Volume II-A Buildings & Civil Works

PT-164 WAREHOUSE PHASE III
PLOT 5330316,5330317,5330318,5338058 , DUBAI INDUSTRIAL CITY
DESIGN & SUPERVISION

CONSULTANCY SERVICES FOR
AT
DUBAI INDUSTRIAL CITY
VOLUME II -A
SPECIFICATIONS
FOR
BUILDING & CIVIL WORKS
FINAL SPECIFICATIONS
January 2015
VOLUME II A
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LIST OF CONTENTS
VOLUME II - SPECIFICATIONS FOR BUILDING & CIVIL WORKS
SECTION A :
GENERAL PROVISIONS
A/1 - A/29
SECTION B :
DEMOLITION & SITE CLEARANCE
B/1 - B/6
SECTION C :
EXCAVATION & EARTHWORKS
C/1 - C/8
SECTION D :
CONCRETE WORK
D/1 - D/43
SECTION E
BLOCKWORK
E/1 - E/11
SECTION F
ROOFING
F/1 - F/8
SECTION G :
CARPENTRY, JOINERY & IRONMONGERY
G/1 - G/14
SECTION H :
STRUCTURAL STEELWORK
H/1 - H/18
SECTION J
METALWORK
J/1 - J/6
SECTION K :
FINISHES
K/1 - K/22
SECTION L
GLAZING
L/1 - L/6
SECTION M :
PAINTING, DECORATING &

PROTECTIVE COATING
M/1 - M/22
SECTION N :
METAL SHEET ROOFING, CLADDING

& CURTAIN WALLING
N/1 - N/34
SECTION P
ROADWORKS, BLOCK PAVING

& KERBS
P/1 - P/56
PARTICULAR SPECIFICATION
Q/1 - Q/6
SECTION Q :
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SECTION A
GENERAL PROVISIONS
1.0
GENERALLY
1.1
Contract Documents
Precedence
1.1.2
(i)
This Specification shall be read in conjunction with the Conditions of Contract

(General Conditions and Conditions of Particular Application). Drawings and
Bills of Quantities (including pricing preambles) and it shall form part of the
Contract.
(ii)
The order of precedence of the various documents comprising the Contract

shall be as follows:
(a)
The Contract Agreement
(b)
The Tender and Letter of Acceptance
(c)
Part II of the General and Particular Conditions of Contract
(d)
Part I of the General Conditions of Contract
(e)
Drawings and Specifications
(f)
Bills of Quantities
(g)
Any other document forming part of the Contract.
Extent of Work
The Works comprise all work specified for the construction, completion and
maintenance of: PT164 , Complete with all associated services, ancillaries and external works.
1.1.3
Drawings
The Drawings used in the preparation of the Contract are listed elsewhere in the
Contract document.
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1.2
Definitions
1.2.1
Definitions Applicable
The following definitions shall apply to the Contract:
(i)
"BS" shall mean British Standard
(ii)
"CP" shall mean British Standard Code of Practice
(iii)
"PD" shall mean British Standard Provisional Document
(iv)
"DD" shall mean British Standard Draft for Development
(v)
"Approved" or "Approval" shall mean approved by or approval of the

Engineer in writing.
(vi)
"Submitted" or "submit" shall mean submitted to or submit to the Engineer in

writing.
(vii)
"Accepted" or "acceptance" shall mean accepted by or acceptance of the

Engineer in writing.
(viii)
"Inspected" or "inspection" shall mean inspected by or inspection of the

Engineer.
(ix)
"Directed" shall mean directed by the Engineer in writing.
(x)
"Authorized" or "authority" shall mean authorized by authority of the Engineer

in writing.
(xi)
"Required" shall mean required by the Engineer in writing.
(xii)
"Rejected" shall mean rejected by the Engineer in writing.
(xiii)
"In writing" shall also mean verbally, later confirmed in writing.
(xiv)
"O.O.E.A.A." shall mean Or Other Equal And Approved.
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1.3
Pricing
1.3.1
Scope of Work to be Priced

The Contractor shall satisfy himself as to the scope of the work shown on the
drawings and described in the Contract Documents and his price shall be deemed to
cover all his obligations under the Contract and all matters and things necessary for
the proper construction, completion and maintenance of the Works. The price shall
include costs for all material labour and plant, whether mechanical or nonmechanical, required for the completion of the Contract in accordance with the
Drawings and Specifications, and for removing site temporary facilities at completion,
making good any surfaces disturbed and for cleaning and polishing the entire works
where relevant inside and out, and if not included in any prices inserted in the Bills of
Quantities; costs for the insurances and bonds required; for the costs of preparing his
tender; for all work in connection with the final account; for profit; and for all other
establishment charges and on-costs of whatever nature. No claim for additional
payment will be allowed for any error or misunderstanding by the Contractor in these
respects.
1.3.2
Items not Priced

The Contractor should price all items for all sections which he considers have a value. If
any items are not priced by the Contractor they will be deemed to be of no value or that
their value has been spread throughout the rates of the other items.
1.3.3
Provisional Sums
Provisional Sums will be dealt with in the manner set forth in the Conditions of
Contract Clause 58 and 59.
1.3.4
Fixing
Pricing of any items for "Fix Only" given after Provisional Sums for goods supplied
by a Nominated Sub-Contractor, supplying materials shall include for loading and
transporting from site, store, hoisting and lowering and distribution to various
positions, assembly as necessary, fixing, cover up and protecting and finally cleaning
down and where appropriate oiling and adjusting and leaving in perfect working
order.
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1.4
Work Inferred
Intent and Meaning
The Contractor shall execute the work in accordance with the intent and meaning of the
Drawings and Specifications taken together and supply all accessories and other items
essential for the proper execution of the Works and shall execute all work which may be
inferred whether or not specifically shown or described.
1.5
Mistakes in Information
1.5.1
Discrepancies, Errors or Omissions

The Contractor shall be responsible for and shall be liable to pay the extra costs, if any,
occasioned by any discrepancies errors or omissions in the drawings, whether the drawings
are approved by the Engineer or not. This shall not apply to errors, omissions or
inaccurate information supplied to the Contractor by the Engineer or his appointed
representative in writing.
1.5.2
Dimensions
Figured dimensions only shall be followed.
drawings.
1.6
No dimensions shall be scaled from the
Competence of Tradesmen
Only competent and experienced tradesmen who have proven their ability in
performing their specialist trades shall be employed on the Works.
2.0
USE AND PROTECTION OF THE SITE
2.1
Care and Protection
2.1.1
General
VOLUME II A
(i)
The Contractor shall take such measures and exercise such care to protect the
Site Plot as shown on the Site Plan (hereinafter called the Site) during the
course of the Works as directed by and to the entire satisfaction of the
Engineer.
(ii)
The Contractor shall not load or permit any part of any structure to be loaded
with a weight that will endanger its safety.
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2.1.2
2.1.3
(iii)
In pursuance of his obligations under the Conditions of Contract, the

