of normal service from completion of the
maintenance period, and shall include, as a minimum, the following basic items:
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1.1.13
five (5) percent but not less than one (1) minimum of each type of plug-in unit, etched
or printed circuit board assembly
(b)
ten (10) percent but not less than one (1) of each type relay and timer used
(d)
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(a)
(e)
2 years supply of expendable items, diskettes, toner cartridges etc.
ten (10) percent but not less than one (1) of each type switch used
twenty (20) percent but not less than ten (10) of each type light bulb and fuse used
(c)
1.1.17
1
Software
The ICA Subcontractor shall be responsible for obtaining all software user licences for
development and runtime systems as necessary. Application software written specifically for
the Owner under this contract shall remain the property of the Owner and shall not be
disclosed, copied or distributed at any time to a third party without the Owners explicit written
consent.
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Page 9
PRODUCTS
1.2.1
Materials
The ICA Subcontractor shall provide instruments, equipment and materials suitable for
service conditions and meeting the appropriate British Standards. The intent of this
Specification is to secure instruments and equipment of a uniform quality and manufacture
throughout the plant; i.e., all instruments in the site, i.e., all instruments supplied by the ICA
Subcontractor, of the same type shall be by the same manufacturer. This allows the stocking
of the minimum number of spare parts.
1.2.2
Structural Steel Fabrications
The ICA Subcontractor shall design all fabrications for dynamic and vibratory loading. Use
structural steel shapes conforming to ASTM A36, A500, A501, A570, A618, or equal and
approved, as applicable. Conform welding to AWS D2.0 Code. Galvanize specific items in
accordance with ASTM A123 or A386 as applicable; use galvanized bolts and fasteners with
galvanized assemblies. Use minimum 6 mm thickness for steel entirely or partially
submerged during equipment operation. Submit design calculations showing adequate
structural integrity for the intended purpose.
1.2.3
Mountings
The ICA Subcontractor shall mount and install equipment as indicated in the Project
Specification. Where not shown, mount site instruments according to best standard practice
on pipe mounts, pedestal mounts, or other similar means in accordance with suppliers
recommendation. Where mounted in control panels, mount according to requirements of
Equipment specified for Site mounting shall be suitable for direct pipe mounting, pedestal
mounting, or surface mounting and non in-line indicators and equipment with calibration
adjustments or requiring periodic inspection shall be mounted not lower than 900 mm nor
higher than 1500 mm above walkways, platforms, catwalks, etc. so as to provide easy
access. All such equipment shall be weather and splash proof, and electrical equipment
shall be in IP 66 enclosures. External equipment shall be protected from direct sunlight by a
well ventilated cabinet, canopy or other type of sunshade. If mounted in a designated
hazardous area, the equipment shall be explosion proof or rated intrinsically safe, whether so
specified herein or not.
The equipment shall be guaranteed suitable for operation under the climatic conditions
specified in under Clause 1.2.6 of this Part and shall be designed:-
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1.2
(a)
such that routine and occasional maintenance throughout its life shall be a practical
minimum compatible with the preservation of maximum reliability
(b)
to withstand the electrical, mechanical, thermal and atmospheric stresses to which it

may be subjected under operational conditions, without deterioration or failure
(c)
constructed to the highest available standards of manufacture, reliability, accuracy and

repeatability
(d)
the degree of protection for equipment enclosures shall be in accordance with

BS EN 60529
Provide protection from direct sun light for all ICA equipment installed outdoors.
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Page 10
Instrument Identification
All instrumentation and equipment items or systems specified in the Project Specification
shall be identified by system and tag numbers. This same number shall appear in the tag
number designations on the Drawings and on the schedules of the Project Specification.
Nameplates for panels and panel mounted equipment shall be as specified in the Project
Specification. Field equipment shall be tagged with assigned instrumentation tag number
and function. Tags shall be black lamacoid with engraved white characters of 5 mm
minimum height. Tags shall be attached to equipment with a commercial tag holder using a
stainless steel band with a worm screw clamping device or by a holder fabricated with
standard hose clamps and meeting the same description. In some cases where this would
2
be impractical, use 0.5 mm stainless steel wires. For field panels or large equipment cases
use stainless steel screws, however, such permanent attachment shall not be on an
ordinarily replaceable part. In all cases the tag shall be plainly visible to a standing observer.
In addition to tags, field mounted control stations, recorders or indicators shall have a
nameplate indicating their function and the variable controlled or displayed. Nameplate shall
be attached by one of the above methods.
1.2.5
Electronic Equipment
If the equipment is electronic in nature, provide solid state equipment to the extent
practicable. Select components of construction for their suitability and reliability. Employ
adequate component derating to preclude failures because of transients and momentary
overloads reasonably expected in normal operation. Provide units for operation without
forced cooling, unless such cooling is an integral part of the device. Provide protection on all
relevant circuits and equipment against the effects of lightning and other induced voltages.
1.2.6
Equipment Operating Conditions
All equipment shall be rated for normal operating performance with varying operating
conditions over the following minimum ranges.
Power:
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electrical. 240 V a.c. 5 %, 50 Hz 1 Hz except where specifically stated otherwise

on the drawings or in the specifications
(b)
air. 1.4 bars.
(a)
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1.2.4
Field Instruments:
all the ICA equipment supplied shall be suitable for operation in the tropical climate
prevalent in Qatar. All ICA equipment shall be designed and constructed to operate
satisfactorily and without any deleterious effect for prolonged and continuous periods
at the following maximum ambient temperature conditions:
(a)
(i)
indoors in normally air-conditioned environment -
(ii)
indoors in a ventilated environment
55 C
(iii)
outdoors under direct sunlight
85 C
50 C
o
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1.2.7
Power Supplies
The ICA Subcontractor shall provide electrical instruments, transmitter power supplies and
control devices for operation on 110 V a.c., 50 Hz. Transmitter power supplies shall be
provided for individual transmitters. Where designated in the Project Specification, process
critical instruments shall receive power from a UPS, as specified in Section 21.
QCS 2014

Part
01: General
Page 11
Signal Isolators, Converters and Conditioners
The ICA Subcontractor shall ensure that input-output signals of all instruments and control
devices (whether supplied by the ICA Subcontractor or not) are compatible. Unless
otherwise specified in the Project Specification, signals between field and panels shall be volt
free contacts or 4 to 20 mAdc, unless specifically approved otherwise. Granting such
approval does not relieve the ICA Subcontractor from the compatibility requirement above.
Provide signal isolators and converters as necessary to obtain the required system
performance. Mount the devices behind control panels or in the Site at the point of
application.
1.2.9
Auxiliary Contacts by Others
The ICA Subcontractor shall provide instruments and equipment to interface with auxiliary
contacts provided under other Contracts, for alarms, status of equipment, interlocking, and
other functions as indicated and as specified in Project Specification.
1.2.10
Air Supply Valves
The ICA Subcontractor shall provide 316S12 valves for instrument air supply shutoff,
regulating, switching, metering, valve manifolds, etc. Provide a separate isolation valve for
each instrument or actuator feed line.
1.2.11
Instrument Piping
The ICA Subcontractor shall provide instrument air header and instrument pneumatic piping,
as specified in the Project Specifications and as necessary and/or as specified herein.
Connect to main instrument air header at a point not more than 3 m distant from air
consuming device(s). Use 10 mm minimum 316S12 tubing. All connections to equipment
shall be made with separable or union type fittings and shall include shut-off valves. All
hydraulic and/or pneumatic piping shall be tested for leaks prior to placing the system in
operation. All instrument pneumatic air fittings, shall be double compression type.
1.2.12
Filter Regulator
The ICA Subcontractor shall provide a filter-regulator and discharge pressure gauge with a
dripwell assembly for each point of use where regulated instrument air is required. Separate
regulators shall be used for each control loop.
1.2.13
Manifolds
The ICA Subcontractor shall furnish an integral three-valve manifold for each differential
pressure transmitter on a flow application.
1.2.14
The ICA Subcontractor shall provide factory paint for all instruments and equipment except
where in pipelines. Provide paint as required for structural supports, brackets, etc. Painting
and protective coatings shall generally comply with the requirements specified in Part 8 of
Section 8.
1.2.15
Electrical
The ICA Subcontractor shall provide all the power supply wiring, instrumentation wiring,
interconnecting wiring and equipment grounding as indicated, specified and required.
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1.2.8
QCS 2014

Part
01: General
Page 12
Wiring installations shall include cables, conductors, terminals connectors, wire markers,
conduits, conduit fittings, supports, hardware and all other required materials not specifically
included in the work of other Sections.
Provide the materials and complete all the required installations for equipment grounding as
specified in Section 21 of these Specifications indicated on the Electrical Drawings or
necessary to complete the Work.
Incidental items, not specifically included in the Contract Documents, that can legitimately
and reasonably be inferred to belong to the instrumentation work shall be provided by the ICA
Subcontractor.
Field Wiring. Ring out signal wiring prior to termination. Provide wire number tags marked in
indelible waterproof form of slip-on type or equal for each termination. Provide preinsulated
crimp-on connectors for wire terminations and splices. Use ratchet type crimping tool which
does not release until proper crimp pressure has been applied.
1.2.16
Process Connections
Piping, tubing, and capillary tubing shall be of stainless steel. If this material is unsuitable for
ambient or process conditions, piping and tubing shall be of a material approved by the
Engineer. Slope lines according to service to promote self draining or venting back to the
process. Terminate connection to process lines or vessels in a service rated block valve,
that will permit closing off the sense line or removal of the element without requiring shut
down of the process. Include drip legs and blow-down valves for terminations of sense lines
at the instruments when mounted such that condensation can accumulate. Process vessels,
line penetrations, connecting fittings, and block valves shall be furnished and installed under
other Sections of these Specifications but coordinated by the ICA Parts. Instrument process
taps shall be a minimum 18 mm BSP except flowmeter taps which shall be 12 mm BSP.
1.3
INSTALLATION
1.3.1
Inspection
Inspect each instrument and piece of equipment for damage, defects, completeness, and
correct operation before installing. Inspect previously installed related work and verify that it
is ready for installation of instruments and equipment.
1.3.2
Ensure that installation areas are clean and that concrete or masonry operations are
completed prior to installing instruments and equipment. Maintain the areas in a clean
condition during installation operations.
1.3.3
Installation and Supervision
Provide the services of suitably trained and experienced personnel in the installation of the
equipment to:
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(a)
complete the installation in accordance with the manufacturers instruction manual
(b)
inspect, check, adjust as necessary, and prepare the equipment for system validation
(c)
calibrate the instruments, in accordance with the specifications herein, until all trouble
or defects are corrected and the installation and operation are acceptable.
QCS 2014

Part
01: General
Page 13
Instrument Calibration
The Contractor shall provide the services of trained and experienced instrumentation
technicians, tools and equipment to site calibrate each instrument to its specified accuracy in
accordance with the manufacturer's specifications and instructions for calibration.
Each instrument shall be calibrated at 10 percent, 50 percent and 90 percent of span using
test instruments to simulate inputs and read outputs that are rated to an accuracy of at least
5 times greater than the specified accuracy of the instrument being calibrated.
Test instruments shall hold a valid calibration certificate from a NAMAS accredited calibration
centre or alternative, subject to the approval of the Engineer
Provide a list and basic specifications for instruments used. Certify to the Engineer that each
instrument has been calibrated to its published specified accuracy. The calibration certificate
shall include all applicable data as listed below plus any defects noted, correction action
required, and correction made. Data shall be recorded on separate proformas attached to
the certificate and shall include not less than the following items:
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1.3.4
facility identification (name, location, etc.)
(b)
loop identification (name or function)
(c)
equipment tag and serial numbers
(d)
scale ranges and units
(e)
test mode or type of test
(f)
input values or settings
(g)
expected outputs and tolerances
(h)
actual readings
(i)
explanations or special notes as applicable
(j)
tester's certification with name and signature.
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(a)
System Validation
Provide the services of trained and field experienced instrumentation engineer(s) to validate
each system to verify that each system is operational and performing its intended function
within system tolerance. System tolerance is defined as the root-mean-square sum of the
system component published specified accuracies from input to output.
Validate each system by simulating inputs at the first element in loop (i.e. sensor) of 10
percent, 50 percent and 90 percent of span, or on/off and verifying loop output devices (i.e.
recorder, indicator, alarm, etc. except controllers).
During system validation, make
provisional settings on levels, alarms, etc. Verify controllers by observing that the final
control element moves in the proper direction to correct the process variable as compared to
the set point. Verify that all logic sequences operate in accordance with the specifications.
Cause malfunctions to sound alarms or switch to standby to check system operation. Check
all systems thoroughly for correct operation. Test equipment shall comply with Clause 1.3.4.
Immediately correct all defects and malfunctions disclosed by tests. Use new parts and
materials as required and retest.
System validation report.

instrument system.
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1.3.5
Provide a report certifying completion of validation of each
QCS 2014

Part
01: General
Page 14
Commissioning
Upon completion of instrument calibration and system validation, test all systems under
process conditions. The intent of this test is to demonstrate and verify the operational
interrelationship of the instrumentation systems. This testing shall include, but not be limited
to, all specified operational modes, taking process variables to their limits (simulated or
process) to verify all alarms, failure interlocks, and operational interlocks between systems
and/or mechanical equipment.
1.3.7
Final Acceptance
Final acceptance report. Immediately correct defects and malfunctions with approved
methods and materials in each case and repeat the testing. Upon completion of final
operational testing, submit certified report, with substantiating data sheets, indicating that
total ICA System meets all the functional requirements specified herein. The Engineer will
countersign this report and it shall constitute final acceptance of the ICA System.
Final Operational Testing shall be witnessed and approved by the Engineer. Notify the
Engineer in writing a minimum of 48 h prior to the proposed date for commencing the test.
Upon completion of this test the Contractor shall begin or have begun system start-up. The
Owner reserves the right to set the schedule.
1.3.8
Commissioning Assistance
When specified elsewhere in this section or designed in the Project Specification, provide the
services of a factory trained and field experienced instrumentation engineer to assist the
Owners personnel during commissioning of the system. Purpose of this assistance is to
support in making final adjustments of settings on the instrument systems.
1.3.9
Instruction and Training of The Owner's Personnel
After the ICA equipment has been calibrated, installed, tested and placed in satisfactory
operation the Contractor shall provide the services of qualified staff approved by the
Engineer, or if specified in the Project Specification, of the manufacturers representatives, to
instruct and train the Owners personnel in the use and maintenance of the ICA equipment.
An instruction and training programme shall be conducted for up to six personnel designated
by the Owner. The Contractor shall give the Owner at least one months written notice of the
proposed instruction and training programme. Instruction and training covering basic system
operation theory, routine maintenance and repair, and hands on operation of the ICA
equipment shall be included. Each trainee shall be provided with a training manual covering
operation and maintenance of the ICA equipment. The duration of the programme shall be
based on the complexity of equipment involved, and the Engineers approval of instruction
adequacy obtained before terminating the programme. Instruction and training periods shall
be acceptable to the Engineer.
1.3.10
Specialised Training Programme for Owners Personnel
Where designated in the Project Specification the Contractor shall provide a specialised
training programme and manual for the Owners key personnel in the equipment, electrical
systems and instrumentation systems, to be conducted by the supplier/manufacturer and
held at locations outside Qatar. The training programme and manual shall be submitted to
the Owner for approval and shall be designed to:
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1.3.6
(a)
provide in depth information and familiarisation of the equipment installed in the

Project
(b)
receive specialised training in the design, proper operation, maintenance and

replacement of the equipment and components
QCS 2014
Page 15
The Contractor shall provide whatever assistance is requested by the Owner to develop
meaningful itineraries for the training programme. The Contractor shall provide hotel
accommodation, travelling expenses by air, land transport and per diem allowance as per the
Ministry of Education guidelines.
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END OF PART

Part
01: General
QCS 2014
Section 10: Instrumentation Control and Automation

Part
02: Telemetry/SCADA
Page 1
TELEMETRY/SCADA .................................................................................... 3
2.1
GENERAL ...................................................................................................... 3
2.1.1
2.1.2
2.1.3
2.1.4
2.1.5
2.1.6
2.1.7
Scope
References
Submittals
Quality Assurance
Site Conditions
Commissioning
2.2
DESIGN ......................................................................................................... 6
2.2.1
2.2.2
2.2.3
2.2.4
2.2.5
Pre-Design Documentation
Hardware Design
Software Design
System Security
Operator Interface
2.3
MASTER STATION HARDWARE ................................................................. 8
2.3.1
2.3.2
2.3.3
2.3.4
2.3.5
2.3.6
2.3.7
2.3.8
2.3.9
2.3.10
Computer
Redundancy
Visual Display Unit (VDU)
Keyboard
Logging / Alarm / Report Printers - Continuous Feed
Colour Printers
Monochrome Printers (Laser)
Audible Alarm
Data Storage
Uninterruptible Power Supply (UPS) System
2.4
MASTER STATION SOFTWARE FUNCTIONS .......................................... 11
2.4.1
2.4.2
2.4.3
2.4.4
2.4.5
2.4.6
2.4.7
2.4.8
2.4.9
2.4.10
2.4.11
2.4.12
2.4.13
2.4.14
2.4.15
2.4.16
2.4.17
2.4.18
General
Display Facilities
Monitoring and Alarms
Equipment Control
Data Archiving
VDU Mimic Displays
Tabular Representation of Data
Trend Displays
Manual Data Entry
Manually Corrected Data
Reports
Point Record
Profiling
Data Manipulation
Database Query Facilities
Downloading PLC Configuration
Diagnostics
Access Levels
6
6
6
7
7
8
9
9
9
9
10
10
10
10
11
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3
3
3
5
5
5
5
11
12
13
14
14
14
15
15
15
15
15
16
16
16
17
17
17
17
QCS 2014

Part
02: Telemetry/SCADA
2.4.19 Control Loop and Sequence Programming

2.4.20 Program - Documentation
Page 2
17
17
2.5
REMOTE TERMINAL UNITS (RTU) FOR TELEMETRY APPLICATION .... 18
2.5.1
2.5.2
2.5.3
Future Expansion
RTU Hardware
RTU Software
2.6
PROGRAMMABLE LOGIC CONTROLLER (PLC) ...................................... 20
2.6.1
2.6.2
2.6.3
2.6.4
PLC Hardware
Input Modules
Output Modules
PLC Software
2.7
DATA COMMUNICATIONS LINKS ............................................................. 23
2.7.1
2.7.2
2.7.3
2.7.4
2.7.5
2.7.6
2.7.7
2.7.8
2.7.9
Communication Standards
Control Room Data Highway
Leased lines or PSTN
Radio
Radio Path Profiles
Radio Transmitters/Receivers
Base Station Radio Transmitter/Receivers
Aerials and Aerial Structures
Fibre Optic Network
2.8
INPUTS/OUTPUTS ..................................................................................... 26
2.8.1
2.8.2
2.8.3
2.8.4
2.8.5
2.8.6
2.8.7
General
Analogue Inputs
Digital Outputs
Analogue Outputs
RTD Input
Thermocouple Input
Pulse Input
2.9
POWER SUPPLY REQUIREMENTS .......................................................... 27
2.10
MIMIC DIAGRAM......................................................................................... 28
18
18
19
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26
27
27
27
27
27
27
28
28
29
FACTORY INSPECTION AND TESTING .................................................... 29
2.11.1 General
2.11.2 Test Plan
2.12
23
23
24
24
24
24
24
24
25
2.10.1 General
2.10.2 Mosaic Tile
2.10.3 Projection
2.11
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20
21
22
22
29
30
INSTALLATION ........................................................................................... 31
2.12.1 Tools
2.12.2 Training for Owners Personnel
2.12.3 Site Inspection and Testing
31
31
32
QCS 2014

Part
02: Telemetry/SCADA
Page 3
TELEMETRY/SCADA
2.1
GENERAL
2.1.1
Scope
This Part includes the hardware manufacture, system software, factory testing, installation,
site testing and training of Owners personnel in Telemetry/SCADA.
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General
Panel Mounted and Miscellaneous Field Instruments
Panels and Control Room Hardware
2.1.2
References
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This Section
Part 1,
Part 4,
Part 5,
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BS 1646......................Symbolic representation for process measurement control functions

and instrumentation.
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BS EN 60073..............Basic and safety principles for man-machine interface, marking and

identification. Coding principles for indicators and actuators
BS EN 60255-22-5 .....Surge protection
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BS EN 61000-6 ..........Electromagnetic Compatibility
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BS EN 61131-3 ..........Programming Languages for Programmable Controllers.
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BS EN ISO 9000-3 .....Recommendation for achievement of quality in software
BS ISO/IEC 6592 .......Documentation of computer based systems
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BS ISO/IEC 9075 .......Structured Query Language (SQL)
ISO 3511 ....................Process measurement control functions - instrumentation symbolic

representation
2.1.3
Submittals
Submittals shall generally be in accordance with Part 1 of this Section.
Functional Design Specification (FDS). FDS shall be submitted to the Engineer and
approved before manufacture and purchasing commences. The ICA Subcontractor shall
include the following information as a minimum :
(a)
(a)
design concept and criteria

details of associated equipment
(b)
functional design description including VDU mimics and report format.
(c)
details of data archiving and trend configuration.
(d)
quality plan
(e)
outline of acceptance test procedures
QCS 2014
(f)

Part
02: Telemetry/SCADA
implementation program for manufacture, installation and commissioning with

Particular reference to interface with existing equipment
(g)
(h)
Page 4
manufacturers literature for each item of equipment supplied

name of the specialist Subcontractor
Drawings and Documentation. All drawings of telemetry and ICA equipment shall be on A3
or A4 size sheets with title blocks approved by the Engineer. The signature of the
Contractors authorised representative shall appear on each drawing to indicate the drawing
has been checked prior to submission.
Subcontractors Drawings. The ICA Subcontractor shall submit four (4) reproducible copies
plus two photocopies of general and detailed dimensioned arrangement drawings,
schematics and wiring diagrams of all major items of equipment for the Engineers approval.
Manufacture of an item of equipment shall not commence until the associated drawings have
been approved in writing by the Engineer. All modifications or revisions to drawings shall be
clearly indicated and the revision reference changed. Drawings affecting work by other
disciplines shall be provided to the Engineer within 6 weeks from the date of placing of the
order for the works. Drawings for electrical equipment shall include:
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Contractors general arrangement drawings for all items showing clearly the position of
all cable glands and main components including, where appropriate, foundation plans
showing the position of all required holes and cutouts
(b)
manufacturers schematic diagrams and connection diagrams for all items showing
all internal wiring and terminal connections suitably referenced. Connection diagrams
shall include existing and proposed outgoing cable connections
(c)
general layout of equipment showing cable routing
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(a)
block diagram showing all equipment, cable runs and cable reference numbers
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(d)
cable schedules giving full details of use, destinations, size and number of conductors,
grade and class
(f)
layout of grounding facilities
(g)
proposed arrangements for cables laid below and above ground showing
identification references, voltage, depth of laying or cable rack size , route and length,
crossings with other services, location of any joints and position of ducts with cross
Sectional arrangements.
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(e)
Where modifications to existing systems are involved, the Contractor shall modify existing
drawings to show the modifications. If suitable existing drawings are not available the
Contractor shall provide drawings showing the modifications.
5
As built Drawings. Comply with Part 1 of this Section.
Instruction Manuals. Comply with Part 1 of this Section and provide the following additional
information:
(a) configuration of data base, reports, logs and screen displays
(b) data communication interface standards and protocols.
The submittal shall be subject to approval by the Engineer. The Contractor shall submit the
final documentation based on the Engineers comments. The Engineers comments/approval
shall be issued to the Contractor within 21 calendar days of the submittal.
QCS 2014

Part
02: Telemetry/SCADA
Page 5
Quality Assurance
All hardware and software proposed shall have been successfully proven in a similar
wastewater application for a period of at least three years, and be from established and
reputable suppliers. A single hardware vendor for each functional component of the system
shall be used exclusively on a given site. If this is not possible full compatibility shall be
demonstrated.
Upgrades and improvements to the manufacturers standard system that are released before
the expiration of the warranty period shall be supplied, installed and commissioned at no
additional cost. These shall include all hardware and software necessary to implement the
upgrade.
2.1.5
The Contractor shall arrange for the delivery to Site, off loading, temporary storage in a
suitable environment.
2.1.6
Site Conditions
Temperature and Humidity Range. The equipment shall be installed in an environment

having a temperature range of 0 C to 55 C and a maximum relative humidity of 100 % (non
condensing). The Contractor shall use, where required, fans, heaters, and air conditioning
units to maintain a correct working temperature for his equipment. All Parts of the equipment
shall be constructed of materials or treated to prevent the formation of mould, fungus or any
corrosion over the temperature and relative humidity ranges specified.
EMI/RFI Noise Immunity. The equipment to be provided shall be adequately protected

against interference from the use of the radio transmitters, at any point external to the
equipment housings, and no malfunction of the equipment shall result from this cause.
Responsibility for the correct and reliable operation of the equipment shall rest with the
Contractor, who must ensure that the equipment is adequately protected against the ingress
of radiated, mains-borne signal-borne interference.
Generated Interference. The Contractor shall ensure that the computer, instrumentation and
communications equipment conforms to BS EN 50081-1 for noise emissions.
Sequencing. The Contractor shall make applications to Qatar Telecom (Q-TEL) for provision
of communications and Qatar General Electricity & Water Corporation (QGEWC) for power
supply services. Applications shall be made in time`qw to ensure services are available for
installation and commissioning of the telemetry equipment.
Coordination. The Contractor shall check with other trades to ensure equipment and material
can be installed in space provided. Provide other trades with information necessary for them
to execute their work. Details on Drawings which are specific regarding dimensions and
locations, are for information purposes. Coordinate with other trades to ensure work can be
installed as indicated.
2.1.7
Commissioning
The Contractor, the Engineer and any appropriate personnel of the Owner shall be present
when the equipment or installation is commissioned.
Commissioning shall include operating the equipment in a variety of modes and sequences
to prove its satisfactory operation, prior to initialising the formal site inspection and testing.
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2.1.4
QCS 2014

Part
02: Telemetry/SCADA
2.2
DESIGN
2.2.1
Pre-Design Documentation
Prior to design of the system the following documentation shall be submitted:

operational functional requirements including MIS functional description;
(b)
process description, including interlocks and alarms;
(c)
process flow diagrams (PFDs)
(d)
process and instrumentation diagrams (P&IDs)
(e)
SCADA I/Os data base (Instrument data base)
(f)
Programmable Logic Controller (PLC) listing
(g)
process control strategies
(h)
process monitoring requirements (manual & automatic)
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(a)
Page 6
Hardware Design
Programmable logic controllers shall be used as the basic SCADA hardware.
PLCs shall be installed at strategic locations throughout the plant areas to make optimal use
of the LAN and to minimize hardwiring of I/Os. Man machine interfaces (MMIs) shall be
strategically located and installed within each nominated process area. These installations
shall form the nodes of a supervisory and distributed control and monitoring system.
PLC nodes and MMI nodes shall be connected via the selected PLC/network communication
system to form a Local Area Network (LAN) for the site.
Loss of the communication shall not impact on the internal control strategy.
All system shall be capable of redundant communication. The failure of either of these links
shall not result in loss of system communication functionality and response. The failure shall
cause an alarm to the operator and to remote monitoring systems where required.
Plant areas and functional groups shall not be split across PLCs unless reliability benefits are
demonstrated. Any PLCs failure shall not interfere with more than a maximum of one plant
area.
Investigation of the surrounding environment (physical and other hardware components) shall
be conducted for all hardware components to optimize components selection and location
for the site.
All PLCs shall be programmable via the SCADA network.
For retrofit installations, PLCs used to replace conventional hard-wired process system
control/starter controls shall be compatible to existing SCADA system and standards.
2.2.3
Software Design
PLCs software shall support higher-level languages such as ladder logic or any other
language (Function Block concept etc) and should comply with the intent of relevant British
Standard and International Standards.
Machine coded program segment shall not be offered nor accepted as solutions for control
implementation.
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2.2.2
QCS 2014

Part
02: Telemetry/SCADA
Page 7
Higher-level programming shall be in structured English statements.
Communication protocols shall be able to communication with PLC manufacturers

equipment currently in use and any new PLCs.
Application software shall be selected from packages with ample support and market base,
proven in the industrial field to which it is applied. They shall have adequate local resources
for support and program development. Provision for automatic upgrade from the delivered
versions and future versions of software for a period of up to five years after delivery, shall be
included in the base contract.
Application software shall provide information in a clear and simple manner, at both summary
and details levels. This information shall include plant operational status, and the ability to
adjust and optimize readily start/stop or isolate the plant processes or individual items of
equipment. The specific control actions required shall be as described in the functional
requirements.
The system shall have provisions for an operator to intervene or select alternative predefined
control strategies.
The software shall allow data exchange and have software to allow external application
software developers to add-on to the functionality of the software.
The system shall be capable of providing additional parts for communication with the
following:
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Existing SCADA systems
(b)
Radio modem where specified in the contract documents
(c)
Existing RTUs
(d)
Future business management systems.
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(a)
No degradation of the plant SCADA system response times shall occur because of overhead
imposed on the SCADA operating system as a result of these interfaces.
2.2.4
System Security
All access to the system shall be via password for operator access control functions and
system configuration. A minimum of two-step multi-level security shall be used. An
automatic timed log-out shall be provided.
Supplementary hardware-type security shall be provided where indicated in the contract

documents.
An automatic timed log-out shall be provided. Timing configuration for the log-out shall be
adjustable and determinable by the sites needs.
External access to the system shall be secured in such methods as dial-back and encryption.
All disk used in the system shall have scanned (including the data) labels and shall have
virus protection maintenance schedules.
The SCADA software shall provide for Console Mode Assignment features, giving the plant
operational team the ability to limit the use of the MMIs to specific levels of control and
monitoring as required.
Interfaces with external systems shall be on a read-only basis.
2.2.5
Operator Interface
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QCS 2014

Part
02: Telemetry/SCADA
Page 8
Number and location of MMIs and input devices such as touch screens or keyboards shall be
determined depending on plant production needs. Full control and monitoring capability shall
be available at each screen.
There shall be no single point of failure, i.e. the failure of one screen or its associated
hardware will not compromise the integrity of other MMIs.
The failure of any one screen or its associated hardware shall not compromise the integrity of
other MMIs.
For services plants a minimum one printer shall be provided for alarms/operators actions.
The use of the printer shall be minimized and all alarms and operator records shall be
electronically stored and shall be periodically (and as required) printed in reporting format.
An additional printer shall be provided as required to satisfy report generation needs. At least
one colour printer shall be provided for serviced sites.
MMIs shall provide a focus for such activities as alarm reports generation, events logging and
the archiving of historical data. Where it can be justified operationally, remote MMI may also
be installed in area equipment rooms for the control of adjacent systems and plant items.
Where the MMI is used in an office environment, it shall be capable of generating business
reports using commonly used packages and shall have access to printer via LAN.
For plants with permanent staffing besides MMI, a programming console shall be provide for
on-line system modifications and maintenance without disruptions to production activities.
For unattended (remote) plants provisions shall be made for the connection of a portable
programming console and printing facility.
The system shall be designed so that data input shall be collected/entered only once and
shall be accessible for various business reports. It shall also be capable of sharing this data
with external computing systems as required, to provide the necessary plant information to
other applications in an accurate and timely manner.
10
The Plant operator/Management shall be able to access the plant from remote sites through
dial-up or secured Internet laptop MMI. Critical alarms shall be reported to the central control
room as required for any emergency response during after hours.
11
A standard library of interface screens, graphics, symbols and colours shall be utilized to
create uniformity between systems. This shall be in accordance with BS 1646, BS EN 60073
unless otherwise stated in the contract documents.
2.3
MASTER STATION HARDWARE
2.3.1
Computer
The SCADA computer shall be an Industrial type PC (personal computer) of server /

workstation category running multitasking real time operating system suitable for process
control operations. These PCs shall have RAID1 implementation of mirroring and controller
duplexing. . The PC shall be latest one available in the market. Unless otherwise specified
in the project specification ,PC shall be minimum Intel core i7 processors with 6GB RAM ,1
Terabyte Hard disk, DVD R/W ,Sound cards and speakers ,2 numbers. Integrated 3 COM
10/100/1000 Ethernet Network Cards with other serial, USB, parallel ports, Keyboard and
mouse
The system shall support hardware and software interconnectivity to Programmable Logic
Controllers (PLCs) over RS 232/RS485 serial link or Ethernet over fibre/copper media using
appropriate protocols, or similar, subject to the approval of the Engineer.
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The memory capacity supplied shall be sized to accommodate an increase in inputs, outputs
or Programmable Logic Controller (PLC) of up to 50% of the original specified without
replacement of the memory unit. Further memory expansion shall be possible. The
Contractor shall state the maximum memory capacity that may be fitted.
3
Local HMI (Panel Mounted)

The local HMI (panel mounted) shall be an industrial type PC of server / workstation category
running multitasking real time operating system suitable for process control operations as
specified in clause -2.3.1 except RAID1 implementation, unless otherwise specified in the
project specification.
Redundancy
The master station shall be supplied with dual redundant computer equipment and suitable
software to ensure high system availability and to prevent loss of operational data.
2.3.3
Visual Display Unit (VDU)
Visual Display Units (VDUs) shall be 22 inch colour monitor screens unless otherwise stated,
capable of displaying information in alphanumeric, bar histogram, graphical.. The TFT shall
be color monitor with a 256-color palette as minimum and shall have the ability of displaying
mixed alphanumeric/semi graphical information. TFT shall be capable of high resolution
graphic displays non - interlaced, low radiation, flat screen with no discernible flicker. Display
of characters shall be legible and stable on a shadow mask tube, having a resolution of not
less than 1024 by 768 pixels and a refresh rate of not less than 70 Hz.The units shall include
all the necessary picture controls to adjust the sharpness, contrast and position of the image.
The VDU shall have non-volatile memory of 2MB minimum. The VDU shall be industrial
type.
Control room VDUs (Monitor) shall be 22inch and VDUs for local HMI at other locations
(PLC panel), shall be 17 inch minimum size.
VDUs shall be fitted with a power management system to reduce consumption upon
detection of a stand-by signal from the PC.
2.3.4
Keyboard
The master station keyboards shall be of an enhanced pattern personal computer (PC)
keyboard, separate from the VDU, low profile and have non-reflecting surfaces and keys of
low intensity to minimise unwanted reflections.
2.3.5
Logging / Alarm / Report Printers - Continuous Feed
Printers used for logging of system wide events and alarms shall comply with the following:-
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2.3.2
(a)
(b)
(c)
(d)
(e)
(f)
(g)
(h)
print speed
print quality
:
:
paper feed
paper width
print pitch
print width
:
:
adjustable width tractor feed mechanism
18 to 38 cm fan fold
:
character set
noise level
letter print with optional draft mode

:
160 characters per second
10 or 12 cpi
132 characters at 10 cpi

:
Full ASCII
50 dBA.
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2.3.6
Colour Printers
Laser printers shall be used for the production of colour screen dumps and reports and shall
have a sufficiently sized buffer memory such that system performance will not be degraded
when the colour printer is operational and comply with the following:
(a)
print speed :
text, 80 characters per second
(b)
print speed :
colour graphics, 2 minutes per page full
colours
(d)
paper feed :
(e)
compatible with VDU graphics

A3 and A4 with auto sheet feeder mechanism and minimum
50 sheets per tray
paper width :
A4/A3
resolution
600 DPI
(g)
RAM
8 MB
(f)
Monochrome Printers (Laser)
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These printers shall comply with the following:

(a)
print Speed
: 8 pages per minute
paper feed
A4 with auto sheet

250 sheet paper tray.
(c)
resolution
600 DPI
RAM
and
minimum
full ASCII
4 MB
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(e)
character set
mechanism
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(d)
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(b)
Audible Alarm
An audible alarm located on the control desk, shall be provided which is initiated by any fault
condition arising and silenced on operator acceptance of all fault conditions. An alarm mute
function shall be provided to silence the audible alarm without accepting any fault conditions.
It shall be possible to enable/disable this audible alarm only at the highest system access
level.
Use of the internal PC audible alarm will not be acceptable.
2.3.9
Data Storage
Provide a historical data storage system with removable media for archive and backup.
The data storage system shall store alarms and events, with the time of occurrence for one
month and selected analogue signals connected to the system. All alarms and events shall
be archived in a first in first out buffer, for a period of 40 days.
A high speed back up device with removable media, such as streaming tape cartridge or
optical disk, shall be provided for each server, suitable for backing up the whole system on a
weekly basis.
Data selected for archive shall be written to removable media which shall be sized to support
at least 180 days worth of archive data. The archive media also shall be sized to store
logged analogue data, at a maximum sample rate of 15 min for a period of 15 months.
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2.3.8
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Uninterruptible Power Supply (UPS) System
The Contractor shall supply a UPS system with sufficient capacity to maintain power to the
computer equipment, its peripherals and process critical instrumentation during a mains
power failure for a minimum period of 8 hours. Refer to Section 21, Part 18 Uninterruptible
Power Supply Systems more detailed specification .
In the event of power failure, the master central system shall be supported by the UPS.
The central system equipment shall be programmed to degrade gracefully once UPS power
is exhausted or execute a shutdown routine after a preset time from the original mains
failure.
The UPS systems shall be monitored by the SCADA and a fault in the UPS system shall be
accorded the highest priority alarm status.
The FDS shall detail modes of failure and process shutdowns and itemise signals to be
supported by UPS.
Power distribution from the UPS in the control room area shall be via protected sockets, the
design of which will be such as to prevent inadvertent connections of non-system hardware.
2.4
MASTER STATION SOFTWARE FUNCTIONS
2.4.1
General
The Contractor shall be responsible for supplying complete software packages to enable the
equipment to operate as stated in this specification. Provision must be made for the adding of
further software tasks as and when required. All software functions shall be user friendly with
instruction and messages to aid the operator. The Contractor shall make available all
standard software functions even if not specifically detailed in the specification. The sever /
operator works stations shall be OPC compliant for communicating to other client works
station
The computers shall utilise a real time multi-tasking and networked operating system with a
proven track record in real time control applications.
It is a requirement that the system be supported by on line configuration and editing of all
VDU mimic displays and database and to create new displays and additional database.
The system shall be capable of supporting the allocation of equipment groups into zones and
these zones may be allocated for the attention of Particular operator workstations (OWs).
Operational mimics and other graphics shall be presented in an industry standard graphical
user interface (GUI) format. A minimum of two active windows should be displayable
concurrently. Both text and graphics shall resize automatically to accommodate changes
made to the size of a window. The system shall be designed to minimise the operators use
of the keyboard. All major functions shall be accessible on-screen through use of the mouse
or track ball.
When designated in the Project Specification additional operator workstations shall be

provided for each process area. Functionality shall be identical to that of the master station
OWs allowing full access to all system functions at the authorised access level. Operator
system entry for each area will be password coded with different levels of entry depending on
the level of authority of the operator. Development and systems level entry passwords will be
provided for engineering workstations. Each action taken by any operator at any level of
entry, or, at any operator terminal shall be log file recorded, and time and date stamped. Log
in and out time and dates will be printed on the control room event logging printer.
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2.3.10
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VDU mimics will display dynamic colour details of flow rates and pressures, pump status, well
levels, alarms, electrical power supplies and other general equipment status conditions. All
requests and commands shall be via icons, whether menu linked or linked to equipment
control actions. A permanent dynamic alarm banner shall be displayed at the bottom or top of
each operator screen. Each control action will be routed through a series of confirmation
routines.
The complete system database shall be available to each master-station OW offering

preconfigured reports per process area. These reports shall be available for printing in graph
or tabular format. Dynamic trend displays shall also be available for all analogue flow, level
and pressure values. Custom, as well as preconfigured reports and trends shall be available
to a higher level of entry. A colour A4 size screen dump printer shall be provided for graph
and trend prints.
An operator help utility shall be provided offering help linked to the particular action being
carried out by the operator at that time. At least one help screen per screen page shall be
available. This facility shall be preconfigured with an option for updating by operators via a
password entry. Typical information available shall consist of guides of actions to take under
Particular equipment conditions, general process information and help in operating the
telemetry system itself.
10
Provide a software watchdog timer function connected to one set of normally closed relay
contacts which are held open whilst the watchdog is healthy.
2.4.2
Display Facilities
The displays shall be user configurable, with the user being able to construct any desired
symbol for display. Any display shall appear (excluding historical recall) within 3 to 5 s of
selection and the displayed data shall be updated from the database as information is
recovered from the Programmable Logic Controllers (PLCs). Alarms shall typically appear
within 3 to 5 s of occurrence and within 1 s of being received into the central system
database.
The Contractor shall configure all display pages as fully as possible. However, facility must
be incorporated to permit easy construction and modification of the display pages by using a
standard library of shapes and symbols. The library shall be added to and modified by the
user as required. The configuration shall be object orientated for ease of use. All layout
details and dimensions, including colours, symbols, line diagrams, legend text and
indications, shall be agreed with the Engineer.
The initial application software shall provide for the display pages listed below and any pages
necessary for the system to function as a complete entity.
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(a)
mimic displays
(b)
alphanumeric configuration pages for the complete I/O and PLCs
(c)
graphic displays
(d)
trend displays
(e)
process alarms with tag, date time and cause
(f)
event logs of past 72 h with date and time
(g)
tabular display of data
(h)
inset windows showing an analogue trends may be mixed with mimic displays. In such
a display the main mimic and inset trend shall all be live with automatic display
updates.
(i)
network status and configuration.
(j)
main power supplies status.
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system alarms with equipment identity, date and time.
Indexing of information and menus shall be presented in the form of active windows on the
screen while the mimics etc. are still available for view.
No display or function shall effect the logging/monitoring of data. It shall be possible for the
master station terminal and auxiliary terminals to perform different tasks within the displays
simultaneously.
2.4.3
Monitoring and Alarms
The operator shall be able to monitor all of the information at all workstations. He shall be
able to view active equipment information on a series of VDU based graphical and tabular
displays.
In the event of an equipment alarm, the following shall occur at the master station:
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alarm message displayed in the alarm message area of the screen
(b)
the audible alarm shall sound
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(a)
the appropriate Section of the display page shall change colour and flash
(d)
a full message shall be written on the alarm page
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(c)
the full alarm message shall be printed on the alarm printer
(f)
the full alarm message shall be recorded, stored on disk and automatically
archived.
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(e)
The operator should be able to acknowledge the alarm by pressing an accept alarm key or
icon. This action shall stop all associated alarm messages and displays flashing, however
the display shall remain in the alarm state fixed colour to indicate an accepted alarm. When
all outstanding alarms have been acknowledged the audible alarm shall be silenced.
Once the alarm has cleared, the messages and displays shall return to normal. The alarm
message shall stay recorded on the event/alarm log and an alarm cleared message shall
also be recorded.
If the alarm clears before being acknowledged the sequence of events shall continue as
above except the message shall change to indicate a cleared alarm.
An audible alarm silence function shall be provided to enable an operator to silence the
audible alarm without acknowledging all alarms. On occurrence of any subsequent alarm the
audible alarm shall sound.
For multiple bit points (where two or more inputs are combined to function as one point) the
assignment of status/alarm levels shall be on the combined signals.
Each signal within the configured system shall be capable of being assigned an alarm based
on the following:
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(a)
(b)
(c)
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four levels per analogue (Lo Lo, Hi Hi, Lo and Hi)

rate of change
deviation from setpoint or other control parameter
Alarms shall be time tagged to 1 second resolution at PLC.
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10
A minimum of four alarm priorities shall be provided so that those requiring immediate
attention may be separated from alarms of lower priority. An audible alarm shall sound for
alarms requiring operator action. It shall be possible to acknowledge alarms from any
operator station provided the operator is logged on to an approved access level.
11
Typical alarm assignments are as follows:

(a)
critical alarm
an alarm that requires immediate operator action
(b)
non critical alarm
(c)
operator guide alarm -
(d)
event
- an alarm that requires

necessarily immediate action
operator
action
but
not
an alarm that provides information to the operator
a low priority condition which is recorded.
The alarm software shall produce an alarm summary which will show all currently active
alarms in priority and chronological order.
2.4.4
Equipment Control
The system shall support a high security equipment control facility and employ revertive
checking of control outputs based on a select, checkback and execute philosophy of
operation. Any command entered at any OW shall complete its action within 2 s.
Command execution performance time excludes the time for call set-up on PSTN and
assumes no transmission errors or re-transmission of data occurs.
2.4.5
Data Archiving
Continuous process (analogue) data, digital event states, alarms and operator actions shall
be archived to a removable media system. The archive media shall be sized to store logged
analogue data, at a maximum sample rate of 15 min for a period of 15 months. Data
recording shall be on dual media. The archive system shall generate an alarm when a file is
90 % full.
Analogues will be stored at a rate selected by the operator in the range 1 second to 1 hour.
The operator shall have the facility to select the way in which an analogue is stored. The
system will provide any combination of the following:
(b)
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(c)
maximum value
(d)
minimum value
(e)
not stored.
instantaneous value
average value
(a)
Maximum, minimum and average values shall be calculated over a period set by the operator
in the range 15 min to 24 h, the default shall be 1 h.
The logging of new data and reception of alarms must be carried out at the same time as the
operator is viewing archived data. Any alarms received must be displayed as an overlay on
the visual display unit.
2.4.6
VDU Mimic Displays
The Contractor shall configure all the mimics to provide total detailed coverage of the
monitoring and control of equipment as detailed in this specification. It is expected that
display modifications will be required in the future and therefore the ability to change the
displays without programming skills is essential.
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Instrumentation shall be displayed using ISO standard symbols. For mimic configuration, it
shall be possible to call up a library of standard symbols representing items (e.g. pumps,
valves) and add new symbols to the library. Building mimics shall be simple and be achieved
by using a mouse or tracker ball pointing device. The mimic displays shall consist of the
following pages:
(a)
a general diagram covering the whole of the system on a single screen with key data
(b)
a general block diagram for each site or area of Site showing the equipment displayed
on a series of single screens with key data
(c)
mimic of the equipment and instrumentation connected to each PLC displayed on as

many screens as necessary.
Tabular Representation of Data
It shall be possible to put any data into a tabular format, with the data entered in row or
columns. The user shall be able to add headings to any of the rows or columns and store the
table as a blank for later use.
2.4.8
Trend Displays
It shall be possible to plot dynamically updated real time data and archived data on a line
graph to represent analogue or digital information. Each graph shall be capable of displaying
8 plots overlaid on a graph of different colours and line texture. Next to the graph, there shall
be a key relating each colour to its function. The horizontal axis shall be time based and user
selectable in minutes, hours, days, weeks, for example, together with a start time.
The vertical axis shall be scaled as a percentage of range and be displayed in the colour of
the selected reading. To avoid cluttering, the vertical axis scale shall be changed by selecting
the individual display. The vertical axis shall be automatically scaled for each selected point
between limits entered by the user. Actual values in engineering units shall be displayed by
positioning a cursor at the desired point of the trend graph.
The display of the data shall also be available in tabular form.
2.4.9
Manual Data Entry
The system shall be provided with facility for entering data manually via the keyboard. This
data will fall into two types.
(a)
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2.4.7
(b)
maintenance related comments.
constants which will be changed infrequently. This data may have time and date
associated with it
2.4.10
Manually Corrected Data
The system shall allow a person with authorised access to manually correct erroneous data
via the keyboard.
2.4.11
Reports
There shall be a real time spreadsheet facility supplied and installed by the Contractor in the
master station. The users shall be able to transfer data from either the archive system or live
data to the spreadsheet. The user shall be able to produce daily, weekly, monthly and annual
reports using any data and a mixture of formats (tables, graphs, summaries, spreadsheets).
Typical reports would be:
(a)
(b)
power consumption
total flows
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(c)
failures of equipment
(d)
maintenance schedules.
Page 16
It shall be possible to configure and store blank templates for later use. Facilities for editing
stored templates shall also be provided.
2.4.12
Point Record
Each input shall have a record covering every characteristic of the input. This data shall be
automatically sent to the appropriate locations when the user has completed entering or
modifying data into the record. The Contractor shall compile all input records as indicated in
the input/output schedules, plus any other I/O to enable the complete and optimum
monitoring and control of the equipment. The user shall be able to modify, amend or create
new records. The Contractor shall ensure all possible characteristics are included in the
record including the following:
point identity
(b)
point description
(c)
point type
(d)
point state
(e)
point range
(f)
point units
(g)
status/alarm and priority levels
(h)
alarm set points - high, low, out of range high/low
(i)
log interval - time between logs
(j)
log type - average, total, and others as required
(k)
log in PLC - for communications failures.
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(a)
Profiling
From an average, typical or manually entered plot, it shall be possible to set an exception
profile whereby readings within an upper and lower level are acceptable. Profiles shall be set
graphically via OW. The user may select for the system to alarm if the reading is outside the
profile and highlight such exceptions as Part of a report and so reduce the need to examine
all data to ensure acceptability. The number of exceptions shall be logged.
2.4.14
Data Manipulation
It shall be possible to perform simple mathematical functions on any data, including the
following functions:
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2.4.13
(a)
addition
(b)
subtraction
(c)
multiplication
(d)
division
(e)
2
square root
It shall be possible to log, display or use in a control loop the resultant data.
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Database Query Facilities
The system shall support the use of database relationships and wild card characters to
provide database query facilities. It shall be possible for applications integration to easily
configure queries and save them for future use. Support of Dynamic Data Exchange (DDE)
or Structured Query Language (SQL), to permit data exchange between the SCADA Master
Station and external applications, including spread sheets and databases.
Data shall be presented in tabular format and contain any combination of fields from the main
system database.
It shall be possible to manipulate the data by specifying search and sort criteria to define data
range limits.
Once a query table has been created it shall be possible to store the configuration and initiate
successive look ups using a point and shoot technique.
2.4.16
Downloading PLC Configuration
It shall be possible to download configuration to the PLCs from the engineers terminal.
2.4.17
Diagnostics
The system shall have on-line diagnostic facilities to report system faults as they occur. A set
of off-line diagnostic routines shall be supplied for more extensive fault diagnosis.
2.4.18
Access Levels
The functions available on the system shall be fully flexible so as to allow users access levels
to be customised by the system operator to suit individual user requirements.
Access to management and engineering levels shall be restricted by user selectable

passwords or keyswitch. The security systems shall be based on a set of privileges which
may be granted or denied to individual uses by the system operator.
2.4.19
Control Loop and Sequence Programming
The method of programming will depend upon the Manufacturers system requirements.
However, the following standards shall be followed:
all programs shall be written such that they lend themselves easily to alterations
and additions
(a)
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2.4.15
(b)
good programming practice shall be followed using structured programming

techniques. All programs shall be tidy in format and logical to follow, and shall be
accompanied by flow diagrams. Programs should be extensively annotated with
comments and be self-documenting
(c)
the system shall be supplied with programs that use a high level language for the OW.
2.4.20
Program - Documentation
As Part of the requirements of this specification full documentation is required as below :

(a)
(b)
(c)
(d)
software user manuals

database point allocation table
complete program listing, flow charts for all sequences and control routines
application software source code
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end user license agreements for the programming software.
REMOTE TERMINAL UNITS (RTU) FOR TELEMETRY APPLICATION
2.5.1
Future Expansion
The system hardware, application software and database shall be sized to accommodate a
total of 10 % increase in signal capacity overall and up to 25 % increase in an individual RTU.
Sufficient plug in modules shall be provided and wired to terminals ready to accept future
signals of up to 10 % or a minimum of one module, for each RTU.
2.5.2
RTU Hardware
Each microprocessor based RTU will be the main device used to control loops in each RTU
process area. Each RTU shall be able to receive analogue and digital inputs from the field,
perform input signal processing and alarm checking, perform algorithms control, and output
to valves and other actuators.
Each RTU controller shall be mounted in an IP65 enclosure and constructed to allow easy
replacement and maintenance of cards.
The RTU shall be suitably protected against exposure to the severe environmental conditions
prevalent in sewerage systems.
The RTU shall be an intelligent device capable of handling data collection, logging, report by
exception, current data retrieval and pump sequence control programs.
Each RTU shall be sized for controlling the specified input/outputs and future expansion.
The RTU shall be of single board construction and as a minimum shall include input/output
circuits:
16 digital inputs
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2.5
8 digital outputs
(c)
4 analogue inputs
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(b)
It shall be possible to add one of the following input/output types on a single plug-in module.
(d)
16 digital inputs
(e)
8 digital outputs
(f)
4 analogue inputs
(g)
4 analogue outputs
(h)
4 pulse inputs
The program and data held within memory shall remain intact and error free if all external
power is removed from the RTU for a minimum period of two weeks.
The Contractor shall supply batteries for each RTU with sufficient capacity to maintain full
power to the RTU for 8 h, or as designated in the Project Specification, after a power failure.
The UPS system shall be integral to the RTU. The batteries shall be of a sealed maintenance
free type.
All field connections shall be made in terminal strips located for easy access. These
terminals shall be clearly marked and identified. Terminals carrying voltages in excess of
24 V shall be fully shrouded. All terminals shall be of the flip up isolator type with test points.
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10
A hand held programmer, shall be provided for local display of signals, programming and
fault diagnosis.
11
RTUs shall be capable of being equipped with RS232/485 links for interconnection to
standalone control systems and standard equipment packages.
(a) connection to other devices will use Modbus ASCII or RTU protocol as standard
(b) details of other protocols available should be included within the tender
RTUs shall be configured such that a single RTU failure will not interrupt or degrade
equipment monitoring and control functions. RTU failure shall be alerted to the operator at
the highest alarm priority.
13
Surge protection shall meet the requirements of IEEE 472-1974
2.5.3
RTU Software
The RTU shall be capable of processing locally input equipment information before
transmitting it to the master station to reduce transmission overheads.
Total internal scan time interval for all inputs and outputs in an RTU shall not exceed 1 s.
There shall be two pairs of alarm settings for each analogue input, one an alarm warning of a
possible fault, the other warning that the input is outside a valid range of readings.
The RTU shall operate on a report by exception basis.
The RTUs shall have sophisticated in built control facilities to permit control loop
configuration using simple building blocks. These blocks shall sequence control, three term
control and other control routine components as required by the Specification. The RTU shall
be capable of routine signal processing including integration, summation, subtraction and
totalisation of one or more inputs. Control loops shall incorporate deviation and rate of
change alarms, bumpless transfer facility, set point and output high and low limits.
The RTU shall be capable of executing sequential control logic. Programming of sequential
control shall be by means of vendor supplied high level function block language or ladder
diagram format as Part of an integrated package.
The RTUs shall have standalone capability, able to continue monitoring equipment and
executing control loops if the communication link to the master station fails. In the event of
such a failure the RTU shall log all alarms and required analogues until all the total memory
is filled. When the communication link is restored the RTU will automatically upload the
logged data to the data archiving system.
The RTUs shall have a watchdog function and full self-diagnostics capable of detecting and
reporting faults to the master station and displayed locally.
The Contractor shall program the RTUs fully under this Contract. It shall be possible to
modify the programs remotely by downloading from the engineers terminal.
10
It shall be possible to initiate a current data retrieval on demand, from the master station,
leaving the original RTU data contents intact for routine up-loading.
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2.6
PROGRAMMABLE LOGIC CONTROLLER (PLC)
2.6.1
PLC Hardware
The PLC system shall comprise of a central processing unit, input/output modules, serial
interface modules and programming units. The PLC shall be of modular construction with
plug in I/O cards and facility to install expansion racks/modules when necessary. The system
shall include 25% spare capacity in hardware and memory for future modifications.
PLCs shall be installed inside Local Control Panels or in separate cubicles, as specified in
the Project Specification. PLC shall be suitable for ambient temperature of up to 50 C and
95% relative humidity.
Power ok
(ii)
Low battery
(iii)
Forced I/O
(iv)
CPU fault
(v)
I/O status indicators
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Central Processing Unit. The CPU shall perform the following function:
(i)
Scan all inputs, execute relay ladder logic programs and generate outputs for
the final control elements
(ii)
Monitor status of system hardware and provide diagnostic information .
(iii)
Central Processing Unit ( CPU) shall 80 s per 1 kb minimum process scan

time. Random Access Memory (RAM) for real time program execution with
lithium battery backup for data retention and EEPROM flash backup for
permanent storage shall be provided. The PLC memory shall be as required for
the programs and future requirements with a minimum of 1 MB flash / I MB
SRAM, with a minimum of 204 K for IEC Logic or equivalent .
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(b)
PLC diagnostic indications shall include the following:
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(a)
PLCs shall be supplied complete with a laptop programming and diagnostic device plus all
necessary leads and programming software & manuals. When a local SCADA computer is
installed and connected to the PLC locally, the PLC programming software is to be installed
in the same computer and the necessary cables/adaptors required for programming are to be
supplied.
PLCs shall have a minimum of 1 x RS 232 plus 1 x RS 232 /485 ports and 1 Ethernet port.
Compact Version and/or Fixed I/O type PLC shall be considered (physical I/O counts only) at
the discretion of the engineer depending upon the application requirements. The compact
version CPUs specification shall meet all other communication parameters.
PLC control equipment shall be housed in the common controls section of the MCC and shall
be fed by non door interlocked MCCB. A separate signal marshalling section shall be
provided to accommodate all input and output signals to the Control and Telemetry section.
The equipment shall accept status and analogue (4-20mA) signals from both field and panel
mounted instruments. Analogue inputs shall be scanned into a 12 bit binary (minimum)
analogue to digital converter with buffered inputs.
PLC power supply shall be 24Vdc, 240 V ac as specified. The equipment shall be maintained
in operation during a period of mains failure drawing power from the battery or UPS system
for a minimum back-up time of 8 hours. The battery/UPS system shall include diagnostic and
automatic self-test routines with volt-free contacts to initiate an alarm in the event of
malfunction.
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Panel mounted display (local HMI) units shall be provided for man machine interface, as a
permanently connected means of accessing set points, timer settings, control and monitoring
locally, unless otherwise specified in the project specification.
10
The HMI shall be pre-programmed to provide a basic graphical display of the process. Realtime numeric display of process variables and alarm messages shall be available. All process
control functions shall be accessible for the operator from the HMI. The application program
shall be stored in "Non Volatile Memory". Local HMI size shall be as specified in the clause
2.3.3 Visual Display Unit (VDU)
11
A schematic block diagrams for an overview of the PLC system and general arrangement in
the MCC section indicating the location and proposed placement shall be submitted for
Engineer's review.
12
The Contractor shall ensure while submitting his proposal that the PLC systems selected
provides high availability and high level of integrity.
13
PLCs used for controller applications require a minimum built-in redundancy of Power supply
,CPU modules, Communication modules and communications with a hot-backup logic
configuration.
2.6.2
Input Modules
Digital input modules shall be 16-point (maximum per Card), 24 VDC, signal source type,
with individual screw terminal connections. Where space restrictions or high-density signal
requirements are apparent 32-point 24VDC digital input modules may be permitted with the
approval of the engineer.
All digital input units shall be capable of accepting, a volt-free contact signal, the source
voltage shall be regulated 24VDC and shall be derived from the PLC panel.
Where the input from an external source is not volt-free then suitable isolation devices shall
be provided in order to prevent cross-connection of different supplies. This device may be
e.g. interposing relay or optical-isolator. For frequencies of operation greater than 30
operations/hours, the use of electromechanical devices shall not be permitted. All
interface/isolation devices shall provide visual indication of Signal State.
All Input modules shall be segregated into groups, which relate to 24VDC supply commons.
Where different supplies are apparent in input connections, these shall be segregated in
accordance with supply common grouping.
Inputs signals from 'DUTY' equipment shall not be allocated to the same input module as
signals from 'STANDBY' equipment performing the same function.
The analogue current input module shall be capable of converting 4, 8 or 16 channels of

inputs in the range of 4 to 20 mA.
Resolution of the converted analogue current input signal shall be minimum 12 bits binary
All analogue signals shall be updated each scan into a dedicated area of data registers.
The conversion speed for all analogue current input channels shall be within
milliseconds
10
All digital input modules shall be provided with LED for each point (channel) for testing and
maintenance purposes.
11
All digital input modulus shall be provided with a dual independent power supply.
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Output Modules
Discrete AC output modules shall have separate and independent commons allowing each
group to be used on different voltages.
Discrete AC output where used shall be provided with an RC snubber circuit to protect
against transient electrical noise on the power line.
Discrete AC outputs shall be suitable for controlling a wide range of inductive and resistive
loads by providing a high degree of inrush current (10x the rated current).
Discrete DC output modules shall be available with positive and negative logic characteristics
in compliance with the IEC industry standard.
Discrete DC output modules shall be provided with a maximum of eight output points in two
groups with a common power input terminal per group.
Discrete DC output modules shall be compatible with a wide range of load devices, e.g.
motor starters, valves, and indicators etc.
The current rating of the relay output shall be capable of supplying the load according to the
applications.
The analogue voltage output module shall be capable of converting digital data to analogue
outputs in the range of -10 to +10 volts.
Resolution of the converted output signal shall be minimum 12 bits.
10
All analogue signals shall be updated each scan into a dedicated area of data registers.
11
The analogue voltage outputs shall be configurable to default to 0 mA, 4 mA or hold-laststate in the event of a CPU failure.
12
Output signals to 'DUTY' equipment shall not be derived from the same output module as
'STANDBY' equipment performing the same function.
13
Digital outputs used for AC inductive loads shall be fitted with arc suppression devices as
close to the load as is practicable.
14
Means shall be provided to allow the disconnection of outputs causing unsafe movements or
actions without removing power from the PLC Processor or inhibiting program execution.
15
All digital input modules shall be provided with LED for each point (channel) for testing and
maintenance purposes.
16
All digital input modulus shall be provided with a dual independent power supply.
2.6.4
PLC Software
PLC Software shall be developed within the BS EN 61131-3 environment. Application

program shall be developed by using software package that only conform to BS EN 61131-3
requirements.
Standard IEC libraries of Functions and Function Blocks shall be used when writing
application software.
All software shall be suitably documented to include the following as a minimum:
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2.6.3
(a)
suitable comments;
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function description;
(c)
symbolic addressing local data areas;
(d)
symbolic addressing global data areas;
(e)
descriptions of all constants;
(f)
Page 23
list of cross-references.
The PLC shall be suitable to employ minimum two programming devices for development of
application programs, a small hand-held device with back-lit LCD readout and a Software
programming package running on a PLC compatible laptop or desktop computer.
On-line and off-line, CPU and I/O configuration and application program development shall
be achieved with a PLC compatible computer and programming and documentation
software.
Both the PC compatible computer and the hand-held programmer shall be connectable to the
PLC via built-in serial communication port. The PLC shall connect to the computer over the
computer's RS 232C serial port for programming.
In addition to the serial communications, the PLC compatible computer shall be connectable
to the PLC via Ethernet TCPIP supporting the SRTP application protocol.
The programming devices shall have access to the application program, the CPU and I/O
system configurations, all registers, CPU and I/O status, system diagnostic relays, and I/O
over-ride capabilities
2.7
DATA COMMUNICATIONS LINKS
2.7.1
Communication Standards
Transmission of data shall conform to a recognised Consultative Committee for International

Telephone and Telegraphy (CCITT) standard. The data transfer system shall be self
monitoring such that any equipment or line failure shall be displayed at both ends.
The protocol used shall safeguard against false data transmission, allow for error detection,
recovery, failure detection and initiate switchover the redundant data highway. A diagnostic
routine shall be included to monitor the highway performance. Data protocols and
diagnostics shall be fully documented.
2.7.2
Control Room Data Highway
All master station operator workstations and control room hardware shall be linked by a
totally redundant local area network to transfer data between the servers, work stations and
serial line multiplexers. The system shall continuously monitor the performance of both links
and output an alarm on detection of an abnormal condition. Fibre Optic cables shall be
provided for control room Data Highway, unless otherwise specified in the project
specification
The following features shall be provided as a minimum:
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(a)
all data highway networks are to monitored at all times
(b)
communications diagnostics are to be continuous such that a failure is alarmed in the

minimum time
(c)
each network node shall have message checking capability
(d)
there shall be no single point of failure
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(e)
the maximum distance between nodes shall be up to 600 meters, with a maximum
highway distance of 3500 meters
(f)
communication rates shall be at least 10 M baud.
Leased lines or PSTN
The system shall use the public switched telephone network (PSTN) or leased data circuits to
transfer data between the master station and the RTUs located at remote sites. The
modems used by the master station and the RTUs shall have auto dial, auto answer
capability and be PTT approved.
All radio equipment shall comply with the appropriate local recommendations and shall have
been approved for licensing by the radio frequency allocation authority. Additionally the
equipment shall comply with the most recent edition of the appropriate national and
international standards specifications.
2.7.4
Radio
Type approval numbers issued by the national frequency allocation committee in the country
of manufacture shall be supplied, together with CCIR recommendations, national and
international standards, specification and recommendations met by the equipment at this
time of tender.
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2.7.3
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The radio system shall be of the following type :

frequency
: UHF/VHF as allocated by Frequency Allocation Authority
modulation
: FM
base mode
: full duplex
outstation mode : two frequency simplex
channel spacing : 12.5 kHz
Radio Path Profiles
The Owner shall provide path profiles and subsequent technical examinations prior to
detailed design of the radio system.
2.7.6
Radio Transmitters/Receivers
Transmitter/receiver radio units shall be single units without standby facilities. These units
shall have sufficient battery back up for the system to function for 8 h in the event of mains
failure. Provision for this may be from the main RTU battery back up supply. The units may
be either wall mounted or incorporated within the RTU enclosure.
2.7.7
Base Station Radio Transmitter/Receivers
Base station transmitter/receiver radio units shall be of a dual main/standby type with auto
changeover of the duty units. The Contractor shall supply within the tender document and
explanation of how this changeover shall be accomplished. An alarm signal shall be
transmitted to the Master Station when a changeover occurs. The base station shall be
provided with power supply equipment, including nickel cadmium battery and 240 V 50 Hz
a.c. mains fed battery charger and have sufficient battery back up to allow for the system to
operate for 4 h in the event of mains failure and capable of automatically recharging the
battery to full capacity within 24 h while the radio equipment continues to operate at full duty.
2.7.8
Aerials and Aerial Structures
The Contractor shall supply and install all aerials and aerial support structures and shall
provide drawings to show how each type of aerial is to be mounted.
The base stations shall have omnidirectional aerials plus any associated duplexers.
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UHF outstations shall have a single 12 element, yagi aerial with a gain of 12 dB with respect
to a half wave dipole on the corresponding base station. Any VHF outstations shall have
3 element yagi VHF aerials planned on the corresponding base station.
The Contractor shall supply and install all necessary low loss coaxial down leads for
connection for the radio unit and lightning protection for the aerial system.
2.7.9
Fibre Optic Network
The Contractor shall carry out a study whether it is necessary to lay a fibre optic
communication media for use as main data highway link. The study shall include the security
level required in the designed site communication where fibre optic cable considered being
highly secured and highly accurate communication medium.
This particular specification is to be read in conjunction with QCS 2010 Section 21 Part 14
Structured Cabling Systems
Qualifications and Responsibility of Contractor
The Contractor shall furnish and install all fibre optic equipment and materials specified in
this section and shown on the tender drawings. The fibre optic system shall be the unit
responsibility of one system supplier. The supplier shall use qualified personnel, possessing
the necessary equipment and having experience in similar installations
(a)
Submittals:
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Submit the following information:
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Catalog data and installation instructions on the splice method, hardware, and
splicing
(ii)
equipment (if any).
(iii)
Catalog data on the fiber optic cable, pull boxes, connectors, cable lubricant,
duct
(iv)
sealant, closures, pull rope, enclosures, identification tape, and mounting

hardware.
(v)
Catalog data on the testing equipment including a written test procedure

outlining the
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(vi)
steps and methods that will be used to test the cable during and after
installation.
(vii)
Include a sample copy of the test form that will be used in the test procedure.
(viii)
Cable installation procedures for the applicable method of installation, outlining

the
(ix)
construction methods that will be used. Identify steps that will be taken to ensure
(x)
that the cable is not damaged during the installation.
(xi)
Complete factory test results for cable reel stating the signal loss for fiber in the
cable
(xii)
prior to and after extrusion of duct around cable if applicable.
(xiii)
Record drawings indicating the locations of all splices (if any) and manholes .
(xiv) Certified test results for each cable after installation stating the signal loss of
each fiber in the cable between splices, across all splices, and from end to end
after splicing is complete.
(b)
Qualifications and Responsibility of Contractor

(i)
The Contractor shall furnish and install all fibre optic equipment and materials
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specified in this section and shown on the tender drawings. The fibre optic
system shall be the unit responsibility of one system supplier. The supplier shall
use qualified personnel, possessing the necessary equipment and having
experience in similar installations.
Material
(i)
The Single mode optical fiber cables which are optimized for use in both wave
lengths 1310 nm and 1550 nm.
(ii)
The multimode optical fibre cables which are optimized for use in both wave
lengths 850 nm and 1310 nm.
(iii)
The optical fibre cables shall meet the requirements stated in ITU-T Rec. by
international telecommunication Union, BS EN 50173-3 standard.
(iv)
The cable shall be new, unused and of current design and manufacture.
Suitable optical fibre cables shall be selected based on the distance travel,
bandwidth, indoor and outdoor application and shall be approved by the
Engineer.
(v)
The single mode fiber shall be used for fibre optic network more than 300 m
distance data transmission, unless otherwise justified by the manufacturer.
(vi)
The material of the fibre shall be silica glass fibre.
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(e)
The fibre utilized in the cable must meet ITU-T: G651.1, G652 and have
maximum attenuation at 850 nm of 3.75 dB/km at 1310 nm of 0.4 dB/km, at
1550 nm of 0.3 dB/km or less. If used for outdoor, then the fibre cable must be
loose-tube non-dielectric type.
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Fibre characteristics
Refer to the QCS Section 21 Part 14, clause 14.2.3
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(c)
INPUTS/OUTPUTS
2.8.1
General
All process I/O and equipment interface boards shall comply with the following:
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Equipment wiring terminations shall accommodate up to 0.9 mm diameter

conductors. Terminals shall be of the test disconnect type to permit ease of signal
isolation and loop monitoring for commissioning and maintenance purposes.
(a)
Hot (powered) removal of I/O boards shall be possible without special tools.
Provision to power two wire loop powered transmitters, where required.
Digital inputs shall meet the following requirements:

(a)
all digital inputs shall be optically isolated.
(b)
all alarm and state indications shall be from dry contacts or 24 V d.c. wet contacts.
An isolated +24 V d.c. supply shall be provided to source the opto-isolated inputs
when connected to dry contacts, adequate filter circuits and software debounce
techniques will be necessary.
(c)
Contact operation shall be as follows :

(i)
Alarms: in the healthy condition the contacts shall be closed with the relay
coil energised: in the alarm condition the contacts shall be opened with the
relay de-energised.
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(ii)
States: contacts shall be open with relay coil de-energised in the off (logic
0) condition, and closed in the on (logic 1) condition.
(iii)
Two bit Digital: One contact shall close when the equipment is in one state
and a second contact shall close when the equipment is in the opposite state.
Analogue Inputs
Independently configured channels in the range 4 - 20 mA, 1-5 V d.c., 0-1 V d.c., 0-5 V d.c.,
0-10 V d.c. or +/-10 V d.c. All analogues shall be screened and segregated from other
cables. The signal ground shall be separate from the system ground. Input impedance shall
be greater than 1 M for voltage inputs. ADC conversion at ten times per second shall be
16 bit, system accuracy 0.2% of span.
2.8.3
Digital Outputs
All digital outputs shall be optically isolated.
All control circuits shall operate from a 24 V d.c. supply. The contact will be normally open
and energised to close when an action is initiated. Outputs shall be either open-collector or
volt-free contacts as follows:
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2.8.2
Open collector
100 mA at 35 V d.c.
(b)
Contact
1 A at 24 V d.c. or 120 VA (resistive) 0.5 A at 24 V d.c. or

120 VA (inductive).
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(a)
Analogue Outputs
In general all analogue outputs shall be 4-20 mA or 1-5 V d.c., selectable, and drive a
maximum loop impedance of 1000 for current outputs and 2000 for voltage outputs. The
signal ground shall be separate from the system ground. DAC conversion shall be 14 bit,
system accuracy 0.2% of span.
2.8.5
RTD Input
Capable of receiving 10 copper or 100 platinum resistance temperature devices directly

without external transmitter. Conditioned signal must be capable of being directly accessed
by the on board RTU controller without external intervention.
2.8.6
Thermocouple Input
Capable of receiving type E, J, K, input directly without an external transmitter. Linearisation

shall be performed at the PLC without external intervention.
2.8.7
Pulse Input
Capable of receiving a zero based pulse or rectangular wave or sinusoidal wave form with
amplitude of 4-6 or 21.6-27 V and rate of 0 to 5000 pulses per second for totalizing. Where
frequency counting is required a rate of 0 to 1000 pulses per second should be provided
2.9
POWER SUPPLY REQUIREMENTS
All power supplies provided by the Contractor shall conform to the following:
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2.8.4
(a)
be comprised of standard available units
(b)
be fitted with adequate input/output fuse protection
(c)
power supplies to be fitted, if applicable, with short circuit protection and current
limiting facilities
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(d)
all power supplies to be selected such that they are derated to allow for future
expansion to improve the reliability, and help increase the MTBF of the units. With all
the expansion described in this specification, the loading on the power supplies shall
not exceed 75 % of their total capacity
(e)
modular with one for N redundancy
(f)
modular failure indicated at the PLC and Master Station
(g)
failed module shall be removed without disconnecting system power or affecting

control.
MIMIC DIAGRAM
2.10.1
General
Where required in the Project Specification a modular mimic diagram shall be provided. The
Mimic will be configured to display the status of all principal items of equipment in the area
covered.
No Part of the mimic panel display area shall be below 760 mm or above 2100 mm from the
floor.
All layout details and dimensions, including main construction, colours, symbols, line
diagrams, legend text and indications, shall be agreed with the Engineer.
The mimic diagram driver shall be housed in either the mimic diagram enclosure or a
separate enclosure. In either case the driver shall consist of modules mounted in standard 19
inch card frames. The mimic driver shall consist of a client device directly connected to the
data centre LAN.
Colour coding shall be in as provided below and where not stipulated in accordance with BS
EN 60073:2000:
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Satus of Operation
Equipment running and normal
Equipment stopped and normal
Equipment tripped
Equipment selected on Auto
Equipment or process unsafe / danger in operation
Panel Energised /isolator or ACB ON
Process Flow ON (e.g. Valves open)
Process flow Stopped OFF (e.g. Valves closed)
Colour Code
Green
White/Grey
Yellow
Blue
Red
White
Green
White
2.10.2
Mosaic Tile
The face of the mimic diagram shall comprise a mosaic of precision formed tiles, which shall
clip into a supporting grid to form a robust construction of flush and neat appearance. The tile
faces shall have a durable, scratch-resistant non-reflective finish. The background colour of
the mimic diagram tiles shall be to the approval of the Engineer. The face dimensions of tiles
shall be subject to approval by the Engineer.
The face of the tile mosaic shall be engraved and/or printed or painted to provide a diagram.
The printing or painting shall be durable throughout the lifetime of the equipment.
The mimic diagram face and supports shall be rigidly held in a robust floor mounting frame.
The surround to the mosaic tile area and the ends of the frame shall be enclosed in
decorative panelling to provide a high quality aesthetic finish. The complete construction shall
be formed into an enclosed panel, with a access to enable the ready replacement of
defective components and the rearrangement of tiles. Tiles and components shall be
replaceable without disturbance to the surrounding areas of the mimic face.
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Wiring troughs or clips shall be provided at the rear of the mimic diagram to enable wiring to
electrically driven components to be neatly dressed and supported. Flexible wiring of
adequate length shall be used to enable electrically driven components to be relocated on the
mimic diagram without the necessity for rewiring.
All illuminated indications shall use high radiance, light emitting diodes (LEDs). Either single
peep-through or multiple-element/planar types shall be used, as appropriate. The illuminated
area shall have even intensity across the whole face. All LEDs shall have a wide viewing
angle in excess of 60 without significant change in perceived luminosity.
A 20 % spare capacity shall be provided (equipped) within the mimic driver and the wiring to
the mimic board to allow for future modifications. The spare capacity shall be evenly
distributed.
All driver outputs shall be protected against overload and short-circuit.
Lamp test facilities shall be provided such that operators can initiate the test from their
workstation positions. This facility shall ensure that both the mimic LEDs and the driver
circuitry are exercised.
2.10.3
Projection
The mimic diagram shall be displayed using high resolution 1280 by 1024 panel rear
projection technology onto multiple projectors and screens arranged in a matrix to produce
an integrated display, or an equivalent quality as specified in the particular Specifications.
The screens shall offer a wide viewing angle, + 40 horizontal and + 12 vertical, and good
contrast in full ambient light conditions. The projector and screen assembly shall occupy a
floor space of less than 1.5 m, deep by the length of the mimic.
Dynamic configuration of the display shall be from X-windows style environment and provide
intuitive on screen menu drive display. The ability to interface multiple sources, up to a
maximum of 10 using an RS232/422 serial interface shall be provided.
A software package shall be provided to adjust brightness, contrast, time, colour, sharpness
and geometry and convergence settings from one computer. Image adjustments shall be
stored for each source such that the projector will automatically select the correct settings for
the Particular source.
An auto convergence system shall be provided to automatically align the projected image on
the screen, manual convergence shall also be possible.
A live video window facility shall be provided to display real time video images anywhere on
the screen matrix. The video signal may originate directly from a site security video camera
or via a live antenna signal.
A remote pointer facility shall be provided to allow the operator to use the local keyboard and
mouse to move the cursor on the mimic display and interact with the applications. The
system shall support upto three operators simultaneously with a security interlock system to
avoid conflicts between users.
2.11
FACTORY INSPECTION AND TESTING
2.11.1
General
The Contractor shall advise the Engineer the date on which the equipment is available for
factory inspection and tests 30 days in advance. No equipment shall be shipped to Site
without written permission of the Engineer.
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Before dispatch from a manufacturers works each item of equipment, software and its
components shall be tested in accordance with the relevant specification or code issued by
the British Standards Institution or similar internationally recognised standards authority. In
the absence of such a specification or code, these tests shall be performed in a manner
subject to the approval of the Engineer, and may be witnessed and approved by the Engineer
or his representative.The equipment will be inspected by the Engineer and his representative,
to ascertain compliance with the functional design specification, satisfactory finish and
workmanship, and relevant functional tests shall be carried out with simulated inputs/outputs
as necessary.
If simulated inputs/outputs are necessary then the simulation equipment shall be provided by
the Contractor as Part of the Works unless otherwise agreed.
Subject to the Engineer agreement, the works system tests shall take place according to the
program detailed by the Contractor.
Any surface coating applied prior to the initial inspection of equipment shall be considered
sufficient reason for its rejection. Where any attempt to conceal defects is discovered the
works may be rejected.
2.11.2
Test Plan
A test plan shall be produced for the Engineers approval, by the Contractor, for the factory
and site acceptance tests. The plan shall indicate a logical step by step schedule comprising
step, action and reaction, e.g.:
(b)
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All hardware including spares shall be required to pass an agreed preliminary

hardware performance test to ensure known hardware operability before
software testing begins.
Functional Testing
Functional testing using the system software shall be comprehensive.

Simulation of the inputs and responses from equipment operation shall be as
realistic a reproduction as possible of Site conditions. Systems to which the
PLC/SCADA is required to interface with but are outside the scope of this
contract shall be emulated to demonstrate correct operation of the hardware and
software.
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Simulate high level

: Tank Symbol Change Colour
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Action
Reaction
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(c)
System Diagnostics
(i)
The means of fault detection and diagnostics provided by the system

software shall be validated. This will involve making provision for including a
sufficient variety of faults and out-of-range conditions in the system to ensure
the detection processes are adequately tested.
(d)
The Engineer shall have the option not to attend these tests and to instruct the
Contractor to carry them out on a Self Certification basis.
(e)
Three copies of all manufacturers tests certificates, log sheets, performance curves,
etc. relating to the tests at manufacturers works shall be dispatched to Site for
the Engineers approval prior to system installation and commissioning.
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Part
02: Telemetry/SCADA
Page 31
INSTALLATION
2.12.1
Tools
The Contractor shall include for the supply of all spanners, key, special tools, gauges and all
other electronic and calibration tools required for the efficient installation, commissioning and
operation of the equipment.
2.12.2
Training for Owners Personnel
Training shall be conducted by personnel employed by the ICA Subcontractor, familiar with
the system supplied, experienced and trained in developing and implementing instructional
courses.
The Contractor shall submit information on the training program for approval prior to
shipment of the equipment. This submittal shall include a course outline, time required,
course schedule, sample workbook and instructor qualification information for each level.
The Contractor make a workbook on each course available to every person taking the
courses listed herein. The workbook shall be of sufficient detail so at a later date a trainee
could review in detail the major topics of the course.
The training times shall be scheduled by Owner in advance so as not to disrupt Owners
ability to operate the equipment.
Specialised training shall be provided for a minimum of three of the Owners personnel in the
operation and maintenance of the system at the manufacturers facility or in Qatar, as
specified in the Project Specification. The training programme shall be divided into two
segments and each shall consist of at least five, eight hour working days.
The maintenance training programme shall be developed for personnel that have electronics
maintenance and repair experience and a general knowledge of computer systems, but shall
not assume any familiarity with the specific hardware furnished. As a minimum, the following
subjects shall be covered:
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2.12
system architecture and layout
(b)
hardware components
(d)
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(a)
(e)
power supplies
(f)
data highway
(g)
programmer connection
(h)
PLC programming and diagnostic techniques
(i)
battery replacement and recording
(j)
PC and workstation familiarization and maintenance
(k)
troubleshooting
(l)
disassembly
(m)
cleaning
(n)
component replacement
(o)
reassembling.
module switch settings (configuration switches)

I/O modules
(c)
QCS 2014
The operation training program shall include the following topics:

(a)
power-up, bootstrapping and shutdown of all hardware devices
(b)
interpretation of all standard displays
(c)
appropriate actions for software and hardware error occurrences
(d)
use of operator interface displays and keyboards
(e)
use of printer including replenishment of supplies
(f)
manual data entries
(g)
creation and editing of graphic operator display screens
(h)
loading of any required software into the system
(i)
data base creation and editing.
System Management:
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The training in this area shall cover the following:

(a)
the daily supervision of the System: e.g., archiving data, system housekeeping, fault
reporting, preventing repetitive alarms
system administration e.g., planning and providing system expansion and
reconfiguration of hardware, control of users and privileges, software and hardware
fault analysis
(c)
Engineering functions, configuration and application programming e.g., additions and

changes to the system, points, displays, reports and logs, preparation and
downloading of sequence control programs and schedules and software development.
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(b)
The Engineer shall have the option to attend the inspection and tests before setting the
equipment to work. The Contractor shall notify the Engineer, in writing, 48 hours before
commencing tests.
A Site Acceptance Test (SAT) shall be conducted as part of the ICA system validation and
shall include all equipment and software within the Contractors scope of supply. This test
shall be conducted after the above equipment has been installed at the Site and the
Contractor is satisfied of the correctness of the installation and of the operation of the
equipment.
Particular Test Requirements
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2.12.3
(a)
communication test
(i)
(b)
hardware test
(i)
(c)
demonstrate correct operation of hardware using off-line diagnostics
functionality test
(i)
(d)
the Contractor shall firstly conduct a test to establish the correct functioning and
ability to correctly transmit data to and from each port on the system
communications network. In the event of any problem or deficiency being
identified in any equipment supplied by others, this shall be reported fully in
writing by the Contractor to the Engineer
demonstrate the system performance and functionality meets the specification
test details
(i)
the SAT shall be carried out in accordance with a test specification produced by
the Contractor, and approved by the Engineer
QCS 2014
test equipment and test software shall be provided by the Contractor to load the
system to the worst case scenario defined in the test specification
(iii)
the Contractor shall prepare a test report following the SAT.
System Commissioning
(a)
where required in the Project Specification the Contractor shall provide staff to
work in conjunction with the Owner to ensure the satisfactory operation in service
of all equipment in the system, and to assist the Owner to adjust configuration data
and to develop/modify application programs e.g., sequence controls.
System Takeover
The criteria for takeover of the system shall be:
submission by the Contractor and approval of as-built drawings
(ii)
submission by the Contractor of all documentation
(iii)
submission of all software design and support documentation and the lodging
of source codes in a place of secure safe-keeping and storage with a third Party
(iv)
provision of information and examples of each type of report and each item of
user-configurable functionality
(v)
issue of all relevant test certificates
(vi)
successful completion of the SAT
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system commissioning and issue of Final System Test Certificate by the

Contractor.
Following satisfactory completion of the above, the Engineer will issue the necessary
system takeover certificate.
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(ii)
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Part
02: Telemetry/SCADA
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Part
03: Primary Elements
Page 1
PRIMARY ELEMENTS .................................................................................. 2
3.1
GENERAL ...................................................................................................... 2
3.1.1
3.1.2
3.1.3
3.1.4
3.1.5
Scope
Submittals
Quality Standards
Warranty
3.2
PRODUCTS ................................................................................................... 3
3.2.1
3.2.2
3.2.3
3.2.4
3.2.5
3.2.6
3.2.7
3.2.8
3.2.9
3.2.10
3.2.11
3.2.12
3.2.13
3.2.14
3.2.15
3.2.16
3.2.17
3.2.18
3.2.19
3.2.20
3.2.21
Electromagnetic Flow Meters

In - Line Ultrasonic Flow Meters
Rotameters
Venturi Flumes
Flow Switches
Ultrasonic Level Measurement
Hydrostatic Level Transmitter
Level Sensing System - Air Reaction Type
Capacitance Level Transmitter
Multiple Level Measurement Systems
Tilting Float Level Switches
Level Switches - Conductivity Probe
Electronic Pressure Transmitters
Electronic Differential Pressure Transmitters
Pressure Gauges
Vacuum Gauges
Pressure Switches
Limit Switches
Temperature Sensors
Gas Detection System
Guided Wave Radar Level Transmitter
3.3
INSTALLATION ........................................................................................... 10
3.3.1
3.3.2
3.3.3
General
Testing and Final Acceptance
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Part
Page 2
PRIMARY ELEMENTS
3.1
GENERAL
3.1.1
Scope
This Part includes specifications for Primary Elements, their design, manufacture, installation
and commissioning.