Contractor shall whenever required or directed by the Engineer cover up and
protect the Works from the weather and from damage by his own or other
workmen performing subsequent operations. He shall provide all necessary
dust sheets, barriers and guard rails and clear away same at completion.
(iv)
The Contractor shall take all reasonable and proper steps for the protection of
all places on or about the Works which may be dangerous to his workmen or
any other persons or to traffic. The contractor shall provide and maintain
signs, red warning lamps and barricades as necessary in such places.
Temporary Work Areas

(i)
All temporary buildings and work areas such as site offices, workshops, stores,
buildings and yards, messrooms etc. shall be constructed inside the Site
boundary, or on adjacent land in positions approved by the Engineer.
(ii)
The Contractor shall confine his apparatus, the storage of materials and the
operations of his workmen to limits indicated by law, ordinances, permits or
direction of the Engineer and shall not unreasonably encumber the premises with
his materials.
(iii)
The Contractor is to allow in his rates for any temporary screens and fencing
as required by the Engineer or by the relevant authority. On completion of the
Contract, the site and any adjacent areas affected by the building operations
shall be properly cleared of all temporary work, debris and other rubbish and
all disturbed works and ground made good to the entire satisfaction of the
Engineer.
Site Access
(i)
Access to and within the site for construction traffic shall be agreed with the
Engineer before use. The Engineer may at any time withdraw approval for the use
of any route until such widening, strengthening or repair as he considers
necessary has been carried out to his satisfaction.
(ii)
Existing roads, accesses and new roads, whether part of the Works or not, used
by the Contractor's traffic for the construction of the Works shall be kept clean
of all dirt and other material. The Contractor shall provide, and use suitable
mechanical road sweepers solely for this purpose, to the approval of the
Engineer.
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2.2
Separate Contracts
Works by other Contractors
2.3
(i)
The Employer reserves the right to let other separate contracts in connection
with this work under similar conditions. The Contractor shall afford other
contractors reasonable opportunity for the introduction and storage of their
materials and the execution of their work, and shall properly connect and
coordinate his work with theirs.
(ii)
If any part of the Contractor's work depends for proper execution or results
upon the work of any other contractor, the Contractor shall inspect and
promptly report to the Engineer any defects in such work that render it
unsuitable for such proper execution and results. His failure so to inspect and
report shall constitute an acceptance of the other contractor's work after the
execution of his work.
(iii)
To ensure the proper execution of his subsequent work the Contractor shall
measure work already in place and shall at once report to the Engineer any
discrepancy between executed work and the drawings.
(iv)
The Contractor shall liaise and co-operate with all other contractors so that
their work shall proceed without delay.
Existing Services and Diversions

Protection of Services
VOLUME II A
(i)
The Contractor shall be responsible for the protection of all existing services
within the Site and shall make good any damage to existing services resulting
from his carrying out the Works to the satisfaction of the Engineer and the
relevant Authority.
The Contractor shall take all measures reasonably
required by any Utility or Authority for the support and
protection of all mains power cables and other apparatus affected by the
Works, all to the satisfaction of the relevant Utility or Authority.
(ii)
The Contractor shall be responsible for giving notice to the relevant authority
where temporary or permanent re-routing of existing services is found to be
necessary and shall provide attendance upon any contractor employed to carry out
such re-routing.
It shall be the Contractor's responsibility to make due
allowance in his Programme of Works for concurrent working by others for the
diversion of existing services.
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2.4
(iii)
The Contractor shall be deemed to have included in his Tender Price for all
Protection and working around existing services.
(iv)
All damage to any cable, pipe duct, building, etc. or charges which may be
claimed for loss of electricity, water, etc., by reason of or owing to any
excavating operations, excavations, subsidence or work before or after filling, or
any other cause shall be the responsibility of the Contractor who shall be liable
for all costs and charges in connection with the necessary remedial work or other
actions and claims.
(v)
The Contractor shall, at all reasonable times, during the progress of the Works
afford facilities to all accredited agents of any Utility or any
Authority for access to their affected apparatus to facilitate inspection,
maintenance, renewal, removal or alteration of such apparatus in connection
with the construction of the Works for any other purpose whatsoever.
(vi)
The costs of locating or verifying the location of existing services, liaison with
the various Service Authorities and complying with the above requirements
shall be borne by the Contractor unless provided for elsewhere in the Contract.
Accommodation Works
(i)
Where, in the Engineer's opinion, the convenience or amenity of an owner or

occupier or of the public generally is affected by the Works, the Engineer may
instruct the Contractor to complete any accommodation works, or part thereof,
with utmost expediency irrespective of the Contractor's overall programme of
the Works.
(ii)
The Contractor will be responsible for making all necessary arrangements with
owner and occupiers for carrying out accommodation works including, where
necessary, access on to or across private land.
3.0
3.1
SUB-CONTRACTORS
Sub-Contractors Generally
3.1.1
Approval of Sub-Contractors
VOLUME II A
(i)
All proposed sub-contractors shall be to the approval of the Engineer.
(ii)
sub-contractors who are registered, licensed and based in Dubai

Emirate will be approved, however suitable and equal sub-contractors will be
considered. This condition is applicable to all sub-contractors in all sections of
the Works.
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(iii)
In the event that any of the proposed sub-contractors do not meet the
Engineer's approval, the Contractor shall re-submit the name or names of
alternative sub-contractors until such time as a complete list of sub-contractors
approved by the Engineer has been achieved.
3.1.2 Co-ordination of Builder's Work

(i)
The Contractor shall co-ordinate the requirements of all builder's work. No

holes or fixings shall be formed without the prior approval of the Engineer.
No claim will be entertained for abortive work executed due to lack of coordination.
3.1.3 Verification of Site Measurements

(i)
The Contractor shall check and verify all site measurements whenever
requested by other specialist contractors or by nominated or other subcontractors to enable them to prepare their own shop drawings, and pass on the
information with sufficient promptness as will not in any way delay the
Works. A copy of all such information passed on shall be given to the
Engineer.
3.2
Nominated Sub-Contractors
3.2.1
Attendance Upon Nominated Sub-Contractors

(i)
The Contractor must allow, when pricing items of 'attendance' given after
Provisional Sums for nominated Sub-Contractors for the following:
(a)
The cost of placing and processing orders as directed by the Engineer.
(b)
The provision of power, light and water points adjacent to the Works
as required by the nominated sub-contractor and the free use thereof.
(c)
The provision, erection, maintenance, dismantling and clearing away

of all external and internal scaffolding required.
(d)
The provision of all plant for receiving, off-loading, storing and

subsequent handling and hoisting of materials and equipment to their final
position.
(e)
The provision and free use of messrooms, latrines, First-Aid facilities,

etc.
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(ii)
3.2.2
(f)
All other facilities necessary for the proper execution of the Works.
(g)
Co-ordinating the nominated sub-contractor's work with all other

works and arranging the nominated sub-contractor's work to coincide with
the main construction programme.
(h)
Co-ordinating the nominated sub-contractor's drawings with all others

to ensure the proper integration of all the work on site and to avoid any
resultant delays.
(j)
Obtaining and providing all measurements and details necessary for

the proper execution of the nominated sub-contractor's work.
All nominated sub-contractors for whom Provisional Sums have been included
shall provide their own offices, accommodation, workshops and stores in areas set
aside specially for this purpose by the Contractor, including all services within
each of these buildings up to the point of connection for power, water and
sewerage by the Contractor.
They shall also provide all labour for
receiving, off-loading, storing and subsequent handling and hoisting of
materials and equipment to their final position but shall require all other items of
"Attendance" as described above.
Goods supplied by Nominated Sub-Contractors

Pricing of any items given after Provisional Sums for goods supplied for
nominated sub-contractors supplying materials shall include for the placing and
processing of orders as directed by the Engineer, checking or ascertaining the correct
quantities to be listed in the order and where appropriate providing the nominated subcontractor supplying materials with correct site dimensions, for dealing with free zone
clearance formalities and unloading from transport on to shore and paying all charges in
connection therewith, for onshore loading and transporting to Site, getting into
store, protecting, unpacking and checking required, initiating and processing
insurance claims and returning packing cases carriage paid if required.
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4.0
SITE FACILITIES
4.1
Services for the Contract
4.1.1
Water for the Works

(i)
The Contractor shall provide water for the Works including that required by
the sub-contractors, pay all charges and provide all necessary temporary
pipework, pumps, storage tanks etc. and remove on completion and make
good all work disturbed.
(ii)
Any cost of importing water by tanker and storing on Site, should this prove
necessary, shall be allowed for by the Contractor. No claims arising from any
failure and or dependence upon a main water supply will be entertained.
4.1.2 Electricity for the Works

(i)
The Contractor shall provide electric light and power for the Works including
that required by the sub-contractors, pay all charges and provide all temporary
installations and remove on completion and make good all work disturbed.
(ii)
Any cost of temporary electricity generating equipment, should this prove

necessary, shall be allowed for by the Contractor. No claims arising from
failure of and dependence upon a main electricity supply will be entertained.
4.1.3. Sanitary Conveniences

(i)
Sanitary conveniences for the use of persons employed on the Works shall be
provided and maintained by the Contractor to the extent and in such a manner
and at such places as shall be approved by the Engineer and the Authority
concerned and all persons connected with the Works shall be obliged to use
them.
(ii)
The Contractor shall make all temporary arrangements for the proper
discharge of sewerage, drainage, storm and rainwater from or in connection
with the Works and shall maintain the same to the satisfaction of the Engineer
and the Authority concerned for as long as they are required.
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4.2
Offices for the Engineer
4.2.1 Office Accommodation

(i)
The Contractor shall provide air conditioned and lighted office

accommodation and furnishings in accordance with the schedule of
accommodation listed in Appendix A. These office facilities shall be for the
exclusive use of the Engineer. Accommodation shall be available within four
weeks of commencement of the Contract.
(ii)
Construction shall be soundproof, waterproof, fireproof and well insulated.

All doors and windows shall be provided with fly screens. Windows shall be
shaded if required. Interior walls shall be emulsion painted. A farash call
shall be provided in each office.
(iii)
Notices are to be provided to the free zone authority and main entrance door lettered in
English and Arabic.
(iv)
Keys to all doors shall be held by the Engineer's Representative. All desks
and cabinets shall be provided with locks and keys.
(v)
Refreshment rooms shall be fitted with:

(a)
kitchen sink with stainless steel top and cupboards below and having a
potable water supply;
(b)
refrigerator of minimum 10 cubic feet capacity;
(c)
electric kettle.
(vi)
The Contractor shall be responsible for the daily cleaning and maintenance of
the offices, their fixtures and fittings. In the event of failure or malfunction of any item of
equipment in the office the Contractor shall provide a substitute item equivalent to the
defective item without undue delay for the full period the item is required
to the approval of the Engineer.
(vii)
The toilet shall have a European W.C., wash hand basin and electric hand
drier.
(viii) The Contractor shall provide all consumables, paper, pens, and other basic
office stationery.
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4.2.2
Telephones
(i)
The Contractor shall provide 1 no. direct telephone line; with 2 extensions and
a fascisimile facility. All charges including connection, disconnection, rental,
calls within United Arab Emirates shall be borne by the Contractor.
4.3
Survey Equipment for the Engineer
4.3.1
Equipment to be Provided
(i)
The Contractor shall provide the following equipment to enable the Engineer
or Engineer's Representative to check the setting out of the Works.
The instruments shall be new or checked and re-conditioned as necessary by
authorised personnel immediately prior to the commencement of the Works.
(ii)
4.3.2
In addition to this equipment the Contractor shall provide pegs, brushes, paint
and other similar items as required.
Survey, Equipment for the Engineer
Theodolite, Wild TIA or similar c/w tripod

Automatic level, Wild or similar c/w tripod
Plumb bob and line
4m Levelling staff
1 no.
1 no.
1 no.
1 no.
30 m Fiberglass tape in case

30 m Steel tape in case
100 m Steel tape in case
3 m Steel pocket tape
2 no.
2 no.
2 no.
7 no.
2.5 m Ranging rod

Spirit level
6 no.
2 no.
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4.4 Operatives for the Engineer

4.4.1
4.4.2
Chainman
(i)
The Contractor shall have available on site a suitable experienced chainman to

the approval of the Engineer for the use of the Engineer whenever required.
The chainman shall be fluent in English.
(ii)
The chainman shall be in the employ of the Contractor and the Contractor
shall pay all costs involved in his employment.
Office Attendant
(i)
The Contractor shall have available on site an office attendant (farash), who
shall have some knowledge of English language and shall be conversant with
office procedure. The farash shall be available whenever required by the
Engineer.
(ii)
The attendant shall be in the employ of the Contractor and the Contractor shall
pay all costs involved in his employment.
5.0
MATERIALS
5.1
Materials Generally
5.1.1
Standards
In various places throughout this Specification and the Bill of Quantities reference is
made to the Standards.
Specifications and Bye-Laws issued by the British Standards Institution and other
similar organisations e.g. American Society for Testing Materials (ASTM) or
Deutsche Industrial Norm (DIN).
These reference shall in every case be deemed to include the latest edition or issue of
such Standards, Specifications and Bye-Laws including all revisions, amendments and
addenda subsequently issued.
Where materials are not specified to be to British Standard and a standard exists in
respect of such materials, then the materials shall in all respects comply with the
relevant and current British Standards. In such cases where British Standards do not
exist, the materials used shall be of the best type available and shall be to the
Engineer's satisfaction.
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5.1.2
Material Quality
The Contractor shall comply with all requirements of the latest local orders issued by
Dubai Municipality pertaining to the quality of the materials.
All the materials and manufactured goods are to be the best of their respective kinds
and as described in the Specifications and Bill of Quantities and the Contractor shall
submit for the approval of the Engineer within a reasonable time after receipt of the
Engineer's order to commence the Works, a list of the names and addresses of the
manufacturers, the trademarks and types of all materials and articles he proposes to
employ together with all specifications and descriptions that may be required in this
connection before any orders are placed. Materials Approval Forms are to be
submitted in duplicate and should include samples and relevant catalogues and data
sheets, etc. Within a reasonable time the Engineer shall issue his written decision on
the Contractor's proposals. If any of the manufacturers, materials, etc., have been
rejected by the Engineer then the Contractor must propose acceptable alternatives to
the Engineer within one week of such rejection. The Engineer's decision shall be final
and binding on the Contractor.
5.1.3
Proprietary Products
(i)
Where proprietary materials or equipment are referred to in the Contract it is