General
General Telemetry/SCADA
3.1.2
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This Section
Part 1,
Part 2,
BS 907........................Dial gauges for linear measurement
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BS 1042......................Flow Measurement
BS 1780......................Bourdon tube pressure and vacuum gauges
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BS 1904......................Industrial platinum resistance thermometer sensors

BS 2765......................Dimensions for temperature detecting equipment and their pockets
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BS 3680......................Open channel Flow and Level Measurement

BS EN 50014 to BS EN 50020
Protection
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BS EN 60529..............Ingress Protection
BS EN ISO 6817 ........Flow measurement for conductive liquids
Submittals
Submittals shall be in accordance with Part 1 of this Section.
Manufacturers literature, illustrations, specifications and engineering data including

dimensions, weight, instrument set point and range, ambient temperature and humidity
rating, process pressure rating, enclosure specifications, installation and wiring diagrams
shall be included.
The submittal shall be subject to approval by the Engineer. The ICA Subcontractor shall
submit the final documentation based on the Engineers comments. The Engineers
comments/approval shall be issued to the Contractor within 21 calendar days of the
submittal.
3.1.4
Quality Standards
Manufacturer. In addition to requirements of Part 1 of this Section, instrumentation and

controls equipment furnished shall be manufactured by a Company regularly and currently
engaged in the design and manufacture of similar equipment. All equipment furnished shall
be new and of current design. The manufacturer shall be approved and designated in the
Project Specification.
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3.1.3
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Maintainability. All equipment shall be designed for ease of maintenance and repair, and
access to critical parts shall not require a major dismantling. Internal field adjustments, where
permitted or required herein, shall be easily accessible upon removal of a panel or cover.
Materials and installation shall comply with the requirements of the current editions of
referenced electrical codes and standards, and the codes and standards referred to shall be
used for establishing the minimum quality of the materials and equipment supplied and
installed. All equipment of the same type shall be products of the same manufacturer.
Capacities of all equipment shall not be less than that indicated on the Drawings or specified
in the Project Specification.
3.1.5
Warranty
The equipment manufacturer shall warrant his product to be free from defects in
workmanship for a period of 400 days from the date of satisfactory completion of
performance test.
Warranties and guarantees by the suppliers of various components in lieu of single-source

responsibility by the equipment manufacturer will not be accepted. The Contractor shall be
solely responsible for the warranty. In the event a component fails to perform as specified or
is proven defective in service during the warranty period, excluding items normally expended
during operation, the equipment manufacturer shall provide the replacement Part without
cost to Employer. The Contractor shall be responsible for the supply for all such spares under
warranty.
The Contractor shall furnish the Employer with manufacturers guarantee and warranty
certificates for all equipment, duly registered with the manufacturer.
3.2
PRODUCTS
3.2.1
Electromagnetic Flow Meters
General. Electromagnetic flow meters shall use electromagnetic induction to produce a dc

voltage proportional to the liquid flow velocity. The flow meter shall be certified intrinsically
safe and suitable for hazardous area Zone 1, gas group IIA to EN 50014, where specified in
the Project Specification. Flowmeter shall be pressure tested and calibrated by the
manufacturer and certified. Overall accuracy shall be better than 0.5 % of the range
throughout the operating range. Repeatability shall be within 0.2 %.
Sensor. Sensor shall have NP16 flanged process connections. Metering tube, flanges and
earthing rings shall be of stainless steel 304 to BS 970. Electrodes shall be of stainless steel
316 to BS 970. The sensor lining shall be of Teflon or equivalent material suitable for the
application, unless otherwise specified in the Project Specification. The sensor enclosure
shall be protected to IP68. Screened and armoured cable between the sensor and the
transmitter shall be fitted and potted by the manufacturer. The preamplifier input impedance
5
of the sensor shall be a minimum of 10 megaohms to minimise errors due to sensor coating.
Ultrasonic electrode cleaning equipment with all accessories for automatic or manual
operations, shall be provided when specified in the Project Specification.
Transmitter. Transmitter shall be remotely installed from the sensor. Transmitter power
supply shall be 240 V a.c , 50Hz, unless otherwise specified in the Project Specification.
Transmitter shall be microprocessor based with programmable range and engineering units.
Outputs shall be isolated 4-20 mA d.c. and pulse with adjustable span. Programmable in-built
alarm relays shall be provided for empty pipe, low and reverse flows. Transmitter shall have
an inbuilt digital display for flow rate, total and alarms. Transmitter enclosure shall be
protected to IP65. Calibration and programming kit shall be provided
3.2.2
In - Line Ultrasonic Flow Meters
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Part
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General. Ultrasonic Doppler type flow meter with nonintrusive sensor permanently bonded to
the pipeline. Overall accuracy shall be within 2 % of the range with a repeatability of 0.2 %
Transducer. Dual transducers shall be permanently bonded or clamped on to the pipe line to
ensure that locked air pockets are eliminated.
Transmitter. Transmitter shall be remotely installed from sensor. 240 V a.c. 50 Hz power
supply, unless otherwise specified in the Project Specification. Wall mounted with in-built
flow rate and total display. Enclosure protected to IP65. Automatic gain adjustments to suit
pipe line material shall be available. Alarm contacts configurable for diagnostic or low flow
alarm shall be provided. Operating velocity range shall be user selectable. Output shall be
isolated 4-20 mA d. and facility for connecting industrial standard fieldbus
3.2.3
Rotameters
Rotameters shall have borosilicate glass metering tube, stainless steel 316 float and wetted
Parts to BS 970, scale shall have black markings on white background with a nominal length
of 250 mm. Graduation units shall be as specified in the Project Specification. Flanged
process connection. 2 % accuracy and 10:1 rangeability. Glass tube shall be easily
removable for cleaning.
3.2.4
Venturi Flumes
Rectangular flumes used for open channel flow measurement to BS 3680 Part 4c, shall be
moulded in a single GRP piece with 5 mm thick walls, reinforcing ribs and internal removable
blocking to prevent distortion during shipment. Provide staff gauge, 50 mm width by full depth
with 1 mm increments recessed into flume. The flume shall be self supporting and be
provided with an adequate number of lugs integral to the structure to enable the flume to be
cast into a reinforced concrete channel without additional internal or external supports.
U-throated flumes to BS 3680 Part 4C, shall be used for measurement of flows in sewers
and other conduits running partly full.
3.2.5
Flow Switches
General. Flow switches shall sense an adjustable preset flow rate of fluid in a pipe and
operate a SPDT switch to actuate alarms or control circuits. The switch shall be rated for 1
ampere load at 110 V a.c., 50 Hz or 1 Ampere at 30 V d.c.
Vane type flow switches shall be housed in a watertight case, unless explosion proof is
specified in the Project Specification, with electrical conduit connection. Switches for
mounting in 40 mm pipe or larger shall be fitted for BSP thread mounting directly in the pipe.
Smaller sizes shall be supplied mounted on a pipe fitting with female BSP threads. The
switch assembly shall be isolated form the flow by a diaphragm or suitable seal. The
actuator vane and other wetted parts shall be stainless steel, monel, brass or other corrosion
resistant material suitable for the fluid in the pipe. These flow switches are suitable for gases
or clear liquid applications only and shall not be used for raw sewage applications.
Thermal type flow switches shall be housed in an explosion proof or watertight case as
specified in the schedule with NPT electrical conduit connection and shall be either of the
probe type of insertion in the pipe or shall incorporate a pipe spool for installation in the line,
end fittings as shown on the Drawings. They shall operate by means of sensing the
differential cooling of heated sensor elements caused by flow and no flow condition, and shall
be all solid state. The switches shall be available for pressure up to 14 MPa and shall be
capable of sensing velocities as low as 3 cm/s. Wetted parts shall be stainless steel to
BS 970 or other materials suitable for the application.
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Operating Conditions. The flow switch shall be sized and adjusted for the pipe, fluid and flow
rate or velocity shown in the Flow Switch Schedule. Repeatability of sensing shall be within
10 percent for any setting, and differential shall be less than 4.0 percent within the flow range
specified. Set point shall be within 10 percent of flow rate of velocity specified. Care should
be taken while installing, to avoid locations with turbulent flow conditions.
3.2.6
Ultrasonic Level Measurement
General. Unless otherwise specified in the Project Specification, the system shall comprise of
a separate transducer and a transmitter. Overall accuracy shall be better than 1% of the
span with a repeatability of 0.5%. Ultra-sonic level measurement is to be accomplished by
the use of non-contact, echo-time measuring equipment operating at ultra-sonic frequency.
The equipment is to transmit pulses, which are reflected back to the sensor from the surface
of the liquid whose level is being measured. Provide equipment with automatic temperature
compensation and suitable for operation in the designated application under the specified
climatic conditions.
Transducer. The enclosure shall be protected to IP68. Automatic compensation for changes
in ambient temperature shall be in-built. The transducer shall be certified for hazardous area
use if necessitated by the installed conditions, unless otherwise specified in the Project
Specification. The transducer shall be supplied complete with all required mounting
accessories.
Transmitter. Surface or panel mounted transmitter with 240 V a.c. 50 Hz power supply.
Microprocessor based transmitter with programmable range and alarms. Transmitter shall
be complete with in-built indication for level or for flow, if used for open channel flow
measurement. 4 Nos. in-built relay contacts, shall be provided for process and diagnostic
alarms. Transmitter shall be provided with an in-built keypad or a hand held programming
unit of programming the instrument. Output shall be isolated 4-20 mA d.c and facility for
connecting industrial standard fieldbus.
3.2.7
Hydrostatic Level Transmitter
Hydrostatic head type level transmitters shall be used for tank level measurement at
atmospheric pressure. Flush diaphragm type capacitance sensor suspended inside the tank.
Sensor shall be certified intrinsically safe and protected to IP68. Sensor material shall be
stainless steel 316 to BS 970. Two wire transmitter with 4-20 mA d.c. output 0.5 %
accuracy. Flanged process connection on top of the tank.
3.2.8
Level Sensing System - Air Reaction Type
General. The level sensing system shall be designed to operate on the back pressure
caused by the level of the liquid above the open end of a pipe through which air is being
discharged. The device shall be capable of sensing a rising or a falling liquid level and shall
translate this rise or fall into a proportional analogue signal. Device shall be two-wire loop
powered 4-20 mA dc output and facility for connecting industrial standard fieldbus with an
accuracy of +/- 0.5% of span. All equipment such as required to meet the operational
requirements set forth herein shall be included and connected to obtain a complete functional
system as specified herein.
Air Supply. The system shall operate from the auxiliary air sources specified below. To
facilitate control, the system shall include a strainer, shutoff valve, pressure regulator with
gage, flow control valve and flow metering rotameter with differential pressure regulator. A 4way purging valve or equivalent shall permit purging of the bubbler tube while isolating the
pressure sensing line.
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Part
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Piping Connections. A "tee" with a removable plug for cleaning purposes shall be provided to
connect the air tubing to the bubbler tubing in the wet well. The plug shall be readily
accessible for cleaning.. The wet well sensing tube shall be 12 mm diameter stainless steel
to BS 970 grade 316 S12 and extend to 150 mm below the low alarm level or as otherwise
shown on the Drawings and be supported on not more than 1200 mm centres using stainless
steel clamps on the wet well wall to avoid movement due to turbulence. Static pressure
connection to the 4-way purging valve shall be 8 mm polyethylene tubing, enclosed in steel
conduit or equivalent protection. The pressure output signal shall be sensed by indicator
dials, pressure switches, electronic or pneumatic transmitters as specified in the Project
Specification.
Auxiliary Air Supply. The system shall incorporate and operate from internally mounted dual
oil-less heavy duty air compressors, each capable of providing the required air flow. The
compressors shall operate in a duty-standby mode. Failure of the duty compressor shall
generate an alarm and start the standby compressor. Facility shall be provided to drain out
condensate from the system.
3.2.9
Capacitance Level Transmitter
General. Radio frequency type level sensors shall sense the varying capacitance admittance
of a sensing probe as function of the level of submersion. Varying capacitance is converted
to a 4-20 mA d.c current signal or volt free contact output as indicated in the Project
Specification.
Specific Requirements. The type of process medium, temperature range, pressure other than
atmospheric, measurement range, indicators, switches, etc. shall be as specified in the
Project Specification. Unless otherwise specified the accuracy shall be 1 % of full scale.
The electronics for the sensor shall incorporate circuitry which shall act to cancel error
caused by coating build-up on the probe.
Construction. The radio frequency level sensor shall consist of a probe and a solid state
electronic unit housed in an IP66 case for surface or panel mounting. Probes shall be
designated for mounting through a threaded flange adapter unless otherwise shown on the
Drawings. The probe mounting parts shall be stainless steel 316 to BS 970 and the probe
shall be in accordance with the manufacturer's recommendation for the application specified.
Rigid probes shall be Teflon coated. Local indicators shall be mounted on the electronics
housing and shall indicate in the engineering units specified in the Project Specification. The
output shall be isolated 4-20 mA d.c. unless otherwise required by the Project Specification.
Power. The level sensing system shall either be a two wire transmitter loop powered by the
receiver or operate from 110 V a.c., 50 Hz power supply.
3.2.10
Multiple Level Measurement Systems
General. Multiple level detection systems shall be used for pump control or multiple level
alarm applications. Each system shall comprise of one or more electrode assemblies and a
controller.
Electrodes. Conductivity type electrode assemblies shall have a weatherproof enclosure to

IP56. Electrodes shall be of 316S12 material to BS 970 Part 1. Process connection shall be
BSP threaded or flanged to BS 4504. The electrode assembly shall have a glazed ceramic
insulator cemented to the metal housing. The measuring electrodes shall be Teflon insulated
except at the tip.
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Controller: Controller power supply shall be 110 V a.c. 50 Hz. Provide double pole
changeover contact for the output relays. Controller shall have LED indication for relay
status. Zener barriers shall be provided for intrinsically safe installations when the electrode
assembly is located in hazardous areas. Multiple level detection signals shall be used by the
Controller for control of up to 4 pumps or level alarm. The number of control modules in
each controller shall depend on the number of level signals and control contacts required.
3.2.11
Tilting Float Level Switches
General. Tilting float level switches shall use the tilting movement of a float, whose specific
weight is less than that of the process liquid, to actuate switches as the level changes. The
switch(es) shall be integrally mounted in the float and connected to a control box by an
appropriate, waterproof electric cable. A movable weight shall be mounted on the cable to
allow adjustment of the setpoint(s). Sufficient cable length shall be provided to facilitate
termination in a control or electrical room unless otherwise stated in the Project Specification.
The float shall be polyethylene, stainless steel or other approved material.
Specific Requirements. The desired switching action Pump-up ("pump-down, or alarm), level
set-points, cable length and optional features shall be as specified in the schedule.
Contractor may utilise either a series of floats or a single float to provide the specified
switching action. The "pump-up" type shall close a contact at a low level and open it at a high
level. The "pump-down" type shall provide the opposite action.
The switch shall be rated for 1 A, 110 V 50 Hz or 1 A, 24 V d.c. inductive load.
3.2.12
Level Switches - Conductivity Probe
General. Level sensing switches of the conductivity probe type shall use the electric
conductivity property of the sensed fluid to close an electric circuit between two or more
sensing probes or between probe and an electrically conductive tank shell. The level
switches shall consist of a probe assembly and an electronic sensing unit.
Sensing Unit. The solid state sensing unit shall operate from a power source of 110 V a.c.,
50 Hz, but shall not apply more than 10 V to probes and the current shall be limited to one
milliampere maximum. The unit shall be housed in an IP66 enclosure, unless explosion proof
is specified in the Schedule, and shall be for pipe stand or surface mounting. The unit shall
be suitable for direct or inverse operation (i.e. output contacts) operate on liquid contact or
non-contact. The output shall have two SPDT switches, rated at 5 A resistive load at 110 V
a.c., with provision for latching or non-latching operation, by appropriate connection of the
output contacts, to provide for "pump-up", "pump down" or alarm type operation.
Probes. The probes shall be either of the rod or flexible wire type when not specified the
Contractor shall select the type most suitable for the application and submit the choice for
approval. Solid rods shall generally be used only where the installation requires less than 2 m
in length. Both rod and flexible wire types shall be insulated except at the sensing end. Either
type shall be suspended from a holder which provides liquid tight connections, and when
installed in a pressure vessel they shall be pressure tight to at least twice the system
operating pressure. Exposed probe ends shall be type 316 stainless steel to BS 970 and
holder shall be cadmium plated cast iron, unless otherwise stated in the Project Specification.
The number of probes per holder shall be as specified in the Project Specification. The
holder mount type (i.e. pipe threaded, flanged or conduit style) shall be selected to suit the
installation unless otherwise specified in the Project Specification.
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Electronic Pressure Transmitters
General. Unless otherwise specified in the Project Specification, the instrument shall be a
two-wire loop powered transmitter with a 4-20 mA dc output, with an accuracy of 0.25% of
span. The wetted parts shall be stainless steel Grade316S31 to BS 970 and the enclosure
protected to IP67. Complete with flush diaphragm or remote seal sensing system. To achieve
optimum accuracy, transducers shall be selected to have a range as close as possible to the
anticipated operating range. A datum point shall be provided adjacent to the transducer
installation. An engraved plate shall define any offsets resulting from its elevation relative to the
tapping point (zero level) and also define the range of the transducer. All elevation
measurement shall be in metres, with the equivalent bar offset shown. Sensors shall be
positioned in a location accessible for safe maintenance. Where separate transducers and
transmitters are used, the transmitter where possible, shall be positioned locally to the
transducer to facilitate calibration. Site operatives shall be provided with a remote readout at a
convenient point.
Construction. The transmitter enclosure shall be IP65 unless explosion proof is specified in
Project Specification. Enclosure and wetted surface material shall be stainless steel to
BS 970 or as indicated in the Project Specification.
3.2.14
Electronic Differential Pressure Transmitters
General.
Electronic differential transmitters shall convert a differential pressure
measurement to a loop powered 4 to 20 mA d.c. output signal. Range shall be as indicated
in the Project Specifications and span shall be field adjustable over at least a 10 to 1 range.
Elevation or suppression facility shall be provided. Overload protection shall be at least +3.5
MPa. Accuracy shall be +0.5 percent of full scale span or better. Integral adjustable damping
shall be provided. An indicating meter shall be provided. Zero and span adjustments shall be
provided.
Construction. The transmitter enclosure shall be IP65 unless explosion proof is specified is
schedule. The process connection shall be 12 mm NPT. Enclosure and wetted surface
material shall be stainless steel to BS 970. Vent drain plug shall be provided on meter body.
A 3-valve manifold shall be provided such that the transmitter can be removed without
disturbing piping connections.
3.2.15
Pressure Gauges
Gauges shall have bourdon tube sensor with 270 degrees pointer travel. Dials shall have
black markings on white background. Dial size shall be 100 mm unless otherwise specified.
Wetted Parts and case shall be 316 stainless steel to BS 970. Accuracy shall be 1 %.
1/2 inch NPT process connection unless otherwise specified. Pressure range and units shall
be as specified in the Project Specification.
Isolation diaphragm shall be stainless steel 316 to BS 970 with silicone fill, pulsation
dampeners or vibration snubbers shall be provided where specified in the Project
Specification.
3.2.16
Vacuum Gauges
Gauges shall have bourdon tube sensor with 270 degrees pointer travel. Dials shall have
black marking son white background. Dial size shall be 100 mm unless otherwise specified.
Wetted Parts and case shall be stainless steel 316 to BS 970. Accuracy shall be 1 %. 1/2
inch NPT process connection unless otherwise specified. 0-760 mm HgA range unless
otherwise specified in the Project Specification. Cases shall be black phenolic.
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Pressure Switches
Pressure switches shall have a diaphragm type sensor with a switching differential adjustable
within 25 % of the range. Contact shall be micro switch SPDT rated 110 V a.c. 5A, 30 V d.c.
2A. Accuracy shall be 1 % of span. Stainless steel enclosure certified explosion proof
where specified in the Project Specification.
3.2.18
Limit Switches
Limit switches shall be provided to sense the limiting positions of equipment, such as valves.
The switches shall be non-contact reed type, magnetically coupled to the actuating device.
SPST contacts shall be rated 110 V a.c. 3A. Reed switch shall have a life expectancy of one
million operations.
3.2.19
Temperature Sensors
General. Temperature sensors shall be (RTD) platinum resistance element. RTD sensors
shall have a temperature resistance relationship and tolerances for 100 ohm platinum
resistance element to BS 1904.
Construction. Temperature sensors shall be equipped with accessory equipment as

specified in the Schedule. In general, accessory equipment shall consist of general purpose,
or explosion proof connection heads; pipe extension with union connectors or bushings; wells
or protecting tubes and spring-loading assemblies. Well or protecting tube material shall be
to BS 2765. Sensors shall be integrally mounted with transmitters to provide a 4-20 mA,
loop powered signal, where specified in the Project Specification.
3.2.20
Gas Detection System
General. Gas detection system shall be rack-mounted. The system shall measure and
display gas concentration and shall provide audio and visual alarms when preset limits are
exceeded. Relay output for alarms and malfunction indications and analogue signal
representing gas concentrations shall be provided. The system shall be configured for fail
safe operation. Failure of a sensor shall generate an alarm. The system shall consist of a
sensor, control module, and calibration check kit including sensor separation accessories
and calibration gas tanks. Sensor and transmitter location shall be as shown on the drawings
and schedule. The gas detection system shall operate from 110 V a.c., 50 Hz power.
Control Module. The control module shall amplify the sensor current signal through a solidstate amplifier for display and alarm functions. The control module shall include a two or
three-digit LED display and three discrete alarm levels: Low, high, and malfunction. Output
relay contact shall be rated at 2 amp, 110 V a.c. and single pole, double throw. Analogue
output signal representing the gas concentration shall be 4-20 mA.
Oxygen Gas Detector. The oxygen gas detector shall have a 0-25 percent range, full scale.
The oxygen sensor shall be housed in an explosion proof enclosure. The sensor shall be the
electrochemical fuel cell type and not require the periodic addition of reagents.
Combustible Gas Detector. The combustible gas detector shall have a 0-100 LEL range, full
scale calibrated on methane gas. The combustible gas sensor shall be the catalytic bead
type. The sensor must have a demonstrated resistance to degradation by silicones and
reduced sulphur gases.
Hydrogen Sulphide Gas Detector. The hydrogen sulphide gas detector shall have a 1-100
ppm range; full scale. The hydrogen sulphide sensor shall be of the electrochemical type
which shall not require periodic addition of reagents.
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3.2.17
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Chlorine Gas Detector. The chlorine gas detector shall have a 0-10 ppm range, full scale.
The chlorine gas sensor shall detect a minimum concentration of 0.5 ppm by volume and a
maximum response time of 30 s for 80 % of range to 10 ppm gas at 20 C. Sensor
recovering time shall be 3 minutes for 90 % of range at 10 ppm chlorine.
3.2.21
Guided Wave Radar Level Transmitter
The probe shall:

have single rod with extended flexible wire, minimum probe diameter 6mm and
constructed of stainless steel to BS970-1 Grade316S31 (partially replaced by BS EN
10084);
(b)
have flange mounted and threaded process connections;
(c)
be able to work with ambient rating of 150 C at 20 bar, for a dieletric range of 10-100;
(d)
have ingress protection and hazardous area protection and shall meet the CE
requirements on Electromagenetic compatibility
(e)
be energised in an intrinsically safe way.
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The transmitter shall:
(a) have locally remote wall/post mounting with a flexible connection to the probe head;
(b)
(b) give a 4-20mA output with a resolution of 0.01mA;
(c)
(c) have a push button keypad and a HART communicator, with menu language
English;
(d)
(d) have ingress protection and hazardous area protection and shall meet the CE
requirements on Electromagenetic compatibility.
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(a)
INSTALLATION
3.3.1
General
Installation, testing and commissioning shall be in accordance with Part 1 of this Section.
3.3.2
Testing and Final Acceptance
All the primary elements shall be calibrated and tested prior to final acceptance, in
3.3.3
Spare Parts for all instruments listed in the schedules shall be provided for two (2) years of
normal service. Refer to Part 1 of this Section for additional spare parts requirements.
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3.3
END OF PART
QCS 2014

Part
04: Panel Mounted and Miscellaneous Instruments
Page 1
PANEL MOUNTED AND MISCELLANEOUS INSTRUMENTS ..................... 2
4.1
GENERAL ...................................................................................................... 2
4.1.1
4.1.2
4.1.3
4.1.4
4.1.5
4.1.6
Scope
Reference Standards
Submittals
Quality Standards
Manufacturers Test Certificates
4.2
PRODUCTS ................................................................................................... 3
4.2.1
4.2.2
4.2.3
4.2.4
4.2.5
4.2.6
4.2.7
4.2.8
Digital Indicators and Totalizers

Trip Amplifiers
Relays-Electromagnetic Type
Timers
Running Time Meters
Programmable Logic Controllers (PLCs)
Alarm Annunciators
Chart Recorders
4.3
INSTALLATION ............................................................................................. 6
4.3.1
General
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PANEL MOUNTED AND MISCELLANEOUS INSTRUMENTS
4.1
GENERAL
4.1.1
Scope
This Part specifies the panel mounted and miscellaneous instruments and equipment to
perform the required functions in conjunction with information and equipment specified in
other Parts of Section 10.
Unit Responsibility. It shall be the responsibility of the ICA Sub-Contractor as described in

Part 1 of this Section to ensure that the panel instruments and equipment supplied under this
Part are compatible with the primary elements and telemetry/SCADA equipment and
equipment specified under other Sections of these specifications, and that the signal
transmission methods are compatible.
Enclosures of front of panel mounted instruments shall be of uniform design and colour
scheme wherever possible. Front of enclosure colours shall be compatible with panel colours
and subject to final approval by the Employer. Normally, compatible standard colours of the
manufacturer shall be acceptable.
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General.
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This Section
Part 1,
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Reference Standards
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4.1.2
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BS 5515......................Documentation of computer based systems
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BS 7165......................Recommendation for achievement of quality in software

BS EN 50081..............Electromagnetic Compatibility
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BS EN 61131-3P ........Programming Languages for Programmable Controllers.
IEEE 472-1974 ...........Surge protection

ISO 3511 ....................Process measurement control functions - instrumentation symbolic
representation
ISO 9075 (BS 6964) ...Structured Query Language (SQL)
4.1.3
Submittals
The following shall be included in the submittals:

(a)
shop drawings, product data, and samples
(b)
complete description, specifications, drawings, and descriptive literature on the

equipment.
(c)
make and model of each component
(d)
number of sizing electrical and control wires and power requirements
QCS 2014

Part
Page 3
(e)
complete wiring and equipment instrumentation diagram
(f)
list of spare Parts to be provided
(g)
recommended procedure for protection of equipment against damage prior to

installation
(h)
complete system diagram showing required components, routing through in-plant

ductbank system.
The submittals shall be subject to approval by the Engineer. The Contractor shall submit the
4.1.4
Quality Standards
Manufacturer: In addition to requirements of Part 1, instrumentation and control equipment

furnished shall be manufactured by a Company regularly and currently engaged in the design
and manufacture of similar equipment. All equipment furnished shall be new and of the most
recent design.
Maintainability: All equipment shall be designed for ease of maintenance and repair, and
access to critical Parts shall not require major dismantling. Internal field adjustments where
permitted or required herein shall be easily accessible upon removal of a panel or cover.
Materials and installation shall comply with the requirements of the current editions of
referenced electrical codes and standards, and the codes and standards referred to shall be
used for establishing the minimum quality of the materials and equipment supplied and
installed. All equipment of the same type shall be products of the same manufacturer.
4.1.5
Manufacturers Test Certificates
Manufacturers shall test and calibrate each input/output to operate within specified limits
Calibration and compliance certificates provided by the manufacturer, shall be authenticated
by the Contractor and submitted to the Employer.
4.1.6
All ICA equipment shall be provided by approved, prequalified manufacturers and suppliers
designated in the Project Specification.
4.2
PRODUCTS
4.2.1
Digital Indicators and Totalizers
Digital indicators shall be panel mounted type. 96 mm (w) by 48 mm (H) dimensions. 110 V
a.c. 50 Hz power supply. 4 1/2 digit LED or backlit LCD display for process variable. Range
shall be programmable in Engineering units. Input shall be 4-20 mA d.c. or volt free contact
as specified in the Project Specification. Loop power for 2-wire transmitter shall be provided
as required. At least two programmable alarm contacts for high or low alarms. Totalizers
shall have 8 digit display with manual reset facility.
4.2.2
Trip Amplifiers
Trip Amplifiers shall be surface or rack mounted with 110 V a.c. 50 Hz power supply. Input
shall be 4-20 mA d.c. 1 or 2 independent adjustable set points shall be provided as specified
in the Project Specification. Outputs shall be SPDT relay contacts rated 110 V a.c. 5A.
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Part
Page 4
Relays-Electromagnetic Type
Relays shall be provided as necessary to perform switching functions required of control

panels and other control circuits.
Control Relays. Control relays shall be provided for the control and alarm circuits as indicated
in the Project Specifications. The relays shall be electrically held, 50 Hz, continuous duty,
multiple connected to 110 V a.c. control circuits and mounted inside control panels or
separate metal enclosures as indicated. Enclosures shall be IP66. The relay base assembly
shall accept from 1 through 8 convertible poles. Relays shall be attached to pre-shaped
mounting channels with captive screws.
4.2.4
Timers
Timers shall be provided as specified herein or indicated in the Project Specifications. Timers
shall have four types of operation: (1) On Delay (2) Off-Delay (3) Single Shot, and (4) Duty
Cycle timers. Time ranges shall be as shown in the Project Specification.
Panel mounted timers shall be of the motor driven adjustable type with dials and presentable
pointers. The timers shall operate from 110 V, single-phase, 50 Hz power and shall be of the
square bezel type for flush panel mounting. Output contacts shall be double throw and rated
for 10 A at 110 V a.c.. The number of contact sets shall be sufficient to perform the required
control functions. Where more contacts are required than supplied as commercial
standards, control relays of equal rating shall be used to supplement the timer contacts.
When specified, relay contacts shall be supplied as Part of the timer and shall be operated by
the timer control power independently of the timed contacts. Repeatability of the preset time
delays shall be within 2%. Timers shall be of the plug-in type and enclosed in dust-proof
cases. Connection shall be by numbered screw terminals in the rear of the timer connector.
On delay timers. When a start signal is applied, the timing cycle begins. Output contacts
change state after the time delay is completed. Contacts shall return to original state when a
reset signal is applied or power is removed.
Off delay timers. When a start signal is applied, the output contacts change state
immediately. When the start signal is removed, the timing cycle begins and the output
contacts return to the original state when the cycle is completed. Timer shall be reset by a
reset signal or by removal of power.
One shot timers. When a start signal is applied, the output contacts change state
immediately and the timing cycle begins. The output contacts return to the original state
when the cycle is completed. Timer shall be reset by a reset signal or by removal of power.
Duty Cycle timers. Two timer cycles shall be incorporated. When a start signal is applied,
the first timing cycle beings. The output Contacts change state at the end of the cycle and the
next timing cycle begins. When this delay is completed the output contacts return to the
original state. This sequence is repeated until a reset signal is applied or power is removed.
4.2.5
Running Time Meters
Running time meters shall be of the synchronous motor driven type having a minimum of six
(6) decimal digits where the least significant digit shall represent tenths (1/10's) of hours.
Unless specified otherwise in the Project Specification, they shall not be equipped with a
reset button. They shall be for panel mounting with a square bezel approximately 60 mm on a
side. Motor voltage shall be 110 V a.c.
4.2.6
Programmable Logic Controllers (PLCs)
See Section 10, Part 2, Telemetry/SCADA for PLC specifications.
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4.2.3
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Part
Page 5
PLCs shall be installed inside Local Control Panels or in separate cubicles, as specified in
Data base development and system configuration shall be the Contractors and the ICA
Subcontractors responsibility. The data base developed by using the P&IDs and I/O point
list shall be submitted to the Engineer for approval prior to installation in the operating system
4.2.7
Alarm Annunciators
All windows in the alarm and status annunciator shall be nominally 36 mm by 76 mm, of
white plastic, and rear lighted with two low voltage, heavy filament lamps. The plastic
windows shall be engraved with black letters in accordance with the Drawings. The windows
shall be removable from the front for lamp replacement. The lamp units and electronic
drivers shall be in one case, unless otherwise approved in writing, with a removable cover
and designed for panel mounting. The lamps shall be mounted such that replacement is
possible from the front of the annunciator panel without tools. Lamp sockets and mountings
shall be robustly constructed, so as not to be loosened or misaligned when lamps are
replaced. The windows shall be in rows of six, unless otherwise shown. The monitoring
modules shall be of all solid state plug-in design. There shall be sufficient electronic modules
to drive all required annunciator windows, including spares. When specified, provide
repeater contacts terminated on a terminal strip for externally monitoring each alarm status.
The annunciator power supply shall be sufficient to drive all required loads. Alarm points
shall be driven by modules with the operating sequence shown below. The windows for
status indication, when specified shall be off and steady on only, colour shall be white or as
shown in Table 4.1:
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Table 4.1
Alarm Module Operational Sequence
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Normal
Alert
Acknowledge
Return to Normal after Acknowledge
Return to Normal before Acknowledge
Display
Audible
Off
Flash
Steady On
Off
Flash
Off
On
Off
Off
On
The alarm and status actuators shall be contacts or as shown on the Drawings. The
annunciator shall accept either Normally Open (N.O.) or Normally closed (N.C) contacts.
The sensing voltage shall not exceed 24 V d.c. The units shall be supplied with audibleflasher cards as required that shall operate on receipt of alarms from any of the alarm points
to the panel. A buzzer shall be provided and mounted in the control panel. A horn in a
weather proof housing shall be provided for external mounting when specified. On receipt of
any alarm the monitor card shall cause the flasher to flash the appropriate indicating window
and sound the alarm.
There shall be a test button and an acknowledge button. The test button shall actuate all
alarm and status points and sound the audible alarm. The acknowledge button shall perform
the functions as outlined in the operational sequence, but shall not prevent any future alarm
points from being annunciated visually and audibly. The unit shall operate from 110 V a.c.,
50 Hz commercial power.
When specified, a "first out" sequence shall be provided in which the first alarm in a related
group, as designated, shall flash red while subsequent alarms in the group shall be nonflashing white. A first out reset button shall be provided for each designated group.
QCS 2014

Part
Page 6
4.2.8
Chart Recorders
Paperless video graphic recorders with colour LCD display and internal and external storage,
networking capability shall be provided having the following specification:
screen size 127mm (minimum) front panel to IEC 529 IP65 standard and cut out size
138mm x 138mm
(b)
required number of input channels but never less than two and capable of 4020mA,
mV, V, RTD, thermocouple inputs
(c)
minimum scan rate of 125ms and chart speed of 1mm/hour to 1200mm/hour
(d)
totaliser with mathematical functions
(e)
RS232 serial Ethernet 10 Base T interfaces
(f)
data storage facilities with a minimum of 1MB internal flash
(g)
integral smart media with 128MB smart card and media door lock
(h)
capability of being configured by both PC keyboard and via tactile membrane front
door key.
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(a)
INSTALLATION
4.3.1
General
Installation, testing, calibration, validation, start-up, and instructions shall be in accordance

with Part 1 of this Section.
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END OF PART
QCS 2014

Part
05: Control Panels and Control Room Hardware
Page 1
CONTROL PANELS AND CONTROL ROOM HARDWARE ......................... 2
5.1
GENERAL ...................................................................................................... 2
5.1.1
5.1.2
5.1.3
5.1.4
5.1.5
5.1.6
Scope
Reference Standards
Submittals
Quality Standards
5.2
PRODUCTS ................................................................................................... 3
5.2.1
5.2.2
5.2.3
5.2.4
5.2.5
Panels General
Panel Construction
Panel Wiring and Termination
Instrument Labelling
Control Desk
5.3
INSTALLATION ............................................................................................. 7
5.3.1
5.3.2
5.3.3
General
Site Inspection
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2
2
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3
3
3
4
5
5
5
7
7
7
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Part
Page 2
CONTROL PANELS AND CONTROL ROOM HARDWARE
5.1
GENERAL
5.1.1
Scope
This Section covers control panels for work of the ICA Sections, and all unit panels unless
modified under other Sections.

This Section
Part 1,
General
Reference Standards
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BS 88..........................Fuses
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5.1.2
BS 546........................Electrical outlets
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BS EN 60898..............Design of MCBs
BS EN 60529,.............Ingress protection
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BS 7430......................Code of practice for earthing
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BS EN 60439..............Low voltage switchgear and controlgear assemblies

Submittals
Shop Drawings. The ICA Subcontractor shall submit shop drawings for all control panels,
including details for the following items, as applicable:
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5.1.3
electric power wiring circuits and schematics
(b)
air supply piping schematics
(c)
electric signal wiring circuits and schematics

pneumatic signal tubing schematics
fabrication drawings
(e)
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(d)
(a)
(f)
details of all panels accessories
(g)
listing of all panel mounted (both front and rear) instruments
(h)
control panel layouts and nameplate inscriptions
The submittal shall be subject to approval by the Engineer. The Contractor shall submit the
Factory Test Reports. The Contractor shall submit from the equipment manufacturer, or his
authorised representative, a certified test report in accordance with the requirements of the
relevant test procedure.
QCS 2014

Part
Page 3
Quality Standards
All equipment furnished shall be of a design that has been used in similar applications and
shall be demonstrated to the satisfaction of the Engineer that the quality is equal to the
specified equipment. The manufacturer shall have successfully designed and furnished
similar sized or larger panels for a similar application.
The Engineer or his representative may inspect the panel at the factory. The Contractor shall
notify the Engineer at least three weeks prior to shipment so that the factory inspection may
be arranged. Factory inspection will be made after the manufacturer has performed
satisfactory checks, adjustments and tests. Approval of equipment at the factory only allows
the manufacturer to ship the equipment to the site and does not constitute final acceptance.
5.1.5
Control panels and all the associated hardware shall be provided by approved, prequalified
manufacturers and suppliers designated in the Project Specification.
5.1.6
Control panels shall be assembled and shipped in sections, properly packed to prevent
damage during shipment. Panel sections shall facilitate easy handling and Site installation.
Panels and associated instrumentation shall be handled carefully to avoid damage. Proper
lifting and handling equipment and accessories such as grounding straps for handling
electronic cards, shall be used.
ICA equipment shall only be delivered to Site just prior to their installation to minimise the
possibility of damage. Delivered instrumentation shall be protected and not scattered or left
unprotected on the Site.
Materials and equipment not required for immediate installation shall be stored in a separate
store protecting them from shock, weather, dust and damage from chemical and construction
material
ICA equipment shall not be stacked unless crated.
5.2
PRODUCTS
5.2.1
Panels General
Control panels shall be free standing and floor mounted cabinets of console or desk pattern.
Console layouts shall permit the operator to readily observe all instruments.
The panels shall be manufactured to a high standard of quality in terms of visual appearance,
colour and finish. The panels located in the main control room shall have an appearance and
quality suitable for a pumping installation environment.
The panel design including colour, style and appearance and detailed specifications of panel
instruments shall be submitted to the Engineer for approval prior to manufacture.
Control voltage. Panel instruments and controls shall operate from 110 V a.c. power supply,
unless otherwise specified in Project Specification. A separate 24 V d.c. circuit shall be
provided for the indicating lamps and panel instruments, as necessary.
Where specified in the Project Specification, panel space shall be provided for instruments
supplied by others. Installation and wiring of such instruments shall be carried out by the
panel manufacturer. Coordination of instrument delivery shall be the Contractors
responsibility.
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5.1.4
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Page 4
Unit Control Panels for mechanical and electrical equipment can be the manufacturers
standard panels. Details of such panels shall be submitted to the Engineer for approval, prior
to manufacture. The Contractor shall be responsible for interfacing the unit control panels
with the main control panel or central control system, as necessary.
5.2.2
Panel Construction
All consoles and auxiliary cabinets shall be fabricated of cold rolled sheet-steel and be of rigid
and stable construction without bows and ripples. The front surface shall be flat and the
corners and edges shall be rounded to give a smooth appearance.
Panels shall be of sufficient size to enclose all the panel instruments with ample interior
clearance to allow for installation and maintenance of instruments. Annunciator displays shall
be located in the top portion of the console assembly. Control panels shall be of sectional
design with provision for easy extension. Pushbuttons shall be provided to enable
acknowledgement and resetting of alarm annuciators and lamps on the console.
Panels shall be formed of IP55 panel sections and each enclosure shall be a maximum of
2100 mm high, 800 mm wide and 600 mm deep unless otherwise specified in the Project
Specification. Each section shall be fully enclosed including the top and bottom with no
visible seams on the front. Externally visible screws and bolts shall not be acceptable.
Each panel section shall be provided with two door rear access. Door hinges shall be knuckle
type. Handles and other hardware shall be chromium plated. Where necessary, removable
access covers secured by quick release fasteners shall be provided to facilitate easy
maintenance.
Undrilled gland plates shall be fitted at a sufficient height above the floor level to provide easy
access under the gland plate. Suitable side covers shall provide access to the gland plates
and also provide the specified ingress protection.
Electrical general purpose outlets for test and repair purpose shall be provided in all consoles
and cabinets. The outlets shall be in accordance with BS 546.
All consoles and auxiliary cabinets shall be ventilated mechanically or by natural circulation to
maintain the internal equipment working temperature to below 10C above ambient.
Panel lighting shall be provided to ensure adequate illumination for carrying out delicate
adjustments or repairs on small items of equipment.
Finish. After fabrication, all external welds must be ground smooth. The entire unit shall be
thoroughly degreased, then filled and sanded. At least one coat of synthetic primer shall be
applied, baked on, and sanded. This first coat shall be followed by two coats of baked-on
synthetic enamel. The first coat shall be sanded after baking. The final two coats shall
provide a glossy or semi-matt finish to a colour and finish approved by the Engineer. The
average overall finish shall be at least 1.25 micrometres in thickness. Any minor damage to
the finish during installation shall be touched up at Site, provided such remedial works are to
10
Panel Earthing. A copper earth bar shall be provided within the panel for earthing of the
panel, all the panel instruments and the cables to BS 7430, code of practice for earthing.
11
Panel Isolation. Isolating switches shall be provided for all incoming power supplies. These
switches shall be clearly identified, labelled and suitably protected from inadvertent operation.
12
Panel Protection. MCBs to BS 3871, shall be provided for the distribution of electrical power
within the panel. The MCBs shall be arranged to minimise disruption to the equipment
operation and also to prevent unsafe operating conditions. Power supplies from control
panels shall conform to BS 5486.
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Part
Page 5
Panel Wiring and Termination
Panel wiring shall be carried out in PVC insulated multi-strand cable of adequate grade and
rating. Wiring within each panel shall be done in a structured manner, grouped and
supported to give a neat appearance.
110 V a.c. wiring shall be colour coded with black-unswitched live phase, red-switched live
phase, white-neutral and green-ground. Signal and d.c. wiring shall also be neatly segregated
under an approved colour coding scheme. Wiring shall be bundled and laced or tied with
plastic ties and supported to prevent ragging or damage.
All control and auxiliary cabinets shall be manufactured and assembled with all internal wiring
connected to terminals blocks, requiring only connection to external wiring at Site.
Separate terminal blocks shall be provided for incoming and outgoing analogue and digital
signals and power supply connections. Each terminal block shall be clearly identified and
labelled. Layout shall permit convenient access to terminals and wires and enable ferrule
numbers to be easily read. Terminals shall be at sufficient height from the cable gland to
facilitate easy routing of wires. Terminals shall clamp the wire between two plates using a
captive screw. Where wires are terminated on screw terminals, insulated crimp spade lugs
shall be used.
5.2.4
Instrument Labelling
All panel instruments shall have engraved nameplates showing their tag number and service
in the English language.
Materials for nameplates shall be selected in accordance with the relevant environmental
conditions and shall be of non-metallic material, with black inscription on a white background.
Name plates on control panels shall be mounted on or near the relevant instruments to
ensure clear identification
An additional nameplate engraved with the instrument tag number only, mounted at the rear
of the panel, shall be provided for each panel mounted instrument. These plate shall be
attached to the instrument, the panel or instrument support near the instrument.
For panels where opening the circuit breaker does not shut off all of the power, the following
sign shall be provided:
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5.2.3
"THIS CABINET CONTAINS CIRCUITS SUPPLIES FROM EXTERNAL SOURCES."

"OPENING THE CIRCUIT BREAKER DOES NOT TURN OFF ALL POWER".
Letters shall be 6 mm high, red colour on a white background.
5.2.5
Control Desk
SCOPE
(a)
This section defines the minimum requirements for the manufacture, supply,
inspection, installation, testing of control desks or consoles required to be used on this
Contract. Control desks or consoles shall be of the custom made industrial type and
material for construction shall comply with MCCs panel construction as specified in
QCS Section 21 Part 2. The requirements for lockable doors, ventilation fans, anticondensation heaters etc. shall complied with as specified in this section.
CODES AND STANDARDS

(a)
The following list of standards indicates the minimum requirements. Any other
standards not listed below
or elsewhere in these documents shall be subject to
review and approval by the Engineer.
QCS 2014

Part
Page 6
BS EN 527-1 Office furniture, Work tables and desks

BS EN 1335-1 Office furniture, Office work chair
BS EN ISO 26800 Ergonomics, General approach, principles and concepts
SITE CONDITIONS
(a)
DESIGN CONSIDERATIONS AND FABRICATION REQUIREMENTS

(a)
The control desks and consoles shall be designed so that it is comfortable to use, thus
enabling operators to maximize their efforts, incorporating the latest principles of
ergonomic design, as described in BS EN ISO 26800.Monitors (and instruments if
applicable) shall ideally be arranged so that they are all are equidistant from the
operators eyes. Similarly, all the associated controls should be equidistant from the
operator's shoulder pivot points. This arrangement avoids any body movement, but
demands a convex panel in both planes. If this is not a practical proposition then flat
panels shall be provided which are angled to each other and which require only some
limited body movements, such as bending the trunk or pivoting a chair, to operate the
keyboards or view the VDUs (monitors) .The display area shall be divided either
vertically or horizontally. Vertical division shall be utilized for mounting VDUs. If small
instruments are fitted then parallax errors may be introduced are mounted above or
below eye level, although this danger can be avoided by using those with digital
displays. In most cases horizontal division is the simplest and gives the greatest area
of panel space free from parallax errors within the operator's control. When a large
number of instruments or controls are involved, horizontal and vertical division shall be
combined. The desk shall then become a winged console.
(b)
Sufficient rack space shall be provided in the base to enclose all control desk
equipment and permit access for installation and maintenance purposes. Cable entry
shall be via floor mounted cable gland plates with facility to route cables through desk
sections as required. All servers/works stations shall be placed inside the control desk
with lockable doors. Ventilation louvers and fans are to be fitted in the desk for
sufficient air circulation.
PANEL LAYOUTS
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It is the Contractors responsibility to furnish and install the control desks or consoles to
withstand and operate properly under the prevailing ambient conditions as described in
the General Technical Requirements. This Specification serves as a guideline to the
Contractor. The Contractor shall include all the necessary equipment based on his
previous experience on similar installations. Control desks or consoles shall be able to
operate continuously without their normal physical and functional reliability being
affected by the tropical environment.
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(a)
Where indicators ,Monitors and controls are to be fitted on panels then the actual
arrangement must receive careful consideration. When designing the layout, the
center of the various instruments should be arranged so as to be opposite the
operator's eye position. Controls should be mounted below shoulder level. Space
above this level shall preferably be utilized to house indicators, or infrequently used
controls.
DESK SIZING
(a)
The design shall such that when the operator is sitting correctly (trunk erect, but
shoulders relaxed) elbows shall be about level with the working surface. Desks used
for keyboards shall be slightly lower than one used for general duties, so as to bring
the actual working surface to the correct level. Draw out type tray arrangement shall
be provided for keyboard and mouse. Care shall be taken that the underside of the
desk will allow the thighs of an operator to fit comfortably between it and the top of the
seat; a minimum of 200 mm clearance shall be allowed. The front surface shall be flat
and the corners and edges shall be rounded to give a smooth appearance
QCS 2014
Page 7
(b)
Desk thickness shall be as specified in Section 21 Part 2 MV Factory Built Assemblies

(FBAs).
(c)
Generous leg space shall be provided to ensure operator comfort. It shall be possible
for the operator(s) to move easily to and from the desk to this end a minimum a
minimum of 400 mm clearance is to be provided.
SEATING
(a)
The seat height shall be no higher than the length of the lower leg when it forms a right
angle with the upper leg and the foot is resting flat, to ensure operator comfort,. An
adjustable seat shall be provided to achieve this. If this leads to a large difference
between the eye positions of short and tall operators then as an alternative a fixed
height seat shall be provided which will suit the tall operator together with an adjustable
foot rest for the use of others.
CONSTRUCTION

Part
Materials of construction shall generally comply with the MCCs panel construction
requirements specified in the Section 21 Part 2 MV Factory Built Assemblies (FBAs).
Consoles shall be built on a plinth fabricated from rolled steel. They shall consist of a
closed skeletal steel or forged aluminum framework with rigid panels screwed or
bonded in place or alternatively hinged or fixed with quick release fasteners . Consoles
shall be prefabricated in the factory. Assembly on site is acceptable but on site
fabrication is not acceptable.
(b)
Console sizes shall be determined by equipment sizes, number of operators. Where

practicable, the unit shall be designed in individual modules, which are then bolted
together. Apertures shall be sized and finished to accept specific equipment and/or
fitted with standard rack mount fixings. All components shall be protected against
corrosion by means of passivation, fusion bonded epoxy coating or high grade epoxy
factory applied spray baked finish. Brush painting is not acceptable. Color shall be a
RAL shade as directed by the Engineer. Areas subject to abrasion or wear shall be
suitably protected with replaceable rubber mats, stainless steel finishes, or similar.
(c)
The desk or console IP rating shall be IP 54 as a minimum or higher to match the

grade of any installed equipment.
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(a)
INSTALLATION
5.3.1
General
Installation, testing, calibration, validation, commissioning, and instructions shall be in

accordance with Part 1 of this section.
5.3.2
Site Inspection
Each instrumentation item shall be checked by the Contractor upon receipt for compliance
with purchase specifications, damage, shortage and shortage of components. Items shall be
repaired, replaced or the vendor notified of non-conformance as instructed by the Engineer.
5.3.3
All control panels and instruments shall be tested and commissioned by the Contractor
according to procedures outlined in Part 1 of this Section, prior to final inspection and
acceptance by the Engineer.
Calibration of all panel instruments shall be tested and corrected as necessary.
Panel wiring shall be tested to ensure that wiring is done as per the submitted wiring
schedules. Correct identification on ferrules and tag plates shall also be verified.
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Page 8
Panel power supply voltages shall be checked to ensure that they are within the operational
limits of each instrument.
Damaged or defective instruments and equipment shall be identified and replaced.
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END OF PART
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Page 1
Part 1.01: Qatar Legislation and Management (Regulatory Document)
REGULATORY DOCUMENT
1.1
QATAR LEGISLATION AND MANAGEMENT
1.1.1
Occupational Health and Safety at Work including Construction Sites ............ 6
1.1.2
Duties, Responsibilities, Offences and Penalties etc. .................................... 11
1.1.3
Safety Policies ............................................................................................... 21
1.1.4
Consultation with Employees ......................................................................... 42
1.1.5
Health & Safety Training and Induction Training ............................................ 54
1.1.6
General Health and Safety ............................................................................. 72
1.1.7
Risk Assessments and Method Statements ................................................... 79
1.1.8
Construction (Design and Management) ....................................................... 82
1.1.9
Safety Inspections and Auditing ................................................................... 142
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1.1.10 Safety at Street Works and Road Works ..................................................... 157
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1.1.11 Setting Up Site ............................................................................................. 176

1.1.12 Security on Site ............................................................................................ 199
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1.1.13 Statutory Forms, Notices and Registers ...................................................... 207
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FORWARD
This Section of the Regulatory Document (RD) was produced as a project deliverable under Ministry of
Municipality and Urban Planning Contract Number P2009/3, entitled Consultancy Services for the
Preparation of Codes and Standards for Safety and Accident Prevention on Construction Sites.
During the latter stages of the project, the Committee responsible for the administration of the project
decided that the RD and the associated Safety and Accident Prevention Management/Administration
Systems (SAMAS) would be best delivered to stakeholders via the portal provided by the Qatar
Construction Standards (QCS).
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The QCS includes references and certain sections which address occupational health and safety. To
ensure that that users of the RD/SAMAS are fully aware of the where occupational health and safety
issues are addressed in the QCS, the following table summarises where potential overlaps may occur.
For consistency, it is recommended that in matters relating to occupational health and safety reference
is made first to the RD/SAMAS. For the purpose of clarity, however, references are made in the
relevant section of the RD/SAMAS to their comparable sections in the QCS and vice versa.
QCS 2014

Page 3
Sr. No
QCS 2014
Section No.
Part No.
Part Name
Submittals
7.5.2
Health and Safety Organization

Chart
Submittals
7.6.1
Health and Safety Plan
10
Health and Safety
All
All
All
11
Engineer's Site Facilities
10
11.4.6
14
14.4
Test Certificates for Cranes and

Lifting Tackle
15
Temporary Controls
All
All
All
16
Traffic Diversions
16.1.3
Safety
General
8.1.6
Safety
General
8&9
1.4.12
10
General Requirements for Piling

Work
1.6
Safety
11
Deep Foundations
37 & 38
4.9.1.7
Safety Precautions
12
Deep Foundations
13
General
14
Asphalt Plants
15
14
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42
Item Name
Page No. Item No.
4.9.1.13 Protection of Testing Equipment

1.6
Temporary Fencing
15
7.8.13
Safety Requirements
14.2.2
Safety
General
7,8, 9 &
10
1.3.2
Health and Safety
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4&5
17
8.1.9
Safety
18
9.2.5
Safety Requirements
19
10
Pipeline Cleaning and Inspection

Survey
4,5&6
10.1.7
Safety Requirements
20
21
22
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11.2.2
Safety
General
16
1.2.8
Safety Guards
General
19
1.2.16
23
11
19
Hot Water Storage
5.1.6
Safety
24
21
General Provisions for electrical

Installation
7&8
1.1.11
Fire and Safety Precautions
25
21

Installation
14
1.1.23
Safety Interlocks
26
24
General
1.1.4
Scaffolding
27
29
Design Aspects
1.1.5
Fire Resistance Period
28
29
2.3.1.5
Safety
29
29
Tunnel
18
4.5.8
Safety Regulations
30
29
Tunnel
19
4.5.9
Fire Prevention
31
29
Tunnel
21
4.6.4
Safety Measures and Systems
32
29
Concrete Structures
7.1.10
Safety Railing
QCS 2014

Page 4
Qatar Regulatory Document

Notes for Users
Legislation and Management
Introduction
This Regulatory Document is designed to help managers, supervisors and safety
representatives comply with their legal, moral and social responsibilities and assist in the
crucial areas of:
accident prevention
(b)
the avoidance of occupational ill health
(c)
Environmental good practice.
(a)
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The Regulatory Document seeks to maintain a balance between outlining the requirements
of legislation, as it applies to the Qatar construction industry, and providing practical
guidance on how to comply with these applicable Regulations.
Contractors will therefore be able to assess the legal responsibilities of themselves and
others and decide how best to organise work activities in a safe and healthy manner.
This Regulatory Document is a set of regulations which makes provision for securing the
health, safety and welfare of persons at work, for protecting others against risks to health or
safety in connection with the activities of persons at work and for controlling the keeping and
use of dangerous substances.
It is an essential piece of legislation covering occupational health and safety in Qatar and
focuses on the construction industry placing legal obligations as from project design concept.
It focuses on planning, design and management of construction projects and places legal
obligations on everyone involved at work and in construction.
The Regulatory Document is designed to help Clients, Designers, Contractors,

Subcontractors and others to comply with their legal, moral and social responsibilities and
assist in the crucial areas of:
Project planning, design and management for better occupational health and safety
performance
(b)
(a)
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It imposes legal requirements for safety consideration in the future stages of the
project life cycle, namely use, operations and maintenance, cleaning,
decommissioning and replacement of facilities, plant and equipment etc
(c)
Safety planning for construction, use and maintenance
(d)
Incident prevention at work
(e)
Avoidance of occupational ill health
(f)
Safety, health and environmental good practice.
Designers and Contractors have legal obligations to promote, plan, implement and
showcase good health, safety and welfare management in relation to their undertakings.
Structure of the Health and Safety Regulations in QCS

1
The Occupational health and safety legislation of the QCS is formed mainly under Section
11 Part 1: Regulatory Document and guidance is given in Part 2: Safety and Accident
Prevention Management Administration System (SAMAS)
Other references of Occupational health and safety in QCS are summarised in the table in
the above section.
The word Regulations is used throughout this document and refers hereafter to the Qatar Regulatory Document
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Page 5
Definitions / Interpretations
These Regulations contain words and phrases with a meaning that is defined in the
legislation.
Words and phrases such as 'construction work', 'structure', 'approved', 'lifting gear' and
'working platform', have such a legal definition.
Definitions of the more common terms are outlined below.
Hazard: The potential to cause harm, including ill health and injury; damage to property,
plant, products or to the environment; production losses or increased liabilities.
Risk: The likelihood that a specified undesired event will occur, due to the realisation of a
hazard by, or during, work activities or by the products and services created by work
activities.
Danger: A person is in danger when they are exposed to a risk. The degree of danger is
dependent on the nature of the hazard or degree of risk.
Competent person: A person who has practical and theoretical knowledge and actual
experience of the work activities that they are required to do. A person's competence will, in
some cases, be tangibly demonstrated by the award of a qualification or other recognition of
training received.
Practicable: Where a legal requirement is qualified by the word 'Practicable', the specified
measures must be taken if it is physically possible, irrespective of cost, difficulty or
inconvenience.
Reasonably practicable: Where a legal requirement is qualified by the term 'Reasonably

practicable', the cost (in terms of money, time and inconvenience) of taking precautions may
be balanced against the risk being considered.
10
If an assessment of the situation shows that the cost of taking the precautions is
disproportionately high in relation to the risk of an accident or injury occurring, the
precautions need not be taken.
11
Employer: means any person, company or organisation who has an employment

relationship with the employees or workers and has responsibility for the undertaking and/or
establishment and includes any self-employed in relation to the undertaking. In relation to
construction site, the Employer is the Contractor.
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Note:
12
Whenever these Regulations are being applied, attention should be paid to the section at the
start of each piece of legislation, entitled 'Interpretation', where definitions and other
important provisions may be listed and explained.
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Page 6

1.1.1
Occupational Health and Safety at Work including Construction Sites
1.1.1.1 Key points

These Regulations place legal duties on Contractors, Employers, Self-employed, Employees
and others with respect to all transactions carried out in Qatar.
Under the Regulations, there is a special focus on construction works, construction sites and
Contractors who undertakes or manages construction work on site.
Legal duties are also placed on manufacturers, designers, contractors, sub-contractors,

importers and suppliers of articles for use in the workplace.
Contravening these Regulations is a criminal offence and punishable in a Qatar Court of Law
These Regulations place a duty on the Qatar Administrative Authority where no other body
has been given the responsibility.
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Note:
Section 1, Part 7 of the QCS covers submittals associated with construction sites
and includes a health and safety organization chart and the health and safety plan. General
safety requirements are specified in Section 1, Part 2 of the QCS.
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1.1.1.2 Aims and scope of this Regulatory Document
The regulations aim to promote and enforce high standards of health, safety and welfare in
the Qatar workplace especially with special regards to construction workplaces or
construction sites. Hence contractors and sub-contractors and others have to implement
effective standards of health, safety and welfare management onsite and in connection with
their business.
This Regulatory Document (Regulations) provides for a comprehensive framework to

promote, stimulate and encourage high standards of health and safety in the Qatar
construction workplace. Its ultimate aim is to promote health and safety awareness and
effective standards of health and safety management by every Contractor.
It is a requirement under these regulations that everyone is involved and made responsible
for their acts towards health and safety. Hence the scope of this document relates to
organisation, companies and individuals and requires everyone to make responsible for
health and safety- starting from-management, the employees, the self-employed, the
employees' representatives, the controllers of premises and the manufacturers of plant,
equipment and materials - in the matters of construction site health and safety. The
Regulatory Document (Regulations) also requires that adequate measures are taken to
protect the public where otherwise their health or safety would be at risk.
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1.1.1.3 Standards of compliance

1
In many instances the Regulatory Document (Regulations) places a legal duty which is
qualified by the words practicable (or best practicable means) or reasonably practicable.
Where a legal duty is qualified by the word practicable the duty must be complied with if it is
'capable of being carried out' or 'feasible within the current state of knowledge and
technology', at whatever expense, taking note of published information, Guidance Notes or
relevant British/International Standards.
In practical terms a legal duty qualified by the word practicable cannot be disregarded on
the grounds that to comply with it would slow up the building programme, be expensive,
difficult or otherwise inconvenient.
QCS 2014

Page 7
Where a legal duty is qualified by the term reasonably practicable Contractors are allowed
to exercise their judgement on the extent of the measures that need to be taken to ensure
the health and safety of whoever is carrying out the job and others who may be affected by
it.
This judgement should be based upon the findings of a risk assessment.
Where the risks to health and safety in carrying out a job are found to be low in comparison
to what would be disproportionately high costs to overcome the risks totally, the Contractors
need only take the measures that are considered to be reasonably practicable.
Should there be a legal dispute as to a decision of what was or was not reasonably
practicable, the onus of proving in court that all reasonably practicable measures were
taken lies with the Contractors.
Managers, supervisors, safety supervisors and safety representatives and others with a
responsibility for ensuring legal compliance will be mainly concerned with the following:
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1.1.1.4 Duties of Contractors
These Regulations place a general duty on every Contractor to ensure, so far as is

reasonably practicable, the health, safety and welfare at work of all their employees.
Contractors must, so far as is reasonably practicable
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protect the health, safety and welfare at work of all their employees.
(b)
provide and maintain plant and systems of work that are safe and without risk to
health.
(c)
ensure safety and absence of risks in the use, handling, storage and transport of
articles and substances.
(d)
provide any necessary information, including information on legal requirements, to

ensure the health and safety of their employees.
(e)
provide adequate supervision and training, as is necessary, to ensure the health and
safety of their employees.
(f)
provide and maintain a safe and healthy place of work, with safe access and egress.
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provide and maintain a working environment that is safe and without risks to health
and is adequate with regard to welfare facilities and arrangements for welfare at work.
(g)
as
(a)
(h)
to ensure, as far as is reasonably practicable, that the conduct of their activities does
not endanger persons not in their employment who may be affected by operations
under their control, for example, subcontractors or the public.
Contractors must not:

(a)
levy a charge, or permit any employee to be charged for anything required to be

provided in pursuance of any of the relevant statutory provisions i.e. Personal
Protective Equipment (PPE) and Respiratory Protective Equipment (RPE).
(b)
The regulations place a general duty on every contractor to conduct his undertaking in
such a way as to ensure, so far as is reasonably practicable, that persons not in his
employment who may be affected thereby are not thereby exposed to risks to their
health or safety.
1.1.1.5 Duties of employees

1
These Regulations place two general duties on employees:
QCS 2014

Page 8
(a)
to exercise reasonable care for the health and safety of themselves or others who may
be affected by their acts or omissions at work.
(b)
to co-operate with the Contractors, as far as may be necessary, to enable them (the
Contractors) to carry out their legal duties in health and safety matters.
1.1.1.6 Duty on 'all people'

This Regulatory Document (Regulations) places a duty on 'all persons' to:
'not intentionally or recklessly interfere with anything provided in the
interests of health, safety and welfare'.
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Not only does it apply to Contractors and employees but it also applies to members of the
public.
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Page 9
1.1.1.7 Duties of manufacturers, designers, importers and suppliers

A general duty is placed on any person who manufactures, designs, imports or supplies any
article, materials or substance for use in a workplace or a construction site shall ensure, so
far as is reasonably practicable, that articles and substances are, by design and
construction, safe and without risks to health when being used, set, cleaned or maintained
by persons at work.
For example, information on design noise levels under normal working conditions should be
supplied if noise levels may be a risk to health, or exceed the lower exposure action value
specified in the Noise at Work section of this Regulatory Document. Similarly, manufacturers
of tools that may be a source of hand/arm vibration must provide details of the levels of
vibration generated.
More specifically, a duty exists to ensure that arrangements are made to carry out the
necessary testing, examination and research, and that steps are taken to provide adequate
information about any conditions necessary to ensure that it will be safe when used.
A general duty is placed on installers or erectors of any article for use at work to ensure, so
far as is reasonably practicable, that it is safe and without risk to health when used by
persons at work.
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1.1.1.8 Administrative Authority
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The Qatar Administrative Authority has the powers under these regulations to examine, to
investigate and to seize and take possession of any matter relating to health, safety and
welfare of workplaces and construction sites. They have the power to advise and enforce the
law on any matter relating to health, safety and welfare of workplaces and construction sites.
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Investigation
Administrative Authority Workplace Inspectors are given a general right to examine and
investigate as may be necessary. They may enter premises (accompanied by a police officer
or other authorised person if necessary), taking with them any equipment or material
required by them for the purposes of the examination. They may direct that anything shall be
left undisturbed if required for examination or investigation, take measurements, samples,
photographs and such recordings as may be necessary. They may have dismantled or
tested any article or substance considered dangerous, or take possession of any article for
examination and evidence.
Administrative Authority Workplace Inspectors may inspect or take copies of books or

documents. They may demand from an employee any information they think necessary and
can ask the employee to sign a declaration of the truth of their answers. In general, they can
demand the full co-operation of any person to provide them with such facilities and
assistance as they may think necessary.
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Advisory
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Inspectors also act as a source of information and advice. It is their duty to inform employees
about anything that may affect their health and safety at work.
Enforcement options
Administrative Authority Workplace Inspectors can use any of the powers listed below
against any person taking part in, or in control of, any work activity, or piece of equipment.
'Any person' means a Contractor, self-employed person, a supplier, or the employee.
QCS 2014

Page 10
(a)
Informal
(b)
Workplace Inspectors may give advice on compliance in the case of minor breaches.
(c)
Formal letter
(d)
A formal letter may contain details of breaches and action needed to comply with the
legislation. It may also contain more detailed and formalised advice. Whilst visiting a
site, a Workplace Inspector can prepare an Instant Visit Report with a date agreed for
work to be completed.
(e)
Improvement Notice
Where a breach is more serious, the Inspector may issue an Improvement Notice, which will
outline the work required and the date for completion. This will be at least 21 days from the
date of receipt.
Prohibition Notice
(a)
Prosecution
In addition to the enforcement outlined above, the Inspector may consider that it is also
necessary to prosecute.
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If an activity involves, or is likely to involve, a serious risk of personal injury, the Inspector
may serve a Prohibition Notice to stop that activity immediately or after a specified time.
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(a)
Appeals
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on appeal following the issue of an Improvement Notice, the Notice will be suspended
until the relevant board meets and decides the issue
(b)
on appeal following the issue of a Prohibition Notice, the Notice will stand until the
appeal has been decided, or the relevant board orders it to be suspended.
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(a)
Where a person has been prosecuted for failing to comply with a duty or requirement of this
Regulatory Document (Regulations), and is claiming that it was not reasonably practicable
for them to carry out that duty or requirement, it is the responsibility of that person to
prove that it was not reasonably practicable to comply, and that there was no reasonably
practicable alternative way in which they could have carried out that duty or requirement.
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Anyone served with an Improvement or Prohibition Notice has the right to appeal. This must
be done within 21 days of the issue of the Notice. The Administrative Authority may cancel or
modify the Notice:
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Occupational Health and Safety Construction Site Safety

1.1.2
Duties, Responsibilities, Offences and Penalties etc.
1.1.2.1 Key points

1
The purpose of this section is to:

(a)
Outline the legal duties placed upon Contractors and employees while at work on
Qatar construction sites.
(b)
Emphasise that where health and safety legislation places legal duties on the
Contractors, in most cases the duties also apply to the self-employed.
1.1.2.2 Introduction
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This section is designed to give both Contractors and employees details of their legal duties /
responsibilities at work.
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1.1.2.3 Responsibilities
1.1.2.4 Legal duties of Contractors
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Set out over the following pages are the principal legal duties of Contractors and employees.
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The Contractor shall protect the health, safety and welfare of their employees and other
people who might be affected by their business. This means making sure those workers and
others are protected from anything that may cause harm, effectively controlling any risks to
injury or health that could arise in the workplace.
Contractors will usually be site-based and in a position to fulfil their legal duties by directly
controlling the workforce and monitoring the standards of health and safety on site. By
comparison, in larger companies the Contractors will not normally be site-based and it is
usual for them to delegate responsibility for day-to-day legal compliance to site-based staff
such as Site Managers. It may be necessary for Site Managers to further delegate the
responsibility for overseeing the health and safety aspects of some work activities to trade
supervisors. Whatever the circumstances, the duty to ensure compliance with health and
safety legislation stays with the Contractors.
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1.1.2.5 Legal duties of the self-employed

Generally, where legislation places legal duties on Contractors with regard to ensuring the
health and safety of their employees, similar duties are also placed on the self-employed
with regard to ensuring their own health and safety.
1.1.2.6 Legal duties of the Employees
All employees and workers have a right to work in places where risks to their health and
safety are properly controlled. The contractor or the employer is responsible for providing for
their health, safety and welfare.
Employees shall take reasonable care of their own and other peoples health and safety.
Employees shall follow the training that they have received when using any work items that
the contractor or employer has provided.
Employees shall co-operate with your employer on health and safety.
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Page 12
Employees shall tell the employer, the supervisor, or the health and safety representative if
they think the work or inadequate precautions are putting anyones health and safety at
serious risk.
1.1.2.7 Construction (Design and Management) CDM

1
The CDM Regulations place legal duties on planning and management arrangements for
construction works. It places duties on everyone involved in construction and contractors
have a set of specific duties under CDM.
The CDM regulations forms section 1.1.8 of the Regulatory Document

Contractor duties / Responsibilities
Plan, manage and monitor construction phase in liaison with sub-contractors
Prepare, develop and implement a written plan and site rules. The initial plan must be
completed before the construction phase begins. Plan is termed Construction Phase Health
and Safety Plan.
Give sub-contractors relevant parts of the plan.
Check competence of all their appointees.
Ensure that expert knowledge/advice is available in relation to highly hazardous activities

(e.g. explosives, cofferdams, caissons etc.) and when works are undertaken on or in
proximity of existing structures.
Coordinate temporary works and cooperate with designers and others as relevant.
Secure the site.
Ensure, as far as is reasonably practicable, the health, safety and welfare of all their
employees.
Provide and maintain plant and systems of work that are safe and without risk to health and
safety and ensure safety and absence of risks in the use, handling, storage and transport of
10
Provide any necessary information, including information on legal requirements, to ensure

the health and safety of their employees.
11
Provide adequate instruction, training and supervision as is necessary, to ensure the health
and safety of their employees.
12
Provide a safe place of work, with safe access and egress. Provide a safe working
environment that is without risks to health.
13
Provide adequate welfare facilities and arrangements for welfare at work.
14
Have a general statement of health and safety policy.
15
Prepare a written health and safety policy, then review and update it as often as is
necessary.
16
Bring the company health and safety policy, and any revisions of it, to the attention of
employees.
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Carry out risk assessments for all work activities undertaken and record the significant
findings of the risk assessment.
18
Implement any control measures identified by your risk assessment.
19
Regularly review risk assessments and any associated control measures.
20
Ensure that work equipment used for working at height and places of work are inspected by
a competent person.
21
Ensure that scaffolding is only erected, altered or dismantled by, or under the supervision of,
a competent person.
22
Have access to competent advice to assist in matters of health, safety and welfare, where
necessary.
23
Establish a safety committee
24
Consult with workers and safety representatives on matters of health and safety.
25
Assess manual handling operations at the workplace and take appropriate steps to reduce
the risk of injury to employees.
26
Ensure that all injury accidents, however slight, are entered in the accident book and
investigated.
27
Report to the Administrative Authority all reportable accidents, dangerous occurrences and
notifiable diseases.
28
Provide employees with personal protective equipment, as necessary.
29
Avoid entry into confined spaces, wherever possible.
30
Protect employees who may be exposed to asbestos at work.
31
Assess all excavations and take appropriate steps to reduce the risk of injury to employees.
32
Appoint trained and competent persons for the purpose of mounting abrasive wheels.
33
Examine, test and properly maintain plant, equipment, cranes, lifting equipment and
accessories at regular intervals, and record the findings.
34
Provide adequate first-aid facilities with sufficient trained first aiders and appointed persons.
35
Consult with your employees on health and safety matters.
36
Engage only competent persons to carry out work on electrical installations and appliances.
37
Take measures to prevent or adequately control employees' exposure to harmful dusts and
fumes.
38
Take the necessary steps to ensure that the health and safety of the public is not put at risk
by works being carried out.
39
Allow only competent people to use plant and equipment and undertake a work activity for
which they are competent to do so.
40
Ensure that guard-rails and toe-boards are installed on all working platforms where a risk
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assessment indicates that any person would be injured as a result of the fall.
41
Prevent hearing damage resulting from exposure to excess noise levels.
42
Prevent occupational health problems resulting from exposure to vibration.
43
Use only competent waste carriers and check their documentation regularly.
44
Carry out COSHH assessments and record the significant findings.
45
Protect the environment by preventing avoidable pollution by, for example, installing diesel
oil tanks correctly.
Employee duties / Responsibilities
All employees must have a basic level of health and safety knowledge if they are to be safe
when working on site and aware of their responsibilities to their Contractors and work
colleagues.
To co-operate with the Contractors and follow any information, instructions and training that
is provided.
Not to interfere with or misuse anything the Contractors has provided in the interests of
health, safety and welfare.
Take reasonable care at all times and make sure that their actions or omissions do not
endanger themselves or any other person.
Use all tools and equipment safely and in accordance with instructions given or training
received.
Report any defects or potential hazards in equipment to the Contractors (or supervisor if
appropriate) as soon as possible.
Make proper use of any safe system of work or mechanical means provided by the
Contractors in connection with manual handling.
Only operate plant and equipment for which training has been provided and authority given
to use.
Use the personal protective equipment supplied by your Contractors correctly, take care of it
and report any loss or defects in the equipment.
10
Report to the Contractors any work situation that might present danger.
11
Not to erect, alter or dismantle scaffolding unless competent to do so or under the

supervision of a competent person.
12
When operating goods hoists: keep the gates closed except when loading, etc. do not override any controls do not allow any passengers.
13
Use only the proper safe means provided for entering and leaving an excavation.
14
Do not block or obstruct any access or means of escape.
15
Make full use of any control measures provided to prevent or limit exposure to substances
hazardous to health, and wear the personal protective equipment provided.
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Observe safe use and handling instructions for hazardous substances.
17
Do not use a mobile elevating work platform for any other use than as a work platform.
18
Co-operate with Administrative Authority Workplace Inspectors, as required.
19
Do not remove safety guards or render inoperative any safety device fitted to any plant or
equipment.
20
Do not ride on plant or vehicles in unauthorised and insecure places.
21
Recognise the importance of personal hygiene, especially when working with substances
harmful to the skin.
22
Never exceed the safe working load of any lifting equipment.
23
Understand and comply with all signs and notices that are displayed.
24
Wear ear protectors in designated areas where mandatory warning signs are displayed.
25
Know how to report accidents and to whom.
26
Follow all company and site health and safety rules.
27
Report to the Contractors any activity or defect relating to work at height that can be
considered unsafe.
28
Use equipment and safety devices for working at height in accordance with training and
instructions received.
29
Attend health surveillance procedures, as required, during working hours and at the expense
of the Contractors.
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1.1.2.8 Powers of the Qatar Administrative Authority, Workplace Inspectors
Set out below is a summary of the main powers which Inspectors possess when carrying out
their duties under this Regulatory Document (Regulations). Officers of the Qatar
Administrative Authority also have enforcement powers when dealing with matters
concerning fire prevention.
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1.1.2.9 Qatar Administrative Authority Workplace Inspectors may do the

following:
1
Prosecute a company or an individual for a breach of this Regulatory Document

(Regulations).
Visit or carry out an inspection of a construction workplace at any reasonable time without
giving prior notice, engaging the assistance of the police if necessary.
Issue a Prohibition Notice stopping a work activity where there is a risk of serious personal
injury.
Stop the further use of any equipment if it is considered to be a serious risk to health or
safety.
Issue an Improvement Notice requiring remedial work to be carried out within a specific time,
where there is a breach of health and safety legislation.
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Investigate accidents or dangerous occurrences in the workplace.
Require that any designated part of a premise remains undisturbed for as long as is deemed
necessary.
Investigate a particular work activity or any plant or equipment following a complaint or

accident.
Take measurements, photographs and records as necessary.
10
Inspect or take copies of any books or records.
11
Demand the full co-operation of any person to assist them in their duties.
12
Demand information from a Contractor or employee and require them to sign a statement of
their answers.
13
Remove or make safe any article or substance considered to be a source of danger or

serious personal injury.
14
Require additional fire precaution work to be carried out on a construction site.
15
Provide information for Contractors and employees about hazards that may affect their
health and safety at work.
16
Act as a source of information on construction health, safety and welfare at work.
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1.1.2.10 Penalties that can be awarded

Qatar Labor Law Fourteen, Part Sixteen details the extent of penalties that may be charged
upon the proof of violations regarding failure to comply with Qatar Construction Regulations.
The Contractor shall maintain an acceptable OHS performance at all times throughout the
Contract duration. The criteria used for determining acceptable OHS performance are at the
sole discretion of the relevant authority. The following items shall be taken into consideration
when making assessments of acceptable performance;
any stop work instructions issued to the Contractor
(a)
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(b)
any adverse comments arising from Occupational Health and Safety inspections
(c)
any adverse comments arising from Occupational Health and Safety audits
(d)
any adverse formal communication from the relevant authority to the Contractor
regarding Occupational Health and Safety performance
(e)
any adverse formal communication between the Contractor and enforcing authorities
or government organizations
(f)
any incidents occurring as a result of the Work undertaken by the Contractor.
Should acceptable Occupational Health and Safety (OHS) performance not be maintained
by the Contractor then the relevant authority may take any action at their discretion in
furtherance to their powers (see sections 1.1.1.8 and 1.1.2.8) or may impose the following
penalties on the Contractor;
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No.
Unacceptable performance criteria

Commencement of Work on the Worksite without an approved Occupational Health and
Safety Plan
2.
Commencement of Work on the Worksite without an approved Occupational Health and

Safety Manager / Officer appointed and employed on a full time basis at the Worksite
3.
Failure to conduct risk assessments and develop method statements prior to work activities
being undertaken
4.
Failure to appoint competent persons for specified activities (other than OSH Staff)
5.
Collapse of any scaffolding, temporary works or excavation
6.
Use of electrical installations in an unsafe conditions or electrocution of any person
7.
Person falling from a height of more than 2 meters due to unsafe working environment
8.
Person working at height of more than 2 meters without fall prevention or arrest
9.
Failure to maintain acceptable housekeeping, site tidiness, waste collection or waste disposal
10.
Collapse of any crane or lifting equipment
11.
Overturning of any mobile plant, equipment or vehicle on the Worksite
12.
Use of cranes, lifting appliances, mobile plant, equipment or vehicles by operators without
valid driving license and the related training certificate
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Use of cranes and lifting appliances without valid 3 party inspection / test certificate
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13.
1.
Person entering into a confined space without a permit to work
15.
Failure to provide safe access and egress at the Worksite and to the surround residential
area
16.
Failure to provide and maintain proper welfare facilities , first aid box / kits and notice / sign
board
17.
Failure to plan and implement fire prevention and firefighting arrangements considering level
of risks, type of work, sufficient quantity of fire extinguisher, escapes, signage, escape routes
etc
18.
Failure to posses and/or follow 'Permit to Work' system
19.
Permitting Contractor Personnel or Subcontractor's employees to enter the Worksite without

proper PPE and clear identification
20.
Failure to conduct emergency drills at periods not exceeding 3 months throughout the
duration of the Work
21.
Failure to notify the relevant authority of an incident or failure to provide an incident report to
the relevant authority in a timely manner
22.
Failure to provide an accurate monthly OHS report or failure to provide a monthly OHS report
in a timely manner
23.
Failure to hold a monthly OHS committee meeting or failure to provide the OHS committee
meeting minutes in a timely manner
24.
Failure to attend meetings or other events related to OHS issues organised by the Employer
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1.1.2.11 Health and safety questionnaire

The Contractor shall assess the level of knowledge of employees to ensure that they have
the understanding and skills to undertake a work activity.
Well informed and safety-conscious employees are a key part of health and safety. Before
they progress further, the following 20 questions should be carefully read and answered by
employees, preferably in writing. At the end of their training or induction, employees should
be asked the questions again. You, the Contractor, will then be able to compare the level of
their knowledge after studying with the level it was before.
If you critically assess the answers you will gain an insight into your employees' need for
further training and instruction.
Are you playing your part? Check against these questions.
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Are you aware that your company has a health and safety policy?
(b)
Have you read your company's health and safety policy?
(c)
Have you been trained to do the job you do or to operate the plant, machinery or tools
you use?
(d)
Do you know who your Safety Representative is or who will represent you?
(e)
Do you know the procedures to be followed if you have an accident?
(f)
Are you aware of the first aid arrangements at your place of work?
(g)
Do you know where to get first aid?
(h)
Do you know where the accident book is kept?
(i)
Would you know what to do if there was a fire at your workplace?
(j)
Do you know how to raise the alarm in the event of fire?
(k)
Do you know the colour coding that is used for fire extinguishers?
(l)
Are you aware of any potentially harmful substances in your place of work?
(m)
Are you familiar with the identification symbols displayed on the containers of harmful
and dangerous substances?
(n)
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(a)
(o)
Have you been issued with all the necessary personal protective equipment?
(p)
Are you fully aware of the hazards and risks in your job?
(q)
Are you aware of the health and safety rules applying to your job?
(r)
Do you know what you should do if you discover a potential risk to health and safety?
(s)
Can you identify a 'confined space'? Are you aware of the potential hazards confined
spaces may present?
(t)
Are you aware of your company's Permit to Work system, if they have one?
Do you use correct manual handling techniques when moving or lifting loads?
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1.1.2.12 Points to consider on implementing of health and safety

1
The following points can be used to stimulate thoughts and ideas whilst developing health
and safety systems.
If you read them through and think about them carefully, there are many 'pearls of wisdom'
that you can adapt to your circumstances.
No one is accident-prone, they are just badly trained; or perhaps they are the wrong
person doing the wrong thing in the wrong place at the wrong time.
(b)
No one wants accidents - not clients, not Contractors, and most of all not employees.
(c)
Safety culture in a company is when people act and behave safely even when no one
is looking.
(d)
Personal protective equipment, however good it is, is no substitute for a proper safe
system of work.
(e)
Hazards and risks! Eliminate the hazard (the thing that can cause harm) and you can
forget about the risk (the chance of an accident occurring) forever.
(f)
Fire destroys property and jobs. Safe systems of work and safe people prevent fires.
(g)
Compliance with these Regulations gives a minimum standard. Do you personally

accept minimum standards?
(h)
A safety policy cannot stop ill health or accidents, but the people who put the policy
into practice certainly can.
(i)
First aid. If you can check the heart and the breathing, and stop the bleeding you
might save a life. If you can't, then you won't.
(j)
In safety, good luck is planning meeting opportunity. Bad luck is just bad
management.
(k)
Compliance with rules does not mean that you are doing everything that is 'reasonably
practicable'.
(l)
Compliance with a rule or a regulation is not in itself a risk assessment.
(m)
You cannot insure against having an accident, it is just that the insurance company
eventually pays some of the costs.
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Accident statistics only really tell you just how often you got things wrong in the past.
Good health and safety performance should not be especially praiseworthy - it should
be the expected norm.
(o)
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(p)
A conviction in a Qatar court of law for a health and safety offence will give you a
criminal record.
(q)
The uninsured costs of an accident are always paid for out of profits, or they help
towards causing losses.
(r)
Risk assessments. What's the hazard, what's the risk and what's the action?
(s)
Actions speak louder than words. If managers act safely, then the employees will
follow the example.
(t)
The three essentials for health and safety are: safe people, safe places, and safe
systems of work,
(u)
If you know where you are as regards health and safety, then and only then, can you
decide where you want to go.
(v)
Every accident is the visible, the very highly visible, face of failure. Safe performance
is the visible face of success.

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(w)
If an employee said 'wouldn't it be a good idea if we sought further advice' I would

rather the Contractors said MAYBE than NO.
(x)
If there is a system failure, don't just blame the system, do something about it.
(y)
Who? What? Why? Where? And how? Are all very good questions to ask when doing
risk assessments?
(z)
I'm alright. I've never had an accident yet, are very famous last words.
(aa)
There is no such thing as an accident. Someone, somewhere, sometime did

something to cause it.
(bb)
Safety has to start at the top; then, and only then, will it percolate down to everyone
else.
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1.1.3
Safety Policies
1.1.3.1 Key points

This Regulatory Document requires every Contractor to have a policy on how health and
safety will be managed within the company.
The policy must explain how matters of health and safety will be organised within the
company and the arrangements that the company has put in place for implementing the
policy.
The policy should be periodically reviewed to ensure that it is still current, and amended
when necessary, with the content and changes made available to all employees.
Off the shelf health and safety policies, obtained from third parties are unlikely to contain
sufficient company-specific content.
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A general statement of health and safety policy is the way in which a company sets out its
intention to manage health and safety. It will vary from one company to another. There is no
such thing as a 'standard' health and safety policy, as a company's policy must be clearly
and directly related to its own operations.
It is common for companies to obtain policies via the internet or purchase them from third
parties. These are generic, rarely reflect the type of work that is carried out and may lead a
company into a false sense of security.
The content of the 'organisation' and 'arrangements' sections of the policy is specific to each
company. If a generic policy is used it is quite likely that there will be serious omissions in its
content and therefore in the way the health and safety is managed. Each company's policy
must be based upon its own work activities, management and organisational structure, and
staff competencies.
The act of compiling a health and safety policy, will focus the Contractor or senior member of
staff to whom the Job is delegated on the day-to-day management of health and safety
issues.
This will help them to become aware of shortcomings, duplications of effort and requirements
for certain competences, which can then be rectified.
Evidence shows that companies with a well-structured and properly implemented health and
safety policy, together with the organisation and arrangements for putting the policy into
effect, have much better overall health and safety performance.
It is through the ongoing development of a company's health and safety policy that
shortcomings can be identified and procedures put in place to help eliminate common
causes of accidents and reverse this unenviable record.
A comprehensive and accurate health and safety policy is the basis of an effective
management system.
There is no difference in the standard of protection required during a house extension

compared to that for a major construction project; what is likely to differ is the complexity of
the management system.
10
Health and safety, and the provision of proper welfare facilities, are crucial to the proper
running of any building, construction or civil engineering project. They are not an add-on, an
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extra or an afterthought, but should be integrated with the normal day-by-day activities of
project planning, tendering and management.
1.1.3.3 Competent contractor

Contractors must be able to demonstrate how they effectively manage health and safety. If
the company cannot demonstrate competence in health and safety issues, it may not be
invited to tender in the future. It is no longer acceptable to simply state that the company has
been in the industry for many years without experiencing an accident.
Generally, this Regulatory Document (Regulations) requires Contractors to provide for their
employees a place of work that is safe and where risks to health are properly controlled.
They are also required to ensure that people who are not their employees are not exposed to
risks to their safety and health.
There should be a carefully planned and systematic approach to health and safety issues,
where all risks have been assessed and the appropriate control measures put into place.
Irrespective of size, a company must have a general statement of health and safety policy in
order to demonstrate to a client or to another contractor that it has committed itself to the
principles of health, safety and welfare.
A health and safety policy is a statement of how a company will, within its overall business
activities, manage health, safety and welfare for the benefit of its employees and all other
persons who may be affected by the company's operations.
These Regulations require that a safety policy should cover three distinct aspects:
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A general statement of the company's health and safety policy highlighting the
intent of the Contractors to have high standards of health and safety in the company,
including what they intend to achieve and how they will achieve it.
(b)
The organisation within the company for the effective maintenance and
implementation of the health and safety management system.
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The arrangements for the effective implementation and ongoing monitoring of the
health and safety management system.
(c)
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1.1.3.4 Section 1 - The statement of policy

1
The statement of policy should demonstrate a clear commitment to health and safety from
senior management by declaring how the company intends to manage health, safety and
welfare matters in relation to employees and other persons.
It should specifically state the name of, and be signed by, the person responsible for health
and safety, who should be the managing director or another director to whom responsibility
has been delegated. The policy should be reviewed at least every twelve months and a new
copy signed, dated and displayed to demonstrate that it is a live document.
There should be a declaration that the necessary resources will be provided to ensure the
health and safety of all employees.
It is usual for the statement of policy to state the importance that the company places upon
the health and safety of its employees and what is required of them to achieve the aims of
the policy. It should also clearly state that all employees will be informed of the contents of
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the health and safety policy and that they will be consulted about its application.
5
An example of a General Statement of Health and Safety Policy for a medium-sized

Contractor is given in Appendix 1.
1.1.3.5 Section 2 - Organisation

This part of the document should:
(a)
identify those people within the company who have specific health and safety
responsibilities, including the person who has ultimate responsibility for health and
safety
(b)
outline the methods by which health and safety procedures and other health and
safety issues will be communicated
(c)
explain the methods by which the effectiveness of the health and safety management
system will be measured, reviewed and updated where necessary.
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The section must clearly state 'who has to do what' in terms of health and safety. For
example, it might say that the Contracts Manager will receive information from the Site
Manager about accidents, how the results of investigations into those accidents will be
managed, and that the Contracts Manager will notify the Administrative Authority when
necessary.
It should also detail how health and safety information is to be discussed with and brought to
the attention of employees, especially those with specific duties highlighted within the
document.
It is important to remember that once this information is written down, if there is a serious
accident, it will be used in court by the Administrative Authority (Administrative Authority).
This means people need to be aware of their responsibilities, and have the competence to
carry them out.
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1.1.3.6 Section 3 - Arrangements

This part of the health and safety policy should clearly show the specific arrangements that a
company has put in place for managing health and safety during its normal work activities. It
should also detail how emergency situations and any other incidents would be handled both
from a management and a site perspective.
One area for consideration is for companies to indicate how they compile risk assessments
and develop safe systems of work. The arrangements in place in relation to compliance with
the Construction (Design and Management) CDM Regulations (see Section 1.1.8 of the
Regulatory Document) can should also be detailed to demonstrate how compliance with
CDM is achieved.
The development of the arrangements section is likely to evolve over a period of time and, to
an extent, reflect the findings of the company's risk assessments. It should encompass who
is responsible, as well as what they will do and when and how they will achieve it. This
section should:
(a)
explain how the need for (health and safety) competencies and training are
established and satisfied and, if necessary, what interim measures will be put in place
whilst shortcomings exist.
(b)
outline the means by which health and safety consultation with the workforce will be
achieved including, as necessary, reference to management and safety
representatives and safety committees.
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(c)
explain the procedures for ensuring that sub-contractors have a satisfactory health
and safety management system and exhibit safe working practices on site.
(d)
list the areas of risk and identify the person who is responsible for managing each risk.
Some of the elements that might need to be addressed are:

Site activities
Hot works
Piling
Electricity
Gas
Noise
10
Vibration
11
Confined spaces
12
Protection of the public
13
Authorisation for the use of plant and equipment
14
Asbestos
15
Lone working
16
Machine guarding
17
Portable hand-tool testing
18
Manual handling
19
Working at heights
20
Roofing
21
Scaffolding
22
Ladders
23
Cradles
24
MEWPs
25
Excavations
26
Hazardous substances
27
Working in occupied premises
28
Any trade-specific items e.g. loading and unloading plant.
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Administration procedures
Emergency procedures
30
First aid
31
Fire
32
Means of escape
33
Accident reporting
34
Welfare facilities
35
Employee consultation
36
Monitoring procedures for the effectiveness of health and safety procedures.
37
The arrangements section of the policy must demonstrate clearly how the company plans to
carry out its work activities and should identify all the specific site risks associated with them.
This Regulatory Document (Regulations) requires that Contractors give their employees all
the information, instruction, training and supervision that is necessary to ensure their health
and safety. However, on small works of short duration or emergency repairs, detailed preplanning may not be possible. Employees may be sent to a client's premises or a customer's
house at very short notice. This type of work may create a number of problems for
employees, including the need for a short notice or on-site 'risk assessment', and the
arrangements section of the company health and safety policy must cater for this type of
eventuality.
38
The arrangements section of the policy should also cover the situation where a manager is
unable to visit a possible work site whilst tendering or preparing a quotation for a job, but
instead sends an estimator. In this case the estimator must be trained to assess the health
and safety risks of the work, and to record the work to be done and the risk control measures
necessary.
39
These notes should indicate all possible hazards, working height, obstructions, plant and
equipment required. Detailed risk assessments can then be carried out and the associated
method statements developed. This will allow for employees to be properly instructed on or
informed about the work that they are to do.
40
Managing health and safety on a large site offers certain challenges, but it is normally far
easier than dealing with a large number of minor works. This is purely down to the level of
supervision and control that can be put in place.
41
There is a certain irony that typically it is the smallest and probably least resourced
organisations that have the biggest challenges in terms of developing management systems.
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1.1.3.7 Updating of safety policies

1
This Regulatory Document (Regulations) requires Contractors to revise their safety policies
'as often as may be appropriate'.
Changes in the type of work carried out and changes in staff will also give rise to the need
for a review of the policy. In addition, the policy should be regularly reviewed to ensure that it
stays meaningful and relevant to the company's overall operations.
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1.1.3.8 Communication
1
Contractors are legally required to bring their health and safety policy and any subsequent
revisions to it, to the notice of all employees. CDM emphasises the need for consultation with
the people who carry out the work. Communicating the health and safety policy is a good
way of doing this.
The only way to find out if the requirements of the policy are realistic and workable is to talk
to the people who have to comply with them in the workplace.

Under the CDM regulations (Section 1.1.8), the client is responsible for ensuring all
contractors are competent.
The Engineer is appointed by the Client to advise and assist the client with his task and shall
formally assess the competence of the Contractor, if requested.
Part of this assessment process must be a review and critical examination of the contractor's
health and safety policy
CDM requires that companies bidding for work will compile a 'competence pack' to show
how their policies, organisation and arrangements meet the stipulated core criteria for
competency demonstration in implementing and managing health and safety.
The appendix to this section contains a suggested layout of a health and safety policy for a
medium-sized company carrying out small building works. Not all of it will be relevant to
some companies and, conversely, it may not contain specific content that some companies
require.
For most companies, the General Statement of Health and Safety Policy should fit onto one
page of A4 paper. The organisation and arrangements sections will be longer depending on
the size of the company and the type of work that is carried out. Overall, the final document
should be a clear indication to clients, employees and other interested parties such as the
Administrative Authority that the company is honestly, openly and totally committed to the
proper and effective management of all aspects of health, safety and welfare.
et
it
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as
qa
ta
rw
.l.
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1.1.3.10 The business case

In addition to the legal considerations, for example, compliance with this Regulatory
Document, there are very strong economic and social drivers for a robust health and safety
policy and its proper implementation. The economic argument is that if there are fewer
accidents on site and no occupational ill health, more employees will be at work, rather than
off sick. This means improved business continuity with a greater prospect of completing
projects on time, to budget and to the satisfaction of the client.
The social argument is similar. Clients and customers are far more likely to place business
with a company who they see is behaving with integrity, and taking proper care of the health,
safety and welfare of their employees and others who might be affected by the activities of
the company.
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Page 27
1.1.3 Appendix 1
GENERAL STATEMENT OF HEALTH AND SAFETY POLICY
The Contractor will comply with his duties in order to provide a safe and healthy working
environment for its employees and others affected by its activities. It will take positive action
to ensure that other contractors' employees, occupiers of premises, and members of the
public do not have their health and safety adversely affected by the work operations of the
company. The only acceptable standard of health and safety, and for welfare facilities, will be
full and proper compliance with the requirements of legislation. Where it is possible and
practical to do so, the company will exceed the minimum requirements of the Qatar
Regulatory Document (Regulations).
The company will seek to ensure that each company with whom it contracts or subcontracts
aspires to a similar high standard of health and safety management.
In recognition of the importance that this company places on the engagement and wellbeing
of its employees, the company will:
.l.
l
consult, on health and safety matters, with its employees and others who may work
under its control to ensure that the arrangements for health and safety management
are practical to implement and effective
(b)
as far as is reasonably practicable, fully and effectively control the health and safety
risks arising from its work activities, in co-operation with employees, other contractors,
clients and other relevant parties
(c)
ensure that accident and ill health prevention is provided the highest priority,
commensurate with business objectives, within all company operations
(d)
investigate lapses in health and/or safety performance and implement remedial

actions to prevent, so far as is reasonably practicable, their recurrence
(e)
provide and ensure that all plant and equipment owned, used or hired by the company
is appropriate, safe to use and properly maintained, inspected and tested
(f)
ensure that all equipment, materials and substances used by the company are
appropriate for their intended use and used, handled and stored safely
(g)
ensure that all employees are provided with adequate supervisory training, information
and instructions to competently carry out their work activities
ta
qa
as
se
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ov
ensure that all working places are maintained in a safe and healthy condition
provide adequate resources, including sufficient finance, and access to competent
health and safety advice, to achieve the aims of this policy
(i)
et
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(h)
rw
(a)
(j)
review and revise this policy statement at regular intervals and also where necessary
due to changes in the company activities.
Signed:.......................................................... Designation: ......................................................................