intended only to indicate the acceptable standard. The Contractor may offer
alternative materials or equipment of an equal standard.
(ii)
The Contractor must submit at the time of tender a statement listing proposed
alternatives together with such information and samples as the Engineer may
require to satisfy himself that the alternatives offered are of equal quality in all
respects to the items specified.
(iii)
All proprietary materials incorporated in the Works shall be fixed or applied

and protected strictly in accordance with the manufacturer's printed
instructions.
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5.1.4 Materials Unobtainable
5.1.5
(i)
If during the course of the Contract certain materials for use in the Works
should be unobtainable despite the best efforts of the Contractor, then the
Contractor may offer for the approval of the Engineer substitute materials.
These substitute materials, although not complying fully with the
Specification, must nevertheless be suitable and appropriate for use in the
Works.
(ii)
Acceptance or refusal of such substitute materials shall be at the sole

discretion of the Engineer. In the event of acceptance of substitute materials a
suitable price reduction shall be made in respect of decrease in quality or
value. No additional cost shall be made in the event of any increase in quality.
In the event of refusal of the substitute materials the Contractor shall not be
relieved of any of his obligations under the Contract and shall be solely liable
for any delay or loss occasioned by his failure to provide materials as
specified.
Materials to be Imported
The Contractor will be held entirely responsible for ensuring that all materials to be
imported arrive on Site in sufficient time to maintain the programme.
(ii)
5.3.2
Materials or manufactured items shall be carefully loaded, transported,

unloaded and stored in an approved manner, protected from damage and
exposure to weather or dampness during transit and after delivery to the Site.
Damaged material or manufactured items damaged during and after fixing in
position shall be removed, repaired or replaced by and at the Contractor's
expense.
Storage of Materials
The Contractor shall erect and maintain ample temporary and weatherproof sheds for
proper storage and protection of his own and for Sub-contractor's materials. Cement
and other perishable material shall have floors raised 150 mm off the ground. The
Contractor shall clear away at completion and make good all work disturbed.
Testing of Materials
5.4
5.4.1 Approved Laboratories
(i)
VOLUME II A
Testing of materials and completed Works which is required under the

Contract shall be carried out by an approved independent laboratory. All
expenses for carrying out required tests shall be paid by the Contractor. The
Contractor shall include all such costs in his price.
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5.4.2 Transportation
(i)
The costs of all transportation of materials and personnel to or from approved

laboratory shall be borne by the Contractor as shall the charges for testing
which shall be in accordance with the standard schedule of rates of approved
independent laboratory.
(ii)
The Contractor shall provide assistance as necessary to permit laboratory

testing.
(iii)
A minimum of 24 hours notice shall be given prior to performing required

tests.
5.4.3 Responsibility
5.5
(i)
The testing of work by the approved independent laboratory shall in no way

absolve the Contractor of his responsibility to ensure that the quality of all
work and materials complies with the Specification. The Contractor shall
carry out any testing he deems necessary to maintain compliance.
(ii)
Acceptance and interpretation of test data shall be the responsibility of the

Contractor and the Engineer respectively.
Witnessing
The Engineer and the Contractor's representative shall be permitted to witness the
testing carried out by the approved independent laboratory.
5.6
Samples
(i)
All sampling for such tests shall be witnessed by the Engineer's Inspectors and
labelled as per relevant standard sampling requirements.
(ii)
Certificates of compliance of materials such as concrete blocks, interlocking

paving blocks, should comply with Local Order No. 44 of year 1990 and
should have a certificate of compliance issued by Dubai Central Laboratory
for each plot.
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6.0
6.1
6.1.1
TEMPORARY WORKS
General
Design, Construction
(i)
The Contractor is entirely responsible for the design, construction,

maintenance and removal of all temporary works employed in carrying out the
Contract. The Contractor shall submit the design and layout of all temporary
works to the Engineer for his approval prior to commencement of work and
the Engineer's approval will in no way relieve the Contractor of his
responsibility for the safety of the Works, operatives, adjoining property,
structures or services and compliance with appropriate regulations and Codes
of Practice. Temporary works supporting adjoining buildings, property public
utilities and roads shall also be submitted to the appropriate authority or agent
for their approval if requested.
(ii)
The temporary works shall be designed and constructed in such a manner as to

enable the permanent structures to be built around them without detriment to
their effectiveness and due allowance will be deemed to have been made for all
necessary adjustments thereto to enable the work to proceed.
(iii)
Timber shoring, boards, struts or similar items shall not be left in position
upon completion of the Works without the written consent of the Engineer.
(iv)
All services or utilities on or adjoining the Site which are required to be

maintained operational shall be protected from movement, subsidence or
damage from any cause whatsoever by adequate temporary props, struts,
shores and protective screens to the approval of the Engineer and agent of the
service or utility.
Dewatering should be conducted appropriately wherever is needed.
6.1.2 Diversion of Traffic
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(i)
The Contractor shall construct temporary diversion ways wherever the

construction of the Works will interrupt existing public or private roads or
rights of way.
(ii)
The standard of construction and lighting of diversions shall be suitable in all

respects for the volume, size and speed of traffic using the existing way.
(iii)
All diversions are to be approved by Tamdeen And Authorities.