Date: ............................................................. Review Date: ....................................................................
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Page 28
ORGANISATION FOR HEALTH AND SAFETY MANAGEMENT

The table below can be used to record the area of responsibilities with respect to the
organisation for implementation of the policy.
First column: Description of the area of responsibility the overall and final responsibility for
ensuring that the health and safety policy is properly implemented and that the health and
safety standards are achieved and maintained.
Second column: Include the contact details of those with the identified responsibility (In
addition to the person(s) named in the arrangements section of this policy) to ensure that
health and safety standards are achieved, maintained and improved.
POSITION or NAME
.l.
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AREA OF RESPONSIBILITY
rw
Contractors
se
qa
as
The person with responsibility for approving the

inclusion of each contractor on to the approved list
of contractors is:
ta
The person responsible for vetting the health and

safety procedures and past health and safety
performance of contractors who bid for contracts,
is:
er
Health and safety management
ov
The person responsible for the management and

updating of the health and safety management
system is:
et
it
The person responsible for monitoring the day-today standards of health and safety, and instigating
improvements where necessary, is:
at the company offices:

on each site:
The person responsible for compiling and
communicating health and safety information to
each site is:
The person responsible for compiling and
comparing year-on-year health and safety accident
statistics is:
The person responsible for ensuring that the
statutory inspections of plant, equipment and
places of work are carried out, and that certificates
are obtained and displayed where appropriate, is:
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Page 29
AREA OF RESPONSIBILITY (continued)
POSITION or NAME
ov
er
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as
Liaison with senior management

The person responsible for keeping senior
management informed of day-to-day health and
safety performance of the company is:
The person responsible for informing senior
management of any event which has attracted the
attention of the Administrative Authority:
The person responsible for submitting the annual
health and safety report to senior management is:
rw
.l.
l
Health and safety procedures

The person responsible for ensuring the adequacy
of the scope and the accuracy of all health and
safety procedures is:
To effectively discharge this duty they will:
monitor the adequacy of existing health and
safety procedures
develop new health and safety procedures as
necessary
maintain the currency of all health and safety
procedures
communicate any change to any health and
safety procedure and the publication of new
health and safety procedure to all users.
et
it
Liaison with external agencies

The person who is the contact for any enquiries
from the Administrative Authority is:
The person responsible for reporting reportable
accidents and other reportable events to the
Administrative Authority is:
The person responsible for liaising with the fire and
rescue service about onsite hazards or hazardous
work activities is:
Worker consultation
The person responsible for ensuring that an
effective system of worker consultation is
maintained is:
The person responsible for ensuring effective
worker consultation at site level is:
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Page 30
Health and safety risks arising from work activities

7
The control of the risks associated with the work done by the company can only be achieved
by the proper use of risk assessments. Risk assessments will be carried out for all work
done by the company. They will be reviewed at regular intervals.
AREA OF RESPONSIBILITY
POSITION or NAME
Accidents
.l.
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The company will investigate accidents as

necessary to establish their root cause and prevent
recurrence. The investigation will be proportional to
the seriousness of the event and its likely
implications.
on each site:
ta
on each site:
ov
er
se
as
The person responsible for investigating the causes

of accidents and suggesting or implementing
remedial action is:
qa
rw
The person responsible for ensuring that all

accidents are properly recorded in the accident
book is:
et
it
The person responsible for ensuring that completed

accident records are securely stored at the
company offices is:
Asbestos
The company will investigate the possible presence

of asbestos within its office premises and on the
sites that it operates and if asbestos is found to be
present, will properly manage it and record its
presence in the asbestos register.
The person responsible for the management of the
presence of asbestos is:
on each site:
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Page 31
POSITION or NAME
Competency
The company will provide induction training and
job-specific training for all employees to ensure that
they are fully competent to carry out the work that is
required of them.
The person responsible for assessing competency
requirements and identifying shortcomings is;
Competent health and safety advice
ov
er
se
The company will endeavour to fully and effectively

consult its employees on matters of health and
safety in such a way that upward feedback will be
welcomed, evaluated and acted upon where
appropriate.
et
it
Employees' health and safety representatives who

will provide two-way communication between
management and employees are:
.l.
l
rw
ta
as
Consultation with employees
qa
The responsibility for engaging competent health

and safety advice lies with:
The company accepts that there will be occasions

where expert health and safety advice is needed for
dealing with matters outside the company's normal
scope of work. On such occasions the responsibility
for raising awareness of the need for competent
health and safety advice lies with:
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Page 32
POSITION or NAME
Electrical safety
The company will endeavour to manage its work
activities so that no employee is put at risk by
electricity.
The following persons are responsible for their
respective areas of electrical safety:
Check for hidden services:
Check for underground services:
.l.
l
Office installation inspection and testing:
rw
On-site installation inspection and testing:
ta
The management of risk from overhead

cables:
se
as
The company will endeavour to ensure that no

person is put at risk from the outbreak of fire. Fire
risks will be addressed by a risk-based fire and
evacuation plan for the company offices and one for
each site.
qa
Emergency procedures - fire and evacuation
er
Fire and evacuation plans will be drafted (and

amended as necessary) by:
on each site:
ov
et
it
Deciding upon the range fire fighting appliances

required and suitable locations for them is the
responsibility of:
on each site:
Arranging for the annual maintenance of fire

fighting appliances is the responsibility of:
Arranging for the maintenance of fire alarms (where
fitted) is the responsibility of:
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Page 33
POSITION or NAME
Emergency procedures - fire and evacuation

(continued)
Initiating and monitoring the effectiveness of office
emergency evacuation (fire drills) is the
responsibility of:
Initiating and monitoring the effectiveness of on-site
emergency evacuation (fire drills) is the
responsibility of:
.l.
l
Arranging for the training of selected employees in

the use of fire fighting appliances is the
responsibility of:
ta
qa
as
The company will endeavour to organise work

activities to eliminate or reduce the occasions when
employees (or others) must enter an excavation or
confined space. When entry into an excavation or
confined space cannot be avoided, the company
will ensure that the work is carried out in a safe
manner by competent persons.
rw
Excavations and confined spaces
er
se
The person responsible for developing safe

systems of work, including rescue procedures, for
working in excavations or confined spaces is:
ov
The person responsible for carrying out, or

arranging, the training of employees to work in
excavations and/or confined spaces is:
et
it
The person responsible for ensuring the attendance

of a rescue team during confined space working
and their training is:
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Page 34
POSITION or NAME
First aid, accidents and work-related ill health

The company will provide sufficient trained first-aid
staff and first-aid equipment to provide adequate
cover at all places where company employees are
working or make arrangements to share the first-aid
arrangements made by others.
First-aid box(es) will be provided at the following Maintaining and replenishing the first-aid box(es)
will be the responsibility of:
locations:
Office:
rw
Trained first aiders or appointed persons work at These people are:

the following locations:
.l.
l
On site:
ta
Office:
qa
On site:
as
Induction and further training
er
se
The company will ensure that each employee

receives an adequate initial induction into the
company and further information, instruction and
training to enable them to work without risks to the
health or safety of any person.
ov
The person responsible for ensuring the effective

health and safety induction into the company of
new employees is:
et
it

arranging for, the induction of new persons on site
is:
The person responsible for carrying out the
induction of office-based staff is:
The person responsible for compiling and updating
the training record of each member of staff is:
The person responsible for establishing the need
for the additional training of any individual is:
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Page 35
POSITION or NAME
Induction and further training (continued)

arranging, the additional training of any individual,
including delivering toolbox talks, is:
Training records:
will be kept at:
by:
rw
.l.
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The person responsible for ensuring that

employees working at locations under the control of
other contractors (Contractors) are given relevant
health and safety information and supervision is:
qa
ta
Supervision of young workers or trainees will be

arranged, undertaken and monitored by:
Manual handling
se
as
The company will endeavour to take all necessary

measures to ensure that no employee is injured as
a result of a manual handling activity.
ov
er

employees are trained in the correct manual
handling techniques, and that these techniques are
applied, is:
et
it
Monitoring the health and safety policy
The company will periodically audit the

effectiveness of its health and safety management
system, in particular adherence to this policy.
Audits will be carried out by:
on each site:
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Page 36
POSITION or NAME
Noise
The company will ensure, so far as is reasonably
practicable, that the hearing of no employee is
damaged as a result of exposure to noise at work.
Where necessary, noise assessments will be
carried out to protect employees from hearing
damage. The person responsible for arranging such
assessments is:
.l.
l
Where the noise survey indicates a noise level of

80 db(A) (lower exposure action value), ear
protection will be provided by:
se
ta
as
assessing the need for health surveillance and

arranging for it where necessary is the
responsibility of:
qa
the setting up of hearing protection zones and

ensuring that employees use the hearing
protection provided by the company will be the
responsibility of:
rw
Where the noise survey indicates a noise level of

85 db(A) (upper exposure action value):
ov
er
The person responsible for ensuring that no

employee is exposed to a noise level above 87
db(A) (exposure limit value) is:
Office safety
et
it
The company will ensure that all work conducted in

the company offices, including that of external
contractors, is carried out without risk to the health
or safety of any person.
The person responsible for general office health
and safety is:
The person responsible for carrying out display
screen workstation assessments is:
The person responsible for ensuring that work in
company offices by external contractors is carried
out without risk to the health or safety is:
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Page 37
POSITION or NAME
Permits to Work
The company will ensure that where appropriate all
potentially hazardous work activities are carried out
under a Permit to Work system and that the system
is robustly developed and monitored.
The person responsible for determining whether or
not any particular work activity should be carried
out under a Permit to Work is:
.l.
l
The person responsible for raising, co-ordinating

and closing Permits to Work is:
ta
rw
The person responsible for training, or arranging

the training, of employees who will have to work
under any form of Permit to Work is:
er
se
as
The company will organise, so far as is reasonably

practicable, its work activities in such a way that the
use of PPE is not necessary. However, when it is
deemed that PPE must be used, the company will
ensure that appropriate PPE is provided and that
adequate training in its use and maintenance is
provided.
qa
Personal Protective Equipment (PPE)
ov
The person responsible for ensuring that all PPE

provided by the company is suitable, issued free of
charge, and maintains an issue log, is:
et
it

employees are instructed in the proper use of PPE
and ensuring that it is used where needed is:
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Page 38
POSITION or NAME
Plant and equipment

The company will ensure that all plant and
equipment is suitable for its intended use, well
maintained, inspected/examined where appropriate
and operators are trained in its proper use.
Identifying appropriate items of plant which must be
hired or bought is the responsibility of:
.l.
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Ensuring the continued serviceability and fitness for

purpose of all plant and equipment is the
responsibility of:
se
ta
as
Any employee discovering a defect in, or other

problem associated with, an item of plant or
equipment should report the facts to:
qa
Identifying the need for and arranging the training

for plant and equipment operators is the
responsibility of:
rw
Monitoring the requirement for routine servicing,

testing, maintenance inspections and statutory
examinations for all plant is the responsibility of:
Risk assessments / method statements
ov
er
The company will carry out suitable and sufficient

risk assessments to cover all of its work activities.
Pre-start site risk assessments will be undertaken

and recorded by:
et
it
Risk assessments for site-based activities will be

reviewed at appropriate intervals and revised as
necessary by:
Risk assessments for the company's office-based
work activities will be carried out, recorded and
reviewed at suitable intervals by:
Method statements for site-based activities will be
compiled where appropriate and reviewed or
revised as necessary by:
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Page 39
POSITION or NAME
Safe handling and use of substances (COSHH)

practicable, that hazardous substances are
handled, transported, used and stored in such a
manner that the health of no person is harmed by
their presence.
All substances which require
assessment will be identified by:
COSHH
COSHH assessments will be undertaken, reviewed

and amended as necessary by:
rw
.l.
l
The implementation and monitoring of all actions

from COSHH assessments will be checked by:
qa
ta
Providing at-risk employees with appropriate

information from COSHH assessments is the
responsibility of:
as
on each site:
se
Arranging for the safe disposal of residues and

empty containers, is the responsibility of:
ov
er
Where necessary, health surveillance will be

arranged by:
Transport
et
it
The company will ensure that it operates its

transport in a way that does not put the safety of
any person at risk.
Where it is necessary to transport staff or materials

by vehicle, either on or off site, the person
responsible for ensuring that proper procedures are
followed is:
The person responsible for ensuring that all
company vehicles are maintained in a legal,
roadworthy and otherwise safe condition is:
The person responsible for ensuring that workrelated road risks are properly managed is:
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Page 40
POSITION or NAME
Vibration
practicable, that the health of no person is put at
risk as a result of exposure to vibration resulting
from the company's work activities.
Where necessary, expert advice on vibration will be
given or arranged by:
.l.
l
The
person
responsible
for
implementing
organisational and engineering controls, to control
vibration at source or reduce exposure, is:
se
ta
as
The person responsible for assessing the need for

health surveillance and arranging for it to be carried
out, where necessary, is:
qa

appropriate actions are taken if the level of personal
exposure reaches the 'exposure action value' or the
'exposure limit value' is:
rw
The person responsible for monitoring employees'

exposure to vibration on site and taking the
appropriate actions, is:
er
Welfare facilities
ov
The company will ensure that adequate and

suitable welfare facilities are provided (or made
available) for all staff.
et
it
The person responsible for ensuring that adequate

and suitable welfare facilities are provided or made
available is:

on each site:
The person responsible for ensuring that welfare
facilities are maintained and kept in a clean and
order condition is:
on each site:
Arrangements for shared welfare facilities will be
organised by:
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Page 41
POSITION or NAME
Work at height
The company acknowledges that working at height
is a major cause of serious injuries and fatalities
and will therefore endeavour to ensure that where
such work cannot be avoided, it is carried out in a
safe manner.
The person responsible for deciding whether or not
work at height can be avoided is:
safe
developing
.l.
l
The person responsible for

methods of working at height is:
er
Young persons in the workplace
se
ta
as
The person responsible for ensuring that the

employees who will carry out work at height are
suitably and properly trained is:
qa

inspections of places of work at height, is:
rw

statutory inspections associated with the equipment
used for work at height, or arranging for them to be
carried out, is:
ov
The company will ensure that the health or safety of

young persons is not put at risk due to their
inexperience, curiosity, lack of hazard awareness or
physical limitations.
et
it
If one or more young persons are present in the

workplace, the person who will ensure that the risk
assessment is suitable and sufficient for their
presence is:
on each site:
The person responsible for managing the presence
of young persons in the workplace is:
on each site:
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Page 42

1.1.4
Consultation with Employees
1.1.4.1 Key points

Employers, in particular Contractors have a duty to consult all their employees on matters of
health and safety.
Consultation must involve two-way communication - Contractors passing relevant health and
safety information to their employees and, conversely, seeking and encouraging the opinions
and views of employees where appropriate.
Effective Contractors / employee consultation is an essential tool in highlighting potential

problem areas, finding solutions and therefore maintaining a healthy and safe place of work.
Construction (Design and Management) CDM places a significantly increased emphasis on

consultation.
The needs of employees, and others, whose understanding of Arabic and/or English is below
average must be allowed for during the consultation process.
Section 1, Part 6 of the QCS covers project meetings, Section 1, Part 17 covers project
coordination and Section 1, Part 18 covers contractors.
ta
Note:
rw
.l.
l
qa
Consulting employees on health and safety matters can be very important in creating and
maintaining a safe and healthy construction working environment.
By consulting employees, a Contractor should motivate staff and make them aware of health
and safety issues.
Businesses can become more efficient and reduce the number of accidents and work-related
illnesses.
Consultation involves Contractors not only giving information to employees, but also listening
to and taking account of employees opinions.
When an employee has raised a health and safety issue, it is essential that feedback is given
on any decision taken so that the employee can be confident that their suggestions are
considered and action taken where appropriate.
Where the need for consultation stems from changes to work practices, new work equipment
or changes in organisation, etc, it is essential that the Contractor consults with the workforce
at a sufficiently early stage to allow them to consider the implications and raise any queries.
Furthermore, there may be special considerations when carrying out consultation, such as to
establish the needs of particular individuals, for example taking into account the
requirements of employees with disabilities.
Every Contractor should, as part of their health and safety policy, have documented
arrangements in place which outline how effective consultation will be achieved.
Consultation cannot take place if there is a barrier to effective communication, such as one
of the parties having a limited understanding of Arabic and/or English, either spoken or
written. This is becoming an increasing challenge.
10
Those people on site who have a responsibility for consulting with the workforce must
identify any such barriers and determine ways in which they may be overcome, such as
adapting the means of communication or using interpreters. It is highly unlikely that the use
et
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ov
er
se
as
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Page 43
et
it
ov
er
se
as
qa
ta
rw
.l.
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of a Labour gangmaster as an interpreter would be judged to be an acceptable means of

consultation for the purpose of communicating health and safety information.
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Page 44
1.1.4.3 Duty of the Contractors to consult

It is the duty of the Contractor to consult with their employees in good time on health and
safety matters. In particular:
(a)
the introduction of any measure that will affect the health and safety of employees
(b)
the arrangements for appointing or nominating the person(s) to assist the Contractors
in complying with this Qatar Regulatory Document (Regulations)
(c)
the provision of relevant information as required under this Regulatory Document

(Regulations)
(d)
any planning or organisation of training required by this Regulatory Document

(Regulations)
(e)
the health and safety implications of the introduction of new technologies into the
Contractors' workplace.
.l.
l
rw
1.1.4.4 Persons to be consulted
Contractors may consult directly with all their employees or through 'representatives of
employee safety' elected by a group of employees to represent them in health and safety
consultation with the Contractors.
The Contractors must provide employees with a list of names of representatives of employee
safety and the groups they are representing in the workplace.
In addition, the Contractors must inform employees of any changes in the form of
consultation, such as a move from dealing with representatives to directly consulting with
each employee.
Employee representatives must also inform the Contractors when they no longer represent a
group or groups of employees.
ov
er
se
as
qa
ta
1.1.4.5 Provision of information

The Contractors must provide all such information as the employees may require in order for
them to participate fully in the consultation procedure. This will either be directly with all
employees or with the elected 'representatives of employee safety'.
This information may cover what the Contractors proposes to do in relation to health and
safety and includes giving the safety representatives an opportunity to express their views in
the light of the information provided. The Contractors shall take account of the safety
representatives' responses.
The issues the Contractors will consult on are:
et
it
(a)
introduction of measures, at the workplace, which may substantially affect the health
and safety of the employees
(b)
arrangements for obtaining or appointing the competent person to assist the

Contractors to comply with health and safety requirements
(c)
information on risks to employees' health and safety and the measures taken to
remove or minimise them.
Specific areas include:

(a)
emergency procedures
(b)
first aid provision
QCS 2014

Page 45
(c)
display screen equipment
(d)
manual handling
(e)
noise
(f)
asbestos
(g)
work at height
(h)
vibration management
(i)
work equipment
(j)
personal protective equipment
(k)
CDM
They may make representation on hazards, risks, dangerous occurrences, ill health and
general health and safety matters, particularly those that the Contractors has a duty on
which to consult.
rw
.l.
l
1.1.4.6 Functions of the representative of employee safety
ta
1.1.4.7 Training, time off and the provision of facilities
The Contractors must provide the employee representative with appropriate and reasonable
training time and reasonable facilities to enable them to perform their functions.
This includes the Contractors meeting reasonable costs associated with training and time off
to perform the function.
The employee is also protected from unfair dismissal or from being otherwise penalised
when participating in consultation with Contractors on matters of health and safety in the
workplace.
er
se
as
qa
ov

The fundamental requirements under CDM, for competence, co-operation and co-ordination,
imply a need for consultation between the various parties working on a project, at all levels.
These requirements apply to all projects.
On all projects the CDM Regulations require that all contractors ensure that their workforce
is properly consulted on matters which could affect their health or safety.
CDM uses the term 'worker engagement' rather than 'consultation'.
Worker engagement requires contractors and others to actively engage their workforce in the
process of identifying and controlling risks as an essential part of accident and incident
reduction; 'one-way consultation' should be a thing of the past. For this process to work
successfully, the workforce must:
et
it
(a)
be provided with a means of promptly reporting health, safety or welfare issues to a

site-based supervisor or manager
(b)
have sufficient knowledge, gained through training where necessary, to appreciate

where health, safety and welfare issues exist
(c)
have sufficient confidence, based upon their knowledge, to report suspected or known
unsafe situations
(d)
be provided with feedback to ensure that the issue raised has been investigated and
corrective action taken where necessary.
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Page 46
In doing this, the Contractor will have to take into account the diversity of the work being
carried out by the various contractors and self-employed people who will be on the project at
the same time, and the duration of their particular work activity.
In that respect, each contractor, sub-contractor and designer has legal duties under CDM to
consult amongst themselves regarding construction work and ongoing design, design
changes and they all have a legal duty to provide information needed for the future stages of
the project (post construction)..
1.1.4.9 The Management of Health and Safety at Work

These Regulations require Contractors to provide information to employees on the
arrangements for dealing with 'serious and imminent danger and danger areas'. The
information required is the nature of the hazard and the measures taken to protect the
employees from it.
In addition, Contractors must provide employees with comprehensible and relevant

information relating to:
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health and safety risks identified by the risk assessment process
(b)
the preventative and protective measures established
(c)
emergency procedures
(d)
health and safety risks that have been notified to the Contractors.
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(a)
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1.1.4.10 Functions of the safety representative
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Consultation with the Contractors Safety Representatives

These Regulations require every Contractor to consult with safety representatives with a
view to making and maintaining arrangements which will enable them and their employees to
co-operate effectively in promoting and developing measures to ensure health and safety at
work, and in checking the effectiveness of such measures. To achieve this, safety
representatives should encourage co-operation between the Contractors and employees.
They should use the established methods of communication within the workplace to keep
their members informed of matters affecting their health, safety and welfare at work.
Safety representatives will need to establish a close relationship with other appointed safety
representatives, including those appointed to develop a common approach to their
responsibility for the group or groups they represent.
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Investigation
occurrences
and
reporting
of
significant
hazards
and
dangerous
This function is placed on the safety representative on behalf of all employees. In practice
this means that the safety representative should bring to the Contractors notice
unsatisfactory conditions, working practices or arrangements which come to their attention
either during formal inspections or day-to-day observation.
Any such reports should normally be in writing. The report does not imply that all other
conditions and working practices are safe and healthy, or that the welfare arrangements are
satisfactory in all other respects. Making a written report should not preclude a direct oral
approach to (for example) the supervisor or shift leaders in situations where speedy remedial
action is necessary or where it can lead to an immediate resolution of the problem.
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It is important that the safety representative should have access to the Contractors
competent representative responsible for safety. Responsibilities for safety should be clearly
defined.
In order to fulfil their functions, safety representatives should keep themselves informed of
the particular hazards and risks of the workplace. They should also keep themselves
informed of the measures deemed necessary to eliminate or minimise the risks as set out in
the health and safety policy of their Contractors, as well as the organisational arrangements
for fulfilling that policy.
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Investigation of accidents in the workplace

5
Safety representatives should examine the causes of accidents at the workplace and make
representations to their Contractors on behalf of all employees they represent using
recording and reporting procedures like those outlined under 'Investigation and reporting of
significant hazards and dangerous occurrences' above.
Representation on general health and safety matters
Again, all employees should be represented and it is advised that similar recording and
reporting procedures are used.
Reception of complaints by employees
The function of the safety representative in this area is similar to that of a shop steward; so
the safety representative should ensure that there is no duplication of effort. It is advisable
that recording and reporting procedures as outlined previously are used.
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Representation in consultation with the Administrative Authority
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Where safety representatives have been appointed they will be the appropriate persons to
represent employees in any consultations with the Administrative Authority, or other
Administrative Authority.
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Safety representatives should attend meetings of safety committees in their capacity as

safety representatives in connection with any of their statutory functions.
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Attendance at meetings of safety committees
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These may occur in four distinct situations:

on a regular basis
(b)
after a substantial change in conditions of work
(c)
after a notifiable accident, dangerous occurrence or contraction of a notifiable disease

after remedial action has been taken.
(d)
(a)
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Inspections of the workplace
On a regular basis
11
Safety representatives are entitled to inspect the workplace, or part of it, at least every three
months. However, there may be special circumstances in which safety representatives and
their Contractors may wish to agree a different frequency of inspections for different areas or
sectors of the workplace, for example, where there is an especially high risk or in rapidly
changing circumstances. In all instances, agreement should be reached with the Contractors
on the frequency of inspections.
12
Safety representatives must give Contractors reasonable notice in writing of their intention to
carry out an inspection.
13
It is preferable that the Contractors and the safety representative should plan a programme
of formal inspections in advance. This will fulfil the conditions as to notice. Variations in this
planned programme should be subject to agreement.
14
There are advantages in formal inspections being jointly carried out by the Contractors or a
representative and the safety representative, but this should not prevent safety
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representatives from carrying out independent investigations or having private discussions

with employees.
The number of safety representatives taking part in any one formal inspection should be
agreed by the safety representatives and the Contractors in the light of particular
circumstances and the nature of the inspection.
16
At large workplaces it may be impracticable to conduct a formal inspection of the entire

workplace at a single session. In these circumstances, arrangements may be agreed for the
inspection to be broken down into manageable units. It may also be appropriate, as part of
the planned programme, for different groups of safety representatives to carry out
inspections in different parts of the workplace. This can be either simultaneously or at
different times, but it should be in such a manner as to ensure complete coverage before the
next round of formal inspections becomes due.
17
The inspection may take various forms and the type to be carried out will be for the safety
representative to agree with the Contractors.
18
Several types of inspection which, on their own or in combination, will over a period of time
be appropriate:
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Safety auditing - systematic checking of every aspect of the company's operations.
(b)
Safety sampling - systematic sampling of the hazardous activities, processes or areas.
(c)
Safety surveys - general inspections of all work activities, processes or areas.
(d)
Safety tours - general inspections of the workplace.
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(a)
Safety representatives should record their findings and notify the Contractors of particulars.
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15
An inspection may take place after a substantial change in the conditions of work, or new
and relevant information concerning hazards in the workplace has been published.
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20
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After a substantial change in conditions of work
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After a notifiable accident, dangerous occurrence or contraction of a notifiable

disease
When there has been a notifiable accident or dangerous occurrence in a workplace or a
notifiable disease has been contracted, safety representatives may carry out an inspection of
the part of the workplace concerned and, so far as is necessary for the purposes of
determining the cause, may inspect any other part of the workplace.
22
Where inspections are carried out, it must be safe for the inspection to be carried out and it
must be in the interests of employees in the group or groups which safety representatives
are appointed to represent.
23
Where it is reasonably practicable to do so, the Contractors, or their representative, should

be notified of the safety representative's intention to carry out such an inspection.
24
It may be necessary, following an accident or dangerous occurrence, for the Contractors to

take urgent steps to safeguard against further hazards. If the Contractors do this, they
should notify the safety representative of the action taken and accompany this in writing.
25
The inspection must not interfere with any evidence or the testing of any machinery, plant,
equipment or substance which could disturb or destroy the factual evidence before a
Workplace Inspector from the appropriate Administrative Authority has had the opportunity to
investigate the circumstances of the accident or occurrence.
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After remedial action has been taken

26
Where remedial action has been taken by the Contractors and the safety representative has
been notified in writing, the representative should be given the opportunity to make any
necessary re-inspection in order to satisfy themselves that the matter(s) notified have
received appropriate attention. They should also be given the opportunity to record their
views. It is advisable that a formal procedure is used.
27
Any remedial actions that are subsequently taken should be publicised throughout the
workplace via the normal channels of communication and should be brought to the specific
attention of the safety committee.
Inspection of documents
Safety representatives are entitled to inspect and take copies of any documents which the
Contractors is required to keep, by virtue of any statutory provision, relevant to the workplace
or to the employees represented.
29
The safety representatives must give a Contractor reasonable notice of their intention to
inspect and take copies of documents.
30
In exercising this right, safety representatives should have regard to the circumstances and
allow the Contractors a reasonable period of time. However, the Contractors must ensure
access to the documents.
31
The only exception is documents consisting of, or relating to, any health record of an
identifiable individual, unless the individual concerned has given their approval.
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1.1.4.11 Provision of facilities
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In addition to the facilities which Contractors must provide for inspections and consultations,
the Contractors must provide whatever assistance may be reasonable in the circumstances.
Note: Throughout these Regulations, reference is made to the facilities that the Contractors
have to provide to the safety representative. All parties should clearly understand that the
facilities should be reasonable, allowing representatives to effectively fulfil their functions.
The necessary facilities should be discussed and agreed on by all concerned.
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1.1.4.12 Establishment of safety committees

1
Consultation about forming a safety committee should cover membership, function,

procedures and the meeting programme of the committee, and take into account start and
finish dates of the contractors who will work on the project.
Once the committee has been established, the Contractors must post a notice stating the
composition and the workplace to be covered by its activities.
1.1.4.13 Objectives and functions

1
The committee should be concerned with all relevant aspects of health, safety and welfare in
the workplace.
It should draw up objectives and agreed terms of reference. These might include:
(a)
study of accidents, dangerous occurrences, disease statistics and trends
(b)
examination of safety audits and other inspection reports
(c)
consideration of reports and factual information from the enforcing authorities
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(d)
reports which safety representatives may wish to submit
(e)
development of safety procedures and safe systems of work
(f)
effectiveness of the safety content of employee training
(g)
adequacy of safety and health communication and publicity in the workplace
(h)
the provision of a link with the appropriate enforcing authorities' inspectors
(i)
the appropriate input into risk assessments, etc.
1.1.4.14 Membership
The number of management representatives should not exceed the number of employee
representatives. Management representatives should be drawn from all levels of
management and supervision, bearing in mind the needs of all contractors. In some
instances, safety experts may be co-opted.
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1.1.4.15 Conduct
The frequency of meetings will depend on the nature of the workplace, and prior consultation
should take place.
It is advisable that meeting programmes should be arranged with agendas and minutes, and
that these should be published and freely available.
It is particularly important that the standing of the committee in relation to management

representatives and safety representatives is clearly defined and that procedures for
reaching decisions are understood.
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A safety representative or other employee cannot be dismissed for drawing the attention of a
Contractor to genuine health and safety concerns.
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1.1.4.16 Employment protection
Construction Site Safety

1.1.4 Appendix 1
Examples of information sought from Contractors
1
Information sought from Contractors on health and safety matters might be such as is
detailed under the following headings. The list should not be taken as exhaustive.
General safety
2
Information relating to safety, health and welfare, such as:

(a)
who the Contractors makes responsible for safety at the office, depot or site; and
where that person can be contacted
(b)
the health and safety policy of the Contractors and the organisation, and the
arrangements for implementing the policy
(c)
a list of members of any health and safety committees and a list of other safety
representatives within the company or on site
(d)
the specific responsibilities of individual managers and supervisors for health and
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safety in the company and on site.
Details of existing procedures for:
(f)
the health, safety and welfare of the workforce and the established procedures for
consultation and negotiation
(g)
the issue, maintenance and replacement of any personal protective clothing and
equipment
(h)
obtaining first aid treatment
(i)
statutory inspections of the workplace, regular inspections and safety drills
(j)
warning notices and signs to be posted around the workplace and any signals which
need to be made during the working day
(k)
accident reporting and investigation
(l)
dealing with unsafe acts and conditions at the workplace, including working with
hazardous materials.
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Information relating to the health, safety, welfare and training of young people, such as:
induction training, the general training methods to be implemented and the facilities
available for that training and how they are to be used
(b)
the people responsible for training and the safety content of on- and off-the-job
training
(c)
the provision of specific safety training for certain tasks and activities undertaken
within the workplace
(d)
who sets and monitors the required safety standards in training
(e)
the records to be kept to indicate what training has been received; where those
records are kept and by whom.
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(a)
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Training of young people
Details of training related to the health, safety and welfare of adult workers, such as:
(a)
the type of training available both on- and off-the-job and the duration of that training
the training available and given to skilled, semi-skilled and unskilled people
(b)
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Training of adult workers
(c)
the extent to which retraining includes health and safety instruction
(d)
the methods of training which are currently being used
(e)
the arrangements for ensuring the effectiveness of the training given to workers whose
first language is Arabic and/or English, for whatever reason, have a lower than
average level of understanding of Arabic and/or English.
Training managers and specialists

5
Details of training related to health, safety and welfare of training managers and specialists,
which is given when:
(a)
any new work methods, equipment or materials are introduced into the company's
operations
(b)
any new standards or legislation are introduced which affect the company's operations
(c)
the existing knowledge and skills of the workforce are inadequate to meet the
requirements of the job.
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The company's organisation and activities

6
General information on health, safety and welfare related to the company's organisation and
activities, such as:
(a)
the organisation, structure and specific site organisation
(b)
the numbers of personnel employed for each of the categories of skills employed and
of the specialists available for consultation
(c)
the methods of personnel recruitment, selection and placement policy
(d)
any significant changes in the company's activity, such as any proposed or anticipated
expansion, or the end of contracts.
Access to documents
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Contractors need to maintain and provide access to the following health and safety
information:
first aid statistics, along with records of absence
(b)
details of both manufacturers' and suppliers' technical data
(c)
reports, Improvement and Prohibition Notices served by the Administrative Authority

Workplace Inspectors
(d)
minutes of meetings, reports and any recommendations made by Safety Committees;

reports of safety officers, etc.
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(a)
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1.1.5
Health & Safety Training and Induction Training
1.1.5.1 Key points

Construction and building sites can be dangerous places to work, even for experienced
workers.
Everyone arriving new on site, whether new to the industry, experienced or even a
temporary visitor, should be given an induction to the site.
Accident statistics show that the majority of accidents happen to people during their first few
days on site.
The threats to health and safety will vary from site to site and even on the same site as work
progresses and the hazards change.
An effective induction process is an essential part of on-site health and safety management.
The content of the induction presentation must:
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be understandable, comprehensive and relevant to the hazards present on site at that

time;
(b)
anticipate and inform inductees of forthcoming changes to the hazards on site;
(c)
allow for the effective induction of inductees who do not have English as their first
language or may otherwise have difficulty in understanding what is being said.
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(a)
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It is a requirement of these Regulations that employees are provided with health and safety
training whenever they are exposed to new or increased risks. When employees first arrive
in the company or at a new site, this training takes the form of an 'induction'. It is accepted
that providing proper and effective health and safety induction training can have a significant
impact on the likelihood of accidents and injuries during a person's first few days, weeks or
months with a company or on a particular site.
Given that every accident occurring to an employee can be seen as an eventual financial
cost to the Contractors, then anything that can be done to reduce accidents is of direct
financial benefit to the Contractors. The costs of giving proper and effective health and safety
induction training are relatively minor when viewed against the cost benefits that can accrue
from accident avoidance and prevention. This also applies to the prevention of long-term ill
health and the avoidance of dangerous occurrences.
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1.1.5.3 Types of inductees

1
Mention of the word 'induction' or 'inductee' would cause many people to think of a person
arriving on site or into the company totally new.
Whilst this is the case for some people, there will be a significant number of people who do
not fall into this category. In wider terms inductees may be:
(a)
young people joining the industry for the first time. This will generally be persons
joining a company as trainees or apprentices
(b)
persons arriving at a new site even though they have been in the industry for some
time
(c)
people transferring between companies within the industry
(d)
persons who have been promoted, for example, from tradesperson to chargehand
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It must be appreciated that different types of inductee will probably require different levels or
styles of induction training because of their varying levels of knowledge, experience and
competence within the industry.
1.1.5.4 Health and Safety at Work (Construction Sites)

1
This Regulatory Document (Regulations) requires that Contractors provide their employees
with sufficient information, instruction, training and supervision as is necessary for their
health and safety.

These Regulations are more specific in that they require the following of the Contractors.
(a)
Every Contractor shall, in entrusting tasks to employees, take into account their
capabilities as regards health and safety.
(b)
Every Contractor shall ensure that employees are provided with adequate health and
safety training:
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on their being recruited into the Contractors undertaking; and
(ii)
on their being exposed to new or increased risks because of:
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(i)
their being transferred or given a change of responsibilities within the

Contractors undertaking
the introduction of new work equipment or a change regarding work

equipment already in use within the Contractors undertaking
the introduction of new technology into the Contractors undertaking
the introduction of a new system of work or a change regarding a system

of work already in use within the Contractors undertaking.
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These Regulations specifically require that:
the Contractor takes all reasonable steps to ensure that every worker is provided with
a suitable site induction.
(b)
contractors provide all of their workers with the necessary information and training
which is necessary for their health and safety, including a suitable site induction,
where it is not provided by a Contractor
(a)
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The above requirement on contractors to provide site inductions means that inductions must
be carried out for all projects
The requirements of other Regulations which in themselves indicate a need for competence
in certain work situations, when viewed against the type of work to be carried out, might
indicate additional topics which need to be covered during site induction.
1.1.5.7 Contractors responsibilities

1
Refer to this section 1.1.2.7
1.1.5.8 Employee responsibilities

1
Refer to this section 1.1.2.7.
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1.1.5.9 Induction training

It will be for the Contractors to decide when and where the training takes place. However,
the sooner the induction training takes place the more opportunity there is to have a
significant influence on the people being inducted. It is important that the induction training is
seen as a formal company procedure, which the company provides for the benefit of the
inductee, so that the Contractors can be seen to be meeting both the letter and the spirit of
the law. If it is seen as 'something that is just necessary, we have to do it anyway' then it will
fail to have the desired long-term effects.
The style and content of the presentation will vary between company and site. However, the
person giving the presentation needs to have both the necessary skills and knowledge,
together with the ability or 'presence' to deliver the programme effectively and in a
meaningful manner.
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Induction difficulties
It is essential that the health and safety messages put across during site induction are fully
understood. Possible barriers to learning will depend largely upon the training methods used.
For example, reliance on written training materials will disadvantage those with dyslexia or
other reading difficulties. Similarly, amongst the increasing number of workers who do not
speak Arabic as their first language, some may find induction training of limited value unless
thought is given to how it is delivered.
It is up to the person organising the training to establish the limitations of those undertaking
induction, remembering that there may be a degree of embarrassment and, therefore, a
reluctance to admit limitations.
To successfully induct those whose first language is not Arabic, but who have some
understanding, it will probably be necessary to modify the presentation in style, speed of
delivery and the aids used, depending upon the level of Arabic. Induction aids may need to
be more visual, with less reliance upon the written word. Where there are operatives who do
not speak Arabic at all, it is likely that specialist help, such as interpreters, will be required.
There may also be scope for training someone on the site who speaks both languages to
carry out specific induction sessions for specific groups.
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Induction content
6
Different companies will have different issues to include in the induction training. The
requirements for on-site training will vary as work on the site progresses. In the early days
there may be excavations, exposed reinforcing bars and other problems at ground level.
As the site and above-ground works progress, the hazards will change and it will be
necessary for the emphasis in the health and safety training to change. As the site develops,
temporary or permanent traffic routes may be introduced, or the circulation of traffic on site
may need to change, for example, due to the repositioning of a crane or the installation of
services. All these issues should be reflected in the induction training that will be provided for
people arriving on site or as the project progresses. It is quite possible, or even likely, that
the induction session delivered on day one of the project will not be valid after three months.
Part of the induction process must be to find out what the audience already knows, identify
key areas that must be covered and use plain language, illustrating with diagrams, drawings
and pictures to ensure that inductees can easily take in the information.
There will undoubtedly be other issues that are specific to a company or site and these will
need to be considered and developed by the company concerned.
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Explain that at the end of the induction session, all inductees will be required to add their
name and signature to an attendance sheet signifying that they have understood what they
have been told.
1.1.5.10 Site and company rules

1
Obviously, users will amend the content in order to reflect the philosophy of their company,
site or organisation regarding health, safety and welfare provisions. There may be items
covered which you feel are inappropriate and these should be omitted.
Conversely, some additional items not covered may be of particular importance to your
company, site or organisation and these should be included.
Access
Explain the rules regarding access to, and egress from, the workplace. Are there any oneway systems? Are there any prohibited areas? Are there any special rules or conditions
applying to the site or workplace?
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The participants should be in no doubt of the requirements for reporting accidents. Explain
when, where and to whom accidents must be reported and, in general, how they will be
investigated. Your procedures may go beyond those required by legislation as a company
policy decision.
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Accident reporting
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Asbestos
If asbestos or asbestos-containing materials are potentially present, it is essential to provide

elementary asbestos awareness training, including details of any prohibited areas, to reflect
the site conditions.
You should have a company policy for dealing with any material suspected of being
asbestos and employees should be informed of this policy.
This may be along the lines of:
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'If you find any material that is off-white or crumbly, or any fibrous
material that looks like dirty cotton wool it may be asbestos or contain
asbestos, so leave it alone and if practical keep other people out of the
area. Contact your supervisor and tell them what you have found.'
Assembly points
8
See also Emergency evacuation. Explain where the assembly points are for site
evacuation in the event of an emergency.
Boundaries
Explain the boundaries of the site if there is no perimeter fence. Include the prevention of
trespass.
Buried services
10
Explain site or company procedures that should be followed if gas, electricity,

telecommunications, fibre optics, water, sewerage and other buried services are discovered
on site.
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Competence
11
You may need to advise employees and others of the levels of competence required for
operating certain types of plant or carrying out particular pieces of work. CDM in particular
places a legal duty on anyone who arranges for or instructs any worker to carry out
construction work, to ensure that they are competent to do so.
Confidential issues
12
Explain the provision for 'whistle blowing'. How can employees raise confidential (including
medical) issues if the need arises?
Confined spaces
Explain the rules that apply on site. Many employees will fail to recognise that a confined
space can be above ground, or be as innocuous as a sub-basement boiler room.
Unfortunately, confined spaces have been responsible for a number of deaths in the
industry, all of which could have been avoided by compliance with proper health and safety
procedures.
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what is the mechanism for workers to bring any health and safety concerns they have
to the attention of site management?
(b)
If there is a health and safety committee on site?
(c)
If so, who are the members?
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(a)
If there is a suggestion box or scheme, explain how employees can put forward ideas for
improvements in health, safety and welfare, waste minimisation and so on, on a day-by-day
basis.
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Contractors have a duty to consult the workforce on matters of health and safety, you must
explain how such (two-way) consultation is achieved:
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Consultation with employees
The raised awareness of environmental matters makes the prevention of ground

contamination of growing importance. Explain how employees can prevent spillage of diesel
fuel, paint, oil, thinners, cement, concrete or any other substance that could lead to
contamination.
16
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Contamination
COSHH (Control of Substances Hazardous to Health)

17
Explain the on-site procedures relating to hazardous substances. Are there any substances
that are additional to the usual cement, oils, paints, etc.?
Dangerous occurrences
18
Explain the policy in relation to the reporting of dangerous occurrences. It is thought that
many go unreported as employees regard them as 'an accident where nobody was injured'.
Dermatitis
19
Explain that contact dermatitis can be caused by some relatively common substances such
as diesel and mould release oil, paints, thinners and cement. Gloves should be worn on
appropriate occasions, and barrier creams should be used properly.
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These occasions should have been identified by the Contractors risk assessments.
Discipline
21
Explain the company policy regarding breaches of this Regulatory Document (Regulations),
site or company rules.
Dress code
22
Explain the effects of sun exposure and the importance of preventing skin cancer. Explain
company or site rules on whether shorts or sleeveless vests are permissible on site.
Drugs
Explain the rules about arriving on site or being on site under the influence of any nonprescribed controlled drugs, or taking these during the hours of employment. It may be that
employees will be asked to leave the site.
24
The issue of prescribed drugs should also be covered as some of these can have side
effects such as drowsiness. If the user is authorised to operate plant or drive vehicles, this
needs to be addressed and resolved with the supervisor or management.
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23
What standard is used? What is the safe system of work for persons working on or near
open or leading edges?
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Edge protection
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temporary or permanent repairs by competent persons on site?
(b)
use of 240v equipment?
(c)
use of RCD or similar circuit breakers?
(d)
use of transformers and 110v equipment?
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(a)
Are there any other general rules regarding working with electricity?
27
What are the site or company rules concerning:
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Electricity
Emergency evacuation
28
Explain site or company procedures. What is the siren or alarm? Where are the emergency
evacuation assembly points?
Emergency procedure
29
Explain the procedures to be followed in the event of an emergency other than fire. This may
be civil disturbance, a bomb scare, structural collapse or other eventuality.
Environment
30
Environmental pollution can include the air, as well as the ground or water. Explain any
specific issues of environmental protection and control concerning the company or site. It is
perhaps worth noting that dust, as well as smoke and fumes, can be considered an
environmental pollutant.
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Escape routes
31
Explain the recognised escape routes on site and from buildings in the event of a fire or
emergency.
32
Explain that access and egress routes must be - well-defined and kept clear. How are they
marked? How will they be lit when it is dark? How will changes to the escape routes be
notified as construction progresses?
Excavations
(a)
excavation support
(b)
proper entry and exit from an excavation
(c)
edge protection around an excavation.
Explain the policy regarding:
.l.
l
33
Explain if there are any specific eye protection problems, or rules applicable to the site or
any particular work that is taking place. See also Personal protective equipment.
ta
34
rw
Eye protection
You may wish to comment on the use of safety nets, safety decking, air bags and other
similar systems.
as
35
qa
Fall-arrest
er
Explain the hierarchy of control measures that are to be used on site to prevent persons from
falling or to catch them safely if they do fall. This will obviously vary depending on the type of
site and work undertaken.
ov
36
Fire
In the induction session, you should at least cover the following:

(a)
fire precautions, fire prevention and good housekeeping

who will be responsible for summoning the fire brigade
(b)
et
it
37
se
Fall prevention
(c)
38
location of:
(i)
fire points
(ii)
fire extinguishers
(iii)
hose reels
(d)
training and competence in the use of fire fighting equipment
(e)
testing of the fire alarm
(f)
fire drills and practice evacuations
(g)
evacuation in the event of an on-site emergency
(h)
policy for 'hot works', including permits.
Explain the company or site policy regarding the burning of rubbish or 'bonfires'. On many
sites, this is prohibited due to the danger of fire spreading and the environmental pollution
caused by fires.
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First aid
39
If there is to be an on-site first-aid facility that can be used by all contractors, clearly explain
the arrangements.
(a)
Where is the first-aid kit?
(b)
Who are the first aiders, and how can they be contacted or identified?
(c)
Who are the appointed persons?
(d)
In the event of an accident requiring more than first aid, who will summon the
ambulance or emergency services?
Flammable liquids
If flammable liquids (such as paint thinners, solvents, spirit-based paints and others) are kept
and used on site, explain the rules for:
(b)
withdrawal from storage
(c)
use
(d)
return to storage.
rw
storage
qa
ta
(a)
.l.
l
40
Health and safety committee
se
as
See also Consultation with employees. If there is a site health and safety committee (and
this may also be reflected in earlier comments for CDM or Consultation with employees),
explain the terms of reference for:
the committee and membership
(b)
how often the committee meets
(c)
agenda items
(d)
how the outcomes of meetings are made known to employees on site (publication of
minutes).
ov
er
(a)
41
Are there any mandatory protection zones on site? How are they marked? Explain the
supply and issue of hearing protectors and when they should be worn.
42
et
it
Hearing protection zones
High visibility clothing

43
Explain the site or company rules for this clothing to be worn and clearly define the
appropriate locations. Also clearly define the standard for high visibility clothing.
Hoists
44
For passenger hoists:

(a)
who is the competent person to operate the hoist?
(b)
if any person can operate it, do they need training prior to being authorised as
competent?
(c)
if the controls are regarded as so simple that the hoist may almost be regarded as a
public lift, is there any danger of controls being overridden?
(d)
what is the maximum number of persons permitted in the hoist?
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(e)
45

Page 62
which rules apply regarding goods carried in the hoist?
For goods hoists:

(a)
who is the authorised competent person to drive it?
(b)
can any other persons be authorised?
(c)
what are the rules for closing the gates?
(d)
what is the safe working load?
(e)
explain that passengers cannot be carried.
Ladders/stepladders
Explain the company standards for:
securing or tying ladders/stepladders
(b)
use of ladders/stepladders for light work of short duration or gaining access
(c)
any restrictions imposed on the use of ladders and stepladders
(d)
movement of ladders around the site.
rw
.l.
l
(a)
ta
46
If lasers are to be used on site, explain what class of laser is to be used and what, if any,
hazards could be caused. Levelling lasers (used, for example, by suspended ceiling fixers)
are not normally regarded as hazardous as long as appropriate health and safety rules are
followed.
se
as
47
qa
Lasers
Explain that different projects and clients will have different rules and that employees should
understand the need for each rule and how it will be enforced.
ov
48
er
Site Rules
Explain the following:
(b)
et
it
49
Lifting equipment
(c)
testing and inspection of equipment
(d)
current colour coding, if such a system is used.
who has the authority to use lifting equipment of varying sizes and types
the duties of slingers and signallers
(a)
Lighting
50
Explain the site or company rules for provision of work lighting and emergency lighting.
Include:
(a)
the placing of luminaires
(b)
extra lighting during winter months or for work outside normal hours.
Liquefied petroleum gas

51
Explain the rules for:

(a)
use and storage
(b)
separation of full and empty cylinders
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(c)
separation from oxygen and acetylene, as appropriate
(d)
use of hose check valves and flashback arresters
(e)
use of fire extinguishers.
Manual handling
52
Explain site or company rules regarding:

(a)
the avoidance of manual handling wherever possible
(b)
the use of mechanical devices to aid manual handling
(c)
company policy or procedures regarding dense or heavyweight concrete blocks
(d)
the importance of good manual handling techniques including team lifting.
.l.
l
Medication
Some prescribed medicines, and some medicines which can be purchased from a Pharmacy
without a prescription for problems such as hay fever, can cause drowsiness or other side
effects.
54
Explain that anyone who is concerned that any medicines prescribed may affect their health
and safety performance should discuss the matter with their supervisor.
qa
ta
rw
53
Explain the importance of supervisors discussing with employees the method statement to
be used for particular tasks, and the benefits to be gained from employee input into method
statements.
se
55
as
Method statements
er
Mobile elevating work platforms (MEWPs)
ov
Explain who has the competence to operate or use MEWPs. Give the evidence required to
prove competence and training. Where can MEWPs be used? Where they are not allowed?
Explain the use of safety harnesses when working from platforms.
56
Explain the importance of reporting all incidents that are 'near misses'. These can then be
investigated and the appropriate remedial measures put into place so that the next 'near
miss' does not become an accident.
57
et
it
Near-miss incidents
Needles and syringes

58
Because of the secretive nature of illegal drug use, these items may be hidden away, which
can increase the danger to those finding them. Employees should be warned to be very
vigilant, particularly regarding the discovery of used hypodermic syringes, razor blades
(needles and needlestick injurys).
59
Explain the action to be taken on:
60
(a)
finding discarded needles
(b)
receiving a needlestick injury.
It should be noted that most gloves in common use on site do not offer very much protection
against a needlestick injury.
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Noise
61
See also Hearing protection zones. Explain the site or company rules concerning the use
of equipment that produces excessive noise. Explain the use of hearing protection and noise
control zones.
Occupational health
62
Stress the importance for employees to report to supervisors any cases of ill health, as it
may be potentially work-related. This is particularly important if employees are working
where there may be rats, or if the area has been used for illegal drug taking and the related
paraphernalia may be found. In the case of refurbishment and renovation works, there may
be residual materials from previous occupants likely to cause ill health.
location
(b)
marking
(c)
allowable proximity for vehicles
(d)
working nearby
(e)
precautions.
as
Permits to work
se
Explain company or site procedures regarding issuing, working with and the cancellation of
permits to work. Where 'lock off systems are used, explain the rules regarding padlock keys.
er
64
ta
(a)
rw
Explain the site or company rules on:
qa
63
.l.
l
Overhead electricity cables
Explain the site or company rules regarding:

safety helmets
(b)
protective footwear
(a)
(d)
et
it
65
ov
Personal protective equipment
(e)
respiratory protection
(f)
any other issues.
high visibility clothing

eye protection
(c)
66
Remind the inductees that PPE in general, and respiratory protective equipment (RPE) in
particular, should only be used as a means of last resort when all other control measures
have been investigated and found to be impracticable. The need for PPE (apart from helmet,
boots and high visibility clothing) should be covered in the risk assessment and method
statement.
Plant and equipment
67
Explain the site rules regarding:

(a)
the authority to operate plant and
(b)
equipment, including the requirement for competence cards, where necessary
(c)
any type of plant/equipment that is prohibited, for example mains-powered hand tools
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(d)
the need for noise control where appropriate
(e)
the requirement for permits to work where appropriate.
Powers of Administrative Authority Workplace Inspectors

68
You may want to explain, in general terms, the powers that Inspectors have when they come
on site and the requirement for employees to co-operate with them.
Reporting defects
Explain the importance of reporting all defects in plant and equipment, scaffolding, supports
for excavations, and so on. Early reporting will bring about swift remedial measures and help
to prevent accidents.
70
The possible consequences of not reporting defects may result in an accident or disciplinary
procedures.
.l.
l
69
Explain whether there are any areas on site that are restricted to all people, or a specific
class of people. Include what identifies a restricted area. Typical examples are areas where
demolition, impact cleaning, water jetting, or asbestos removals are taking place.
qa
ta
71
rw
Restricted or prohibited areas
Risk assessments
as
Explain the significant findings of risk assessments, as they will affect staff on site as a
whole, or those working on a particular activity. It may be useful to explain the risk
assessment process and the health and safety benefits that can be gained by employees.
See also Method statements.
ov
Safe systems of work
er
se
72
The crucial need arising out of risk assessments and method statements is for safe systems
of work. Explain that site rules require employees to work in accordance with any safe
systems of work that have been developed by the Contractors.
74
Explain also the benefits of working to a safe system of work and the potential for accidents
and disciplinary action if it is not followed properly.
et
it
73
Safety harnesses
75
Explain the company or site requirements for wearing and using safety harnesses and
lanyards. See also Fall-arrest.
Safety policy
76
Explain any relevant areas of the company's health and safety policy, together with the
organisation and arrangements for the implementation of the policy. If relevant, explain
where a copy of the policy is displayed on site.
Safety signs and notices
77
Remind the audience that all employees must comply with all safety signs and notices at all
times. Explain the whereabouts of any site notice board, and how changes and modifications
to site rules will be made known to the workforce.
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Scaffolding (including mobile scaffolds)
79
Explain the site rules regarding:

(a)
who is allowed to erect, alter or dismantle tube and fitting or system-built scaffolds
(b)
the implications (safety and disciplinary) of unauthorised dismantling or alteration of

scaffolds
(c)
assessing competency to erect proprietary aluminium or tower scaffolds
(d)
the safe use of mobile tower scaffolds
(e)
safe access/egress to and from scaffolds.
Explain any other company or site-specific rules about the use of scaffolding as either a
working place, or as access to the working place.
78
rw
Explain whether any specific rules apply to pedestrian and traffic movement. This will
depend on the size and complexity of the site. You may also include where contractors may
lay down materials and which areas they may use for the prefabrication of components.
ta
80
.l.
l
Site layout
Security is very much allied to health and safety in that a breach of security can lead to
trespassers on site and possible exposure to a risk of injury. Open a discussion if you have
any particular company or on-site rules concerning security. Also consider the issue of health
and safety awareness of site security staff, whether they are employees or a subcontracted
security company.
se
as
81
qa
Site security
er
Skin protection
It may be appropriate to discuss the need for skin protection, both in terms of gloves and
barrier creams. If barrier creams are used, where are they dispensed? Also explain that the
types of gloves used must be the most suitable for the levels of protection needed.
83
If it is likely to be a significant hazard, you should also include details of the risk of skin
cancer associated with excess exposure to the sun.
et
it
ov
82
84
Smoking
Explain the policy on smoking in the workplace and the canteen, clearly identifying those
areas where smoking is not allowed. Include details of the measures taken to protect nonsmokers from the discomfort caused by tobacco smoke.
Tidiness (housekeeping)
85
Explain the importance of maintaining a tidy site in order to eliminate many of the slip, trip
and fall hazards. Include:
(a)
rubbish skips
(b)
separation of waste
(c)
who is responsible for organising the delivery of and removal of skips
(d)
good housekeeping
(e)
sweeping up - general tidiness.
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Toilets
86
See also Welfare facilities. Explain the site or company rules regarding cleanliness, abuse
of facilities and graffiti, and how such behaviour will be dealt with. Include the reporting of
defects.
Traffic routes
87
These are dependent on the size and complexity of the site.
88
Explain:
one-way systems
(b)
the need to minimise or avoid reversing
(c)
signallers (formerly banksmen)
(d)
segregation of pedestrians from vehicles and machines - pedestrian walkways.
.l.
l
(a)
What training will be given to persons on site? Explain the need for all contractors to ensure
that persons working for them on site have been trained and are competent to carry out the
work they are required to do.
qa
ta
89
rw
Training
Due to the nature of the project or the ground, some sites will have specific issues to deal
with and there may be the potential for a particular type of injury. Take the opportunity to
explain this in order to prevent injuries occurring. For instance, working at height raises
specific issues and working at height over or alongside water may introduce additional
hazards.
Explain the site rules for the presence and operation of vehicles on site. Include:
the parking of private vehicles
(c)
et
it
(a)
91
ov
Vehicles
er
se
90
as
Types of injury
(d)
keeping clear of site (working) vehicles
(e)
who is allowed to operate plant on site
(f)
providing proof of competence to operate plant
(g)
the security of vehicle keys when not in use
(h)
security measures to make vehicles unavailable to trespassers and children during

non-working hours
(i)
traffic routes and speed limits
(j)
the need for signallers and slingers.
delivery vehicles, for example,

constraints on the access to off-loading bays
(b)
Vibration
92
Many people are still unaware of the problems that can be caused by high-speed rotary and
percussive equipment. Explain the potential severity of vibration white finger and the
company or site policy regarding:
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Page 68
(a)
the use of vibrating equipment
(b)
the limitations of personal protective equipment
(c)
design and selection of tools and equipment
(d)
rest breaks and the rotation of work
(e)
the symptoms of vibration white finger
(f)
the need for employees to seek medical advice if they have any symptoms.
Waste disposal
Describe the location of skips and other waste containers. Explain the segregation of waste.
Who is responsible for the removal of waste from the workplace? Explain the company or
site policy if contractors do not clear away their own waste.
93
rw
Explain that this is a financial issue as well as an environmental matter. It is also closely
linked with site tidiness, pollution control, housekeeping and accident prevention. Effective
waste minimisation is also an issue within sustainable construction and there are company
and national benefits to be gained. There is more likelihood of a project being completed on
time and to budget if waste is minimised.
qa
ta
94
.l.
l
Waste minimisation
Welfare facilities
as
Explain:
the location of the welfare facilities
(b)
if appropriate, the opening hours of site canteens
(c)
responsibilities for the cleaning and maintenance of the facilities
(d)
the provision of barrier creams and rehydrating lotions
(e)
the need for good personal hygiene
(f)
the company policy regarding damage and graffiti
(g)
the location of facilities for men
er
ov
the arrangements (if any) made for smokers.
(h)
se
(a)
et
it
95
Working at height
96
This is allied to fall prevention, safe systems of work and PPE. Explain the company or site
rules for:
(a)
working at height, including safe systems of work
(b)
competence of employees
(c)
protection of those below, including the public

(i)
the prevention of materials falling - use of containment and debris nets.
Working near, on or over water

97
Explain the site or company rules for working near, on or over water, including:
(a)
the wearing of life jackets or life preservers or flotation devices
(b)
prevention of falls into water
(c)
safety harnesses
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(d)
the rescue of anyone who has fallen into water
(e)
safety lines and safety boats
(f)
lookouts
(g)
alarms.
Conclusion
It is extremely important that records are kept showing which workers have attended site
induction, together with details of the training they have received and the date it was carried
out.
99
Appendix 1 of this module is an example of an attendance list that can be copied and used
for record purposes on induction training. It may also be copied into a computer and
electronic records maintained.
100
Appendix 2 is a checklist that can be:
'ticked' as appropriate and attached to the induction attendance list as a record of

which topics were covered
(b)
used by the trainer to ensure that the important basic facts are included in an induction
training talk.
qa
ta
rw
(a)
et
it
ov
er
se
as
Operatives may also find the checklist helpful in identifying gaps in their knowledge.
101
.l.
l
98
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1.1.5 Appendix 1
Health and Safety Induction Training
Title:
Date
Location
Start time
Duration (minutes)
End time
Presenter's name
Presenter's signature
Name of inductee's Contractors
Inductee's signature
et
it
ov
er
se
as
qa
ta
rw
.l.
l
Inductee's name
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1.1.5 Appendix 2
Induction training checklist
CDM
Competence
Confidential issues
Confined spaces
Consultation with
employees
Edge protection
Electricity
Emergency
evacuation
Emergency
procedure
Environment
Escape routes
Excavations
COSHH
et
it
Contamination
Competence
Risk assessments
Safe Systems of
Work
Safety harnesses
Safety policy
Safety signs and

notices
Scaffolding (incl.
mobile scaffolds)
Eye protection
Fall-arrest
Site layout
Site security
Skin protection
Smoking
Tidiness
(housekeeping)
Toilets
Health and safety

committee
Flammable liquids
.l.
l
Drying rooms
First aid
Hearing protection
zones
rw
Buried services
Drugs
Fire
High visibility
clothing
ta
Boundaries
Dress code
Fall prevention
Hoists
qa
Assembly points
Discipline
as
Asbestos
Dermatitis
se
Working near, on or
over water
Dangerous
occurrences
er
Accident reporting
ov
Access
Ladders/
stepladders
Lasers
Legal issues
Lifting equipment
Lighting
Liquefied petroleum
gas
Manual handling
Traffic routes
Training
Types of injury
Vehicles
Vibration
Waste disposal
Medication
Method statements
Mobile elevating
work platforms
Near-miss incidents
Needles and
syringes
Noise
Occupational health
Overhead electricity
cables
Permits to work
Personal protective
equipment
Plant and equipment
Powers of
Inspectors
Registration
schemes
Reporting defects
Restricted or
prohibited areas
Waste minimisation
Waste minimisation
Working at height
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1.1.6
General Health and Safety

Contractors are required to access the risks to workers in their undertakings, and to any
other person whose health and/or safety may be adversely affected by a Contractors work
activities. The phrase 'any other person' clearly encompasses contractors, members of the
public, site visitors, employees of other contractors etc.
Contractors are required to implements any protective or preventive measure to control a

risk or risks, they must do so in line with the following general principles:
These include:
Avoiding risks where possible.
(b)
Evaluating the risks that cannot be avoided.
(c)
Combating risks at source.
(d)
Adapting the work of an individual with a view to alleviating monotonous work and
reducing its effects on health.
(e)
Adapting to technical progress.
(f)
Replacing the dangerous with the safe or less dangerous.
(g)
Developing a coherent policy which influences the factors relating to the working
environment.
(h)
Giving collective measures priority over measures that protect the individual.
(i)
Giving appropriate instructions to employees.
er
se
as
qa
ta
rw
.l.
l
(a)
Contractors have a requirement to make effective arrangements, as are appropriate for the
nature of the work activities carried out and the size of the company, for the management of
all aspects of health and safety. Contractors must record the arrangements made for the
effective planning, organisation, control, monitoring and review of the preventative and
protective measures implemented.
Contractors are required to ensure that employees are provided with health surveillance
where the findings of a risk assessment identify risks to the health and safety of employees
that can be eliminated or reduced by applying health surveillance techniques.
Health surveillance should be introduced where the risk assessment indicates that:
et
it
ov
(a)
there is an identifiable disease or adverse health condition related to the work

concerned
(b)
there are valid detection techniques
(c)
there is a reasonable likelihood that the disease or condition may occur under the
particular conditions of work
(d)
health surveillance has the potential to increase the protection of the health of the
employees concerned.
Health surveillance techniques can be as simple as:

(a)
hand-checks for the early signs of dermatitis being carried out by a site manager or
supervisor, who has received the appropriate training, or
(b)
employees being asked to complete a short questionnaire on occupational health
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issues.
Alternatively, health surveillance can necessitate the engagement of medically trained

persons and specialist equipment, for example, audiometry (hearing) checks.
Contractors are required to appoint one or more 'competent persons' to assist them in
interpreting and complying with Qatar health and safety legislation, where the Contractors
does not have the necessary training, experience or knowledge to carry out this duty
themselves. If more than one competent person' is appointed, the Contractors must ensure
that there is adequate co-operation between them.
10
Where the Contractors him/herself is not competent in matters of construction health and
safety, the requirements of this Regulatory Document are normally satisfied by the
employment of a suitably qualified and experienced health and safety adviser or the
engagement of an appropriately experienced consultant.
11
The Contractors must ensure that any competent person who is not an employee, for
example, a consultant, is adequately informed of all relevant facts in relation to site health
and safety.
12
Given that in-house safety advisers or external consultants will usually only visit sites at a
frequency that is deemed to be appropriate, the responsibility for the day-to-day
management/monitoring of health and safety is often delegated to the site manager. In these
circumstances, this regulation places a duty on the Contractors to ensure that the site
manager is adequately trained and competent to discharge this duty.
13
A competent person is someone who has sufficient training and experience, or knowledge
and other qualities, to enable them to properly assist the Contractors in complying with
relevant health and safety legislation.
14
Competence may be indicated by membership of a recognised Institution of Occupational

Safety and Health and/or possession of a qualification in Occupational Safety and Health
from an appropriate accrediting body.
15
Contractors are required to implement procedures to be developed for any particular serious
and - imminent dangers that may arise. This will very much depend on both the activities of
the Contractors and the location. Fire is a real risk for everyone almost everywhere, but
bomb threats in rural locations may not be.
16
Other serious and imminent dangers may relate to LPG, HFL, collapse of scaffold,
excavations, confined spaces or virtually anything else. Again, Contractors should know their
industry.
17
Once such procedures have been developed, the workforce must receive the appropriate
information, instruction and training.
18
Contractors are required to establish contact with external agencies as necessary,

particularly with regard to first aid, emergency medical care and rescue work.
19
Contractors must provide their employees with comprehensible (understandable) and

relevant information on:
et
it
ov
er
se
as
qa
ta
rw
.l.
l
20
(a)
the risk to their health as identified by any part of the Contractors risk assessments
(b)
any preventive or protective measures taken to eliminate or reduce the risks identified
(c)
any risks notified to the Contractors that arise out of the work activities of another
Contractors.
Where there is more than one Contractor in the workplace, they must co-operate with each
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other with regard to health and safety, to enable both (or all if there are more than two)
Contractors to fulfil their legal duties.
This may require planning exchanges of information on hazards and risks, or deciding who
works where and when and, on larger sites, a health and safety co-ordinator may be needed.
The client, the Contractor or a nominated contractor may have, or have been given, by
contract or arrangement, the co-ordination role.
22
Contractors are required to ensure that when allocating a task to any employee, the
Contractor takes into account the employee's capabilities (knowledge, training, experience
etc.) with regards to health and safety.
23
The Contractors also has a duty to ensure that employees are provided with adequate health
and safety training:
upon being exposed to new or increased risk.
rw
This training must be:
.l.
l
(b)
repeated periodically where appropriate
(b)
reviewed and adapted to take account of any new or changed risks
(c)
during working hours.
qa
ta
(a)
Employees are required to:
use all tools, equipment, dangerous substances, safety devices etc, in accordance
with any training received.
(b)
report to the Contractors (or Contractors health and safety 'competent person') any
work situation which the employee feels is not safe.
as
(a)
se
25
on recruitment
er
24
(a)
21
Contractors (and in some cases self-employed persons) with regard to the employment of
workers who are employed under a temporary contract or supplied by a Labour agency.
27
Before starting work, such workers must be supplied with comprehensible (understandable)
information on:
(a)
any special occupational qualifications or skills required to enable the temporary

worker to work safely
the requirement for any health surveillance arising out of the work to be carried out.
(b)
et
it
ov
26
28
The above bullet points have obvious implications where temporary workers, whose first
language is not English, are to be employed. See notes below.
29
Contractors are required to inform any Labour agency who are to supply temporary workers
of:
(a)
any special occupational qualifications or skills that must be held by the temporary
worker(s) to enable them to work safely
(b)
any features of the work to be carried out by the temporary workers insofar as those
features are likely to affect their health and safety.
30
Contractors should respond after notification that the employee is pregnant. Exposure limits,
working conditions and working hours for such workers must be taken into consideration.
31
Contractors are required to specifically assess and review the risks to the health and safety
of young persons who are on site. Due account must be taken of their lack of maturity or
experience and their lack of knowledge of potential risks.
QCS 2014
it is necessary for their training
(b)
they are under the supervision of a competent person
(c)
the risks are reduced to the lowest level that is reasonably practicable
No Contractors may employ a young person for work which:

(a)
is beyond their physical or psychological capacity
(b)
involves exposure to agents which are toxic, carcinogenic or otherwise have serious
specific health implications
(c)
involves harmful exposure to radiation
(d)
involves the risks of accidents because of their lack of experience and/or training
(e)
involves a risk to health from extreme cold or heat, noise or vibration.
A 'young person' is anyone over the minimum school leaving age but under 18 years of age.
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(a)
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Unless:
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1.1.6.2 Construction workers for whom Arabic is not their first language
Contractors shall, in entrusting tasks to his employees, take into account their capabilities as
regards health and safety.
Steps must be taken to ensure that effective two-way communication is established so that
they can work safely and without risk to their health or to the health and safety of any other
person who might be affected by their action or omissions.
Ultimately, if a contractor decides to engage workers who cannot speak and/or understand
Arabic the situation will have to be managed. This could be achieved by the employment of a
bilingual supervisor who, in the appropriate language, can give information, instructions,
training and supervision. If a contractor is responsible for engaging workers who cannot
speak English then the Contractor should ensure that the contractor provides suitable
translators. Equally, the same criteria will need to be implemented on other smaller sites.
Contractors are required to ensure that employees are trained and competent for the job
they have to do. Not being able to communicate using the language of the country of
residence does not mean that workers are not competent in their trade. Provided they are
here legally, it would be extremely unwise to ban workers who can prove their competence,
just because they cannot speak the language effectively or fluently. Provisions for such
situations can and should be made.
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1.1.6.3 Manual Handling Operations

1
These require that simple, common sense measures be taken to prevent injuries to workers
resulting from carrying or otherwise moving loads manually.
Definitions of the terms injury, load and manual handling, all of which are as would be
expected.
An injury is any injury, not just to the back, and would include cuts from sharp edges or
broken toes caused by dropped objects.
A load is virtually anything, including a person, an animal, a bag of cement, heavyweight

building blocks - in fact, any moveable object. The only proviso is that a tool is not a 'load'
while it is being used. A Labourer carrying a chainsaw to a carpenter would be carrying a
load.
Manual handling means transporting, supporting, lifting, putting down, pushing, pulling,
carrying or moving anything by hand or bodily force.
Contractors are required to avoid manual handling operations which involve a risk of
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employees being injured, as far as is reasonably practicable and, where manual handling
cannot be avoided, to carry out risk assessments and introduce alternatives to manual
handling, control measures and appropriate training.
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Employees are required to make full and proper use of all equipment or systems provided by
the Contractors.
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1.1.6.4 Provision and Use of Work Equipment

1
Every Contractor must ensure that all work equipment is constructed or adapted to be
suitable for the purpose for which it is intended.
Definition of work equipment: Any tool or piece of equipment for use at work.
There is a non-exhaustive list of work equipment, and construction-related examples

including:
dumper truck
(b)
ladder
(c)
air compressor
(d)
crane
(e)
tractor
(f)
hoist
(g)
mobile work platform
(h)
hammer
(i)
lifting sling
(j)
podger
(k)
drill bit
(l)
socket set
(m)
scaffolding.
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(a)
Use is defined as any activity involving work equipment.
All vehicles used on site are covered by these Regulations.
Contractors are required to ensure that work equipment is suitable for the purpose, and only
used under conditions for which it is suitable.
Contractors are required to ensure that work equipment is properly and adequately
maintained.
Contractors are required to ensure that specific risks are identified, information and
instructions to employees and the training of employees take place.
Contractors must ensure that all work equipment, whether European Conformity (CE)
marked or not, complies with all current British or International standards.
10
The basic principle is that every dangerous part of any machine or piece of equipment must
be effectively and properly guarded at all times, but provisos do exist for certain
circumstances, such as the use of push sticks on woodworking machines.
11
Controls should be efficient, effective, easy to use, clearly marked and easily accessible. The
main requirement is to provide safe equipment for the employee, with controls that allow it to
be used in a safe manner. It goes without saying that emergency stop controls feature quite
significantly.
12
Contractors are required to ensure that lighting must be suitable and sufficient, taking
account of the work operation in progress.
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13
Contractors may also have to consider the need for both access lighting and task lighting.
14
Contractors are required to ensure that all markings must be clear and appropriate, and
'warnings' which may be audible or visible and they must be unambiguous, easily perceived
and easily understood.
1.1.6.5 Personal Protective Equipment

The main consideration when dealing with personal protective equipment is that it should
always be the last form of protection, or control, considered for the protection of the
employees' health and safety.
No distinction is made between equipment and clothing. Personal protective equipment

(PPE) includes all types of respiratory protective equipment (RPE).
Contractors are required to ensure that personal protective equipment is suitable and
provided, where a risk cannot be adequately controlled in some other manner.
Contractors are required to ensure compatibility if more than one item of personal protective
equipment needs to be worn at any time, so that one item does not detract from the
protection offered by another.
This is of particular importance to the building and construction industry as, on many
occasions, a combination of safety helmet, eye protection, ear protection or respiratory
protection needs to be worn.
Contractors are required to ensure assessments to be made of the suitability of the

equipment with regard to the nature of the risk.
The requirements of the assessment are specified and, in general, require the problem to be
thought through in a structured manner and - the right equipment chosen for the right
reasons.
A key factor is the competence of the person carrying out the assessments. If they do not get
it right, the consequences for the health and safety of employees could be very serious.
Assessments must be reviewed when they become out of date or there are any significant
changes.
10
Contractors are required to ensure that personal protective equipment provided shall be
properly maintained, cleaned or replaced as appropriate; that adequate and suitable storage
or accommodation is provided for it; and that employees receive all necessary information,
instruction and training.
11
Training must be comprehensible and the question of language use must be considered.
12
Employees are required to use personal protective equipment in accordance with any
instructions or training given, and to report any loss or defects.
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1.1.7
Risk Assessments and Method Statements
1.1.7.1 Interpretation
contractor means any organization or person who carries out or manages construction
work or a place of work and includes any employer or self-employed in relation to a
business
business means a trade, business or other undertaking including construction work

(whether for profit or not)
Construction work means the carrying out of any building, civil engineering or engineering
construction work and includes:
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the construction, alteration, conversion, fitting out, commissioning, renovation, repair,

upkeep, redecoration or other maintenance, de-commissioning, demolition or
dismantling of a structure;
(b)
the preparation for an intended structure, including site clearance, exploration,

investigation and excavation, and the clearance or preparation of the site or structure
for use or occupation at its conclusion;
(c)
the assembly on site of prefabricated elements to form a structure or the disassembly

on site of prefabricated elements which, immediately before such disassembly,
formed a structure;
(d)
the removal of a structure or of any product or waste resulting from demolition or

dismantling of a structure or from disassembly of prefabricated elements which
immediately before such disassembly formed such a structure; and
(e)
the installation, commissioning, maintenance, repair or removal of mechanical,

electrical, gas, compressed air, hydraulic, telecommunications, computer or similar
services which are normally fixed within or to a structure
(f)
Any associated temporary works associated with construction works and a work
activity
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(a)
Work activity means any activity part of construction work and includes temporary works
Young person means any person who has not attained the age of eighteen. A young
person under 16 years of age cannot be employed at all in a Qatar workplace, as per Qatar
Labour Law 14, Article 86.
These duties are held by the contractor who carries out the work, irrespective of whether he
is an employer or is self-employed.
These duties are also held by those who do not do construction work themselves, but control
the way in which the work is done or manages construction work or owns and manages a
place of work.
Suitable and sufficient means the risk assessment should identify the risks arising from or in
connection with the work and the level of detail should be proportionate to the risk. The level
of risk arising from the work activity should determine the degree of sophistication of the risk
assessment.
A method of work shall mean a method statement describing the logical sequence of how a
work activity is to be carried out safely and without risk to health
1.1.7.2 Risk assessment
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Every contractor shall make a suitable and sufficient risk assessment:

(a)
To the health and safety of his employees to which they are exposed whilst they are
at work; and
(b)
To the health and safety of persons not in his employment arising out of or in
connection with his undertaking
Any assessment referred to in paragraph (1) shall be reviewed if:

(a)
There is reason to suspect that it is no longer valid; or
(b)
There has been a significant change in the matters to which it relates.
A contractor shall not employ a young person unless he has undertaken or reviewed his risk
assessment in accordance with paragraphs (1) and (4) below in relation to risks to the health
and safety of young persons.
In making or reviewing the assessment, a contractor who employs or is to employ a young

person shall take account of:
The lack of awareness of risks in relation to the work to be undertaken and or the risks
impacting on the role of young persons
(c)
The extent of the health and safety training provided or to be provided to young
persons
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(b)
Any risk assessment referred to in paragraph (1) shall take into account
language difficulties and language barriers of employees
(b)
safety culture and other behavioural safety issues of employees
(c)
The development and implementation of effective techniques as essential mitigations

to (a) and (b) above.
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The contractor shall record:
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(a)
The significant findings of the risk assessment; and
(b)
Any group of his employees and others identified by it as being especially at risk.
(d)
the controls to be put in place to control risks
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(a)
The contractor is required to ensure that employees are provided with health surveillance
where the findings of a risk assessment identify risks to the health and safety of employees
that can be eliminated or reduced by applying health surveillance techniques.
The inexperience and immaturity of young persons;
(a)
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1.1.7.3 Method of work

1
Risk assessment shall be supported by effective and suitable written method of work
describing the logical sequence of how a work activity is to be carried out in a manner which
is safe and without risk to health.
Any written method of work referred to in paragraph (8) shall be developed by a competent
person who has knowledge and experience of the work activity being assessed and its
development shall involve consultation with those undertaking the work activity.
Any risk assessment and method of work referred to in paragraph (1) and (8) respectively
shall be developed before undertaking of any work activity and shall be communicated to
and acknowledged by those who will undertake the work activity.
Any risk assessment and method of work referred to in paragraph (1) and (8) respectively
shall identify the requirements for the contractor to provide for his employees:
(a)
information about how to undertake the work safety and without risk to their health
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(b)
implementation of instructions for undertaking the work safety and without risk to their
health
(c)
identify and conduct necessary training to employees so that they have the
understanding and skills to undertake the work activity without risk to their health and
safety
(d)
implementation of supervision of the work
Note
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Guidance on Risk assessment and written method of work can be found in Section 2.4
(Section 11, Part 2 of QCS).
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1.1.8

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Construction (Design and Management)
1.1.8.1 Key points

1
The overall concept of Construction (Design and Management) (CDM) regulations is to focus
on planning, design and management to improve health and safety standards on Qatar
construction industry without creating unnecessary paperwork and bureaucracy.
The key aim of the CDM Regulations is to integrate health and safety into the management
of construction projects and to encourage everyone involved to work together to:
(a)
improve the planning, design and management of projects from the very start
involving subject matter experts to ensure that risks associated with all aspects of
business, particularly in terms of hazardous activities are properly assessed;
(b)
identify hazards early on, so they can be eliminated or reduced at the design or
planning stage and the remaining risks can be properly managed;
(c)
target effort where it can do the most good in terms of health and safety; and
(d)
discourage unnecessary bureaucracy.
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These Regulations are intended to focus attention on planning and management

throughout construction projects, from design concept onwards. The aim is for health
and safety considerations to be treated as an essential, but normal part of a projects
development not an afterthought or addition.
The effort devoted to planning and managing health and safety should be in proportion to the
risks and complexity associated with the project. When deciding what you need to do to
comply with these Regulations, your focus should always be on action necessary to reduce
and manage risks. Any paperwork produced should help with communication and risk
management. Paperwork which adds little to the management of risk is a waste of effort, and
can be a dangerous distraction from the real business of risk reduction and management.
Time and thought invested at the start of the project will pay dividends not only in
improved health and safety, but also in:
reductions in the overall cost of ownership, because the structure is designed for
safe and easy maintenance and cleaning work, and because key information is
available in the health and safety file;
(a)
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(b)
reduced delays;
(c)
more reliable costings and completion dates;
(d)
improved communication and co-operation between key parties; and
(e)
improved quality of the finished product.
1.1.8.3 Definitions / Interpretations

1
Client: A client means a person or an organisation or a company who seeks or accepts the
services of another person, organisation or company to carry out a project for him. The
Client can carry out the project himself.
Designer: Any person or organisation or company who in the course of a project or business
prepares or modifies a design; or arranges for or instructs any person under his control to do
so.
Design: Includes drawing, design details, specification, bills of quantities and calculations
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prepared for the purpose of designing all aspects of a structure or any products or electrical
or mechanical systems intended for a particular structure.
Construction work: Any building, civil engineering or engineering construction work. It
includes any of the following:
any construction, alteration, conversion, fitting out, commissioning, renovation, repair,
upkeep, redecoration or other maintenance, cleaning (using water, abrasives at high
pressure, or the use of corrosive or toxic substances), decommissioning, demolition or
dismantling of a structure
(b)
preparatory works including site clearance, exploration and investigation (but not site
survey) and clearance or preparation of the site or structure for use or occupation
(c)
assembly of prefabricated structures or their disassembly
(d)
demolition or dismantling of any structure and the removal of materials and waste.
(e)
fabrication of elements which will form parts of offshore installations
(f)
the construction of fixed offshore oil and gas installations at the place where they will
be used
(g)
the installation, commissioning, maintenance, repair or removal of mechanical,

electrical, gas, compressed air, hydraulic, telecommunications, computer or similar
services which are normally fixed within or to a structure.
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The activities listed below have been defined as not being construction work. However,
given the complexities of many modern projects, thought may have to be given to how health
and safety is managed in connection with these activities where they form a part of the
project to which CDM otherwise applies:
putting up and taking down tents
(b)
normal maintenance of items of plant unless it is structural work, for example,

maintaining a large silo, chemical or nuclear reactor
(c)
tree planting and general horticultural work
(d)
work with removable lightweight
(e)
partitions, such as those used to divide open-plan offices or to create exhibition stands
and displays
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(a)
(f)
erection of scaffolds for support or access in non-construction work

surveying - this includes taking levels, making measurements and examining a
structure for faults
(g)
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(h)
work to or on vessels such as ships and mobile offshore installations
(i)
off-site manufacture of items for later use in construction work (for example, roof
trusses, pre-cast concrete panels, bathroom pods and similar prefabricated elements
and components)
Engineer: Refer to QCS Section 1 (General) Part 1 (Introduction) 1.4 (Terms and
Definitions).
Contractor: Refer to QCS Section 1 (General) Part 1 (Introduction) 1.4 (Terms and
Definitions).
Sub-Contractor: means any person or organisation selected by the contractor for execution
or management of construction works. A sub-contractor works under the control of the
Contractor on site.
The construction phase starts when actual construction work on the project commences,
and normally ends on the transfer or handing over of the structure to the client. If there is
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more than one structure (or building), the construction phase does not end until the work on
the last structure is complete.
10
Construction Phase (Health & Safety) Plan: The Contractor must develop a plan suitable
for managing health and safety in the construction phase of the project, which includes
developing information provided by the client, designer and Engineer. This must be
completed, submitted and approved as suitable and sufficient by the client before
construction work on site can proceed.
who is responsible for what
the hazards and risks which have been identified
how the works are controlled
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who does what
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The Construction Phase (Health & Safety)) plan is the foundation for good management and
clarifies:
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The plan should be regarded as a live document, reviewed at regular intervals and, where
necessary, amended to reflect changes in the scope of work or programme changes where
the planned interface of trades may alter.
Construction site: includes any place where construction work is being carried out or to
which the workers have access, but does not include a workplace within it which is set aside
for purposes other than construction work.
12
Principles of Prevention: means the hierarchy of hazard and risk control specified in
section 1.1.8.6 and which applied to every duty holder and everyone on a construction
project.
13
Project: means an undertaking (whether for profit or not) which includes or is intended to
include construction work and includes all planning, design, management or other work
involved in a project until the end of the construction phase.
14
Structure: This is defined as:

any building, any masonry, timber, metal or reinforced concrete structure, railway line
or siding, dock, harbour, inland navigation, tunnel, shaft, bridge, viaduct, waterworks,
reservoir, pipe or pipe-line, cable, aqueduct, sewer, sewage works, gasholder, road,
airfield, sea defence works, drainage works, earthworks, lagoon, dam, wall, caisson,
mast, tower, pylon, underground tank, earth retaining structure or structure designed
to preserve or alter any natural feature, fixed plant and any structure similar to the
foregoing;
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(b)
any formwork, falsework, scaffold or other structure that provides temporary support or
access
1.1.8.4 Co-operation
1
These Regulations require that every duty holder involved in a project:

(a)
seeks the co-operation of any other person involved in any project, whether on the
same or an adjoining site co-operates with all other persons involved in any project,
whether on the same or an adjoining site
So far as it is necessary for all persons involved in the project(s) to comply with their duties
or functions under these Regulations.
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Every person involved in a project, who is working under the control of another person, must
shall inform that person of anything believed to endanger the health or safety of himself or
others.
Common examples of co-operation are:

(a)
one contractor allowing the workforce of another company to use their scaffold to
enable work at height to be carried out safely.
(b)
site management on one site allowing oversailing by a tower crane on an adjacent

site.
(c)
Designers of a project providing residual hazard and safety information to another

designer on an interfacing project.
(a)
carrying out construction work; and
(b)
otherwise affected by the construction work
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These Regulations require that every duty holder involved in a project co-ordinates their
activities with the activities with one another in a manner which ensure so far as is
reasonably practicable the health and safety of persons who are:
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1.1.8.5 Co-ordination
There are many examples of where the various contractors involved in a project can coordinate their work activities, agreeing who works where and when so that construction work
runs smoothly and without the risks created by one set of workers endangering the health
and safety of other workers.
All construction projects require co-operation and co-ordination between all members of
the project team. For low risk projects, a low-key approach will be sufficient. In higher
risk projects, for example those involving demolition, a more rigorous approach to coordination, co-operation and planning will be needed. Under the Regulations, any action
taken should be in proportion to the risk which the work creates. The architect, lead
designer or contractor who is carrying out the bulk of the design work should normally
co-ordinate the health and safety aspects of the design work; the main Contractor
should co-ordinate construction work.
It is vital that those doing the work understand the risks involved and what to do about
them. If the risks are low and the precautions well understood by those carrying out the
work, then there will be no need for a written health and safety plan. Where the risks are
higher, a written comprehensive construction phase health and safety plan will be
required. for example where the work involves:
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(a)
structural alterations;
(b)
deep excavations, and those in unstable or contaminated ground;
(c)
unusual working methods or safeguards;
(d)
ionizing radiation or other significant health hazards;
(e)
nearby high voltage power lines;
(f)
a risk of falling into water which is, or may become, fast flowing;
(g)
diving;
(h)
explosives;
(i)
heavy or complex lifting operations;
(j)
demolition works.
A comprehensive construction phase health and safety plan will be required.
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1.1.8.6 Taking account of the general principles of prevention

1
These Regulations require that:

(a) Every person involved on a construction project, in relation to its design, planning
and preparation shall take account of the general principles of prevention in the
performance of those duties during at all the stages of the project.
(b) Every person involved on a construction project, in relation to the construction phase
of a project shall ensure so far as is reasonably practicable that the general
principles of prevention are applied in the carrying out of the construction work
When considering what precautions are necessary to control risks associated with a
project, everyone who has a duty under these Regulations must take account of the
general principles of prevention specified below:
avoiding risks;
(b)
evaluating the risks which cannot be avoided;
(c)
combating the risks at source;
(d)
adapting the work to the individual, especially as regards the design of

workplaces, the choice of work equipment and the choice of working and
production methods, with a view, in particular, to alleviating monotonous work and
work at a predetermined work-rate and to reducing their effect on health;
(e)
adapting to technical progress;
(f)
replacing the dangerous by the non-dangerous or the less dangerous;
(g)
developing a coherent overall prevention policy which covers technology,

organisation of work, working conditions, social relationships and the influence of
factors relating to the working environment;
(h)
giving collective protective measures priority over individual protective measures;

and giving appropriate instructions to employees.
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1.1.8.7 Summary of the duties under these Regulations
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A summary of the duties and how they are applied with respect to each duty holder is given
in the following table and chart:
All construction projects
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(a) Check competence and resources of all appointees

(b) Ensure there are suitable management arrangements for the project, including
welfare facilities
(c) Allow sufficient time and resources for all stages
Clients
(d) Provide pre-construction information to designers and contractors

(e) Appoint an Engineer
(f) Appoint Contractor
(g) Make sure that the construction phase does not start unless there are suitable:
welfare facilities, and
construction phase plan in place
(i) Retain and provide access to the health and safety file
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(h) Provide information relating to the health and safety file to the Engineer
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(j) (*There must be an Engineer and Contractor until the end of the construction phase)
(a) Advise and assist the client with their duties
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(c) Facilitate good communication between client, designers and contractors
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(d) Liaise with Contractor about ongoing design

(e) Identify, collect and pass on pre-construction information
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(b) Co-ordinate health and safety aspects of design work and co-operate with others
involved with the project
(f) Ensure that expert knowledge/advice is available in relation to highly hazardous

activities (e.g. explosives, cofferdams, caissons etc.)
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(g) Prepare and update health and safety file
(b) Eliminate hazards and reduce risks during design
Designers
(a) Check that client is aware of their duties
(c) Provide information about remaining risks

(d) Check client is aware of duties and Engineer has been appointed
(e) Provide any information needed for the health and safety file
All construction work
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(a) Plan, manage and monitor construction phase in liaison with sub-contractors
(b) Prepare, develop and implement a written plan and site rules. (Initial plan must be
completed before the construction phase begins. Plan is termed Construction Phase
Health and Safety Plan.
Contractor
(c) Give sub-contractors relevant parts of the plan

(d) Make sure suitable welfare facilities are provided from the start and maintained
throughout the construction phase
(e) Check competence of all their appointees
(f) Ensure all workers have site inductions and any further information and training
needed for the work
(g) Ensure that expert knowledge/advice is available in relation to highly hazardous

activities (e.g. explosives, cofferdams, caissons etc.)
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(h) Consult with the workers
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(j) Secure the site
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(b) Provide Contractor with details of any sub-contractors) engaged

(c) Provide any information needed for the health and safety file
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(d) Inform Contractor of problems with the Construction Phase Health and Safety Plan
(e) Inform Contractor of reportable accidents, diseases and dangerous occurrences
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(f) Plan, manage and monitor own work and that of workers
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(g) Check competence of all their appointees and workers
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(h) Train own employees and provide information to their workers
Sub-Contractors
(a) Co-operate with Contractor in planning and managing work, including reasonable
directions and site rules
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1.1.8.8 Duty holders under CDM

1
The following groups have specific duties under these Regulations:

(a)
Clients
(b)
Designers
(c)
Engineers
(d)
Contractors
(e)
Sub-Contractors
1.1.8.9 Clients Duties

Under these Regulations there is a greater focus on the client's responsibilities. The term
'client' excludes 'domestic' clients; people must be having construction work carried out as a
part of their business activities (whether for profit or not) to be classified as a client under
these Regulations. Clients must ensure that arrangements are made for managing the
projects and providing relevant information.
In relation to the arrangements for managing the project, the client must take reasonable
steps to ensure that:
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so far as is reasonably practicable, the project will be managed in such a way

(including the allocation of sufficient time and other resources) that the construction
work can be carried out without avoidable risks to health or safety of any person
(b)
there are suitable welfare facilities for the people engaged in the construction work
(appendix 1)
(c)
any structure which is to be built complies with the requirements of the latest revision
for QCS
(d)
these standards are maintained and reviewed throughout the project.
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(a)
In relation to the provision of information, the client's duties are to ensure that all
designers and contractors are promptly provided with relevant pre-construction information.
The pre-construction information must include all relevant information which is in the client's
possession, or can be reasonably obtained, including information that relates to:
anything likely to affect the site or the construction work, for example the presence of
asbestos or underground services
(a)
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(b)
the proposed use of the structure as a workplace
(c)
the minimum amount of time before the construction phase starts allowed for planning
and preparation (mobilisation)
The purpose of the provision of information by the client is to:

(a)
(b)
secure, so far as is reasonably practicable, the health and safety of anyone who will:
(i)
be involved in the construction work
(ii)
be otherwise affected by the construction work
(iii)
use the structure as a place of work
assist the persons to whom information is provided to:

(i)
perform their duties under these Regulations
(ii)
determine the resources allocated to them to manage the project
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In situations where there are a number of organisations, any of which could be the client,
one of the organisations must elect in writing to take on the role of client. This needs to be by
agreement. In this case, none of the other organisations have any duties under these
Regulations.
The client has one of the biggest influences over the way a project is run. They have
substantial influence and contractual control and their decisions and approach determine:
the time, money and other resources available for projects
(b)
who makes up the project team, their competence, when they are appointed and
who does what
(c)
whether the team is encouraged to co-operate and work together effectively
(d)
whether the team has the information that it needs about the site and any existing
structures
(e)
the arrangements for managing and co-ordinating the work of the team
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(a)
Because of this, they are made accountable for the impact their approach has on the health
and safety of those working on or affected by the project. However, these Regulations also
recognise that many clients know little about construction health and safety, so clients are
not required or expected to plan or manage projects themselves. Nor do they have to
develop substantial expertise in construction health and safety, unless this is central to their
business. Clients must ensure that various duties are discharged, but are not normally
expected to do them themselves.
Those clients without construction expertise should rely on the engineers advice on how
best to meet their duties, but the engineer will need the clients support and input to be able
to carry out their work effectively. The client remains responsible for ensuring that client
duties are met.
10
Clients can also, intentionally or unwittingly, take on additional responsibilities. If they specify
materials or methods of working they may well become designers in relation to those specific
matters. They will also be contractors if they directly manage or carry out construction work
on site.
11
Client shall ensure that the construction phase does not start unless:
the contractor have made arrangements for suitable welfare facilities to be

provided from the start and throughout the construction phase
(b)
the contractor has prepared a construction phase plan which complies with
Section 1.1.8.32); and
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In addition to the duties set out above, clients must:

(a) appoint an Engineer to advise and assist with their duties and to co-ordinate the
arrangements for health and safety during the planning phase;
(b) appoint a Contractor to plan and manage the construction work preferably early enough
for them to work with the designer on issues relating to building safety issues, usability
and maintainability;
(c) ensure that the construction phase does not start until the Contractor has prepared a
suitable construction phase plan and made arrangements for suitable welfare facilities to
be present from the start of the work;
(d) make sure the health and safety file is prepared, reviewed, or updated ready
for handover at the end of the construction work. This must then be kept
available for any future construction work or to pass on to a new owner.
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Getting the right people for these roles and making early appointments is particularly
important for clients with little construction or health and safety expertise, as they will need to
rely on the advice given by the Engineer on matters relating to the competence of those who
they intend to appoint, and the adequacy of the management arrangements made by
appointees.
1.1.8.10 Who are clients?