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6.1.3
Scaffolding
The Contractor shall provide, erect, maintain, dismantle and clear away at completion
proper and adequate internal and external scaffolding including that required for all
sub-contractors and specialists. Any holes shall be made good to match the adjacent
surfaces as the scaffolding is dismantled. The Contractor shall be entirely responsible
for all safety precautions in connection with scaffolding and for its entire sufficiency
for the work.
6.1.4 Cleaning of site

(i)
The Contractor shall maintain the Site in a reasonable neat and orderly
condition free from accumulation of waste materials and rubbish during the
entire construction period and all to the satisfaction of the Engineer.
Immediately prior to handing over of the Works all drain pipes, ducts, gullies,
manholes, chambers, etc., are to be cleared by rodding or by other approved
means.
(ii)
On completion the entire site and its environs are to be cleaned of all
construction materials, etc., to the satisfaction of the Engineer.
6.1.5 Protection
(i)
In pursuance of his obligations under the Conditions of Contract, the

Contractor shall wherever required or wherever directed by the Engineer cover up
and protect the Works from the weather and from damage by his own or other
workmen performing subsequent operations.
He shall provide all
necessary dust sheets, padding, protective strips, sheets, panels layers, barriers
and guard rails and clear away the same at completion.
(ii)
The Contractor shall take all reasonable and proper steps for the protection of
all places on or about the works which may be dangerous to his workmen or
any other persons or to traffic. The Contractor shall provide and maintain
signs, red warning lamps and barricades as necessary in all such places.
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7.0
CONTRACTOR'S DRAWINGS
7.1
General
Drawings Provided to the Contractor
7.2
(i)
The Contractor will receive from the Engineer the drawings listed together
with any further drawings issued under Clause 7 of the Conditions of Contract.
(ii)
The Contractor shall be solely responsible for providing all sub-contractors,

whether nominated or otherwise, with sufficient copies of all relevant
drawings in order that they can complete their work within the approved
construction programme under Clause 14 of the Conditions of Contract.
Workshop Drawings
Drawings by Contractors
The Contractor and all sub-contractors, whether nominated or otherwise, shall prepare
the following drawings and information based upon the drawings issued by the
Engineer:
(a)
Bar Bending Schedules

The Contractor shall prepare bar bending schedules for all reinforcement in a
format to be agreed with the Engineer.
(b)
(c)
(i)
Workshop Drawings for Architectural, Mechanical, Electrical and Plumbing

Installations and all other services involved in the project.
(ii)
The Contractor shall prepare all workshop drawings for Architectural, Mechanical,
Electrical and Plumbing Installations to a scale of 1:50 for Layouts and
1:20 for Details.
The Contractor and all sub-contractors, whether nominated or otherwise, shall

provide workshop drawings for their own trades, where applicable, or when
requested by the Engineer. The workshop drawing shall clearly show all
dimensions, details, specifications, connections or joints to other trades,
incorporation of the work of other trades, etc.
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(d)
Builder's Work Drawings

Sub-Contractors whether nominated or otherwise, shall provide drawings
showing the exact dimension and location of all holes, ducts, recesses, access
points, etc. These drawings shall also specify all necessary Builder's Work in
connection with movement precaution, sound and thermal protection etc.
(e)
Manufacturer's Drawings
The Contractor and all sub-contractors whether nominated or otherwise shall
provide manufacturer's drawings for their own trades, where applicable, or
when requested by the Engineer. The manufacturer's drawings shall clearly
show all dimensions, details, specifications, connections or joints to other
trades, incorporation of the work of other trades, etc. During the currency of
the Contract, the Contractor and all sub-contractors whether nominated or
otherwise, shall arrange for the manufacturers to prepare and submit for
approval by the Engineer five copies of manufacturer's drawings of major items
of equipment such as boilers, refrigeration plant, air handling plant, cooling
towers, switchgear, starter panels, etc. in plant rooms and associated areas. In
addition they shall also provide workshop drawings of any portions of the
work which the Engineer may require to be shown in greater detail than that
indicated on the manufacturer's drawings.
(f)
As Built Drawings and Operation and Maintenance Instruction Manuals

(i)
The Contractor shall provide to the Engineer at the time of completion

of the Works as defined in Clause 48 of the Conditions of Contract,
"AS BUILT" Drawings for the Architectural ,Mechanical, Electrical
and
Plumbing
Installations etc. and Operation and Maintenance Instruction Manuals
for other installations or sections of the Works where required by the
Engineer. Immediately on completion of any Sub-Contract Works all
sub-contractors shall prepare a set of "AS BUILT" drawings of the
Sub-Contract Works. These drawings shall be a complete record of the
Sub-Contract Works showing the position of pipe runs, valves,
equipment, automatic controls, etc., for the Mechanical Services and
cable routes, switchgear, distribution boards, switches, socket outlets,
lighting points, auxiliary equipment, etc., for the Electrical Services.
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(ii)
(iii)
(iv)
(v)
7.3
7.3.1
The Electrical As Built Drawings shall indicate the position of all

access panels for encased works. During the preparation of these
drawings the sub-contractor shall agree with the Engineer a logical
system of switchboard distribution and circuit reference numbers, and
these numbers shall be shown on the As Built Drawings.
The Contractor shall provide the Engineer with five bound sets of
Operation and Maintenance Instruction Manuals for all services,
installations and equipment installed. The Operation and Maintenance
Instruction Manuals shall contain all manufacturer's operating and
maintenance instructions and detailed drawings of all equipment
supplied. The detailed drawings do not require to be specially
prepared and can comprise copies of the manufacturer's workshop
drawings with suitable titles and reference numbers added. The exact
scope and details of the Operating Instructions shall be agreed with the
Engineer. The provision of the above Operation and Maintenance
Instruction Manuals shall form part of the Contract, which shall not be
deemed to be complete until they are received.
After approval by the Engineer the Contractor shall forward to the
Engineer four prints and one reproducible copy of each drawing.
Area services, surface levels and setting out/general detail drawings are
to be provided to a scale matching the Employers 1:500 series record
drawings.
Contractor's Responsibilities
Co-ordination
(i)
The Contractor shall be responsible for co-ordinating all Drawings including
those produced by sub-contractors whether nominated or otherwise and
Government, Municipality Authorities or others employed direct
in connection with the Works so that the work of each may be installed in such
a manner as to ensure proper performance and adequate fixing to the structure
and to avoid conflicts in the positioning of various ducts, pipes, cables, other
items of service installation and other like items.
(ii)
The Contractor shall employ a competent person experienced in the coordination of engineering and other installations to perform this duty. He shall
arrange for his sub-contractors, including nominated sub-contractors,
Government, Municipal Authorities, or others employed direct to attend any
necessary co-ordination meetings.
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(iii)
7.3.2
Any amendments to the Drawings consequent upon the co-ordination of the

various installations shall be made by the sub-contractors or others concerned
prior to such drawings being submitted to the Engineer for approval.
Approval of Drawings
(i)
All drawings prepared by the Contractor, his Sub-Contractors whether

nominated or otherwise, or Government, Municipal
Authorities or others employed directly in connection with the Works, shall be
submitted at the appropriate time to the Engineer by the Contractor and this
will be the only accepted and contractual method. The Engineer shall check
and approve these drawings in a reasonable time and issue them to the
Contractor as "Approved for Construction". Such approval shall not relieve
the aforementioned parties of responsibility for any discrepancies, errors or
omissions in their submittal.
(ii)
If the Engineer shall instruct the re-drawing, alteration or amending of any of

the submitted drawings which, in his sole opinion, do not properly interpret
the intent of the Contract or for any reason do not comply with good building
practice, then the Contractor shall ensure the carrying out of the Engineer's
instructions and no claim for extra payment shall be allowed for any reason in
this respect.
(iii)
Should the Engineer instruct the alteration or amending of any drawing

prepared by any of the parties above then the Contractor shall ensure that this
is done immediately in order to avoid any delay to the construction
programme and no claim for extra payment or extension of time for
completion of the Works shall be allowed for any reason in this respect.
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5330316,5330317,5330318,5338058
, DUBAI
INDUSTRIAL
(iv) PLOT
The
Contractor shall prepare a detailed
programme
for CITY
the production of the
drawings and any information required immediately upon receipt of the
Engineer's order to commence the Works. The programme , which will be
subject to the scrutiny of the Engineer who may alter or amend it as he sees fit,
shall be compatible with the programme for the construction works. The
programme shall show the following in detail:
(a)
Dates on which the Contractor and sub-contractors whether nominated

or otherwise shall commence the drawings.
(b)
Dates on which the Contractor shall submit the drawings to the

Engineer.
(c)
Reasonable period for the Engineer to check and approve the submitted
drawings.
(d)
Date of commencement of the relevant work on Site.
(e)
All trades and/or elements as appropriate in their proper sequence.
(f)
Any other information the Engineer may request.
The Contractor shall ensure that all involved parties above meet the dates in
this detailed programme. None of the said parties shall put in hand any related
manufacture or installation before drawings called from them, together with
any explanatory literature, are approved in writing by the Engineer.
VOLUME II A
(v)
All drawings by the Contractor shall be prepared in a clear and proper manner,
with adequate lettering size so that the drawings will be easily legible even
when reproduced on a reduced scale. They shall be drawn in black on a white
background to facilitate printing bearing at the bottom right corner the
approved Contract reference, title block and number.
(vi)
All drawings by Contractors shall be orientated to match the design drawings

and shall have a key plan identifying the location or area of the Works to
which they apply. They shall also bear indication and make reference to the
geographic co-ordinates of the Site.
(vii)
When a drawing is revised, the particulars of the current revision shall be

clearly marked or circled, to facilitate checking. All prior revision numbers
and references of drawings possibly superseded by the current issue shall also be
clearly shown.
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(viii) When drawings are submitted for approval without complying with these
requirements, they may be rejected.
(ix)
The Contractor shall submit to the Engineer two prints of each drawing or
document. If the drawing or document is approved, one will be returned to the
Contractor bearing the "Approved for Construction" mark. The Contractor
shall then submit a further five prints of the approved drawing or document to the
Engineer.
If the drawing is not approved, one will be returned to the
contractor bearing the "Not Approved" mark for re-submission.
(x)
Re-submission of drawings not approved shall be made using the same

procedures as in the original submission.
(xi)
The Contractor shall ensure that drawings, etc., which are submitted for
approval are forwarded in sufficient time to allow the Engineer a reasonable
time to examine them.
(xii)
The Contractor shall ensure that drawings are submitted at regular intervals,
on an even flow basis, with sufficient and reasonable time prior to the date
required for approval to permit amendments to be made.
8.0
PROGRAMME AND PROGRESS MONITORING
8.1
Programme of Works
8.1.1
Programme to be Submitted
The Contractor shall submit to the Engineer for approval a Programme of Works
within one week of the award of the Contract.
Five copies of the approved
programme shall be provided by the Contractor. The programme shall incorporate the
following:
(a)
all construction activities by the Main Contractor and sub-contractors,

including nominated sub-contractors;
(b)
all works to be completed concurrently by Statutory Authorities or other

Contractors;
(c)
indication of all critical activities;
(d)
a projected manpower and plant schedule to include sub-contractors labour,

but excluding non-productive labour (e.g. cooks, etc.);
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8.1.2
(e)
a critical path network and flow chart detailing earliest start dates, earliest
completion dates, latest start dates and latest completion dates;
(f)
a weekly testing programme including the date, type and number of tests to be
performed.
(g)
quantities of the various elements of the work along with outputs expected.
Programme to be Updated
Should progress vary from the Programme of Works the Contractor shall, if so
instructed by the Engineer, provide a revised programme, updated to show measures to
be taken to complete the Works within the Contract Programme, or anticipated
overrun if such measures are not feasible.
8.1.3
Progress Reports
The Contractor shall submit prior to each site meeting in a format to be agreed with the
Engineer a typed progress report including a schedule of all Programme activities
indicating the programmed percentage completion and actual percentage completion of
each activity at the date of reporting. The report shall include details of any
information required from the Engineer.
8.1.4
Schedule of Material Orders

Within four weeks of commencement of the Contract the Contractor shall submit for the
Engineer's approval a schedule of materials including all horticultural plant
material to be ordered and sub-contract activities showing the required latest
commencement date on site or latest date of delivery of materials and latest date for
ordering, in order to meet the Programme of Works.
8.1.5
Daily Report on Plant, Equipment & Manpower

The Contractor shall submit at the beginning of every working day a report indicating
details of plant equipment and manpower available on site.
8.1.6
Daily Work Report

At the beginning of every working day the Contractor shall submit a report to the
Engineer indicating the works which are in progress as well as the works which will be
taken up in hand. In this report the Contractor shall also indicate schedule of tests to be
carried out on that day.
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8.2
Site Meetings
Frequency of Meetings
(i)
The frequency and timing of site meetings shall be at the discretion of the
Engineer.
(ii)
The Engineer shall if deemed appropriate convene meetings in addition to

regular site meetings to discuss specific aspects of the Works.
8.3
Progress Photographs
8.3.1
General
8.3.2
(i)
The Contractor shall provide monthly record photographs of the Works.

Photographs shall be taken by an approved photographer and shall cover such
extent of the construction of the Works as the Engineer shall direct.
(ii)
All progress photographs shall be taken by a camera which will incorporate on

the print the date of exposure.
(iii)
Photographs shall be in a standard 35 mm format.
(iv)
A permit is required to be obtained from the Employers Security Department

before bringing a camera into the Free Zone.
Photographs to be Provided
(i)
The Contractor shall supply each month 4 sets of up to 12 photographs as

directed by the Engineer. Prints shall be 180 x 130 mm (7" x 5").
(ii)
Copyright
The copyright of all photographs shall be vested in the Client and negatives
and prints shall be delivered to the Engineer within one week of the date of
exposure.
The photographs shall not be used for any other purpose without the written
approval of the Client.
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8.4
Monthly Valuations
8.4.1
Information to be Submitted
The Contractor shall submit to the Engineer at the end of each calendar month, or as
otherwise agreed, an approximate valuation of the total work done with all items set out
in full, in accordance with Clause 60 of the Conditions of Contract.
8.5
Completion Certificates
The Contractor shall not be granted a completion certificate or partial completion
certificate until such time as he has obtained approval in writing from the service
authorities for the applicable portion of the installation.
Duplicate copies of the approvals issued by the various Authorities should be passed to
the Engineer for his records.
9.0
PUBLICITY
9.1
Notice Boards
9.1.1
Boards to be Provided
The Contractor shall provide, erect and maintain two substantial illuminated notice
boards on the Site to the Engineer's approval. The boards shall be to an approved size
constructed of plywood and shall be signwritten, by a skilled signwriter, in Arabic and
English with the title and particulars of the Contract, Owner's name and the names
and addresses of the Consultants and General Contractor. Under no circumstances
shall Sub-Contractor's and Supplier's nameboards be fixed on hoardings or elsewhere
on the Site. Notice boards and their location must be approved by the Engineer's
Representative before erection.
The Contractor is responsible for obtaining all
necessary approvals.
9.1.2 Engineer's Approval