1
A client is an organisation or individual for whom a construction project is carried out. Clients
only have duties when the project is associated with a business or other undertaking
(whether for profit or not). This can include for example, Qatar Ministrys, Insurance
Companies or Private Developers.
1.1.8.11 Domestic clients

Domestic clients are people who have work done on their own home or the home of a
family member, that does not relate to a trade or business, whether for profit or not. It is
the type of client that matters, not the type of property.
Domestic clients have no client duties under CDM.
Designers and contractors working for domestic clients have to manage their own work
and co-operate with and co-ordinate their work with others involved with the project so
as to safeguard the health and safety of all involved in the project.
In some circumstances it may not be immediately obvious who is the client and there
can sometimes be more than one client involved in a project. To avoid confusion, this
needs to be resolved by those involved at the earliest stage possible. Take into
account who:
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(b)
commissions the design and construction work (the employer in contract

terminology);
(c)
initiates the work;
(d)
is at the head of the procurement chain;
(e)
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ultimately decides what is to be constructed, where, when and by whom;
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(a)
engages the contractors.
If there is still doubt, then all of the possible clients can appoint one of them as the only
client for the purposes of these Regulations. Someone will always be the client. It is in
the interests of all possible contenders to identify who it is. If not, they run the risk that all will
be considered to carry the clients duties under these Regulations.
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1.1.8.12 What clients must do for all projects

1
Clients must make sure that:

(a)
designers, contractors and other team members that they propose to engage are
competent (or work under the supervision of a competent person), are adequately
resourced and appointed early enough for the work they have to do.
(b)
they allow sufficient time for each stage of the project, from concept onwards;
(c)
they co-operate with others concerned in the project as is necessary to allow other
duty holders to comply with their duties under these Regulations;
(d)
they co-ordinate their own work with others involved with the project in order to
ensure the safety of those carrying out the construction work, and others who may
be affected by it;

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(e)
there are reasonable management arrangements in place throughout the project

to ensure that the construction work can be carried out, so far as is reasonably
practicable, safely and without risk to health. (This does not mean managing the
work themselves, as few clients have the expertise and resources needed and it
can cause confusion);
(f)
contractors have made arrangements for suitable welfare facilities to be provided

from the start and throughout the construction phase;
(g)
any fixed workplaces (for example offices, shops, factories, schools and any other
structures which can be a place of work for end users including maintainers)
which are to be constructed will comply, in respect of their design and the
materials used, with any requirements of latest version for QCS
(h)
relevant information likely to be needed by designers, engineer, contractors or

others to plan and manage their work is passed to them in order to comply with
these Regulations.
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1.1.8.13 Co-operation, co-ordination, timeliness and resources

Co-operation between parties and co-ordination of the work are key to the successful
management of construction health and safety. Co-operation and co-ordination can only
be meaningful if the relevant members of the project team have been appointed early
enough to allow them to contribute to risk reduction. This is particularly important during
the design stage when both clients and contractors should contribute to discussions on
building safety issues, usability and maintainability of the finished structure. Clients
should seek to appoint those who can assist with design considerations at the earliest
opportunity so that they can make a full contribution to risk reduction during the planning
stages.
Unrealistic deadlines and a failure to allocate sufficient funds are two of the largest
contributors to poor control of risk on site. When engaging designers, contractors, and
appointing engineers, clients have to consider the resources (for example staff,
equipment and, particularly, time) needed to plan and do the work properly. Any
contractors who are being considered for appointment should be informed of the
minimum time period allowed to them for planning and preparation before construction
work begins on site. Contractors should be given sufficient time after their appointment
to allow them to plan the work and mobilise the necessary equipment (for example
welfare facilities) and staff to allow the work to proceed safely and without risk to health.
This is particularly important where the project involves demolition work - contractors
must be given sufficient time for the planning and safe execution of any demolition
activities.
Clients should consult with appointees (including the contractor) to find out how much
time they will need for planning and preparation before work is expected to start in order
that both parties can agree a suitable time period. Similarly, engineers will need
sufficient time after their appointment to carry out their duties under these Regulations.
Clients must then inform their appointees how much time the client has allowed for
planning and preparation before the work starts.
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1.1.8.14 Arranging design work

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Clients must only employ designers who are competent to carry out their CDM duties.
Clients often employ more than one designer, for example architects, civil, structural and
services engineers. In such cases they all need to know who does what, and the timing
of the appointments needs to enable the design work to be co-ordinated from an early
stage. Nominating one designer as the lead designer is often the best way to ensure
co-ordination and co-operation during work which involves a number of designers.
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1.1.8.15 Management Arrangements

1
Clients, particularly those who only occasionally commission construction work, will not
be experts in the construction process and for this reason they are not required to take
an active role in managing the work. Clients are required to take reasonable steps to
ensure that suitable management arrangements are in place throughout the life of the
project so that the work can be carried out safely and without risk to health. The
arrangements put in place should focus on the needs of the particular job and should be
proportionate to the risks arising from the work.
The client will need to ensure that arrangements are in place to ensure that:
there is clarity as to the roles, functions and responsibilities of members of the
project team;
(b)
those with duties under CDM have sufficient time and resource to comply with
their duties;
(c)
there is good communication, co-ordination and co-operation between members

of the project team (for example between designers and contractors);
(d)
designers are able to confirm that their designs (and any design changes) have
taken account of the requirements of their (designers duties), and that the
different design elements will work together in a way which does not create risks
to the health and safety of those constructing, using or maintaining the structure;
(e)
that the contractor is provided with the pre-construction information.
(f)
contractors are able to confirm that health and safety standards on site will be
controlled and monitored, and that welfare facilities will be provided by the
contractor from the start of the construction phase through to handover and
completion.
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(a)
Most of these arrangements will be made by others in the project team, such as
designers and contractors. Before they start work, a good way of checking is to ask the
relevant members of the team to explain their arrangements, or to ask for examples of
how they will manage these issues during the life of the project. When discussing roles
and responsibilities, on simple projects all that may be needed is a simple list of who
does what.
When deciding whether management arrangements are suitable and maintained

throughout the project, clients will need to make a judgement, taking account of the
nature of the project and the risks that the work will entail. If this judgement is
reasonable and clearly based on the evidence requested and provided, clients will not
be criticised if the arrangements subsequently prove to be inadequate, or if the company
who has made the arrangements fails to implement them properly without the clients
knowledge.
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1.1.8.16 Providing the pre-construction information

1
Clients must provide designers and contractors who may be bidding for the work (or who
they intend to engage), with the project-specific health and safety information needed to
identify hazards and risks associated with the design and construction work (the preconstruction information).
The information should be provided as part of the early procurement process or tendering,
and responses to the issues identified can be a real help when judging competence of
those tendering for the work. It therefore needs to be identified, assembled and sent out
in good time, so that those who need it when preparing to bid or when preparing for the
work can decide what resources (including time) will be needed to enable design,
planning and construction work to be organised and carried out properly. Where design
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work continues during the construction phase, the pre-construction information will need
to be provided to designers before work starts on each new element of the design.
Similarly, where sub-contractors are appointed during the construction phase, each subcontractor (or those who are bidding for the work) must be provided with the preconstruction information in time for them to take this into account when preparing their
bid, or preparing for work on the site.
Clients may already have all, or much of the information needed. However, where there
are gaps in this information, the client should ensure that these are filled by
commissioning surveys or by making other reasonable enquiries. Where no existing
information is available from the Client, designers shall identify and commission relevant
surveys to enable them to complete their design and prepare preconstruction
information that will be used to inform preparation and planning for construction. The
information shall consist of relevant health and safety information of anyone affected by
the design over the project life cycle.
The pre-construction information provided should be sufficient to ensure that significant

risks during the work can be anticipated and planned for. It should concentrate on those
issues that designers and contractors could not reasonably be expected to anticipate or
identify, and not on obvious hazards such as the likelihood that the project would involve
work at height.
The information needs to be in a form that is convenient, i.e. clear, concise and easily
understood, but it can be included in other documents, for example the specification,
providing the relevant health and safety issues are fully covered. Brief notes on as built
drawings are particularly useful, but should be checked in case significant alterations have
been carried out. will advise the client as to what is needed and arrange for relevant
information to be given to designers and contractors.
Clients are also required to tell Contractors who they engage to carry out construction work
the minimum notice that they will be given before they are expected to start construction
work. This is to ensure that Contractors have sufficient time to plan and prepare for
example mobilise their workforce and equipment, and make arrangements for welfare
facilities to be provided.
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1.1.8.17 Pre-construction information

When drawing up the pre-construction information, each of the following topics should
be considered. Information should be included where the topic is relevant to the wor k
proposed. The pre-construction information provides information for those bidding for or
planning work, and for the development of the construction phase plan. The level of
detail in the information should be proportionate to the risks involved in the project.
Description of project
(a)
project description and programme details including:

(i)
key dates (including planned start and finish of the construction phase), and
(ii)
the minimum time to be allowed between appointment of the contractor and

instruction to commence work on site;
(b)
details of client, designers, engineer and other consultants;
(c)
whether or not the structure will be used as a workplace (in which case, the
finished design will need to take account of the relevant requirements of the latest
version for QCS).
(d)
extent and location of existing records and plans.
Clients considerations and management requirements
(i)
planning for and managing the construction work, including any health and
safety goals project,
(ii)
communication and liaison between client and others,
(iii)
security of the site,
(iv)
welfare provision;
requirements relating to the health and safety of the clients employees or

customers or those involved in the project such as:
site fencing requirements,
(ii)
site transport arrangements or vehicle movement restrictions,
(iii)
client permit-to-work systems,
(iv)
fire precautions,
(v)
emergency procedures and means of escape,
(vi)
no-go areas or other authorisation requirements for those involved in the

project,
(vii)
any areas the client has designated as confined spaces,
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(viii) smoking and parking restrictions.
Safety hazards, including:
boundaries and access, including temporary access for example narrow

streets, lack of parking, turning or storage space,
(ii)
any restrictions on deliveries or waste collection or storage,
(iii)
adjacent land uses for example schools, railway lines or busy highways.
(iv)
existing storage of hazardous materials,
(v)
location of existing services particularly those that are concealed water,

electricity, gas, etc,
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(i)
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Environmental restrictions and existing on-site risks
(vi)
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(b)
arrangements for:
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QCS 2014
(vii)
ground conditions, underground structures or water courses where this

might affect the safe use of plant, for example cranes, or the safety of
groundworks,
information about existing structures stability, structural form, fragile or
hazardous materials, anchorage points for fall arrest systems (particularly
where demolition is involved),
(viii) previous structural modifications, including weakening or strengthening of

the structure (particularly where demolition is involved),
(ix)
fire damage, ground shrinkage, movement or poor maintenance which may

have adversely affected the structure,
(x)
any difficulties relating to plant and equipment in the premises, such as

overhead gantries whose height restricts access,
(xi)
health and safety information contained in earlier design, construction or

as-built drawings, such as details of pre-stressed or post-tensioned
structures;
(xii)
Health hazards, including:
(xiii) asbestos, including results of surveys (particularly where demolition is

involved),
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(xiv) existing storage of hazardous materials,
(xv)
contaminated land, including results of surveys,
(xvi) existing structures containing hazardous materials,

(xvii) health risks arising from clients activities.
Significant design and construction hazards
(a)
significant design assumptions and suggested work methods, sequences or other

control measures;
(b)
arrangements for co-ordination of ongoing design work and handling design

changes;
(c)
information on significant risks identified during design;
(d)
materials requiring particular precautions.
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The Health and Safety File
Description of its format and any conditions relating to its content.
The information needs to be in a form that is convenient, i.e. clear, concise and easily
understood, but it can be included in other documents, for example the specification,
providing the relevant health and safety issues are fully covered. Brief notes on as built
drawings are particularly useful, but should be checked in case significant alterations have
been carried out. Engineers will advise the client as to what is needed and arrange for
relevant information to be given to designers and contractors.
Clients are also required to tell contractors who they engage to carry out construction work
the minimum notice that they will be given before they are expected to start construction
work. This is to ensure that contractors have sufficient time to plan and prepare for
example mobilise their workforce and equipment, and make arrangements for welfare
facilities to be provided
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Clients do not have to provide welfare facilities for construction workers, but if there are
particular constraints which make it difficult for facilities to be provided, the client should
co-operate with contractors and assist them with their arrangements.
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1.1.8.18 Welfare arrangements
1.1.8.19 Additional duties for clients

1
Refer to 1.1.8.9.
1.1.8.20 Appointment of the Engineer

1
The client must appoint a competent, adequately resourced engineer as soon as

practicable after initial design work or other preparations for construction work have
begun.
The engineer provides clients with a key project advisor in respect of construction health
and safety risk management matters. Their main purpose is to help clients to carry out
their duties; to co-ordinate health and safety aspects of the design work and to prepare
the health and safety file.
Early appointment is crucial for effective planning and establishing management

arrangements from the start. CDM requires the appointment to take place as soon as is
practicable after initial design work or other preparation for construction work has begun.
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This allows the client to appraise their project needs and objectives, including the
business case and any possible constraints on development to enable them to decide
whether or not to proceed with the project before appointing the engineer. The engineer
needs to be in a position to be able to co-ordinate design work and advise on the
suitability and compatibility of designs, and therefore they should be appointed before
significant detailed design work begins. Significant detailed design work includes
preparation of the initial concept design and implementation of any strategic brief. As a
scheme moves into the detailed design stage, it becomes more difficult to make
fundamental changes that eliminate hazards and reduce risks associated with early
design decisions.
Proper consideration of the health and safety implications of the design for those who
build and maintain the structure will make a significant contribution to reducing its whole
life cost, and will make delivery to time, cost and quality more likely.
The engineer can be an individual or a company. Engineers can be appointed

independently of any other role on the project team, or they may combine this work with
another role, for example, project manager, designer or contractor. Where the role is
combined, it is crucial that the engineer has sufficient independence to carry out their
tasks effectively. The tasks can be shared out, but when this happens it is important to
make sure that all of the duties are discharged. On simple projects, one person should
be able to provide all of the support that clients need, but a team approach will be more
common for larger or more complicated projects because of the workload and skills
required.
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1.1.8.21 Appointment of the Contractor
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Clients must appoint one competent, adequately resourced contractor to plan, manage
and monitor the construction work. The appointment needs to be in writing.
The contractor can be an organisation or an individual. A contractors key duties is to coordinate and manage the construction phase to ensure the health and safety of
everybody carrying out construction work, or who is affected by the wor k.
The contractor must be appointed as soon as the client knows enough about the project
to select a suitable contractor. Early appointment allows the contractor and other
specialists, for example maintenance contractors and facilities management experts to
make a substantial contribution to ensuring the building safety issues and maintainability
of the structure under construction. This helps to eliminate and reduce risks to health
and safety, and to avoid interruptions, delays and other problems, which can add
significantly to the costs of a project.
Early appointment is essential for the contractor to have sufficient time to develop an
adequate construction phase plan and to arrange for appropriate resources, including
welfare facilities, to be available when work commences on site. (Ensuring that welfare
facilities are provided when work starts on site is a specific duty of the contractor, but the
client also has a duty to make sure that the contractor has done so). Contractors should
be told as part of the pre-construction information the minimum amount of time which
they will be given for planning and preparation before the construction work is expected
to start on site.
There can only be one contractor (the main Contractor of construction works and having
authority and control of the construction site) at any one time. To ensure continuity,
clients should normally keep the same contractor for the whole project from site
clearance and preparation to final completion. However, there may be exceptions, for
example where:
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(a)
preliminary works, for example involving demolition or site preparation work,

where there is a substantial delay between site clearance and the start of new
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construction work;
(b)
separate projects for different clients, for example for a building shell and
subsequent fitting-out work.
(c)
In these cases, any change in contractor should:
(d)
be clear to, and agreed by all those involved, particularly in relation to the timing of
the change;
(e)
be clearly recorded;
(f)
provide the practical authority to enable the contractor to discharge his duties.
1.1.8.22 Management arrangements

Clients must appoint a competent engineer who will assist them with the assessment of
the adequacy of the management arrangements made by others in the project team.
Having appointed a competent engineer, the client is entitled to rely on their advice
when making these judgements.
1.1.8.23 Before the construction phase begins
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Before construction work begins clients must check to ensure that suitable welfare
facilities have been provided, and that the construction phase plan has been prepared
by the contractor. With the help of the engineer, clients must ensure that the plan is
project-specific and suitable. Example content of the construction phase plan is:
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1.1.8.24 Construction Phase (Health & Safety) Plan

When drawing up the construction phase plan, you should consider each of the
following topics. Information should be included in the plan where the topic is relevant to
the work proposed. The plan sets out how health and safety is to be managed during the
construction phase. The level of detail should be proportionate to the risks involved in
the project. Once the construction phase has begun, it is the responsibility of the
Contractor to update the Plan as per the development of the construction works.
Description of project
(b)
details of client, engineer, designers, Contractor and other consultants;

extent and location of existing records and plans that are relevant to health and
safety on site, including information about existing structures when appropriate.
(c)
project description and programme details including any key dates;
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Management of the work

(a)
management structure and responsibilities
(b)
health and safety goals for the project and arrangements for monitoring and
review of health and safety performance
(c)
arrangements for;
(i)
regular liaison between parties on site,
(ii)
consultation with the workforce,
(iii)
the exchange of design information between the client, designers, Engineer and
contractors on site,
(iv)
handling design changes during the project,
(v)
the selection and control of contractors,
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(vi)
the exchange of health and safety information between contractors,
(vii)
site security,
(viii)
site induction,
(ix)
on site training,
(x)
welfare facilities and first aid,
(xi)
the reporting and investigation of accidents and incidents including near misses,
(xii)
the production and approval of risk assessments and written systems of work;
site rules (including drug and alcohol policy);
(e)
fire and emergency procedures.
(f)
Arrangements for controlling significant site risks
(a)
Safety risks, including:
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(d)
delivery and removal of materials (including waste) and work equipment taking
account of any risks to the public, for example during access to or egress from
the site,
(ii)
dealing with services - water, electricity and gas, including overhead power lines
and temporary electrical installations,
(iii)
accommodating adjacent land use,
(iv)
stability of structures whilst carrying out construction work, including temporary

structures and existing unstable structures,
(v)
preventing falls,
(vi)
work with or near fragile materials,
(vii)
control of lifting operations,
(viii)
the maintenance of plant and equipment,
(ix)
work on excavations and work where there are poor ground conditions,
(x)
work on wells, underground earthworks and tunnels,
(xi)
work on or near water where there is a risk of drowning,
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(i)
work involving diving,
(xiii)
work in a caisson or compressed air working,
(xii)
(xiv) work involving explosives,

(xv)
traffic routes and segregation of vehicles and pedestrians,
(xvi) storage of materials (particularly hazardous materials) and work equipment,

(xvii) any other significant safety risks;
(b)
health risks, including:

(i)
the removal of asbestos,
(ii)
dealing with contaminated land,
(iii)
manual handling,
(iv)
use of hazardous substances, particularly where there is a need for health

monitoring,
(v)
reducing noise and vibration,
(vi)
work with ionising radiation,
(vii)
exposure to UV radiation (from the sun),
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(viii) any other significant health risks.
The health and safety file

(a)
layout and format;
(b)
arrangements for the collection and gathering of information;
(c)
storage of information.
Once the construction phase has begun, neither clients nor engineers have a duty to
check that the plan is updated; this is the responsibility of the contractor.
1.1.8.25 Completion and handover (all projects)

One of the most important stages in a project is when it nears completion and is handed
over to the client. It is rare for all construction work to be completed before handover.
Sometimes clients, in their eagerness to have things up and running, assume control
when a great deal of construction work remains.
Risks to employees and others not engaged in construction work can increase
substantially as they visit the site or spend more time there. The risks to the construction
workers can also increase, due to the presence and work of others not directly engaged
or experienced in construction work.
To minimise such risks, the management of this phase needs to be considered well in
advance to address:
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the nature, scope and duration of any finishing-off work;
(b)
how this work will be managed and by whom;
(c)
how the site will be split up, and access controlled, to safeguard construction
workers as well as clients employees and/or members of the public.
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For simple projects these arrangements can be discussed and agreed between the
various parties. In more complex situations, the arrangements should be recorded as
part of the construction phase plan.
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Clients are not required or expected to:
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1.1.8.26 What clients dont have to do
(a)
plan or manage construction projects themselves; or
(b)
specify how work must be done, for example requiring a structure to be

demolished by hand. Indeed they should not do so unless they have the expertise
to assess the various options and risks involved. (They should, of course, point
out particular risks that would inform this decision.)
(c)
provide welfare facilities for those carrying out construction work (though they
should co-operate with the contractor to assist with his arrangements);
(d)
visit the site (to supervise or check construction work standards) but it is good
practice for the client to appoint someone to ensure the contents of the
Construction Phase (H&S) Plan is being complied with. This may be in the form of
an appointed H&S advisor / consultant and / or the Engineer which may assist in
the resolution of any onsite design issues.
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1.1.8.27 The Engineer

Appointment of an Engineer
1
The role of engineer may be filled by an individual, an organisation or by a professional

practice such as an architect's practice or a specialist consultancy.
The more complex the project and hence the more construction disciplines involved, the less
likely it is that the role of engineer can be satisfactorily carried out by a single person.
The selection of a competent engineer should be based upon the complexity of the work and
the range of knowledge required.
The duties of the engineer are seen to be to:
(d)
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the start of the construction phase as outlined previously in the client's duties
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(ii)
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ensure that suitable arrangements are made and implemented for the co-ordination of
health and safety measures during the planning and preparation phases of the project
with regard to:
co-operation and co-ordination between all parties working on the project
(ii)
the implementation of the general principles of prevention
as
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liaise with the contractor with regard to:
the information required for the health and safety file
(ii)
the information needed by the contractor for the preparation of the health and
safety plan
(iii)
any design developments which may have an impact on the planning and
management of the work
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(i)
take all reasonable steps to identify and collect pre-construction information and
promptly provide it, as necessary, to designers and contractors
take all reasonable steps to ensure that designers comply with their duties
(e)
taking reasonable steps to ensure that the necessary arrangements are made
for managing health and safety
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(c)
(i)
(b)
give suitable and sufficient advice and assistance to enable the client to comply with
the client's duties under these Regulations, in particular with regard to:
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(a)
(f)
take all reasonable steps to ensure the co-operation between designers and the
contractor with regard to designs and any changes in design
(g)
prepare the health and safety file and pass the file to the client at the end of the
construction phase
The purpose of the engineer is to provide the client with key project information about
construction health and safety risk-management matters.
They should assist and advise the client on:

(a)
the appointment of competent contractors
(b)
the adequacy of the arrangements for managing health and safety
(c)
ensuring proper co-ordination of the health and safety aspects of the design process
(d)
facilitating good communication and co-operation between all project team members
(e)
preparing the health and safety file,
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Early involvement of the engineer with the client and designers should significantly contribute
to the reduction of risk to construction workers and to anyone who has to subsequently work
on the completed structure.
The role demands a comprehensive knowledge of the design process and construction
methods, plus a thorough understanding of construction health, safety and welfare issues.
It is suggested that if the position is filled by a competent person or organisation who/which

possesses the necessary range of knowledge, experience and resources, compliance with
the rest of these Regulations should flow relatively smoothly.
10
These Regulations require that the role of the engineer must be filled at all times by a
competent person. It has, therefore, to be accepted that the appointment of the engineer can
be terminated by the client if the duties are not being carried out satisfactorily, for example:
the engineer has not generally displayed the required level of competence
(b)
the job has reached a stage where it involves construction activities outside the scope
of the experience of the current engineer and a pre-planned handover to another
engineer takes place. For example, the original engineer is appointed for the ground
works and structural stage of a project, but another appointment is made for the fitting
out and commissioning stages.
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(a)
The role of an engineer is to provide the client with a key project advisor in respect of
construction health and safety risk management matters. They should assist and advise
the client on appointment of competent contractors and the adequacy of management
arrangements; ensure proper co-ordination of the health and safety aspects of the
design process; facilitate good communication and co-operation between project team
members and prepare the health and safety file.
12
Through early involvement with clients and designers, an engineer can make a
significant contribution to reducing risks to workers during construction, and to
contractors and end users who work on or in the structure after construction.
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Appointing the Engineer
Refer to 1.1.8.20.
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1.1.8.28 What Engineers should do

An engineer should:
(a)
give suitable and sufficient advice and assistance to clients in order to help them
to comply with their duties, in particular:
(i)
the duty to appoint competent designers and contractors; and
(ii)
the duty to ensure that adequate arrangements are in place for managing
the project;
(b)
co-ordinate design work, planning and other preparation for construction where
relevant to health and safety;
(c)
identify and ensure collection of the pre-construction information and advise the
client if surveys need to be commissioned to fill significant gaps;
(d)
promptly provide in a convenient form to those involved with the design of the
structure; and to every contractor (including the contractor) who may
(e)
be or has been appointed by the client, such parts of the pre-construction

information which are relevant to each;
(f)
manage the flow of health and safety information between clients, designers
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(g)
and contractors;
(h)
advise the client on the suitability of the initial construction phase plan and the
arrangements made to ensure that welfare facilities are on site from the start;
(i)
produce or update a relevant, user friendly, health and safety file suitable for
future use at the end of the construction phase.
Advising the client on competency of designers and contractors

2
Clients are responsible for appointing competent and adequately resourced designers
and contractors. A competent engineer will have the knowledge and expertise to assist
clients with these assessments.
Managing information flow
Co-operation and co-ordination can only be achieved if there is good communication

between all parties involved in a particular aspect of a project. During planning stages
the engineer needs to make sure that there are appropriate systems in place to
encourage communication and the sharing of relevant information, and engineers
should manage the flow of information between the team members. They may need to
convene special meetings if they are not satisfied there is sufficient co-operation
between designers or with other team members, or if adequate regard is not being given
to health and safety. It is, however, better for these issues to be addressed in routine
project meetings.
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Clients must provide designers and contractors who may be bidding for the work (or who
they intend to engage), with the project-specific health and safety information needed to
identify hazards and risks associated with the design and construction work. (The preconstruction information). Clients are required to provide this information to the
engineer. The engineer should check the information to ensure that it is complete,
advise the client if there are any significant gaps or defects, and ensure these are filled
by commissioning surveys or by making other reasonable enquiries. The engineer
should then provide designers or contractors who may be bidding for, or preparing to
carry out construction work on site, with such parts of the pre-construction information
that are relevant to each.
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Providing information
Advising the client on adequacy of management arrangements

5
Clients must make sure that there are suitable (project-specific) arrangements for
managing each project so that the work can be carried out safely and without risk to
health. Most clients, particularly those who only occasionally commission construction
work, will not be experts in the construction process. These Regulations do not require
clients to take an active role in managing the work, but they do require clients to take
reasonable steps to ensure that suitable management arrangements are in place
throughout the life of the project.
The engineer should assist with the development of these arrangements, and should
advise clients on whether or not the arrangements are adequate. They should assist the
client with decisions about how much time a contractor will need to prepare before
construction work begins. When advising and assisting the client, the following issues
should be considered.
(a)
Is the client aware of their duties and do they understand what is expected of
them?
(b)
Has the client prepared relevant information about the site?
(c)
Have the necessary appointments been made?

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(d)
Is there an established project team who meet regularly to discuss and coordinate activities in relation to the project?
(e)
Are project team members clear about their roles and responsibilities?
(f)
Are there arrangements in place for co-ordinating design work and reviewing the
design to ensure that designers duties are being addressed?
(g)
Are there arrangements in place for dealing with late changes to the design, and
for co-operating with contractors, so that problems are shared?
(h)
Has the contractor been given enough time to plan and prepare for the work, and
mobilise for the start of the construction phase?
(i)
Has the contractor made arrangements for providing welfare facilities on site from
the outset, and have they prepared a construction phase plan that addresses the
main risks during the early stages of construction?
(j)
Are there suitable arrangements for developing the plan to cover risks that arise
as the work progresses?
(k)
Has the format for the health and safety file been agreed, and are arrangements
in place for collecting the information which it will contain?
(l)
Has the contractor put in place suitable arrangements for consulting with workers
on site; for carrying out site induction and for ensuring that workers are adequately
trained and supervised?
Not all of these questions will need answers at the start of the project, and the
arrangements will need to evolve as the project develops. The key thing is to plan ahead
so that arrangements are in place before the risks that need managing materialise on
site.
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QCS 2014
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1.1.8.29 Co-ordinating design work: Design reviews

The engineers responsibility in respect of design work only extends to health and safety
aspects of the design checking that the requirements of the designers duties have
been addressed and that the different design elements work together without causing
danger. This is best achieved through design reviews during which health and safety
issues are addressed alongside practicality and cost in a wider review of the designs
building safety issues, maintainability and usability.
When considering building safety issues, meetings should where possible include the
contractor(s) so that difficulties associated with construction can be discussed and
solutions agreed before the work begins. When discussing usability and maintainability,
involving the client or those who will be responsible for operating the building or
structure will mean that proper consideration can be given to the health and safety of
those who will maintain and use the structure once it has been completed. Doing this
during the design stage will result in significant cost savings for the client, as rectifying
mistakes after the structure has been built is always expensive.
As part of design reviews, engineers need to ensure that the designers have identified a
safe method for construction for unusual or complex designs, and that the designs
include the information needed by other designers and contractors to allow them to work
safely and without risk to health. This information needs to be clear and concise.
The timing of the reviews also needs careful consideration. Design needs to be far
enough developed for people to have a clear view of what is in mind, but not so far
developed that it is too late to modify the proposals, if necessary. Design is an iterative
process so it may need review at several different stages. The effort devoted to design
review should be in proportion to the risks and complexity.
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Engineers who identify important health and safety issues that have not been addressed
in the design must draw them to the attention of the designer.
1.1.8.30 The Engineer and the construction phase

Design often continues throughout a project and engineers have a continuing role during
the construction phase ensuring that designers, including those engaged by a
contractor and contractors who carry out design work themselves, co-operate with each
other, and designs meet the requirements of these Regulations. Where design changes
and decisions during the construction phase have significant health and safety
implications, engineers should liaise with the contractor about any implications for the
construction phase plan.
The design of temporary works, such as falsework, formwork and scaffolding, falls within
the scope of CDM. Engineers have to take reasonable steps to ensure co-operation
between permanent and temporary works designers, in particular to ensure that
arrangements are in place to ensure that designs are compatible and that the
permanent works can support any loadings from temporary works.
Engineers need to pay particular attention to late designs or late change s to designs.
Examples would be revisions on architects instructions, when clients require changes or
when unforeseen problems are encountered on site. The engineer should make sure
that there are arrangements in place to ensure that such changes do not result in
significantly increased risks on site.
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Engineers dont have to:
approve the appointment of designers, contractors, although they normally advise

clients about competence and resources;
(b)
approve or check designs, although they have to be satisfied that the design
process addresses the need to eliminate hazards and control risks;
(c)
approve the contractors construction phase plan, although they have to be able to
advise clients on its adequacy at the start of construction;
(d)
supervise the contractors implementation of the construction phase plan - this is

the responsibility of the contractor; or
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supervise or monitor construction work this is the responsibility of the contractor.
(e)
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(a)
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What Engineers dont have to do
1.1.8.31 The health and safety file

1
Engineers must prepare a suitable health and safety file.

It is important that they
discuss this with the client before work starts on site so that the format can be agreed,
along with who should provide what information and when. This requires the cooperation of several duty holders, so engineers need to make sure that designers and
contractors know, early on in the project, what information they will need to provide
The health and safety file (the file) is a source of information that will help to reduce the
risks and costs involved in future construction work, including cleaning, maintenance,
alterations, refurbishment and demolition. Clients therefore need to ensure that the file is
prepared and kept available for inspection in the event of such work. It is a key part of
the information, which the client, or the clients successor, must pass on to anyone
preparing or carrying out work to which CDM applies.
Clients may need to provide incentives or include requirements in contracts to ensure

that the information is given to the engineer immediately after relevant design or
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construction work is completed. At the end of a project the engineer should give the
completed file to the client for safekeeping.
The contents of the health and safety file
When putting together the health and safety file, you should consider including
information about each of the following where they are relevant to the health and safety
of any future construction work. The level of detail should allow the likely risks to be
identified and addressed by those carrying out the work:
(a)
a brief description of the work carried out;
(b)
any residual hazards which remain and how they have been dealt with (for
example surveys or other information concerning asbestos; contaminated land;
water bearing strata; buried services etc);
(c)
key structural principles (for example, bracing, sources of substantial stored

energy including pre- or post-tensioned members) and safe working loads for
floors and roofs, particularly where these may preclude placing scaffolding or
heavy machinery there;
(d)
hazardous materials used (for example lead paint; pesticides; special coatings
which should not be burnt off etc);
(e)
information regarding the removal or dismantling of installed plant and equipment

(for example any special arrangements for lifting, order or other special
instructions for dismantling etc);
(f)
health and safety information about equipment provided for cleaning or

maintaining the structure;
(g)
the nature, location and markings of significant services, including underground

cables; gas supply equipment; fire-fighting services etc;
(h)
information and as-built drawings of the structure, its plant and equipment (for
example, the means of safe access to and from service voids, fire doors and
compartmentalisation etc).
The file should be useful to:
(b)
designers during the development of further designs or alterations;

engineers preparing for construction work;
(c)
clients, who have a duty to provide information about their premises to those who
carry out work there;
(a)
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(d)
contractors and sub-contractors preparing to carry out or manage such work.
The file should form a key part of the information that the client, or the clients
successor, is required to provide for future construction projects. The file should therefore
be kept up to date after any relevant work or surveys.
The scope, structure and format for the file should be agreed between the client and
engineer at the start of a project. There can be a separate file for each structure, one for
an entire project or site, or one for a group of related structures.
What you must do
Clients, designers, contractors, other sub-contractors and engineers all have duties in
respect of the health and safety file:
(a)
Engineers must prepare, review, amend or add to the file as the project
progresses, and give it to the client at the end of project;
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(b)
clients, designers, contractors and other sub-contractors must supply the

information necessary for compiling or updating the file;
(c)
clients must keep the file to assist with future construction work; and
(d)
everyone providing information should make sure that it is accurate, and provided
promptly.
The client should make sure that the engineer compiles the file. In some cases, for
example design and build contracts, it is more practical for the contractor to obtain the
information needed for the file from the specialist contractors. In these circumstances
the contractor can assemble the information and give it to the engineer as the work is
completed.
10
The file does not need to include things that will be of no help when planning future
construction work, for example:
the pre-construction information, or construction phase health and safety plan
(b)
construction phase risk assessments, written systems of work and COSHH

assessments
(c)
details about the normal operation of the completed structure
(d)
construction phase accident statistics
(e)
details of all the contractors and designers involved in the project (though it may be
useful to include details of the contractor and engineer)
(f)
contractual documents
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(a)
information about structures, or parts of structures, that have been demolished

unless there are any implications for remaining or future structures, e.g. voids
(ii)
information in other documents, but relevant cross-references should be

included.
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Storing the file after the work is complete

To be useful the file needs to be kept up to date, and retained for as long as it is relevant
normally the lifetime of the structure. It may be kept electronically (with suitable
backup arrangements), on paper, on film, or any other durable form.
12
Where clients dispose of their entire interest in a structure, they should pass the file to
the new owners and ensure that they are aware of the nature and purpose of the file.
Where they sell part of a structure, any relevant information in the file should be passed
or copied to the new owner.
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1.1.8.32 Designers
1
Designs develop from initial concepts through to a detailed specification, often involving
different teams and people at various stages. At each stage, designers from all disciplines
can make a significant contribution by identifying and eliminating hazards, and reducing
likely risks from hazards where elimination is not possible.
Designers earliest decisions fundamentally affect the health and safety of construction
work. These decisions influence later design choices, and considerable work may be
required if it is necessary to unravel earlier decisions. It is therefore vital to address
health and safety from the very start.
Designers have duties regardless of whether the client is a domestic or non-domestic Client.
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Designer's duties
1
Designers are in a unique position at an early stage of a project to reduce the potential risks
to health and safety that could arise during the construction phase or at a later stage such as
during maintenance of the completed structure.
Designers have duties regardless of whether the client is at work or is a domestic client.
No designer shall commence work in relation to a project unless any client for the project is
aware of his duties under these Regulations.
Every designer shall in preparing or modifying a design avoid foreseeable risks to the health
and safety of any person
(b)
liable to be affected by such construction work;
(c)
cleaning any window or any transparent or translucent wall, ceiling or roof in or on a

structure;
(d)
maintaining the permanent fixtures and fittings of a structure; or
(e)
using a structure designed as a place of work.
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In discharging their duties, the designer shall
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carrying out construction work;
(a)
eliminate hazards which may give rise to risks; and
(b)
reduce risks from any remaining hazards,
as
(a)
and in so doing shall give collective measures priority over individual measures
The duties on designers are:
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no design work should be carried out unless the client is aware of their duties under
these Regulations.
(b)
not carry out detailed design work until an Engineer has been appointed.
(c)
designers must ensure so far as is reasonably practicable that their designs avoid
foreseeable health and safety risks to anyone who is:
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(a)
carrying out the construction work
(ii)
liable to be affected by the construction work
(iii)
cleaning any window or other transparent or translucent surfaces
(iv)
maintaining the permanent fixtures and fittings
(v)
using the structure as a place of work.
(i)
It will include aspects of design such as positioning a vehicle loading bay to ensure that
delivery vehicles are routed safely away from pedestrians. The intention is that all designers
consider the implications of their designs with regard to the structures being built and
maintained reasonably safely.
In discharging their duties, designers:

(a)
must so far as is reasonably practicable:
(b)
eliminate hazards that give rise to risks, and
(c)
reduce the risk from any hazards that remain
(d)
give collective protection measures priority over individual protective measures.
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An example of hazard elimination is to design out the use of fragile roofing materials or the
installation of fragile roof-lights in an otherwise load-bearing roof.
11
Reducing risk can be achieved by reducing the likelihood of harm occurring, the severity of
any incident that does occur, the number of persons exposed to the harm and the frequency
or duration of the exposure to harm.
12
Designers must ensure that any structure designed for use as a workplace conforms to the
requirements latest edition of QCS with regard to the design and the materials used.
13
In designing any structure for use as a workplace the designer shall ensure that the design
conforms to the requirements latest edition of QCS with regard to the design and the
materials used.
14
Designers must take all reasonable steps to provide sufficient information about the aspects
of the design or its construction or maintenance to adequately assist the following to comply
with their duties:
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10
the client;
(b)
the Engineer;
(c)
other designers;
(d)
contractors;
(e)
Sub-contractors;
(f)
Other consultant/interfacing organisations identified as relevant
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(a)
Historically, risks were created at the design stage as a result of an attitude by some
designers that it 'is someone else's problem to build/clean/maintain' the structure once it has
been designed. CDM is emphatically not trying to stifle creative design, but merely ensuring
that the practicalities of carrying out any of the above activities are considered during the
design process.
16
Having completed their design, designers are obliged to pass on information about the risks
that they have not been able to design out. For example, having designed an external
overhead pipe run for a factory, the engineer consults the client's maintenance team about
the need for access. The designer establishes that the maintenance team will only need to
access the pipe-run every 4 years and that they can quite safely use a scissor lift for the
task.
17
The designer then simply passes on the information as to how the risk of working at height
during maintenance can be carried out in a safe manner.
18
Designers responsibilities extend beyond the construction phase of a project. They also
need to consider the health and safety of those who will maintain, repair, clean, refurbish
and eventually remove or demolish all or part of a structure as well as the health and
safety of users of workplaces. For most designers, building safety issue considerations
and ensuring that the structure can be easily maintained and repaired will be part of their
normal work, and thinking about the health and safety of those who do this work should
not be an onerous duty. Failure to address these issues adequately at the design stage
will usually increase running costs, because clients will then be faced with more costly
solutions when repairs and maintenance become necessary.
19
Where significant risks remain when they have done what they can, designers should
provide information with the design to ensure that the engineer, other designers and
contractors are aware of these risks and can take account of them.
20
In addition to the duties outlined above designers should:
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(a)
ensure that the client has appointed an Engineer;
(b)
ensure that they do not start design work other than initial design work unless
an Engineer has been appointed;
(c)
co-operate with the Engineer, Contractor and with any other designers or
contractors as necessary for each of them to comply with their duties. This
includes providing any information needed for the pre-construction information
or health and safety file.
Early appointment of the Engineer is crucial for effective planning and establishing
management arrangements from the start. These regulations require the appointment to
take place as soon as is practicable after initial design work or other preparation for
construction work has begun.
22
Once the Engineer has been appointed, the designer will need to co-operate with them
and provide the information which the Engineer needs to comply with their duties.
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Designers are those who have a trade or a business which involves them in:
(a)
preparing designs for construction work, including variations. This includes

preparing drawings, design details, specifications, bills of quantities and the
specification (or prohibition) of articles and substances, as well as all the related
analysis, calculations, and preparatory work; or
(b)
arranging for their employees or other people under their control to prepare
designs relating to a structure or part of a structure.
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Who are designers?
It does not matter whether the design is recorded (for example on paper or a computer)
or not (for example it is only communicated orally).
25
Designers therefore include:
architects, civil and structural engineers, building surveyors, landscape architects,

other consultants, manufacturers and design practices (of whatever discipline)
contributing to, or having overall responsibility for, any part of the design, for
example drainage engineers designing the drainage for a new development;
anyone who specifies or alters a design, or who specifies the use of a particular
method of work or material, such as a design manager, quantity surveyor who
insists on specific material or a client who stipulates a particular layout or material
for a new structure;
(d)
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(e)
building service designers, engineering practices or others designing plant which

forms part of the permanent structure (including lifts, heating, ventilation and
electrical systems), for example a specialist provider of permanent fire
extinguishing installations;
(f)
those purchasing materials where the choice has been left open, for example
those purchasing building blocks and so deciding the weights that bricklayers
must handle;
(g)
contractors carrying out design work as part of their contribution to a project, such
as an engineering contractor providing design, procurement and construction
management services;
(h)
temporary works engineers, including those designing auxiliary structures, such

as formwork, falsework, faade retention schemes, scaffolding, and sheet piling;
(i)
interior designers who also develop the design;
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Page 111
those determining how buildings and structures are altered, for example during
refurbishment, where this has the potential for partial or complete collapse.
Manufacturers supplying standardised products that can be used in any project are not
designers under CDM. The person who selects the product is a designer and must take
account of health and safety issues arising from its use. If a product is purpose-made for
a project, the person who prepares the specification is a designer under CDM, and so is
the manufacturer who develops the detailed design.
What designers should do for all projects
make sure that they are competent and adequately resourced to address the
health and safety issues likely to be involved in the design;
(b)
check that clients are aware of their duties;
(c)
When carrying out design work, avoid foreseeable risks to those involved in the
construction and future use of the structure, and in doing so, they should eliminate
hazards (so far as is reasonably practicable, taking account of other design
considerations) and reduce risk associated with those hazards which remain;
(d)
provide adequate information about any significant risks associated with the
design;
(e)
co-ordinate their work with that of others in order to improve the way in which risks
are managed and controlled.
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In carrying out these duties, designers need to consider the hazards and risks to those
who:
carry out construction work including demolition;
(b)
clean any window or transparent or translucent wall, ceiling or roof in or on a

structure or maintain the permanent fixtures and fittings;
(c)
use a structure designed as a place of work;
(d)
may be affected by such work, for example customers or the general public.
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(a)
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Designers should:
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27
These duties apply whenever designs are prepared which may be used in construction
work in Qatar. This includes concept design and relevant work carried out as part of
feasibility studies.
29
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When do these duties apply?
Making clients aware of their responsibilities

30
Designers are often the first point of contact for a client, and CDM requires them to
check that clients are aware of their duties under these Regulations
Preparing a design
31
Designers have to weigh many factors as they prepare their designs. Health and safety
considerations have to be weighed alongside other considerations, including cost,
fitness for purpose, aesthetics, building safety issues, maintainability and environmental
impact. CDM allows designers to take due account of other relevant design
considerations. These Regulations do not prescribe design outcomes, but they do
require designers to weigh the various factors and reach reasoned, professional
decisions.
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Designers are required to avoid foreseeable risks so far as is reasonably practicable, taking
due account of other relevant design considerations. The greater the risk, the greater the
weight that must be given to eliminating or reducing it. Designers are not expected to
consider or address risks which cannot be foreseen, and these Regulations do not
require zero risk designs because this is simply impossible. However, designers must
not produce designs that cannot be constructed, maintained, used or demolished in
reasonable safety.
33
Designers should critically assess their design proposals at an early stage, and then
throughout the design process, to ensure that health and safety issues are identified,
integrated into the overall design process and addressed as they go along. It is pointless
to complete the design first, then try to address the risks which the design has
introduced. By then, all of the key decisions are likely to have been taken and no one
will be willing to make any changes because of the time and cost involved.
34
The first thing that designers need to do is eliminate hazards (things with a potential to
cause harm) from their designs so far as is reasonably practicable, taking account of
other design considerations. Examples would be to design out things like fragile roofing
materials or products; eliminating roof lights from areas where roof access is needed;
positioning plant which needs regular maintenance at ground level so there is no need
for work at height or providing permanent safe access for work at height. Eliminating
hazards removes the associated risk, and is therefore the best option and should always
be the first choice.
35
It is not always reasonably practicable to eliminate hazards, and where this is the case
consideration should be given to incorporating design solutions which reduce the overall
risk to an acceptable level. This can be done by reducing the:
as
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32
likelihood of harm (injury or adverse health effect);
(b)
potential severity of the harm;
(c)
number of people exposed to the harm; and
(d)
frequency or duration of exposure to harm.
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(a)
The amount of effort put into eliminating hazards and reducing risks should depend on
the degree of risk. There is little point in spending a lot of money, time and trouble on
low risk issues. There is also little to be gained by detailed comparison of construction
techniques that present similar risks, for example whether to specify a steel frame or
concrete portal building. The focus should be on issues that are known to have the
potential to cause significant harm, and where there are known solutions that reduce the
risks to everyone exposed.
37
Designers also need to take account of other relevant health and safety requirements
when carrying out design work. Where the structure will be used as a workplace, (for
example factories, offices, schools, hospitals and any other structures which can be a
place of work for end users including maintainers) they need to take account of the
provisions of the latest version for QCS requirements.
et
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36
38
Designers must provide information that other project team members are likely to need
to identify and manage the remaining risks. This should be project specific, and
concentrate on significant risks which may not be obvious to those who use the
design. For example, providing generic risk information about the prevention of falls is
pointless, because competent contractors will already know what needs to be done, but
if the design gives rise to a specific and unusual fall risk which may not be obvious to
contractors, designers should provide information about this risk.
39
Designers also need to provide information about aspects of the design that could
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create significant risks during future construction work or maintenance. If in doubt about
the level of information needed, the best way to find out is to ask those who will use it.
40
(a)
not likely to be obvious to a competent contractor or other designers;
(b)
unusual; or
(c)
likely to be difficult to manage effectively.
Information should be brief, clear, precise, and in a form suitable for the users. This can
be achieved using:
(a)
notes on drawings this is preferred, since the notes will then be immediately
available to those carrying out the work. They can refer to other documents if
more detail is needed, and be annotated to keep them up to date;
(b)
written information provided with the design - this should be project specific, and
should only contain information which will be useful to those constructing or
maintaining the structure;
(c)
suggested construction sequences showing how the design could be erected

safely, where this is not obvious, for example suggested sequences for putting up
pre-cast panel concrete structures. Contractors may then adopt this method or
develop their own approach.
It is not always possible to provide all the information at the same time, particularly when
design work is continuing whilst construction work is underway. In these circumstances
information should be released as the design develops, but construction work should not
be allowed to proceed unless all the information necessary for the work to be carried out
safely has been provided.
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42
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41
Significant risks are not necessarily those that involve the greatest risks, but those,
including health risks that are:
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Co-operation
Designers must co-operate with the client, and other designers and contractors,
including those designing temporary works. This is to ensure that incompatibilities
between designs are identified and resolved as early as possible, and that the right
information is provided in the pre-construction information.
44
For smaller projects where most of the work is done by a single designer, this can be
achieved through discussion with those who use or are affected by the design. For
larger projects or those involving significant risks, a more managed approach will be
necessary.
45
Co-operation can be encouraged by:
et
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43
46
(a)
setting up an integrated team involving designers and contractor.
(b)
the appointment of a lead designer, where many designers are involved.
(c)
agreeing a common approach to risk reduction during design;
(d)
regular meetings of all the design team (including the engineer) with contractors,
and others;
(e)
regular reviews of developing designs;
(f)
site visits, through which designers can gain a direct insight into how the risks are
managed in practice.
Regular reviews of the design involving all members of the design team are particularly
important in making sure that proper consideration is given to building safety issues,
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usability and maintainability. When considering building safety issues, meetings should
include the contractor so that difficulties associated with construction can be discussed
and solutions agreed before the work begins. When discussing usability and
maintainability, involving the client or those who will be responsible for operating the
building or structure will mean that proper consideration can be given to the health and
safety of those who will maintain and use the structure once it has been completed.
Doing this during the design stage will result in significant cost savings for the client, as
rectifying mistakes after the structure has been built is always expensive.
What designers dont have to do
Under CDM, designers dont have to:
(a)
take into account or provide information about unforeseeable hazards and risks;
(b)
design for possible future uses of structures that cannot reasonably be anticipated
from their design brief;
(c)
specify construction methods, except where the design assumes or requires a

particular construction or erection sequence, or where a competent contractor
might need such information;
(d)
exercise any health and safety management function over contractors or others;
or
(e)
worry about trivial risks.
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47
Designers are not required to keep records of the process through which they achieve a
safe design, but it can be useful to record why certain key decisions were made. Brief
records of the points considered, the conclusions reached, and the basis for those
conclusions, can be very helpful when designs are passed from one designer to
another. This will reduce the likelihood of important decisions being reversed by those
who may not fully understand the implications of doing so.
49
Too much paperwork is as bad as too little, because the useless hides the necessary.
Large volumes of paperwork listing generic hazards and risks, most of which are well
known to contractors and others who use the design are positively harmful, and suggest
a lack of competence on the part of the designer.
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et
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1.1.8.33 The Contractor
Contractor
Under these Regulations, the duties of the contractor are to:

(a)
plan, manage and monitor construction work to ensure so far as is reasonably

practicable that it is carried out without risks to health and safety, including ensuring:
(i)
that there is adequate co-operation and co-ordination between all parties

involved in the project
(ii)
that the general principles of prevention are applied
(b)
liaise with the engineer with regard to ensuring the co-operation between designers
during the construction phase
(c)
ensure that adequate welfare facilities are provided in accordance with Appendix 1
(d)
where necessary in the interests of health and safety, draw up site rules which are
appropriate to the site and the activities that will be carried out on it
(e)
give reasonable directions to subcontractors to enable the contractor to fulfil their
duties under these Regulations
(f)
ensure that all sub-contractors are informed of the minimum amount of time that will
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be allowed to them for planning and preparation, before their construction work starts
(g)
where necessary, consult with sub-contractors before finalising the parts of the
construction phase plan that are relevant to the work to be undertaken by each subcontractor
(h)
ensure that before each sub-contractor's work begins, the sub-contractor is given
sufficient time to access the parts of the health and safety plan that are relevant to the
sub-contractor's work and that the relevant parts of the plan contain sufficient detail for
the sub-contractor's needs
(i)
ensure that before each contractor's work begins, the contractor is given sufficient
time to enable them to prepare such information as they need with regard to:
the prompt provision of welfare facilities
(ii)
carrying out their work without risks to health and safety so far as is reasonably
practicable
(i)
identify to each sub-contractor the information needed by the engineer for the health
and safety file and to ensure that the information is promptly provided
(k)
take reasonable steps to prevent unauthorised access to the site
(l)
take all reasonable steps to ensure that all workers are provided with a suitable site
induction and other information and training as may be necessary
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(j)
There is an emphasis on trying to keep documentation to a minimum. This is based on the

idea that a competent workforce only needs to be told about site-specific risks and working
practices.
While these requirements might seem onerous they are all principles of good management
of health, safety and welfare and many companies have been implementing them for a long
time.
The avoidance of accidents and the prevention of ill health by the use of good management
techniques have proven to result in significant benefits, not least to the 'bottom line'.
Good management of health and safety on site is crucial to the successful delivery of a
construction project. The key duty of contractors is to properly plan, manage and coordinate work during the construction phase in order to ensure that the risks are properly
controlled. Contractors must also comply with the duties placed on all contractors under
these Regulations.
This allows the management of health and safety to be incorporated into the wider
management of project delivery. This is good business practice as well as being helpful
for health and safety purposes.
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Co-operation and co-ordination

7
Good co-operation and co-ordination of work between all of the parties involved in a
project is essential if risks are to be identified early on and properly controlled.
Contractors should take the lead and actively encourage co-operation and co-ordination
between sub-contractors from an early stage. A team approach involving the client,
designers, contractors and even manufacturers who work closely together will often
produce the best results. This allows the client, designers, contractors and facilities
management experts, together, to identify the best solution for the clients needs, taking
account of the practicalities of construction work, maintenance and use. Even on
projects where it is not practical to formally establish an integrated team, the client,
designer, contractors and others involved in the project still need to work together.
If there are other projects on the same or neighbouring sites then the co-operation and
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co-ordination needs to extend to those involved with such projects. If this need can be
identified early on, the risks that one project may cause for the other can also be
identified and addressed in the early stages of project planning. If potential problems are
not identified until the actual work has started they can be much more difficult to
address.
9
Good, timely communication is essential to co-operation and co-ordination of activities.

Information about risks and precautions needs to be shared sensibly (i.e. relevant
information, not everything) when it is needed to plan and manage work. Drawings can
be used to highlight hazards or unusual work sequences identified by designers, with
advice on where to find more information, if required. Induction training and toolbox talks
help to ensure workers understand the risks and precautions, and are a good
opportunity to inform workers of site rules or any special risks relating to the project.
How many Contractors can there be for each project?

There can only be one main contractor for a project at any one time. However,
sometimes two or more projects take place on a site at the same time. This can occur if
different clients commission adjacent work, or if a client procures two truly independent,
unrelated packages of work which do not rely upon one another for their viability or
completion.
11
Where overlapping projects are running on a single construction site, it is best to appoint
one Contractor for them all. If this is not done, all the contractors must co-operate, and
their plans must take account of the interfaces for example in traffic management.
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Planning and managing health and safety in the construction phase

Contractors must plan, manage and co-ordinate work during the construction phase
taking account of the information contained in the pre-construction information provided
by the client, and any other information provided by subcontractors.
13
The effort devoted to planning and managing health and safety should be in proportion
to the risks and complexity associated with the project.
14
The Contractor should work with other sub-contractors to identify the hazards and
assess the risks related to their work, including the risks they may create for others.
Using this information and applying the general principles of prevention the Contractor,
in discussion with the sub-contractors involved, must plan, manage and co-ordinate the
construction phase. This includes supervising and monitoring work to ensure that it is
done safely and that it is safe for new activities to begin.
15
Where the project involves high-risk work, for example alterations that could result in
structural collapse, work on contaminated land, specialist advice is likely to be needed at
the planning stage.
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12
The construction phase plan

16
The way in which the construction phase will be managed and the key health and safety
issues for the particular project must be set out in writing in the construction phase plan.
This plan should set out the organisation and arrangements that have been put in place
to manage risk and co-ordinate the work on site. It should not be a repository for
detailed generic risk assessments, records of how decisions were reached or detailed
method statements, but it may, for example set out when such documents will need to
be prepared. It should be well focused, clear and easy for sub-contractors and others to
understand emphasising key points and avoiding irrelevant material. It is crucial that
all relevant parties are involved and co-operate in the development and implementation
of the plan as work progresses.
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17
The plan must be tailored to the particular project. Generic plans that do not contain
the information relevant to the particular risks associated with the work will not satisfy
the requirements of CDM. Photographs and sketches can greatly simplify and shorten
explanations. It should also be organised so that relevant sections can easily be made
available to designers and sub-contractors.
18
Often the design and preparation for later work is not complete at the start of the
construction phase. Nevertheless, the plan for the initial phase of the construction work
must be prepared before any work begins. It should also address later activities that will
require careful planning. It may only be practical to address such activities in outline
form before work starts and most will require revision in the light of developments.
Implementing and monitoring the plan
A plan is no use if it is treated as merely a paper exercise and gathers dust. To improve
Qatar standards, it must be a practical aid to the management of health and sa fety on
site. Contractors and other sub-contractors have a particular role in both implementing
and monitoring the plan to ensure that it works in practice. Monitoring arrangements will
need to be discussed and agreed with the client as they form part of the management
arrangements.
20
The purpose of monitoring is to ensure that the precautions described in the

construction phase plan are appropriate and followed in practice. Where contractors do
not work safely or comply with the plan, Contractors must take appropriate action to
deal with the risk.
21
The contractor is responsible for ensuring the health and safety of everyone on site.
Everyone on site (including the client, anyone working for the client and workers of utility
companies) must co-operate with the contractor to enable them to comply with their duties.
22
The plan needs to be routinely reviewed, revised and refined by the contractor as the
project develops. For example, where the plan is not being followed, and health and
safety is put at risk, those involved must take appropriate action to deal with the risk.
Monitoring may show the plan has shortcomings and needs to be modified. Any
significant changes in the plan should be brought to the attention of all those affected.
Contractors should include any necessary rules for the management of construction
work in the construction phase plan, which others on the site have to follow. These may
cover issues such as restricted areas, permit-to-work systems, hot work and emergency
plans. In order to avoid cluttering the plan with detailed arrangements for implementing
site rules, the plan should refer to other documents or put detailed arrangements in
appendices. Site rules should be:
23
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Site rules
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19
24
(a)
set out in writing;
(b)
understandable to those who have to follow them;
(c)
brought to the attention of everyone who has to follow them;
(d)
enforced by the Contractor
Copies of the site rules should be displayed on site in a place where they can be seen
by those who work there.
Controlling access onto sites
25
A contractor must take reasonable steps to prevent access by unauthorised persons to

the construction site. Only people who are explicitly authorised, individually or
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collectively, by the contractor, should be allowed access. The authorisation may cover
the whole site or be restricted to certain areas. Authorised people should have relevant
site rules explained to them and undertake any necessary site induction, and should
comply with site rules and co-operate with the contractor. Some authorised visitors may
need to be supervised or accompanied while on site or visiting specific areas.
rights of way cross sites;
(b)
sites are in, or next to, other work areas;
(c)
new houses are being built on a development where some houses are already
occupied; or
(d)
there are children or other vulnerable people nearby.
qa
a suitable induction; and
(b)
any further information and training needed for the particular work.
se
(a)
er
This does not mean that the contractor has to train everyone on the site - this will be the
responsibility of individual sub-contractors.
Induction
(a)
et
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Inductions are a way of providing workers with specific information about the particular
risks associated with the site and the arrangements that have been made for their
control. Induction is not intended to provide general health and safety training, but it
should include a site-specific explanation of the following:
senior management commitment to health and safety
30
as
Site induction, training and information are vital to securing health and safety on site.
The Contractor has to ensure, so far as is reasonably practicable, that every worker has:
ov
29
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The effectiveness of the arrangements needs to be reviewed in the light of experience.

In particular, their adequacy should be carefully reviewed if there is evidence of children
playing on, or near the site.
Site induction, training and information
28
(a)
rw
27
How access is controlled depends on the nature of the project, the risks and location.
The boundaries of all sites should be physically defined, where necessary, by suitable
fencing. The type of fencing should reflect the nature of the site and its surroundings.
Special consideration is needed where:
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26
(b)
the outline of the project
(c)
the individuals immediate line manager and any other key personnel
(d)
any site-specific health and safety risks, for example in relation to access,
transport, site contamination, hazardous substances and manual handling
(e)
Control measures on the site, including;

(i)
any site rules,
(ii)
any permit-to-work systems,
(iii)
traffic routes,
(iv)
security arrangements,
(v)
hearing protection zones,
(vi)
arrangements for personal protective equipment, including what is needed,

where to find it and how to use it,
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(vii)
arrangements for housekeeping and materials storage,
(viii) facilities available, including welfare facilities,

(ix)
emergency procedures, including fire precautions, the action to take in the

event of a fire, escape routes, assembly points, responsible people and the
safe use of any fire-fighting equipment;
(f)
arrangements for first aid
(g)
arrangements for reporting accidents and other incidents
(h)
details of any planned training, such as toolbox talks
(i)
arrangements for consulting and involving workers in health and safety, including
the identity and role of any:
(ii)
safety committees;
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safety representatives,
information about the individuals responsibilities for health and safety.
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(j)
(i)
1.1.8.34 Sub-Contractor
Sub-contractors and those actually doing the construction work are most at risk of injury
and ill health. They have a key role to play, in co-operation with the contractor, in
planning and managing the work to ensure that risks are properly controlled.
All sub-contractors (including utilities, specialist contractors, contractors nominated by

the client and the self-employed) have a part to play in ensuring that the site is a safe
and healthy place to work. The key to this is the proper co-ordination of the work,
underpinned by good communication and co-operation between all those involved.
Anyone who directly employs, engages construction workers or controls or manages

construction work related tasks is a sub-contractor for the purposes of these
Regulations. This includes companies that use their own workforce to do construction
work on their own premises. The duties on contractors apply whether the workers are
employees or self-employed and to agency workers without distinction.
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ta
For all projects sub-contractors must:

(a)
check clients are aware of their duties;
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What sub-contractors must do on all projects
(b)
satisfy themselves that they and anyone they employ or engage are competent
and adequately resourced;
(c)
plan, manage and monitor their OWN work to make sure that workers under their
control are safe from the start of their work on site;
(d)
ensure that any sub-contractor who they appoint or engage to work on the project
is informed of the minimum amount of time which will be allowed for them to plan
and prepare before starting work on site;
(e)
provide workers under their control (whether employed or self-employed) with any
necessary information, including about relevant aspects of other contractors work,
and site induction (where not provided by a contractor) which they need to work
safely, to report problems or to respond appropriately in an emergency;
(f)
ensure that any design work they do complies with these Regulations
(g)
co-operate with others and co-ordinate their work with others working on the
project;
(h)
ensure the workforce is properly consulted on matters affecting their health and
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safety; and
(i)
obtain specialist advice (for example from a structural engineer or occupational

hygienist) where necessary when planning high-risk work for example
alterations that could result in structural collapse or work on contaminated land or
carrying out modification works on an existing structure.
Planning and managing construction work

5
Sub-contractors should always plan, manage, supervise and monitor their own work and
that of their workers to ensure that it is carried out safely and that health risks are also
addressed. The effort invested in this should reflect the risk involved and the experience
and track record of the workers involved. Where sub-contractors identify unsafe
practices, they must take appropriate action to ensure health and safety.
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Site induction, information and training

Contractors must not start work on a construction site until they have been provided with
basic information. This should include information from the client about any particular
risks associated with the project (including information about existing structures where
these are to be demolished or structurally altered), and from designers about any
significant risks associated with the design.
Sub-contractors must ensure, so far as is reasonably practicable, that every worker has:
qa
ta
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a suitable induction; and
(b)
any further information and training needed for the particular work
as
(a)
Site induction should be provided by the contractor, and the sub-contractor must cooperate with the contractor to ensure that an adequate site induction is provided.
Where sub-contractors are involved in design work, including for temporary works, they
also have duties as designers.
10
Sub- contractors must also:
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(b)
co-operate with the contractor, the Engineer and others working on the project
or adjacent sites;
et
it
(a)
inform the contractor about risks to others created by their work;
(c)
provide details to the contractor of any supply chain or specialist sub-contractor

whom he engages in connection with carrying out the work;
(d)
comply with any reasonable directions from the main contractor, and with any
relevant rules in the construction phase plan;
(e)
inform the contractor of any problems with the plan or risks identified during
their work that have significant implications for the management of the project;
(f)
inform the contractor about accidents and dangerous occurrences;
(g)
provide information for the health and safety file.
Reporting incidents
11
The Reporting of Injuries, Diseases and Dangerous Occurrences (RIDDOR) require s the
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responsible person to notify any death, reportable injury, disease or dangerous

occurrence to the Qatar Administrative Authority. The responsible person is the
employer or, for the self-employed, the contractor.
Sub-contractors must co-operate with the contractor, and assist them in the
development of the construction phase plan and its implementation. Where subcontractors identify shortcomings in the plan, the contractor should inform the contractor.
13
Sub-contractors must promptly inform the contractor about risks to other site workers or
members of the public resulting from their work. This includes anything, for example
from risk assessments and written systems of work, which might justify a review or
update of the construction phase plan. Sub-contractors must also provide details to the
contractor of any other sub-contractors who they engage to assist in the carrying out of
the work. Contractors must be in a position to know who is working on the site.
Contractors also have duties relating to the provision of information to sub-contractors,
and they will not be in a position to discharge these duties if they are not told that such
sub-contractors have been engaged.
14
Sub-contractors must also provide information about RIDDOR incidents to contractors

so that they can monitor compliance with health and safety standards and, if necessary,
review the arrangements for the management of health and safety.
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12
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Site Specific Duties (Contractors/Sub-contractors)
Every contractor and subcontractor carrying out construction work shall comply with the
regulatory requirements of this section insofar as they affect him or any person carrying out
construction work under his control or relate to matters within his control.
16
Every person (other than a contractor carrying out construction work) who controls the way
in which any construction work is carried out by a person at work shall comply with the
regulatory requirements under this section insofar as they relate to matters which are within
his control.
17
Every person at work on construction work under the control of another person shall report to
that person any defect which he is aware may endanger the health and safety of himself or
another person.
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as
15
Safe places of work

There must be, so far as is reasonably practicable, safe access to and egress from a place
of work and to any other place provided for the use of any person at work. Such means of
access must be properly maintained.
19
Places of work must, so far as is reasonably practicable, be maintained without risk to health
or safety of the person(s) who will work there.
20
Suitable and sufficient steps must be taken to ensure, so far as is reasonably practicable,
that no-one gains access to any place which does not comply with the requirements of these
Regulations
21
Every place of work must, so far as is reasonably practicable, be of sufficient size and be
arranged so that it is suitable for any person who has to work there, taking account of any
work equipment used.
18
Good order (Housekeeping)

22
Every part of a construction site shall, so far as is reasonably practicable, be kept in good
order and every part of the site which is used as a place of work shall be kept in a
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reasonable state of cleanliness.

23
Where it is necessary in the interests of health and safety, the perimeter of the site shall be
identified by suitable signs so that the arrangements and extent of the site is readily
identifiable, or fenced off, or both.
24
No timber or other material with projecting nails or other similar sharp objects shall be used
in any work or be allowed to remain in any place where the nails will be a source of danger
to any person.
Stability of structures
All practicable steps must be taken to ensure that any structure or part of a structure which
may become unstable or weak due to construction work does not collapse.
26
Any buttress, temporary support or temporary structure:
.l.
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25
must be installed and maintained to withstand any strains and stresses that may be
imposed on it
(b)
only be used for the purposes for which it was designed, installed and maintained.
rw
(a)
No part of a structure may be loaded in such a way that it becomes unsafe.
28
The client is responsible for providing reasonable information, and issues relating to the
stability of the structure would fit into that category.
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27
as
Demolition or dismantling
The demolition or dismantling of any structure must be planned and carried out in such a
way as to prevent danger, or reduce the danger so far as it is reasonably practicable to do
so.
30
Demolition or dismantling must not be carried out unless the arrangements for ensuring that
is carried out in a safe manner have first been recorded in writing.
31
The demolition or dismantling of any structure must be planned and carried out as safely as
possible, under the supervision of a competent person. Demolishing buildings and structures
remains high risk work.
32
It will normally be impossible for the contractor to comply with these Regulations without
reports such as an asbestos survey, information on underground services and structural
surveys.
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Explosives
33
So far as is reasonably practicable, explosives must be stored, transported and used safely
and securely.
34
Explosives may only be used when steps have been taken to ensure that there is no danger
from the explosion, projected or flying materials.
35
Any blasting would categorically be considered high risk work and a written method
statement required.
Excavations
36
All practicable steps, such as the provision of supports or battering, must be taken where
necessary to prevent danger to any person, to ensure that:
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(c)
no part of an excavation collapses
(d)
any accidental fall or dislodgement of material is prevented
(a)
no person is buried or trapped by the fall or dislodgement of any material.
37
Suitable and sufficient steps must be taken to prevent the fall of any person, equipment or
material into the excavation.
38
Suitable and sufficient steps must be taken to prevent, where necessary, any part of an
excavation or ground adjacent to it from being overloaded by work equipment or material.
39
Work must not be carried out in any excavation where supports or battering have been
provided, unless:
(b)
the person who inspected it is satisfied that work can be carried out in it safely.
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the excavation and any equipment and materials which affect its safety have been
inspected by a competent person.
Work must not be carried out in any excavation if an inspection reveals any defect rendering
the excavation unsafe, until that defect has been rectified.
The decision as to whether or not to install shoring must be made with regard to the
circumstances prevailing at the time. Suitable and sufficient steps must be taken to
prevent any person working in an excavation from becoming trapped or buried by a
fall of materials.
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Excavations must be supported as soon as possible by the provision of sufficient and

suitable materials. Such supports must only be installed, altered or dismantled under the
supervision of a competent person and without the person(s) installing the supports being
put at risk.
of suitable design and construction and have sufficient strength and capacity for the
purpose for which it is being used
(b)
equipped to enable workers to gain shelter or escape, if water or materials should

enter it
properly maintained.
Work must not be carried out in any cofferdam or caisson unless:

(a)
(b)
44
(a)
(c)
43
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Every cofferdam or caisson must be:
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Cofferdams and caissons
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40
(a)
it and any work equipment or materials which affect its safety have been inspected:
(i)
before any person carries out any work at the start of every shift, and
(ii)
after any event likely to affect the strength or stability of the cofferdam or
caisson or any part of it
the person who inspected it is satisfied that work can be carried out in it safely.
Work must not be carried out in any cofferdam or caisson if any inspection reveals any
defect rendering the cofferdam or caisson unsafe, until that defect has been rectified.
Reports of inspections
45
Where a statutory inspection of an excavation, cofferdam or caisson has been carried out,
the person carrying out the inspection must, before the end of the shift during which the
inspection was carried out:
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(a)
inform the person for whom the inspection was carried out of any matter that renders
the excavation or caisson unsafe as a place of work
(b)
prepare a written report.
Note: The report must contain the particulars listed in Appendix 2.
47
The person who prepares the written report must provide a copy of the report within 24 hours
to the person on whose behalf the inspection was carried out.
48
The employer Contractor of the person authorised to carry out inspections, or the person in
control, must ensure that the inspections are only carried out by persons who are authorised
to do so.
49
The report or a copy of it must be kept available for inspection by a Administrative Authority
Workplace Inspector
for a period of three months (at the company offices)
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on the site until the project is completed, and thereafter
No report of a cofferdam or caisson inspection is required if one has been written within the
previous seven days.
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(a)
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Energy distribution installations
Where it is necessary to prevent danger, every energy distribution installation must be

located, checked and clearly identified.
52
Where there is a risk from electric power cables, in order of priority, they must be;
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repositioned out of the area of risk, or
(b)
made dead by cutting off the current, or
(c)
where it is not reasonably practicable to carry out the above actions erect warning
notices and:
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(a)
barriers, or
(ii)
a suspended means of protection where vehicles have to pass beneath

overhead cables, or
(iii)
other measures which provide an equivalent or better level of protection.
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(i)
53
Construction work must not be carried out where there is a risk of danger from damaging or
disturbing underground services unless suitable and sufficient steps have been taken so far
as is reasonably practicable.
54
Whilst electrical cables are specifically mentioned, the title indicates that the general
requirement outlined in the first paragraph applies to all sources of energy, for example
hydraulic and pneumatic distribution systems.
Prevention from drowning
55
Where any person is liable to drown from falling into water or any other liquid, suitable and
sufficient steps must be taken to:
(a)
prevent, so far as is reasonably practicable, a person falling
(b)
minimise the risk of a person drowning in the event of a fall
(c)
ensure that suitable rescue equipment is provided, maintained and properly used so
that anyone who falls into the water may be promptly rescued.
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56
Suitable and sufficient steps must be taken to ensure the safety of any person transported to
their place of work by water.
57
Any vessel used to convey a person to or from a place of work, by water, must not be
overcrowded or overloaded.
Traffic routes
Every construction site must, so far as is reasonably practicable, be organised in such a way
that pedestrians and vehicles can move about safely and without risk to health.
59
Traffic routes must be suitable for persons or vehicles using them, sufficient in number, in
suitable places and of sufficient size.
60
To be suitable, each traffic route must:

enable pedestrians and vehicles to use it without causing danger to persons who are
near it
(b)
doors or gates used by pedestrians which lead into a traffic route must be adequately
separated from that route so that pedestrians may see approaching vehicles
(c)
provide sufficient separation between vehicles and pedestrians to ensure safety, or,
where that is not reasonably practicable, provide:
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(a)
other means of protecting pedestrians and
(ii)
an effective means of warning any at-risk pedestrian of the approach of any

vehicle
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(i)
have at least one exit in any loading bay for the exclusive use of pedestrians
(e)
provide one or more pedestrian-only gates, clearly marked and kept free of
obstructions where it is unsafe for pedestrians to use a gate intended primarily for
vehicles.
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Traffic routes must be:
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(d)
identified by suitable signs, where necessary
(b)
regularly checked and
(c)
(a)
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58
satisfactorily maintained.
No vehicle must be permitted to drive on a traffic route unless, so far as is reasonably

practicable, the route is free from obstructions and permits sufficient clearance.
63
All traffic routes must be indicated where necessary.
62
Vehicles
64
Suitable and sufficient steps must be taken to prevent the unintended movement of any
vehicle.
65
Suitable and sufficient steps must be taken to ensure that persons who are in control of
vehicles give warning to other persons who may be endangered by the movement of the
vehicle.
66
Any vehicle being used for construction work must be:

(a)
driven, operated or towed in a safe manner
(b)
loaded in such a way that it can be driven, operated or towed in a safe manner.
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67
No person shall ride or be required to ride on any vehicle unless they are in a safe place that
is purposely provided (i.e. the vehicle is designed to carry passengers).
68
No person may remain or be required to remain on any vehicle while it is being loaded or
unloaded with any loose material unless a safe place of work is provided for them and
maintained as necessary.
69
Suitable and sufficient steps must be taken to prevent the vehicle from falling into an
excavation or pit, or into water, or over the edge of an embankment or earthwork.
Prevention of risk from fire
Suitable and sufficient steps must be taken to prevent, so far as is reasonably practicable,
the risk of injury to any person during the carrying out of construction work arising from any
fire or explosion, flooding, or any substance that is liable to cause asphyxiation.
70
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Where necessary, in the interests of health and safety, suitable and sufficient arrangements
must be prepared and, where necessary, implemented to deal with any foreseeable
emergency, and such arrangements must include procedures for evacuation of the site, or
any part of it.
72
When making these arrangements, account must be taken of:

the type of work being carried out
(b)
the characteristics and size of the site and the number of work locations on it
(c)
the work equipment being used
(d)
the number of persons likely to be present on the site at any one time
(e)
the physical and chemical properties of any substances or materials likely to be on the
site
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(a)
Such arrangements must be communicated to all persons on site and tested at suitable
intervals.
73
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Emergency routes and exits

Sufficient emergency routes and exits must be provided to enable any person to quickly
reach a place of safety in the event of danger.
75
Any emergency route or exit must lead directly, or as directly as possible, to an identified
safe area.
76
Any emergency route or exit must be kept clear of obstructions and, where necessary,
provided with emergency lighting so that it can be used safely at any time.
77
All emergency routes and exits must be indicated by suitable signs.
74
Fire detection and fire-fighting

78
Where necessary in the interests of health and safety, suitable fire-fighting equipment,
together with fire alarms and fire detection systems, must be installed in suitable locations.
79
A fire risk assessment will be required for the site including storage areas, with particular
emphasis on the storage highly flammable or explosive substances, and site welfare
facilities.
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80
Fire-fighting equipment and fire detection/alarm systems must be properly maintained and
subjected to periodic tests and examination so as to ensure that the equipment remains
effective.
81
Any fire-fighting equipment that is not designed to operate automatically must be easily
accessible.
82
Every person at work on a construction site must, so far as is reasonably practicable, be

instructed in the use of any fire-fighting equipment that it may be necessary for them to use.
83
Where any work activity gives rise to a particular risk of fire, no person shall be authorised to
carry out such work unless that person has received suitable instructions.
84
All fire-fighting equipment must be indicated by suitable signs.
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Fresh air
Suitable and sufficient steps must be taken to ensure, so far as is reasonably practicable,
that every workplace or approach to it has sufficient fresh or purified air to ensure that the
place or approach is safe and without risk to health.
86
Where plant is used for the purpose of providing fresh or purified air, it must be equipped
with an effective device to give visible and audible warning of the failure of the plant.
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Temperature and weather protection
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85
Suitable and sufficient steps must be taken during working hours to ensure, so far as is
practicable, that the temperature at any indoor place of work is reasonable, having regard for
the purpose for which the place is being used.
88
Every place of work outdoors must, where necessary to ensure the health and safety of the
people at work there, be arranged so far as is reasonably practicable, to provide adequate
protection from adverse weather, having regard for the purpose for which the place is used
and any protective clothing or work equipment provided.
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Lighting
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Every place of work, every approach to it and every traffic route must be provided with
suitable and sufficient lighting. The lighting should, as far as is reasonably practicable, be
natural lighting.
90
The colour of any artificial lighting must not adversely affect or change a perception of any
sign or signal that is provided for the purposes of health and safety.
91
Secondary or emergency lighting must be provided where there may be a risk to the health
and safety of any person in the event of the failure of any primary artificial lighting.
89
1.1.8.35 Competence and training

92
This section gives guidance about assessing the competence of organisations and
individuals engaged or appointed under CDM engineers; designers; contractors and
sub-contractors.
93
Assessments should focus on the needs of the particular project and be proportionate to the
risks, size and complexity of the work.
94
To be competent, an organisation or individual must have:
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(a)
sufficient knowledge of the specific tasks to be undertaken and the risks which the
work will entail.
(b)
sufficient experience and ability to carry out their duties in relation to the project; to
recognise their limitations and take appropriate action in order to prevent harm to
those carrying out construction work, or those affected by the work.
Organisations and individuals will need specific knowledge about the tasks they will be
expected to perform, and the risks associated with these tasks. This will usually come
from formal or on the job training.
96
Appropriate experience is also a vital ingredient of competence. People are more likely
to adopt safe working practices if they understand the reasons why they are necessary,
and past experience should be a good indicator of the persons/ companys track record.
97
The development of competence is an ongoing process. Individuals will develop their

competence through experience in the job and through training which is part of life-long
learning. Professionals such as designers, engineers and advisors should be signed up
to a Continuing Professional Development CPD programme either through their
company or professional institution membership schemes. This will allow them to remain
up to date with changes in best and professional practice. Construction trades workers
and labourers should also receive refresher training or regular training updates either
through an in-house planned programme of learning and development, or a more formal
skills-based training programme.
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What you must do
All those with duties under CDM must satisfy themselves that businesses that they
engage or appoint are competent. This means making reasonable enquiries to check
that the organisation or individual is competent to do the relevant work and can allocate
adequate resources to it. Those taken on to do the work must also be sure that they are
competent to carry out the required tasks before agreeing to take on the work.
99
A key duty of the engineer is to advise clients about competence of designers and
contractors.
100
Doing an assessment requires you to make a judgement as to whether the organisation or

individual has the competence to carry out the work safely. If your judgement is reasonable,
taking into account the evidence that has been asked for and provided, you will not be
criticised if the organisation you appoint subsequently proves not to have been competent
to carry out the work.
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How to assess the competence of organisations

101
Competency assessments of organisations (including contractors, sub-contractors,

designers and engineers) should be carried out as a two-stage process:
102
Stage 1: An assessment of the companys organisation and arrangements for health

and safety to determine whether these are sufficient to enable them to carry out the
work safely and without risk to health.
103
Stage 2: An assessment of the companys experience and track record to establish that
it is capable of doing the work; it recognises its limitations and how these should be
overcome and it appreciates the risks from doing the work and how these should be
tackled.
104
In order to provide more consistency in the way in which competency assessments of

companies are carried out, a set of core criteria is set out below.
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Competence chart
Core criteria for demonstration of competence:
106
Companies, contractors, engineers and designers
107
You need to meet the standards set out in the core criteria table on the next page.
108
Column 1 of the table lists the elements which should be assessed when establishing
whether or not a company is competent for the work which they will be expected to do.
109
Column 2 lists the standards against which the assessment should be made. Column 3
gives some examples of how a company might demonstrate that it meets these standards.
110
Companies do not have to produce all of the evidence listed in column 3 to satisfy the
standard - they simply need to produce enough evidence to show that they meet the
standard in column 2, taking account of the nature of the project and the risks which the work
entails. This requires you to make a judgement as to whether the evidence provided meets
the standard to be achieved. If your judgement is reasonable, and clearly based on the
evidence you have asked for and been provided with, you will not be criticised if the
company you appoint subsequently proves not to be competent when carrying out
the work.
111
Remember that assessments should focus on the needs of the particular job and should be
proportionate to the risks arising from the work. Unnecessary bureaucracy associated with
competency assessment obscures the real issues and diverts effort away from them.
112
'contractor', 'designer' and 'engineer' relate to your function, not to the type of organisation.
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Section
11: Health and Safety
Part
1.01: Qatar Legislation and Management (Regulatory Document)
Page 130
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QCS 2014
Standard to be achieved
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Criteria
Health and safety policy and You are expected to have and implement an A signed, current copy of the company policy (indicating when
organisation for health and appropriate policy, regularly reviewed, and signed off it was last reviewed and by whose authority it is published).
safety
by the managing director or equivalent.
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Stage 1 assessment
Examples of the evidence that you could use to

demonstrate you meet the required standard
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The policy must be relevant to the nature and scale of

your work and set out the responsibilities for health and
safety management at all levels within the organisation.
Arrangements
Competent advice -corporate Your organisation, and your employees, must have Name and competency details of the source of advice, e.g. a
and construction related
ready access to competent health and safety advice, safety group, trade federation, or consultant who provides
preferably from within your own organisation.
health and safety information and advice.
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These should set out the arrangements for health and A clear explanation of the arrangements which the company
safety management within the organisation and should has made for putting its policy into effect and for discharging
be relevant to the nature and scale of your work. They its duties under CDM .
should set out how the company will discharge their
duties under CDM. There should be a clear indication
of how these arrangements are communicated to the
workforce.
The advisor must be able to provide general health and An example from the last 12 months of advice given and
safety advice, and also (from the same source or action taken.
elsewhere) advice relating to construction health and
safety issues.
.
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Section
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Training and information
You should have in place, and implement, training

arrangements to ensure your employees have the skills
and understanding necessary to discharge their duties
as contractors, designers or Engineers. You should
have in place a programme for refresher training, e.g. a
continuing professional development programme or life
long learning which will keep your employees updated
on new developments and changes to legislation or
good health and safety practice. This applies
throughout the organisation - from board or equivalent
to trainees.
Headline training records.

Evidence of a health and safety training culture including
records, certificates of attendance and adequate health and
safety induction training for site-based workforce.
Evidence of an active learning programme. Sample 'tool box
talks'.
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Individual qualifications and Employees are expected to have the appropriate

experience
qualifications and experience for the assigned tasks,
unless they are under controlled and competent
supervision.
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QCS 2014
Details of qualifications and/or experience of specific

corporate post holders, e.g. board members, health and
safety adviser etc. Other key roles should be named or
identified and details of relevant qualifications and experience
provided.
FOR CONTRACTORS: details of number/percentage of
people engaged in the project that have passed a
construction health and safety assessment and hold industry
qualifications.
For professionals, details of qualifications and/or professional
institution membership.
Evidence of a company-based training programme suitable
for the work to be carried out.
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Section
Part
Page 132
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Individual qualifications and

experience (cont'd)
FOR
DESIGN
ORGANISATIONS:
details
of
number/percentage of people engaged in the project who
have passed a construction health and safety assessment
Details of any relevant qualifications and/or professional
institution membership and any other specific qualifications
such as NEBOSH Certificate or equivalent.
FOR ENGINEERS: details of number/percentage of people
engaged in the project who have passed a construction health
and safety assessment. Evidence of health and safety
knowledge such as NEBOSH Certificate or equivalent.
Details of professional institution membership and any other
specific qualifications.
Evidence of a clear commitment to training and the continuing
professional development of staff.
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Monitoring, audit and review
You should have a system for monitoring your Could be through formal audit or discussions/reports to senior
procedures, for auditing them at periodic intervals, and managers.
for reviewing them on an ongoing basis.
Evidence of recent monitoring and management response.
Copies of site inspection reports.
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Section
Part
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Workforce involvement
You should have, and implement, an established Evidence showing how consultation is carried out.
means of consulting with your workforce on health and
Records of health and safety committees
safety matters.
Names of safety representatives.
Accident
reporting
and You should have records of all RIDDOR reportable Evidence showing the way in which you record and
enforcement action; follow up events for at least the last three years. You should also investigate accidents and incidents.
investigation
have in place a system for reviewing all incidents, and
Records of the last two accidents/incidents and the actions
recording the action taken as a result.
taken to prevent recurrence.
You should record any enforcement action taken
Records of any enforcement action taken over the last five
against your company over the last five years, and the
years, and what action was taken to put matters right.
action which you have taken to remedy matters subject
to enforcement action.
For larger companies, simple statistics showing incidence
rates of major injuries, over three-day injuries, reportable
cases of ill-health and dangerous occurrences for the last
three years.
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Records should include any incidents that occurred whilst the

company traded under a different name, and any incidents
that occur to direct employees or Labour-only subcontractors.
Subcontracting/
consulting You should have arrangements in place for appointing Evidence showing how you ensure subcontractors are
procedures (if applicable)
competent subcontractors/ consultants.
competent.
You should be able to demonstrate how you ensure Examples of subcontractor assessments you have carried
that subcontractors will also have arrangements for out.
appointing competent subcontractors or consultants.
Evidence showing how you require similar standards of
You should have arrangements for monitoring competence assessment from subcontractors.
subcontractor performance.
Evidence showing how you monitor subcontractor
performance.
.
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Section
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Hazard elimination and risk You should have, and implement, arrangements for Evidence showing how you:
control (Designers only)
meeting your duties under CDM
ensure co-operation and co-ordination of design work
within
the
design
team
and
with
other
designers/contractors
11
ensure that hazards are eliminated and any remaining

risks controlled
ensure that any structure which will be used as a

workplace will meet relevant requirements of the
latest revision for QCS.
Examples showing how risk was reduced through design. A

short summary of how changes to designs will be managed.
(Note: the emphasis here should be on practical measures
which reduce particular risks arising from the design, not on
lengthy procedural documentation highlighting generic risks.)
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Risk
assessment You should have procedures in place for carrying out risk Evidence showing how the company will identify significant
leading to a safe assessments and for developing and implementing safe health and safety risks and how they will be controlled.
method of
work systems of work/method statements.
Sample risk assessments or safe systems of work or method
(Contractors only)
statements.
The identification of health issues is expected to feature This will depend upon the nature of the work, but must reflect
prominently in this system.
the importance of this risk area.
12
Co-operating
with
others
and
coordinating your work
with that of other
contractors
(Subcontractors)
You should be able to illustrate how co-operation and co- Evidence could include sample risk assessments, procedural
ordination of your work is achieved in practice, and how you arrangements, project team meeting notes.
involve the workforce in drawing up method statements/safe
Evidence of how the company co-ordinates its work with other
systems of work.
trades.
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Welfare
provision You should be able to demonstrate how you will ensure that Evidence could include, for example, health and safety policy
(Contractors)
appropriate welfare facilities will be in place before people start commitment; contracts with welfare facility providers; details
work on site.
of type of welfare facilities provided on previous projects.
14
Engineers duties
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You should be able to demonstrate how you go about The evidence should be in the form of actual examples rather
encouraging co-operation, co-ordination and communication than by generic procedures.
between designers.
Standard to be achieved
Examples of the evidence that you could use to

demonstrate you meet the required standard
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Criteria
Stage 2 assessment
Work experience
You should give details of relevant experience in the field of work A simple record of recent projects or contracts should be kept,
for which you are applying.
with the phone numbers and addresses of contacts who can
verify that work was carried out with due regard to health and
safety.
This should be sufficient to demonstrate your ability to deal
with the key health and safety issues arising from the work you
are applying for.
Where there are significant shortfalls in your previous
experience, or there are risks associated with the project which
you have not managed before, an explanation of how these
shortcomings will be overcome.
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Section
Page 136
Part
Organisations who are bidding for work should put together a package of information
that shows how their own policy, organisation and arrangements meet these sta ndards.
If regularly updated, this information should then be used each time they are asked to
demonstrate competence as part of a tender process.
114
Where the project is much larger than any that the organisation being assessed has
worked on before, or where the work will involve them managing new risks, this should
not automatically rule them out for consideration for the work.
115
The assessor should look for an appreciation of these risks; an understanding of how
they will be managed, and some indication of how any shortcomings in their current
arrangements for managing such risks will be addressed.
116
It may be that an organisation is weak in certain areas. This can be addressed by

putting arrangements in place to cover these weaknesses, or by employing people with
particular expertise for relevant parts of the contract. What really matters is that the
organisation has access to the expertise which it needs, and the ability to control the
risks which arise from the work.
117
Remember that assessments should focus on the needs of the particular project and be
proportionate to the risks, size and complexity of the work. Unnecessary bureaucracy
associated with competency assessment can obscure the real issues and divert effort
away from them.
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How to assess the competence of High Hazard Activities

These regulations require clients to ensure that their proposed project engineers, designers,
contractor and sub contractors (including their employees) are competent, adequately
resourced and appointed early enough for the work they have to do. In turn, these duty
holders must assess their own competency and that of their employees and other duty
holders (except in the case of a client where the test does not apply) as they cannot accept
an appointment unless they are competent to do so.
119
In every case, a client must assess the competency of the organisations to be appointed for
high hazard activities.
120
The client must assess the competence of an organisation using a two-stage process:
121
Stage 1: Procedures and arrangements for ensuring health and safety (a client should ask
for evidence of written health and safety policies and these must in turn be checked for
relevance); and
122
Stage 2: Experience and track record.
123
Organisations should provide information as to their competence with reference to the above
when tendering for work. In the case of high specialist activities such as:
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124
(a)
Use of explosives
(b)
Cofferdams and caissons
(c)
Work in compressed air
(d)
Tunnelling and underground works
Clients are required when reviewing competences of specialist contractors who are
tendering for construction projects involving high hazard activities to appoint consultant
health and safety advisers with specialist knowledge pursuant to the high hazard activities.
The appointed consultants experience will aid the clients to discharge their responsibilities
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when reviewing duty holders tender and competence documentation.