(i)
The Contractor or any agents in his employ shall not give information
concerning the Works for publication in any form without the written approval
of the Engineer.
(ii)
The Contractor or any of his sub-contractors shall not erect a placard or

advertisement within the site without the written approval of the Engineer.
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10.0
SAFETY
10.1
Safety Rules and Regulations

The Contractor shall at all times strictly observe the requirements for safety of any
Statutory Regulations published.
10.2
Safety Officers
The Contractor shall inform the Engineer in writing within 2 weeks of the start of
Works the name of responsible persons resident on the Site who will be undertaking the
duties of Safety Officer and Safety Supervisor on Site.
11.0
PROTECTION
The Contractor shall provide and maintain suitable protective covering throughout the
Contract and the Period of Maintenance to all external lights, signage and other such
similar items and remove on expiry of the period.
12.0 GENERAL REQUIREMENTS

KEY stakeholders comprising all of but not limited to designers and builders should be a
part of integrated design development process wherein important aspects such as ENERGY
EFFICIENCY GOALS, COMMISSIONING SCOPE, EASE OF OPERATIONS &
MAINTENANCE, etc are deliberated. The process should include discussions on envelope,
HVAC options, lighting schemes, innovative day lighting technologies benefits / costs,
Renewable technologies, pay back periods etc as applicable for the project.
1) A detailed presentation is made on Sustainability (As applicable to this project), to all the
stakeholders.
2) The presentation has to be a part of the Agenda during formal "Project Kick-off" meeting.
3) The key stakeholders should comprise ALL of but not restricted to the following:
a) Civil and MEP contractors
b) Project Architect and consultants
c) Client representative
d) Product and technology suppliers.
13.0 FACILITY / BUILDING SERVICES TUNING
A Tuning report has of the essential building services of the facility comprising the HVAC,
Renewable and Lighting systems and other systems if relevant has to be submitted after
12 months of the operations date
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APPENDIX A
OFFICE ACCOMMODATION FOR THE ENGINEER
Engineers on site:
Resident Engineer
Quantity Surveyor
LAND |Surveyor Infrastructure
Electrical Engineer
Mechanical Engineer
Civil Engineer
Assistant Resident Engineer
Site |inspector - Civil
Site Inspector - Electrical
Site Inspector mechanical
Document Controller
Secretary
Offices
Overall floor area comprising the following for the above Engineers.
Offices, separate office for the resident Engineer and
Electrcial and Mechanical Engineers
Toilets
Pantries
Conference Room for at least 18 persons
Samples/Materials Room
Furniture & Equipment for all the Engineers on site;
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Desk with lockable drawers, adjustable swivel chair and side board for all enginerrs and
inspector
Executive desks with lockable drawers adjustable swivel chair and side
board for the engineers
AO size drafting boards
Drafting chairs
Vertical drawing holders
Filing cabinets
Conference table with 18 chairs
Materials and samples storage unit 12
nr Side board for conference room 6
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Attendance:
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nr Dustbin Crockery for 16 persons

Hot plate and kettle
Consumable paper, pens, and other office stationery, etc., as required. 1 nr
Telephone line
Extension Telephones
Facsimile facility
Photocopier / scanner
Printer A4 / A3 size
Computers
Two four-wheel drive car .Facilities:Parking (covered) bay
for 16 cars
Full cleaning facilities
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OFFICE ACCOMMODATION FOR THE CLIENT
Offices:
Offices
Toilet
Pantry
Furniture & Equipment;

Desk with lockable drawers, adjustable swivel chair and side board
Executive desk with lockable drawers adjustable swivel chair and side
board
Telephone
Computer
Curtain
Cabinet high and low
Filing cabinets
Facilities: Parking (covered) bay for 3 cars

Attendance: Full cleaning facilities
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SECTION B
DEMOLITION AND SITE CLEARANCE
1.0
GENERAL
1.1
Scope of Specification
This Specification deals with the general requirements for the demolition of buildings,
other structures and services above and below ground level and/or for the clearance of
site of other superficial obstructions.
1.2
Survey before Commencement

Before commencing the Works, the Contractor shall study all available drawings and
carry out a thorough survey and examination of buildings, structures or services to be
demolished or of the site to be cleared. The Engineer shall be fully informed of the
results of this survey. The amount and extent of the demolition and/or site clearance
together with the time schedule shall then be agreed with the Engineer.
1.3
The Contractor shall follow the recommendations of BS 6187 and HSE publication
29, unless specified otherwise within this Section.
2.0
DEMOLITION
2.1
Extent of Work
The Contractor shall demolish, break up and remove buildings, structures and
superficial obstruction on the Site in the way of or otherwise affected by the Works.
He shall clear each part of the Site at times and to the extent required or approved by
the Engineer.
2.2
Demolition Techniques
(i)
Demolition shall be carried out using techniques which will not be detrimental
to adjacent or adjoining structures or parts of structures which are not to be
demolished.
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(ii)
Underground structures and chambers shall be demolished and removed to the

depths shown in the Contract or as directed by the Engineer. Building
foundations shall be removed to a depth of 1m below ground level, unless
otherwise indicated in drawings or instructed by the Engineer.
(iii)
Where directed by the Engineer, the Contractor shall excavate in trenches and
break out redundant pipes, ducts and surrounds. Trenches and pits resulting
from site clearance below ground level shall be properly cleaned out and
filled with compacted suitable material in accordance with the Earthworks
Specification
3.0
GENERAL SITE CLEARANCE
3.1
Debris and Obstructions

Before commencing any excavation or fill, the area shall be cleaned of all debris,
materials or obstructions which in the opinion of the Engineer would adversely affect
the uniformity or stability of fill.
3.2
4.0
Removal of Trees and Shrubs

(i)
Before removal of any trees or shrubs the Contractor shall obtain written
consent from the Engineer and any relevant authority at least two weeks in
advance of planned removal.
(ii)
The Engineer's approval of any removal of trees and undergrowth must be

obtained before commencement of work. Where directed all bushes,
undergrowth, etc. shall be grubbed up and burnt or otherwise disposed of in
tips off site. Holes left by stumps or roots shall, within one week, be filled
with suitable material, compacted to the Engineer's satisfaction.
PRESERVATION OF PROPERTY
Existing Facilities
(i)
Existing highways, facilities, adjacent property, trees and plants designated for
preservation shall be suitably protected from injury or damage by the
Contractor from his operations.
(ii)
The form of protection of vegetation within the Site shall be of a type and
standard approved by the concerned authority.
(iii)
The Contractor shall ensure that access to adjoining properties is not impeded
by his work.
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5.0
DISPOSAL OF OLD MATERIAL
5.1
Materials to remain property of Employer

(i)
Where specified, certain materials arising from the Site clearance are to
remain the property of the Employer. All fossils, antiquities and other objects
of interest or value which may be found or uncovered on the Site shall remain
or become the property of the Client and the Contractor shall forthwith:
(a)
Use his best endeavours not to disturb or damage the object.
(b)
Cease work which would endanger the object or prevent or impede its
removal.
(c)
Inform the Engineer of the discovery and precise location of the object.
(ii)
The Engineer will issue instructions on the procedure to be adopted which

may include conditions to permit the examination, excavation or removal of the
object by a third party.
(iii)
Subject to the provision of clause 27 of the Conditions of Contract and of this

Specification, all materials arising from site clearance which are surplus to or
unsuitable for use in the Works shall become the property of the Contractor
and shall be disposed of by him either off the Site to an
approved Dubai Municipality tip or if agreed by the Engineer on the Site in an
approved manner.
(iv)
Where the Contract requires surplus material to remain within the DIC
the Contractor shall propose two sites for disposal of unsuitable or surplus
material, one of which shall be specified as having priority and which must
be filled before the second is used, together with a separate location where
hard debris, such as concrete, kerbing, etc. shall be disposed of
(v)
Asbestos waste shall be disposed of in accordance with local Authorities and

Dubai Municipality regulations.
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Existing items to be stored

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6.0
6.1
6.2
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(i)
Existing items which are to be stored shall be removed, cleaned and stored at
site. The materials shall be labelled to show their original location.
(ii)
The materials shall be handled and stored in such a manner as to minimise any
damage which will impair their re-installation and re-use. 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.
(iii)
Roofing and cladding sheets which are to be retained shall be stored on a level
foundation on timber bearers at 1m spacing along the length of the sheet.
Stacked sheets should not exceed 1.2m in height with intermediate timber
bearers at mid height placed immediately above lower bearers.
EXISTING SERVICES
(i)
Existing services shall be relocated, diverted if necessary, and protected in

accordance with Section A. The Contractor shall submit to the Engineer
details of proposed measures to make safe existing services which are to be
retained and proposed measures to keep safe any nearby thoroughfares.
Contractor shall provide and maintain sufficient and adequate temporary
supports throughout the demolition period.
(ii)
The Contractor shall ensure that services to unused installations are safely
disconnected prior to demolition. Notification of disconnection shall be given to
the appropriate Authorities.
(iii)
Before commencing any work on or around existing services the Contractor

shall ensure that they are rendered absolutely safe and that all necessary
hot/cold work permits are obtained.
Existing Drains
(i)
Drains, manholes and gullies that are to remain shall be protected and kept
clear at all times. They shall be left clean and in working order.
(ii)
Unless directed otherwise by the Engineer, all abandoned services above and
below ground obstructing the Works shall be taken up and removed from the
Site. Any remaining pipes, ducts and drains shall be plugged with lean
concrete mix A1 (as defined in Table D.1 of Section D Concrete Works).
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Underground Voids
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The Contractor shall report to the Engineer details of any underground caverns,
chambers or wells, etc. discovered during demolition operations and protect and
illuminate if necessary any dangerous openings.
6.3
6.4
Gas or Vapour
(i)
The Contractor shall take precautions to prevent leakage or formation of

flammable, explosive, unhealthy or environmentally hazardous gas or vapour.
(ii)
Pits, drains and manholes shall be checked before entry to ensure that the
atmosphere is fit for respiration. Where necessary respirators in accordance
with BS 2091 and stand-by men trained in the use of rescue equipment shall
be provided.
Asbestos
The recommendations of HSE publication 44 and the Asbestos Regulations 1969 shall be
followed when removing asbestos articles.
6.5
Dust
The quantity of dust in the atmosphere shall be minimised by spraying the demolition
works with water.
6.6
Vibration and Noise

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 where noisy machinery is used.
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7.0 STANDARDS
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British and other standards and codes of practice referred to in this section are as
follows:
BS 2091:1969:
Specification for respirators for protection against harmful

dusts, gases and scheduled agricultural chemicals.
BS 5228:
Noise control on construction and open sites.
Part 2:1984
BS 6187:1982
Guide to noise control legislation for construction and

demolition, including road construction and maintenance.
Code of practice for demolition.
Asbestos Regulations 1969 (SI 1969 No. 690)

HSE Publication 29
Part 1
Part 2
Part 3
Part 4
Health and Safety in Demolition Work.

Preparation and planning
Legislation
Techniques
Health Hazards
HSE Publication 44 Asbestos: Health precautions in industry.

DIC Health and Safety Regulations.
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SECTION C
EXCAVATION & EARTHWORKS
1.0
GENERAL
1.1
Scope of Works
Earthworks shall include all operations necessary for excavating, filling and
compacting and protecting any material above 0.0 metre level to the dimensions,
lines, levels and profiles required in the Works.
The Contractor shall take and be responsible for any necessary measures to protect
faces of excavation or fill which are exposed during construction.
1.2
Definitions of Earthworks Materials

The following definitions of earthworks materials shall apply to this and other Clauses
of the Specification in which reference is made to the defined materials:
(i)
suitable material shall comprise all that which is acceptable in accordance

with the Contract for use in the Works.
(ii)
unsuitable material shall mean other than suitable material and shall
comprise:
(a)
refuse and man-made materials;
(b)
vegetation and perishable materials;
(c)
materials susceptible to spontaneous combustion;
(d)
clay of liquid limit exceeding 90 and/or plasticity index exceeding 65

both determined in accordance with BS 1377: Part 2.
(e)
materials having a moisture content greater than the maximum

permitted for such materials in the Contract, unless otherwise
permitted by the Engineer.
(f)
materials containing chlorides, sulphates or other chemicals in

quantities which will be injurious to the Permanent Works;
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1.3
(iii)
rock shall mean geological strata or deposits so described in the Contract and
any hard natural or artificial material requiring the use of blasting or approved
pneumatic tools for its removal but excluding individual masses less than
0.25 m in excavations having a width less than 2 metres or less than 1.0 m in
general excavation.
(iv)
artificially hard material shall mean placed material such as foundation bases
and buried previous works encountered, requiring the use of blasting or
approved pneumatic tools for its removal but excluding individual masses less than
0.25 m.
Record Surveys
Before commencing excavating or filling the Contractor and the Engineer shall jointly
survey and agree the ground levels on the Site as specified in Section A. The levels
shall be recorded by the Contractor on the Survey Drawings.
1.4
Site Clearance
Before commencing any excavation or filling the Contractor shall clear the ground in
accordance with Section B and to the satisfaction of the Engineer.