125
The list of high hazard activities listed above is not definitive and when projects are out of the
scope of their internal health and safety advisors capability, the appointment of an external
consultant must take place to aid in establishing the competence of construction tendering
contractors.
How to assess the competence of individuals
The information in this section will help clients, engineers or others who control the way
in which construction work is carried out to assess the competence of key individuals.
127
Remember that assessments should focus on the needs of the particular job and should be
proportionate to the risks arising from the work.
128
As with organisations, assessing the competence of an individual should be a two-stage

process:
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Stage 1: An assessment of the persons task knowledge to determine whether this

is sufficient to enable them to carry out the work safely and without risk to health;
(b)
Stage 2: An assessment of the individuals experience and track record to

establish that they are capable of doing the work; they recognise their limitations
and how these should be overcome and they appreciate the risks from doing the
work and how these should be controlled.
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(a)
Stage 1 assessments will look at an individuals qualifications and training records, and
arrangements which have been made for their Continuing Professional Development or
lifelong learning. This will include an assessment as to whether the individual has a basic
understanding of the risks arising from construction work which is essential for all people
who work on or regularly visit sites.
130
Stage 2 assessments should concentrate on the persons past experience in the type of
work which you are asking them to do. Where the work is more complex than any that
the person has done before, or where the work will expose them to new risks, this
should not automatically rule them out for consideration for the work. In these
circumstances, the assessor should look for an appreciation of these risks; an
understanding of how they will be managed, and some indication of how any
shortcomings in their current knowledge will be addressed. Working under the
supervision of someone who is competent and familiar with the work is one way in which
people can learn how to do work safely.
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1.1.8.36 Worker engagement and communication

1
Involving the workforce in identifying and controlling risks is crucial to reducing the high
accident rate associated with construction work. The workforce has first-hand
experience of site conditions and is often the first to identify potential problems. Worker
engagement is the participation by workers in decisions made by those in control of
construction activities, in order that risks on site can be managed in the most effective
way.
Participation will be most effective when the workforce has sufficient knowledge and
confidence to provide feedback, and can identify risks and explain their importance.
People have the confidence to do this when they are properly trained, know how to
report their concerns, and see prompt action being taken as a result. Training should
include, where necessary, the skills required to participate in decision-making
processes, and consultation with managers.
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What you are required to do for all projects

All those in control of construction work are required to provide workers (including the
self-employed) under their control with any information that worker needs to carry out
the construction work safely and without risk to health.
All workers should be provided with a suitable site-specific induction to inform them of
the arrangements for health, safety and welfare at their work site. This should include
any relevant findings resulting from a risk assessment, including risks arising from the
activities of other workers working nearby. If contractors have site rules these should be
explained, along with the procedures to be followed in the event of any worker finding
themselves in a position of serious and imminent danger. Contractors must
communicate to their workers the identity of the person who is responsible for
implementing health and safety procedures on site. Every worker has a duty under CDM
to report anything, which is likely to endanger the health and safety of himself or others.
To ensure involvement of the entire workforce, contractors may need to make special
arrangements for workers who have little or no understanding of Arabic and or English,
or who cannot read Arabic and or English. These could include providing translation,
using interpreters or replacing written notices with clearly understood symbols or
diagrams.
Arrangements for worker engagement on smaller sites should always be tailored to the
size and nature of the project and risks involved. On smaller sites informal arrangements
for collecting workers views can be effective. An effective way of achieving this is to
arrange reviews of method statements immediately before the work itself is being
carried out. Those workers who will be involved in the work can then comment directly
on the risks and the ways in which these are being controlled.
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Employers must consult their workers on matters relating to their health and safety. This
can often be done most effectively through worker representatives.
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Worker representatives
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Requirements for welfare facilities

1.1.8 Appendix 1
The Contractor must provide:
Sanitary conveniences
1
Suitable and sufficient sanitary conveniences must be provided or made available at

readily accessible places. So far as is reasonably practicable, the rooms containing
sanitary conveniences must be;
(a)
adequately ventilated and lit
(b)
kept in a clean and orderly condition.
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Welfare facilities
Suitable and sufficient washing facilities including showers, if required by the nature of
the work or for health reasons, must, so far as is reasonably practicable, be provided or
made available at readily accessible places.
Washing facilities must be provided:
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adjacent to sanitary conveniences, whether or not provided elsewhere
(b)
adjacent to changing rooms, where provided, whether or not provided elsewhere.
Washing facilities must include:
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(a)
a supply of clean hot and cold (or warm) water, which so far as is reasonably
practicable shall be running water
(b)
soap or other suitable skin cleansers
(c)
towels or other suitable means of drying.
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(a)
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Rooms containing washing facilities must be lit and sufficiently ventilated.
Washing facilities and the rooms containing them must be kept in a clean and orderly
condition.
Except for washing facilities which are intended for the washing of hands and forearms
only, separate rooms must be provided for men and women except where they:
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(a)
are in a room, the door of which can be locked from the inside and
(b)
the room is intended to be used by one person at a time.
Drinking water
7
An adequate supply of wholesome drinking water, conspicuously marked with the

appropriate sign, should be provided or made available at readily accessible places.
Sufficient cups or other drinking vessels must be provided, unless the water supply is in
the form of a jet (drinking fountain) from which a person can easily drink.
Changing rooms and lockers
Suitable facilities must be provided or made available at readily accessible places if:
(a)
the worker has to wear special clothing for the purposes of work, and,
(b)
for reasons of health or personal privacy, changing cannot be carried out
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elsewhere.
10
Where necessary, in the interests of personal privacy, separate changing rooms for men
must be provided.
11
Changing rooms must:

(a)
be provided with seating
(b)
include, where necessary, facilities to dry clothing and personal effects
(c)
include, where necessary, facilities for locking away:

special clothing that is not taken home
(ii)
a person's own clothing which is not worn at work
(iii)
their personal effects (property).
(i)
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Suitable and sufficient facilities for rest must be provided at readily accessible places.
They must:
include suitable arrangements to protect non-smokers from the discomfort caused
by tobacco smoke
(b)
be equipped with an adequate number of tables and adequate seating (with

backs)
(c)
where necessary, include facilities for any pregnant woman and nursing mother to
rest, lying down
(d)
where necessary, include a means of boiling water and suitable arrangements to

ensure that meals can be prepared and eaten
(e)
be maintained at an appropriate temperature
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Facilities for rest
An 'enclosed' workplace is one which has a roof or ceiling and, except for passageways,
doors and windows, is wholly enclosed, whether on a temporary or permanent basis.
14
A 'substantially enclosed' workplace is one which has a roof or ceiling but there are
permanent openings in the walls, the combined area of which is less than 50% of the
total wall area. When calculating the total 'open area' of any workplace, doors and/or
windows which can be closed must not be counted.
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Particulars to be included in a report of inspection

1.1.8 Appendix 2
Name and address of the person on whose behalf the inspection was carried out.
Location of the place of work inspected.
Description of the place of work or part of that place inspected (including any work
equipment and materials).
Date and time of the inspection.
Details of any matter identified that could give rise to a risk to the health or safety of any
person.
Details of any action taken as a result of any matter identified in paragraph 5 above.
Details of any further action considered necessary.
Name and position of the person making report.
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1.1.9
Safety Inspections and Auditing
1.1.9.1 Key points

Inspections of the workplace, from a health and safety point of view, can form a productive
part of the consultation between management and the workforce.
There are several forms of workplace inspection described in this section.
While they are often carried out by a safety professional, they do not have to be.
The successful outcome of any inspection is that remedial actions are put in place where
shortcomings have been identified.
Workplace inspections should be carried out against a predetermined checklist incorporating

some method of recording the findings.
Whereas workplace inspections tend to be a 'snapshot in time', an audit is a thorough

examination not only of the site conditions prevailing at any one time but also of:
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the commitment of management to health and safety;
(b)
the procedures that underpin the health and safety management system.
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(a)
Contractors being able to demonstrate their competence in matters of health and safety
management potentially puts a greater importance on them being able to show that audits
are carried out and acted upon.
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Section 1, Part 21 covers inspections and handovers.
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Note:
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identifying the hazards which employees face within the workplace
(b)
understanding how accidents are caused by unsafe acts, unsafe systems of work and
unsafe conditions on site
(c)
taking steps to control the activity of the worker, the work method and the workplace.
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(a)
Contractors, managers, supervisors and safety representatives all have equally important
roles to play. By obtaining and providing information through the inspection, investigation
and examination of the workplace, they can help provide a basis for effective management
action to promote safer and healthier workplaces, and induce a greater awareness of health,
safety and welfare on the part of all concerned.
It is well-established and documented that accidents can be prevented by:
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1.1.9.3 Safety inspections

Regular and random inspections
1
Formal inspections at reasonably regular intervals should augment the site manager's dayto-day checks, inspections and examinations which occur as part of any job task. These
should involve safety representatives using a properly designed safety checklist for a
systematic inspection of the workplace.
An example of such a checklist can be found in Appendix 1.
The advantages of regular safety inspections are that they ensure that good housekeeping is
maintained within the workplace and that awareness is developed, amongst employees at all
levels, of the need to promote and maintain safety standards. The disadvantage or danger of
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regular inspections is that they may become a rather mechanical routine for all concerned,
and that their impact might be lessened.
4
Random inspections, however, carried out without any prior notice to the workforce, on
different days of the week, at irregular intervals and at different times of the day, avoid the
shortcomings of a predictable inspection and help to encourage a continuous interest in
safety by all personnel.
In practice, a combination of the two approaches of both regular and random inspections is
probably the best course of action.
1.1.9.4 Remedial actions

A clear understanding of what remedial actions are required to eliminate or less the risks to
health and safety, and when those actions should be taken, is an essential part of health and
safety management.
The following lists suggest how shortcomings, as highlighted during health and safety
inspections, should be prioritised for remedial action.
Items requiring immediate action:
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the contravention of this Regulatory Document
(b)
the occurrence of accidents or incidents which produce situations of immediate danger

to the health and safety of employees or other people, including members of the public
(c)
the risk of financial liabilities, as a result of damage to plant and equipment, or

compensation to workers or members of the public
(d)
the risks of fire, explosion or other hazards involving electricity, toxic materials or
substances
(e)
the existence of unsafe working practices and unsafe places of work
(f)
any shortages of correct and adequate personal protective clothing and equipment
(g)
any accident or incident that is reportable under RIDDOR
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(a)
Items requiring prompt action:

(a)
any potential hazards which may exist, but which do not cause any imminent or
immediate danger
any signs of inadequate information, instruction or supervision, which should have
been provided by either the management or others
(b)
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(c)
any first aid facilities and training that fall short of statutory requirements
(d)
occasions when new plant, new work methods, new equipment, or different materials
are to be introduced into the workplace.
Items requiring short-term action:

(a)
where there is a lack of planning and control affecting safety within the workplace,
either directly or indirectly, e.g. through the inadequate supply of materials and
equipment to enable the workforce to carry out their tasks satisfactorily and safely
(b)
where there are signs of inadequacies in the personal skills, knowledge and
experience of the workforce, which may have an adverse effect on safety.
Items requiring long-term planning and action:

(a)
where there is a lack of certain categories of safety skills and trained personnel
amongst the workforce
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(b)
where there is a need for the training of safety advisers, supervisors and safety
representatives
(c)
where there is a need for training to take place to keep abreast of the future needs of
the company and its employees
(d)
where there is a need for the improvement of standards of health, welfare and safety
within the company.
1.1.9.5 Safety tours

Managers, engineers, foremen, supervisors and operatives should have the opportunity to
take note of safety conditions prevailing within the workplace during normal construction
work. Production, however, will often be their first priority and this need to get the job done
may adversely affect their judgement on safety matters. Familiarity with certain activities and
hazards may further cause them to overlook, fail to recognise or ignore real or potential
dangers which are present at the workplace.
For these reasons, safety tours (general inspections of the workplace) made by safety
advisers, supervisors and safety representatives should take place at regular intervals.
In attempting to reach agreement with Contractors on the frequency of safety tours, the
following factors should be considered:
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the size of the site to be inspected, the number of people employed and the number of
types of activity which are carried out on that site
(b)
the categories of skill and the experience of the operatives
(c)
the existing safety policy and safety organisation within the company
(d)
the accident record of the site, company or organisation
(e)
the degree of risk to employees in carrying out specific activities or to groups of other
people.
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1.1.9.6 Safety sampling
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(a)
Safety sampling of a particular work activity, process or work area may be necessary in the
following circumstances:
where the activity, process or work area presents particular health and safety
concerns
(a)
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(b)
where there have been changes to an activity, process or work area that are relevant
to health and safety
(c)
where there is a need to improve the safety performance of the company in a

particular area of operations
(d)
where there have been changes in Qatar legislation or safety standards which affect
the operations of the company
(e)
where there are high accident rates or increasing accident rates
(f)
where there are areas of high labour turnover.
Safety sampling should be carried out by someone totally familiar with the work activity,
process or work area under inspection.
1.1.9.7 Safety surveys

1
These are general inspections which are carried out at longer intervals (yearly or once every
two years) to assess the current safety standards and activities of the company, and to
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compare these with other sites of the same company, or other companies within the industry.
2
The survey should be used to determine the future safety objectives and activities of the
company, in the light of planned requirements.
It provides an opportunity to:

compare the current safety performance of the company against previous years
(b)
review safety objectives and determine the future objectives and safety policy of the
company
(c)
examine current levels of safety activity and training within the company to decide
whether they are adequate and suitable
(d)
decide where changes, if any, need to be made, and to make recommendations to the
company as to where and how those changes may be implemented
(e)
improve procedures, records, communications and information supplied by and to the

Contractors or their representative
(f)
determine whether any additional resources are required to enable the company's
operations to be carried out more safely and effectively
(g)
decide whether the numbers of existing safety staff (including safety representatives)
are adequate.
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(a)
1.1.9.8 Hazard-spotting exercises
Hazard-spotting exercises are a modified version of the safety sampling method, where a
particular department, section, work area or work activity is singled out for a closer and more
thorough examination.
The exercises should be arranged by the safety adviser, in conjunction with the company
management. It should involve supervisors, safety representatives and operatives.
Observers may include first line or senior managers, but there should be at least an equal
number of operatives. Some management may prefer a predominant number of operatives
up to chargehand/ganger level in the party, thereby encouraging workers to take an active
interest in safety and accident prevention at the workplace.
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1.1.9.9 Hazard-spotting party

Members of the proposed hazard-spotting party should have had some previous training or
experience in safety matters and be able to:
(a)
recognise any unsafe acts of people at work
(b)
recognise unsafe or potentially unsafe conditions of work or methods of work.
One person should be appointed leader, and their functions should include:
(a)
the collection of the written findings of the members of the party
(b)
the study of these findings and the summary of unsafe acts and conditions which have
been observed during the tour
(c)
the preparation of a brief report, setting out the unsafe acts and conditions which were
observed during the tour and making recommendations for action by
(d)
the management or their representative to rectify any situation that may have been
observed
(e)
noting and recording the response of the line or senior management, satisfying
themselves that action will be taken by management to rectify any situations observed
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(f)
reporting back, to members of the party, what action will be taken by the line manager
concerned.
The participants should be informed in advance of their involvement in the hazard-spotting

exercise, given a time and place to meet, and told who is the leader of the party to whom
they should report.
They should be:

briefed on which work processes and activities are to be inspected and the hazards
which they will be looking for
(b)
informed that they can ask any questions, but not interfere with the normal work
processes and activity
(c)
instructed in the use of any checklists or forms which are to be used to record their
findings. See examples in Appendix 2
(d)
asked to differentiate between unsafe acts and unsafe conditions
(e)
instructed to record their findings independently, without fear of recrimination or

interference.
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(a)
The leader of the party spots at the same time as everyone else and is responsible for
seeing that the inspection tour is completed within the agreed timescale.
Employees working in the section to be inspected should be informed of the intent to inspect,
but not of the date or time when the inspection will be carried out.
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A set and properly structured programme of inspections and sampling will ensure that all of
the main activities of a company are continuously under scrutiny. Hazard-spotting exercises
should be used not only where there is seen to be a need to ensure the safety and health of
people at work, but also as a continuing monitoring exercises.
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1.1.9.10 Hazard-spotting programme
1.1.9.11 Inspection reports
Supervisors and safety representatives should record the findings of their inspections.
Commercially produced versions of inspection report forms are often multi-copy, and 'self
duplicating', with each copy on a different colour paper to identify the intended recipient.
These are called PAD format.
See an example of a report form in Appendix 3.
Whatever the type of checklist or form used, it should provide a record of any action
requested to remedy conditions and working practices considered to be unsafe. Space
should be provided on the form to record the date and place of the inspection and details of
the action taken or, if no action was taken, an explanation of why this was so.
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1.1.9.12 Investigation at the workplace

4
Safety representatives are expected to;

(a)
investigate potential hazards and dangerous occurrences at the workplace
(b)
carry out inspections where there has been a RIDDOR accident, occurrence or
disease at the workplace
(c)
investigate any complaints by employees relating to health and safety
(d)
make representations to the Contractors on behalf of the workforce on general and
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specific matters relating to the health and safety of employees at the workplace.
These functions do not affect a Contractors rights and obligations to manage an enterprise
or site as they should wish, or to investigate any type of accident or occurrence.
1.1.9.13 Safety auditing

1
Many clients are now asking for detailed safety management information, such as that
gathered during safety auditing, as part of their pre-qualification procedures. This will be part
of the client's competence assessment of contractors, as required under CDM. Such
information has the potential to indicate a proactive approach to safety management and
whether or not identified issues are satisfactorily dealt with.
What is a safety audit, and what is in it for you?
A safety audit is a demonstration of the management's commitment to improve the overall
safety of the workplace. The typical definition of an auditing system is a systematic, critical
examination of an operation in its entirety to identify hazards and levels of risk, to detect
falling standards and to ensure that operations are performed in an efficient and safe way in
accordance with the policies and procedures laid down by the organisation.
Therefore, the key requirements of a safety audit include:
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a critical examination of the whole operation
(b)
an assessment of how the risks to health and safety are being handled
(c)
the identification of the efficient and safe performance of people
(d)
the detection and identification of falling standards, ineffective company procedures,

and non-compliance with industry standards and Qatar legal requirements
(e)
the use of meaningful standards consistent with the organisation's operations.
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(a)
Health and safety auditing should also be seen as an integral part of the overall monitoring of
health and safety within an organisation.
The aim of such an audit is to identify problem areas that may exist, so that you can make
improvements to your standard of safety. The audit should look at the interaction of all the
activities of your company, as well as at the activities themselves.
An audit supports the company's safety policy; it measures performance against it and will
help management to judge just how well safety is being managed and, if carried to its logical
conclusion, will prompt the question: 'What caused this accident to happen?'
By adopting safety auditing, the Contractors will be acting to identify problems and possible
causes of accidents before they happen.
If any are identified, the Contractors will be able to change the health and safety
management system, improve working practices, identify health and safety training needs
and strengthen other weaknesses. These changes will help ensure that no unsafe actions
occur, thereby preventing accidents, and may include the setting of new standards of health
and safety performance by managers and employees.
The aim of any health and safety auditing system should be to constructively assist site
management to safely organise the company's construction activities. The application of a
well thought out auditing system will undoubtedly repay the time and money that the
company initially invests in developing it.
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There is an additional benefit to the company
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The result of safety audits carried out correctly is an improved safety performance so that the
ultimate of NO ACCIDENTS is achieved.
12
A good audit will benefit everyone from senior management to the youngest employee, and
will hopefully be accepted on its merits as the resultant changes bring improvements in
safety performance.
13
The health and safety audit should be carried out, as far as possible, by independent
auditors. This overcomes the problems faced by line managers auditing their own area of
work, or even a second line manager being critical of their peers. Auditing must be carried
out objectively and with a high degree of honesty when identifying non-compliance with
management systems and techniques.
14
The frequency of safety audits should ensure that the health and safety management system
of the organisation does not degrade over time or through changes in the company
organisation, personnel or the activities it carries out.
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performance against internal systems
(b)
performance against legal standards.
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(a)
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One of the most difficult things about auditing is deciding whether the measured
performance is satisfactory. Within health and safety, experienced external auditors will
typically audit against two parameters:
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1.1.9.14 Benchmarking
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1.1.9 Appendix 1
Observation checklist
The worker
gloves
(b)
clothing
(c)
boots
(d)
helmets
(e)
goggles
(f)
ear defenders?
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safety signs and signals
machine and equipment guards
(ii)
warning notice
(iii)
barriers
safety equipment
(d)
first aid training?
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alarm systems
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(b)
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use of:
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Is the worker aware that they must exercise good behaviour at work whilst paying attention
to the following:
(a)
avoiding messing around
(b)
distractions
(c)
staying out of prohibited areas
(i) use of:
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Is the worker aware of safeguards which exist in relation to:

(a)
(a)
Is the worker able to obtain and correctly wear personal protective equipment, such as:
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machinery
plant
power tools
hand tools
transport
access equipment
working platforms
hazardous activities?
When handling materials, does the worker take into account the following:
(a)
good manual handling and lifting techniques, including wearing appropriate PPE
(b)
mechanical methods available
(c)
proper stacking
(d)
correct storage
(e)
transporting and moving loads
(f)
loading and unloading
(g)
dangerous materials?
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(a)
at heights
(b)
above or near to water
(c)
near live electrical conductors
(d)
in confined spaces
(e)
in excavations, tunnels and shafts
(f)
in other hazardous environments?
Is the worker aware of, and using, welfare facilities which are provided relating to:
first aid
(b)
changing rooms
(c)
canteen
(d)
washing
(e)
seating
(f)
toilets
(g)
drinking water
(h)
drying facilities
(i)
workspace
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(a)
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If required to work in hazardous areas, is the worker competent to work:
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ventilation
(b)
temperature
(c)
lighting
(d)
noise
(e)
dust
(f)
fumes
welfare facilities?
(g)
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Is the working environment satisfactory in relation to:
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The workplace and the work method
Is the condition of machinery, plant and equipment, tools and materials acceptable as far as
the following are concerned:
(a)
machinery, transport, plant
(b)
workplace
(c)
working platforms
(d)
tools, equipment, appliances
(e)
hazardous work areas?
Are adequate fire precautions in place including:

(a)
exits and emergency escape routes
(b)
extinguishers
(c)
alarms
(d)
procedures?
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(a)
warning notices
(b)
general health and safety signs
(c)
colour codings
(d)
work methods
(e)
adequacy of:
information
instruction
supervision
work procedures?
Is good housekeeping a part of normal procedures when considering:

general layout
(b)
site conditions
(c)
ground, floor conditions
(d)
storage areas
(e)
gangways, walkways
(f)
access, egress?
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Are safety notices displayed, relating to:
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1.1.9 Appendix 2
Observation report
Unsafe conditions
1.
1.
2.
2.
3.
3.
4.
4.
5.
5.
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Unsafe acts
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7.
8.
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8.
10.
9.
9.
10.
Location.......................................................................
Name...........................................................................
Date.........................................................
Comments:
This illustration constitutes only an example of the kind of form which could be used during a hazard-
QCS 2014
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spotting exercise of the workplace. Contractors may choose to use this example or create their own.
QCS 2014
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1.1.9 Appendix 3
Health, Safety and Welfare Inspection Report
Company..................................................................................Report no....................................................................
Workplace.....................................................................................................................................................
Welfare
Storage areas
Canteens
18 Tidiness
34
Services
Rest rooms
19 Flammables
35
Security
Changing rooms
20 Gases
36
Fire precautions
First aid training
21 Fuels, lubricants
37
Electrical
First aid facilities
22 Fire precautions
38
Hoists
Washing
23 Tools & equipment
Sanitation
24 Access equipment
Protective clothing
25 Timber
Protective equipment or
substances
26 Dangerous materials
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27 Stores procedures
Offices
39
Tower cranes
40
Mobile cranes
41
Lifting gear
42
Excavations
43
Transport
44
Other plant
Construction site
Accident records
28 Scaffolding
45
Machinery
11
Statutory forms,
29 Ladders, trestles
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46
Power tools
30 Working platforms
47
Hand tools, equipment
31 Access/egress
48
Tidiness
32 Signs & notices
49
Noise levels
33 Accommodation
50
Traffic management
51
Restricted area
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registers, etc.
General cleanliness
13
Fire precautions
14
Environmental factors
15
Seating
16
Access/egress
17
Alarms, notices
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12
Action required for items........................................................................................................................................

(Details on reverse of form)
Signature(s).................................................................
Date of inspection.......................................................
(Safety representative(s)
Circulation:
Original
1st copy
2nd copy
3rd copy
(pink)
(blue)
(white)
(yellow)
to safety officer / supervisor

to site manager / agent
to be retained by auditor
for management action and return
QCS 2014
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1.1.9 Appendix 4
Contractor NCR Template
SAFETY NON-CONFORMANCE REPORT

Contract Name:
Contractors Name:
NCR No:
Contract Number:
Date Opened:
Date Closed:
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PART A: DETAILS OF NON-CONFORMANCE:

Details:
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Classification of Defect:
Critical
Major
Minor
Cause of Non-conformance:
Material
Process
Equipment
Documentation Reference (QCS, Local Legislation, Other Specification / Standard etc.):
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CONSULTANT /ENGINEER
REP*
*Delete as applicable
Work Area / Location:
Title:
Documentation
Date:
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Name & Signature:
Unknown
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Reject/Replace
Target Date to Close NCR:
Name & Signature:
Re-work
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CONTRACTOR
PART B: PROPOSED REMEDIAL / CORRECTIVE & PREVENTIVE ACTION:

Details:
Repair
Title:
Use as-is
Date:
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- Contractors proposals are acceptable and remedial work / Corrective & Preventive Action may proceed.
- Contractors proposals are unacceptable for the following reasons. (Contractor should revise & resubmit):
CONSULTANT
PART C: CONSULTANT ACCEPTANCE OF CONTRACTORS PROPOSALS IN PART B:
Name & Signature:
Title:
Date:
PART D: REMEDIAL WORKS / CORRECTIVE & PREVENTIVE ACTION PROPOSED IN PART B ARE
COMPLETE & READY FOR INSPECTION:
CONTRACTOR
Name & Signature:
Title:
Date:
ENGINEER REP.
PART E: FOLLOW UP & CLOSE-OUT:

- Remedial Works / Corrective & Preventive Action have been undertaken and are acceptable. This NCR may be
closed out.
- Remedial Works / Corrective & Preventive Action undertaken by the Contractor are not acceptable for the
following reasons and this NCR may not be closed out. (Contractor must address these issues):
Name & Signature:
Title:
Date:
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NOTES AND ATTACHMENTS (Photographs, Sketches etc.):
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1.1.10 Safety at Street Works and Road Works
1.1.10.1 Key points
1
Will someone coming along the road or footway from any direction understand exactly what
is happening and what is expected of them?
These Regulations specifies minimum safety requirements for:

signage and lighting
(b)
working on different classes of roads
(c)
methods of traffic control
(d)
speed control of passing traffic
(e)
works near to tramways and railway level crossings.
(f)
Operatives who carry out work on the highway must be competent to do so,
particularly anyone involved in laying out the site, positioning signage or lighting,
implementing traffic control measures and undertaking similar jobs.
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(a)
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Note:
Section 1, Part 3 of the QCS covers traffic safety management. Section 1, Part 16
of the QCS covers traffic diversions. Section 6 of the QCS covers roadworks..
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This places a duty of care on Contractors, employees and the self-employed. It requires not
only the safety of employees to be considered, but also the safety of those affected by the
work i.e. members of the public using the highway.
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Health and Safety at Work (Construction Sites)
When you give notice that you intend to start work, they will inform the other utility service
providers in an attempt to co-ordinate works so that the utilities may each carry out their
work during one excavation in order to avoid the same piece of roadway being continually
excavated.
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1.1.10.3 Commencement of work
1.1.10.4 Measures necessary where apparatus is affected by major works

(diversionary works)
1
Definition: Apparatus is any pipe or ducting buried within the highway or pavement which is
owned by one of the utilities. It may take the form of gas pipes, water mains, sewers,
electricity cables, telephone cables and, where installed, cable TV cables.
1.1.10.5 Major works

1
The term major works covers works carried out by the Civil Engineering Department
Ministry of Public Works such as:
(a)
the reconstruction or widening of the highway
(b)
works on dual carriageways and at roundabouts
(c)
other similar major works
(d)
the construction of vehicle crossings over footways and verges.
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1.1.10.6 Diversionary works

1
The term diversionary works covers:

(a)
works to protect apparatus on site
(b)
works to relocate apparatus elsewhere.
1.1.10.7 Construction risk factors

Construction factors to be considered in deciding whether apparatus is at risk include:
the removal of the footway or carriageway construction
(b)
construction plant crossing or working in the vicinity of apparatus
(c)
the undermining or removal of side support to apparatus
(d)
any deep construction adjacent to apparatus
(e)
piling or ground consolidation operations.
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1.1.10.8 Vehicle crossings
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The construction of vehicle crossings is included because the works put apparatus at risk in
a number of ways, such as:
the majority of 'service' apparatus is located in footways
(b)
the footway construction layers must normally be excavated to accommodate thicker

construction layers
(c)
the new construction may no longer provide adequate cover to apparatus
(d)
the vehicular loading may be greater than the apparatus can withstand
(e)
vibrations from vehicles may weaken joints over a period of time.
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(a)
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1.1.10.9 Minimising construction risks
(a)
(b)
provide suitable and safe vehicle crossing and access points.

temporarily move apparatus to a safe location, during any construction work.
protect or temporarily support apparatus in situ.
(c)
To minimise construction risks, you should:
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Note: Methods of supporting apparatus during excavation form part of the assessment
process incorporated within the relevant operative and supervisor qualifications.
1.1.10.10
Safety of gas apparatus
Depth of cover
1
The normal minimum depth of cover for gas mains operating in the low and medium
pressure ranges is:
(a)
600 mm in footway or verges
(b)
750 mm in carriageways
although these figures may vary, as each area gas companies can have its own standards.
In certain circumstances, depending upon the mains material, operating pressure and depth
of cover, it may be acceptable for the mains to remain in situ when only subjected to light
QCS 2014
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traffic, e.g. a vehicle layby or crossing.

4
It is not generally permissible to allow cast iron mains previously in the footway or verge to
be subjected to vehicular traffic.
Risks during construction
Liaison with the gas services provider during the planning stage is essential because existing
mains, specifically older materials such as cast iron, cannot be raised, lowered or moved
laterally even for a few millimetres without risk. Gas apparatus must not be undermined and
certain apparatus is particularly vulnerable to deep excavations adjacent to the apparatus.
Any proposals to dig deep trenches may mean that gas apparatus will have to be diverted.
Safety of water apparatus
Decisions on the protection or diversion of water mains are likely to be influenced by

considerations of access to mains for repair purposes.
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1.1.10.11
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Depth of cover
The minimum depth of cover for the three types of water mains, i.e. trunk mains, distributor
mains and service pipes, will vary according to its type.
Further information can be found by consulting with the Qatar General Electricity & Water
Company.
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Construction plant and lorries travelling over water apparatus with temporarily reduced cover
can be an unacceptable risk. Therefore, diversions may be necessary unless protective
measures are practicable.
Factors influencing the decision to divert water pipes must include:
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the maintenance of the continuity of supply and the water quality
(b)
material types and condition

the inability to raise, lower or slew pipes
the possible loss of ground support to pipes with the consequential risk of damage.
(d)
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(c)
(a)
1.1.10.12
Safety of telecommunications apparatus
The need for the rigorous exclusion of moisture from telecommunication cables and joints
places constraints on what can be done to older cables, in respect of their movement during
works.
For maintenance purposes there is the added need for vehicles to have access and be
located at or near jointing chambers.
Preferred depth of cover
Varying depths of cover may be found with this type of equipment, depending on the types
and design of the cables. As a rough guide, television and telecom cabling can be found at
depths varying from 250 mm in the verge or footway up to 900 mm in the carriageway.
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According to circumstances, the apparatus may be left in situ if ducts are adequately
protected from construction plant and vehicles by the use of metal plates or tracks.
In some cases, it may be possible to accommodate small temporary or permanent

alterations in the line of a duct track by bodily slewing, raising or lowering a nest of ducts with
the cables in situ.
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1.1.10.13
1
Overhead telecommunication lines
Poles must be positioned to:

(a)
minimise the risk of damage to cables by vehicles
(b)
give the minimum inconvenience to pedestrians
(c)
avoid obstructing access to premises.
Road alterations may necessitate the replacement of poles if the clearance under the cables
becomes inadequate.
Minimum heights above ground for overhead telecommunication lines are typically:
6.1 m at any point over a street
(b)
6.1 m on bus routes
(c)
6.5 m on designated roads.
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Safety of electrical apparatus
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The following factors should be considered when protecting cables in situ or diverting
apparatus.
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1.1.10.14
(a)
Underground cables
The need to protect and support potentially hazardous equipment from mechanical
impact, damage, strain and vibration during and after road works.
(b)
A requirement to maintain the security of supply if alternative circuits are not available.
(c)
The operating voltage of the apparatus. Depth of cover
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(a)
The depth at which electricity cables or ducts are usually laid in the ground is decided by the
need to avoid undue interference or damage.
Dependent on the type of cable and the power that it may be carrying, the depth of cover
may vary from 450 mm up to 900 mm. It is common to find electrical cables much shallower
than these depths, particularly over bridges or culverts and extreme caution must be
exercised.
In all cases where the depth of cover is likely to increase or decrease, the apparatus owner
must be consulted.
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Overhead lines
(a)
The supports and stays of overhead lines may have to be relocated.
(b)
Ground clearance may be affected.
(c)
Earth wires from supports may have to be re-sited.
(d)
Buried pilot wires may be associated with the route of overhead lines.
Height above ground of overhead lines

1
The minimum height of overhead lines above ground varies according to the voltage of the
cable and as directed by the service provider. They can be as low as 5.2 m for lines carrying
33 kV, up to 6.7 m for lines carrying 132 kV.
QCS 2014
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(a)
Additional protection or temporary diversion may be necessary to prevent damage to

any apparatus during the construction stage.
(b)
The hazards of accidental electrical contact by persons on site must be fully assessed.
(c)
Damage to underground cables can, in certain circumstances, cause widespread loss

of electrical supplies for a long period.
1.1.10.15
Traffic signs and other apparatus for the control of traffic must comply with relevant Qatar
Work Zone Traffic Management Guide latest revision.
1.1.10.16
Basic principles of signing
Signs and equipment
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Fix signs properly
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Visibility of signs
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Traffic on two-way roads
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Surplus signs
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Clearing up
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Refer to Qatar Work Zone Traffic Management Guide latest revision.
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Be seen
Whether working on site or just visiting, all personnel must wear a high visibility jacket or
waistcoat to BS EN 471 at all times. Ensure the garment is in good condition and is properly
fastened at the front.
Refer to Section 11 Part 1(RD) 1.2.2 (PPE) Personnel Protective Equipment.
Refer to Section 11 Part 2 (SAMAS) 2.3.9 (PPE) Personnel Protective Equipment.
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1.1.10.17
1
1.1.10.18
1
Site layout definitions
Signs for Street Works and Road Works
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1.1.10.19
Foamed concrete for reinstatement (FCR)
FCR hazards
1
Cement-based materials that can be poured into an excavation to any required depth without
the need for compaction are called FCRs.
Because FCRs are fluid, they present a hazard for children and animals. Reinstatements
must therefore be guarded until a sufficient set has occurred.
Like all cement-based materials, FCRs should be handled with care because:
excessive contact with mixed FCRs can cause contact dermatitis or skin burns
(b)
excessive exposure to cement dust when FCRs are mixed on site can lead to
respiratory problems.
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Precautions
Use barrier creams on hands and wear gloves.
Wear long-sleeved shirts, full length trousers and Wellington boots.
Cement on skin should be washed off immediately.
Reinstatement
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1.1.10.20
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All utilities that have carried out work upon a highway or pavement, or have employed a
contractor to carry out work on their behalf, are responsible for the satisfactory reinstatement
of the highway or pavement.
Any interim reinstatements must be made permanent within six months.
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Reinstatement faults
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Settlement
1.1.10.21
This is the most common and obvious fault, and has implications for the short-term
acceptability of the reinstatement to the public, and the long-term cost of maintaining the
highway.
If the reinstatement material is soft in comparison with the surrounding undisturbed material,
the latter will tend to move laterally towards the excavation and downwards until equilibrium
is reached.
The area at risk on each side of the excavation is roughly equal to the thickness of the poorly
compacted material, regardless of the vertical position of such material.
Crowning
4
The practice of deliberately filling the reinstatement high is an acknowledgement that

settlement is going to occur.
The same processes of adjacent ground movement, and road structure cracking that
accompany settlement can also be present with crowning, since they are a function of poor
compaction and little influenced by surface profile.
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Edge cracking
6
If the vertical edges between the reinstatement and original surfacing have not been sealed
properly with bitumen, water can enter the joint, freeze, and open up a crack.
Alternatively, relative movement between the reinstatement and the original surface can
cause fretting, initiating a crack which is subsequently worsened by the ingress of water.
Lateral spread in the surfacing
This can be caused by too soft a binder being used in the surfacing which then spreads due
to traffic and temperature.
Bleeding or fatting up
In hot weather the binder softens. If the binder is soft initially, it may rise to the surface and
either be picked up by vehicles or lie on the surface. If this is not rectified, the binder will
harden during the colder months and form a very smooth, slippery surface.
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The development of fine surface cracks not accompanied by settlement results from fatigue
of the material under traffic loading.
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10
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Crazing
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Fretting
This is defined as the loss of aggregate particles from the surface of bituminous materials.
12
A variety of causes can be identified, including inadequate compaction, low bitumen content,
and an excessive degree of fluxing for the conditions.
13
The most serious consequence is the increased risk of skidding on the freshly exposed
bitumen and loose particles of aggregate.
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Cracking
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11
Cracking in reinstatements remote from the edges is generally due to the tensile strain
produced by settlement.
15
Another contributing factor is the use of thin surfacing layers which are consequently
overstressed and suffer fatigue cracking.
14
Open texture
16
Delayed set materials need to be open textured to some degree so that fluxing oils can
evaporate through the air passages.
17
By the same token, water can also soak down through the material into the underlying
material.
18
Open textured materials should be replaced or surface sealed as soon as possible after they
have hardened, especially in winter.
Lateral spread due to trenches in the edge of the carriageway
19
This happens in carriageways where the foundations of edge of the carriageway are
weakened. Consequently they give way and allow the full depth of construction to spread.
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1.1.10.22
Surface profile
The following requirements apply to the immediate, interim and permanent reinstatements of
all service providers excavations.
If at any time during the immediate, interim or permanent guarantee periods the surface
profile of a reinstatement exceeds any of the intervention limits, remedial action must be
carried out in order to return the surface profile of the reinstatement to the as-laid condition.
As-laid profile
The reinstatement of any surface must be completed so that the edges of the reinstatement
are flush with the adjacent surfaces and the reinstatement does not show any significant
depression in between.
The maximum allowable tolerance at the edge of the reinstatement between the levels of the
reinstatement and the adjacent surface must not exceed + 6 mm.
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Edge depression - intervention
An edge depression is an essential vertical step or trip at the interface of the reinstatement
and the existing surface.
Intervention is required where the depth of any edge depression exceeds 10 mm over a
continuous length of more than 100 mm.
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Edge depression limits
Surface depression - intervention

A surface depression is a depressed area within the reinstatement. It generally has smooth
edges and gently sloping sides forming a shallow dish.
Intervention is required where the height of any area of surface crowning spanning more
than 100 mm in any plan dimension exceeds the limits shown in the table.
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Surface depression limits
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Intervention limits - surface depression

Reinstatement width
W (mm)
Intervention limit X
(mm)
10
over 400 to 500
12
over 500 to 600
14
over 600 to 700
17
over 700 to 800
19
over 800 to 900
22
over 900
25
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up to 400
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Surface crowning - intervention
Surface crowning is an upstand of the reinstatement above the mean level of the existing
adjacent surfaces.
10
Intervention is required where the height of any area of surface crowning spanning more
than 100 mm in any plan dimension exceeds the limits shown in the table.
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Surface crowning limits
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Intervention limits - surface crowning
Reinstatement width
W (mm)
Intervention limit Z
(mm)
up to 400
10
over 400 to 500
12
over 500 to 600
14
over 600 to 700
17
over 700 to 800
19
over 800 to 900
22
over 900
25
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1.1.10.23
Inspections
During work and after completion, personnel from the Civil Engineering Department Ministry
of Public Works will inspect work being carried out by services providers.
There are two distinct inspections:

(a)
sample inspections
(b)
defect inspections.
1.1.10.24
Sample inspections
These are routine inspections of random samples of services providers work at various
stages of excavation and reinstatement and after reinstatement.
It enables the Civil Engineering Department Ministry of Public Works to monitor the level of
compliance with prescribed standards including:
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applicable reinstatement specification
(b)
the requirements for signing, lighting and guarding of works in progress
(c)
verification that requirements for qualified supervisors and operatives are met.
Defect inspection
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1.1.10.25
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(a)
This is a procedure for dealing with individual reinstatements which fail to comply with the
reinstatement specification.
A special procedure applies to non-complying reinstatements which are causing a danger to

persons using the street.
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Five stages of inspection have been identified for monitoring purposes:
Types of sample inspection
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1.1.10.26
Type
Category
During excavation
Whilst reinstating (including

interim phase)
Immediately after permanent

reinstatement (within 1 month)
Between 6 and 9 months after

permanent reinstatement
During one month preceding end

of guarantee period
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1.1.10.27
Inspection checklists
Two standard forms are used to report on the inspection carried out and include entries on
whether the items checked were acceptable or non-acceptable.
The form for categories 1 and 2 covers signing and guarding requirements in addition to
excavation and reinstatement works.
The form for categories 3, 4 and 5 cover performance requirements of the finished surface.
Sample forms are provided in Appendices 3 and 4.
1.1.10.28
(b)
by members of the public
(c)
by routine inspections by the Civil Engineering Department Ministry of Public Works
Reinstatements that are found to be defective are divided into two types:
Non-complying reinstatements not causing danger
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1.1.10.29
These are reported to the party undertaking the work and normally require remedial action to
be taken within seven days.
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as a result of sample inspections
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(a)
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Defective reinstatements may be identified:
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Types of defect
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1.1.10.30
Non-complying reinstatements causing danger to pedestrians &
vehicles
Where the Civil Engineering Department Ministry of Public Works considers a defect to be
causing danger, the overriding aim is to remove the danger as soon as possible. The exact
procedure may differ in and out of normal working hours.
The Civil Engineering Department Ministry of Public Works may make the site safe by
signing, lighting and guarding and request the attendance of the service provider.
Reported defects trigger a further two inspections.
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1.1.10.31
1
Qualifications
Contractors must ensure that:

(a)
the execution of street works is supervised by a person having a prescribed

qualification as a supervisor
(b)
there is on site at all times, whilst work is in progress, at least one person having a
prescribed qualification as a trained operative
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1. 1.10 Appendix 1
Safety checklist for the supervisor
Before work starts
Has a site-specific risk assessment been carried out?
Have you planned how you will sign and guard the works?
Have all the appropriate authorities been notified?
Is everyone on the site wearing high-visibility clothing?
What are the correct positions for the first warning sign?
What other signs are needed approaching the works?
What signs are needed at the works?
What length of coned taper is required?
How many lamps and cones will be needed?
10
What width of carriageway can be kept open and will it be enough for two-way traffic?
11
What width of footway can be kept open and will it be enough?
12
What form of traffic control is needed?
13
Have any misleading permanent signs been covered?
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When work is in progress
If circumstances change, have you altered the signs, cones and lamps to suit?
15
Are signs, cones and lamps being regularly inspected, cleaned, maintained or replaced?
16
Has authorisation been obtained to accommodate any changed circumstances?
17
When traffic control changes are made at night or weekends, have the warning signs been
changed?
18
Are traffic control arrangements reviewed and changed to reduce delays as works change?
19
Are the works adequately signed, guarded and lit for the overnight period?
20
Have you cleared away any mud that may have spread onto the surrounding road or
footway?
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14
When work is complete and before you leave

21
Have all signs, cones and lamps been removed?
22
Have all permanent signs been restored?
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Have appropriate authorities been notified that work is complete?
24
Have you cleared away any mud that may have spread onto the surrounding road or
footway?
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1.1.10 Appendix 2
Situations where further advice may be needed
Examples of situations where an operative will need to consult a supervisor
Where the Civil Engineering Department Ministry of Public Works restricts work to certain
times of the day.
When the roadworks make it impossible for drivers to follow the permanent traffic signs.
At times of poor visibility or bad weather conditions, when additional signs may be required
or work suspended.
When stronger than normal barriers are needed for deeper excavations.
Whether traffic control is needed at a site and which type would be appropriate for the
circumstances.
Where it is intended to use portable traffic signals, as the traffic authority must give approval
if these signals are to be used at a site which contains a junction.
When tailbacks occur at portable traffic signals.
Where a width of at least 3.25 metres cannot be provided on both sides of a site which is in
the middle of a two-lane single carriageway road.
When the works affect a pedestrian crossing, in which case the traffic authority should be
told in advance of the works. This is particularly important in the case of pelican crossings.
10
Where work affects tramways.
11
Where Stop/Go boards are proposed to be used in a shuttle lane containing a junction.
12
Where it may be necessary to close a road and therefore provide a diversion route.
13
When work on the approach to a traffic signalled junction disrupts the traffic flow through the
junction.
14
If work has to be undertaken at permanent traffic signals on a road with a speed limit of 64
km/h or more.
15
Where works are located at roundabouts.
16
Where mobile works are located in the centre of carriageways.
17
Where mobile lane closure techniques are to be used.
18
Where works are to be undertaken within 200 metres of a level crossing or are likely to
cause congestion in the area around a level crossing or where ramps as part of the works
may cause long low vehicles to ground.
19
Where the works are near the junction of roads joining and leaving high speed roads.
20
Where works are located on three-lane single carriageway roads.
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Where work is to be carried out over the carriageway and the headroom is reduced.
22
When work is likely to affect any bus route or bus stop.
23
Where work is located near to schools.
24
Where works are located near buildings likely to be used by large numbers of elderly or
disabled people, e.g. old people's homes.
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1.10 Appendix 3
Service Provider works
Inspections checklist
FOR USE ON INSPECTIONS 1 AND 2
Authority reference
DATE
Service Providers reference
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Location o/s of or from __________________________to __________________________________

________________________________________________________________________________
________________________________________________________________________________
________________________________________________________________________________
Time taken for inspection ____________________________________________________________
_________________________________________________________________________________
Acceptable
Unacceptable
Excavation
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Backfill & reinstatement

Surround to apparatus
Backfill material
Compaction
Sub-base
Roadbase
Basecourse
Wearing course
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Signing & guarding

Correct type
Distance
Safety zones
Barriers
Traffic control
Pedestrian control
Other
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1. Signing & guarding and excavation

Insert inspection number
2. Signing & guarding and backfill and reinstatement
State reasons for unacceptability
Name
Signature
Date
Unseen/inapplicable
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1.1.10 Appendix 4
Service Provider works
Inspections checklist
FOR USE ON INSPECTIONS 3, 4 AND 5
Authority reference
DATE
Services Providers reference
Insert inspection number
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3. Immediately after permanent reinstatement (within 1 month)

4. Intermediate (between 6 and 9 months)
5. One month preceding end of guarantee period
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Location o/s of or from __________________________to __________________________________

________________________________________________________________________________
________________________________________________________________________________
________________________________________________________________________________
Time taken for inspection ____________________________________________________________
_________________________________________________________________________________
Acceptable
Unacceptable
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Edge depression/trips
Surface depressions
Surface crowning
Edge cracking
Texture depth
Surface regularity
Other
Signature
Date
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Name
Name
Signature
Date
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1.1.10 Appendix 5
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Size and siting distance: details of signs and cones and safety zone dimensions
Type of road
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Minimum and
normal maximum
Minimum
siting distance (D) clear visibility Minimum size
of first sign in
to first sign of signs (mm)
advance of lead-in
(metres)
taper (meters)
Single carriageway road,

restricted to 48 km/h or less
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20 to 45
Minimum
Sideways Details of lead-in cone tapers (but
height of
safety zone see Notes below) Recommended
cones
(S)
lengths
(mm)
Width of Hazards (metres) including safety zones(s)

1
2
3
4
5
6
7
60
600
450
0.5m
Length of taper (T) in metres

Minimum number of cones
Minimum number of lamps at night
13
4
3
26
4
3
39
6
5
52
7
6
65
9
8
78
10
9
91
12
11
45 to 110
60
750
450
0.5m

20
4
3
40
6
5
60
8
7
80
10
9
100
13
12
120
15
14
140
17
16
All-purpose dual
carriageway road, restricted
to 64 km/h or less
110 to 275
60
750
450
0.5m

25
4
3
50
7
6
75
10
9
100
13
12
125
15
14
150
18
17
175
21
20

with speed limit of 80 km/h
or more
275 to 450
75
750
450
1.2m

25
4
3
50
7
6
75
10
9
100
13
12
125
15
14
150
18
17
175
21
20
All-purpose dual
carriageway road, with
speed limit of 80 km/h or
more
725 to 1600
105
1200
750
1.2m

32
5
4
64
9
8
96
121
1
128
16
15
160
19
18
192
23
22
224
26
25
et

restricted to speeds of 49 to
64 km/h inclusive
Speed limit (km/h)

Minimum longways
clearance (L) metres
48 or less
64
80
95
112
1/2
15
30
60
100
Notes:
1. Lead-in tapers used with traffic control, and all exit tapers, shall be at about 45 to the kerb line with cones spaced 1.2 metres apart.
2. The maximum spacing distance of cones in longitudinal lengths of coning shall be 9 metres, but no fewer than 2 cones shall be used in any length between tapers.
3. In certain circumstances on congested roads with speed limits of 48 km/h or under, the taper may also be reduced to 45.
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1.1.11 Setting Up Site
1.1.11.1 Key points
Consideration must be given to the initial design, creation and layout of a site, and its effect
upon the people who work on it, visit it, or live nearby.
The footprint of the structure(s) to be erected will dictate what space remains for other
purposes, which must be used to its best advantage.
Consideration should be given to early contact with local residents, local schools, adjacent
properties etc. prior to, or at the start of, setting up a site.
Time and effort put into properly planning and setting up a site has the distinct potential to
forestall problems as the job progresses.
Note:
Section 1, Part 1 of the QCS covers setting up a site and site management.
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CDM places a legal duty upon the client for any project to ensure that every person involved
in the design process and every Contractor is provided with adequate and relevant
information about the site to enable the health and safety of anyone engaged in the
construction phase to be secured. This information should be included in the health and
safety plan which then enables decisions to be taken with regard to setting up the site.
The health and safety plan should give the Contractor details of specific issues that will need
to be considered when setting up a site. These, together with the contracts and architects'
drawings and specifications, will give information about specific factors to be incorporated. It
is likely that the responsibility for setting up the site will in many cases be delegated to the
site manager.
Contractors are require to plan, manage and monitor the construction phase (which includes
setting up a site) to ensure that, so far as is reasonably practicable, it can be carried out
without risks to health and safety.
Suggested factors to be considered when setting up a site can be found in the appendix at
the end of this section.
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1.1.11.3 Temporary works

1
By the nature of construction, much work will not be left in place at the end of the project but
still requires the same care and attention that the main structure attracts. Many accidents
occur through poor planning, design and installation of temporary works which begin as soon
as site set up commences.
These include, but are not confined to:

(a)
Foundation assessment for new porta cabin install, and in particular multi-storey
complexes.
(b)
Excavation support assessment to be carried out for below ground service

connections.
(c)
Services may require protection to prevent damage during site set up. Also material
storage areas should be sited away from shallow services that may be susceptible to
damage.
(d)
Site hoardings and gates to be designed to withstand wind loadings. Particular
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attention should be taken with swing gates, and ensuring that these can be managed
by an individual under high wind conditions.
Any supporting structures on a cabin set-up must be designed, e.g. cabins elevated to
provide parking below on congested city sites.
(f)
Generally there will always be a need for craneage on site, so ground bearing
capacities require checking for outrigger loadings on and around the site.
(g)
Any temporary access roads on site should be assessed to ensure that they are
suitable to withstand loadings that may occur during site works.
(h)
Site establishments that are at risk of objects falling from above should be protected
with the use of designed crash decks or fans.
(i)
Where site establishments are close to the public highway or temporary haul roads
where heavy plant is to be used, there must be suitable barriers in place to protect the
office from collision damage.
(j)
When crane lifts are required from a neighbouring street then the temporary works
engineer must be aware of any below ground services, including basements and
subways and so on, and their proximity to the crane.
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1.1.11.4 Human factors
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These Regulations require that:'No person may arrange or instruct a

worker to carry out or manage design or construction work unless the
worker is:
competent, or
(b)
under the supervision of a competent person.'
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Competence
This is now the fundamental requirement of the requirement for health and safety in
construction. Competence has been defined as: 'possessing practical and theoretical
knowledge, which combined with actual experience so as to enable errors, faults and
weaknesses to be detected and their importance accurately assessed'.
Depending upon the nature of the site and the type of work to be undertaken, the
competence of people who will come on to the site might be an issue for the person setting
up the site. It may be necessary, for example, to check the competence of those who will;
erect, alter or dismantle scaffolds
(a)
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(b)
operate site plant
(c)
dig excavations and install the supports
(d)
install traffic management systems.
In any case the most likely competence required early on is that of a crane coordinator to
ensure the planning and management of lifts associated with site cabins and welfare units.
Consultation
Contractors are required to consult on matter of health and safety. Generally, this may be
summarised as:
(a)
Contractors must consult their employees, or their representatives on issues of heath

and safety
(b)
employees must be able to raise any concerns they have over health and safety with
the Contractors either directly or through their health and safety representative
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As part of the process of setting up a site, consideration must be given to how effective
Contractors/employee consultation on matters of health and safety will be achieved.
Co-operation
CDM requires that everyone concerned in a construction project, whether a contractor, selfemployed person or an individual worker, must- co-operate with each other in the interests of
health and safety.
How such co-operation can be effectively achieved, must be decided at the stage where a
site is being set up.
Contact with the emergency services
It is advisable:
to inform the emergency services of the location of the site, particularly if it is difficult
to locate
(b)
particularly to inform the fire and rescue service if materials that represent a significant
fire risk will be present on site
(c)
if considered necessary, to display in the site office a road map showing the quickest
route to the nearest hospital with an Accident and Emergency Department in the site
office
(d)
on larger sites, to identify the position of emergency controller to oversee site actions
and communication with emergency services.
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1.1.11.5 Site features and facilities
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Existing buildings, features and ground conditions

Consider the current and past uses of the site.
This could involve issues such as:
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ground water levels and/or underground water sources and the prevention of their
contamination
(b)
the existence of contaminated ground and the possible need for extensive site
transport movements, both within and off site
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(a)
(c)
the previous storage of dangerous goods or hazardous substances in buildings,

cellars or tanks
(d)
the location of underground services and whether they have been, or need to be,
isolated or protected from surcharging, for example stockpiling heavy materials over
shallow services
(e)
the location of overhead cables and whether they need to be isolated or repositioned
(f)
the need for equipment to create barriers and goalposts where overhead cables cross
or border the site and remain live
(g)
if working on an existing structure, whether the electrical distribution system is still live
and whether or not it should be
(h)
the condition of existing buildings -strength/condition of roofs, floors, stairs, hand-rails,

walls and structural members. Advice from a structural engineer may be required to
assess the suitability of a structure for its intended use
(i)
the possible presence of asbestos (where existing surveys exist these should be
included)
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(j)
the possible presence of other hazardous substances, viruses and organisms such as
lead, leptospirosis and anthrax
(k)
the possible need for demolition
(l)
the possible need for site lighting
(m)
the existence of a health and safety file for work on existing structures.
1.1.11.6 Site security

Ideally, the site boundary will be secured immediately on possession, with lockable gates
and suitable fencing or hoarding to prevent unauthorised access by the general public,
particularly children, and to prevent the unauthorised tipping of waste. Where it is not
possible to secure the whole site, adequate steps must be taken to ensure that potential
locations of hazardous operations can be appropriately secured.
Gates and hoardings should be designed and able to withstand wind loadings. Particular
attention should be given to swing gates to ensure they can be operated by one person and
stops should be in place to prevent gates swinging into pedestrian/public areas.
In many cases it will be necessary to make separate provision for the security of individual
items of equipment and plant.
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Access will be needed not only for plant, other vehicles and equipment, but also for people,
therefore segregation is the safest method. Ideally traffic routes will be organised so that
pedestrians are not put at risk by incorporating such measures as:
site entrances and exits positioned so as not to cause a traffic hazard on the public
road
(b)
segregated traffic and pedestrian routes and, if practical and necessary, segregated
site entrances
(c)
one-way systems
(d)
turning areas to avoid the need to reverse
(e)
speed limits that must be enforced as necessary
(g)
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(a)
reversing vehicles being under the control of a qualified signaller

the need for published traffic priorities where site vehicles and private traffic both use
site roads
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1.1.11.7 Pedestrian/traffic routes, movement of plant and people
(h)
the need for the provision of traffic control measures (e.g. traffic lights), both on and off
site
(i)
the provision of parking areas for delivery vehicles which are waiting to unload; if
necessary, for example tightly-bound city centre sites, this may need to be off site
(j)
the provision of a car park for privately owned vehicles which preferably:
(i)
is entered directly from a public road without having to pass through

construction areas
(ii)
does not permit access to the construction area by private vehicles
(iii)
is connected to the site offices and welfare facilities by a safe, segregated

pedestrian route
(k)
the possible need for a vehicle wheel wash where there is the potential for mud or
other debris to be deposited on public roads
(l)
the possible need for a mechanical road sweeper to keep site and public roads clear
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of mud or other debris
(m)
the provision of a secure vehicle compound.
When planning traffic/pedestrian routes, consideration should also be given to the possible
need for rapid emergency evacuation of the site and/or the attendance of the emergency
services.
1.1.11.8
Provision must be made for the safe storage of materials and equipment. Consideration
should be given to:
ensuring that site roads and any access road to the site are kept clear of obstructions
(b)
where possible avoiding 'double handling' by arranging for items (particularly heavy
items that may have to be moved by hand) to be stored close to where they will be
needed
(c)
the provision of proper storage facilities for flammable substances such as bottled
gases and fuels
(d)
ensuring that materials that are delivered on pallets are stored in stable stacks, with a
safe limit on the height of each
(e)
ensuring that there is no chance of stored materials toppling and breaching the site
boundary
(f)
the possible need for access by lifting equipment such as telehandlers, mobile and
tower cranes.
1.1.11.9 Utility services
(a)
a 230 volt (mains) supply (or a 415 volt, 3-phase supply where there will be heavy
electrical loads such as a tower crane)
a supply of fresh water. This should be tested to ensure it is of suitable quality for
drinking and, if a new connection, should only be made by Qatar General Electricity &
Water Company
(b)
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Where necessary, early consideration must be given to the need for the installation of utility
services to support the running of the welfare facilities and other site accommodation. This
could include:
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Materials storage and lay-down areas
(c)
the drainage of surface and foul water. New connections should only be made with the
knowledge of the local authority. Particular attention should be given if hydrocarbons
are to be used extensively near to watercourses. Petrol interceptors may be required,
as are discharge consents if discharging into rivers
(d)
the provision of gas or oil for heating
(e)
appropriate telecommunication links
(f)
the provision of a stand-by generator and the appropriate fuel.
1.1.11.10
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110 volt power system
Whilst not strictly speaking a 'utility', consideration must be given to whether a 110 volt
distribution system will be required, and if so:
(a)
is there a live 230/415 volt system to power it?
(b)
who will design and install it?
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(c)
who will test and inspect to ensure it meets British (BS) or other International
standards?
1.1.11.11
Work at height
If work at height is to be carried out, it must be done so safely using the most appropriate
access equipment.
If scaffolds (including alloy towers) are to be used, they must:

(a)
only be erected, altered or dismantled by a competent person, or someone who is

under the direct supervision of a competent person
(b)
be periodically inspected by a competent person
If mobile elevating platforms are to be used, they must be suitable for the job and only
operated by competent persons.
Ladders should only be used in situations where the findings of a risk assessment show it is
not reasonably practicable to use other safety access equipment.
Excavations
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If excavations are to be dug, which by virtue of their depth, size or position could lead to an
injury if a person, material or vehicle fell into them, suitable equipment such as guard-rails
will be required to form an effective barrier around each such excavation.
Where the sides of excavations have to be supported to prevent the fall of soil, rock or other
material, the system of support must be designed by a competent person.
Usually the competent person, a temporary works co-ordinator, will gather such information
as required including ground reports and liaise with designers to ensure adequate support is
designed and installed.
A safe means of access and egress must be provided for the people who will work in
excavations. Where dictated by the depth, this will usually be a ladder.
If vehicles have to approach excavations for any reason, for example to tip material, the
vehicle should be under the control of a qualified signaller and suitable anchored stop-blocks
(or a similar device) must be employed to prevent vehicles getting too near the edge. This
must be communicated to the temporary works co-ordinator to ensure the design considers
this activity.
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1.1.11.13
The site office
It is acknowledged that, depending upon the size of the site and the nature of the project, the
term 'site office' can cover office accommodation ranging from a single portable cabin to an
office complex comprising multiple-cabins on more than one level in which non-construction
workers, such as administrative staff, are employed.
Administrative staff, and others who may not usually carry or wear PPE, should ideally have
access to site offices from outside the site via a safe route that does not entail passing
through the construction area.
The site office should offer reasonably comfortable accommodation for all types of weather
and normal ranges of temperature.
When setting up the site office the following must be considered:
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a suitable and safe form of heating, including the safe location of LPG cylinders if used
(b)
the need for an electrical supply (with each circuit protected by a residual current
device [RCD]) and telecommunications
(c)
obtaining a suitable, fully stocked first-aid kit unless first-aid facilities are located
elsewhere
(d)
obtaining a suitable accident book
(e)
displaying information on how to identify and contact site first aider(s), where the firstaid box is located and the actions to take in an emergency
(f)
displaying a copy of the Contractors Health and Safety Policy
(g)
obtaining and displaying as necessary appropriate company-specific information
(h)
obtaining registers for the recording of statutory inspections, for example inspections
of excavations and scaffolds
(i)
compiling registers for other purposes, for example:
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(a)
portable electrical appliance (PAT) testing
(ii)
tests of the fire alarm and other emergency procedures
(iii)
a site-visitors' log
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Welfare facilities
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1.1.11.14
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(i)
Workers will need clean and hygienic portable buildings or suitably protected areas where
they can change and securely store clothing, make a hot drink, heat and eat their meals, and
take shelter in the event of bad weather.
Workers will also need access to clean, well maintained toilets and appropriate washing
facilities with hot and cold or warm water, soap and towels, for example basins or sinks large
enough to wash their faces, hands and forearms in. In appropriate circumstances it will be
necessary for showers to be provided.
Where there will be males and females on site appropriate provision must be made in
relation to:
toilets
(c)
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(d)
rest facilities.
washing (and if necessary shower) facilities

changing rooms
(b)
1.1.11.15
First aid
The appropriate number of qualified first aiders and/or appointed persons for the job will be
required. Details of the first aider(s) and the location of first-aid kit(s), with details of
emergency telephone numbers, must be displayed and given out during site induction.
Where justified by the size of the site, or in a small number of cases the type of work being
carried out, it may be decided that it would be beneficial to establish a first-aid room staffed
by a qualified nurse at all times that work is being carried out.
1.1.11.16
1
Fire safety
Consideration must be given to the level of fire risk arising out of the work to be undertaken
(not forgetting the masses of paperwork, drawings etc. that can accumulate in site offices)
and the nature of any other flammable substances that may be stored and used.
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A sufficient number of fire extinguishers appropriate to the type of fire which may occur
should be obtained and located in highly visible fire points in appropriate places, including
office and welfare accommodation.
Fire exit and emergency escape route signs must be obtained and displayed and must, in
the interests of health and safety, be illuminated in periods of darkness, as necessary.
An early decision must be made with regard to whether smoking will be allowed in any area
of the site. If smoking is to be allowed in certain areas, those areas must be equipped with
signs that clearly indicate the extent of the 'smoking area'. Equipment must be provided for
the safe disposal of spent smoking materials. Official signs indicating that smoking is not
permitted must be clearly displayed at the entrance(s) to all site accommodation.
1.1.11.17
Emergency plans
During the setting up of a site provision must be made for dealing with emergency situations
which may involve evacuation of the site. It is likely that this will be simpler for an open site
than, say, for the refurbishment of a multi-floor structure.
Liaison with the Civil Defence (Fire Department) may be useful in identifying a fire-fighting
strategy within the plan and locations of fire-fighting cores and dry riser locations.
Emergency escape routes must be determined, identified by appropriate signs and

communicated to all on site. On larger, more complex sites it may be necessary to:
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compile a fire safety/emergency evacuation plan, which may or may not as

appropriate, be a part of the construction health and safety plan
(b)
appoint evacuation wardens who have responsibility for ensuring that particular areas
of the site has been totally evacuated.
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(a)
The location of a suitable assembly point, which can accommodate the maximum number of
people expected on site and is a safe distance from the potential hazard, must be
determined. On larger sites it may be considered appropriate to designate more than one
assembly point.
However, unless the evacuation procedure is well thought out and effectively communicated
to all on site, this has the potential to make accounting for everyone more difficult.
Information must be displayed regarding actions to be taken in the event of an emergency,

for example:
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(a)
what the fire/evacuation alarm sounds like
(b)
the days/times that tests will be carried out
(c)
where the fire assembly point(s) is/are.
Suitable arrangements should also be provided for dealing with environmental emergencies
and incidents such as the accidental release of oils or fuels. The site must consider the type
and location of spill kits and any necessary training in their proper use and disposal.
1.1.11.18
Contractors have a legal duty to provide the necessary personal protective equipment (PPE)
for their employees. Depending upon the type of work that will be undertaken and other
control measures that are in place, it is quite likely that a stock of appropriate PPE will be
required at the time the site is set up.
It may be necessary to discuss with a reputable PPE supplier the standards of PPE required
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where there is a choice, for example when purchasing:

(a)
respiratory protective equipment
(b)
eye protection
(c)
hearing protection
(d)
gloves
1.1.11.19
It is usual to post one or more signs at site entrances to inform all persons who enter of the
health and safety requirements of the site. It is usual for these to specify:
the minimum standard of personal protective equipment required (usually safety
helmet, safety boots and hi-vis waistcoat)
(b)
that all visitors must report to the site office.
(c)
Other signs that must be obtained for display are:
(d)
a selection of appropriate, mandatory, warning, prohibition and safe condition signs
(e)
appropriate traffic-management signs
(f)
if appropriate, signs to indicate the presence of liquid petroleum gases and other
flammable substances, particularly vehicle fuels
(g)
other fire safety signs as are necessary, for example to indicate the location of fire
points.
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Consideration must be given to the quantities and types of waste (possibly including food
waste) that might be generated and arrangements made for its lawful disposal.
Environmental considerations
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1.1.11.21
(b)
defining responsibilities on site for managing the environmental issues
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(a)
Much construction work has the potential to impose a severe impact upon the environment.
Measures must be taken to prevent environmental damage including:
making everyone on site aware of the project environmental issues through inductions
and briefings
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Waste disposal
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Signs and notices
(c)
identifying and protecting any water courses and drainage systems
(d)
implementing measures that will avoid the spillage of harmful fluids, but where spillage
does occur, preventing it from seeping into the ground and contaminating water
courses, including sources of drinking water
(e)
the appropriate handling, storage and disposal of construction waste and other types
of waste
(f)
adequately protecting the site against theft and damage
(g)
identifying and dealing with the existence of protected species of mammals, insects,
plants etc.
(h)
reducing noise pollution as far as it is reasonable to do so, which may involve

restricting some construction processes to certain times of the day
(i)
providing well-maintained haul routes to reduce dust, mud and noise
(j)
reducing the amount of substances used that give off environmentally damaging
vapours or fumes
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paying appropriate attention to other sources of nuisance to neighbouring properties
and the public in general
(l)
not leaving the engine of any item of construction plant running when it is not in use
(m)
maintaining good housekeeping to prevent wind-blown debris or waste leaving the site
and to reduce damage and waste to materials
(n)
turning off other power sources when the equipment is not in use.
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(k)
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1.1.11 Appendix
Setting up site checklist
This checklist suggests the common factors that should be checked when setting up a site; the list is
not exhaustive. If necessary, refer back to the main text of this section, or other sections that cover
specific topic areas, for greater detail.
Human factors
Competencies
Y
Have measures been put in place for accurately assessing the competency
of everyone who will come on to the site? In particular, attention to
competence should be applied to:
1.1 carrying out risk assessments and extracting the significant findings
rw
.l.
l
1.
1.2 writing method statements and disseminating the content
1.3 raising, monitoring compliance with and cancelling permits to work
ta
1.4 carrying out any type of training
qa
1.5 designing, erecting, altering or dismantling scaffolds (including alloy

tower scaffolds)
as
1.6 carrying out scaffold inspections

1.7 raising scaffold hand-over certificates
se
1.8 planning, supervising and working at height, using any means of access
er
1.9 designing and installing excavation support systems

1.10 carrying out the inspection of excavations
ov
1.11 the identification and isolation (as necessary) of buried services
1.12 operating all types of construction plant

1.13 carrying out inspections and examinations of construction plant
et
it
1.14 planning and supervising lifting operations

1.15 inspecting and examining lifting equipment and accessories
1.16 planning, supervising and carrying out work in confined spaces

1.17 carrying out rescues from confined spaces
1.18 the use of any power tool or hand tool that has the potential to be
harmful if not properly maintained, inspected and/or used
1.19 assessing exposure to noise and/or vibration
1.20 the use of any flammable or hazardous substance
1.21 any work on the public highway
1.22 designing temporary works for site establishment
continued on next page
N/A
QCS 2014
Section
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Part
continued from previous page

The spaces below are for competences, not included above, to be added.
1.23
1.24
1.25
1.26
1.27
1.28
1.29
1.30
Consultation
Have measures been put in place to ensure effective two-way consultation

and communication on matters of health and safety?
.l.
l
2.
Have measures been put in place to ensure effective co-operation between

everyone who will be on site?
ta
3.
rw
Co-operation
Has contact been made with the relevant emergency services to ensure
that they have sufficient information to deal with any foreseeable
emergency that might arise?
se
as
4.
qa
Contact with the emergency services
Site features and facilities
3.
4.
et
it
2.
Have checks been made of the previous use of existing structures and the
land?
Have checks been carried out for land that may be contaminated, for
example, by leakage of fuels or oils?
Have the appropriate authorities been asked for details of water levels
and/or underground water sources?
Is there evidence of previous storage in buildings, cellars or tanks of
dangerous goods or hazardous substances?
1.
ov
er
Existing buildings, features and ground conditions
5.
Has all information, relating to any underground services, been provided?
6.
Have the appropriate measures been taken to prevent an electrical hazard

from overhead cables?
7.
Has the existing electrical distribution system been made safe?
8.
With regard to buildings on the site, is the strength/condition of roofs, floors,

stairs, guard-rails, walls and structural members known?
N/A
QCS 2014
Section
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Part

9.
Have checks been made to establish whether or not asbestos is present?
10.
Have checks been made to establish the presence of other hazardous

agents, such as chemicals, gases, viruses or organisms?
11.
Will any demolition required be carried out by competent contractors?
12.
Has the delivery and installation of site-lighting been arranged?
13.
Has the Health and Safety File for any existing structure(s) been consulted?
Site security
N
N/A
N/A
Has the delivery and erection of materials to form a secure site boundary
been arranged?
Have those people who will be on site as it is set up been informed of the
security arrangements?
rw
2.
.l.
l
1.
Have out-of-hours contact details been displayed at the site entrance?
4.
Have separate security measures been put in place to prevent theft and to
prevent access into identified hazardous areas?
5.
Is a plan in place that outlines the actions that should be taken to deal with
unauthorised visitors?
as
qa
ta
3.
er
se
Management of vehicular and pedestrian traffic
Have traffic routes been designed to segregate vehicles from pedestrians?
2.
Have site entrances and exits been positioned so as not to cause a traffic
hazard on the public road?
3.
Have traffic management measures such as one-way systems, speed limits

and turning areas been implemented?
4.
Are there clear priorities, for example using traffic lights, where site transport
and private vehicles use the same routes?
5.
Has a safe area been designated for delivery vehicles waiting to unload?
6.
Has a car-park for private vehicles, with a safe entrance and exits (separate
exit for pedestrians), been established?
Have measures been taken to prevent mud and debris from accumulating on
public roads?
7.
et
it
ov
1.
8.
Has a secure construction plant compound been established?
9.
Have haul roads been designed to prevent blind spots and prevent build up
at pedestrian crossings?
QCS 2014
Section
Page 189
Part
Materials storage and lay-down areas

Y
Have these areas been planned so that traffic and pedestrian routes will not
be obstructed?
2.
Have these areas been positioned to avoiding the 'double handling' of heavy
items that may have to be moved by hand?
3.
Have proper storage areas been created for flammable substances, such as
bottled gases?
4.
Are palletised materials stored safely, with stacks of materials stable and
limited in height?
5.
Are storage areas located away from site boundaries, particularly in areas
where the general public have access to the other side?
N/A
N/A
N/A
.l.
l
1.
ta
2.
Have arrangements been made for the installation and commissioning of a

suitable electrical supply?
Is a supply of fresh drinking water available?
qa
1.
rw
Utility services
Have arrangements been made for the installation and commissioning of

drainage systems for surface and foul water?
4.
Have arrangements been made for the supply of other types of heating
fuel?
5.
Have arrangements been made for the installation of the required number
of telephone lines and other forms of telecommunication links?
6.
Have appropriate measures been taken for the supply of stand-by power?
7.
Have arrangements been made for the design and installation of a 110 volt
distribution system?
et
it
Working at height
ov
er
se
as
3.
1.
Have arrangements been made for scaffolds to be erected, altered and

dismantled by a competent person?
2.
Have arrangements been made for the statutory inspection of scaffolds to

be carried out by a competent person?
3.
Will all work at height be planned, supervised and carried out by a

competent person?
4.
In all cases, will work at height be carried out using the most appropriate
means of access to height?
5.
Have arrangements been made to ensure that competent operators will be

available for mobile elevating work platforms (MEWPS)?
QCS 2014
Section
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Part

6.
Has consideration been given to whether the ground conditions are suitable
for the use of MEWPs?
7.
Will a survey be carried out to investigate the existence of cellars, drains and
other underground voids?
8.
Has consideration been given to the possible existence of overhead power

lines or other high-level hazards?
9.
Will the use of ladders be restricted to tasks where it is not reasonably

practicable to use an alternative, safer means of access?
Excavations
Y
Has suitable equipment been obtained to form an adequate barrier (for
example guard-rails) around each excavation into which a fall could cause a
person to be injured?
2.
Where installed, will the system of supporting the sides of all excavations
be designed and installed by a competent person?
3.
Will a safe method of installing the supports, that does not involve anyone
going into an unsupported trench, be employed?
4.
Will a safe means of access/egress be provided (where necessary) for each

excavation?
5.
Where vehicles have to approach an excavation:

5.1 will they be under the control of a trained signaller?
se
as
qa
ta
rw
.l.
l
1.
ov
7.
Have arrangements been made for the statutory inspections of excavations

to be carried out by a competent person?
If the sides of the excavation are sloped or battered, is the angle of batter
sufficient to prevent collapse?
6.
er
5.2 will anchored stop-blocks (or a similar device) be installed to prevent the
vehicle over-running?
Has consideration been given to the possibility of any excavation affecting

the stability of neighbouring structures?
9.
Will materials, spoil or plant be stored away from the edges of the
excavation, to reduce the likelihood of collapse?
et
it
8.
N/A
QCS 2014
Section
Page 191
Part
The site office

Y
2.
3.
4.
N/A
N/A
Have arrangements been made for the delivery and siting of adequate
office accommodation, including carrying out any enabling work?
Is the site office located so that it can be accessed without the need to wear
PPE?
Does the site office have a safe form of heating, with the fuel stored in a
safe manner?
Are the electrical circuits in the office protected by an RCD and regularly
tested and inspected?
Is there a suitable, fully stocked first-aid kit in the office?
6.
If the answer to 5 is 'NO', have alternative provisions been made for first
aid?
7.
Is information on how to locate and identify first aiders displayed?
8.
Is a copy of the company Health and Safety Policy displayed?
9.
10.
Have registers been set up for recording statutory inspections?

Have other registers, as may be necessary, been set up?
12.
Are emergency plans and routes to the nearest hospital available?
qa
ta
rw
.l.
l
5.
1.
as
Welfare facilities
Are adequate welfare facilities available in respect of:
se
1.
toilets which are adequately ventilated and lit?
1.2
washing facilities (including showers if necessary), which are

equipped with hot and cold (or warm) water, soap and towels or a
means of drying?
rest areas (including facilities for a female person who is pregnant, or
a nursing mother, to lie down)?
ov
1.3
er
1.1
drying and/or changing rooms with secure lockers?
1.5
1.6
where necessary, separate facilities for men and women?

the cleaning and keeping in good order of welfare facilities?
1.7
et
it
1.4
a supply of fresh drinking water complete with suitable cups, unless

from a 'water fountain' or similar?
QCS 2014
Section
Page 192
Part

1.8
a means of preparing hot food?
1.9
arrangements to enable food to be eaten in reasonable comfort (an

adequate number of tables and chairs with backs)?
1.10
a means of boiling water?
First aid
Y
Have sufficient and suitable first-aid kits been obtained?
2.
Has an assessment been made as to whether more extensive first-aid

facilities are required?
3.
Have 'travelling first-aid' kits been obtained for site vehicles and anyone who
works in a remote location?
4.
Are sufficient qualified first aiders available?
5.
Are sufficient 'appointed persons' available?
6.
7.
Has initial or refresher first-aid training been arranged as necessary?

Has a scheme whereby first aiders can be quickly located and identified
been implemented?
8.
Has an adequate number of first-aid signs been obtained and displayed?
9.
Has an accident book been obtained and made available?
N/A
NA
se
as
qa
ta
rw
.l.
l
1.
er
Fire safety
Has an adequate number of serviceable fire extinguishers of the

appropriate type(s) been obtained?
2.
Has an appropriate number of site-staff been trained in the selection and

use of hand-held fire extinguishers?
3.
Are fire extinguishers located at well-signed and easy to find fire-points?
4.
Has an effective fire alarm system been devised?
5.
Will everyone on site be made aware of what the fire alarm sounds like?
6.
Has a means of preventing the accumulation of flammable waste material

been established?
7.
Have suitable and sufficient fire safety signs been obtained and displayed?
8.
Have proper storage areas for flammable substances like LPG been
established?
9.
Will smoking be allowed in well-defined safe areas of the site and/or

welfare facilities?
10.
Have signs been erected to clearly define the boundaries of the areas in
which smoking is allowed?
et
it
ov
1.
QCS 2014
Section
Page 193
Part

11. Has equipment been obtained and positioned to enable the safe disposal
of spent smoking materials?
12.
Has a time been set each day, after which smoking is not allowed?
Y
N/A
1. Has an emergency evacuation plan been drawn up and communicated to all

on site?
.l.
l
3. Has an adequate number of 'evacuation wardens' been appointed and

informed of their duties?
2. Will a nominated person monitor the evacuation plan and ensure that it is
always up to date?
rw
4. Have one or more assembly points, which are a safe distance from the
potential hazard, been selected?
ta
5, Have 'assembly point' signs been obtained and clearly displayed?
qa
6. Has everyone on site been informed of:
as
6.1 the location of the assembly point to which they are to report in the event
of an evacuation?
6.2 what the evacuation signal sounds like?
se
6.3 what to do when they get to the assembly point?

6.4 the days/times when the evacuation signal will be tested?
ov
er
6.5 the fact that the evacuation plan will be periodically practised on a 'nonotice' basis?
et
it
Has an assessment of the needs for personal protective equipment (PPE)

been made, engaging the assistance and advice of a reputable supplier if
necessary?
2.
Has everyone on site been issued with all of the PPE that they need to
carry out the jobs allotted to them?
3.
Does everyone on site know how and where to obtain any extra PPE that
they might need in the future?
4.
Does everyone on site know how to obtain replacement PPE for that which
is lost or defective?
5.
Has a PPE issue log been started?
1.
N/A
QCS 2014
Section
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Part
Signs and notices
1.
Has a 'combination' safety sign been erected at each site entrance to inform
everyone who needs access of the minimum standards of safety on site?
2.
Has an adequate selection of warning, prohibition, mandatory and safe

condition signs been obtained and displayed?
3.
Has an adequate stock of other signs, such as traffic management signs,

been obtained and displayed?
4.
Has a person been nominated to ensure that additional signs are erected and
existing signs are moved or removed to reflect changing conditions as the job
progresses?
N/A
N/A
.l.
l
Waste disposal
Have arrangements been made for the delivery of sufficient skips or other
suitable containers to enable different types of waste materials to be stored?
2.
Have the arrangements for the segregation and disposal of waste been
communicated to everyone on site?
3.
Has an area of the site that is readily accessible by large vehicles been set
aside for the siting of skips?
as
qa
ta
rw
1.
se
Environmental considerations
Has responsibility for environmental management, monitoring and

inspection been defined?
2.
Has the potential overall environmental impact of the project been

considered?
3.
Have the project environmental issues been included in the site induction?
4.
Have measures been put in place to avoid or reduce the more obvious
environmental problems, such as:
6.1 the spillage of environmentally damaging fluids?
et
it
ov
er
1.
6.2 any spillage that does occur is not able to seep into the ground,
drainage systems or watercourses?
6.3 the management, storage and disposal of waste materials?
6.4 noise and dust pollution, arising out of construction activities?
6.5 the number and quantity of substances used that give off
environmentally damaging vapour or fumes?
6.6 air pollution resulting from the unnecessary running of construction plant
engines?
5.
Has the existence of protected species of mammals, insects, plants etc.

been investigated?
6.
If protected species are known to be on site, have appropriate measures

been taken to ensure that they remain undisturbed or undamaged?
7.
Have arrangements been defined to adequately deal with environmental

emergencies such as the accidental release of oil and fuels?
N/A
.
.l.
l
Section
Part
Page 195
ta
rw
QCS 2014
qa
Action plan
as
If you have answered NO to any of the questions in the checklist, please provide further information in the columns below.
Question
number
er
Section
se
Human factors
ito
ov
Competence
et
Consultation
Co-operation
Contact with the

emergency services
Action to be taken
By whom
Date for
completion
Comments
.
.l.
l
Section
Part
qa
Question
number
Action to be taken
er
se
as
Existing buildings,
features and ground
conditions
ov
Site security
et
ito
Management of vehicular
and pedestrian traffic
Materials storage and

lay-down areas
Utility services
Working at height
Excavations
ta
Site features and facilities

Section
Page 196
rw
QCS 2014
By whom
Date for
completion
Comments
.
.l.
l
Section
Part
Page 197
ta
rw
QCS 2014
Question
number
Action to be taken
qa
Section
se
as
The site office
ov
er
Welfare facilities
Fire safety
et
ito
First aid
Personal protective
equipment
Signs and notices
By whom
Date for
completion
Comments
.
.l.
l
Section
Part
Page 198
ta
rw
QCS 2014
Question
number
Action to be taken
qa
Section
se
as
Waste disposal
et
ito
ov
er
Environmental
considerations
By whom
Date for
completion
Comments
QCS 2014
Section
Page 199
Part

1.1.12 Security on Site
1.1.12.1 Key points
Generally, site security is as much about the health and safety of 'other persons' as it is
about contractors, employees and other people who would be expected to be on site.
Site security must be effective both during and out of working hours.
Effective site security will keep children and other trespassers off the site; even outside
working hours, construction sites can be hazardous places for the unwary, particularly
children.
There are actions that can be carried out to prevent the theft of construction plant.
The nature of some sites means that whilst they cannot be completely fenced off from the
public, for example scaffolds erected in public places, unauthorised access must be
prevented.
rw
.l.
l
ta
Note: Section 1, Part 3 of the QCS covers site access and Section 1, Part 4 covers site
protection.
qa
Security is a subject that in many circumstances is closely associated with health and safety
on building, construction or civil engineering sites. A poor standard of security with the
resulting risk of trespass, theft and damage can have implications for the health and safety of
the trespassers and possibly the people who are authorised to be there.
There are several reasons why the security of a site might be breached, not all of which are
malicious.
There are common examples of construction activities taking place in premises, which are
still partially occupied by the owner, landlord, members of their staff and possibly members
of the public. For example, where construction work is taking place in a:
newly built, partially occupied housing estate
(b)
supermarket or department store that is still open to the public but is undergoing an
extension or renovation
et
it
(a)
ov
er
se
as
(c)
block of occupied flats undergoing maintenance or renovation.
It might be possible for unauthorised persons to inadvertently stray into the site quite
innocently unless adequate security measures are taken.
However, in many cases, the reasons for trespass have been shown to be malicious. This is
usually for the purpose of theft or criminal damage, both of which can have health and safety
implications for site staff when they return to work.
Children might also try to gain access to sites out of curiosity and the mistaken belief that
they are safe and 'fun' places to play.
Equipment designed to physically control access to sites is readily available. Even a modest
investment (in terms of finance, time and effort) can easily result in a significant improvement
in the standard of site security and therefore reduce the potential for financial and other
losses.
QCS 2014
Section
Page 200
Part
1.1.12.3 Site visitors

1
It can be taken that a 'visitor', for the purpose of these Regulations, can be anyone who is
not an employee. Therefore, a visitor may be any person who is a lawful visitor with a
genuine reason to visit the premises, or a trespasser, who at any time during the day or the
night may be intent on committing a crime.
1.1.12.4 Lawful visitors

Examples of visitors who may have reason to visit construction sites and are:
(a)
postmen/women and couriers
(b)
telephone engineers and other communications specialists
(c)
electricity, gas, telephone and water company employees
(d)
visiting engineers and other construction professionals
(e)
customers and other beneficial visitors
(f)
Administrative Authority Workplace Inspectors
(g)
QCS Inspecting Officers
(h)
delivery drivers
(i)
trainees.
rw
.l.
l
1.1.12.5 Unlawful visitors and trespassers
ta
Examples of unlawful visitors are:

(a)
any person entering the site for the purpose of theft or to commit criminal damage
(b)
any person entering the site by accident
(c)
any (unauthorised ) person deliberately passing through the site, e.g. as a short-cut
(d)
children entering the site to play.
In respect of all trespassers, including those with criminal intent and children, it is illegal to
set any form of trap or to deliberately do anything that is intended to cause injury to, or to
damage the health of, the intruder.
et
it
Employees may be well aware of the risks, and have safe systems of work, use protective
equipment or have procedures that would be unknown to a visitor. In these cases, the
occupier must make suitable provision for the protection of all visitors.
An example might be the provision of eye, foot or head protection where necessary, or
barriers to keep visitors away from machines.
ov
er
1.1.12.6 Foreseeable risks
se
as
qa
1.1.12.7 Children and young persons
If children or young persons are allowed on the premises (as children of customers, invited
school parties, and so on), it must be remembered that they cannot be considered to have
any concept of hazard and risk and cannot be expected to behave as would an adult.
Whereas an adult may stand behind a guardrail that is set at a height of 1 metre, a small
child could walk under it. It may be necessary to install two intermediate guard-rails at 330
mm and 660 mm.
It should also be appreciated that children may not be able to read, understand or comply
with safety signs and notices.
QCS 2014
Section
Page 201
Part
1.1.12.8 Site security and crime prevention

The crimes that cause the greatest problem on site include theft, criminal damage and arson.
While it may be usual to think about offenders being unauthorised people who come onto
site to steal or cause damage, it must be remembered that a substantial number of offences
are committed by employees either for the direct gain of what they steal or out of malice
against the Contractors. It is not unknown for employees to damage property to delay the
progress of work, so they can be employed for longer repairing the damage that they have
caused.
Sometimes, site employees will give information to other persons who will later come and
commit the crime. This is very often the case with regard to the theft of larger items of
construction plant and equipment, or where substantial amounts of material are taken. Even
if the offenders are caught, it is very difficult to identify the employee who passed on the
information.
.l.
l
ta
The four most important things that can be done for site security are to:
remove temptation by hiding from view any 'attractive' item that might tempt a potential
thief
(b)
make it more difficult for the trespasser to get onto the site or into the building
(c)
make it harder for the trespasser to gain access to 'attractive' items if they do manage
to get onto the site
(d)
make it more difficult for the criminal to profit from their crime.
as
qa
(a)
se
Removing temptation
ov
er
1.1.12.10
1.1.12.11
This simply involves ensuring that 'attractive' items such as hand-held power tools are
removed from view when not in use, particularly out of normal working hours. On sites
surrounded by a solid hoarding, this should not be an issue.
Making it difficult for the trespasser to gain access to the site
et
it
rw
1.1.12.9 Managing security
The first consideration in attempting to make it difficult for the trespasser to effect an entry
will include the provision of site fencing.
This should be at least a 2-m high security fence with the posts securely anchored. 'Mesh'
type fencing, which includes 'anti climb' panels, can be hired. The panels have small gaps in
the mesh to make it more difficult to obtain footholds.
Alternatively, a close-boarded wooden perimeter fence or hoarding, at least 2 m high, may

be needed in a city or town centre site or at other high-risk premises.
It should be remembered that if employees are used as security staff, they must be given the
appropriate health and safety training before they start work, or whenever they are exposed
to a new or an increased risk.
Guard dogs
1
As work on most sites only takes place during the normal working week, serious
consideration must be given to 'out-of-hours' security.
QCS 2014
Section
Page 202
Part
Again, an assessment is needed and the use of guard dogs may be considered.
Locks, alarms and other security measures
If buildings are to be made secure, special attention should be paid to doors where high
quality locks should be used. Windows may need to be protected by steel grilles as well as
locks. The use of padlocks, other than very high security padlocks, is questionable, as
criminals using bolt croppers frequently cut the exposed shank.
The walls of a building are not very often broken through but it is reasonably common for
criminals to gain access through ceilings, particularly to get into shop premises.
It is relatively common for thieves to use cutting equipment to enter storage containers.
There are a number of proprietary products, particularly toolboxes/chests, which advertise
that they are designed to be more thief resistant.
A burglar alarm, whilst not adding anything to the physical security of premises, may well
deter a criminal from trying to break in, or cause them to run away without stealing anything
when the alarm sounds.
If perimeter fencing is to be made secure, special attention should be paid to entrance gates,
in respect of which high quality locks should be used.
ta
rw
.l.
l
Because of the nature of building, construction and civil engineering activities, it is difficult to
have a totally secure site. As unlawful visitors will get onto site occasionally, and some
employees may be dishonest, measures need to be taken to prevent criminal offences from
being committed. There are two main areas where action can be taken to make it harder for
people to steal property:
er
se
as
Making it harder for the criminal to steal or damage anything
qa
1.1.12.12
put it somewhere where it cannot be stolen
(b)
secure it or immobilise it.
ov
(a)
Making it more difficult for the criminal to profit from their crime
1.1.12.13
This is something that can easily be done with all property that may be stolen, and is
probably one of the most cost-effective areas of crime prevention.
A simple example is with scaffolding, where many companies, ever mindful of the risk of
theft, paint their tubes and fittings with brightly coloured bands. It becomes immediately
obvious that something is wrong if they appear on another contractor's site.
Highly visible markings may be a deterrent, but professional criminals are still prepared to
steal items and then remove the markings.
The rising value of metals has made some crime even more lucrative, as there is little need
to consider the risks associated with resale and reuse if the stolen item is simply exported for
reprocessing. It is important to consider at what stages of construction progress a site is
more likely to be the target of theft. For example, one strategy is to move to a full-time
security presence at second fix and to install high value white goods immediately prior to
handover/practical completion.
et
it
1.1.12.14
1
Construction plant and equipment
The health and safety implications if the equipment is not there, or has been damaged, may
be that the job cannot now be done properly or safely. Often shortcuts are taken and such
QCS 2014
Section
Page 203
Part
'makeshift' or temporary works will expose employees to additional risks to their health and
safety.
2
Where possible, isolate plant and machinery at the end of each shift, and park it in a secure
area such as a plant compound that is locked and visible to site security.
1.1.12.15
1
Photographic evidence of ownership
It can be difficult to identify stolen property because many people have no idea what a
compressor, excavator or a backhoe loader really looks like. Photographs of plant and
equipment are useful when trying to describe stolen items to the police or to your insurance
company, especially when they are not common or standard pieces.
1.1.12.16
Security of plant
Security of plant has implications for health and safety on building, construction or civil
engineering sites as well as for the financial viability of a company.
Having a well-managed security programme, to restrict the theft of equipment, may help in
reducing premiums to insurance companies.
The theft of plant which is not properly secured, or that can be moved or started, could have
serious financial consequences for a company.
The actual cost of security arrangements can be insignificant when compared with the
financial loss that theft incurs.
Costs which may be encountered could be in terms of production time lost due to missing
equipment, the administration in acquiring replacement equipment, as well as dealing with
the police and insurance companies.
Losses may also be incurred due to the damage caused to plant and equipment by
unsuccessful theft or by wanton vandalism, such as broken cab windows or spray paint
graffiti. Steps must be taken to minimise the possibility of either.
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Theft of plant and equipment is one of the most common crimes that occur on site, some by
chance and some to order. The damage that the thief does in trying to steal the plant can be
substantial, not only to the plant but also to perimeter fencing, even if the theft fails.
Site security and crime prevention
1.1.12.17
1.1.12.18
Managing the security of plant and equipment
An overall theft prevention plan should be produced and constantly reviewed. Each of the
anti-theft methods outlined in the following, and the ways to identify and locate plant, should
be considered as part of this plan.
There tends to be a lack of responsibility by people towards the security of plant, tools and
equipment, particularly where these are hired in.
It is the responsibility of management to ensure that staff are aware of the problems created
by plant theft, including the possible effect on the company's viability and the consequent
damaging effect on jobs.
1.1.12.19
1
Closed circuit television (CCTV)
As the cost of closed circuit television (CCTV) has reduced, the affordability and wider use of
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Part
the equipment has made the deterrent effect of its use considerable.
2
Cameras need to be well placed and:

(a)
capable of viewing the perimeter in darkness, with or without the aid of security
lighting
(b)
difficult for a thief to interfere with or steal.
On an unstaffed site, it is essential that the potential criminal knows recording is taking place
and that the recorder itself is in a secure location.
1.1.12.20
Put it somewhere where it cannot be stolen
On most sites, small, valuable hand tools and pieces of plant or equipment will be locked in a
site hut or tool store, or in a secure tool chest out of sight. The storage place should be as
substantial and secure as possible so that it is difficult to break into.
If a mobile tool store or chest is used, it should be recognised that some types of site
equipment and lorry-mounted cranes can be used to lift or drag tool chests and stores onto a
vehicle and stolen intact with their contents.
They should, therefore, be put in a secure site hut or container and securely bolted or
welded to the floor. If the tool store or vault has to be left externally, it should be bolted to a
concrete floor or block, or chained to an immovable object.
Often high security steel freight containers are used. These have no windows, virtually
impenetrable walls, floors and roofs, and doors that are designed to be securely locked. This
is a great advantage over the average site hut, which is usually a portable building with no
integral security features beyond normal door locks.
When using these containers, however, it should be remembered that they must never be
used for the storage of LPG cylinders or any other gas bottles, or quantities of solvents.
There have been instances when cylinders and gas bottles have leaked overnight, allowing a
dangerous build-up of gas inside the container.
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Secure it or immobilise it
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1.1.12.21
Non-driven mobile plant and trailers

Non-driven mobile plant and trailers should be immobilised by the use of specialist
mechanical devices, such as eye-locks and wheel clamps, and should also be secured by a
security chain to an immovable object, thus preventing lifting by lorry-mounted cranes or
other site equipment.
Their visibility acts as a deterrent. Removal requires much physical effort and time and the
use of specialised tools. Their removal is also likely to be accompanied by noticeable noise
and light.
Immobilisation could also include smaller items being chained to larger items of plant,
concrete posts or steel columns.
'Security' chains should be strong enough to defeat files, hacksaws, levers and large bolt
croppers, and be difficult to attack with power tools.
Where possible, chains should be kept off the ground as this makes attack more difficult.
QCS 2014
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Part
Driven plant
Larger items of driven plant and equipment that cannot be put into a store should be
immobilised by simple specialist mechanical or electronic devices.
It should be appreciated that the smaller the plant, the less likely it is that an electronic
immobiliser can be adequately concealed and that mechanical devices will be more
practical. Mechanical devices can immobilise stabiliser legs, steering mechanisms,
excavator booms and tracks.
On items of plant such as large earthmovers, road graders and large dump trucks, or where
the machine is complex, it is easier to conceal an electronic immobiliser. A mechanical
device to do the same job would be too large to manually handle.
Many pieces of plant have either mechanical devices and/or electronic devices fitted by the
manufacturer at the time of manufacture. All aspects of their operation should be understood
and full use made of them when the item of plant is left.
10
When the plant is left overnight or longer, there should be a disciplined approach to security.
The plant should be parked in a location where any wrongdoing would be noticed by
passers-by and away from easy access by a lorry-mounted crane to reduce the possibility of
it being lifted off site.
11
The ignition keys should be removed which will, in many instances, set an alarm and an
immobiliser. If the alarm or immobiliser does not set automatically then it must be set
manually.
12
A mechanical immobilisation device, where fitted, should be in such a position that it is

visible to passers-by to ensure any suspicious tampering is noticed. If such mechanical
devices allow equipment to be locked together, then this facility should be used whenever
possible.
13
Immobilisation could also include smaller items being chained to larger items of plant.
14
Any labels supplied by the manufacturer that indicate that immobilisation devices are fitted
should be prominently displayed.
1.1.12.22
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Create a series of barriers
One of the key problems for any prospective thief is lack of time, and overcoming barriers is
time consuming. For instance, a fence or gate may be the first barrier to overcome, the
second a security container, the third a security chest or a series of physical locks and
chains within the container.
Individually each barrier might not present the prospective thief with too much difficulty but,
added together, they may prove so time consuming that the thief abandons the attempt.
Similarly, for larger equipment, fencing is the first barrier. The secure location of the
equipment, and the setting of mechanical and electronic immobilisers, then adds further
barriers, increasing the difficulty and the time required to overcome them.
A bright corporate colour scheme for all pieces of plant owned by a Contractor, as well as
the vans and lorries visiting the site, dissuades the thief. It identifies the equipment and
makes it more difficult to resell without repainting. Also, when a van or truck parked next to
the plant is not in the same corporate colours, and any work being undertaken is suspicious,
it can alert passers-by.
Painting plant and equipment in corporate colours could be used as part of an overall theft
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Part
prevention plan.
1.1.12.23
1
Recovery of plant and equipment
Once stolen equipment has left the site, the cost of inconvenience has started to mount up.
Although any subsequent recovery device will mitigate the final cost of the theft, it will not
change the cost of lost time and administration.
Stolen vehicle and plant location
A popular way of recovering plant is through a tracking device. This relies on the ability of the
police or a central monitoring station to locate the plant through signals emitted from devices
located on the equipment.
Although the success of recovering plant fitted with trackers is high, thieves are becoming
more sophisticated in their actions and technology, and are finding ways to neutralise the
devices.
Keys
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1.1.12.24
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Another recommendation is the elimination of single keys for plant. (As with cars, some sets
of keys will give access to a variety of vehicles, not necessarily of the same make or year of
manufacture.) Plant manufacturers will eventually undertake this move, but until all machines
have different keys, the fitting of either a mechanical or electronic immobilisation device, or
both, is essential.
Whilst manufacturers will also be upgrading the security of cabs and canopies, it is still
necessary to lock them to reduce the possibility of hot-wiring plant to start it or the damage
caused whilst trying.
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Plant theft - summary
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1.1.12.25
Among the items most commonly stolen are mini-excavators, floodlighting equipment,
generator sets and compressors. All are of high value and relatively portable. Once removed
from site, they may prove impossible to track down.
Construction plant or equipment that is securely locked, immobilised, and clearly and visibly
marked is less likely to be stolen than plant which is not secured or marked.
Equipment that is fitted with an electronic tracking device or is registered with a database is
more likely to be recovered after being stolen.
Electronic tracking devices may be active or passive. Active devices allow the owner to know
exactly where the item of plant is at all times, while passive devices are only activated once
that piece of plant has been stolen or unlawfully removed.
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1.1.13 Statutory Forms, Notices and Registers
1.1.13.1 Key points
1
The selection of the forms or notices, etc., will necessarily be as appropriate or applicable to
the individual site or premises, and the circumstances that exist on that site.
1.1.13.2 Statutory Forms, Notices and Registers

Accident Book
The keeping of an accident book is required by these Regulations
All accidents that cause any injury to an employee, no matter how slight, must be entered.
Entry may be made either by the employee or anyone acting on their behalf.
Completed book stubs and records must be kept for three years from the date of the last
entry.
F100 Report of an injury or dangerous occurrence (Pad of forms) Injuries
Form F100, report of an accident or dangerous occurrence, is required by RIDDOR - The

Reporting of Injuries, Diseases and Dangerous Occurrences.
Unless notification has been made by telephone, fax, email, Form F100 must be completed
and sent by the person completing the report to the Administrative Authority which is the
Administrative Authority, this action is required under the following circumstances:
If an employee or other person dies or suffers any major injury as a result of an accident at
work.
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Note: (i) This type of accident must also be reported immediately by the quickest practical
method (usually the telephone).
any fracture of any bone other than the fingers, thumbs or toes
(a)
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Note: (ii) A major injury or serious condition such as:
(b)
any amputation, the dislocation of the shoulder, hip, knee or spine
(c)
the loss of sight (whether temporary or permanent) or any other listed eye injury
(d)
electric shock or burn causing unconsciousness
(e)
any injury leading to hypothermia, heat-induced illness or to unconsciousness

requiring resuscitation or admittance to hospital for more than 24 hours
(f)
unconsciousness due to asphyxia or exposure to a harmful substance or biological

agent
(g)
acute illness or unconsciousness caused by any poisoning by any route
(h)
acute illness caused by exposure to infected material or a biological agent
(i)
if an employee has an accident at work and is unfit or is off work for more than three
days (weekends and rest days included) as a result of the accident.
Dangerous occurrences
8
Form F100 must be sent to the Administrative Authority whenever a scheduled dangerous
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Part
occurrence has occurred. Alternatively, notification may be given by telephone, fax or email.
Dangerous occurrences listed include (briefly):
collapse, overturning or failure of any load-bearing part of any lift, hoist, crane, derrick,
mobile powered access platform, access cradle, window cleaning cradle, excavator,
piling rig or forklift truck
(b)
explosion, bursting or collapse of any closed vessel, boiler, etc.
(c)
contact with, or arcing from, any overhead electric cable caused by any plant or
equipment
(d)
electrical short-circuit with fire or explosion
(e)
explosion or fire caused by any material resulting in stoppage of work or plant for more
than 24 hours
(f)
uncontrolled release of 100 kg or more of a flammable liquid, 10 kg or more of a

flammable liquid above its normal boiling point or 10 kg of a flammable gas, inside a
building, and 500 kg or more of such substances outside a building
(g)
collapse or partial collapse of any scaffold over 5 metres in height or fall of any cradle,
etc.
(h)
collapse of 5 tonnes or more of any building or structure, or any falsework, or any wall
or floor in any workplace
(i)
uncontrolled release of any biological agents
(j)
accidental ignition of any explosive
(k)
failure of any load-bearing part of a freight container
(l)
bursting, explosion or collapse, or fire involving a pipeline
(m)
specific incidents involving road tankers
(n)
specific incidents involving dangerous substances being conveyed by road
(o)
escape of any substance in a quantity sufficient to cause death, injury or damage to

health
(p)
malfunction of any breathing apparatus whilst in use or when being tested before use
(q)
contact with or arcing of any overhead power line.
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F100A Report of a case of disease

10
A report on form F100A is required by RIDDOR the Reporting of Injuries, Diseases and
Dangerous Occurrences.
11
It must be sent, by the person completing the report, to the Administrative Authority, when a
registered medical practitioner has diagnosed in writing that an employee is suffering from a
scheduled reportable disease
AND
12
the person has been employed in a scheduled work activity by the Contractors.
13
Alternatively, notification may be given by telephone, fax or email.

COSHH assessments, etc.
14
The Control of Substances Hazardous to Health require assessments to be made of

substances hazardous to health and, except in the simplest and most obvious of cases, for
the assessments to be written and kept accessible for those who need to know the results.
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This specifically includes safety representatives.

15
If health surveillance is appropriate, the health records of employees under health

surveillance must be maintained and kept for 40 years after the date of the last entry.
16
All mechanical control measures, such as dust extraction, must be subject to routine
examination in accordance with the Regulations and records kept.
17
Substances hazardous to health must be properly labelled.

Danger areas
Identify with signs
19
Dangerous substances and explosive atmospheres
18
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A substance or preparation which is explosive, oxidising, extremely flammable, highly

flammable or flammable, or any dust which can form an explosive mixture with air or an
explosive atmosphere.
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Dangerous substances
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Explosive atmosphere
A mixture, under atmospheric conditions, of air and one or more dangerous substances in
the form of gases, vapours, mists or dusts in which, after ignition has occurred, combustion
spreads to the entire unburned mixture.
22
Where an explosive atmosphere may occur, a specific sign is to be erected.
23
The sign must consist of black letters on a triangular yellow background with black edging.
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24
Diving
Records have to be kept of the written appointment of all diving supervisors and of the
qualifications and medical certificates of divers. All dives have to be recorded in the divers'
log books. Diving rules have to be in writing.
Electrical equipment
25
All electrical equipment, including portable equipment, should be inspected on a regular

basis by a competent person and records kept. Portable electric tools should be PAT-tested
on a three-monthly basis, with a sticker showing the test date and the date the next test is
due fixed to each item.
Electric shock placard

26
Notices or placards giving details of emergency resuscitation procedures in the event of an
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Part
electric shock should be displayed in locations where people are at an enhanced risk of
electric shock.
Emergency evacuation
27
Emergency routes and exits must be established and indicated by suitable signs.
Excavations, cofferdams and caissons
28
Excavations, cofferdams and caissons must be inspected and written reports of the
inspections made.
Explosives
Possession of explosives requires an explosives certificate which is issued by the local Chief
Officer of Police.
30
Detailed records have to be kept of all movements or usages of explosives.
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It is required that records should be kept of all design calculations, drawings, estimated
loadings and specifications for falsework, together with written permissions to pour concrete
or to 'load' falsework, and to dismantle it.
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Falsework
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Documentary information relating to fire safety should include:

records of staff training in the use of extinguishers
(b)
record of fire extinguisher servicing
(c)
record of practice evacuations
(d)
written fire risk assessment and a written fire safety plan.
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32
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Fire
33
First aid
First-aid notices are required to be displayed as an effective means of informing the

workforce of the Contractors arrangement for first aid.
Food hygiene
34
Toilets adjacent to food rooms must be separated by a lobby. A notice stating 'NOW WASH
YOUR HANDS' must be displayed.
35
Employees in food rooms must not smoke. A notice is displayed to that effect. Checks and
inspections of equipment and staff training should be recorded. Certificates of staff training in
food hygiene and handling must be displayed.
Fragile surfaces
36
Appropriate warning notices must be clearly displayed at all approaches to the area.
QCS 2014
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Part
Hazardous substances
37
All containers containing hazardous substances should be clearly marked with their contents
and the appropriate hazard warning symbol.
38
Assessments must be made and, with minor exceptions, recorded.

Health and safety policy
39
The policy must be brought to the notice of all employees.

Holes in floors and similar openings
If a cover is used over a hole, it must be clearly marked to show its purpose.
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The appropriate warning signs and notices for controlled areas must be displayed.
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Ionising radiation
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Lifting operations
All machinery and accessories used for lifting are marked to indicate their safe working load
for each configuration in which they can be used.
43
Lifting equipment designed to lift persons is clearly marked as such.
44
Lifting equipment not designed for lifting persons but which could be easily mistaken for such
is marked appropriately.
45
All lifting equipment and accessories are subjected to a scheme of thorough examination.
Records of thorough examination are made and kept available for inspection.
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Management of health and safety

Risk assessments must be made of all work activities and the significant findings must be
recorded.
47
Health surveillance, if it is needed, individual health records must be kept.
48
Emergency procedures need to be displayed
46
Manual handling
49
Assessment to be made where risks from manual handling cannot be avoided. It is required
that all but the most simple assessments should be recorded.
Noise
50
Hearing protection zones need to identified by means of a sign.
51
A hearing protection zone is anywhere where an employee is likely to be exposed to a daily

personal noise exposure of 85 dB(A) or a peak sound pressure of 137 dB(C).
QCS 2014
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Plant and equipment

52
If it is not otherwise provided for, it is strongly recommended that all plant, tools and
equipment are subject to inspection and examination, and proper records kept.
53
A daily inspection and a six-monthly examination may be appropriate.

Pressure vessels
54
All pressure vessels intended to contain air or nitrogen at a greater pressure than 0.5 must
have details of the maximum working pressure, maximum and minimum working
temperatures, and cubic capacity clearly displayed on it.
Assessment of the need for personal protective equipment. In all but the simplest cases the
assessments should be recorded.
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Protective clothing and equipment
Where a safety committee has been established, proper minutes and records should
be kept. Safety representatives may give written reports to management concerning safety
in the workplace.
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Safety representatives and safety committees
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Scaffolding
(1) Display of 'Incomplete scaffold notice.
58
Designated 'danger areas' must be created where there is a risk of a person falling or being
hit by a falling object. In the case of incomplete scaffolding, suitable notices must be
displayed to discourage attempted access on to the scaffold.
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(2) Reports of inspections
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The maximum working pressure of any steam boiler must be clearly marked. Boilers must be
inspected at the scheduled intervals and proper records kept.
60
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Steam boilers
Training
61
It is most strongly recommended that all such information, instruction and training is properly
and fully recorded so that Contractors are in a position to prove that duties under these
Regulations have been met.
VDUs - Visual display units or display screens
62
Suitable and sufficient analysis of workstations for the purpose of assessing health and
safety risks. All but the simplest and obvious cases must be recorded.
Work equipment
63
Maintenance, records of maintenance, written instructions. Maintenance log should be

recorded. All work equipment must be marked in a clearly visible manner where necessary,
in the interests of health and safety.
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Warnings, audible or visible, to be incorporated into work equipment as necessary.

Working at height
65
Any training carried out to achieve competency should be recorded. Where any person at
work may pass across or near to a fragile surface, or actually work on it, prominent signs
indicating that it is a fragile surface must be fixed at every approach to that place. Where
any person could be injured by falling or being hit by a falling object, 'danger areas' must be
created to prevent such an occurrence. Danger areas must be clearly indicated, usually by
signs and/or barriers Where inspections of work equipment are carried out a record of the
inspection must be made and retained as specified.
Safety signs
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END OF PART
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All signs giving health or safety information or instructions must comply with the relevant
British Standard. A safety sign is anything that combines geometrical shape, colour and
pictorial symbols to give safety information.
66
QCS 2014

Page 1
Part 1.02: Occupational Health and Hygiene (Regulatory Document)
REGULATORY DOCUMENT........................................................................... 1
1.2
OCCUPATIONAL HEALTH AND HYGIENE .................................................... 1
1.2.1
The Management of Health on Site ............................................................... 4
1.2.2
Personal Protective Equipment .................................................................... 15
1.2.3
Control of Substances Hazardous to Health (COSHH) ................................ 29
1.2.4
First Aid at Work .......................................................................................... 57
1.2.5
Food Safety on Site ..................................................................................... 70
1.2.6
Working with Lead ....................................................................................... 73
1.2.7
Manual Handling .......................................................................................... 88
1.2.8
Asbestos in the Workplace ........................................................................ 104
1.2.9
The Control of Dust and Fumes ................................................................. 112
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Control of Noise ..................................................................................... 129
1.2.11
Protection of the Eyes ............................................................................ 149
1.2.12
Protection of the Skin ............................................................................. 161
1.2.13
Control of Vibration ................................................................................ 175
1.2.14
Compressed Air ..................................................................................... 199
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1.2.10
QCS 2014

Page 2
FORWARD
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This Section of the Regulatory Document (RD) was produced as a project deliverable under Ministry of
Municipality and Urban Planning Contract Number P2009/3, entitled Consultancy Services for the
Preparation of Codes and Standards for Safety and Accident Prevention on Construction Sites.
During the latter stages of the project, the Committee responsible for the administration of the project
decided that the RD and the associated Safety and Accident Prevention Management/Administration
Systems (SAMAS) would be best delivered to stakeholders via the portal provided by the Qatar
Construction Standards (QCS). The QCS includes references and certain sections which address
occupational health and safety. To ensure that that users of the RD/SAMAS are fully aware of the
where occupational health and safety issues are addressed in the QCS, the following table
summarises where potential overlaps may occur. For consistency, it is recommended that in matters
relating to occupational health and safety reference is made first to the RD/SAMAS. For the purpose
of clarity, however, references are made in the relevant section of the RD/SAMAS to their comparable
sections in the QCS and vice versa.
QCS 2014

Page 3
Sr. No
QCS 2014
Section No.
Part No.
Part Name
Submittals
7.5.2
Health and Safety Organization

Chart
Submittals
7.6.1
Health and Safety Plan
10
Health and Safety
All
All
All
11
Engineer's Site Facilities
10
11.4.6
14
14.4
Test Certificates for Cranes and

Lifting Tackle
15
Temporary Controls
All
All
All
16
Traffic Diversions
16.1.3
Safety
General
8.1.6
Safety
General
8&9
1.4.12
10
General Requirements for Piling

Work
1.6
Safety
11
Deep Foundations
37 & 38
4.9.1.7
Safety Precautions
12
Deep Foundations
13
General
14
Asphalt Plants
15
14
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42
Item Name
Page No. Item No.
4.9.1.13 Protection of Testing Equipment

1.6
Temporary Fencing
15
7.8.13
Safety Requirements
14.2.2
Safety
General
7,8, 9 &
10
1.3.2
Health and Safety
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4&5
17
8.1.9
Safety
18
9.2.5
Safety Requirements
19
10
Pipeline Cleaning and Inspection

Survey
4,5&6
10.1.7
Safety Requirements
20
21
22
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11.2.2
Safety
General
16
1.2.8
Safety Guards
General
19
1.2.16
23
11
19
Hot Water Storage
5.1.6
Safety
24
21

Installation
7&8
1.1.11
Fire and Safety Precautions
25
21

Installation
14
1.1.23
Safety Interlocks
26
24
General
1.1.4
Scaffolding
27
29
Design Aspects
1.1.5
Fire Resistance Period
28
29
2.3.1.5
Safety
29
29
Tunnel
18
4.5.8
Safety Regulations
30
29
Tunnel
19
4.5.9
Fire Prevention
31
29
Tunnel
21
4.6.4
Safety Measures and Systems
32
29
Concrete Structures
7.1.10
Safety Railing
QCS 2014

Page 4

1.2.1
The Management of Health on Site
1
Note:
One of the reasons why Contractors have safe systems of work is to avoid accidents and
keep employees at work instead of being off sick.
Section 1, Part 13 of the QCS covers setting out of the works.
1.2.1.2 Benefits
The benefits that arise from adopting a positive policy of health risk management can be
measured in legal, economic, social and moral terms.
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Freedom from prosecution by the administrative authorities, or either Government Officials

stopping or delaying Contractors works.
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Legal
Uninterrupted production and lower staff turnover and having a good reputation with the
prospect of future business.
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Economic
Being recognised by employees and others as a 'caring' Contractor and a good company to
work for.
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Social
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Moral
Knowing that the Contractor and work activities are not damaging the health of staff or
anyone else, given the fact that no Contractor has the right to damage the health of any
employee.
While social and moral issues are not usually mentioned, it can be seen that they are
becoming of greater importance, particularly when clients or contractors are looking for
contractors who have a demonstrated commitment to health as well as to safety.
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1.2.1.3 Some of the specific health areas that need to be addressed

Manual handling
1
Giving employees the appropriate training in the correct manual handling techniques and the
use of mechanical lifting aids is highly cost effective. Adequate supervision is necessary to
ensure that employees then use the proper equipment and techniques and do not take 'short
cuts'. This will reduce accidents, the amount of time lost on site, and the disruption to work
that is caused when something goes wrong.
The part of the body most vulnerable if bad manual handling techniques are used is the
back, particularly the lower back. Once it has been damaged, it is usually weakened for the
rest of a person's life.
All the other major joints and muscle groups can also be easily damaged if the correct
manual handling techniques are not used.
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The consequences of an injury due to bad manual handling, or a musculo-skeletal injury or

illness as they are often called, can be a long-term or permanent inability to work. The cost
to the Contractor is reduced productivity and having to find others to carry out the work.
Noise
annoyance and irritation
(b)
loss of concentration
(c)
reduced efficiency
(d)
fatigue
(e)
increased accident risk
(f)
masking of other warning signals.
(a)
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The damage can range from temporary hearing loss to total deafness. As well as hearing
problems, excess noise is also known to cause:
On site, the failure of an employee to understand instructions that have been given, or to
hear a warning signal, can have serious consequences, both for them and for the Contractor.
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1.2.1.4 Vibration
A considerable number of the tools and other pieces of equipment that are currently used in
the Qatar building and construction industry have a rotary or percussive action and so can
cause hand-arm vibration. This even applies to some widely used small tools, such as
hand drills that have a 'hammer' action. Other examples of tools that create vibration include
pneumatic breakers, vibrating pokers, vibrating rollers, plate compactors and scabbling
machines.
The most commonly caused ill-health effect is 'vibration white finger' where the effect of the
vibration damages the nerves and blood vessels in the fingers. The fingers become white
and there is a loss of feeling which prevents smaller tools from being held or used properly.
Hand-arm vibration is also known to cause other vascular, neurological and muscular
damage in the hands, wrists, elbows and shoulders.
Whole-body vibration, which is caused by the transmission of vibration to the body from
sources such as moving plant or vehicles, can bring about long-term back pain.
The effects of both hand-arm vibration and whole-body vibration can be reduced by carrying
out risk assessments, appropriate purchasing policies, the correct use of the equipment and
the use of the appropriate anti-vibration devices such as special handles or grips.
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1.2.1.5 Stress
1
In the workplace, stress is a growing problem but one that has not been widely recognised or
generally accepted within the Qatar building and construction industry.
Stress can cause physical problems such as:

(a)
high blood pressure
(b)
heart disease
(c)
depression as well as behavioural problems, such as:
(d)
anxiety
(e)
irritability
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(f)
failure to cope as usual
(g)
bad time-keeping. Some of the causes of stress are:
(h)
too much work/long working hours
(i)
confusion as to what is expected
(j)
uncertainty as to responsibilities
(k)
conflict of interests.
Work-related factors that lead to stress can be managed but this will require appropriate
training for management and operatives. If left unchecked, the following signs of stress may
quickly emerge at the workplace and cause problems.
Loss of motivation, commitment and work output.
(b)
Increased absence due to sickness and unauthorised reasons.
(c)
Decline in the relationships between staff on site.
(d)
Poor decision-making and increased errors.
(e)
Physical illness, and perhaps stomach ulcers and heart problems.
(f)
Mental illness.
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(a)
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While a reasonable degree of challenge and stress is acceptable as providing an added

incentive to work, excess stress among employees is counterproductive and should be
avoided if employees are to work to their best potential.
Some things that can be done to avoid or prevent stress are:
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1.2.1.6 Management-related
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The fostering of good relationships between staff and management
Well-set, clear and achievable objectives
Good and effective two-way communications
Employee involvement
Good management support
Staff training
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1.2.1.7 Task-related
1
Well-defined tasks
Clear responsibilities
Proper use of skills
Good control of hazards and risks
Support from senior management
The benefits that come from reducing stress include:
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(a)
less sickness and absence from the workplace
(b)
increased performance and productivity
(c)
better staff relationships
(d)
lower staff turnover
(e)
increased morale
(f)
lower overall costs.
The elements of the work-related stress standards are:
Demands - Issues that should be considered are workload, work patterns and the working
environment.
Control - How much control does the individual have over the way they do their work?
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Support - Do workers feel that adequate encouragement and resources is provided by the
company, managers and colleagues?
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Relationships - Workers at any level must not be subjected to unacceptable behaviours by

anyone at work and conflicts must be effectively dealt with.
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Role - Workers at all levels must understand their role (how they fit into the organisation)
and there must not be any conflicting roles.
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Change - People can be suspicious of the real motives behind organisational change which,
whether large or small, must be well managed and effectively communicated.
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1.2.1.8 Radiation, sunshine and heat stress

If all the signs and other procedures are obeyed, no-one should be at risk from ionising
radiation.
One area of risk that does exist is the radiation from sunshine. The short-term dangers are
blisters and sunburn while the well known long-term danger is skin cancer.
On site it is tempting for employees to take their shirts off on sunny days to get a suntan, but
a suntan does not protect against the risk of skin cancer.
People most at risk include those with fair or freckled skin that does not tan or that burns
before it tans. People with red or fair hair and light coloured eyes, and those who have a
large number of moles (more than 50), are also at a higher level of risk.
As well as protecting against the possibility of sunburn and the long-term risk of skin cancer,
a shirt will also provide protection against minor cuts, abrasions and some of the chemicals
or dusts that can be found on site.
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Heat Stress
1
The body reacts to heat by increasing the blood flow to the skin's surface, and by sweating.
This results in cooling as sweat evaporates from the body's surface and heat is carried to the
surface of the body from within by the increased blood flow. Heat can also be lost by
radiation and convection from the body's surface.
Typical example of a heat stress situation:

(a)
Someone wearing protective clothing and performing heavy work in hot and humid
conditions could be at risk of heat stress because:
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(i) Sweat evaporation is restricted by the type of clothing and the humidity of the
environment.
(ii) Heat will be produced within the body due to the work rate and, if insufficient
heat is lost, deep body temperature will rise.
(iii) As deep body temperature rises the body reacts by increasing the amount of
sweat produced, which may lead to dehydration.
(iv) Heart rate also increases which puts additional strain on the body.
(v) If the body is gaining more heat than it can lose the deep body temperature
will continue to rise.
(vi) Eventually it reaches a point when the body's control mechanism itself starts
to fail.
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(vii) The symptoms will worsen the longer they remain working in the same
conditions.
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Heat stress effects
Heat stress can affect individuals in different ways, and some people are more susceptible to
it than others.
Typical symptoms are:
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an inability to concentrate
(b)
muscle cramps
(c)
heat rash
(d)
severe thirst - a late symptom of heat stress
(e)
fainting
(f)
heat exhaustion - fatigue, giddiness, nausea, headache, moist skin
(g)
heat stroke - hot dry skin, confusion, convulsions and eventual loss of consciousness.
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(a)
Heat stroke is the most severe disorder and can result in death if not detected at an early
stage.
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Workplace examples
People might suffer from heat stress because of the hot environment created by the process,
or restricted spaces:
(a)
construction sites
(b)
confined spaces
(c)
operating machinery
(d)
tunnels
(e)
mines
(f)
compressed air tunnels
(g)
foundries and smelting operations
(h)
brick-firing and ceramics plants
(i)
boiler rooms
(j)
kitchens
(k)
laundries
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Control Measures
7
Over time people adapt to hot conditions by sweating more, and by changing their behaviour
to try and cool down, e.g. removing clothing, taking cool drinks, fanning themselves, sitting in
the shade or a cool area, and/or reducing their work rate. However, in many work situations
such behavioural changes may not be possible, e.g. during asbestos removal. Where there
is a possibility of heat stress occurring you will need to carry out a risk assessment.
Contractors must undertake a risk assessment.
When carrying out a risk assessment, the major factors you need to consider are:
work rate - the harder someone works the greater the amount of body heat generated;
(b)
working climate - this includes air temperature, humidity, air movement and effects of
working near a heat source;
(c)
worker clothing and respiratory protective equipment - may impair the efficiency of
sweating and other means of temperature regulation;
(d)
workers age, build and medical factors - may affect an individual's tolerance.
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(a)
Firstly, you will need to talk to the workers involved (and their safety representatives), to see
whether they are suffering early signs of heat stress. If it seems likely that there is a problem,
you may need to consult with people who are more experienced in determining the risk from
hot environments, e.g. occupational hygienists, nurses or doctors.
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Contractors must remove or reduce the sources of heat by:

CONTROLLING THE TEMPERATURE using engineering solutions, e.g.
change the processes,
(ii)
use fans or air conditioning,
(iii)
use physical barriers that reduce exposure to radiant heat.
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(i)
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(a)
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PROVIDE MECHANICAL AIDS where possible to reduce the work rate.
(c)
REGULATE THE LENGTH OF EXPOSURE to hot environments by:
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(b)
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(iv) allowing workers to enter only when the temperature is below a set level or at
cooler times of the day,
(v) issuing permits to work that specify how long your workers should work in
situations where
there is a risk,
(vi) providing periodic rest breaks and rest facilities in cooler conditions.
(d)
PREVENT DEHYDRATION. Working in a hot environment causes sweating which

helps keep people cool but means losing vital water that must be replaced. Provide
cool water in the workplace and encourage workers to drink it frequently in small
amounts before, during (this is not possible in some situations e.g. respiratory
protective equipment use or asbestos removal) and after working.
(e)
PROVIDE PERSONAL PROTECTIVE EQUIPMENT. Specialised personal protective

clothing is available which incorporates, for example, personal cooling systems or
breathable fabrics. This may help protect workers in certain hot environments.
Protective clothing or respiratory protective equipment is often required when there will
be exposure to some other hazard at work e.g. asbestos. This type of equipment,
while protecting from the other hazard, may increase the risk of heat stress
(f)
PROVIDE TRAINING FOR YOUR WORKERS, especially new and young employees,
telling them about the risks of heat stress associated with their work, what symptoms
to look out for, safe working practices and emergency procedures.
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(g)
ALLOW WORKERS TO ACCLIMATISE to their environment and identify which

workers are acclimatised/assessed as fit to work in hot conditions.
(h)
IDENTIFY EMPLOYEES WHO ARE MORE SUSCEPTIBLE to heat stress either

because of an illness/condition or medication that may encourage the early onset of
heat stress, e.g. those with heart conditions. Advice may be needed from an
occupational health professional or medical practitioner.
(i)
MONITOR THE HEALTH OF WORKERS AT RISK. Where it is considered that a

residual risk remains after implementing as many control measures as practicable,
you may need to monitor the health of workers exposed to the risk. You should then
seek advice from occupational health professionals with a good working knowledge of
the risks associated with working in heat stress situations.
During the period from June 15th until August 31st, work under direct sun rays is prohibited
from 11:30 am to 3:00 pm unless special arrangement is taken by the Contractor to control
and ease effect of the direct sun on the workers unless otherwise announced by the
concerned authorities. This arrangement should be approved by the Engineers
Representative and should be agreed upon before implementation.
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Respiratory problems Dust
The inhalation of any dust will eventually cause respiratory problems, including or
contributing to such conditions as asthma, bronchitis, pneumoconiosis and certain types of
lung cancer. Some dusts cause an allergic reaction where breathing problems are caused
immediately after a dust is breathed in. As well as presenting a health hazard, many airborne
dust clouds are also flammable or explosive.
14
Whenever practicable, the generation of dust should be avoided, and where it cannot be
avoided it should be controlled by ventilation or extraction. The use of personal protective
equipment by employees must be regarded as the very last resort when all other methods of
control have been examined and found not to be practicable.
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Fumes including solvent fumes
The vapour given off by many substances has the potential to cause respiratory illness or
other symptoms of ill health if not adequately controlled. Other symptoms include
headaches, coughing, feeling sick, feeling light-headed, shortness of breath or feverishness.
16
As well as being inhaled and causing direct problems in the lungs, many fumes can be
absorbed into the bloodstream and bring about complications in other parts of the body.
17
An example of this type of response is cancer of the bladder which can be caused by
inhaling certain aniline fumes (a chemical made for use in textile dyes).
18
Potential sources of hazardous fumes, which may be inhaled if control measures are not
taken, are:
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(a)
solvent-based adhesives, spirit-based or solvent-based paints
(b)
welding, especially welding galvanised metals
(c)
oxyacetylene cutting
(d)
engine exhausts.
If the generation or release of the fumes cannot be avoided, for example by using a waterbased solvent or paint instead, then adequate natural or mechanical ventilation should be
used. The use of personal protective equipment for employees must be regarded as the last
resort.
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1.2.1.9 Bird and bat droppings

1
The presence of large populations of roosting birds or a bat colony can present significant
risks to health if their droppings are disturbed. This has obvious implications for some types
of construction work and preliminary work such as surveys.
The main hazard is the inhalation of fungus spores which become airborne as a result of
disturbance of the droppings.
1.2.1.10 Dermatitis
Occupational dermatitis causes lost time in the building and construction industry. Yet with
proper attention to risk assessments, control measures and good working practices it could
be avoided. The prevention of dermatitis would save the Qatar construction industry and
Contractors large amounts of money, and also assist in improved productivity on site, as well
as improving conditions for the workers.
The agents which cause dermatitis can be divided into five classes as follows:
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mechanical factors such as friction, pressure and trauma
(b)
physical factors including heat, cold, electricity, sunlight and radiation
(c)
the use of some chemicals
(d)
contact with some plants and their products
(e)
contact with biological agents, organisms, insects and mites.
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(a)
Contact dermatitis
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There are two main types of dermatitis, commonly known as 'contact dermatitis' and 'allergic
dermatitis'.
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This is sometimes also called irritant dermatitis. It is the commonest form of occupational
dermatitis and results from repeated contact with any substance that irritates the skin. Such
substances can include cement, lime, plaster, paint, solvents, adhesives, sawdust, oils,
pitch, tar, fibreglass, white spirit, thinners and most acids and alkalis.
The effect of the substances is usually to cause the skin to dry out and crack due to the
removal of the natural oils. Skin damaged in this way is very vulnerable to other infections.
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Allergic dermatitis
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This is sometimes also called sensitive dermatitis. It is an allergic reaction by the skin to a
specific substance that the skin has been exposed to in the past, and which has caused the
skin to become especially sensitive to it. Once a person's skin has become 'sensitised', any
future exposure to the substance will cause an immediate skin reaction.
The main sensitising substances on site are cement, resins, glues, hardeners, hardwoods,
chrome and nickel compounds. The allergic response is usually specific to an individual as
opposed to affecting everyone, and can also appear suddenly after many years' exposure.
The prevention of dermatitis is basically one of good personal hygiene, good housekeeping,
safe systems of work that avoid contact with substances that are known to cause dermatitis,
and the use of personal protective equipment (as a control measure of the last resort), in the
appropriate cases.
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1.2.1.11 Needlestick injuries

A needlestick injury is an accidental puncture of the skin by a hypodermic needle.
It is a sad fact that the current drug culture affects the construction industry as much as other
industrial sectors. The abuse of both legal and illegal drugs brings with it the risk of
discovering discarded hypodermic syringes or discarded needles.
Employees in the refurbishment sector of the industry are probably at greatest risk,
especially if the property is derelict or has been occupied by unauthorised occupants.
However, any work in occupied or previously occupied premises carries with it some risk of
finding needles that have been randomly discarded or hidden away in areas where they are
difficult to see, until it is too late.
If not handled in a safe manner, discarded needles can pose serious health risks to anyone
whose skin is accidentally pricked. Blood on a needle could be infected with a hepatitis or
HIV virus.
As part of site induction in the appropriate circumstances, employees should be told to

assume that any needle they find has been used by a drug user and is potentially
contaminated by infected blood.
Contractor site procedures should cover the actions that employees and supervisors should
take whenever discarded needles are found. The removal and disposal of such items should
be properly covered.
Generally, employees should be clearly told not to touch or move any needles or hypodermic
syringes they find, but ask a responsible person to guard it whilst reporting the matter to their
supervisor.
If a needle or syringe must be moved then suitable instructions to employees might be:
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if possible, use a pair of pliers to pick it up
(b)
carry it with the needle pointing downwards
(c)
do not wrap it in paper or put it into a litter bin
(d)
if available, place it in a clear glass bottle or jar
(f)
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(a)
(g)
wash hands thoroughly.
place the bottle or jar in a secure location

carefully follow site or company procedures regarding disposal
(e)
Employees should not panic if a needle punctures the skin. Gently squeeze the area around
the wound to encourage bleeding but do not suck the wound. Wash the site of the injury
thoroughly with soap and water at the first opportunity, and obtain medical assistance as
soon as possible from the nearest hospital with an accident and emergency department. If
you can do so safely, take the syringe or needle with you.
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If dealt with properly and promptly, the risks of a resulting health problem are small.
1.2.1.12 Leptospirosis (Weil's disease)

1
When working near to water or on sites that are otherwise wet, consideration must be given
to the health implications associated with the presence of rats.
Leptospirosis is an occupational hazard for anyone working near water, damp areas or
anywhere else where rats might be present. It is a disease caused by bacteria that is present
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in the urine of infected rats and is therefore also in the water where they live. The bacteria
thrives in damp conditions, typical of banks of rivers or streams, and can enter the body
through unprotected cuts and scratches, by swallowing infected water and through the lining
of the nose.
If anyone thinks they may have come into contact with the disease, they should be aware
that the early symptoms closely resemble the symptoms of influenza, namely:
fever
(b)
headache
(c)
chill. Later symptoms include:
(d)
tightening of the skin
(e)
a yellowing of the skin (similar to jaundice)
(f)
internal bleeding.
(a)
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It is essential that anyone who is at risk, and who becomes unwell with flu-like symptoms,
should visit their doctor, describe where they have been working and that they are at risk
from leptospirosis.
Persons regularly at risk, for example, canal or sewage workers should carry a card
explaining their occupation and the occupational hazard of leptospirosis.
Personal precautions that should be taken include the following:
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discourage the presence of rats on site: do not leave food lying about or throw away
food scraps
(b)
do not handle the carcasses of dead rats
(c)
avoid inadvertent entry or immersion in water that could be infected
(d)
if this happens and you think that you may be infected, particularly if you swallowed
any water, see a doctor as a matter of urgency
(e)
wear appropriate PPE
(f)
prior to entering the work area, wash any cuts or grazes in clean water. Apply
antiseptic to the wound, then cover with gauze, a waterproof dressing and PPE as
necessary
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upon completion of work, wash hands, forearms and all other exposed areas of skin
thoroughly. Remove any wet protective clothing as soon as possible and dry it
(g)
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(a)
(h)
avoid rubbing your nose, mouth or eyes with your hands during work
(i)
do not smoke, eat or drink without first washing your hands.
Leptospirosis can be fatal, typically within four to six weeks, if the early symptoms are not
recognised and treated.
1.2.1.13 Contaminated ground

1
The disturbance of contaminated ground can release hazardous fibres such as asbestos,
hazardous gases or fumes.
Where ground that has been previously used is to be disturbed, a risk assessment must be
carried out to determine whether there will be residual risks to health.
The findings of a thorough assessment of the risks will determine exactly what the hazards
are and how the risks can be eliminated or controlled to an acceptable level. Given the
possible wide range of contaminants, the potential for ill health may result from inhalation,
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ingestion or skin contact with the hazardous substance.
1.2.1.14 Smoking
1
Although smoking is totally prohibited on many sites, Contractors in control of a site may
make provision for smoking in areas which are not 'enclosed' or 'substantially enclosed', as
long as non-smokers are not exposed to tobacco smoke.
1.2.1.15 Repetitive strain injury
(b)
carpenters
(c)
painters
(d)
plant operators.
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plumbers
Methods by which workers can limit the potential for RSI are:
avoiding long periods of repetitive tasks - job rotation
(b)
alternating the use of the hands - picking up left- then right-handed
(c)
taking more short breaks rather than one long break
(d)
wearing looser fitting clothing to increase ease of movement
(e)
keeping warm - cold muscles don't expand properly
(f)
not overstretching - move closer to the task
(g)
reporting pain or other symptoms immediately - RSI is easier to treat in the early
stages.
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(a)
Contractors can make a big difference to the health of their workers, which will have
business benefits, by:
(a)
assessing each job for the potential for RSI
(b)
(c)
(a)
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With regard to the construction industry, the jobs where workers are most likely to develop
RSI are:
encouraging early reporting

allowing workers to organise their work and take breaks as necessary.
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1.2.2
Personal Protective Equipment
1.2.2.1 Key points

The correct use of personal protective equipment (PPE) is essential in many cases to protect
the wearer from harm.
Given the nature of most construction sites, the use of some items of PPE, such as safety
helmets and safety footwear, is a daily occurrence.
However, it must be remembered that the use of PPE as a means of protecting against risks
to health or safety is the last resort; it only protects the wearer and only then if it is:
the right PPE for the job
in good working order
being used properly.
Contractors have a legal duty to investigate the use of other protective measures before
resorting to the issue of PPE.
Employees must look after the PPE that has been issued to them and inform their Contractor
if it becomes damaged or is lost.
Contractors have a duty to supply the necessary PPE free of charge.
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Respiratory protective equipment (RPE) is a sub-group of PPE.
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Section 1, Part 11 of the QCS covers safety equipment and clothing.
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Note:
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Construction workers will have to wear some items of personal protective equipment (PPE),
such as safety helmets and safety footwear, as a matter of course. Other PPE will have to be
provided and worn as required, as indicated by the findings of a risk assessment. Generally,
PPE is thought of as equipment that is designed to protect the head, ears, eyes, respiratory
system, skin, hands and feet, and includes such items as gloves, safety goggles and hearing
protectors. However, other categories of PPE are designed to protect individuals from falling
from height and to keep them afloat in water or other liquids.
Respiratory protective equipment (RPE) is a significant sub-group of PPE. As its name

suggests, it is designed to protect the respiratory system of users from hazardous and
hostile atmospheres.
For simplicity, wherever any reference is made to 'PPE', it will include 'RPE', although at
appropriate places RPE will be referred to in its own right.
All PPE must bear the CE mark to show conformity with European Standards. When
Contractors are deciding how best to protect employees from a risk to their health and safety
at work, the decision to issue PPE may only be made where it is found that the risk cannot
be adequately controlled by other means that are equally or more effective. In effect, the
issue and use of PPE is the 'last resort' in terms of risk control.
PPE must be selected by a competent person who, if necessary in conjunction with the
suppliers, can identify the PPE that will be effective against the hazards present in the
workplace. An example of this is the selection of the correct type of respirator or filter to
protect the user against the various types of airborne substances, either particles or gases.
It must be remembered that failure of an item of PPE, or the wrong type of PPE being used,
could expose an employee to the possibility of occupational ill-health, serious injury or death.
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These Regulations place a requirement on every Contractor to make a suitable and sufficient
assessment of every work activity in order to identify any hazard that employees, or any
other persons, might encounter as a result of the work being carried out.
When hazards are identified, it is then the Contractor's duty to either eliminate the hazard or
to put control measures into place to reduce the risks to health and safety arising out of the
hazards, as far as is reasonably practicable.
Where the hazard cannot be eliminated or the risks to health and safety controlled in any
other way, as determined by a risk assessment, the Contractor must supply suitable PPE
and ensure that it is used and looked after.
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The following requirements of these Regulations all have a relevance to the selection and
use of PPE:
Contractors must provide employees with comprehensible and relevant information on
any risks that exist in the workplace, details of the existing control measures that are
in place and any measures to be introduced to reduce the residual risks
(b)
Contractors must ensure that employees are provided with appropriate health
surveillance where indicated as necessary by the risk assessment
(c)
Contractors must take into account each employee's capability with regards to health
and safety when allocating work, and provide them with adequate health and safety
training
(d)
employees, in turn, have a duty under these Regulations to:

use equipment (e.g. PPE) in accordance with any training and instruction given
(ii)
inform the Contractor of any work situation or other matter which they consider
presents a risk to the health and safety of themselves or others.
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(i)
The emphasis is firmly towards engineering and organisational controls and away from
'person-based' controls such as the wearing of PPE.
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(a)

These Regulations require that where a risk has been identified by a risk assessment and it
cannot be adequately controlled by other means which are equally or more effective, then
the Contractor must provide suitable PPE and ensure that it is correctly used and cared for
by employees.
Detailed requirements of any such risk assessment require the problem to be thought
through in a structured manner and the right equipment chosen for the right reasons.
A key factor is the competence of the person carrying out the assessments. If they do not get
it right, the consequences for the health and safety of employees could well be very serious.
In essence, personal protective equipment may only be used as a last resort after all other
means of eliminating or controlling the risk have been considered.
In deciding which type to issue, the Contractor must take into account the hazard that the
PPE is being used to protect against and ensure that the PPE will fit the wearer and allow
them to work safely. If more than one item of PPE is being used at any one time, the
Contractor must make sure that individual items of PPE are compatible and do not adversely
affect the performance of each other.
Whenever PPE is to be issued, the Contractor must ensure that employees have been given
adequate and appropriate information, instruction and training to enable the employees to
understand the risks being protected against, the purpose of the PPE and the manner in
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which it is to be used.
properly use the PPE provided, in accordance with the information, instruction and
training that they have been given
(b)
return PPE to its storage facility, where provided, after use
(c)
know the procedures for reporting loss of any PPE or defects in it to their Contractor.
The assessment must consider:

an assessment of the risks to health and safety that have not been controlled by other
means
(b)
the nature of the risks to health and safety against which the PPE is to protect the user
(c)
a comparison of the nature of the risks and the performance capabilities of the PPE
(d)
the compatibility of the PPE under consideration and any other PPE that will be worn
at the same time.
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(a)
Contractors and self-employed persons must:
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(a)
(a)
review such assessments if it is thought that they are no longer valid or if there has
been a significant change in the matters to which it relates
(b)
incorporate any changes that are indicated by the review.
qa
Whilst the Contractor must ensure that personal protective equipment is supplied and used,
the employee has duties to:
as
These Regulations requires that Contractors ensure that PPE that has been provided to
employees is maintained (which includes replacement or cleaning) in an efficient state,
efficient working order and good repair.
11
These Regulations require that Contractors provide suitable storage facilities for PPE that
has been issued, for when it is not in use.
12
These Regulations require that Contractors who have provided employees with PPE also
provide adequate and appropriate information, instruction and training to enable employees
to know:
(a)
the risk or risks for which the PPE has been provided
the purpose for which, and the manner in which, the PPE is to be used
(b)
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10
(c)
any actions that they (users) must take to keep the PPE in the suitable condition.
13
Training can be theoretical and/or practical. Where appropriate the Contractor should, at
appropriate intervals, arrange suitable demonstrations in the correct wearing of PPE.
14
These Regulations place a legal duty on:

(a)
Contractors to take reasonable steps to ensure that the PPE provided to employees is
used correctly
(b)
employees to use the PPE provided in accordance with any instruction and training
provided
(c)
employees to take reasonable steps to return PPE to any storage facilities provided.
1.2.2.4 Construction (Head Protection)

1
These Regulations require that all at-risk persons involved in construction and engineeringconstruction activities are provided with, and wear, suitable head protection on site.
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Under these Regulations, the term 'suitable head protection' means any head protection
that is designed to protect the wearer against any foreseeable risk of head injury, other than
by falling. It must, with necessary adjustment, fit comfortably.
Whilst generally the Contractor's interpretation of this legislation means that safety helmets
are worn at all times on site except when in safe areas such as site offices and canteens,
individual Contractors may decide that on certain sites they are able to designate other 'safe
areas' or 'safe routes' where helmets need not be worn.
This decision must be based on the findings of a risk assessment which must investigate
fully the danger of workers being hit by anything falling from above or of them hitting their
head and being injured. It is not unknown for 'protected routes' to be created on larger sites
enabling people to gain access to office complexes etc. from the site entrance, without the
need to wear full PPE.
any head protection provided under these Regulations has to comply with any relevant
European Standards and must therefore carry a CE mark
(b)
before selecting any head protection for employees, the Contractor or self-employed
person must carry out an assessment to determine whether it is suitable.
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(a)
In order to determine whether it is suitable, the assessment must compare the required
protection characteristics of the head protection with the known risks.
Contractors must:
qa
review such assessments if it is thought that they are no longer valid or if there has
been a significant change in the matters to which it relates
(b)
incorporate any changes that are indicated by the review.
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as
(a)
In general, suitable head protection will be an industrial safety helmet conforming to BS EN

397. For work in confined spaces, a bump cap designed to BS EN 812 may be more
suitable, but is restrictive in use.
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1.2.2.5 Contractor's duties
(a)
carry out an assessment to determine the suitability of head protection

produce written rules on the use of head protection or provide directions (such as
verbal instructions and safety signs) to reinforce when and where head protection
must be worn and bring those rules to the attention of any persons who might be
affected by them
(b)
The Contractor must:
et
it
(c)
provide each employee with suitable head protection and adequate storage facilities
(d)
ensure that all head protection is adequately maintained and, where necessary,
replaced.
The Contractor must also keep records of the assessment and details of the control
measures implemented. These will need to be reviewed as a result of any significant change
in the work to which the protection relates or when its suitability is no longer valid.
1.2.2.6 Employees' duties

1
Employees must:
(a)
co-operate with their Contractor
(b)
wear the head protection provided in accordance with instructions or written rules
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(c)
take reasonable care of the head protection provided and report any loss, defect or
concerns about its serviceability.
No other workers are covered by this exemption.

Provision, maintenance and replacement of suitable head protection
Every Contractor must provide each employee with suitable head protection where, due to
the nature of the work or activity, they are at risk from head injuries. All self-employed
persons have an obligation to provide themselves with suitable head protection in similar
circumstances. In both cases, the head protection must be adequately maintained to ensure
serviceability, and it should be replaced as necessary.
The assessment should be reviewed as a result of any significant change in the work to
which the protection relates or it is no longer suitable. Contractors should ensure that
storage for head protection is available when it is not in use.
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Every Contractor and anyone who has control over persons at work have a duty to ensure
suitable head protection is worn.
qa
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Ensuring suitable head protection is worn
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Rules and directions
As part of pre-planning for the commencement of work, written rules on the use of head
protection should be established by site management, particularly on multi-contractor sites.
Rules should be clear, unambiguous and brought to the notice of those affected. Persons in
control should consult with any interested parties in matters relating to head protection.
Where written rules are not in place, verbal instructions or the provision of safety signs may
help to provide a procedure and a reinforcement of when and where to use suitable head
protection.
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Wearing of suitable head protection

In compliance with written rules or instructions given by those in control of operations or
works, employees should wear suitable head protection as directed.
Reporting the loss of, or defect in, head protection

10
Every employee, having been provided with head protection, should take reasonable care of
it, reporting any loss, obvious defects or concern about its serviceability to the Contractor,
under the arrangements that have been made. These arrangements should enable repairs
or replacement head protection to be provided, before the employee concerned is allowed to
restart work.
1.2.2.7 Personal Protective Equipment (Control of Substances Hazardous to Health)

1
These Regulations place a duty on Contractors to ensure that the exposure of their
employees to substances hazardous to health is either prevented or, where this is not
reasonably practicable adequately controlled.
These control measures include:

Page 20
(a)
Contractors must either prevent exposure of employees to substances hazardous to

health or, where this is not reasonably practicable, adequately control exposure.
(b)
The preferable method of prevention or control is to substitute the substance or

process with a non-hazardous or less hazardous substance or process.
(c)
Controls shall be, in order of priority, by engineering controls, by providing ventilation,

by implementing organisational controls then, as a last resort, providing suitable
personal protective equipment.
(d)
All employees must make proper use of any PPE, and must take all steps to return it
to its place of storage after use and report any defects to their Contractor.
(e)
Adequate maintenance, examination and testing of control measures provided must

be undertaken to ensure they are in efficient working order and, in the case of PPE,
maintained in a clean condition.
(f)
Information, instruction and training must be provided for persons who may be
exposed to substances hazardous to health so that they are aware of the danger of
exposure and the precautions which should be taken.
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1.2.2.8 Personal Protective Equipment (Work at Height)
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QCS 2014
These Regulations are relevant where PPE in the form of a safety harness, lanyard, a fallarrest block or other personal fall-arrest equipment is used.
The key provisions of these Regulations are that Contractors should:
qa
where it is reasonably practicable, avoid the need to carry out work at height
(b)
where such work cannot be avoided, select the most appropriate equipment for the
work and to prevent falls
(c)
reduce the distance of, and potential consequences of, any fall
(d)
ensure that the work is risk
(e)
assessment-based and that it is carried out safely
(f)
ensure the work is carried out by trained and competent persons who are adequately
supervised.
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as
(a)
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These Regulations require that Contractors follow current best industry practice when
selecting equipment for work at height. In particular, Contractors are required to take account
of:
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(a)
working conditions and risks to the safety of the persons at work
(b)
access and egress, and distances to be negotiated
(c)
distance and consequences of any potential fall
(d)
duration and frequency of use of the work equipment
(e)
need for and ease of evacuation and rescue in an emergency
(f)
any additional risks posed by the installation, use or removal of the work equipment,
and any evacuation or rescue from it.
The requirements are:

(a)
a personal fall protection system shall only be used if a risk assessment has shown
that the work can be done safely while it is being used, and that the use of other, safer
work equipment is not reasonably practicable
(b)
the user and a sufficient number of others have been trained in its use and in rescue
procedures
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(c)
it shall be suitable and of sufficient strength for the purpose for which it is to be used
and will withstand any foreseeable loading
(d)
it fits the wearer and is correctly fitted or worn
(e)
it is designed to minimise injury to the user in the event of a fall, and is such that the
user will not fall or slip out of it if they do fall
(f)
it is designed, installed and used so as to prevent unplanned or uncontrolled

movement of the user.
Any anchorage point must be suitable and of sufficient strength to support any foreseeable
loading. If designed to do so, the equipment must be securely attached to at least one such
anchorage point when in use.
All safety harnesses, lanyards and other fall prevention or fall arrest equipment must comply
with the appropriate British and European standards.
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1.2.2.9 Common-use types of PPE

Hearing protection
Construction activity and equipment generate excessive noise, which can cause permanent
hearing damage in those exposed to it unless appropriate control measures are put in place.
Excessive noise can also cause annoyance, fatigue, loss of concentration and disrupted
communication, and may lead directly or indirectly to an increased risk of accidents.
There are two basic types of hearing protection:
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qa
ta
ear plugs - either disposable or reusable
(b)
ear defenders.
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Disposable ear plugs
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(a)
These are made of very fine mineral fibre, sometimes ready shaped. They must be inserted
correctly and, if taken out, should not be reused. They should only be handled with clean
hands.
Employees need to be instructed on how to insert disposable ear plugs correctly or the
assumed level of protection will not be reached.
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Reusable ear plugs

6
These are made of rubber or plastic, and need regular and careful washing. They must be a
good fit. A competent person should be responsible for instructing employees in their correct
fitting and use. Different sizes may be required for each ear. Reusable ear plugs, like
disposable ones, must be fitted with clean hands as any contamination by dirt, grease or
swarf may cause ear irritation.
Ear defenders
Ear defenders, sometimes referred to as 'ear muffs', completely cover the ear, and are
sealed to the head with a foam or liquid-filled seal.
Badly designed or badly produced ear defenders may give little or no protection against the
noise.
Facial hair and the side arms of spectacles may interfere with the seal and reduce the
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amount of protection given by ear defenders.
1.2.2.10 Eye protection

1
Construction personnel engaged in a wide range of activities (for example, grinding, welding,
cutting, hammering, handling chemicals) run the risk of eye injury. The risks include:
(a)
impact of solids
(b)
ingress of liquid, dust or gas
(c)
splashes of hot metal
(d)
exposure to glare.
Contractors have a duty to provide eye protection to employees who may be exposed to eye
injury, and must take all reasonable steps to ensure that it is worn. Assessments must be
carried out to determine when eye protection is required and what type is appropriate for the
work activities.
The two main types of eye protection -safety spectacles (including safety goggles) and face
shields
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comply with British or International Standards
(b)
suit the type of work or risk involved -including resistance to impact, heat, dust and
chemical penetration
(c)
suit the user to ensure minimum discomfort and ease of movement whilst working
be marked to identify their type and suitability

be kept clean and disinfected.
(e)
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(a)
(d)
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All types of eye protection must:
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Lasers that are now widely used on construction sites for setting datums, levelling,
surveying, and so on can pose a particular hazard. They must be operated by competent
and fully trained persons. If high powered lasers are used, eye protection equipment will be
needed to give the required level of protection to those at risk. A safe system of work must
be in place to exclude anyone not involved in the activity from the area.
1.2.2.11 Respiratory protection

The hazards
1
Dust has long been known as hazardous to the health of construction workers, especially
when inhaled for long periods. While the health issues associated with asbestos are well
recognised, the greater part of the dust problem in the industry currently relates to more
common substances, for example, cement, plaster, wood, MDF, stone, silica, fillers and
plastics. High speed cutting of most materials can produce sufficient dust to cause a health
hazard.
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Dust that is visible in the air is generally accepted as being hazardous. However, dust that is
too fine to be seen by the naked eye also causes many health problems, the symptoms of
which may take many years to manifest themselves. Small dust particles of any material
entering the lungs can be absorbed into the body and can cause scarring and sometimes
cancer within the lungs. Skin irritation, dermatitis and ulceration can be caused by contact
with some dusts.
Eating food with dirty or dust-covered hands can cause stomach disorders.
Fumes from certain substances, such as solvents, paints and adhesives, can have serious
health implications. When used in poorly ventilated or confined spaces, it is not uncommon
for fatalities to occur.
Whenever respiratory protective equipment (RPE) is to be used for work, a test check that a
facepiece (the respirator) matches the person's facial features and seals adequately to the
wearer's face. It will also ensure that incorrectly fitting facepieces are not selected for use.
This test must be carried out by a competent person.
The training of employees in the correct use of RPE is essential before first use and should
be repeated at suitable intervals. It is essential that training is carried out by a competent
person and covers:
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why the RPE is necessary
(b)
the hazards, the risks and the effects of exposure
(c)
what RPE is to be provided
(d)
how the RPE works
(e)
why facepiece fit testing might be necessary
(f)
how to wear and check the RPE correctly
(g)
fit-checking the RPE before use
(h)
what maintenance is required and when
(i)
where and how to clean the RPE and store it
(j)
how to report defects in the RPE or any other problem with it
(k)
the Contractor's responsibilities and those of employees
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use and misuse of the RPE.
(l)
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(a)
Selecting RPE
7
The provision and use of RPE must only be considered when equally or more effective
protective control measures cannot be used. The failure of RPE could have serious
consequences. The importance of the correct type of RPE being provided and used cannot
be overstated as it must be assumed that the user will be working in a hostile environment.
However, there are several potential problems arising from the selection and/or use of RPE:
(a)
the failure of an item of RPE, where for whatever reason, such as lack of routine
maintenance, it fails to provide the necessary level of protection
(b)
the misuse of RPE, such as it being mistreated or not used in accordance with the
manufacturer's instructions, or the training given
(c)
it being the wrong type of RPE, for example there would be no protection from a
filtering respirator designed solely to capture airborne dust if being used, where the
workplace hazard is in fact a toxic gas
(d)
the effectiveness of the 'face fit'. Many types of RPE depend upon a good seal
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between the facepiece and the skin of the user at all times, including where physical
activity and exertion are required. Factors such as facial hair or the shape of the face
can interfere with a good fit.
Each type of RPE is assigned a 'protection factor' which gives the user some idea of the
level of protection that the device will provide. For example, a filtering half-mask marked:
10
FF P1
is a low efficiency device offering a protection factor of 4
11
FF P2
is a medium efficiency device offering a protection factor of 10
12
FF P3
is a high efficiency device offering a protection factor of 20
13
A protection factor of 10 means that in controlled conditions, for every 10 units of

contaminant outside the mask, only 1 unit will get inside the mask, or for every 20 units
outside the mask there will be 2 units inside, and so on. It is important, therefore, that the
correct filter is selected for the type and level of contaminant in the air.
14
There are many types of RPE, including:
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disposable face mask respirators
(b)
half-mask dust respirators
(c)
high efficiency dust respirators
(d)
positive pressure powered respirators
(e)
ventilator visor or helmet respirators
(f)
compressed air line breathing apparatus
(g)
self-contained breathing apparatus.
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(a)
It should be noted that nuisance dust masks (simple gauze filters or cup-shaped filters often
held in place by a single strap) are not classed as personal protective equipment or
respiratory protective equipment. They do not meet any current standards.
16
The Contractor must carry out an assessment to determine when RPE is required and what
type is appropriate for controlling exposure to the hazardous material. Selecting RPE that is
both suitable for the user and the job must be carried out by a competent person. This is
because this choice will depend on a number of interacting factors, such as:
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15
(a)
the nature of the hazards and materials
(b)
the measured dust concentrations
(c)
the period of exposure
(d)
if working outdoors, the prevailing weather conditions.
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(e)
suitability for each user - field of vision, provision for communication and the need to
move in cramped or difficult working places, such as confined spaces.
Using and maintaining RPE

Both the Contractor and the employee have a duty to ensure that all RPE provided is used
correctly and that it is stored correctly after use.
18
Contractors must also ensure that non-disposable RPE is thoroughly examined and tested at
appropriate intervals. Such examinations and tests should be carried out at least every
month, and more frequently where conditions are particularly severe. Longer intervals may
be more appropriate in the case of certain RPE, for example, half-mask respirators used
infrequently for short spells against air contaminants of relatively low toxicity. However, the
longest interval between examinations and tests should not exceed three months.
19
Disposable RPE, provided it is only used for one working day or shift then disposed of, does
not require any examination or tests.
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1.2.2.12 Skin protection
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Industrial dermatitis
Industrial dermatitis is caused by contact between the skin (usually the hands) and irritant
substances. Many types of gloves are available to prevent such contact. It is essential that a
risk assessment identifies the properties of the hazardous substance so that the correct type
of glove can be provided.
Dermatitis, an inflammatory skin disease, accounts for over half of all working days lost
through industrial sickness. There are two general types:
contact or irritant dermatitis - usually where the skin comes into contact with an irritant
substance
allergic or sensitive dermatitis - where a person develops an allergic reaction to a substance.
With different people, some substances are known to have the effect as either an irritant or a
sensitiser, such as turpentine.
In the course of their work, many construction workers are likely to come into contact with
one or more possible skin irritants, such as:
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as
qa
(a)
cement, lime and plaster
(b)
certain types of wood, resins, fungicides and pesticides
(c)
paint
(d)
tar, pitch and bitumen
(e)
solvents, thinners and degreasers
(f)
mineral oils and grease.
Cuts and abrasions

7
Many people working in the construction industry will carry out manual work that will render
them susceptible to cuts and abrasions if the correct type of gloves are not provided and
worn.
Again, gloves designed to protect the hands against cuts and abrasions are freely available.
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Generally, rigger gloves offer adequate protection for most activities although for some
activities, such as handling sheet glass, specialist Kevlar-impregnated gloves will be
necessary.
1.2.2.13 Hot works

1
Activities such as welding and grinding will require that the hands, forearms and face are
protected against high temperatures and welding fumes or grinding sparks. To achieve this
level of protection it is necessary for those who carry out such activities to wear specialist
PPE made for the purpose. For example, welders should wear welding gauntlets that extend
up to the elbow and a face shield.
1.2.2.14 Acid and alkali burns

Some substances that are in common use in the construction industry have sufficiently
strong acid or alkali properties to cause burns to the skin.
Gloves are available to protect the users of such substances from chemical burns.
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Special anti-vibration gloves will help lessen the effects of using rotary or percussive hand
tools (which can lead to vibration white finger) but most are ineffective at the most damaging
frequencies and are of more value in keeping the hands warm.
1.2.2.16 Selection of hand protection
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1.2.2.15 Vibration
British Standards cover many types of protective glove but care is needed in selecting the
right type for a particular hazard. For example, a glove suitable for handling abrasive
materials may offer no protection against chemicals, while the appropriate glove to protect
the skin against contact with diesel oil may offer no protection against some solvents.
All manufacturers offer advice on the most suitable gloves for specific types of hazard, some
of which are summarised in the following table.
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Hazard
Recommended type
Acids, concrete, brickwork, stain removers,

Neoprene, nitrile, PVC, rubber
solvents, alkalis
Esters, ethers, ketones (mastic, sealers),
aldehydes, petroleum-based products
Medium and heavy weight rubber, neoprene,

nitrile, PVC
High and low temperatures
Nitrile, PVC, medium and heavyweight rubber
Abrasion, unloading bricks and blocks,

general materials handling
Rubber, nitrile, PVC, neoprene, chrome-leather

with reinforced palm
Bitumen, hot work
Asbestos substitute or 'Nomex' gloves
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It should be noted that industrial safety gloves are rated from 1-4 for their resistance to
abrasion, tear and puncture, and 1-5 for blade cut. Those specifying and purchasing work
gloves must ensure that the correct grade is obtained, if necessary by speaking to the
manufacturers or suppliers.
1.2.2.17 Foot protection

It is essential that protective footwear is worn when people are on site, both from a
Contractor's point of view, in being able to provide a safe place and a safe method of
working, and from an employee's position where safety footwear has a benefit in preventing
injuries.
Wellington boots, for example, whether reinforced with protective toecaps or soles or not, are
essential in preventing burns from wet cement or concrete. The cement content, when mixed
with water, becomes highly corrosive and will cause severe burns to body tissue.
The above picture shows the severely burnt legs of a man who was ignorant of the dangers
of wet cement, the effect it can have on skin, and the need to wear Wellington boots to
protect the legs.
Other clothing
Other clothing that protects the wearer against any risk to their health or safety, for example
a high-visibility waistcoat, is classified as PPE whereas clothing such as uniforms, the
primary purpose of which is to promote a corporate image, is not.
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1.2.2.18 Fall protection

1
Items of equipment that are used by a person to prevent that person falling from height are
also classified as PPE. Examples of this type of equipment are:
(a)
safety harness
(b)
fall-arrest or restraint lanyard
(c)
inertia reel fall-arrest block.
All the Contractors' and employees' duties that apply to other types of PPE apply to this type
of equipment also.
A major additional consideration regarding the use of this type of PPE is the prompt rescue
of anyone who has fallen and is suspended in a harness. A medical condition known as
suspension trauma, which at worst can result in the death of the suspended person, can
occur if rescue is not carried out within 10 minutes.
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1.2.2.19 Life jackets

Another category of PPE is that which enables the user to keep afloat should they fall into
water or other liquids. These are broadly divided into life jackets and buoyancy aids.
In many circumstances it will be necessary for operatives to simultaneously wear more than
one item of PPE.
Whilst this is entirely acceptable, attention should be given to ensuring that the different
types of PPE are compatible with each other, to avoid the possibility of a dangerous
situation.
For example, hearing protectors that are fitted directly to a safety helmet will not be effective
if the safety helmet is poorly fitting and, by moving around on the head, does not allow the
hearing protectors to form an effective seal around the ears.
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1.2.2.20 Consultation with employees
Contractors are likely to be far more successful in persuading employees to wear the PPE
provided if the employees themselves are involved in the process of selecting the PPE
purchased.
PPE can be cumbersome and uncomfortable and the cheapest may not be the most suitable
for the wearer. In such circumstances the likelihood is that it will not be worn, at least not for
long, leaving the worker unprotected against the hazard.
It is much better to purchase PPE that fits comfortably and will be used willingly.
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1.2.3
Control of Substances Hazardous to Health (COSHH)
1.2.3.1 Key points

Many of the substances used or created during work processes have the potential to cause
harm to the health of anyone exposed to them.
In construction many COSHH issues relate to substances created such as dust or fumes, as
opposed to chemicals that have been bought in.
Hazardous substances that are already present on site when it is first occupied can also
pose hazards to health.
All purchased products that are hazardous to health must carry an appropriate warning
symbol on the packaging, however those hazardous substances which are created by the
work process or are already present on site will carry no such 'health warning'.
Contractors have duties to establish the health risks to their employees, and others who may
come into contact with hazardous substances, by carrying out an appropriate assessment
and must put in place adequate control measures.
The assessment should take into account how the substance is used and should not merely
be a copy of the supplier's information.
Ideally, exposure to any hazardous substance would be rendered impossible by:
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the substitution of safer substances
(b)
changing the way that the job is carried out so that the substance is not necessary
(c)
modifying the method of its use, for example total enclosure of the process.
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as
(a)
In many cases, none of these measures is practical in a construction site environment: if the
prevention of exposure is not possible, the level of exposure must be controlled.
Using PPE to control exposure must only be considered as a last resort after other methods
have been explored and found not to be reasonably practicable.
10
In some cases employees exposed to hazardous substances must be offered health

surveillance.
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These Regulations are based on very simple principles. The intention of these Regulations is
to protect human health from exposure to hazardous substances by either totally preventing
exposure or, where that is not reasonably practicable, controlling the level of exposure to
safe values, by appropriate means.
COSHH deals with all harmful substances in relation to their health effects. However, these
Regulations do not cover any flammable or explosive properties that the substances might
also possess.
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1.2.3.3 Sources of harm

1
Many of the basic substances (products) bought in and used in the construction industry
have the potential to harm the health of people using them, for example sand, cement,
synthetic mineral fibre, adhesives, solvents, resins, and mineral oils.
Additionally, many of the essential construction processes can create potentially hazardous
substances, for example the inhalation of:
dust from mixing cement, taking down ceilings and walls, chasing out or cutting blocks
(b)
solvent fumes arising from the application of adhesives for surface finishes
(c)
metal fumes and toxic gases, such as carbon monoxide, nitrous fumes and ozone,
which can be created by welding or hot cutting processes.
A third group of substances, also covered by these Regulations, are harmful substances
(including micro-organisms) that may already be on site when a project commences.
Examples are:
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(a)
leptospirosis, which can be spread by the urine of infected rats
(b)
discarded needles and syringes, which have the potential to pass on blood-borne
diseases such as HIV and hepatitis
(c)
hazardous materials buried or simply left by a previous user of the land.
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(a)
The Regulations cover substances that have chronic or delayed effects, for example,
substances that are carcinogenic (cause cancer), mutagenic (cause mutation of the body) or
teratogenic (cause malformation of an embryo).
The purpose of these Regulations is to safeguard the health of people using or coming into
contact with any substance that is harmful to health.
These Regulations apply to those substances that are classified as being very toxic, toxic,
harmful, corrosive or irritant.
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1.2.3.4 Workplace exposure limits (WEL)

Unsurprisingly, some hazardous substances have legal limits to which people may be
exposed. All of these substances have a Workplace Exposure Limit (WEL) that represents a
concentration of a substance in the air measured over a specific period of time. The taking of
such measurements (workplace monitoring) is a specialist activity which must be carried out
by someone who is competent to do so and who possess the appropriate equipment.
Such monitoring must be carried out where a (COSHH) risk assessment indicates it is
necessary.
The following substances, all of which have a WEL, are commonly used in or produced by
construction activities:
(a)
general dust
(b)
hardwood dust
(c)
softwood dust
(d)
silica
(e)
white spirit
(f)
pulverised fuel ash
(g)
synthetic mineral fibre - rock wool/ fibreglass
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(h)
asphalt
(i)
welding/cutting fume
(j)
gypsum
(k)
Portland cement
(l)
micro-organisms associated with:

(i)
blood products
(ii) Weil's disease
(iii) tetanus
(iv) sewage
(v) certain 'black mould' species
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(vi) anthrax.
This list is not exhaustive. Every Contractor has a legal duty to access competent health and
safety advice. Failing to establish that an in-use substance has a WEL, or failing to control
exposure to it, are criminal offences under Qatar Law.
A list of all WELs is published by the UK Health and Safety Executive (HSE) in Guidance
Note EH40/2005, available in hard copy or for download via the:
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HSE website at www.hse.gov.uk/coshh/table1.pdf
1.2.3.5 Is there a COSHH problem?
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Those who plan and carry out work that could result in exposure to hazardous substances
may have difficulty in appreciating that there is a (real or potential) problem. This is
particularly true when a hazardous substance is created by the work process.
For example, a hardwood plank should not pose any serious health issues in the form that it
is delivered to site. However, cutting or sanding it will produce dust that, unless controlled,
has the potential to cause irritation of the nasal passages, sensitisation or, on rare
occasions, nasal cancer. Cutting, sawing, grinding or sanding any substances has the
potential to liberate harmful dust. Furthermore, many types of hot works will create harmful
fumes or gasses which may be inhaled unless the process is closely controlled.
The COSHH Regulations place a duty on the Contractor to assess whether or not a hazard
to the health of the employees, or other persons, will arise from the presence of hazardous
substances during work activities. This process is known as carrying out a COSHH
assessment.
The decision-making process that must be worked through when carrying out an
assessment will be familiar to anyone who has completed risk assessments.
Establishing the degree of risk can require expertise and experience. For example, if the only
way to complete an activity involves using a particularly hazardous substance (for example
dry rot treatments), the work will have to be well planned, managed and closely controlled.
This would result in a high hazard/low risk situation.
Conversely, it is possible to create very high exposures that may be harmful to health from
apparently low risk substances like dust, which is a common COSHH problem in
construction.
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1.2.3.6 Definitions
1
The meanings of the following words need to be clearly understood.
Substance means any natural or artificial substance, in solid, liquid, gaseous or vapour
form, and includes micro-organisms.
Hazard is the potential for the substance to cause harm, illness or damage to health.
Risk is the likelihood that the hazardous potential of the substance will be realised.
1.2.3.7 Control of Substances Hazardous to Health

These Regulations place a duty on Contractors.
These duties cover:
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people actually working with substances
(b)
other people such as the public or other contractors who might be affected.
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(a)
Significant findings of the COSHH assessment and the actions that will be taken to control
exposures must be written down.
The main requirements of these Regulations are as follows.
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Assess the health risks to employees or other people created by work activities that
involves substances hazardous to health.
(b)
Implement suitable control measures to effectively protect employees and others from
exposure.
(c)
Review the assessment if there have been any changes that may invalidate it, such
as:
a change in the way the work is carried out, or
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(a)
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(ii) the results of monitoring indicating that existing control measures are not
effective.
The emphasis under COSHH is to avoid exposure to hazardous substances unless it is not
reasonably practicable to do so, in which case adequate control measures must be put in
place to control exposure to a safe level.
These Regulations require the following thought process in relation to control:
(a)
Can the work be carried out by a less hazardous method that does not require the use
of hazardous substances?
(b)
If not, can the substance be changed (substituted)?
If the answer to both of these questions is 'no' then the introduction of measures to control
exposure will be necessary.
'Engineering' controls should be the first controls to be considered, such as pouring devices
to stop splashes, the use of dust extraction, increasing ventilation and so on. PPE should not
be considered as a control until engineering control options have been exhausted. PPE:
(a)
can be expensive
(b)
can be unpleasant to wear
(c)
only protects the wearer and then only if it is being used correctly and maintained
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often requires considerable management effort to ensure that it is used correctly.
Removing the need to buy and use it makes good occupational health and business sense.
10
The requirements of these Regulations are very thorough and one of those requirements is
to ensure that the control measures which have been identified as suitable are properly
used.
11
To ensure that the control measures are effective, the Regulations require that:
extract ventilation systems must be thoroughly examined periodically
(b)
if using substances which are known to damage health, part of the assessment is
likely to identify that health surveillance is necessary. Any records must be kept for 40
years and made available to the people who have been exposed to the hazard
(c)
there is a duty to communicate the information and provide relevant training to people
who may be exposed
(d)
emergency arrangements are put in place and, where required, practised.
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(a)
1.2.3.8 Summary of COSHH
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Contractors must carry out a risk assessment of health risks created by work involving
substances hazardous to health. Each assessment must take account of:
the hazardous properties of the substance
(b)
information provided by the supplier on the potential harmful effects
(c)
the type, level and duration of exposure
(d)
the way in which the job will be carried out, including the amount of the substance
used (or present in the case of substances created by a work process)
(e)
activities such as maintenance where there is the potential for high levels of exposure
(f)
any published WEL for the substance (EH40 Benchmarked Standards to which the
Qatar Construction Industry will adopt)
(g)
the effects of any control measures which are, or will be, in place
(h)
the results of any health surveillance and/or exposure monitoring that has been
undertaken
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the risks where there is exposure to more than one hazardous substance at any one
time
(i)
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(j)
other information that the Contractor may need or have in order to complete the
assessment.
Any assessment must be reviewed regularly if there is reason to suspect that the
assessment is no longer valid, or if there has been a significant change in the work to which
the assessment relates, or exposure monitoring results indicate it is necessary.
Contractors must record significant findings of the risk assessment and the steps taken to
prevent or control exposure.
Contractors must either prevent exposure of employees to substances hazardous to health

or, where this is not reasonably practicable, adequately control exposure.
The preferable method of prevention or control is to replace the substance or process with a
non-hazardous or less hazardous substance or process.
Controls shall be, in order of priority: engineering controls, organisational controls, then, as a
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last resort, providing suitable personal protective equipment (PPE).

7
The control measures must:

(a)
ensure the safe handling, storage, transportation and disposal of hazardous

substances
(b)
ensure maintenance procedures, which involve exposure to hazardous substances,

are suitable
(c)
reduce to a minimum the number of people exposed, the level and duration of
exposure and the quantity of hazardous substances present in the workplace
(d)
include control of the working environment, including the provision of adequate

ventilation
(e)
include adequate hygiene and washing facilities.
These Regulations contain further details of measures that must be taken to control
exposure to carcinogens, mutagens and biological agents.
With regard to these Regulations, it is considered that control of exposure will be generally
adequate if:
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work activities are organised to minimise the release and spread of hazardous
substances
(b)
account is taken of the routes of exposure - inhalation, skin absorption and ingestion
(c)
the control measures selected:
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(a)
are proportionate to the degree of health risk
(ii)
are effective in minimising the escape and spread of the substance
(iii)
may, where necessary, include a combination of control measures, including

PPE
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(i)
the control measures selected are periodically reviewed for their effectiveness
(e)
users of hazardous substances are informed of the hazards and risks and trained in
the use of the control measures provided
(f)
it does not increase the overall risks to health or safety from other sources.
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(d)
1.2.3.9 Control Measures

Contractors who provide any control measure are required to ensure that it is properly used
or applied. All employees must:
(a)
make proper use of any control measure (including PPE) provided
(b)
take all steps to return it to its place of storage after use
(c)
report any defects in the control measure to their Contractor.
Where control measures are provided, adequate maintenance, examination and testing of
control measures, including any PPE provided, must be undertaken to ensure they are in
efficient working order and remain clean.
Where engineering controls are undertaken, the Contractor must ensure thorough
examinations and testing are carried out on a regular basis.
1.2.3.10 Monitoring
1
Where indicated as necessary by the COSHH assessment, monitoring of the exposure to
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hazardous substances must be undertaken using suitable procedures, unless it can be

demonstrated by another method of evaluation that exposure is adequately controlled.
2
Suitable records of any monitoring should be kept tor five years, or 40 years if personal
exposures occur.
1.2.3.11 Health surveillance

Health surveillance, where it is appropriate for protecting employees' health, must be carried
out and recorded.
Where an employee requires medical surveillance following exposure, and it has been
decided that the employee cannot continue in that work, the Contractor must take steps to
ensure the employee adheres to the medical decision unless it has been cancelled.
Upon reasonable notice, a Contractor must allow the employee to access any medical
records applying to them.
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Information, instruction and training must be provided for persons who may be exposed to
substances hazardous to health so that they are aware of the danger of exposure and the
precautions which should be taken.
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1.2.3.12 Information, instruction and training
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Procedures to deal with accidents, incidents and emergencies involving hazardous

substances must be provided. These procedures should include:
first-aid provisions
(b)
the use of safety drills and their regular testing
(c)
identification and details of hazards
(d)
specific hazards that are likely to occur during any accident, incident or emergency,
together with warning and communication systems and emergency actions.
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(a)
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1.2.3.13 Procedures
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These procedures must be made available to accident and emergency services, and be
displayed on site.
1.2.3.14 COSHH responsibilities

Designers
1
The chain of responsibilities starts at the design stage of a project. Under CDM, designers
have a duty to consider the risks created for the construction, maintenance, cleaning and
use of a structure that could arise out of their designs. This must include consideration of
COSHH issues.
It is important to be aware that this may not eliminate all 'COSHH risks'. Consider, for
example, the periodic painting of a high level structure. It may be considered preferable to
continue to use a solvent-based paint, as opposed to a water-based paint (a less hazardous
product) on the grounds that the periods between painting will be longer, thereby reducing
the frequency of working at height.
Furthermore, designers must take all reasonable steps to provide sufficient COSHH
information about aspects of the design or its construction or maintenance, to adequately
assist the client, other designers and contractors to comply with their duties under these
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Regulations.
Clients
4
CDM places a duty on the client to provide pre-construction information to other parties
involved in a project to protect the health and safety of anyone carrying out construction
work, anyone affected by it or those who will use the structure as a place of work.
This will obviously include providing information on any known existing hazardous
substances, such as the presence of hazardous residues in pipework or the existence of
contaminated ground. Where necessary, this may involve commissioning surveys or taking
samples to enable accurate information to be available for a risk-based control. It is no
longer acceptable for the client to say: 'there may be the presence of x'.
co-operate with the Contractor and help them ensure the work is carried out safely
(b)
have undertaken their own COSHH assessments in relation to the work they are to
undertake
(c)
have effective arrangements to ensure that control measures are put in place and are
monitored.
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(a)
Some risks are likely to have been highlighted in the information provided by the client and
designers. Often designers may simply not be aware of what the job entails, or they may
believe the risks are commonplace and therefore any competent contractor should be aware
of them.
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Under CDM, organisations that share a workplace must:
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Shared Workplace
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Employees have duties to:
work with their Contractor to enable them to comply with the law
(b)
make proper use of any control measures provided (including PPE)
(c)
return any control measure, where provided (mainly PPE), to its accommodation after
use
report any defects in the control measures to their Contractor
(d)
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Employees
(e)
attend health surveillance medicals where required (the Contractor must pay for the
medical and it must be in paid work time).
1.2.3.15 Work on another Contractor's premises

1
Under CDM the client has a duty to provide pre-construction information to the Contractor,
including the information necessary for maintenance or other work to be carried out, where
this work is being done in an occupied premises.
Examples of such information are:
(a)
details of the substances contained in pipework or tanks, if for example a pipefitter is

to break into a pipe to replace a valve.
(b)
what gases, vapours or fumes may be discharged through a rooftop ventilation duct
during the time a roofer has to work next to it.
There is also a requirement for the client to make sure that contractors are aware of
emergency procedures that might arise out of the use of any particular substance(s) on the
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site. Obviously, this duty is reciprocal. The contractor has a duty to inform the client or the
site occupier if (the contractor's) work poses risks to the client's staff and visitors and to
outline how the risks will be controlled. This is particularly important where the client has outof-hours security staff. Often, arrangements that are effective during the working day, to
ensure that the contractor and client liaise, can become non-effective after normal working
hours, for example by the security staff entering an agreed exclusion zone due to ignorance
of the hazards present.
1.2.3.16 Information
1
Information about hazards from substances purchased can be found in several sources:
(a)
Information on labels.
(b)
Information provided by the manufacturer or supplier of the substance
Many suppliers have Material Safety Data Sheets (MSDS) on their websites.
Data sheets must contain certain information:
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Identification of the substance or preparation and the company or undertaking

providing the substance.
(b)
Composition and information on ingredients.
(c)
Hazard identification.
(d)
First-aid measures.
(e)
Fire-fighting measures.
(f)
Accidental release measures.
(g)
Handling and storage.
(h)
Exposure controls and personal protection.
(i)
Physical and chemical properties.
(j)
Stability and reactivity.
(k)
Toxicological information.
(l)
Ecological information.
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(n)
(o)
Other information.
Disposal considerations.
Transport information.
(m)
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(a)
If the substance is a carcinogen or a mutagen, i.e. capable of causing cancer or mutation of

the body, every possible step should be taken to eliminate the need for its use.
It is considerably harder to find out information about substances created by the work
process.
1.2.3.17 Carrying out an assessment

1
An assessment is the fundamental requirement of COSHH. It is in two parts.
Firstly, a Contractor must not carry out any work that is liable to expose employees to any
substance hazardous to health, unless a suitable and sufficient assessment of the risks
created by the work has been made.
Secondly, if the first step indicates that substances hazardous to health will be used or
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created, Contractors must identify the actions to be taken to comply with these Regulations.
The procedure itself is fairly simple but does take time and effort. It involves:
(a)
identifying jobs, working processes and procedures that involve the use or generation
of substances that are hazardous to health
(b)
identifying all the hazardous substances in use in the workplace, very toxic, toxic,
harmful, corrosive or irritant
(c)
identifying how the hazardous substances are stored and used. This means how they
are used, not how they should be used
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Very toxic or toxic

Substances that, in low quantities, cause death or acute or chronic
damage to health when inhaled, swallowed or absorbed via the skin
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Harmful
Substances that may cause death or acute or chronic damage to health
when inhaled, swallowed or absorbed via the skin.
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Corrosive
Substances that may, on contact with living tissues, destroy them.
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Irritant
Non-corrosive substances that through immediate, prolonged or
repeated contact with the skin or mucous membrane, may cause
inflammation.
(d)
identifying how these hazardous substances might enter the body. Normally these
methods are classed as:
(i) inhalation into the lungs, when the substance is in the form of a gas, vapour,
fume, mist, aerosol or dust
(ii)
absorption through the skin or eyes by contact with a substance that can
penetrate unbroken skin, or is absorbed through unprotected cuts or grazes
(iii)
injection by contact with contaminated sharp objects or high-pressure

equipment, e.g. water jetting
(iv)
ingestion by swallowing particles of a hazardous substance resulting from handto-mouth transfer
(e)
identifying the amount of exposure. This involves knowing how much of the substance
will be used, how people will be exposed to it and if there are is a workplace exposure
limit
(f)
investigating the possible health effects of such exposure
(g)
identifying who is at risk, for example the persons using it or anyone who enters the
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area within the following 24 hours
(h)
considering the effectiveness of the control measures already in place, for example
whether the concentration of vapour is likely to be above the WEL
(i)
identifying the risk to workers if control measures deteriorate or fail or if an emergency

occurs, for example if a volatile solvent is accidentally spilt resulting in a high
concentration of hazardous vapour in the workplace
(j)
finally, from the above considerations, making a decision upon whether a substance
represents a health risk or not. If the answer is 'no', the findings should be recorded. If
'yes', action will be necessary to either prevent or control exposure.
Completed assessments must be made available to the person who is going to carry out the
work so that they are aware of the health hazards present and the control measures that
they must use.
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Anyone who is competent.
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1.2.3.18 Who can make an assessment?
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1.2.3.19 So how do you do one?
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General requirements
The process must be carried out at an early stage to ensure that safe systems of working are
developed before anyone is exposed to potentially harmful substances. However, further
details can be added as the job progresses.
The process of compiling the list of substances must consider the whole lifespan of the site,
for example the chemical treatment of vegetation, and the removal and treatment of
contaminated land before construction starts to the treatment of new timber fencing at the
end of the project.
When carrying out an assessment, in addition to considering normal usage, it is important to

also consider the potential for exposure when the substance is:
handled or stored
(b)
transported
accidentally released as the result of an accident
(c)
(a)
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as
(d)
used for cleaning or maintenance
(e)
disposed of as waste.
1.2.3.20 Step 1: Find out what is (or will be) on site

Bought-in products
1
The first, and easiest, stage is to look at the substances that are bought in. This involves
identifying what is used and what is not hazardous to health. Most construction processes
are relatively simple as they rarely use a large number of substances or involve mixing of
substances. Mechanical workshops, for example where plant is serviced, tend to be more
challenging simply because of the amount of chemicals present in the substances that they
normally use.
Another consideration is the substances that will be brought onto site by other contractors,
how those substances might affect other people and the quality of the contractors' COSHH
assessments.
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Furthermore, the site office and other accommodation must not be overlooked. For example,
it is not unreasonable to suppose that strong cleaning materials will be used in catering and
other welfare facilities.
Having made a list of all substances, it is then sensible to identify any products that are
obviously not hazardous, so that they can be ruled out.
Taking cleaning chemicals as an example, washing-up liquid does not have any warning
symbols on it and therefore, other than noting its presence, no further action is necessary.
However, the information on a container of bleach should provide the basis for determining
how it can be used safely. Of the two products that have been considered, one requires no
control measures to be Identified but the second does.
Created by the work process

The situation becomes more complicated when potentially harmful substance, such as many
forms of dust or fumes, are created by work processes. The situation is further complicated if
the substance created has a WEL that must not be exceeded. This may require that
exposure levels are measured unless exposure can be eliminated or controlled to a known
safe level. Again, it will be necessary to also consider potentially harmful processes that will
be carried out by other contractors.
Depending upon the complexity of the project, it may not be possible to complete this part of
the exercise prior to the start of the project unless all work processes and substances that
will be created are known. In these circumstances, it will be a case of building up the
COSHH information as the job progresses, but this must be achieved in such a way that noone is exposed to a potentially harmful substance until the assessment of it has been carried
out and appropriate controls are in place.
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Already present on site
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A third category of potentially harmful substances is those substances, including microorganisms, that may already be present on site.
10
Examples are:
residues of hazardous substances left in pipework, underground tanks and drums
(b)
land heavily contaminated with fuels, oils and other hazardous liquids which have
seeped into the ground over many years
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(c)
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substances such as asbestos and polychlorinated biphenyls (PCBs) that were

deliberately buried by the past users of the land.
Also in contaminated land there could be sources of micro-organisms. These include:

(a)
leptospirosis (Weil's disease) from the presence of infected rats or their carcases
(b)
infected syringes, needles and other items associated with drug-taking, for example
where a derelict site is being refurbished
(c)
tetanus from infected ground or other materials
(d)
a range of respiratory diseases arising from the disturbance of accumulated bird or bat
droppings
(e)
pipework and sumps containing sewage sludge residue.
1.2.3.21 Step 2: Substitution

1
If there is a way around using a potentially hazardous substance, designers and planners
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should take advantage of it.

2
Returning to the cleaning materials example, there is no reason why a COSHH assessment
cannot be carried out for bleach, but the first rule of COSHH is to not use the potentially
hazardous product.
Can a safe alternative product be identified? If nothing else, it will be one less COSHH
assessment to carry out.
There are many similar situations, when simply changing the product is either no risk or a
risk that is easier to control.
Other examples include:

altering the work method so the process that produces the exposure is no longer
necessary, e.g. using a demolition shear to cut structural steelwork rather than gas
cutting and therefore avoiding a process that may produce metal fumes and toxic
gases
(b)
changing the work method to prevent the production of a hazardous waste product,
e.g. purchasing panels of the correct size, rather than cutting oversize panels on site
and producing dust. Given the pressure on reducing waste and manual handling, this
is another example where 'good health and safety is good business'
(c)
it may be possible to obtain and use the hazardous substance in a safer form, e.g. as
a liquid or paste rather than as a powder, if using the powder may result in airborne
dust being inhaled by workers.
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These examples of controlling the 'COSHH risk' may indicate that some companies are
already doing COSHH assessments without realising it.
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(a)
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1.2.3.22 Step 3. Exposures - who, what, how much and how often?
Now the assessment process really starts -having identified the substances that may be
harmful for health, the assessment needs to consider the exposures.
Who is exposed? Is it just the person using the substance or can it affect other people?
What are they going to do with it? The decision to either spray or apply paint by brush may
make a significant difference. Spray application will probably mean a much smaller droplet
size, creating a more severe respiratory hazard. This assessment needs to be honest and
objective. For example, paint removal gels state on the tin that they are only for brush
application, although it is physically possible to spray them. However, the controls required
to spray without potentially damaging the skin, eyes or lungs are completely different to
those required for brush application.
How often and how much of a substance is used and for how long are also very important
factors.
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1.2.3.23 Step 4. Implementing controls

1
The first step is to consider in detail how the work practices involving potentially hazardous
substances will be carried out. The person carrying out the assessment must be sufficiently
familiar with each process to know exactly how it is carried out.
As an example, a woodworking company purchased vacuum cleaners to remove sawdust in

the woodworking machine shop. They believed that this would result in airborne dust being
reduced to a safe level. However, it was found that the employees continued to use brushes
to sweep the dust into large heaps, which they then vacuumed up. This obviously
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circumvented the intended control measure of vacuuming instead of sweeping.

Elimination/substitution
3
As has already been stated, the first and most effective controls are elimination or
substitution, which means either changing the task completely or changing the substance for
a less harmful one.
Engineering controls
The next tier of control is referred to as 'engineering controls'. This encompasses a wide
range of solutions, which traditionally would have been more common in a workshop or
manufacturing environment as they encompass such techniques as completely enclosing
processes, automating a process or installing high efficiency ventilation. However, as the
Qatar construction industry responds to occupational health issues, it is becoming more
common to see features such as:
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hand-powered tools fitted with dust extraction apparatus (either in-built or with a fitting
which enables a vacuum cleaner to be attached)
(b)
free-standing dust extraction and collection units
(c)
air handling units that dilute the concentration of any airborne substance
(d)
motorised table-saws that enable wet-cutting to be carried out
(e)
using hydraulic croppers to cut brick pavers rather than disc-cutting them, to reduce
exposure to dust
(f)
lead paint removal by a system that does not heat the paint sufficiently to liberate lead
fumes.
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(a)
Some control measures are very simple, for example damping down the dust on a floor slab
before sweeping. Other situations may require a little more thought and ingenuity.
However, it is not always possible or 'reasonably practicable' to introduce engineering

controls and so the implementation of certain organisational controls may be possible.
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Organisational controls
These are concerned with investigating whether the way in which the job is carried out can
be changed so that individual exposure is reduced. For example, by carrying out a job out of
normal working hours, the number of persons exposed, who would otherwise have to wear
PPE, will be significantly reduced.
Further examples include:
(a)
job rotation so that no individual person is exposed to a substance above its WEL
(b)
moving a work activity into the open air to prevent the accumulation of vapour or
fumes.
Personal protective equipment (PPE)

9
If it is found that it is not reasonably practicable to implement any of the above control
measures, the use of PPE may be the only control measure that can be effectively used.
Where the health hazard is an airborne substance, respiratory protective equipment (RPE)
will be required.
10
It is important to remember that anyone wearing a mask must be face-fit tested for that type
of mask, and have no facial features, such as a beard, which would interfere with the seal
between the face and the mask. This problem can be overcome by using the loose fitting
QCS 2014

Page 43
'airstream' type of RPE where the mask does not seal to the face and a stream of filtered air
from a blower unit not only aids breathing but also creates an 'over-pressure' around the face
area to stop substances from entering it.
11
As with all PPE, there need to be arrangements to check that it is:

(a)
adequate and suitable for the job
(b)
a proper fit
(c)
stored safely when not in use
(d)
checked for defects and maintained as appropriate
(e)
disposed of safely
(f)
replaced as necessary
Users need to be trained on all these points and must be informed of the operational limits of
the equipment, i.e. what it cannot do as well as what it can do.
13
In some circumstances the application of control measures will continue after the actual work
activity is completed. For example, some jobs will require the operatives to go through a full
decontamination procedure, e.g. working with heavily contaminated land. Anyone who has
been in the live working area may have to follow a strict procedure about where they take
boots and overalls off, or even go through a shower, and it may involve wearing additional
gloves to ensure that contaminants are kept off their skin when decontaminating.
14
Often, simply washing hands with hot soapy water will suffice. Good COSHH practice and
the provision of good welfare facilities are very closely linked. This may mean in some
circumstances that eating and drinking are not allowed other than in designated clean zones.
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12
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The assessment
The assessment is a 'considered Judgement' that balances the hazardous properties of the
substance, the method by which it will be handled and the environment in which it will be
used.
16
The skill of the COSHH assessor is to:

sift through the information contained on the material safety data sheet (MSDS) and
other sources such as on the container
(b)
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(a)
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15
(c)
incorporate their knowledge of how, when and where the substance is used
(d)
from the information available, produce a useful and useable COSHH assessment to
guide those who will be doing the work.
extract the useful information
17
Examples of an MSDS and a COSHH assessment are in Appendices 2 and 3, and show
how the mass of information on the MSDS can be condensed into a usable assessment.
Emergencies
18
If significant or dangerous accidental releases or leakages of a hazardous substance are

possible, despite the control measures which have been implemented, an emergency plan
should be drawn up and instigated for achieving suitable control and for safeguarding the
health of anyone who may be affected.
19
The emergency plan should include first-aid provisions and safety drills, including the testing
of drills at regular intervals. Any particular hazards that are likely to occur as a result of the
emergency must be specified.
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20

Page 44
The emergency plan should be made available to all people potentially affected and be
displayed on site. It should also be made available to the accident and emergency services.
1.2.3.24 Review of assessments and control measures

1
An assessment should be reviewed regularly, and at once, if:

(a)
there is reason to believe that it is no longer valid, e.g. new information on health risks
has come to light
(b)
the work to which it relates has changed significantly, e.g. new substances have been
introduced, or the method of working is to change, such as the use of a spray gun to
apply paint instead of a brush or roller
(c)
environment and/or health monitoring results indicate it is necessary.
The definition of 'regularly' will depend on a number of factors, such as the nature of the risk.
However, the maximum period between reviews should not exceed five years.
Each review should trigger an opportunity to consider whether exposure can now be
prevented, for example, by substituting a less hazardous substance or by process changes.
Similarly, control measures should be reappraised to see whether they are still adequate or if
further improvements are necessary and possible.
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Use of control measures
Contractors should have procedures in place to ensure that measures provided to control
exposure to hazardous substances, including the provision of PPE, are properly used or
applied. These procedures should include regular inspections of working practices and a
system to ensure that, where remedial action is found to be necessary, it is promptly taken.
Employees have a duty to:
er
make full and proper use of any control measures and to properly wear any PPE
provided for their use
(b)
take all reasonable steps to return the PPE after use to the accommodation provided
(c)
notify any defects at once to management.
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(a)
These are all common sense measures. Work with hazardous substances also dictates that
employees make every effort to practise a high standard of personal hygiene, for example,
by:
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(a)
removing any protective clothing (this may be contaminated) and thoroughly washing
before eating and drinking
(b)
consuming food and drink only in mess rooms or canteens
(c)
making full use of shower facilities
(d)
using the storage facilities provided and keeping personal protective clothing separate
from ordinary clothing, to avoid possible contamination
(e)
smoking only in designated areas and thoroughly washing hands before handling
cigarettes or tobacco, otherwise contamination may spread from hands to the mouth
and ingested into the stomach, which can lead, in some circumstances, to serious
health problems.
Maintenance, examination and test of control measures

7
Contractors are required to ensure that all measures installed to prevent or control exposure
to substances hazardous to health under these Regulations are maintained in efficient
QCS 2014

Page 45
working order and in good repair.

8
Certain engineering controls require thorough examination and tests, as follows.

Local exhaust ventilation plant
Local exhaust ventilation plant should be examined and tested at least once every 14
months.
10
Any defects in local exhaust ventilation systems must be reported and promptly rectified.
Non-disposable respiratory protective equipment (RPE)
Thorough examinations and tests of non-disposable respiratory protective equipment (RPE)
should be carried out, where appropriate, at suitable intervals.
12
Examinations and tests should be carried out at least every month, and more frequently
where the conditions of use are particularly severe. Longer intervals may be more
appropriate in the case of certain RPE, e.g. half-mask respirators used infrequently for short
spells against air contaminants of relatively low toxicity. However, the longest interval
between examinations and tests should not exceed three months.
13
Face-fit testing by someone who is competent is required for any tight-fitting masks. For full
face masks, this needs to be quantitative testing using a computerised method.
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Disposable RPE
No examinations or tests are required, provided that the disposable RPE is used for only one
working day or shift and then disposed of.
15
Again, face-fit testing by a competent person is required. This can be qualitative testing
using a sweet/bitter solution to check the effectiveness of the fit.
Records
All examinations, tests and repairs carried out on engineering controls and non-disposable
RPE should be suitably recorded in any format provided they are easily retrievable. These
records should be kept for at least five years.
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16
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1.2.3.25 Monitoring exposure at the workplace

1
There are certain situations, outlined below, in which the monitoring of exposure to a
hazardous substance is required. Sometimes, however, it is so obvious that there is a
problem that the money may be better spent on solving the problem rather than simply
confirming what was already suspected.
Monitoring is required in the following circumstances:
(a)
where a serious health hazard could arise because of failure or deterioration of the
control measures
(b)
where it is necessary to ensure that a workplace exposure limit (WEL) or Contractorimposed working standard is not exceeded. Significant exposure to silica dust may
require monitoring
(c)
when it is necessary to carry out an additional check on the effectiveness of any

control measure
An example of monitoring would be the use of a personal sampler to monitor an airborne
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Page 46
contaminant in the breathing zone of an employee.

Monitoring records
4
Monitoring records must be kept in a suitable format and be available either as individual
records or as a suitable summary for five years. If they are representative of the personal
exposures of identifiable employees, the records must be kept for at least 40 years.
1.2.3.26 Health surveillance

The main purpose of health surveillance is to detect problems with the health of employees
at the earliest possible stage. The purpose of control measures is to prevent damage to the
health of employees; this is something that health surveillance cannot do. However, adverse
health surveillance results may indicate that the existing control measures are not working
properly.
Health surveillance has to be undertaken when:
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an employee is exposed to a substance that is hazardous to health and there is an

identifiable disease or adverse health effect related to this exposure (which may occur
because of the conditions of the work) and there are valid techniques for detecting
indications of the disease or effect. For example, isocyanates used in 'two pack paints'
are respiratory irritants and can result in sensitisation and asthma.
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(a)
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Working on contaminated land often requires some form of health surveillance. This may
include lung function testing or direct analysis of blood, urine or hair samples. Normally this
would occur before during and after the work. It allows a personal baseline to be established
and then simply acts as a check that the control measures are working.
Suitable health surveillance can be undertaken by an appointed doctor or a registered

medical practitioner or an examination by an occupational health nurse. At the other end of
the scale, health surveillance could simply involve a trained manager or supervisor
inspecting an employee's hands and forearms, looking for the early signs of dermatitis.
Contractors are required to keep health records of employees under health surveillance for
at least 40 years from the date of the last entry.
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1.2.3.27 Information, instruction and training for people who may be exposed to
hazardous substances
If an employee is likely to be exposed to substances hazardous to health, the Contractor
must provide sufficient information, instruction and training so that the employee is aware of:
(a)
the health risks, and
(b)
the precautions that should be taken.
It is important that workers do not put themselves at risk due to lack of information,
instruction or training.
Therefore, they should be knowledgeable of the health risks, the precautions they should
take (including the control measures), and be able to use the supplied personal protective
equipment effectively.
They should also know what procedures to follow in the event of an emergency.
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Page 47

1.2.3 Appendix 1
Management action plan
Compile an inventory of all hazardous substances to which employees may be exposed,
which are either purchased (proprietary products) or created by a work process (dust, fumes
etc.) or may be already on site (micro-organisms, contaminated land, residues etc.).
2.
Gather relevant technical information about each substance from sources such as labelling,
safety data sheets. For each substance, evaluate the work task(s) and working practices
associated with it. If necessary, observe the work activity in which the hazardous substance is
used or created.
3.
From information and observations made, decide if there are any risks to health.
4.
Assess what action needs to be taken to prevent exposure (PRIORITY), or to control it to an

acceptable level. Record the significant findings of the assessment.
5.
Take the actions necessary to ensure that the appropriate control measures are provided,
properly used and maintained as necessary. Provide all users of (or those creating) each
hazardous substance with the necessary information, instruction and training. From the
information gained, decide if there is any requirement for exposure monitoring and health
surveillance.
6.
Review the assessment regularly and revise it as necessary.
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1.
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Page 48

1.2.3 Appendix 2
Example of a material safety data sheet - diesel fuel
Sheet
1 of 8
Revision no.
10
Product name: AUTO DIESEL / DERV

Synonyms: G.O.R.V., Ultra-Low Sulphur Diesel,
AD10
Last revision
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This is an uncontrolled copy
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1. Identification of the substance / preparation and of the company
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Facsimile:
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Telephone:
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Name and address of manufacturer/supplier:
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Emergency contact:
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Health and safety emergency telephone:

Application:
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For use as a fuel in diesel engines only. Any other use implies a processing operation which may
change its essential characteristics and liability for safety of the product will transfer to the processor.
2. Composition / information on ingredients
Petroleum hydrocarbons >99%

Saturated olefinic and aromatic:
PAHs.
C10 to C26 - may contain Polycyclic Aromatic Nydrocarbons -
CAS No. 068334-30-5. EINECS No. 269-822-7, R40.

Additives
1. Middle distillate flow improvers (various) up to 1000ppm. (Dispersion of Ethylene vinyl acetate in
an organic solvent).
2. Cetane improvers (AlkyI Nitrates) - up to 500ppm. CAS No. 27247-96-7, EINECS No. 269-822-7.
3. May contain dye and chemical marker - gas oil marker concentrate. CAS No. 68334-30-5.
4. Antistatic additive 1-3ppm
5. May contain a multifunctional detergent
January
2006
QCS 2014

Page 49
Sheet
AUTO DIESEL / DERV
2 of 8
Revision no.
10
Last revision
January 2006
3. Hazard identification
Health hazards:
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This product contains amounts of Polycyclic Aromatic Hydrocarbons, some of which are known from
experimental animal studies to be skin carcinogens. Prolonged and repeated exposure may therefore
cause dermatitis and there is a risk of skin cancer. The risk of skin cancer will be very low, providing
the handling precautions are such that prolonged and repeated skin contact is avoided and good
personal hygiene is observed. Aspiration of liquid into the lungs directly or as a result of vomiting
following ingestion of the liquid can cause severe lung damage and death.
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Safety hazards:
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Product can accumulate static charges, which may be a possible ignition source (see Section 7).
However product does contain an antistatic additive.
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Environmental hazards:
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4. First aid measures
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Dangerous for the environment. Toxic to aquatic organisms. May cause long-term adverse effects in
the environment.
Eyes:
Rinse immediately with plenty of water until irritation subsides. If irritation

persists, obtain medical attention.
Skin:
Immediate flush with large amounts of water, using soap if available.

Remove contaminated clothing, including shoes, after flushing has begun. If
irritation persists, get medical attention.
Inhalation:
In emergency situations use proper respiratory protection to immediately

remove the affected victim from exposure. Administer artificial respiration if
breathing has stopped. Keep at rest. Call for prompt medical attention.
Ingestion:
DO NOT INDUCE VOMITING, since it is important that no amount of the

material should enter the lungs (aspiration). Keep at rest. Get prompt
medical attention.
Pressure injection:
ALWAYS OBTAIN IMMEDIATE MEDICAL ATTENTION EVEN THOUGH

THE INJURY MAY APPEAR MINOR.
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Page 50
Sheet
3 of 8
Revision no.
10
Last revision
January 2006
5. Fire-fighting measures
Foam, dry chemical powder, carbon dioxide.
Fire and explosion

hazards:
Flammable liquid, moderate hazard. Liquid can release vapours that readily
form flammable mixtures at or above the flash point.
Static discharge:
Material can accumulate static charges which may cause an incendiary

electrical discharge. However, this product does contain an antistatic
additive.
Special fire-fighting
procedures:
Water fog or spray to cool fire exposed surfaces (e.g. containers) and to
protect personnel, should only be used by personnel trained in firefighting.
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Extinguishing media:
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Cut off "fuel"; depending on circumstances, either allow the fire to burn out
under controlled conditions or use foam or dry chemical powder to
extinguish the fire. Respiratory and eye protection required for fire-fighting
personnel exposed to fumes or smoke.
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Hazardous
Smoke, sulphur oxides and carbon monoxide in the event ofincomplete
combustion products: combustion.
6. Accidental release measures
Personal precautions: See Section 8

Environmental
precautions:
Land spill: Eliminate sources of ignition. Shut off source taking normal safety
precautions. Prevent liquid from entering sewers, watercourses or low lying
areas; advise the relevant authorities if it has, or if it contaminates soil/vegetation.
Take measures to minimise the effects of groundwater.
Water spill: Eliminate the spill immediately with booms. Warn shipping. Notify port
and other relevant authorities.
Decontamination
procedures:
Recover by skimming or pumping using explosion-proof equipment, or contain

spilled liquid with booms, sand or other suitable absorbent and remove
mechanically into containers. If necessary, dispose of absorbed residues as
directed in Section 13.
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Page 51
Sheet
4 of 8
Revision no.
10
Last revision
January 2006
7. Handling and storage
Store product in cool, well ventilated surroundings, well away from sources of ignition. Provide suitable
mechanical equipment for the safe handling of drums and heavy packages.
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Electrical equipment and fittings must comply with local Regulations regarding fire prevention with this
class of product.
Load/unload temperature: Ambient to 40C
Storage temperature:
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Special precautions:
Ambient to 40C
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Use the correct grounding procedure. Store and handle in closed or properly vented containers.
Ensure compliance with statutory requirements for storage and handling. Check for and prevent
potential leaks from containers.
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8. Exposure controls / personal protection
Substance
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Workplace exposure
limit:
STEL
Source / Other Information
5 mgm-3
10 mgm-3 HSE Guidance: not listed in EH 40
Mineral oil mist
8-hour TWA
Personal protection:
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In open systems where contact is likely, wear safety goggles (EN 166),
chemical-resistant overalls and chemically impervious gloves (EN 374). Where
only incidental contact is likely, wear safety glasses with side shields. No other
special precautions are necessary provided skin/eye contact is avoided. Where
concentrations in air may exceed the OES approved respirators may be
required (EN 405).
Monitoring methods:
Health & Safety Executive (HSE), Methods for the determination of Hazardous
Substances (MHDS); MDHS 84 www.hsl.gov.uk/search.htm
Sheet
5 of 8
Revision no.
10
Last revision
January 2006
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Page 52
9. Physical and chemical properties
Appearance:
Clear straw-coloured Odour:

liquid
Density at 15C:
0.82 g/ml
Pungent petroleum
Not applicable
Vapour pressure at 20C: < 0.3 Kpa
Vapour density (air=1):
< air
Boiling point:
Pour point:
-24C
Flash point (closed cup): > 55C
Auto-ignition
temperature:
250- 270C
Flammability limit, in air, % by volume:
LEL: 0.5, UEL: 6.0

4.8
2 -1
3.0
Solubility:
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Kinematic viscosity at 40C, mm s
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2 -1
Kinematic viscosity at 20C, mm s
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180 - 390C
pH:
Negligible
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PLEASE NOTE THAT THESE PROPERTIES DO NOT CONSTITUTE A SPECIFICATION.
Stability:
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Conditions to avoid:
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10. Stability and reactivity
The product is stable and not subject to polymerisation.

Avoid exposure to extreme heat.
Avoid contact with strong oxidising agents such as liquid chlorine.
Hazardous decomposition products:
Product does not decompose at ambient temperature.
Materials to avoid:
Sheet
6 of 8
Revision no.
10
Last revision
January 2006
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Page 53
11. Toxicological information

The following toxicological assessment of health effects is based on a knowledge of the toxicity of the
product's components.
Slightly irritating but does not damage eye tissue.
On skin:
Low order of acute toxicity. Irritating. Prolonged or repeated contact may also lead to
more serious skin disorders, including skin cancer. Certain components present in this
material may be absorbed through the skin, possibly in toxic quantities.
By inhalation:
In high concentrations and/or at elevated temperatures, vapour or mist is irritating to

mucous membranes, may cause headaches and dizziness, may be anaesthetic and
may cause other central nervous system effects. Elevated temperatures or mechanical
action may form vapours, mists or fumes, which may be irritating to the eyes, nose,
throat and lungs. Avoid breathing vapours, mists or fumes.
By ingestion:
Low order of acute/systemic toxicity. Minute amounts aspirated into the lungs during
ingestion or vomiting may cause severe pulmonary injury and death.
Chronic:
Contains Polycyclic Aromatic Hydrocarbons (PAHs). Prolonged and/or repeated skin

contact with certain PAHs has been shown to cause skin cancer. Prolonged and/or
repeated exposure by inhalation of certain PAHs may also cause cancer of the lung
and of other sites of the body.
Acute:
Based upon animal test data from similar materials and products, the acute toxicity of
this product is expected to be:
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On eyes:
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ORAL LD50 > 5000 mg/kg DERMAL LD50 > 2000 mg/kg
12. Ecological information
Mobility:
Ecotoxicity:
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In the absence of specific environmental data for this product, this assessment is based on information
developed with other crude oils. Gas oils released into the environment will float on water and spread
on the surface; on release to soils, gas oils show some mobility and predominantly absorb.
Dangerous for the environment. Toxic to invertebrates and slightly toxic to fish.
Some mobility in soils.
Persistence and
degradability:
Lighter components volatilise and in air undergo photolysis to give half-lives of less
than a day. Photoxidation of liquid hydrocarbons on the water surface also
contributes to the loss process. Slow to moderate degradation in water and soil.
Bioaccumulation
potential:
Potential to bioaccumulate, but metabolic processes may reduce this tendency.
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Page 54
Sheet
7 of 8
Revision no.
10
Last revision
January 2006
13. Disposal considerations
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14. Transport information
Rails cars, tank trucks, tankers, barges, drum.
Shipping name:
Diesel Fuel
Packaging group:
III
Marine pollutant:
See Section 6
ICAO/IATA:
Class 3
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Classification for transport:
1202
UN Class:
ADR/RID:
Class 3
Emergency action
code:
3Y
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UN Number:
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15. Regulatory information

Hazard label data:
o
R40
N Dangerous for the Environment
Limited evidence of carcinogenic effect
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R & S phrases:
Xn Harmful
R51/53 Toxic to aquatic organisms, may cause long-term adverse effects in

the aquatic environment
EC Directives:
Statutory information:
S2
Keep out of reach of children
S36/37
Wear suitable protective clothing and gloves
S61
Avoid releases into the environment, see Section 6
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Page 55
Sheet
8 of 8
Revision no.
10
Last revision
January 2006
16. Other information
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The data and advice given apply when the product is sold for the stated application or applications.
The product is not sold as suitable for any other application. Use of the product for applications other
than as stated in this sheet may give rise to risks not mentioned in this sheet. You should not use the
product other than for the stated application or applications.
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If you have purchased the product for supply to a third party for use at work, it is your duty to take all
necessary steps to ensure that any person handling or using the product is provided with the
information in this sheet.
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If you are an Contractor, it is your duty to tell your employees and others who may be affected about
any hazards described in this sheet and about any precautions that should be taken.
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Page 56

1.2.3 Appendix 3
COSHH assessment - diesel fuel
Auto diesel
Substance hazard classification:
Flammable, harmful/irritant
Trade name(s):
Any auto fuel production company
Substance used for:
Motive power for plant and other diesel powered vehicles
Safety precautions
Remove to fresh air. Seek medical
attention if conditions severe.
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Inhalation: can lead to nausea Avoid inhaling vapour or mist;

and headaches.
ensure good ventilation.
Remove the victim from
exposure.
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Potential hazards
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Name of hazardous substance:
Avoid prolonged/repeated
contact. Wear PVC gloves. Do
not use as a cleaning agent.
Eye contact: will cause

irritation.
Wear eye protection if splashing Rinse immediately with plenty of

can occur.
water until irritation subsides. Seek
medical advice.
Remove contaminated clothing.

Wash skin thoroughly with soap
and warm water.
Do not eat, drink or smoke

during use.
Do not induce vomiting. Wash

mouth with water. Seek immediate
medical attention.
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Ingestion: will irritate mouth,

throat etc.
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Skin contact: can be irritating

and have a defatting effect.
Fire: products of combustion

Do not smoke during use. Avoid Clear the area. Do not inhale
are toxic. Vapour/air mixture is heat sources and open flames. vapours, smoke etc.
explosive.
Spillage: fumes/vapour likely to Do not allow to enter drains.
collect in low areas.
Eliminate ignition sources.
Ensure good ventilation.
Contain with sand or granules.

Remove into a container. Dispose
of as hazardous waste.
Additional information: Environmentally damaging.

Assessment date
Approved for use by (print name and position)

Signature
Next
date
review
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Page 57

1.2.4
First Aid at Work
1.2.4.1 Key points

Trained first-aid staff and first-aid equipment must be available on site.
The level of provision of trained staff and first-aid equipment will depend upon several
factors.
Everyone working on site should know where the first aiders and the first-aid kits can be
found.
All accidents causing injury must be recorded in an accident book.
In an emergency, assess the situation but do not put yourself in danger.
Don't move casualties who are obviously injured unless it is necessary to do so - summon
the first aider immediately and contact external emergency services.
Cover severe bleeding with a clean pad and apply direct pressure.
First Aiders have the potential to save lives.
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The following four factors will influence decisions:

workplace hazards and risks
(b)
the nature of the undertaking and its history of accidents
(c)
the size of the establishment and distribution of employees
(d)
the location of the establishment and the locations to which employees go in the
course of their work.
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(a)
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These Regulations provide a flexible framework within which Contractors can develop
effective first-aid arrangements appropriate to their workplace and the size of their workforce.
DANGER
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Your own safety is your first priority

RESPONSE
Does the casualty respond to voice/touch?
AIRWAY
Does the casualty have a clear airway?
BREATHING
Is the casualty breathing?
If
you
are
not
there
are
brief
notes
to be taken in an emergency.
a
in
PROMPT ACTION SAVES LIVES!
trained
Appendix
first
on
aider,
actions
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Page 58
1.2.4.3 Definition of first aid

1
First aid is defined as the follows:

(a)
in cases where a person will need help from a doctor or a nurse: treatment for the
purpose of preserving life and minimising the consequences of injury or illness until
such help is obtained.
(b)
treatment of minor injuries which would otherwise receive no treatment or which do

not need treatment by a doctor or nurse.
It should be noted that the definition covers any illness at work and not just accidents. You
must, therefore, plan for times when someone has a heart attack or just collapses.
Emergency fist aiders can give a restricted range of first aid treatment to someone who is
injured or becomes ill at work. Fully trained first aiders can do the above, plus apply first aid
to a range of specific injuries and illnesses.
Contractors are required to:
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provide adequate first-aid equipment and facilities appropriate to the type of work or
operations undertaken
(b)
appoint a sufficient number of suitable and trained people to render first aid to
employees who are injured or become ill at work
(c)
appoint a sufficient number of suitable people who, in the temporary absence of the
first aider, will be capable of dealing with an injured or ill employee needing help from
a medical practitioner or nurse, and who are able to take charge of first-aid equipment
and facilities
(d)
inform employees of the first-aid arrangements, including the location of equipment

and personnel. This will require that notices be posted and signs displayed. Provision
should be made for employees with language or reading difficulties.
Shared facilities
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(a)
To avoid the unnecessary duplication of facilities where employees of more than one
Contractor are working together, arrangements may be made to share facilities. Whilst there
is no requirement for shared facilities to be formally recorded, industry best practice is that
the arrangements are recorded in writing, with each Contractor retaining a copy.
In such circumstances, it is the responsibility of each Contractor to ensure that the agreed
facilities are actually provided, and that all their employees are aware of these
arrangements.
et
it
Trained and suitable personnel

7
First aiders must have received training and hold a current first-aid certificate issued by a
recognised training organisation.
Where first aiders have received first-aid instruction relating to special or unusual hazards in
the workplace, they should undergo refresher training and re-examination as necessary. The
Contractor must keep a written record of such training.
Number of first aiders required
For construction, which the table categorises as 'higher risk', the recommendation is as
follows.
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Number of employees
Number of first aid trained staff
10
Less than 5: At least one appointed person
11
5-100: At least one first aider or emergency first aider per 50 employees or part thereof
12
More than 100: At least one first aider per 50 employees or part thereof
13
In determining the total number of qualified first aiders required, additional factors should be
considered. These are:
the type of work or operations being carried out
(b)
whether or not employees work alone or in scattered and isolated locations
(c)
whether there are special or unusual hazards
(d)
whether or not there is shift work -first-aid cover will be required at all times that work
is being carried out
(e)
the maximum number of people likely to be on site at any one time
(f)
the remoteness of emergency medical services
(g)
cover for first-aiders' holidays and sickness absence - first-aid cover will be required at
all times that work is being carried out
(h)
the presence of work-placement trainees.
qa
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(a)
On sites where special or unusual hazards are present, a proportionately larger number of
first aiders, having regard to the factors already mentioned, will be needed. Good practice
should encourage all the contractor's site personnel to be trained in basic emergency aid.
15
On major construction projects where there is a site nurse, and/or a doctor on call, their
advice in connection with first aid should be followed.
ov
1.2.4.4 Appointed persons
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as
14
An appointed person is someone who has been nominated by the Contractor to take charge
of a situation, e.g. to call an ambulance if there is a serious illness or injury.
They will act in the absence of the trained first aider or in situations where it is deemed that a
first aider is not required, such as in a small non-hazardous working area, and where there is
easy access to professional medical assistance, such as a hospital accident and emergency
department.
Emergency first-aid training should be considered for all appointed persons.
Appointed persons must not be regarded as an alternative to qualified first aiders and they
must not be required to render first aid. The appointed person is responsible for first-aid
equipment in the absence of the first aider or in the circumstances described above.
et
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1.2.4.5 Equipment and facilities

Location of first-aid facilities
1
It is essential that all employees should have quick and easy access to first-aid facilities on
site. Where employees are working in large numbers and in close proximity, facilities should
be centralised in that area. When employees are spread over a wider area, it is necessary to
distribute first aiders and equipment accordingly. Sometimes, a combination of these
arrangements may be appropriate.
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All employees must be aware of the location of first-aid facilities and the arrangements for
providing treatment. The location of first-aid facilities should be clearly marked with the
appropriate symbol:
White symbol and letters on a green background
.l.
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First-aid boxes
Every Contractor must provide one or more first-aid boxes. They should be strategically
placed, readily accessible and clearly marked with a white cross on a green background.
The container should hold first-aid equipment and nothing else, and should protect the
contents from dust and damp.
It is essential that the contents of first-aid boxes are replenished after use and checked
frequently by the first aider or appointed person. Some of the items are prone to deterioration
after a certain period. The minimum recommended contents of the first-aid box are listed in
Appendix 1, which should be adjusted following an assessment of the first aid needs of a
specific site.
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rw
who are working alone or in small groups in isolated locations, e.g. maintenance
gangs
(b)
whose work involves travel in remote areas
(c)
who use potentially dangerous tools or machinery.
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(a)
The first-aid kit should only contain the items as recommended in Appendix 1.
Special or small travelling first-aid kits should be provided to those employees:
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Travelling first-aid kits
Supplementary equipment
7
Where first aiders are employed, stretchers or appropriate carrying equipment, such as a
carrying chair or wheelchair, should be provided in an accessible location clearly identified
by a sign. If a site covers a large area, or contains a number of distinct working areas, it will
be necessary to provide such equipment at a number of suitable locations.
However, it is recommended that, in most incidents, casualties are moved as little as

possible before the emergency services arrive.
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First-aid rooms
On a large building or construction site, a first-aid room, suitably staffed and equipped,
should be provided. The need for such a room cannot be decided purely on the numbers of
persons employed, but should be assessed on the type of work being carried out and
whether hospital A&E or other emergency facilities are close to hand.
10
The first-aid room will normally be under the control of the first aider who should be nearby
or on call, with access to the room when employees are at work. The name of this person
should be displayed, together with the names and locations of all other first alders and
appointed persons. On some larger sites, the first-aid room will be staffed by a qualified
nurse.
11
The room should be clearly identified, available at all times and used only for rendering first
aid. It should be of sufficient size to contain a couch with adequate space around it to allow
people to work, and provided with an access door to allow the passage of a stretcher or
other carrying equipment. Pillows and blankets should be provided and be frequently
cleaned.
12
The room itself should be cleaned each working day, have smooth-topped impermeable
working surfaces and provision for privacy and refuse disposal.
13
Heating, lighting and ventilation should be effective. In addition to the first-aid materials (see
Appendix 1) which should be stored in a suitable cabinet, there should be:
(b)
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as
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(c)
soap, nail brush and paper towels
(d)
clean garments for use by first-aid personnel
(e)
a suitable container for disposal of clinical waste (yellow bags).
a sink with running hot and cold water

drinking water
(a)
14
In first-aid rooms that are supervised by the site nurse, other items may be provided on their
advice.
15
The room should have a telephone, where possible, and a siren or klaxon to alert personnel
on call.
16
A sufficient number of first aiders should be provided in any work area that is not within easy
reach (approximately three minutes) of the first-aid room.
1.2.4.6 Training and qualifications

1
The Contractor is responsible for ensuring that those people who have been selected as fully
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qualified first aiders have undergone training and possess adequate qualifications. Additional
training may be necessary to cope with any special hazards in a particular working
environment.
2
Instruction in emergency first aid, such as resuscitation, control of bleeding and treatment of
unconsciousness, is desirable for all staff.
Initial selection of first aiders
Whilst it is desirable to appoint staff who have already received first-aid training and utilise
their skills, in many instances this may not be an option. On most new sites it is unlikely that
a trained first aider will be available, and it will be necessary to arrange training for a suitable
member of staff.
.l.
l
In selecting people for this role, the following factors should be considered:
friendly, reassuring disposition
acceptable to male and female staff
able to cope with stressful and physically demanding emergency procedures
able to remain calm in an emergency
employed on a task which they can leave immediately in order to go to the scene of an
emergency
capable of acquiring the knowledge and qualifications required.
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qa
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ov
The First Aid training course, including examination will:

(a)
normally take three full days (18 'classroom' hours), however
(b)
it need not be completed in a period of three consecutive days - 'split courses' will be
permitted.
On completion of the course, each student must be able to demonstrate that they are able
to:
11
et
it
10
er
Training of fully qualified first aiders
12
(a)
recognise minor and major illnesses
(b)
act safely, promptly and effectively with emergencies at work
(c)
use first-aid equipment, including the contents of the first-aid container
(d)
understand the duties of Contractors and the legal framework
(e)
maintain simple factual records on the treatment or management of emergencies
(f)
recognise the importance of personal hygiene in first-aid procedures.
Students must also be able to deal with a casualty who:

(a)
requires cardiopulmonary resuscitation
(b)
is bleeding or wounded
(c)
is suffering from shock
(d)
is unconscious
(e)
is suffering from an injury to bones, muscles or joints
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(f)
has an eye injury
(g)
has been overcome by gas or fumes
(h)
has been burned or scalded
(i)
has been poisoned or exposed to a harmful substance.
13
Students must also be able to manage the transportation of the casualty as required by
workplace circumstances.
14
It may be necessary to provide specialised instruction in the use of protective equipment or

rescue techniques, where these are important in the trainee's workplace or if special hazards
exist there.
Expiry of certificates
First-aid certificates should be valid for three years. Re-qualification training, with reexamination, will be required before re-certification.
16
First aiders can undertake re-qualification training up to 3 months before the expiry of their
current first-aid certificate. The certificate will be dated to 'run on' from the expiry date of the
previous one. Ideally, Contractors will take advantage of this period.
17
However, where this is not possible or practical, re-qualification training can be taken within
28 days after the previous certificate expires.
18
Where within the 28 day period, the student:
as
qa
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15
passes the re-qualification training, a certificate will be issued, backdated to the expiry
of the previous one
(b)
fails to pass the re-qualification training, the full First Aid at Work course must be
taken again, and passed, for a certificate to be issued.
er
se
(a)
In effect, these arrangements provide Contractors with a four month window in which to get
each first aider re-certificated.
ov
19
(a)
(b)
can be 'split' over a longer period, but
(c)
must be completed within a period of six weeks.
Re-qualification training for fully qualified first aiders including re-examination:

must last at least 12 hours (two days)
20
et
it
Re-qualification training
Refresher training
21
Contractors are strongly recommended that fully qualified first aiders attend a three-hour
refresher course each year to brush up on their basic skills and learn about new techniques
and developments.
Training of first aiders for special or unusual situations
22
First aiders should have completed training in the subjects described for first aiders, and
been given any specialised training related to the particular requirements of their workplace
and its hazards.
23
Some workers carry their own medication, such as inhalers for asthma or 'Epipens' which
contain injectable adrenaline for the treatment of severe allergic (anaphylactic) reactions, for
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example to peanuts. These medications are prescribed by a doctor. If an individual needs to

take their own prescribed medication, the first aider's role is limited to helping them do so
and contacting the emergency services as appropriate.
Training of emergency first aiders
24
Emergency first aiders must undertake a six-hour course, with their certificate being valid for
three years. Similar to fully qualified first aiders, the Contractor is recommended that
emergency first aiders undertake an annual three-hour basic skills update and refresher
course.
25
To requalify and retain their certification for a further three years, emergency first aiders must
retake the six-hour course within their three-year qualification period.
what to do in an emergency
(b)
cardio-pulmonary resuscitation
(c)
first aid for the wounded or bleeding
(d)
first aid for an unconscious casualty.
as
Training records
Contractors must keep written records of all training that has been given to employees and
the results of that training.
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27
er
1.2.4.7 Miscellaneous
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Ambulance
The local ambulance service should be informed about large sites and of any particularly
hazardous operations being undertaken. It is helpful to supply a map locating the site and its
entrances and, where appropriate, the first-aid room.
et
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(a)
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Training courses cover the following subjects:
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26
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Training of appointed persons
Induction
Induction training for employees and other persons joining the site should include details of
the location of first-aid boxes, qualified first-aid personnel and actions to be taken in cases of
injury or illness.
Record of treatment
First-aid treatment should be recorded. The use of an accident book does not normally allow
enough detail to be gathered and an additional treatment book may be necessary,
particularly in order to keep a record of the use of first-aid materials.
1.2.4.8 Accident reporting

1
All accidents causing any injury must be recorded and, where necessary, reported to the
Administrative Authority.
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1.2.4 Appendix 1
Recommended contents of first-aid boxes
First-aid boxes
Travelling first-aid
kits
Guidance card*
Individually wrapped sterile adhesive dressings (assorted

sizes)
20
Sterile eye pads, with attachment
rw
Individually wrapped triangular bandages
qa
ta
Safety pins
as
Medium-sized, individually wrapped, sterile, unmedicated

wound dressings (approx. 12 cm x 12 cm)
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Large, sterile, individually wrapped, unmedicated wound

dressings (approx. 18 cm x 18 cm)
Nil
Nil
Nil
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Individually wrapped, moist cleaning wipes (suggested

minimum number)
Disposable gloves (pair)
.l.
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Item
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Where tap water is not readily available for eye irrigation, sterile water or sterile normal saline (0.9%)
in sealed disposable containers should be provided.
Travelling first-aid kits

Small travelling first-aid kits are designed for use where the workforce is dispersed widely (possibly
with hazardous tools), for employees working away from their Contractor's establishment.
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1.2.4 Appendix 2
Health and Safety (First Aid)
Checklist
First-aid provision
How many employees are involved?
How is the workforce distributed/grouped? (Widely dispersed, etc.?)
Are remote locations involved?
Are shirts worked?
What is the nature of the work?
Does it involve special operations?
Can particular hazards be identified, such as falls, electric shock, dangerous substances?
How many first aiders are needed -consider holiday and sickness cover?
Training
qa
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Which personnel require first-aid training?
10
Does the training offered meet foreseeable needs?
11
Is there a system to trigger a warning to management when a first aider is within three
months of their certificate expiring?
12
Are training records kept?
13
Are individuals working in isolated locations trained to cope with emergencies?
14
Where appointed persons are in charge, do they understand their duties?
15
Does induction training cover first-aid arrangements?
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Equipment
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Is first-aid equipment placed in locations where it is likely to be needed?
17
Does it meet foreseeable needs, special hazards, etc.?
18
Are travelling first-aid kits available when required?
19
Is a first-aid room needed, or available, and suitably equipped?
20
Are information signs provided?
21
Are first-aid boxes and kits properly stocked and maintained?
16
General
22
Has responsibility for first-aid provision and organisation been assigned to an individual?
23
Are there established procedures for reviewing:

(a)
training and equipment needs?
(b)
new work processes?
(c)
special operations?
(d)
changes in work patterns, site locations, size of labour force?
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arrangements with contractors?

1.2.4 Appendix 3
Health and Safety (First Aid)
Basic advice on first aid at work
What to do in an emergency
Assess the situation - do not put yourself in danger.
Make the area safe.
Assess all casualties and attend first to any unconscious casualties.
Send for help - do not delay.
Follow the advice given below.
rw
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Priorities
ta
Check for consciousness
If there is no response to gentle shaking of the shoulders and shouting, the casualty may be
unconscious. Your priorities are to:
shout for help
open the airway
check for normal breathing
10
take appropriate action.
11
The priority is to check the Airway, Breathing and Circulation. This is the ABC of
resuscitation.
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A - Airway
To open the airway:

(a)
Place one hand on the casualty's forehead and gently tilt the head back.
Remove any obvious obstruction from the casualty's mouth.
(b)
et
it
12
as
qa
(c)
Lift chin with two fingertips.
B - Breathing
13
Look along the chest, listen and feel at the mouth for signs of normal breathing, for no more
than 10 seconds.
If the casualty is breathing:
14
Place in the recovery position and ensure the airway remains open.
15
Send for help.
16
Monitor that the casualty continues to breathe until help arrives.

If the casualty is not breathing:
17
Send for help.
18
Start chest compressions (see CPR below).
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C-CPR
To start chest compressions:
Lean over the casualty and, with your arms straight, press down on the centre of the
breastbone, 4-5 cm, and then release.
20
Repeat at a rate of about 100 times a minute (more than one compression per second!)
21
After 30 compressions, open the airway again.
22
Pinch the casualty's nose closed and allow the mouth to open.
23
Take a normal breath and place your mouth around the casualty's mouth, making a good
seal.
24
Blow steadily into the mouth while watching for the chest rising.
25
Remove your mouth from the casualty and watch for the chest falling.
26
Give a second breath and then start 30 compressions again without delay.
27
Continue with chest compressions and rescue breaths in a ratio of 30:2 until qualified help
takes over or the casualty starts to breathe normally.
rw
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19
ta
Severe bleeding
Apply direct pressure to the wound.
29
Raise and support the injured part (unless broken).
30
Apply a dressing and bandage firmly in place.
as
If a broken bone or spinal injury is suspected, obtain expert help. Do not move casualties
unless they are in immediate danger.
er
31
se
Broken bones and spinal injuries
qa
28
ov
Burns
Burns can be serious so, if in doubt, seek medical help. Cool the part of the body affected
with cold water until pain is relieved. Thorough cooling may take 10 minutes or more, but this
must not delay taking the casualty to hospital.
33
Certain chemicals may seriously irritate or damage the skin. Avoid contaminating yourself
with the chemical. Treat in the same way as for other bums but flood the affected area with
water for 20 minutes. Continue treatment even on the way to hospital, if necessary. Remove
any contaminated clothing which is not stuck to the skin.
et
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32
Burning clothing
34
To extinguish the burning clothing of anyone involved in a fire, lay, push or knock the person
to the floor to reduce the spread of flames. Cover the burning area with a blanket, coat or
other items to smother the flames but do not use synthetic materials (for example, polyester).
DO NOT REMOVE ANY OF THE VICTIM'S CLOTHES.
35
Apply large amounts of water to the area of the burns as quickly as possible to cool the
affected parts, and then keep them wet with more water. Seek medical help urgently.
Eye injuries
36
All eye injuries are potentially serious. If there is something in the eye, wash out the eye with
clean water or sterile fluid from a sealed container, to remove loose material. Do not attempt
to remove anything that is embedded in the eye.
37
If chemicals are involved, flush the eye with water or sterile fluid for at least 10 minutes,
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whilst gently holding the eyelids open. Ask the casualty to hold a pad over the injured eye
and send them to hospital.
Record keeping
It is good practice to record in a book any incidents involving injuries or illness that have
been attended, including the following information in your entry:
39
Date, time and place of incident.
40
Name and job of injured or ill person.
41
Details of injury/illness and any first aid given.
42
What happened to the casualty immediately afterwards (for example, went back to work,
went home, went to hospital).
43
Name and signature of the person dealing with the incident.
44
This information can help identify accident trends and possible areas for improvement in the
control of health and safety risks.
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38
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1.2.5
Food Safety on Site
1.2.5.1 Key points

1
Getting food hygiene wrong can have severe implications for many other people.
Anyone who handles food for consumption by others:

must have training in basic food handling techniques;
(b)
must report to their supervisor details of any illness that they may be suffering from;
(c)
may have to be suspended from work if they contract an infectious illness.
Premises in which food is handled, prepared and served must conform to certain standards
of construction and cleanliness.
.l.
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(a)
rw
Food poisoning is caused by bacteria (germs or bugs) which have lain dormant in most
uncooked or unprepared foods, whether meat, fish, poultry and some vegetables.
Food poisoning keeps people off work through sickness, just as accidents do.
Applying appropriate hygiene standards on site are essential because of the potential for:
qa
ta
time lost through sickness absence being reduced
(b)
avoiding lost production
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as
(a)
er
1.2.5.3 Definitions
Food - food or drink of any description, or any of the ingredients used in the preparation of
food.
Food area - any room or food area in which a person engages in the handling of food,
including a server, counter or outside grill preparation area.
et
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The premises
The siting, design and construction of the premises must aim to avoid the contamination of
food and harbouring of pests. It must be kept clean and in good repair so as to avoid food
contamination.
Surfaces in contact with food must be easy to clean and, where necessary, disinfect. This
will require the use of smooth, washable, non-toxic materials.
Adequate provision must be made for cleaning foodstuffs, and the cleaning and (where
necessary) disinfection of utensils and equipment. You must take all reasonable, practical
steps to avoid the risk of contamination of food or ingredients.
Washbasins must be designated for washing hands, have hot and cold (or appropriately
mixed) running water, and be equipped with soap and suitable hand-drying facilities, such as
disposable towels. Lavatories must not lead directly into food rooms and they must be kept
clean, maintained in good repair and ventilated.
Adequate arrangements and facilities for the hygienic storage and disposal of hazardous and
inedible substances and waste (whether liquid or solid) must be available. Food waste must
not be allowed to accumulate in food rooms and should be deposited in closable containers.
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Adequate facilities and arrangements for maintaining and monitoring suitable food
temperature conditions must be available. (See also below.)
The food
Stored raw materials and ingredients must be kept in appropriate conditions which will
prevent harmful deterioration and be protected from contamination likely to make them unfit
for human consumption.
Water
10
There must be an adequate supply of potable (clean, drinkable) water which must be used
whenever necessary to ensure foodstuffs are not contaminated. This includes the use of ice
which must also be made, handled and stored in a way that protects it from contamination.
.l.
l
Foods intended for supply which need temperature control for safety must be held either
HOT at or above a minimum temperature of 63C or CHILLED at or below a maximum
temperature of 8C.
ta
rw
11
Temperature control
qa
Food handlers
Anyone who works in a food handling area must maintain a high degree of personal
cleanliness. The way in which they work must also be clean and hygienic. Food handlers
must wear clean and, where appropriate, protective over-clothes. Adequate changing
facilities must be provided where necessary.
13
Food handlers must protect food and ingredients against contamination, which is likely to
render them unfit for human consumption or create a health hazard. For example, uncooked
poultry should not contaminate ready-to-eat foods, either through direct contact or via work
surfaces or equipment.
14
Anyone whose work involves handling food should:
ov
er
se
as
12
observe good personal hygiene
(b)
routinely wash their hands before handling foods

never smoke in food handling areas
report any illness (like infected wounds, skin infections, diarrhoea or vomiting) to their
manager or supervisor immediately.
(d)
et
it
(c)
(a)
15
If any employee reports that they are suffering from any condition or illness, Contractors may
have to exclude them from food handling areas. Such action should be taken urgently.
16
Food handlers must receive adequate supervision, instruction and training in food hygiene.
Microwave ovens
17
On sites where microwave ovens are used, the following points must be noted.
(a)
Metal containers or utensils must not be placed in a microwave oven.
(b)
Door seals of microwave ovens should be periodically examined to see that they are
not damaged.
(c)
Microwave ovens should not be overloaded by trying to cook too many things at the
same time.
(d)
Frozen food should be properly thawed.

Page 72
(e)
Food should be thoroughly cooked. Follow instructions on the packaging and leave to
stand.
(f)
Do not attempt to add anything to or stir any liquid which has just been removed from
a microwave oven and has not been allowed to stand, by using a metal spoon or
utensil. Such an action may cause the liquid to boil violently.
(g)
Always adhere to the supplier's or manufacturer's instructions.
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1.2.6
Working with Lead
1.2.6.1 Key points

1
Lead can be a major health hazard if exposure is not prevented or adequately controlled.
Lead is a cumulative poison that can find its way into the bloodstream and collect in tissues,
particularly the bone marrow.
The ways that lead is likely to get into the body are through:
(a)
the inhalation of fumes or dust;
(b)
the ingestion of lead particles through hand to mouth contact.
All work with lead, or lead-containing products, must be the subject of a risk assessment.
Builders, carpenters, decorators etc., who remove old paint, particularly if involved in window
renovation, may be exposed to 'significant' quantities of lead without realising it.
Where the risk assessment indicates that employees' exposure to lead is likely to be
'significant', certain monitoring actions must be taken with regard to the employees affected
and the workplace itself.
'Significant exposure' is defined in these Regulations.
During health surveillance, employees' exposure to lead is measured by the concentration of

lead in their blood or urine.
Above a certain level of exposure, Contractors have a legal duty to temporarily suspend the
affected worker(s) from further work with lead.
se
as
qa
ta
rw
.l.
l
ov
Exposure to lead, dust, fumes and vapour constitutes a major hazard in the construction
industry who work with lead and lead products. Construction workers most at risk include:
plumbers working on lead flashing, upstands and gutters
(b)
operatives handling old architectural lead work
(c)
painters rubbing down or burning off old paintwork

demolition operatives
(d)
(a)
et
it
er
(e)
anyone involved in structural renovation or refurbishment, including conservation or

heritage projects.

1
assessment of every work activity in order to identify any hazard that employees or any other
person might encounter as a result of the work being carried out.
Once those hazards have been identified, it is then the Contractor's duty to put control
measures into place in order either to eliminate the hazard or, where this is not possible, to
reduce the risks of injury or ill health arising from the hazards, as far as is reasonably
practicable.
The Contractor must provide employees with comprehensible and relevant information on
any risks in the workplace and on any control measures in place to reduce those risks.
Employees, in turn, have a duty to tell their Contractor of any work situation which presents a
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risk to themselves or to others, or of any matter which affects the health and safety of
themselves or other persons. The main consideration will be identifying where lead is
present and taking the appropriate actions to protect the health of lead workers and, if
necessary, other people who may be affected by the work.
1.2.6.4 Control of Lead at Work

These Regulations aim to give greater health protection to people at work by reducing their
exposure to lead and thus the concentrations of lead in their blood. Where concentrations
are too high, Contractors are required to remove employees from work with lead. This is
known as the 'suspension level'.
Concentration levels of lead in blood, which are below the suspension level and known as
'action levels', have been set.
If these lower levels are breached, Contractors have a duty to investigate and remedy the
cause. Contractors are also required to take steps to reduce the concentrations of lead in air
to a level not exceeding the occupational exposure limits stated in these Regulations.
The main requirements of these Regulations include:
qa
as
A Contractor who is working with lead, or a substance or material containing lead, has to
protect from exposure anyone who may be affected by the work as well as their own
employees. This includes:
the workers of other Contractors including those not engaged in work with lead, such
as maintenance staff and cleaners
(b)
visitors to the work site
(c)
the families of those who are exposed to lead at work who may become affected by
lead carried home unintentionally on the clothing and footwear of the employee are
particularly at risk of lead poisoning, and therefore have lower blood-lead action and
suspension levels than other people.
(d)
the occupiers of premises, including private dwellings, irrespective of whether the

occupiers are present whilst the work is carried out or they reoccupy the premises
later.
er
se
(a)
et
it
ov
ta
Duties under these Regulations
rw
.l.
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Assessment of the risks to health

Every Contractor is required to make a suitable and sufficient assessment of the risk to the
health and safety of employees while at work. This includes other people who are not
employees but who may be exposed as a result of the way the Contractor carries out the
work concerned. The assessment must be reviewed as often as is necessary and in other
certain specified circumstances, and a record made of any significant findings. Such an
assessment is to allow the Contractor to make a decision whether the work concerned is
likely to result in an employee being significantly exposed to lead, and to identify the
measures needed to prevent or adequately control exposure.
Control of exposure
7
Every Contractor must ensure that the exposure of employees to lead is either prevented or,
where this is not reasonably practicable, adequately controlled by means of appropriate
control measures.
As the preferred control measure, the Contractor must consider the use of alternative
materials or processes as a means of eliminating or reducing the risks to the health of
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employees.
(a)
the design and use of the work process, systems and engineering controls
(b)
control of exposure at source, including ventilation systems, and
(c)
where adequate control cannot be achieved by other means, the provision and use of
suitable PPE.
The control measure(s) must include:

the safe handling, storage and transportation of lead and waste which contains lead
(b)
suitable maintenance procedures
(c)
reducing to the minimum required for the task in hand, the number of employees
exposed, the level and duration of exposure and the quantity of lead present in the
workplace
(d)
control of the working environment, including, where appropriate, general ventilation
(e)
appropriate hygiene measures, including washing facilities.
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(a)
rw
10
Where it is not reasonably practicable to prevent exposure to lead, the Contractor must
introduce protective measures which are appropriate to the work activity and consistent with
the findings of the risk assessment. In order of priority, these must be:
ta
Irrespective of these control measures, where the exposure to lead is, or is likely to be
significant, the Contractor must provide suitable and sufficient protective clothing.
12
Where the inhalation of lead fumes is possible, the control measures will only be regarded as
adequate if:
as
qa
11
the occupational exposure limit is not exceeded
(b)
or if it is, the Contractor identifies the reason and takes immediate steps to rectify the
situation.
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se
(a)
Contractors must take reasonable steps to ensure that any control measure provided is
properly used or applied.
14
Employees must make full and proper use of any control measure provided, and:
take all reasonable steps, where appropriate, to return anything provided as a control
measure to its accommodation (storage) after use
(a)
et
it
13
(i)
15
report any defect in any control measure provided to the Contractor.
Adequate control of exposure to lead covers all routes of possible exposure, such as
inhalation, Absorption through the skin and ingestion.
Eating, drinking and smoking
16
Adequate steps must be taken to control the ingestion of lead. A Contractor must ensure
that, as far as is reasonably practicable, employees do not eat, drink or smoke in any place
which is, or is liable to become, contaminated by lead. In practical terms, employees must be
warned against doing so. Furthermore, under these Regulations employees have a legal
duty not to eat, drink or smoke in any place that they have reason to believe is contaminated
by lead.
Maintenance, examination and testing of control measures
17
All control measures provided, including PPE, must be well maintained, kept in a good state
of repair and cleaned as necessary. Any defect in the equipment, or failure to use and apply
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it properly, which could result in a loss of efficiency or effectiveness, thus reducing the level
of protection, should be identified and rectified as soon as possible.
Air monitoring
18
Where employees are liable to receive significant exposure to lead, Contractors must
establish a programme of air monitoring including keeping records of the findings of such
monitoring.
Medical surveillance
Where exposure to lead is significant, the Contractor must:
(a)
make sure that employees are under medical surveillance by a 'relevant doctor'
(b)
provide suitable facilities for health surveillance to be carried out where the
procedures are to be carried out at the Contractor's premises
(c)
maintain health surveillance records and retain them for 40 years
(d)
allow employees reasonable access to their personal health records
(e)
take steps to determine the reasons why any employee's blood sample exceeds the
appropriate action level and take appropriate remedial action
(f)
take the necessary actions, including reviewing the risk assessment, where an
employee's blood or urine sample reaches the 'suspension level'.
rw
ta
qa
Employees for whom health surveillance has been arranged must, when required by the
Contractor (and at the cost of the Contractor), make themselves available for the necessary
health surveillance procedures and supply the relevant doctor with such health-related
information as the doctor may require.
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Contractors who undertake work liable to expose employees to lead shall provide such
information, instruction and training as is suitable and sufficient to know the risks to health,
and the precautions which should be taken.
21
er
Information, instruction and training
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as
20
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19
The Contractor, in attempting to protect the health of employees from an accident, incident
or emergency, must ensure that procedures, including the provision of first aid facilities and
safety drills, have been prepared and can be put into effect should such an occasion arise.
The Contractor must also ensure that information on such emergency arrangements has
been notified to accident and emergency services and that all such information is displayed
within the workplace.
22
et
it
Arrangements for accidents, incidents and emergencies
1.2.6.5 Training
1
There is a specific requirement to ensure that the information, instruction and training
provided for persons working with lead includes:
(a)
the type of lead being worked, the potential health hazards and symptoms
(b)
the relevant occupational exposure limit, action level and suspension level (as
explained)
(c)
any other sources of information
(d)
the significant findings of the risk assessment
(e)
the control measures that are in place and which must be used to enable work to be
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carried out safely
(f)
the results of any monitoring carried out
(g)
the results of previous health surveillance, in such a way that the confidentiality of
individual cases is not breached.

These Regulations require that where a risk of exposure to lead has been identified by a risk
assessment and it cannot be adequately controlled by other means which are equally or
more effective, the Contractor must provide personal protective equipment (PPE) and ensure
it is properly used by employees.
Users of PPE must be trained in its use and care as appropriate.
In essence, PPE may only be used as a last resort after all other means of eliminating or
controlling the risk have been considered and are not reasonably practicable.
In the context of this section the important requirements of these Regulations are for
provision of adequate welfare facilities, particularly in respect of personal hygiene.
Contractors must provide or make available:
qa
ta
rw
.l.
l
suitable and sufficient washing facilities, including showers if necessary due to the
nature of the work
(b)
hot and cold (or warm) water, soap or other cleanser and towels or other effective
means of drying
(c)
suitable and sufficient changing rooms
(d)
lockers or other facilities in which to secure work clothing that is not taken home and
personal clothing that is not worn at work
(e)
suitable rest facilities where meals may be prepared and eaten.
ov
er
se
as
(a)
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1.2.6.8 Provision and Use of Work Equipment

These Regulations require that a Contractor only supplies work equipment that is correct and
suitable for the job for which the equipment is going to be used.
These Regulations also require that users of work equipment are trained in its use, as
appropriate.
1.2.6.9 Control of exposure to lead in the workplace

The hazard
1
Lead is a cumulative poison that will find its way into the bloodstream and can collect in
tissues, particularly the bone marrow. Lead poisoning may occur through exposure to lead in
its pure form or exposure to products containing lead.
Lead affects the body's ability to produce haemoglobin, which is the protein in blood that
carries oxygen to the tissues.
Inorganic lead, the type likely to be encountered during construction activities, can enter the
body in one of two ways:
(a)
by inhalation of dust or fumes
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via the digestive tract from hand-to-mouth transfer of lead particles.
Inhalation is by far the most common route of entry.
Whilst the control of exposure through inhalation will be largely controlled by actions taken
by the Contractor, the control of exposure through ingestion depends upon the good
personal hygiene practices of employees working with lead.
Risk assessment
Contractors must not carry out any work that may expose employees to lead unless a
suitable and sufficient risk assessment has been carried out.
The purpose of the risk assessment is to enable the Contractor to:

assess whether the exposure of employees to lead is likely to be significant
(b)
identify the measures necessary to prevent or control exposure.
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(a)
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Control measures
Control measures involve substituting lead with less hazardous substances or, if this is not
possible, using engineering and organisational methods, similar to those outlined for
COSHH, to control exposure.
The control of exposure to lead (by inhalation) will only be regarded as adequate:
qa
ta
if the concentration of lead in air is kept below the OEL (see below)
(b)
if, where the OEL is exceeded, the Contractor identifies the reasons and takes
immediate steps to remedy the situation.
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as
(a)
er
Air monitoring
Where a risk assessment indicates that employees may be liable to significant exposure to
lead, the Contractor must arrange for air monitoring to be carried out to establish the levels
of lead in the air at the place of work.
11
Air monitoring will involve using specialist equipment, which is fitted to the employee being
monitored, to take an air sample from the employee's 'breathing zone' over a set period of
time.
12
Using static air-monitoring equipment to take air samples is not acceptable as the results will
not be representative of any employee's personal exposure.
13
Generally, depending upon the circumstances, monitoring must be carried out at either
three-monthly or yearly intervals. Air monitoring will determine whether the OEL has been
breached.
14
The Contractor has a duty to retain records of air monitoring results for a period of five years.
15
Given the temporary nature of construction sites, and the even shorter periods when
employees might actually be exposed to lead, the above requirement is considered to be
largely academic for the construction industry. With tradesmen such as plumbers and
painters being potentially exposed to lead many times but over relatively short periods, it will
be for the Contractor to decide how frequently air monitoring should be carried out to confirm
whether or not existing control measures are adequate.
et
it
ov
10
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Occupational Exposure Limit (OEL)

16
The standard for inorganic lead in air is 0.15 milligrams of lead per cubic metre of air
determined on an eight-hour time-weighted concentration.
17
This quantifies the standard to be met by the control measures for airborne lead under these
Regulations.
Medical surveillance to detect exposure to lead involves measuring the concentration of lead
in the blood or urine and therefore necessitates the involvement of suitable trained, medical
staff.
19
Where a risk assessment indicates that employees' exposure to lead is likely to be

significant, the Contractor has a duty to arrange medical surveillance for the affected
employees.
20
If medical surveillance detects blood-lead concentrations at or above those outlined below,

this will trigger continued surveillance:
all employees: 35 micrograms of lead, or greater, per decilitre of blood.
ta
(a)
rw
.l.
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18
as
young persons (aged 16-17): 40 micrograms of lead per decilitre of blood
(b)
all other employees: 50 micrograms of lead per decilitre of blood.
se
(a)
er
If medical surveillance detects blood-lead concentrations at or above these action levels, the
Contractor must:
recognise that the employee's blood-lead level is near the 'suspension level'
(b)
investigate the effectiveness of existing control measures and take the necessary
actions to reduce employees' blood-lead levels below the action level
(c)
prevent the blood-lead level of affected employees from reaching the suspension
level.
ov
(a)
22
The action levels for lead are:
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it
21
qa
Action levels
Suspension levels
23
24
If medical surveillance reveals that an employee's blood-lead level has reached or exceeded
the levels outlined below, a doctor must decide whether to temporarily suspend them from
work which exposes them to lead:
(a)
young persons (aged 16-17): 50 micrograms of lead per decilitre of blood
(b)
all other employees: 60 micrograms of lead per decilitre of blood.
In such circumstances, the Contractor must:

(a)
ensure that a doctor makes an entry in the health record of affected employee(s) as to
whether, in the doctor's professional opinion, they should be suspended from further
work liable to expose them to lead
(b)
review the relevant risk assessment
(c)
review the actions taken to prevent exposure to lead
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(d)
provide for a review of the health of any other employees who may have been
similarly exposed.
25
If the doctor thinks that there is no need to suspend the affected employee(s) from work, the
doctor must note in their health records:
(a)
the reasons for that decision
(b)
any conditions under which working with lead may continue.
26
A Contractor must act on the doctor's decision and an employee will not be able to work with
lead again or be exposed to it until the doctor considers it safe to do so.
27
(Refer to Appendix 2 for an example of a health surveillance record form.)
.l.
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Significant exposure to lead can occur where:
any employee is, or is liable to be, exposed to a concentration of lead in the

atmosphere exceeding half the occupational exposure limit for lead
(b)
there is a substantial risk of an employee ingesting lead
(c)
there is a risk of contact between the skin and lead alkyls or other substances
containing lead which can be absorbed through the skin.
ta
rw
(a)
qa
28
Significant levels
Contractors must provide employees with protective clothing, monitor lead in air
concentration, and place the employees concerned under medical surveillance.
30
Personal protective equipment will be required where control measures are not practicable.
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as
29
Some types of work with lead carried out as part of construction or decorating activities, have
the potential to result in significant exposure to lead unless the Contractor provides adequate
controls and ensures that they are used. For example:
ov
31
er
Types of work liable to result in significant exposure to lead
burning off old paint
(b)
dry-sanding old paint
et
it
high temperature lead-work such as lead smelting, burning and welding
(c)
(a)
32
(d)
working with metallic lead and alloys containing lead, for example, soldering
(e)
disc abrasion of lead surfaces and cutting lead with abrasive wheels
(f)
spray painting with lead-based paints
(g)
work inside tanks that have contained petrol
(h)
manufacture of leaded glass
(i)
hot cutting, demolition and dismantling operations
(j)
otherwise removing or disturbing old lead sheet thereby raising contaminated dust
(k)
recovering lead from scrap and waste
(l)
welding galvanised metal and flame cutting steelwork that has been painted with leadbased paint.
Those operations which do not usually produce significant levels include low temperature
work, ordinary plumbing, soldering, handling clean sheets or pipes of lead, rough painting.
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How does lead affect your health?

33
If the level of lead in the body gets too high, it can cause headaches, tiredness, irritability,
constipation, nausea, stomach pains and loss of weight. Continued uncontrolled exposure
could cause far more serious symptoms, such as kidney damage, nerve and brain damage.
A developing unborn child is at particular risk from exposure to lead, particularly in the early
weeks before a pregnancy becomes known.
Prevention of exposure
The Contractor has a duty to assess the nature and extent of the exposure to lead and, on
the basis of this assessment, to determine the measures necessary to control exposure and
comply with these Regulations.
35
Action should be taken to reduce the amount of lead breathed by operatives to below the
lead in air standard.
36
The basic need is to prevent the liberation of lead dust, fumes or vapour into the workplace.
37
If surface finishes are to be disturbed, always check for the presence of lead paint or, if this
is not possible, assume the worst (that it is a lead-based paint) and take the appropriate
precautions.
38
Ways of testing for the presence of lead include:
qa
ta
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.l.
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34
a variety of destructive tests for paint sampling, although these result in damage to
painted surfaces in order for samples to be taken
(b)
disposable test kits: instant, on-site lead/no lead result with 95% accuracy. (These are
an indicator only, not a laboratory-standard test)
(c)
paint-sampling kits which are ready-to-use (for non-lab professionals) for submission
of samples for chemical analysis. A laboratory-standard test
(d)
dust-wipe sampling kits which are ready-to-use dust sampling kits (for non-lab
professionals) for submission of samples for chemical analysis. A laboratory-standard
test
(e)
hand-portable devices that use XRF (x-ray fluorescence) technology to obtain

laboratory standard readings instantly, on site.
et
it
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as
(a)
1.2.6.10 Personal protective equipment

Respiratory protective equipment
1
Where control measures do not reduce the lead in air levels to below the control limits,
respiratory protective equipment of a type suited to the hazard or process involved must be
provided, and all employees must be properly trained to use it. All such equipment should be
serviced, cleaned, maintained and stored correctly, as is appropriate.
Depending upon whether the hazard is lead dust or fumes, adequate protection will be given
by the use of compressed air-line breathing apparatus, self-contained breathing apparatus,
or a full-face positive pressure powered respirator fitted with a high efficiency filter.
Protective clothing
Wherever exposure is significant, protective clothing must be provided. It must be suited to

the hazard or process involved, should resist the permeation of lead dust, and not collect or
harbour dust. Employees must be instructed to report any damaged or defective ventilation
plant or protective equipment, without delay, to their supervisor or safety representative.
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1.2.6.11 Working with lead-based paints

1
The residues of lead-based paints are a health hazard. Operatives carrying out the removal
of old lead-based paint, and anyone else who might be adversely affected, must be
adequately protected when applying or removing paints containing lead.
Similarly, the occupiers of premises (including the residents of private housing) must be
protected by not being allowed to return to their premises (or contaminated parts of those
premises) until they have been thoroughly and effectively cleaned (see below).
The findings of a risk assessment, carried out before any surface finish is disturbed, will
indicate the most appropriate of removal and safety precautions which must be taken.
See Appendix 3 for specimen record details.
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Sanding
Unless appropriate RPE and protective clothing are worn, old lead paint should never be drysanded by hand as this activity will liberate lead-rich dust into the air. Again, unless
appropriate RPE and protective clothing are worn and effective measures are taken to clear
up the residue, mechanical sanding can only be used if the sander is fitted with a dust
extraction/ collection unit incorporating a high efficiency particle air HEPA filter.
Wet sanding of lead-based paint is acceptable, providing the residue is collected before it
dries out with the potential to become airborne dust.
As a result, the subsequent dry sanding of apparently 'clean' wood can liberate a significant
amount of lead-containing dust into the air.
se
as
qa
ta
rw
Unless appropriate RPE is worn, blow-lamps or gas torches must not be used to burn off old
lead paint as these will heat the paint sufficiently to liberate lead fumes into the air.
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Burning
et
it
Lead paint may be removed by using a solvent or water-rinseable paint remover. If a solvent
is used, the work area must be well-ventilated and no smoking or naked flames allowed.
Suitable RPE and other appropriate PPE should be used.
Solvents
Hot-air gun
10
These must not be confused with blow-lamps and gas torches. A hot-air gun will not raise
the temperature of the paint sufficiently to allow lead fumes to be created. When using a hotair gun, the old paint must be scraped off as soon as it is sufficiently soft and before it rehardens. Care must be taken to ensure that the paint does not burn as this indicates that it is
reaching too high a temperature where fumes may be given off. The use of RPE to protect
against lead-containing dust may be necessary.
Infra-red heating
11
A product is available that safely lifts the old paint from the base material by heating it to a
safe temperature using an infra-red heater. Whilst warm, the paint can be safely scraped off.
This method is particularly suitable where large surface areas have to be stripped.
12
The main benefits of using this method, which acts by heating the resins in the wood and
breaking the bond between the wood and the first layer of paint, are:
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(a)
all layers of paint are removed in 'a single hit'
(b)
virtually all residual lead is removed from within the grain of the wood
(c)
large surface areas can be safely stripped more quickly than by using other methods.
Spraying
13
Spraying methods should not normally be employed for applying lead-based paints.
Cleaning up the work area
All surfaces that have been stripped of paint should be washed down thoroughly, either with
a proprietary lead-specific detergent or with a solution of dishwasher detergent in hot water,
and then wiped down again with clean water.
15
Any residual dust and other debris should be removed using a vacuum cleaner fitted with a
HEPA filter. Depending upon the level of contamination, it may be necessary to wear
appropriate RPE whilst doing this.
16
Normal vacuum cleaners (domestic or industrial) should not be used as their filters are not
sufficiently efficient to retain the lead-containing dust.
ta
rw
.l.
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14
Anyone who works with lead should take simple personal hygiene measures to prevent the
inhalation or ingestion of lead during and after work.
se
Changing and washing facilities
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qa
1.2.6.12 Personal hygiene
To avoid any risk to health or damage to any clothing concerned, the Contractor must
provide separate accommodation for an employee's own clothing and any protective clothing
the employee may have to wear at work. This requirement will normally apply for protective
clothing worn for work with lead.
Adequate and suitable washing facilities are required where operatives are exposed to lead.
Where employees are exposed to lead, washing and changing facilities provided should
allow them to meet a high standard of personal hygiene so as to minimise the risk of them
ingesting or otherwise absorbing lead.
The design of the washing facilities should be related to the nature and degree of exposure
to lead as indicated by the assessment. Where employees are significantly exposed to lead,
and if washbasins alone would not be adequate, the washing facilities should include
showers or baths.
An example would be where work is carried out in dusty conditions which could result in the
whole body being contaminated by lead. Then the provision of showers or baths would be
essential.
Washing facilities should provide at least:
et
it
ov
er
(a)
one washbasin for every five persons. Basins should be of sufficient size to permit
arms to be immersed up to the elbow
(b)
a constant supply of hot and cold or warm water (running water where reasonably
practicable)
(c)
soap or other cleaning materials
(d)
nail brushes
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7

Page 84
warm air dryers or roller towels; communal towels should not be used.
For certain types of work, such as lead work, carried out at premises or sites where such
work is not regularly done (for example, certain tank cleaning and lead burning operations),
mobile caravan type washing/showering facilities of suitable design should be provided.
Eating, drinking and smoking
These Regulations require Contractors to reduce the risk of ingestion of lead by ensuring
that employees do not eat, drink or smoke in places which are contaminated, or likely to be
contaminated, from lead arising from work activities. Therefore, Contractors should reduce
the risk of employees ingesting lead by ensuring that they are given adequate information on
the specific areas that might be contaminated by lead and in which they should not eat
(including chewing gum or tobacco), drinker smoke.
The information should be reinforced by displaying a prominent notice to identify those areas
in which employees may, or may not, eat, drink or smoke.
10
The following points should be noted:
rw
.l.
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clean areas, canteens or mess rooms should be isolated from lead-contaminated work
areas
(b)
protective clothing should be removed before entering these areas
(c)
washing should take place before eating meals or drinking
(d)
the Contractor must advise employees where they may not eat, drink or smoke
(e)
Employees are not to eat, drink or smoke in any place where there is risk of
contamination by lead.
et
it
ov
er
se
as
qa
ta
(a)
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1.2.6 Appendix 1
Lead hazards
Safety checklist
Has a risk assessment been carried out?
Have all persons who have to work with lead received adequate information, instruction and
training?
Has the nature and extent of any exposure to lead been assessed?
Is the monitoring of lead in air levels carried out?
Is medical surveillance of individuals necessary and, if so, undertaken?
If medical surveillance is necessary, are medical records kept as required?
Are measures in place to control levels of exposure to lead?
Is protective equipment and clothing in use, as necessary and required?
Is the correct type of respiratory equipment being used for the hazard being encountered?
10
Are measures being taken to control the spread of any lead contamination?
11
Is there adequate provision of washing and changing facilities?
12
Are separate areas provided for eating and drinking?
13
Are all operatives adequately trained in safe working procedures?
14
Are operatives aware of the risks to health that can arise from not working safely?
15
Are records being kept as required by these Regulations?
16
Are arrangements in place to deal with accidents, incidents and emergencies?
et
it
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er
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as
qa
ta
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1.2.6 Appendix 2
Specimen health surveillance record
Recorded details of an employee under medical surveillance because of exposure to lead
Employee's details
Name:
.l.
l
Permanent address:
rw
Place of birth:
ta
Date of birth:
as
qa
Sex:
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Doctor's details
er
Name:
ov
Address:
et
it
Telephone number:
Contractor's details
Name:
Address:
Telephone number:
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Employment details
Years exposed to lead before starting of
current employment:
Date of first exposure to lead in current
employment: (Day Month Year)
.l.
l
Date of end of exposure to lead in current

employment: (Day Month Year)
rw
Additional information
qa
ta
a) the reason for medical surveillance

b) the dates of initial and periodic medical surveillance
se
as
c) the results of clinical assessments
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er
d) the results of measuring blood-lead concentrations and

of any other biological tests in enough detail to allow
adverse trends to be identified, and
et
it
e) action taken, including periods moved to work not

involving exposure to lead, and periods of suspension.
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1.2.7
Manual Handling
1.2.7.1 Key points

1
Poorly thought out or badly performed manual handling activities are the cause of many
injuries to construction workers.
'Manual handling' includes lifting, lowering, pulling, pushing or carrying a load by physical
effort.
Several factors will determine whether it is safe for an individual to manually handle any
particular load.
Contractors must:
(b)
where that is not reasonably practicable, assess the risks to the employee;
(c)
put in place control measures to prevent such an injury occurring.
rw
.l.
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avoid so far as reasonably practicable their employees having to carry out manual
handling activities likely to result in an injury;
ta
Employees must:
make full and proper use of the Contractors safe system of work;
(b)
use (lifting) equipment and machinery in accordance with instruction and training
given;
(c)
report to the Contractor any situation where it is considered that the system of working
is not safe.
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Where sustaining an injury is a possibility and handling a load cannot be avoided, using a
mechanical means of carrying out the activity is the best solution.
Note:
Section 1, Part 9.2 of the QCS covers the manual handling of materials.
All construction and building work involves lifting and handling to some extent. Although
mechanical equipment should be used whenever practicable, much of the work will inevitably
continue to be done manually. The risk of injury can be greatly reduced by a knowledge and
application of correct lifting and handling techniques and by taking a few elementary
precautions.
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1
assessment of every work activity, including those that involve manual handling, to identify
any hazard to employees which might be encountered during their work, or to any other
person who might be affected by their operations.
measures into place, either to remove the hazard or, where this is not possible, to reduce the
risk of injury resulting from manual handling activities, as far as is reasonably practicable.
any (manual handling) risks that exist in the workplace and any control measures that are in
place to reduce those risks.
Employees, in turn, have a duty under these Regulations to inform the Contractor of any
work (manual handling) situation that presents a risk to themselves or others.
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1.2.7.4 Manual Handling Operations

1
These Regulations specify how Contractors have to deal with risks to the safety and health
of employees who have to carry out manual handling in the course of their employment, as
follows:
(a)
Assess the manual handling task to identify any risk that may be inherent in the
operation.
(b)
Avoid the need to carry out manual handling as far as possible.
(c)
Where a risk is identified, implement control measures to reduce that risk.
The requirements relevant to lifting and handling are described below.
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make a suitable and sufficient assessment of all such manual handling operations to
be undertaken by their employees.
(b)
take appropriate steps to implement control measures, thereby reducing the risk of
injury to those employees undertaking any manual handling operations, to the lowest
level which is reasonably practicable
(c)
take appropriate steps to provide any of those employees who are undertaking any
manual handling operations with general indications and, where it is reasonably
practicable to do so, precise information on:
(d)
the weight of each load
(e)
the heaviest side of the load whose centre of gravity is not positioned centrally.
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(a)
Any assessment that a Contractor has made must be reviewed where:

(a)
there is reason to suspect that it is no longer valid, or
(b)
there has been a significant change to the manual handling operations to which that
assessment relates.
Each Contractor shall, so far as is reasonably practicable, avoid the need for employees to
undertake any manual handling operations at work, that involve a risk of their being injured;
or where this is not reasonably practicable, each Contractor shall:
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Contractor's duties
Where changes to an assessment are required, as a result of any review, a Contractor shall
make them.
When determining for the purposes of these Regulations whether manual handling
operations at work involve a risk of injury, and to determine the appropriate steps needed to
reduce that risk, particular regard shall be taken to check:
(a)
the physical suitability of the employee to carry out the operation
(b)
the clothing, footwear and other personal effects worn by the employee
(c)
the employee's knowledge and training
(d)
the results of any relevant risk assessment carried out
(e)
whether the employee is within a group of employees identified by that assessment as

being especially at risk
(f)
the results of any health surveillance already carried out
Contractors must additionally:

(a)
provide safe systems and places of work
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(b)
ensure the safety of their employees and, where possible, the absence of risks in the
handling, storage and transport of all types of articles and substances
(c)
provide the information, instruction, training and supervision necessary to ensure the
health and safety of their employees.
Employee's duties
It is the duty of each employee, while at work, to:
(a)
make full and proper use of any system of work provided for use by the Contractor in
connection with manual handling.
(b)
Use any machinery or equipment provided by the Contractor in accordance with any
training or instruction received.
(c)
Inform the Contractor, or anyone else responsible for safety, of any dangerous work
practice or shortcomings in the Contractor's arrangements for safety.
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Designers have the potential to minimise the amount of manual handling that is necessary
during any construction project and therefore the injuries that might arise from it. Examples
of how this might be achieved are:
designing site layouts such that 'double handling' is eliminated and manual handling
distances are minimised
(b)
incorporating mechanical lifting points into components that would otherwise have had
to be manually handled into. place
(c)
taking advantage of technological advances by specifying modern components made

from lighter material
(d)
ensuring that designs allow for adequate access for construction plant, such as
excavators and dumpers, where excavation work and other earth-moving activities are
necessary.
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Strains and sprains to muscles and joints, torn ligaments and tendons, disc trouble
and hernias. These are often caused by sudden and awkward movements, for example,
twisting or jerking while lifting, or handling heavy loads. They are also caused by persons
attempting to lift loads beyond their physical capabilities. The muscles of the abdominal wall
are particularly vulnerable, and excessive strain may lead to ruptures.
1.2.7.6 Common injuries
(a)
Cuts and abrasions from rough surfaces, sharp or jagged edges, splinters, projections,
etc. Personal protective equipment and clothing should be worn as necessary, such
as leather gloves to protect the hands.
(b)
Back injuries are most frequently sustained while lifting and handling manually. They
may be the cumulative effect of repeated minor injuries, or the result of an abrupt
strain. Stoop lifting (see below) should be avoided; it greatly increases the chances of
sustaining back injuries.

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The risk of injury is reduced by a knowledge of correct lifting techniques and by not
attempting to lift excessively heavy loads without assistance.
Crushing of limbs, etc. by falling loads, or by fingers, hands or feet becoming

trapped by loads.
(a)
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Correct positioning of hands and feet in relation to the movement of the load is essential.
Timber wedges or other blocks should be used when beginning to raise or lower heavy loads
to enable a secure grip to be achieved and to prevent fingers and hands becoming crushed
when lowering the load. Safety shoes with steel toecaps will protect the feet. Soles of
footwear should also provide a secure grip.
1.2.7.7 Making an assessment

1
Completing the assessment is the Contractor's responsibility. Expert help may be needed in
difficult or unusual cases.
Often assessments can be done by a team of people and, although employees should not
make their own assessments, their involvement will often be beneficial.
A Contractor should make provision for properly trained manual handling assessment teams,
but if there are special difficulties and it is decided to call in outside assistance, the
Contractor should ensure that the person engaged is competent to make the type of
assessments required and that clear instructions are given.
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The wide range of manual handling tasks that arise on every building and construction site
need to be fully identified. This should be systematically carried out by looking at individual
tasks and the way in which they are carried out.
By grading these factors, e.g. low/medium/high, the assessor will be able to more clearly
identify the overall risk.
Whilst carrying out the assessment, the assessor should consider ways of reducing any risk
found.
An assessment should not just be a paper exercise but should be used to pinpoint the
unsafe features of the work task, so that the Contractor may improve the situation, by
implementing control measures.
It is quite acceptable to group any manual handling tasks which have common features into
a single manual handling assessment, but care must be taken to ensure that the range of
risks is common to all tasks covered by the single risk assessment. However, when taking
this approach, it can be tempting to make a task fit the assessment rather than make the
assessment fit the task. The important thing is to identify any risk of injury, and then point the
way to practical improvements.
Significant findings should be recorded and kept, but this is not necessary if the findings are
obvious and the assessments easily repeated.
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1.2.7.8 Lifting capacities
The weight that can be lifted by any individual will vary according to personal physique, age,
condition and practice, and the techniques employed. Lifting capacity declines with age and
an older person may not be capable of lifting the same load as a younger person; this,
however, can be offset to some extent by employing a better technique.
The general rule is that the load should not be lifted if it causes a feeling of strain. Assistance
should be available if required, and employees must not be required to lift loads beyond their
capacity.
Youthful exuberance and bravado often tempt younger employees to attempt to lift loads that
are too heavy. While they may succeed in the short term, long-term damage may be done to
the ligaments, muscles and back.
If single person handling is needed, either blocks or other materials of 20 kg or lighter should
be specified and used, or other precautions should be implemented to reduce the risk by, for
example, the provision of mechanical handling.
With blocks or other materials weighing less than 20 kg, manual handling risks are still
significant and suitable precautions should be taken to minimise these risks as much as
possible.
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1.2.7.9 Abdominal belts

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Research has shown that abdominal belts do not necessarily prevent manual handling
injuries and may, in some cases, make things worse.
1.2.7.10 Preparing to lift

1
Before lifting and handling any load, the following points should be established:
(a)
What has to be moved?
(b)
Does it really have to be moved?
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(c)
What does it weigh?
(d)
Can it be broken down into smaller loads?
(e)
Can the process that requires it to be moved be changed?
(f)
Where is the load's centre of gravity?
(g)
Can it be safely handled by one person?
(h)
Will assistance be required?
(i)
Can the move be carried out more safely with mechanical assistance?
(j)
How far does it have to be moved and from where to where?
(k)
Is the route clear of obstructions?
(l)
Can it be put down safely?
Suitable protective clothing should be worn. This may include gloves, safety footwear, safety
helmets, and special overalls if hot or corrosive substances are to be carried.
Ensure that the lifting and lowering areas are clear of tripping hazards, and likewise check
the route over which the load is to be carried.
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1.2.7.11 The load
Large, heavy loads should, if possible, be broken down into smaller, lighter and more
manageable sizes. It is obviously easier to lift 10 kg five times than to try and lift 50 kg once.
Where the load has to be moved by a woman, the weight should be reduced by
approximately 30%.
As a rough guide, where lifting is repetitive, weights should be reduced as follows:
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Special factors in operation
Rough guide
Reduce weight by 30%
Operation repeated five to eight times a minute
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Operation repeated once or twice a minute
'Average' female
Operation repeated more than 12 times per minute
Handler twists through 45 degrees
Handler twists through 90 degrees
Handler seated and twisting
Less than 5 kg
Handler seated
About 5 kg
About 25 kg for starting or

Pushing or pulling a load (assuming that force is applied with
stopping a load About 10 kg
hands between knuckle and shoulder height)
for keeping a load in motion
The size and shape of a load may be as significant as its weight in determining whether
assistance is required. Large awkward loads, which require the arms to be extended in front
of the body, place more strain on the back and abdomen than compact objects carried close
to the body.
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The absence of natural or designed handling points can also make it difficult to raise and
carry objects without strain and may require barrows or other lifting and handling aids.
Not all loads need to be carried, of course. It may be easiest to roll or push them, depending
on the contents. Even so, assistance might still be required to avoid the risk of injury.
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1.2.7.12 Kinetic method of lifting
Kinetic handling must be taught by trainers. It cannot be 'picked up'. It is important that
postural errors are corrected during training before bad habits are established.
The main features of this method are that it:

utilises the strong leg and thigh muscles - not the weaker back muscles as in stoop
lifting
(b)
maintains the natural shape of the spine throughout the lift. Although the body may be
bent over, the spine remains straight
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(a)
uses the momentum of body weight to initiate forward movement.
(c)
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The correct posture (such as the position of various parts of the body) in performing a task is
essential. Important points are:
(a)
correct position of feet
(b)
knees bent
(c)
straight back
(d)
arms close to body for lifting and carrying
(e)
correct grip or hold
(f)
chin in, head up
(g)
use of body weight.
Some lifting and handling techniques employing the kinetic method are described on the
next page.
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Bend at the knees (1)

5
The weight to be lifted must be within the lifting capacity of the individual worker and the load
should be approached squarely, facing the intended direction of travel. The feet are
positioned about a hip's width apart, one foot SLIGHTLY in front of the body. The knees are
bent and the body lowered as close to the load as possible while remaining relaxed and
balanced. The back should be straight from hips to shoulders, but not necessarily vertical.
Grasp the load (2)
The load is tilted with one hand (if necessary) so that the other hand can obtain a secure grip
at the corner nearest the body. The free hand is then transferred to the furthest corner of the
load and drawn as close to the trunk as possible. Arms should be well tucked in to provide
maximum support to the load.
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Lift, using the legs (3)
The load can then be lifted by straightening the legs so that the body and load move
upwards in unison. All movements should be smooth and natural. Jerking, twisting or
straining movements should be avoided.
Lifting should feel comfortable. Lifting movements will remain smooth and natural providing
the back and head are kept naturally erect. This is achieved by looking straight ahead when
straightening the legs, instead of looking down at the load.
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Carrying the load (4)
The load should be held firmly into the body and carried to where it is to be deposited. The
closer the centre of gravity of the load can be kept to the body, the easier and more natural
the lift. It is important to be able to see over or around the load so as to avoid tripping
hazards.
10
When the weight is approaching the maximum lifting capacity of the individual, it will be
necessary to lean back on the hips with the load to bring the trunk to the erect position
before straightening the legs to lift the load. In this instance the body is being used simply as
a counterbalance to keep muscular effort to a minimum.
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1.2.7.13 Changing grip

1
Grips should not be changed while carrying the load. First

rest the load on a ledge or other firm support, then change
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the grip if necessary.
1.2.7.14 Stacking
1
Loads should not be lifted above shoulder height. When it is impossible to lift and stack with
the elbows tucked into the sides of the body, a platform should be used to stand on. An
intermediate platform should also be used when lifting loads down from a higher level.
1.2.7.15 Use of a lifting platform

The squat position is adopted as near to the load as possible. Keeping a straight back and
using the leg muscles, the load should be lifted onto a platform. The person lifting the load
then stands as near to the platform as possible and, bending at the knees and hips (NOT the
back), eases the load onto their shoulder, adjusts for balance and straightens at the knees
and hips.
For lowering the load, the procedure is reversed.
Carrying a load under one arm, supported on the hip, causes strain and should be avoided.
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1.2.7.16 Hand hook or lifting aids
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Hand hooks or lifting aids should be used if loads are unwieldy or so irregular in shape that a
good grip cannot be maintained. If hooks are being used, care must be taken to ensure that
the contents of the load are not damaged.
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1.2.7.17 Team lifting
When large or awkward weights are involved, assistance should be sought. The person
assisting should be of similar height and build, so that the raised load does not become
unbalanced or unevenly distributed.
Co-ordinating team activity is important in team lifting. One person should give directions
during all lifting, carrying and lowering operations.
Properly designed lifting aids will enable some tasks to be performed more quickly and
easily, and eliminate the risk of injury or damage.
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1.2.7.18 Using rollers to move a load

1
Lengths of steel pipe or proper rollers can be used to roll or slew heavy crates. The load is
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pushed gently forward on two or more rollers, and further rollers are inserted under the front
end as necessary.
Care must be taken by the person placing the rollers to avoid being trapped as the load
moves forward, and to ensure that those pushing do not trip over the rollers that have
previously been used.
Whenever practical, mechanical handling and lifting should replace manual techniques. This
will reduce the risk of fatigue, improve efficiency and reduce the risk of accidents.
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1.2.7 Appendix 1
Safety checklist
Manual handling and lifting
Preparation
What is being lifted?
Where to and how far?
Has a manual handling risk assessment been carried out?
Would mechanical means be more practical or appropriate?
Is the operation part of a routine? If so, could it be more effectively planned and executed?
How many people will be needed to move the load safely?
Are they all trained in kinetic lifting and handling?
Are proper (kinetic) lifting methods being employed?
What methods and equipment will be required?
10
Is the required equipment available?
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Is the lifting and handling area clear of hazards?
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Lifting and handling
Is the proper personal protective clothing in use?
Is co-ordination satisfactory in dual and team lifting with one person taking charge of the lift?
Is the necessary equipment in use or to hand?
Are excessively heavy weights being lifted?
Are loads being deposited or stacked safely and securely?
Is adequate supervision employed where necessary?
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After lifting and handling

Are any incidents or accidents reported and recorded?
Where injuries have been sustained, has medical attention been sought?
Is the damage or loss of equipment recorded?
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1.2.7 Appendix 2
Manual handling of loads: Assessment checklist
Section A - Preliminary
Task name:
Is an assessment needed? (An assessment will be

needed if there is a potential risk of injury, eg if the
task falls outside the guidelines) Yes/No*
Task description:
Load weight:
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Frequency of lift:
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Carry distances (if applicable):
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Are other manual handling tasks carried out by

these operators?
Assessment discussed with employees/safety
representatives
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* Circle as appropriate
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If 'Yes' continue. If 'No' the assessment need go no further.
Diagrams (other information including existing

control measures):
Locations:
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Operations covered by this assessment

(detailed description):
Personnel involved:
Date of assessment:
Overall assessment of the risk of injury?

* Circle as appropriate
Low/ Medium/ High*
Make your overall assessment after you have completed Section B.
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Section
Part
1.02: Occupational Health and Hygiene (Regulatory Document)
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Section B: Lifting and carrying - More detailed assessment, where necessary

If yes, tick appropriate
level of risk
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Questions to consider:
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Low
er
Do the tasks involve:

holding loads away from trunk?
twisting?
stooping?
reaching upwards?
large vertical movement?
long carrying distances?
strenuous pushing or pulling?
unpredictable movement of loads?
repetitive handling?
insufficient rest or recovery?
a work rate imposed by a process?
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Are the loads:
heavy?
bulky/unwieldy?
difficult to grasp?
unstable/unpredictable?
intrinsically harmful (eg sharp/hot)?
Med
High
Problems occurring from the task (Make rough

notes in this column in preparation for the possible
remedial action to be taken)
Possible remedial action e.g. changes to be made to the

task, load, working environment etc. Who needs to be
involved in implementing the changes?
.
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Section
Part
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If yes, tick appropriate
level of risk
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Low
er
Consider the working environment - are there:

constraints on posture?
poor floors?
variations in levels?
hot/cold/humid conditions?
strong air movements?
poor lighting conditions?
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Consider individual capability - does the job:
require unusual capability?

pose a risk to those with a health problem or
a physical or learning difficulty?
pose a risk to those who are pregnant?
call for special information/training?
Med
High
Problems occurring from the task (Make rough

notes in this column in preparation for the possible
Possible remedial action e.g. changes to be made to

the task, load, working environment etc. Who needs to
be involved in implementing the changes?
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Section
Part
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Yes/No
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Other factors to consider
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Is movement or posture hindered by clothing

or personal protective equipment?
Is there an absence of the correct/suitable
PPE being worn?
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Protective clothing
Yes/No
Yes/No
Work organisation (psychosocial factors)
Yes/No
Do workers feel that there is poor /

communication between managers and
employees (eg not involved in risk
assessments or decisions on changes in
workstation design)?
Yes/No
Are there sudden changes in workload, or

seasonal changes in volume without
mechanisms for dealing with the change?
Yes/No
Do workers feel they have not been given

enough training and information to carry out
the task successfully?
Yes/No
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Do workers feel that there has been a lack of

consideration given to the planning and
scheduling of tasks/rest breaks?
Problems occurring from the task (Make rough notes Possible remedial action e.g. changes to be made to
in this column in preparation for the possible
the task, load, working environment etc. Who needs
to be involved in implementing the changes?
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Section C - Remedial action to be taken
Remedial steps that should be taken, in order of priority: Person responsible for
implementing controls
Target implementation Completed

date
Y/N
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Date by which actions should be completed:

Date for review of assessment:
Assessor's name:
Signature:
TAKE ACTION ... AND CHECK THAT IT HAS THE DESIRED EFFECT
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1.2.8
Asbestos in the Workplace
1.2.8.1 Key points

All asbestos-containing material (ACM) is hazardous when airborne and dangerous when
fibres are inhaled.
Before any work with asbestos is carried out a written risk assessment must be made.
The priority for any Contractor is to prevent exposure to, and spread of, asbestos.
A written, site specific plan of work must be kept on site and followed.
Anyone who does any work with asbestos must be specifically trained to do it, and this
training must be repeated annually.
Do not forget other hazards besides asbestos, e.g. working at height or in a confined space,
when working with/removing asbestos.
Note:
Section 1, Part 9 of the QCS covers manual handling of materials.
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The key is a risk assessment, which needs to be carried out by someone who is competent
in terms of:
(a)
working with asbestos
(b)
the requirements of these Regulations
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Asbestos is a risk to health when airborne fibres are breathed in. The greater the number of
fibres, and the longer the period over which they are breathed in, the greater the risk of
incurable asbestos-related diseases developing. These include cancers in the lungs and
chest lining.
However, asbestos that is in a good condition, which is not damaged and is not likely to be
worked on or disturbed, does not pose any immediate problem.
Although asbestos building materials and products have been largely replaced by safer
alternatives, there remains the issue of the ongoing and long-term management of existing
asbestos where its removal is not practicable.
Locating and identifying asbestos can be difficult, as its appearance may be changed by
surface coatings, heat or ageing. It may also be encapsulated by, or be concealed beneath,
other materials. Past uses of asbestos include:
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Insulation and sprayed coatings using moulded or pre-formed lagging

6
boilers, plant and pipework
fire protection to steel work
thermal and acoustic insulation of buildings, including loose packing

Insulation board
fire protection to doors
10
claddings on walls and ceilings
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11
partitioning
12
ceiling tiles
13
fire breaks in ceiling voids
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Asbestos cement
corrugated roof sheets
15
flat sheets for cladding and partitions
16
roof and rainwater drainage goods
17
underground pipes
18
bath panels
19
artificial roof slates
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Other uses
vinyl or thermoplastic floor tiles
21
insulation of electrical equipment
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some textured coatings
23
bakelite sanitary ware, and other products.
24
Asbestos-based friction materials were widely used in brake and clutch linings in vehicles
and plant, together with gaskets and packing in engines and heating or ventilation systems.
Substitute materials have been developed in most cases.
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1.2.8.3 Types of asbestos and its identification
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Asbestos is a naturally occurring fibrous silicate mineral material, which does not burn and is
resistant to most acids and alkalis. The fire protection and insulative properties of asbestos
were the main reason for its use over the years. Three main types of asbestos have been
used in the construction industry:
(a)
chrysotile (white)
(b)
amosite (brown)
(c)
crocidolite (blue).
Although the colours are often used to differentiate between the different types of asbestos,
the actual colour of a material suspected of being asbestos is not necessarily an accurate
indication as to whether or not it is asbestos or an asbestos-containing material, or if it is, of
what type.
Changes in colour may occur due to:

(a)
it ageing or simply becoming dirty
(b)
the effects of heat
(c)
surface coatings being applied
(d)
encapsulation
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oil or chemical splashes.
The type of asbestos used in the lagging of boilers can be particularly difficult to identify
visually. Repairs and modifications can mean that boilers or pipework may be lagged by a
mixture of different types of asbestos.
Asbestos was widely used as fire protection in building materials, for thermal insulation and
also as a sprayed coating to steel structural members. All of these uses now present
significant management issues associated with the maintenance of the asbestos over the
remaining life span of the building, or the removal of the asbestos during renovation,
refurbishment or demolition.
Working with, among, or alongside asbestos materials demands stringent control, and
compliance with recommended precautionary measures and methods of work.
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1.2.8.4 Control of Asbestos
Risk assessment - an assessment of risk carried out by someone with both the theoretical
background and practical experience of the intended work with asbestos-containing
materials.
While a competent construction manager may be able to form an opinion as to whether a

material may be asbestos or an asbestos-containing material, the decision as to who can do
the work, and the standards that the work should be carried out to, are likely to require
specialist advice.
If you are a contractor working on someone else's premises, you should be given information
about the presence of asbestos and what they expect you to do about it. If you are not
given this, you should not start work.
Note 1. This requires a survey by a competent person. If representative samples are needed
for laboratory analysis, this may well be a task for a competent technician. Where multiple
samples are taken, each sample and the sample point should be numbered. If samples are
being sent for analysis, it is a requirement that any laboratory carrying out analysis has the
necessary facilities, expertise and quality control procedures. Any samples should be well
sealed, for example inside two zip lock plastic bags.
Note 2. If in doubt presume that the material is asbestos or ACM until you can prove that it is
not. It is better to 'overprotect', than to expose employees and others to asbestos.
Note 3. A plan of the premises showing where the materials are will always be extremely
useful, and will be essential in larger premises. Such a plan would form an integral part of
the ongoing management of the asbestos or ACM.
Note 4. A risk assessment should be undertaken by a competent person who has sufficient
knowledge of the subject.
If the materials are in good condition, not liable to be damaged, and will not be disturbed or
worked on, then the risk is probably low. If the materials are flaky, crumbling, in a place
where they can be damaged by, for example, forklift trucks, then the risk is high. Given the
known ill health caused by asbestos, then a high risk of damage calls for urgent actions.
Note 5. This could be work by your employees, or any contractors or subcontractors brought
in for carpentry, flooring, partitioning, ceiling fixing, plumbing, electrical or other work.
10
Note 6. If material is not going to be removed by an asbestos removal contractor, consider

how you are going to manage the long-term presence of the asbestos. If it is in good
condition and not liable to be damaged, then routine inspection and monitoring may be
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enough if records are kept. A sealing coat may be needed, or other protective works
necessary, to lower and to further control the risk.
Note 7. Make it happen by putting your plan into action. What is the organisation, what are
the arrangements for the implementation of the plan and who has the responsibility?
12
Note 8. A regular review of the action plan will ensure that it is working that the control
measures are still effective, and that inspection, monitoring and recording are in fact taking
place. It may be the case that procedures, notices and policies that have been in place for a
length of time tend to be overlooked. A fresh approach may therefore be needed.
13
Note 9. Part of this information will be the signs that will have been placed to identify the
asbestos or ACM. In a large workplace or premises, this may also mean keeping a register
that describes every individual room or workplace and the asbestos or ACM that is in there.
This means that visiting subcontractors can be told exactly what asbestos or ACMs to expect
in the areas in which they will be working.
14
These Regulations also impose duties on Contractors for the protection of employees who
may be exposed to asbestos at work, and other persons affected or who may be at risk of
being affected by such work.
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1.2.8.5 Representative sampling
To confirm or identify the type of asbestos or ACM on the premises, a series of samples may
have to be taken for laboratory analysis. Methods employed in taking samples of asbestos
will vary according to its type and location. Guidance on taking samples is available in the
UK publication MDHS100.
Anyone removing samples for analysis must be competent to do so and use appropriate
protective clothing and respiratory equipment, particularly if the work involves cutting, boring,
drilling or otherwise creating airborne dust or fibres. Precautionary measures to be observed
include:
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no people, other than those taking the sample, to be in the area
(b)
the area from where the sample is to be taken should be dampened using a 'killer
spray'
(c)
a knife, core borer or hand drill should be used to place the sample in a suitably
labelled, scalable container. Do not use any tools that will create airborne fibres
(d)
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(a)
(e)
any disturbed or damaged surfaces should be sealed after a sample has been taken.
other surfaces on which asbestos dust may fall should be covered with an impervious
sheet. The area should be subsequently cleaned by using a dustless method, e.g. a
damp cloth, which should be disposed of in a sealed polythene bag
The results of the analysis will determine what action should be included in the management
plan.
1.2.8.6 Asbestos surveys

1
All asbestos surveys must be carried out by a competent person who can demonstrate the
following:
(a)
evidence of their training and experience in such work
(b)
types of survey outlined below they are qualified to carry out
(c)
that they are going to carry out the survey in accordance with the HSE guidance
MDHS100
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If an individual surveyor is to be appointed, a check should be made as to whether they have

personnel certification for asbestos surveys from a certification body which has been
approved by a recognised accreditation body under the standard ISO 17024,
All surveys should be subject to a quality assurance process. It is important to note that ISO
9000 accreditation is not the correct standard for assessing asbestos surveys. ISO 17020 is
the relevant standard.
The competence schemes are:

The United Kingdom Accreditation Service UKAS. This is accreditation by the United
Kingdom Accreditation Service against ISO 17020, and is normally held by an
organisation such as the surveying division of a licensed contractor or an asbestos
laboratory. www.ukas.org.uk
(b)
National Individual Asbestos Certification Scheme (NIACS) is a scheme jointly run by

the Asbestos Removal Contractors Association and the Royal Institute of Chartered
Surveyors. It accredits individual surveyors. www.niacs.org.uk
(c)
Asbestos Building Inspectors Certification Scheme (ABICS) is a scheme run by the

British Occupational Hygiene Society. It also accredits individual surveyors.
www.bohs.org/standardTemplate.aspx/Home/Professional/ABICS
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(a)
A UKAS or equivalent laboratory should have carried out all analysis of asbestos samples.
Three types of survey are defined within HSE's publication MDHS 100:
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Type 1 - presumptive survey - during which the surveyor does not take any samples.
Instead, using their skill and judgement alone, the surveyor identifies materials as
containing asbestos or not. The survey is of the asbestos risks that the building poses
to its occupants in normal use.
(b)
Type 2 - sampling survey - the surveyor makes use of sampling and subsequent
laboratory analysis to confirm whether or not a material contains asbestos. The survey
is of the asbestos risks that the building poses to its occupants in normal use.
(c)
Type 3 - invasive survey - the surveyor samples and breaks into the structure and
fabric of the building to try to find the asbestos-containing materials, before a
contractor does so in the course of their work.
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(a)
Anyone applying the results of a survey should initially check if the surveyor has written any
caveats on the survey. It is common to exclude access to areas which are over 3 metres
above ground level, as it is not possible for a single surveyor to safely use a ladder higher
than this because they cannot foot it. There may be other areas that have not been
accessed.
Asbestos surveyors are taught to identify the 'spaces' where asbestos is likely to be found
and to survey accordingly. The meaning of 'spaces' can be anything from a boiler room, to a
roof void, an office, an underground duct, a cavity between the two leafs of a wall or
anywhere else that asbestos or an asbestos-containing material might have been used.
A 'no access' comment on an asbestos report could be simply because:
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(a)
the door of a room was locked and the surveyor could not gain entry
(b)
the 'space' was an underground duct and a mini digger was required to lift the covers
(c)
a suspended floor had no access other than by destroying the floor
(d)
the electrical system being live during the survey.
To understand the difference between a Type 2 and Type 3 survey, the simplest explanation
is to consider a studwork wall which forms a firebreak. It was originally covered in asbestos
insulation board and then covered over with plasterboard. In a Type 1 and Type 2 survey,
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the surveyor would correctly identify the outer surface as being plasterboard.
During these surveys there would be no need to carry out any invasive testing and therefore
the asbestos insulation board lies undiscovered. Type 3 surveys would be invasive and the
surveyor would be expected to check under the plasterboard for other materials. In the
previous case, if a building contractor only commissioned a Type 2 survey upon which to
plan their work, they may find the asbestos insulation board unexpectedly. Invasive checks
must be made before invasive work is carried out.
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Just because the surveyor did not find any asbestos does not mean that there is no asbestos
present. In all cases it is important to remember that surveying is as much an art as a
science and there will be mistakes. There are also some asbestos-containing materials
which would only be found by luck rather than judgement, for example, asbestos cement
shuttering in a slab, or asbestos insulation board used as packers inside a stud work wall. It
is important to be wary of unidentified building products and for everyone to have sufficient
asbestos awareness training. There should also be management who are in a position to
stop work if necessary and question the presence of any 'funny looking plasterboard' found.
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1.2.8.7 Working with asbestos
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A Contractor who carries out any work in a building or structure is required to:
make a suitable and sufficient assessment as to whether asbestos is, or is liable to be,
present in the premises where work is being carried out. Under CDM, the client has a
duty regardless of the size of the project to provide information such as the presence
of asbestos
(b)
note that:
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(a)
this information should normally be in the form of Type 3 surveys as defined in

the HSE publication MDHS 100 for most invasive construction work
(ii)
any information on the presence of asbestos supplied by the client based upon
a Type 2 survey, must be closely scrutinised to ensure that the construction
work will not disturb more of the structure than the surveyor checked
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Requirements of the Regulations
identify that the material does not contain asbestos or assume it contains brown or blue
asbestos
ensure that a competent person carries out an assessment to decide the likely exposure for
the proposed work methods.
prepare a suitable written plan of work
provide adequate information, instruction and training, for employees and others
ensure that training is repeated on an annual basis for any work with asbestos
prevent or reduce asbestos exposure to the lowest level reasonably practicable by means
other than the use of respiratory protective equipment (RPE), for example use an asbestos H
class vacuum cleaner or other fibre suppression techniques
ensure the proper use of respiratory protective equipment and that face-fit testing is carried
out
maintain respiratory equipment in a clean, efficient state, good order and repair. Regularly
examine and test exhaust ventilation equipment
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provide adequate and suitable protective clothing and ensure that it is cleaned or disposed of
appropriately
11
prevent the spread of asbestos from the workplace
12
ensure premises and plant involved in work with asbestos are kept clean
13
monitor the air where employees are exposed to asbestos and keep suitable records for a
specific period
14
ensure that air monitoring is only carried out by a UKAS or equivalent accredited laboratory
15
provide washing and changing facilities that are adequate and suitable for employees
exposed to asbestos, and storage for protective clothing and personal clothing (not worn
during working hours)
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Asbestos areas and respirator zones
Where an asbestos removal contractor is undertaking the removal of asbestos, in order to

ensure that people other than those involved in asbestos work are not exposed to asbestos
by entering 'asbestos areas', such areas should be designated and clearly identified, using
notices.
17
Areas where the removal contractors are working, and where control limits for exposure to
airborne fibres are liable to be exceeded, will be designated as respirator zones to ensure
that only removal contractors wearing respiratory protective equipment are allowed to "
enter.
18
Contractors with asbestos removal contractors on their premises should strictly prohibit entry
into these areas by their own employees.
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Asbestos removal contractors must ensure that their employees, who are liable to be
exposed to asbestos, are under regular medical surveillance by an employment medical
adviser or appointed doctor.
20
Medical examinations should be provided before work with asbestos starts and at prescribed
periods thereafter, currently every two years.
21
Health records containing information on medical examinations have to be maintained and

kept for 40 years after the date of the last entry.
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Washing and changing facilities

22
Asbestos removal contractors must provide adequate and suitable washing and changing
facilities for their employees. Where protective clothing and respiratory equipment are in use,
storage must be provided for contaminated items.
23
Separate storage must be provided for personal clothing not worn during working hours.
Storage, dispatch, labeling of asbestos waste
24
Asbestos waste is considered to be of two types - combined or fibrous. Combined was

previously called bonded and effectively the asbestos is well bound into the material. Roofing
felt, vinyl floor tiles and most asbestos cement is categorised as combined. Asbestos
insulation board, pipe lagging and sprayed coating are fibrous. Professional advice may be
needed to ensure that the waste is correctly categorised.
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25
There is no requirement to bag or wrap asbestos cement sheets, or gutters removed

externally, where they can be placed straight into a suitable skip. The skip should be secured
if it is left overnight. It is good practice to bag or wrap waste from internal work to guarantee
that when the waste is carried outside there will be no asbestos debris dropped. If a van is
being used to carry asbestos waste, the material must be double bagged and the bags
secured by putting them in a lidded bin, for example.
26
Any fibrous asbestos removed should be sealed in proper containers and correctly marked
before despatch. Typically, this will be double-bagged with the inner bag being red and the
outer clear.
27
Containers should be designed and constructed so as to retain the asbestos without any
spillage or loss during normal handling.
Labelling of asbestos waste and used protective clothing

Where the asbestos removal contractor uses labels on waste or removed asbestos, the label
must be clearly and indelibly printed so that the words in the lower half can be easily read.
These words must be printed as specified in the diagram.
29
The label has to be firmly affixed to the packaging using an adhesive type label, or directly
printed onto the packaging (plastic bag).
Labelling requirement
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Disposal of removed asbestos

30
In essence, there is a duty of care put on everyone in the waste disposal chain. Clients,
whether they are at work or domestic, have a responsibility to ensure that the waste is
disposed of correctly. They can be prosecuted if the waste is fly tipped. Where asbestos has
been removed as part of a project, a prudent contractor would ensure that proof of disposal
formed part of the information that was given to the client.
Other aspects
31
Concerns regarding aspects of health and safety that are often associated with working with
asbestos, such as working at height, the risk of fire, working in confined spaces, the use of
machinery, burning, cutting and lifting. It is important not to view asbestos as a hazard in
isolation.
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1.2.9
The Control of Dust and Fumes
1.2.9.1 Key points

The inhalation of dust or fumes has the potential to cause severe respiratory illness.
Asbestos fibres and lead dust are particularly hazardous if inhaled.
The dust of some types of wood can be irritating to the skin.
The creation of airborne dust or fumes should ideally be prevented although this is often not
possible in a construction site environment.
Where the prevention of dust or fumes is not possible, the extent of exposure must be
controlled to a level that is safe.
Control of dust can be achieved by the:
(b)
collection of dust in 'collector bags' attached to powered hand tools
(c)
wet cutting of solid materials such as thermal blocks, bricks or ceramic tiles
(d)
where practical, carrying out of work activities in the open air rather than in enclosed
spaces.
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Hazardous fumes usually result from:
processes in which materials are heated, such as welding, lead burning or grinding
(b)
uncontrolled use of substances such as solvents and adhesives
(c)
the use of equipment and plant powered by internal combustion engines.
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(a)
Section 1, Part 15.2.3 of the QCS covers the control of dust.
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Note:
The exposure of employees to airborne dust or fumes can result in severe respiratory
illnesses, such as occupational asthma. Such diseases can be totally disabling, causing
those affected to give up work or change their employment. Exposure of the skin to some
hazardous dusts can result in severe irritation and ulceration of the affected areas.
1.2.9.3 Dust
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extraction of dust and fumes through stand-alone extractor units
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Dust is the name for a mix of tiny solid particles. It consists of a wide mix of components. In
the construction context, the mix will reflect the work activities.
It is widely known that almost any excess levels of dust can cause health problems. Harmful
effects range from simple skin irritation to severe respiratory illness.
Not all harmful dusts are visible. Dusts that are too fine to be seen by the naked eye are the
cause of many serious health problems. Like most occupational health problems, it can take
several years for symptoms of ill health to manifest themselves.
Skin irritation, dermatitis and ulceration can be caused by contact with some types of dusts.
Other types of dust, being soluble, may be absorbed through the skin via cuts and abrasions.
The inhalation of dust can cause wheezing, coughing, breathlessness, bronchitis, nasal and
other types of cancer. Dust also contains bacteria and viruses and therefore has the
potential to cause stomach disorders. These can result from ingesting airborne dust or from
eating food with contaminated hands.
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Such problems are not likely to arise if occupational exposure limits are not exceeded and
safe systems of work are maintained.
1.2.9.4 Fumes
1
Hazardous fumes can be produced when some building materials are heated or otherwise
worked. A common form of respiratory illness, which has flu-like symptoms, is caused by the
inhalation of welding fumes. Other sources of hazardous fumes are:
(a)
uncontrolled exposure to liquid substances such as solvents or paints
(b)
the use of equipment and plant which is powered by internal combustion engines.
1.2.9.5 Health and Safety at Work (Construction Sites)
Contractors must provide and maintain plant and systems of work that are safe and
without risks to health.
(b)
Contractors must make arrangements for safe handling, storage, and transport of
(c)
Contractors must provide adequate information, instruction, training and supervision.
(d)
Contractors have a duty to ensure persons not in their employment are not exposed to
risks to their health and safety.
(e)
Persons in control of premises must use the best practicable means to ensure that
noxious or offensive substances do not enter the atmosphere
(f)
Contractors must not charge an employee for personal protective equipment that is
provided in accordance with statutory requirements relating to health and safety.
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Employees have a duty to:
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(a)
exercise reasonable care for their own health and safety and that of others who may
be affected by their acts or omissions; to co-operate with their Contractor in enabling
him or her to carry out his or her duties under the relevant statutory provisions
(b)
not intentionally or recklessly interfere with, or misuse, anything provided in the

interests of health, safety and welfare.
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The relevant provisions are as follows.

1
These Regulations place a legal duty on every Contractor to make a suitable and sufficient
assessment of every work activity to identify any hazard that employees or any other person
might encounter as a result of the work being carried out.
measures in place to either eliminate the hazards or, where this is not possible, reduce the
risk of injury or ill health resulting from those hazards, so far as is reasonably practicable.
Where a hazard is identified that requires it, the Contractor must offer appropriate health
surveillance to employees. This must take into account all the risks to their health and safety
that have been identified.
the risks that exist in the workplace and inform them of the control measures that are in
place to reduce those risks.
Employees, in turn, have a duty under these Regulations to tell their Contractor of any work
situation which presents a risk to the health and safety of themselves and to any other
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person who may be affected.

6
These Regulations require that Contractors assess the health risks to their employees
arising out of exposure to hazardous dusts and fumes, and, if reasonably practicable, put
control measures in place to eliminate the work processes and the use of substances that
cause exposure. If this is not reasonably practicable, Contractors must:
(a)
control exposure to an acceptable level, and
(b)
inform employees of the hazards involved and the control measures in place
(c)
mitigate the effects of any exposure by providing health surveillance where necessary.
1.2.9.7 Control of Substances Hazardous to Health

When dust is inhaled, the body's defence mechanisms can usually deal with the larger
particles. However, they struggle to cope with the very small particles. In occupational
hygiene terms, dust is divided into two categories:
(b)
the much smaller particles which are called 'respirable dust'.
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inhalable dust, sometimes called 'total dust', and
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Because dust is a mix of very small particles, all dusts have been assigned a concentration
in air above which they are considered hazardous. It is important to remember that this
applies to all dusts, for example those caused by:
sweeping a dusty floor
(b)
clearing out a building
(c)
driving plant on dusty sites
(d)
mixing sand and cement to make mortar
(e)
sanding down Medium density fibreboard (MDF) or timber.
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The technical descriptions of the two types of dust are:

(a)
total inhalable dust approximates to the fraction of airborne material that is inhaled and
is available for deposition in the respiratory tract
(b)
respirable dust approximates to the fraction of airborne material that is inhaled and
penetrates to the gas exchange region of the lung (the alveoli).
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Any concentration of an inhalable dust in excess of 10 milligrams of dust per cubic metre of
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air (10 mg/m ) averaged out over eight hours, or any respirable dust in excess of 4 mg/m
averaged over eight hours, is deemed to be a substantial concentration of dust and therefore
within the definition of a substance hazardous to health.
The official list of exposure limits is updated periodically and published in the Health and
Safety Executives Guidance Note EH40. The most recent edition is EH40/2005. This has
been supplemented by a table on HSE's website, which is updated more frequently and has
the up-to-date list of workplace exposure levels:
www.hse.gov.uk/coshh/table1.pdf
This lists specified workplace exposure limits (WEL) for a number of dusts, in addition to
other substances. Dusts are therefore classified as substances that are hazardous to health.
Further guidance on the health hazards posed by dust is included on pages 29-31 of
EH40/2005.
The principal points of these Regulations place requirements on the Contractor to protect
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employees, or any other persons who may be affected by their operations, by:
(a)
assessing the health risks created by work involving substances hazardous to health.
(b)
ensuring that the exposure of employees or others is prevented or adequately

controlled, by putting in place any measures necessary to control the exposure to risks
(c)
ensuring that any control methods provided are properly used and maintained, and by
monitoring the work environment as necessary
(d)
carrying out health surveillance in specified circumstances
(e)
providing information, instruction and training for employees on the risks to health and
precautions to be taken regarding any work with substances hazardous to health
(f)
providing procedures for dealing with accidents, incidents and emergencies, including
first-aid and safety drills.
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Designers have the potential to eliminate or reduce the exposure of operatives, and possibly
others, to dust or fumes through their designs.
Examples of how this can be achieved are:
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specifying construction methods that avoid hot-works and therefore the creation of
fumes, particularly in enclosed areas and confined spaces
(b)
specifying that construction materials are cut to size at the point of manufacture,
eliminating the need for cutting, planing, sanding and so on, on site
(c)
designing enclosures to contain hazardous dust where its creation is unavoidable.
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(a)
Contractors and sub-contractors have the potential to reduce exposure to dust and/or fumes
by co-ordinating work activities, co-operating with each other and adopting work methods.
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These Regulations require that where a risk has been identified by a risk assessment and it
cannot be adequately controlled by other means which are equally or more effective, then
the Contractor must provide and ensure that suitable personal protective equipment is used
by the at risk employees.
In essence, personal protective equipment (PPE) may only be used as a last resort after all
other means of eliminating or controlling the risk have been considered and are found not to
be reasonably practicable.
In deciding which type to issue, the Contractor must take into account the nature of the
hazard that the PPE is being used to protect against, and ensure the PPE will fit the wearer
and allow them to work safely. If more than one item of PPE is being used, the Contractor
must make sure that individual items of PPE are compatible and suitable for the task that is
to be undertaken.
Whenever PPE is to be issued, the Contractor must ensure that employees have been given
adequate and appropriate information, instruction and training to enable the employees to
understand the risks being protected against, the purpose of the PPE and manner in which it
is to be used.
Whilst the Contractor must ensure that personal protective equipment is supplied and used,
the employee has a duty to properly use the equipment provided, follow the information,
instruction and training that they have been given, and know the procedures for reporting
loss or defects to their Contractor.
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1.2.9.10 Training
1
It should be noted that these Regulations place a legal duty on the Contractor to provide
employees with adequate information, instruction, training and supervision to be able to carry
out any work task safely and without risks to their health.
1.2.9.11 Respiratory hazards

The following paragraphs describe the main respiratory hazards which may be encountered
on site.
Dusts are produced when solid materials are broken down into finer particles. The longer
that the dust stays in the air then the easier it is to breathe in. Airborne dust is usually
respirable dust.
Mists are tiny liquid droplets formed by atomisation of the liquid, for example, when spraying
or using an aerosol. Mists may be a combination of several hazardous substances.
Metal fumes occur when metal is vaporised at high temperatures, for example, when
welding and gas cutting. The physical properties of fumes can be confusing, particularly
when identifying suitable respiratory protective equipment (RPE). Usually, metal 'fume' is
actually a solid particle by the time it is inhaled.
When welding is taking place the temperature of the metal at the weld is sufficiently high for
the elements in the metal to become gaseous. However, 2-3 mm away from the weld the
gases have cooled down sufficiently for the fume to solidify out as small particles.
Consequently, when purchasing RPE to protect against fume, a device that protects against
solid particles rather than gases is required.
Gases are airborne at room temperature and normally mix with the air that we breathe.
Examples include propane, butane, acetylene, carbon monoxide and hydrogen sulphide.
Gases can spread very quickly.
Vapours are the gaseous state of substances that are liquids or solids at room temperature.
They usually form when substances evaporate.
One example is the vapour from a tin of glue or solvent that has been left open.
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1.2.9.12 Exposure limits

1
Exposure to any unlisted substance or general nuisance dust should be limited by reducing
dust levels to the minimum reasonably practicable. These levels should not exceed 10
milligrams of dust per cubic metre of air, when measured over an eight hour period (10
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mg/m 8H TWA). Within that figure, only 4 mg/m should be respirable dust.
Generally speaking, if visible dust can be seen in the air, it is highly possible that the 10 mg
limit is being approached (or exceeded), and the application of COSHH should be
considered.
1.2.9.13 Control of dust

1
Dust in its many forms has been the cause of health problems throughout the history of the
building and construction industry. While much attention has been given to newly recognised
hazards, the greater part of the dust problem relates to more common substances.
Dust is taken here to mean anything that forms a powder or cloud and is a nuisance,
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including cement, wood, stone, silica, fillers and plastics. The high speed cutting and
grinding of most materials can produce dust.
Dust in confined spaces is a particular hazard, because of the potential risk of explosion. The
most obvious example is in coal mines. Flour dust can also be explosive, and whilst that is
normally a process industry risk, for companies who may maintain or cut up extraction plant
in bakeries and flour/feed mills, it is something that does require consideration.
In all cases, knowledge of the hazards associated with materials, processes and operations
is required, and of the specific precautions and protective equipment necessary to reduce or
eliminate the risk to health and safety.
In many cases, the control of dust will not be difficult to achieve. The accumulation of
'general dust' can be controlled by good housekeeping and simple measures, such as
'damping down'.
Where the creation of dust is more localised, such as during the cutting, grinding or sanding
of solid materials, satisfactory control will often be achieved by the extraction and collection
of the dust through attachments fitted to power tools or by 'wet cutting'. Even where the
collection of dust is not practical, it will often be possible to create an enclosure around the
activity and ensure that the person carrying it out uses appropriate RPE.
Conversely, carrying out some dust-generating activities in the open air may be preferable to
allow the dust to disperse, depending upon the hazard posed by the quantity and nature of
the dust so created.
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Wood dust
Impregnated timber and some hardwoods (such as teak, African mahogany and iroko) are
known to be health hazards. The inhalation of hardwood dusts through the nose is a known
cause of nasal cancer.
A list of some timbers known to present risks is given below. Protection is not normally
required when working on these timbers with hand tools in the open, but harmful dusts can
be produced when using machine tools (e.g. sanders or saws) in enclosed or poorly
ventilated areas. An assessment should be made and, if ventilation or dust extraction cannot
be improved to remove or reduce the dust problem, a dust respirator should be worn.
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Medium density fibreboard

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Medium density fibreboard (MDF) is a commonly used material in the construction sector. It
is manufactured from wood dust glued together with a urea-formaldehyde binder.
11
The risks associated with MDF are exposure to dust and dried urea-formaldehyde during
use.
12
The primary issue for construction workers is simply the huge amount of dust that any work
with MDF generates. Given the makeup of the product this is not really surprising. The
3
exposure level normally used is the same as softwood dust - 5 mg/m on a time weighted
average exposure of eight hours
Selection of timbers and their irritant effects
13
The severity and frequency of any symptoms will vary with individuals. They are also doserelated.
(a)
Camphor wood - asthma, dermatitis
(b)
Red cedar - asthma, bronchial trouble, sneezing, watering of eyes, rhinitis, dermatitis,
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septic wounds from splinters

Dahoma - irritation of mucous membranes and chest, sneezing, coughing, running
eyes and nose, dermatitis
(d)
Ebony - irritation of nose and throat, dermatitis
(e)
Guarea (also West African cedar) - mild nasal irritation, sneezing, coughing, running
eyes; can cause severe vomiting, chest irritation, blisters around the eyes and
dermatitis
(f)
Iroko - skin and eye irritation, asthma and symptoms of the common cold
(g)
Machaerium - dermatitis
(h)
Sapele - dermatitis, allergic extrinsic alveolitis
(i)
Mahogany - asthma, dermatitis
(j)
Chestnut - asthma, dermatitis, rhinitis
(k)
Mansonia - irritation of mucous membranes, sneezing, nasal haemorrhage, eyes sore

and bloodshot, dizziness, dermatitis
(l)
Satinwood - dermatitis, headache, coughing
(m)
Teak - dermatitis, eye inflammation. Effects are severe once the skin's protective layer
has been penetrated
(n)
Walnut - asthma, dermatitis, conjunctivitis, rhinitis
(o)
Yew - bronchial asthma and dermatitis
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(c)
Generally speaking, the greater the amount and the finer the dust, the greater the risk of
health problems.
15
Both hardwood and softwood dusts have a workplace exposure limit of 5 mg/m on a time
weighted average exposure of eight hours. As both are known causes of asthma dust levels
need to be controlled to as low a level as possible.
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Other common sources of dust

When cleaning stone, brick and concrete facades, or any metal structure with dry or wet grit
blasting, control measures will include the use of respiratory protective equipment. This is
likely to be a high performance type such as a powered respirator. When cleaning siliceous
masonry, air line equipment may be required.
17
Although this type of cleaning operation is commonly called 'sand blasting', sand must not be
used for blast cleaning because of the known health hazard caused by airborne sand and
silica.
18
Effective preventative measures must be taken if exposure to crystalline silica is possible.
19
Protection is also necessary when using mechanical cleaning methods.
20
Exhaust ventilation devices should be fitted to power tools, or the operative should be
provided with high efficiency breathing apparatus.
21
The cutting and chasing of masonry, stone, brickwork, plaster, thermal insulating blocks and
concrete, creates a dust hazard. Therefore, extraction equipment should be provided, the
process performed wet or respirators worn, depending on the assessment made.
22
Crystalline silica (also known as quartz) is present in sand and rock and can also be found in
building materials such as cement, concrete, plaster, bricks and tiles.
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Dust from plastic fillers can damage the lungs if inhaled, as can dust from resin-based fillers,
and fibrous particles of glass fibre, rockwool and similar insulation materials.
24
The dry sanding of lead-based paint can result in exposure to hazardous levels of lead dust.
Softening with heat guns and scraping, or the use of chemical stripping agents, will usually
be effective. If sanding is required, wet and dry paper with a solution of dishwater detergent
can be used. A dishwasher tablet dissolved in about 5 litres of water will give the required
solution strength. The form of detergent used for dishwashers is effective at binding and
stabilising the lead chromate used in paint.
25
The disturbance of asbestos is likely to result in airborne fibres (dust) which can result in
cancer, and other respiratory illnesses, if inhaled.
26
Where a work activity involves the creation or disturbance of dust, a COSHH assessment
must be carried out.
23
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1.2.9.14 Control of fumes
Within the wide range of activities carried out in the construction industry there are numerous
operations which liberate fumes into the atmosphere and cause risks to the health and safety
of people at work. Every effort must be made to minimise these risks. Fumes may be
classified as a substance hazardous to health and thereby require an assessment of the risk
to health to be carried out.
If a risk does exist, control measures such as mechanical extraction systems and adequate
natural air ventilation can prevent high concentrations of fumes forming to create a hazard,
particularly in confined areas.
The HSE publication EH40 'Occupational exposure limits' lists a level of exposure for each
type of fume or pollutant. This represents the maximum limit at which it is considered safe for
work to take place.
EH 40/2005 has been supplemented by a table on HSE's website, which has the up-to-date
list of workplace exposure levels:www.hse.gov.uk/coshh/table1.pdf
Every reasonably practicable measure should be taken to reduce any exposure as far below
the limit given as is possible.
If the fume type is listed in EH40, or is otherwise a hazard to anyone's health, the provisions
of the COSHH Regulations will apply. Therefore, an assessment of the risk and the provision
of any necessary precautions must be made.
Some of the more common causes of fumes are listed below and discussed under
subsequent headings:
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(a)
welding or flame cutting
(b)
lead burning (both cutting and melting)
(c)
cable burning (this practice must not be carried out on site)
(d)
the use of solvents, paints, adhesives and soon
(e)
internal combustion engines.
1.2.9.15 Welding
1
During welding and flame cutting, toxic fume hazards can arise from:
(a)
nitrogen oxide gases
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(b)
ozone
(c)
phosgene gas
(d)
carbon monoxide gas.
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These are mainly caused by the very high temperatures and the presence of volatile
substances, sometimes as contaminants, but often as shielding agents or flux.
The inhalation during welding of freshly formed metal oxides (such as zinc, cadmium,
chrome, nickel, copper and mercury) may lead to an acute 'flu-like' illness termed 'metal
fume fever'.
The fever is most commonly caused by fumes created while working with galvanised or zinccoated metals, especially in confined spaces.
Fumes arising from the cutting and welding of cadmium are especially dangerous, even in
the open air. Prolonged or recurrent exposure may result in cadmium poisoning.
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Precautionary measures
A risk assessment, including a COSHH assessment, as appropriate.
The use of extraction systems and fume hoods to remove fumes from the breathing zone.
The use of respiratory equipment, particularly in confined spaces where high concentrations
of fumes can be anticipated.
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1.2.9.16 Lead burning
Lead burning is the process whereby lead is heated to its molten state so that it can be
poured into joints, or flame cut to shape, or flame heated so that it can be bent and formed
into various shapes.
This process is employed extensively in sheet lead work by workers in the plumbing trades,
in the formation of roof drainage, guttering, chimney flashings and so on.
This will mean that the operatives will need to be under health surveillance.
The creation of fumes by the heating of lead exposes operatives to risk. The following safety
points should be observed:
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(a)
the use of local exhaust ventilation, or other means, to evacuate fumes from the
immediate working area where reasonably practicable
(b)
the use of respiratory equipment of an approved type in the appropriate cases
(c)
the provision of protective clothing and storage for that clothing, along with adequate
washing facilities.
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Wear respirator
Quite simply this is not an acceptable practice at anywhere other than a specialised
processing facility. This method of recovering metal from cables, by burning off the
insulation, often results in the creation of fumes which can be very toxic.
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1.2.9.17 Cable burning
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Chlorinated solvents, paints, adhesives and thinners all require precautions to be taken
during their use. If they are hazardous to health, they must be handled and used in
accordance with these Regulations.
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1.2.9.18 Solvents
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Avoid breathing the vapour
Most solvents are safe when used correctly but, in common with other compounds of
hydrocarbons, the inhalation of a high concentration of vapour will cause drowsiness,
headaches and giddiness. Severe exposure may lead to unconsciousness or even prove
fatal. Extraction or exhaust ventilation may be needed or, where this is not available,
respiratory protective equipment must be used.
Long term exposure to solvents may affect the central nervous system. Other chemicals may
also have adverse effects. An example is isocyanate, which is a component of expanding
foams contained in aerosol tins.
Some of the vapours are considerably heavier than air and may collect at low levels,
particularly in still conditions. This can cause displacement of the oxygen present and lead to
the risk of suffocation. It can also lead to a build up of solvent fume at explosive
concentrations.
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Other precautions with solvents

5
DO NOT
(a)
take solvents internally or 'sniff' any solvent
(b)
smoke when using solvents
(c)
use the solvent in a place which is not well ventilated - but avoid draughts
(d)
lean over any vessel containing the solvent liquid or vapour
(e)
store solvents in buckets or other open storage vessels
(f)
enter vessels which have contained or have been cleaned with solvents, unless
proper tests have been made to ensure it is safe to do so
(g)
allow solvent liquid or vapour to come into contact with naked flames or red hot
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surfaces, e.g. welding arcs. Acidic and toxic decomposition products will be formed.
1.2.9.19 Internal combustion engines

The nature of the construction industry, the activities carried out and the drive to get a job
finished may lead some people into taking unnecessary risks. The majority of people are
aware that internal combustion engines should not be used within confined spaces unless
the exhaust gases are led directly to the open air. However, when for example the concrete
is too hard, or a pipe will not cut by hand and the job is late, people will often ignore such a
basic safety requirement and start a petrol engine disc cutter in a cellar. It is an error which
could be fatal.
There is a potential for excavations to be contaminated by exhaust gases which are heavier
than air and could simply roll down into the excavation. On projects with forced ventilation
systems such as tunnels and shafts, the additional loading on the system needs to be
factored in before petrol or diesel powered equipment is used.
In large buildings the use of forklift trucks, and other vehicles with internal combustion
engines, can cause carbon monoxide to reach unacceptable levels, if there is no system to
extract exhaust pollution. Simply opening the doors may not be enough.
In all cases of doubt, a COSHH assessment should be made by a competent person and,
where necessary, the appropriate controls introduced.
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The following points are especially important:
the identification of potentially hazardous work processes, materials and substances

before work starts
(b)
the provision of information, instruction and training to employees
(c)
the strict observance of all
(d)
recommendations and procedures advised by the manufacturer
(e)
the effective supervision of employees, and the monitoring of work methods and
practices
(f)
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the provision of protective clothing and equipment before any work starts
the correct disposal of waste materials and containers as recommended by the
manufacturers
(g)
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1.2.9.20 Precautions
(h)
cleaning, for example, by extracting dust using a vacuum cleaner, rather than stirring it
up by sweeping
(i)
personal hygiene, including the cleansing of hands before consuming food, the use of
barrier creams, the removal and storage of contaminated clothing during meals, and
the correct laundering or disposal of contaminated clothing
(j)
to avoid, where practical, carrying out potentially hazardous work activities in confined
areas to lessen the chances of dust concentrations or fumes building up.
1.2.9.21 Protective equipment

1
Given the nature of some work activities, it is not always practical to completely contain the
airborne dust or fumes created. In these circumstances, if no other control measure is
reasonably practicable, respiratory protective equipment (RPE) and other PPE as necessary,
must be provided for each person working with, or otherwise exposed to, airborne dust or
fumes.
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There are various types of respiratory protective equipment approved for use. Details of
types and permissible uses are available from the manufacturers.
1.2.9.22 Respiratory protective equipment

Selection
Selecting the wrong type of RPE could have serious, even fatal, consequences. Selection
must be carried out by a competent person. Some of the factors that will determine the
appropriate type of RPE are:
the hazardous nature of the substance
(b)
the airborne concentration of the substance
(c)
the period of exposure
(d)
the wearer's required field of vision
(e)
the provision for communication
(f)
the need to move in cramped or difficult working places
(g)
the prevailing weather conditions
(h)
the suitability of the protective equipment for the individual
(i)
the need for an external source of breathable air.
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(a)
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Notes:
When selecting suitable respiratory protective equipment (RPE) it may be necessary to seek
expert advice from manufacturers/suppliers.
Training in the types of, and in the use of, respiratory equipment must be given.
A face fit test is required for any tight fitting face piece - this will include all disposable masks,
half masks and most powered masks.
All masks, other than disposables, require regular examination by a competent person and
records to be kept.
The following are some types of respiratory protective equipment (RPE) that are used in the
construction industry:
disposable face mask respirators
(a)
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(b)
half-mask dust respirators
(c)
powered respirators
(d)
ventilated visor and ventilated helmet respirators
(e)
compressed air line breathing apparatus
(f)
self-contained breathing apparatus.
Each type of RPE is given an 'assigned protection factor' (APF), which gives the user some
idea of the level of protection that the device will provide. For example, a disposable mask
marked:
(a)
P1
offers a protection factor of 4
(b)
P2 offers a protection factor of 10
(c)
P3 offers a protection factor of 20
The APF assumes that the user has passed a face fit test, is wearing the mask correctly, is
clean shaven and there is no other interference in fit such as facial piercing.
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The APF is a simple multiplier that can be used in two ways. An example is:
(a)
a particle mask with an APF of 10.
This simply means that for every 10 units of contaminant outside the mask, only one unit will
get inside the mask, so the mask filters out 9 of 10 of the units.
If there is a time exposure limit, then a mask extends the time by the same factor - so if
someone can be exposed to a concentration of a contaminate for 10 minutes without
needing to wear a mask, then a mask with an APF of 10 would allow the person to be
exposed for 100 minutes (10 x 10).
The same protection factors are used for all particle masks. This does create some
surprising results such as the highest protection level on half masks and disposable masks
are the same, P3 or an APF of 20, and the normal protection factor of a powered mask fitted
with a P3 filter is an APF of 40.
If there is any doubt regarding the level of protection required, which type of respiratory
protective equipment should be provided or which cartridge should be used on a respirator,
advice should be sought from a competent person, or advice taken from the respiratory
protective equipment manufacturers/suppliers.
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Disposable face mask respirators
These are simple face masks designed to filter out harmful dust and particles. They are
lightweight, comfortable and cheap. They should only be worn by one person and for no
longer than a single eight-hour shift. They should be disposed of after use.
11
In areas of high dust levels, it may be necessary to dispose of dust masks more frequently,
since they may become clogged and, subsequently, breathing will become more difficult.
12
The big advantage of disposable masks is that they do not need any inspection or record
keeping as they are designed to be simply thrown away. This may be a major factor in
choosing them as a solution, particularly if the wearers of such masks are normally out on
different sites.
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Nuisance dust masks

It should be noted that nuisance dust masks are not classed as personal protective
equipment or respiratory protective equipment. They do not meet any current standards o
legal requirements, and are dangerous in the respect that they give the uninformed user a
false impression that they are providing a level of protection. The filter size used in their
construction is so large that any particles that they manage to keep out would have been
safely dealt with by the body's own defence mechanisms.
14
They typically come in two forms which are either a metal plate that holds a piece of gauze
over the nose and mouth or a lightweight cup-shaped filter, again fitting over the nose and
mouth, and looking like a disposable dust respirator.
15
Nuisance dust masks are often identifiable by only having one strap and the device is not
marked with a protection factor (e.g. P1, P2 or P3). They should not be confused with
approved disposable dust masks which will bear the appropriate EN number and a
protection factor.
16
Nuisance dust masks should not be issued or used in any circumstances where these
Regulations (COSHH) apply or may apply.
17
People who work with harmful dusts should always be provided with, and use, the correct
type of CE-marked dust mask or respirator to ensure proper and effective protection.
13
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Half-mask dust respirator

18
This is one of the most common types of respirator used. It consists of a face mask which
covers the nose and mouth of the wearer, and a suitable filter through which air is drawn by
breathing.
19
The main advantages of this type of respirator are its low cost, easy maintenance, and the
fact that it provides the wearer with freedom of movement.
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Half masks
The filtering canisters or cartridges used in these respirators may be round, oval or
triangular, and are often colour-coded to indicate the type of contaminant they give
protection against. If a 'use by' date or shelf life is specified, it must be adhered to.
21
High efficiency dust respirators provide protection by drawing air in through the filter system
by inhalation.
22
The advantage that this type of mask offers over a disposable mask is that it is usually
possible to fit filter cartridges of different types, for example, changing from a dust filter to a
fume filter.
23
The disadvantage is that as well as face fit testing, the mask needs some form of
identification and regular inspection by a competent person, who then records the detail of
the inspection. This exercise can be logistically challenging.
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20
Powered respirators
24
A powered respirator has a filtered air supply provided to the wearer by a small, batteryoperated pump and filter unit which will deliver air continuously for approximately seven
hours. The air pressure inside the mask facepiece is slightly higher than normal air pressure,
and therefore filtered air leaks out rather than letting potentially contaminated air enter.
25
These respirators are most suitable for specialised applications, as they are relatively
comfortable, and they can be worn where long periods of exposure are involved. The users
must be face fit tested and the fit test method must be the so called 'quantitive test', which
usually involves the use of a computer and test equipment called a portacount.
26
Batteries must be changed or recharged and filters cleaned or replaced at scheduled

intervals to maintain peak efficiency.
Ventilated visor and ventilated helmet respirators
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In this type of equipment, a small axial fan housed in the back of the helmet draws in dustladen air through a series of filters situated in the crown of the helmet. Filtered air is then
passed downwards over the user's face, maintaining a positive pressure in the region of the
nose and mouth. The unit is powered by a rechargeable battery pack worn on a belt.
28
This type of respirator is comfortable and combines protection against dust with the
protection afforded by a safety helmet (manufactured to BS EN 397) and face and eye
protection (to BS EN 166). Advice should be taken from the manufacturer with regard to the
substances the mask will protect against. They are quite comfortable to wear. Tunnelers will
be familiar with a version that includes hearing protection, lamp and hard hat as an all-in-one
headpiece.
29
Efficient maintenance and cleansing procedures are essential. If the flow of air is reduced by
clogged filters or low battery power, unfiltered air can be drawn in around the side of the
facepiece.
30
This type of mask does not require a face fit test as it does not seal tightly on the wearers
skin. It is the only type of commonly used mask that someone with a full beard can wear.
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Compressed air line breathing apparatus

With this equipment, air is supplied to the user from a compressed air supply, via a hose to
the face mask or hood. The correct air pressure, temperature and humidity must be
maintained.
32
The air supplied must be of breathable quality, thus the selection, siting and maintenance of
the compressor and filtration of the air supply is vitally important.
33
The presence of an air hose can, on some occasions, restrict the user's movements.
34
As with all types of breathing equipment, operators should be properly and adequately
trained and, unless experienced in the type of work to be carried out, should be properly
supervised.
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Self-contained breathing apparatus

35
In a set of self-contained breathing apparatus, air is usually supplied from compressed air
cylinders carried on the worker's back and is fed to a full face mask via a regulator. As with
the air line apparatus, operators must be properly and adequately trained and, unless
experienced in the type of work to be carried out, must be properly supervised.
36
A limitation is that the typical duration of a compressed air cylinder is between 20 minutes
and two hours. The equipment should therefore only be selected by competent persons with
a full knowledge of their use.
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1.2.9.23 Dust sampling

Sampling is usually carried out by a specialist using metered pumps with membrane filters.
The dust collected is weighed in relation to the amount of air sampled. Dust samples can
also be examined for type.
There are also some direct-reading dust sampling monitors available. However, there is
some doubt as to the accuracy of these instruments. They are very useful for a long-term
project where they can be calibrated regularly by comparing their readings against samples
taken from membrane filters.
They are not recommended as the sole means of measuring a personal exposure to dust. It
is also important to be aware that there are a number of different laboratory techniques
required for analysis, for example, measuring exposure to silica normally requires X-ray
diffraction.
Use of Tyndall Beam to identify dust clouds
The Tyndall Beam is a useful way to determine whether a problem exists before
investigating further. It uses the common phenomenon of dust being highlighted in a shaft of
light.
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1.2.9.24 Training and supervision

1
New employees should receive full instruction before starting work and should be
familiarised with the following:
(a)
the health risks associated with dust and the preventative measures in operation, as
identified by the risk assessment
(b)
the correct use and cleaning of protective clothing and equipment
(c)
the reasons for air sampling
(d)
their duties in respect of the correct use of equipment and of safe systems of work in
operation
(e)
the procedures for reporting defective or inadequate equipment.
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Construction site Safety

1.2.9 Appendix 1
Control of fumes
Safety checklist
An assessment must be carried out.
All hazardous processes and operations have been identified.
All personnel have been fully instructed in the types of hazard likely to be encountered.
There is adequate supervision of all work operations.
All personnel are competent to carry out the work operations.
Correct and adequate protective clothing is provided and used.
Respiratory protective equipment is provided and used, as necessary.
Face fit testing and records for the RPE are available.
Exhaust ventilation or extraction equipment is used, as required.
10
The correct type of eye protection is provided and used, as necessary.
11
Safe working methods are being adhered to.
12
No one under 16 years is employed (lead burning).
13
Chlorinated solvents, paints, adhesives, and so on are:

stored safely
(b)
used safely.
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Personnel have been made aware of the hazards that exist when working with chlorinated
solvents, paints, adhesives, and so on.
15
Engine exhaust gases are led directly out of confined spaces.
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Dust hazards
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There is adequate supervision of all work operations.
17
Materials, substances and associated hazards have been properly identified.
18
Manufacturers' or suppliers' instructions are available and observed.
19
Power tools are fitted with a dust extraction and collection facility.
20
Local exhaust ventilation is fitted to workshop machinery.
21
The correct protective equipment is supplied and clothing provided.
22
Operatives have been instructed in the use of materials and are aware of the hazards
associated with those materials.
23
There is provision for the ongoing training of employees.
24
There is provision for, and operation of, safe systems of work.
25
There is adequate provision of washing facilities, and facilities for storing overalls, and other
work wear during meal breaks.
26
Correct procedures for the storage, identification and disposal of waste materials or
substances are followed.
27
Adequate arrangements have been made for air sampling, as necessary.
16
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1.2.10 Control of Noise
1.2.10.1 Key points
Contractors and employees have duties under these Regulations.
Noise experienced at work, in the home and social environments can cause permanent
damage to hearing.
There are often early signs that the hearing is being damaged; these should not be ignored.
Contractors should seek to control noise by other, equally or more effective, ways before
resorting to personal protective equipment.
Effective pre-planning of site activities and the active management of noise during the
construction process can significantly reduce noise exposure on site.
In addition to hearing damage, excessive noise can have other health and safety
implications, such as not being able to hear alarms or shouted warnings.
Establishing the noise levels on site might not necessarily involve arranging for noise
measurements to be taken.
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Note:
Section 1, Part 15.2.3 of the QCS covers noise control.
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High levels of noise on construction sites often come from machinery used for demolition,
excavation or piling, from compressors and concrete mixers, etc. Other operations, such as
hammering, riveting and the use of cartridge-operated fixing tools, may also be the source of
excessive noise.
The degree of nuisance or damage caused by noise is related to the nature of the noise
generated as well as its loudness. Intermittent noise is often more disruptive than a
continuous noise and high-pitched sounds are more disturbing than low frequency ones.
Exposure to high levels of noise can cause permanent damage to hearing in the form of
partial or total deafness.
Contractors have a duty to control noise and protect their workers and other persons from its
effects. Noise is also a source of annoyance and disruption, and may directly or indirectly
lead to an increase in the risk of accidents. Every reasonably practicable step should be
taken to control it.
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1
assessment of every work activity to identify any hazard that employees or any other person
might encounter as a result of the work being carried out.
When hazards are identified, it is then the Contractor's duty to either eliminate the hazard or
to put control measures into place to reduce the risks to health and safety arising from the
hazards, as far as is reasonably practicable.
any risks that exist in the workplace and on any control measures that are in place to reduce
those risks.
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Employees, in turn, have legal duties under these Regulations to:

(a)
tell their Contractor of any work situation which presents a risk to the health and safety
of themselves or any other persons who may be affected by their work activities
(b)
use all machinery and equipment in accordance with any training provided.
These Regulations require that, additionally, the Contractor provides employees with
adequate information, instruction, training and supervision to be able to carry out any work
safely and without risks to their health.
Contractors must assess the risks to employees' health arising from noise and put effective
control measures in place.
1.2.10.4 Control of Noise at Work
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These Regulations:
place duties on Contractors and employees
(b)
allow personal exposure to noise to be measured over a weekly, rather than an 8hour, period in situations where employees are exposed to widely varying noise levels
(c)
give employees the right to hearing checks where a noise assessment indicates their
hearing could be at risk.
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Action and limit values
These Regulations specify the following three levels of exposure to noise, each of which
requires that certain actions be taken:
Lower exposure action value. This is reached when a daily or weekly personal exposure
reaches 80 dB(A) or a peak sound pressure of 135 dB(C) occurs.
Upper exposure action value. This is reached when a daily or weekly personal exposure
reaches 85 dB(A) or a peak sound pressure of 137 dB(C) occurs.
Exposure limit value. This is the maximum level of noise to which anyone at work may be
exposed. It is set at 87 dB(A) at the ear, measured on a daily or weekly basis as appropriate
or when a peak sound pressure of 140 dB(C) occurs.
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Contractor's duties
6
These Regulations place a duty on Contractors with respect to the health and safety of
employees, the Contractor is, so far as is reasonably practicable, also under a similar duty to
anyone else at work who may be affected by the noise created by the Contractor's work
activities
When applying the 'exposure limit value', Contractors may take account of any hearing
protection worn; it is the level of noise actually entering the ear. Therefore, the performance
characteristics of any hearing protection worn can be taken into account when assessing the
noise exposure of individuals. Similarly, it must be taken into account when decisions are
taken on the purchase of personal hearing protectors.
If employees are likely to be exposed to noise at or above the lower exposure action
value, the Contractor must:
(a)
carry out a suitable and sufficient assessment of the risks to employees and ensure
that it identifies the measures necessary to adequately control the level of noise at
work. When carrying out the risk assessment the Contractor must assess noise
exposure by:
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observing work practices
(ii)
referring to information on the probable level of noise issued by tool and

equipment manufacturers
(iii)
only if necessary, arranging for noise levels to be measured.
If employees are likely to be exposed at or above the 'upper exposure action value' or the
'exposure limit value', the risk assessment must also include consideration of:
the level and type of noise and its duration, including any exposure to 'peak sound
pressure'
(b)
the effects that the noise might have on the health of employees exposed to it
(c)
so far as is practicable, the effects on the health of employees resulting from an

interaction between exposure to noise and any ototoxic substances (mainly commonuse solvents) that are in use or between noise and vibration
(d)
the possibility of warning alarms or other audible systems not being heard
(e)
information provided by the manufacturers of equipment that generates the noise
(f)
the possibility of using alternative, less noisy equipment
(g)
exposure of employees to noise when not actually working, such as in rest areas and
canteens
(h)
the results of previous health surveillance and published information
(i)
the availability of suitable personal hearing protectors, taking into account their
performance.
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The Contractor must regularly review the risk assessment and immediately if:
there is reason to believe that it is no longer valid
(b)
there has been a significant change in the work to which the assessment applies and
implement changes to the risk assessment as identified by the review process.
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(i)
The Contractor must inform at-risk employees of the findings of the risk assessment and
record:
(a)
the significant findings of the risk assessment as soon as is practicable after it has
been made or changed
the control measures that have been put in place to eliminate or reduce the noise,
including the provision of hearing protection and employee training.
(b)
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Records may be kept in any form so long as they are easily retrievable and can be printed.
13
The Contractor must also:
14
(a)
generally eliminate at source the risk of hearing damage or reduce it to the lowest
level that is reasonably practicable, irrespective of noise levels
(b)
where exposure is likely to be at or above the upper exposure action value, reduce
the noise, as far as is reasonably practicable, by implementing organisational and
technical measures other than by providing personal hearing protectors.
Contractors must consider the following:

(a)
alternative, less noisy methods of carrying out the work
(b)
alternative, less noisy tools for carrying out the work
(c)
the layout of the workplace, including any rest facilities
(d)
providing employees with adequate information and training so that they can minimise
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their exposure to noise

the reduction of noise by technical means
(f)
effective maintenance programmes for equipment that can generate noise, the
workplace itself and workplace systems
(g)
limiting the duration and intensity of exposure to noise
(h)
adjusting work schedules and ensuring adequate rest periods.
The Contractor must ensure that employees are not exposed to noise above the exposure
limit value, or if they are, immediately:
(a)
reduce exposure to below the exposure limit value
(b)
identify the reasons for the exposure limit value being exceeded
(c)
take appropriate actions to prevent it occurring again.
Contractors must:
ensure that the level of noise in rest facilities that are under their control is reduced to
a suitable level for their purpose
(b)
adjust and adapt any measures taken to prevent exposure to noise to take account of
any person(s) whose health is likely to be particularly at risk from exposure to noise
(c)
inform employees of the measures taken to eliminate or control the level of noise in
the workplace.
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(e)
Where employees are exposed to noise at or above the lower exposure action value but
below the upper exposure action value, the Contractor must make suitable personal
hearing protectors available to employees who request them.
18
Where employees are exposed to noise at or above the upper exposure action value, the
Contractor must:
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designate the affected part of the workplace as a 'Hearing Protection Zone'
(b)
identify the extent of the area by signs indicating that hearing protectors are to be
worn
(c)
restrict access to the area where practicable and it is justified by the level of risk
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ensure so far as is reasonably practicable that all employees entering the hearing
protection zone wear personal hearing protection.
(d)
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(a)
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Hearing protectors must be selected, so as to eliminate the risk to hearing or reduce it to as

low a level as is reasonably practicable
20
Contractors must:
(a)
ensure so far as is practicable that anything provided to comply with these

Regulations, except personal hearing protectors, is fully and properly used
(b)
ensure that anything provided to comply with these Regulations is maintained in good
working order and in a good state of repair
21
If the risk assessment indicates that there is a risk to the health of employees exposed to
noise, the Contractor must ensure that those employees are placed under suitable health
surveillance, including providing them with hearing tests.
22

(a)
ensure that a record is kept and maintained for each employee who undergoes health
surveillance and that records are readily available in a suitable format
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(b)
Where, as a result of health surveillance, an employee is found to have identifiable hearing

damage, the Contractor must ensure that the employee is examined by a doctor and, if
necessary, a specialist. Where the hearing damage is found to be as a result of exposure to
noise at work, the Contractor must:
ensure that the employee is informed by a suitably qualified person
(b)
review the risk assessment
(c)
review existing control measures, taking into account any advice given by a doctor,
occupational health professional or administrative authority
(d)
consider reassigning the employee to other work where there is no risk of further
exposure, taking into account any advice given as above
(e)
continue with the health surveillance of affected employees.
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Where employees are exposed to noise at or above the lower exposure action value, the
Contractor must provide the employees with suitable and sufficient information, instruction
and training, which must include:
the nature of the risks arising from exposure to noise
(b)
the control measures taken to eliminate or reduce exposure
(c)
the exposure limit value and the lower and upper exposure action values
(d)
(e)
the availability and provision of personal hearing protectors and how to use them
correctly
(f)
why and how to detect and report signs of hearing damage
(g)
the employees' entitlement to health surveillance
(h)
how to work safely to minimise noise exposure and thereby avoid hearing damage
(i)
the collective results of any health surveillance carried out, anonymised so as not to
reveal the personal health record of any individual.
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(a)
The information, instruction and training provided as above must be updated by the
Contractor to take account of any significant changes of the type of work carried out or
method of working.
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allow employees to see their health surveillance records on being given reasonable
notice
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Employees' duties
26
Employees must:
(a)
make full and proper use of personal hearing protectors if the noise exposure exceeds
the upper exposure action value
(b)
make full and proper use of other control measures provided by the Contractor
(c)
report any defects in the personal hearing protectors or other control measures to their
Contractor
(d)
make themselves available for health surveillance checks (during working hours) as
required by the Contractor, the health surveillance being at the Contractor's expense.
1.2.10.5 The nature of noise

1
Sound is the transmission of air vibrations at different frequencies. Noise is sometimes

defined as unwanted sound. The ear is a pressure-sensitive mechanism, detecting small
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changes of air pressure over a wide range of frequencies of 20-20,000 cycles per second.
The unit of frequency is the hertz (Hz). Those with impaired hearing due to age or other
forms of hearing loss are less likely to be able to hear the higher frequency range.
Audiometry is the technique used to determine the capacity of the ear to detect sounds of
varying loudness over a range of frequencies. It can be used to measure an individual's
hearing capacity against a recognised standard. Successive audiometric checks can confirm
whether or not a person is suffering from progressive hearing loss.
When judging the level of noise, the 'rules of thumb' are that if you have to raise your voice
to make yourself understood at 2 metres from the other person, the background noise is
around 85 dB(A). If the distance is only 1 metre, the noise is around 90 dB(A).
A peak sound pressure of 137 dB(C) will be produced by many impact tools such as
cartridge-operated tools.
Two "types' of noise may damage the hearing of the people who are exposed to it:
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Continual or periodic noise, which even if varying over the course of time, can be
measured and averaged out over an eight-hour (or in some circumstances a weekly)
reference period. This is known as the 'daily (or weekly) personal noise exposure' as
referred to in these Regulations. This is the common everyday noise that is
experienced on many construction sites.
(b)
Sudden, short bursts of loud impulsive noise such as experienced during the driving of
piles, the use of explosives or the use of some hand tools. The references in these
Regulations to 'peak sound pressure' are to this type of noise.
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1.2.10.6 Effects of noise at work
Noise levels may fluctuate widely or be relatively steady. A reasonably steady sound level is
where the level fluctuates through a total of less than 8 dB(A) on a slow response scale.
Exposure to noise can have the following consequences:
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It can cause annoyance and irritation.
(b)
It may affect concentration and efficiency.
(c)
It may cause fatigue and the likelihood of accident proneness.
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It can mask out other sounds, preventing a person's ears from registering instructions
and warnings.
(d)
(a)
(e)
It can result in temporary hearing loss.
(f)
Regular exposure to loud noise can cause damage to the ear and permanent loss of
hearing.
There is also growing evidence that continued exposure to noise has consequential effects
on some other illnesses.
Hearing loss
Hearing loss can be temporary or permanent. Temporary deafness is often experienced after
leaving a noisy place. It is often accompanied by a ringing in the ears. Although hearing
usually recovers within a few hours, this symptom should not be ignored. It should be taken
as a sign that further or continued exposure to noise is likely to result in permanent damage.
Permanent hearing damage can also be caused immediately by sudden and loud noises, for
example from explosives or cartridge-operated tools.
Hearing loss due to prolonged exposure to noise is usually gradual. It may only be when
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damage caused by exposure to noise over the years combines with normal hearing loss due
to ageing that people realise how deaf they have become.
6
Prolonged exposure to noise can also cause tinnitus, which can be described as a
permanent ringing, whistling or buzzing in the ears. This distressing condition can lead to
disturbed sleep which, in turn, can lead to fatigue even before an employee arrives at work.
Other adverse effects of noise
At work, noise can also be a safety hazard, interfering with communication, the
understanding of instructions and, most serious of all, making warnings harder to hear. Noise
can also cause stress.
1.2.10.7 Establishing noise levels
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Unit of measurement
The unit of measurement for sound levels (noise) is called a decibel (dB). This scale is
logarithmic and means that 90 dB is ten times the intensity of 80 dB and one hundred times
the intensity of 70 dB.
An increase of 3 dB doubles the energy in the sound. This means that, for example, 87 dB is
actually twice as damaging as 84 dB, even though the 3 dB difference in sound level is
difficult to perceive.
Sound level meters, used for measuring noise levels, have standard 'filters' built into them
that attenuate or emphasise signals at different frequencies in order to simulate how the
sound affects the ear. This is known as 'frequency weighting'.
An instrument with a frequency weighting known as an 'A' weighted scale is commonly used
on construction sites to measure noise from the working environment. Readings are
expressed as dB(A).
Sudden impact noises, hammer blows, etc. are measured in terms of maximum pressure. In
this case measurements are 'C' weighted and therefore expressed as dB(C).
Risk assessments should be based on measurements of the 'Leq', which is an average of

the level of noise for the duration of the measurement.
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Risk assessments
7
If any employee is likely to be exposed to noise at or above the lower exposure action
value, the Contractor must carry out a risk assessment which may or may not result in the
need for a competent person to measure the actual level of noise exposure.
Any new tool or equipment that generates a potentially harmful level of noise should state
the actual level of noise generated, either on the tool itself or in the accompanying
documents. This can be useful in identifying potentially problematic tools, but it is important
to remember that the actual noise experienced by the operator depends on many factors,
such as the acoustics of the working environment, tool configuration and material being
worked.
Survey of noise levels
If it is necessary to resort to the measurement of noise, someone who is competent in

evaluating the type of workplace, the use of the equipment and the interpretation of the
results must be engaged. They must be able to draw valid conclusions from the information
obtained and advise management on the actions needed to comply with the requirements of
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legislation.
(a)
identify workers who may be at risk of hearing damage to enable an action plan to be
prepared to control the noise exposure
(b)
determine the daily personal noise exposure (LEP,d) of workers (including times when
not actually working (for example, rest areas) and from non-occupational sources such
as personal entertainment systems)
(c)
identify additional information to comply with these Regulations, for example, whether
noise control measures or hearing protection are needed and, if so, where and what
type.

keep a record of the noise assessments and the employees exposed to the noise
(b)
regularly review those assessments. This should be done biannually or whenever it is

considered that the assessment is no longer valid, for example, whenever there is new
equipment or a change to the process that may alter noise levels
(c)
use the assessment to develop an action plan for introducing noise control measures
(d)
deal with the immediate risk by providing personal hearing protectors (this should only
be until other controls have been investigated and implemented)
(e)
identify what steps are reasonably practicable to reduce the noise exposure of
employees by engineering or other organisational means
(f)
establish priorities for action and consider what changes may need to be phased in
over the course of time.
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The aim of the noise assessment is to:
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Ideally, one person, with sufficient authority, will be given the responsibility for ensuring that
these Regulations are complied with and for co-ordinating and monitoring the noise
reduction programme where necessary.
13
Nomograms (see Appendix 4) can be used to establish the equivalent continuous sound
level for an eight hour period or daily personal noise exposure (LEp,d)
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Typical sound intensities
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1.2.10.8 Avoiding exposure to noise
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Attention should be given at the planning stage to developing a noise control strategy that
considers the following factors:
The design of the project, and of the processes and equipment which will be involved.
(b)
The phasing of differing operations, especially if a number of contractors are working

on site.
(c)
The location of the site; or sites if the project involves more than one location.
(d)
The noise levels that are likely to be produced by the work being carried out.
The layout of the site, including the siting of access points, batching plants, etc.
(e)
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Planning against excess noise levels
(f)
The hours of working which are planned.
(g)
The provisions available for controlling noise on site.
(h)
The possibility of disturbance to nearby residents and properties. (If this is likely, the
situation and measures to be taken to reduce noise should be explained to persons
likely to be affected.)
Failure to plan the control of noise may lead to delay and increased cost later. Where
appropriate, noise levels must be a consideration for designers under CDM.
Reference BS 5228 Noise and vibration control on construction and open sites
Managing noise levels during construction
Exposure to noise can be eliminated or reduced by:

(a)
controlling noise at source
(b)
employing engineering controls where possible
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(c)
using a purchasing/hire policy for plant, equipment and tools that takes noise into
account
(d)
introducing alternative methods and processes that eliminate or reduce noise levels
(e)
giving consideration to the careful siting of noisy plant, and equipment
(f)
where practical, storing bulk materials to form an acoustic screen
(g)
carrying out job rotation for employees to reduce exposure to noise
(h)
providing rest rooms or acoustic refuges for staff during breaks from work
(i)
rearranging work locations for staff, if possible, away from noisy equipment
(j)
as a last resort, providing personal hearing protectors.
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Controlling the noise at its source can be achieved by a variety of means, by:
the design and manufacture of the equipment.
(b)
the use of acoustic covers and exhaust silencers for equipment
(c)
the use of alternative, less noisy equipment or methods of working
(d)
enclosing noisy equipment within temporary structures
(e)
regular inspection and maintenance of the equipment being used
(f)
fitting noise-absorbent mountings to reduce the transmission of noise through adjacent

structures.
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Control of noise at source
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Reference BS 5228 Noise and vibration control on construction and open sites
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Measures that can be taken include ensuring that all equipment which has the potential to
create excessive noise:
is kept well maintained
(b)
is kept in good order, including ensuring that there are no loose panels or casing and
that exhaust mufflers are in good condition
is not left running when it is not actually in use.
(c)
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Engineering controls
Siting or location
6
Effective siting or location includes:

(a)
Removing the source of the noise to a distance whenever possible (see Appendix 2).
(b)
Orientating plant to direct the noise away from the work area.
(c)
Placing site buildings, stores, etc. between the noise source and noise sensitive
areas.
(d)
Screening the noise source with a barrier, wall, acoustic screen, spoil heap, or by
locating the source behind partly completed buildings.
The effectiveness of a noise barrier will depend on its dimensions, its position relative to the
source and the listener, and the material used in the construction of the barrier. Care must
be taken to ensure that barriers do not, by reflecting sound, transfer the noise nuisance from
one sensitive area to another and so create a health problem for someone else.
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Effect on working hours

8
The effect on maximum working times of exposures to equivalent continuous sound levels
without any hearing protection are listed in Appendix 1 of this section.
1.2.10.9 Personal hearing protectors

All hearing protectors produced or imported by reputable companies are manufactured to
British or International Standards. As with all PPE for use at work, ear protectors should be
selected by a competent person who can ensure, in discussion with the supplier, that it
possesses the necessary performance characteristics. Most leading manufacturers and
suppliers will offer their own advisory service.
Competence in the selection of this type of PPE is particularly important as ear protectors
that give good protection against noise at a high frequency may not offer very much
protection against low frequency noise, and vice versa.
All reasonably practicable methods must be used to reduce noise levels, but where these
remain at or above the upper exposure action value, after control measures have been
implemented, ear protectors must be made available and worn. Ear protectors are not a
substitute for other methods of noise control, they are an absolute last resort.
Employees may initially be reluctant to wear ear protection and those who are at risk must
be made aware of the potential for hearing loss that can be caused by exposure to excessive
noise levels.
Mandatory warning sign:

'Wear ear protectors'
Colour: white symbol on circular blue background
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Other considerations
5
Personal hearing protectors must be provided on an individual basis.
A competent person must be responsible for any training that may be necessary in the
correct use of personal hearing protectors.
Personal hearing protectors should normally be provided as an interim measure while more
effective and permanent methods of control are sought.
Employees must be trained in the use, care and storage of ear protectors.
Ear protectors must be suited to the user and suitable for the type of noise.
10
They must provide an effective seal.
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11
They should be stored in a clean place when not in use, unless disposable.
12
They should be inspected regularly for deterioration or damage and replaced when
necessary, unless disposable.
13
Personal hearing protectors should not 'over protect' whereby users can become isolated
from their work environment and unable to hear warnings.
14
Note: A check should be made to ensure that hazard warning signals are audible to
individuals wearing ear protectors, and the volume, tone, or method of signalling changed if
necessary.
1.2.10.10
Types of personal hearing protectors
The two basic types of protector are ear plugs and ear defenders.
Disposable ear plugs: These are made of very fine mineral fibre or foam, sometimes ready
shaped. They must be inserted correctly and, if taken out, should not be reused. They should
only be handled with clean hands.
Reusable ear plugs: These are made of rubber or plastic, and need regular, careful
washing. The initial supply and fitting should be carried out by trained persons. Different
sizes may be required for each ear and must be a good fit. They must be fitted with clean
hands as any contamination by dirt, grease or swarf may cause ear irritation. Ear plugs are
therefore unsuitable on site for intermittent use, such as can occur when operating a
breaker.
Ear defenders (or muffs): These completely cover the ear and are sealed to the head with a
foam or liquid-filled seal. Badly designed or badly produced defenders may give little or no
protection against noise. Other points are as follows:
pressure from the seal may cause wearers to complain of tightness, but loose
defenders lose most of their protective capability and are ineffective
(b)
damage and deterioration to seals also results in ineffectiveness and loss of protection
(c)
in fitting, account needs to be taken of people with different sized or shaped heads or
ears, hair styles and spectacles
(d)
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defenders fitted to safety helmets may cause problems by not fitting tightly to the ear,
or by moving as the helmet moves
(e)
facial hair and the arms of spectacles may interfere with the seal on ear defenders
(f)
defenders must be chosen to deal with a particular noise problem; ones that offer
protection against low frequency sound may be ineffective at high frequency, and vice
versa.
Ear defenders which incorporate a sound enhancement system are available. When noise
levels are low, sound detected by a microphone is replayed to the wearer enabling them to
communicate normally. When noise levels are high, the sound replay system is automatically
cut, such that the defenders act as regular ear protectors. Such products are particularly
suitable for those exposed to unpredictable short bursts of noise.
Ear protectors are only effective while they are being used. If protectors are worn for only
half the shift, only some 10% protection is gained; if worn for 7% out of 8 hours, the
protection factor is still only 75%.
Contractors providing hearing protectors that perform 4 dB better than the required
minimum, in order to take into account 'real world' factors such as poor fitting.
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1.2.10. Appendix 1
The effect on maximum working times due to exposure without protection
Maximum exposure in one working day if 80

dB(A) (LEp,d) is not exceeded
80
8 hours
83
4 hours
86
2 hours
89
1 hour
92
30 minutes
95
15 minutes
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Average noise level dB(A)
98
7.5 minutes
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101
3.75 minutes
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Increase of protection gained in relation to time if ear protectors are worn
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1.2.10. Appendix 2
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How sound levels vary with distance from source
Notes:
1
This assumes that the sound at the measurement point only comes directly from the source
and there are no reflections from the ground or any other objects
This is the noise level at the ear and not at the source
The graphs on pages 14 and 15 of this module are based on the International Organisation
for Standardisation standard where an increase of 3 dB(A) is regarded as doubling the noise
level or halving the exposure time.
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B10. Appendix 3
Calculating personal noise exposure
Nomogram for calculation of equivalent continuous sound level for an eight hour period, so
giving the daily personal noise exposure.
For each exposure, connect sound level dB(A) with exposure duration t and read fractional
exposure f on centre scale.
Add together values of f received during one day to obtain total value of f,
Read equivalent continuous sound level opposite total value of f, by drawing a line through
f9 from the time scale t = 8 to read LEP,d on the L scale.
The noise exposure figures on the nomogram are illustrative only and do not represent a
legal or safe level of exposure to noise.
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1.2.10 Appendix 4
Some typical sound levels of construction and piling equipment
(Levels given are average at source)
Construction equipment
95
Hand tools - electric
100
101
102
Hand tools - air

Forklifts
Hammer drill
103
Dumpers
104
Concrete mixer
105
Hand tools - petrol
106
107
108
109
Tower cranes
Circular bench saw
Trucks
Excavators
110
Crawler cranes
111
Heavy lorries
112
113
Ready mix
Hoists diesel
114
Loading shovel
115
116
Rock drill
Batching plant
117
118
Generators
Loaders
119
Cranes - lorry mounted
120
Compressors - compactors
128
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6 tonne drop hammer (cased piles)
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126
Bulldozers - graders
121
125
Piling equipment
Sound level dB(A)
Trench hammer (sheet piles)

Rotary bored piles
Screen drop hammer (sheet piles)
Impact boring (driving case method)
2 tonne drop hammer (pre-cast concrete piles)
Vibration system (sheet piles)
Resonant system 'h' section
Single acting air hammer (pre-cast concrete)
Diesel hammer (sheet piles)
Double acting air hammer (sheet piles)
These sound levels are for guidance only. Information should be sought from the manufacturer or the
plant hire company regarding machines on site.
Noise levels emitted from the machines will be affected by the competence of the operator and the
quality of maintenance.
For accurate measurement of site noise, a survey is necessary.
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1.2.10 Appendix 5
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Summary of legal requirements
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Contractors' duties
Exposure below the

Exposure at or
Exposure at or
Exposure at or
lower exposure
above the lower
above the upper
above the
action value of 80 exposure action
exposure action
exposure limit
values of 80 dB(A) values of 85dB(A) values of 87dB(A)
dB(A)
or peak sound
or peak sound
or peak sound
pressure of
pressure of
pressure of 140 dB
135dB(C)
137dB(C)
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Assessment of noise exposure
Record of significant findings and control measures put in place
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Risk assessment to be carried out and reviewed as necessary
Risk assessment to include extra considerations in higher risk situations

General duty to reduce risk
Risk of hearing damage to be eliminated or reduced to the lowest level
reasonably practicable
Implement organisational and technical control measures, excluding

issue of personal hearing protection
Reduce exposure below exposure limit value (ELV), if ELV breached,

identify why and modify organisational and technical measures
Ensure noise exposure in rest facilities is kept to acceptable level
Adapt control measures as necessary to take account of employee(s)

who may be particularly at risk from exposure to noise
Consult with employees on protective measures taken
.
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Section
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QCS 2014
Exposure below
the lower
exposure action
value of 80dB(A)
Exposure at or
Exposure at or
Exposure at or
above the lower above the upper
above the
exposure action exposure action
exposure limit
values of 80
values of 85
values of
dB(A) or peak
dB(A) or peak
87dB(A)or peak
sound pressure of sound pressure of sound pressure of
135dB(C)
137 dB(C)
140 dB
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Contractors' duties (continued)
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Provision of hearing protection
Ensure that personal hearing protectors are:

provided to employees who ask for them
provided to all those exposed
used by all those exposed.
et
ito
Create hearing protection zones, designated by appropriate signs and:
restrict access if justified by the level of risk
ensure as far as is reasonably practicable that all who go into a

marked hearing protection zone use hearing protection.
.
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Section
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QCS 2014
Exposure below
Exposure at or
Exposure at or
Exposure at or
the lower
above the lower above the upper
above the
exposure action exposure action exposure action
exposure limit
value of 80 dB(A)
values of 80
values of 85
values of 87
dB(A) or peak
dB(A) or peak
dB(A) or peak
sound pressure of sound pressure of sound pressure of
135dB(C)
137 dB(C)
140 dB
se
as
qa
ta
ito
all equipment provided under these Regulations, except personal

hearing protectors, are fully and properly used
all equipment is maintained in an efficient state and good
working order.
ov
er
Maintenance and use of equipment

Ensure so far as is reasonably practicable that:
the nature of the risks to hearing from noise

the organisational and technical measures taken
the action and limit values
et
Information instruction and training

Provide adequate information, instruction and training and update it as
necessary, on:
}
}
}
}
how to obtain a personal hearing protector

}
how to detect and report signs of hearing damage }
the entitlement to health surveillance
}
the results of any collective health surveillance. }
Provide information, instruction and training for anyone who has
responsibilities for ensuring the Contractor's legal duties are carried out.
.
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Section
Part
rw
QCS 2014
Exposure below
the lower
exposure action
value of 80dB(A)
Exposure at or
above the lower
exposure action
values of
80dB(A) or peak
sound pressure
of 135dB(C)
Exposure at or
above the upper
exposure action
values of
85dB(A) or peak
sound pressure
of 137 dB(C)
Exposure at or
above the
exposure limit
values of
87dB(A) or peak
sound pressure
of 140 dB
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Page 148
Health surveillance
er
Provide as appropriate if the risk assessment indicates there to be } a risk

to employees' health resulting from noise at work }
ito
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Keep and maintain records of health surveillance }

Enable employees access to their own health surveillance }
et
Where employee found to have hearing damage: }

ensure the employee is informed by a suitably qualified person }
review the risk assessment and control measures }
consider assigning the employee to alternative (non-noisy) work }
continue with health surveillance. }
Employee's duties
Use of equipment
Employees must:
make full and proper use of personal hearing protectors
use any other control measures provided by the Contractor
report any defects discovered in the protective measures to the

Contractor.
Health surveillance
Attend health surveillance procedures as required by the Contractor in
working hours and at the Contractor's expense.
QCS 2014
Section
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1.2.11 Protection of the Eyes
1.2.11.1 Key points
Many eye injuries occur to people at work each year because eye protection is not being
worn.
These accidents are easily preventable simply by wearing the correct type of eye protection.
The loss of sight, even in one eye, will have a profound effect on the sufferer.
Given the nature of most construction sites, in many cases protection of the eyes will be
achieved by the issue and wearing of appropriate personal protective equipment (PPE).
In common with other types of PPE, Contractors must:
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identify the correct type of eye protection necessary;
(b)
provide it at no charge to employees who need it;
(c)
provide adequate information, instruction and training in its use;
(d)
make sure that it is worn.
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(a)
qa
Users of eye protection must:
wear it when there is a risk of eye injury as indicated by a risk assessment;
(b)
look after it, particularly with regard to protecting the lenses or face shield;
(c)
return it to any accommodation allocated to it when not in use;
(d)
report to the Contractor any defect, such as scratched or crazed lenses, and obtain a
replacement;
(e)
report to the Contractor if it is lost and seek a replacement.
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(a)
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A person's eyes are very vulnerable and an accident or injury can completely change that
person's way of life.
Analysis of the injuries to people's eyes shows that damage is caused as follows:
et
it
(a)
75% by impact
(b)
10% by abrasion following ingress of dust or other foreign body
(c)
15% by burns or chemical contamination.
The majority of these injuries would have been prevented if the correct eye protection had
been worn.
Contractors must make a provision for the protection of the eyes of employees at work.
The protection provided must conform to the approved specifications and includes goggles,
visors, spectacles, face screens and fixed shields, either free standing or attached to
machinery or plant.
QCS 2014
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The Management of Health and Safety at Work
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If a risk assessment identifies that employees may be exposed to a risk of injury to their eyes
then, unless the risk can be adequately controlled by other means, the Contractor has a duty
to supply eye protection and must take all reasonable steps to ensure that it is worn.
Selection of all personal protective equipment should be carried out by a competent person.
ta
Duties of Contractors
as
Eye protectors should be:
issued on a personal basis to the person at risk
(b)
maintained and readily available in sufficient numbers for persons occasionally

employed.
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(a)
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Eye protectors and shields Issue and availability
Eye protectors should be kept available in sufficient numbers so that any which become lost,
destroyed or defective can be replaced.
ov
Replacement of eye protectors
All eye protectors and shields provided must comply with British or International
specifications and be:
et
it
Construction and marking
(a)
suitable for the type of work or risk involved
(b)
suitable for the user to give them minimum discomfort and ease of movement whilst
working
(c)
marked to identify their type and suitability
(d)
maintained, kept clean and disinfected.
Fixed shields
5
Fixed shields provided must:

(a)
conform to the relevant European Standard specification
(b)
be cleaned regularly, disinfected and properly maintained
(c)
be so constructed and kept in position as to protect the eyes.
QCS 2014
Section
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Duties of employees
6
It is the duty of an employee:

(a)
to tell their Contractor of any work situation which presents a risk to the health and
safety of themselves or others
(b)
where there is any risk of injury to the eyes, to use the protection provided in
accordance with the instructions and training given
(i)
to take care of eye protectors
(ii)
to report any loss or defect to the Contractor.
1.2.11.4 Eye Protection
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Identifying the type of hazard

Only when the Contractor has carried out a risk assessment to determine the hazards can
the correct type of eye protector be supplied.
Some of the types of hazard detailed require eye protectors to have sufficiently strong lenses
or shield to withstand the impact of particles or fragments striking them.
The effectiveness of the seal made between the eye protectors and the operator's skin is
very important in affording protection against the type of hazard where irritant or corrosive
materials are involved.
The ability to withstand high temperatures or reduce strong light and glare is a main
requirement for the other types of eye protector.
For further information concerning specific requirements or combinations of different kinds of

protection, manufacturers' literature should be consulted.
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1.2.11.5 Types of eye protector
There are several types of eye protector and it is important to select and issue the correct
type to give the required protection. The types and their markings are listed in Appendix 1.
Examples of the types of work for which the various standards of eye protection might be
used, are listed in Appendix 2.
et
it
1.2.11.6 Eye protection safety checklist

1
Have operations requiring eye protection been identified?
QCS 2014
Section
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Has the work activity been assessed to determine what, if any, hazards exist?
Are appropriate types of eye protection available for the various work activities to be carried
out?
Does all eye protection comply with the relevant standard?
Is the eye protection supplied on a persona] basis to employees?
Are there sufficient quantities of eye protectors available for occasional users?
Is the use of eye protection satisfactorily monitored?
Have employees been informed of work activities requiring eye protection?
Have employees been trained in the correct use and maintenance of eye protection?
10
Are employees aware of their
11
responsibilities with regards to the care and reporting of loss or defective eye protectors?
12
Are appropriate safety signs displayed?
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1.2.11.7 Lasers
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Items of equipment producing light amplification by the stimulated emission of radiation,

more normally known as lasers, are widely used on construction sites, mainly for alignment
and levelling in civil engineering. Most are of the helium or neon continuous wave type and
emit visible light, but some lasers emit in the invisible infrared region of the electromagnetic
spectrum, and these require extra caution.
The optical radiation produced by a laser is absorbed by the first few centimetres of the body
and so the skin and eyes are the tissues most at risk of damage.
All lasers should comply with BS EN 60825. This standard groups laser products into five
classes (with some subclasses), based on acceptable emission levels, and is intended to
ensure that the manufacturer and user of laser products comply with current requirements.
Appendix 3 reproduces an extract of information contained in BS EN 60825.
The use of Class 1 and 2 products is preferred on construction sites because these
represent the lowest risk of eye injury. However, even these lower power lasers can cause
eye damage if they are misused, for example, staring directly into the beam or viewing the
beam through any magnifying device.
Class 3R and 3B lasers, which may sometimes be in use, can involve hazards to both the
user and other personnel. Those who maintain, operate and supervise the use of these
products must be fully trained, competent and capable of implementing the necessary safety
and hazard control procedures.
Where lower power lasers are used, the human 'blink reflex' will offer some protection.
However, this should not be relied upon and is unlikely to offer any protection from higher
power lasers.
Appendix 4 outlines the hazards arising out of the uses of the various classes of laser and
control measures necessary.
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General procedures
Full training and information must be given to persons using lasers.
10
There should be no unauthorised access to any laser equipment.
11
All personnel must be aware of the hazards when working with lasers, the safe working
procedures and accident reporting procedures.
12
Any necessary eye protection equipment, hazard signs, barriers, etc. must be available and
in use as necessary.
13
Any eye protectors used in conjunction with lasers must be suited to the wavelength of the
laser in use. General purpose safety glasses offer no protection whatsoever against lasers
and should not be used.
14
All hazard areas must be clearly defined with signs and barriers.
15
The laser beam should only be directed at non-reflecting surfaces. Any adjacent reflective
surfaces must be covered, otherwise the beam will diverge and could affect other areas and
people not directly involved in the job.
16
Extra care must be taken when working near reflective surfaces (e.g. water, dust, spray)
which cannot be marked or covered.
17
Special precautions must be taken when working near roads, airfields and other public
areas, where a stray beam could cause a hazard.
18
When work activities require the use of high powered lasers, the work should, when
possible, be undertaken when the site is vacated (such as evenings or weekends). If this is
not possible, special precautions will be necessary to ensure that unauthorised persons do
not enter the work area or any designated area.
19
See Appendix 3 for specific precautions.
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In the event of an eye injury caused by a laser

No medication is to be applied to the eye.
21
The eye involved should be covered with a clean, dry material.
22
Immediate medical attention should be sought.
23
A thorough ophthalmic examination should be carried out within 24 hours, with a full
biophysical investigation.
20
QCS 2014
Section
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Laser safety checklist

Has a risk assessment been carried out?
25
Only competent and trained people must be allowed to operate laser equipment.
26
The hazard area should be defined and clearly marked.
27
Create an 'exclusion zone' when the more powerful classes of laser are being used.
28
When work with lasers is taking place, only authorised people should be allowed in the area.
29
The correct eye protection must be in use during all laser operations.
30
There should be no danger to any other person(s) resulting from stray reflections or from any
activity involving the use of lasers.
31
Where necessary, the source and direction of the laser beam should be clearly identified.
32
The laser beam should only be directed at a non-reflecting surface.
33
Any other reflective surfaces should be covered.
34
All laser equipment should comply with British Standard EN 60825.
35
Beam attenuators and any other safety devices must be in use when using Class 3R and 3B
products.
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24
QCS 2014
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1.2.11 Appendix 1
The standards of eye protection
Hazard description
Marking
BSEN 166 (1 or 2).S
Low energy impact (45 m/sec)
BSEN 166 (1 or 2).F
Medium energy impact (120 m/sec)
BSEN 166 (1 or 2).B
High energy impact (190 m/sec)
BSEN 166 (1 or 2).A
Droplets and splashes of liquid
BS EN 166 (1 or 2).3
Large dust particles
BSEN 166 (1 or 2).4
Gas and fine dust particles
BSEN 166 (1 or 2).5
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Increased robustness
BSEN 166 (1 or 2).8
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Short circuit electric arc
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Molten metal and hot solids

Hard coat (resistance to fine particles)
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Non-mist (resistance to fogging)
BSEN 166 (1 or 2).K

BSEN 166 (1 or 2).N
BS EN 175
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Face shields (welding)
BSEN 166 (1 or 2).9
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Notes:
The 1 or 2 in the BS EN numbers refer to the optical characteristics of the PPE.
Eye protectors manufactured to the British and European Standard are subjected to a
number of tests (including temperature, robustness and optical quality) before approval.
In the test of robustness, for example, general purpose goggles to EN 166.1 .S must
withstand the impact of a 6 mm steel ball travelling at 12 m/sec (43.45 km/h). Impact goggles
to EN 166.1.F must withstand the impact at 45 m/sec (160.93 km/h) and for EN 166.1.B they
must withstand an impact at 120 m/sec (434.52 km/h).
Eye protection to BS EN 166 A is for specialist applications and is only available in the form
of a face shield.
Safety goggles are marked with a combination of letters and numbers to indicate the
standard of protection provided, for example:
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(a)
BS EN 166.1 .F is impact-resistant to a low energy projectile.
(b)
BS EN 166.1.B.3.4 is impact-resistant to medium energy projectiles, droplets,

splashes of liquid and large dust particles.
(c)
BS EN 166.1.A.9 is impact-resistant to high energy projectiles, molten metal and hot

solids.
QCS 2014
Section
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1.2.11 Appendix 2
Selecting eye protection
The following hazards are those most likely to be encountered in construction operations.
Approved eye protection is required and must be provided for all persons engaged in any of
the processes specified below.
The protection listed below is recommended as containing good practical value, but should
be regarded as the minimum standard required.
Eye protection must be selected in the light of the work activity to be undertaken and the
assessed level of risk. A suitable and sufficient risk assessment will identify hazards and
indicate the control measures required to minimise the likelihood and severity of potential
risks.
Hazard
Recommended protection
Goggles
Face shield
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Use of compressed air with shot or

High speed flying
other abrasives for blasting or cleaning fragments or particles
(1, 2)
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PART I Processes in which approved eye protectors are required
Flying fragments or
particles
Use of hand or power tools to strike

masonry nails (4)
Flying fragments or
particles
BS EN 166.B
Goggles
Spectacles
Face shield
BSEN 166.S
Goggles
Spectacles
Face shield
BSEN 166.F
Handling and use of cartridge-operated High speed flying

tools (5)
fragments or particles
Goggles
Face shield
BS EN 166.B
Chipping of metal, chipping; knocking Flying fragments or

out or cutting of cold rivets, bolts, nuts, particles
lugs, pins, collars etc. using hand or
power tools (6)
Goggles
Spectacles
Face shield
BSEN 166.F
Chipping or scuffing of paint, scale,

slag, rust etc. from metal and other
hard materials using hand or power
tools (7)
Goggles
BS EN 166.4
Goggles
Face shield
BSEN 166.B
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Cleaning by means of high pressure

water jets (3)
BS specification
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Process to be considered
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Flying particles, dust
Use of power-driven high-speed metal High speed flying

cutting saw, or abrasive cutting-off
wheel or disc (8)
Section
Part
Page 157
Goggles
BSEN 166.3 and 4
Handling in open vessels or

manipulation of the substances
described above (12)
Flying particles, chemical

splash, injurious dust
Goggles
BSEN 166.3 and 4
Pressure injection of liquids or

solutions into buildings or structures
(14)
Chemical splashes
Goggles
BSEN 166.3
Use of hand or power tools to drive in

bolts, pins, collars etc. (13)
Flying fragments or
particles
Goggles
Spectacles
Face shield
BS EN 166.F
Breaking up of metal by use of a

Flying fragments or
hammer (whether power-driven or not) particles
or a tup
Goggles
Spectacles
Face shield
Use of compressed air to remove

swarf, dust, dirt etc. (17)
Goggles
Spectacles
Face shield
BS EN 166.S
Pouring or skimming molten metal (18) Molten metal, splash,

sparks
Goggles
Face shield
BS EN 166.9
Goggles
Spectacles
Face shield
BSEN 166.F
BS EN 166.F
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Breaking, cutting, dressing, carving or Flying fragments or

drilling with hand or power tools the
particles
following materials:(i) Glass, hard
plastics, concrete, fired clay, plaster,
slag, natural or artificial stone, and any
similar materials. Also any articles
consisting wholly or partly of these
materials(ii) Stonework, brickwork, or
blockwork(iii) Bricks, tiles, or blocks
(16)
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Flying fragments or
particles
Operation, maintenance, dismantling Flying particles, chemical

or demolition of plant which contains
splash, injurious dust
or has contained acids, alkalis,
corrosive materials, or other
dangerous substances, whether liquid
or solid (11)
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QCS 2014
Cutting of wire and related operations

(21)
Flying fragments or
particles
Goggles
Spectacles
Face shield
BSEN 166.S
Cutting of wire or metal strapping

under tension (22)
High speed flying

Goggles
Spectacles
Face shield
BSEN 166.B
Processing and handling of glass or

cullet (23)
Flying fragments or
particles
Goggles
Spectacles
Face shield
BS EN 166.S
QCS 2014
Section
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PART 11 Processes in which approved shields or approved fixed shields are required
Electric arc welding (24)
Glare, radiation, heat,

spatter
Fixed shield and/or welding Housing BS EN 175 Filters

helmet or band screen
BS EN 169
PART III Processes in which approved eye protectors or approved shields or approved fixed shields are required
Glare, radiation, heat,

splatter
Goggles
Housing BS EN 175 Filters

BS EN 169
Cutting, boring, cleaning, surfaceconditioning, or spraying of material

using apparatus supplied with oxygen
or flammable gas under pressure (27)
Flying fragments or
particles
Goggles
Housing BS EN 175 Filters

BS EN 169
Processes involving the use of lasers

(28)
Radiation and burning
Fixed shield Goggles
BS EN 60825
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Gas welding (25)
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PART IV Process in which approved eye protectors or approved shields or approved fixed shields are required
High speed particles or

fragments
Fixed shield and/or

goggles
BSEN 166 B
Dry grinding of materials or articles

using a power-driven wheel, disc or
band, or a portable tool (31)
Flying particles or hot

sparks
Goggles
Spectacles
Face shield
BS EN 166 F
Flying particles
Goggles
Spectacles
BSEN 166 S
Flying particles, spatter
Goggles
Spectacles
Face shield
BS EN 166 S
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Truing or dressing of abrasive wheels

(29)
et
it
Machining of metals including any dry

grinding process not elsewhere
specified (34)
Welding of metals by an electric

resistance process or a submerged
electric arc (35)
Cases in which protection is required for persons at risk from, but not employed in, the process
Chipping of metal, chipping; knocking Flying fragments or
out or cutting of cold rivets, bolts, nuts, particles
lugs, pins, collars, etc. using hand or
power tools (1)
Goggles
Spectacles
Face shield
Fixed shield
BSEN 166 F
Electric arc welding (2)
Glare, radiation, spatter
Cover
Goggles
Spectacles
BSEN 166 S Filters BSEN

169
Process involving lasers
Radiation and burning
Goggles
Spectacles
BS EN 60825
.
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QCS 2014
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1.2.11 Appendix 3
as
Summary of technical requirements when using lasers
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This table constitutes a quick reference guide for the safe use of lasers. For further authoritative information, consult BS EN 60825:1991.
Class 1
Labelling
Hazard warning label Yellow

background with black symbol
and border, with the words
CLASS 1 LASER PRODUCT
Class 2
Class 3R
(formerly Class 3A)
Class 3B
Class 4
1) Hazard warning label Yellow

background with black symbol
and border 2) Explanatory label
(black/yellow) LASER
RADIATION DO NOT STARE
INTO BEAM CLASS 2 LASER
PRODUCT
As 1 - 2 except explanatory label

to read: LASER RADIATION DO
NOT STARE INTO BEAM OR
VIEW DIRECTLY WITH
OPTICAL INSTRUMENTS
CLASS 3R LASER PRODUCT
As 1 - 3 except explanatory
label to read: LASER
RADIATION AVOID
EXPOSURE TO BEAM
CLASS 3B LASER PRODUCT
As 1 - 3 except explanatory
label to read: LASER
RADIATION AVOID SKIN
OR EYE EXPOSURE TO
DIRECT OR SCATTERED
RADIATION CLASS 4
LASER PRODUCT
Key control
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Classification
Requirement
Beam attenuator
Not required
Remove key when not in use
Not required
When in use prevents inadvertent exposure
Emission indicator device Not required
Indicates laser is energised
Warning signs
Not required
Follow precautions on warning signs
Beam path
Not required
Specular reflection
Not required
Eye protection
Not required
Required if engineering and administrative procedures not applicable and MPE exceeded
Protective clothing
Not required
Sometimes required
Training
Not required
Terminate beam at end of useful length

Prevent unintentional reflections
Required for all operator and maintenance personnel
Specific requirements
.
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Section
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QCS 2014
Laser health risks and control
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1.2.11 Appendix 4
Health risks
Class 1M
Potentially harmful to the eye but only if deliberately viewed

through an optical magnifying device, such as binoculars.
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Class of laser
No one must be allowed to deliberately look at the beam or to direct the beam into
another person's eyes.
Magnifying devices such as binoculars must not be used by any person who may be
exposed to a laser beam whilst using them.
May be harmful to the eyes if deliberately misused, for

example, if someone stares directly into the beam.
As above.
Harmful to the eyes if viewed through an magnifying optical

device.
As above.
Class 3R
(formerly Class 3A)
These are higher power lasers that can cause eye injuries,
generally exposure is no more hazardous than to a Class 2
device because of the human 'blink reflex'.
BS EN 60825 specifies minimum training requirements for the users of Class 3 and 4
lasers. This will include information on the risks from the beam and the advice
against misuse.
Class 3B and Class 4
A higher power laser that can cause eye injury, either

directly from viewing the beam or from reflections.
Appropriate eye protection (PPE) must be worn whenever Class 3R or more

powerful lasers are used. Class 3B and Class 4 lasers. Particular training on these
classes of laser is required. The human 'blink reflex' is not likely to offer any
protection to anyone accidentally exposed to the beam.
et
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Class 2
Control measures
Class 2M
QCS 2014
Section
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1.2.12 Protection of the Skin
1.2.12.1 Key points
Many of the substances used or created during construction activities have the potential to
cause severe skin problems.
The (COSHH) risk assessment and the information on the accompanying data sheet and a
substance's container should indicate the degree of risk and the preventative

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QCS 2014

QUALITY ASSURANCE AND QUALITY CONTROL

Foundations and Retaining Structures

Vehicle Crash Barriers

MECHANICAL AND ELECTRICAL EQUIPMENT

Settlement Tank Equipment

INSTRUMENTATION, CONTROL AND AUTOMATION

HEALTH & SAFETY

EARTHWORKS RELATED TO BUILDINGS

SECTION 15 INSULATION OF BUILDINGS

CARPENTRY, JOINERY AND IRONMONGERY

DRAINAGE WORKS FOR BUILDINGS

AIR CONDITIONING, REFRIGERATION AND VENTILATION

FIRE FIGHTING AND FIRE ALARM SYSTEMS

Analogue Addressable Fire Alarm Systems

GLASS AND GLAZING

PAINTING AND DECORATING

We welcome any observations, suggestions or additions for future issues.

Qatar Construction Specification 2002

Qatar National Construction Standards 2007

Qatar Construction Specifications 2010

Qatar Construction Specifications 2014

Qatar Construction Specification

Eng. Khalid Al-Emadi

Dr. Mohammed Saif Al-Kuwari

Abdul Hameed M. Al-Yahri

Yousef Mahmoud Ahmed Nooh

Meshal Saoud Al Mesallam

Nasser Al- Naimi

Technical Committee for Preparing and Development of QCS

Dr. Noureddin Daas

Dr. Khaled Hassan

Chairperson of Concrete Committee

Chairperson of Road Committee

Member of Concrete Committee

Chairperson of Rail Committee

Sub Committees Members

Ahmed Mohd. Sayd

Hazem Abdel Rahman

Rania Hashim Abadi

Richard James Ellis

Saleem Purayil Purayil

Preparing and Development of Qatar Building Code Committee

Eng. Khalid Al-Emadi

Khalid Al- Emadi

Road Lighting Work Group

Yousef Mahmoud Nooh

Section number and title

QCS 2014 Feedback

Section name and title

Clause and paragraph number

Comments / Suggestions / Technical Justifications

Name and contact details

Part name and title

Section 01: General

Scope of this Section

Compliance with the Qatar Construction Specification

TERMS AND DEFINITIONS .......................................................................... 5

ABBREVIATIONS AND SYMBOLS ............................................................... 7

Section 01: General

Scope of this Section

Scope of the Qatar Construction Specification

The following standards are referred to in this Part: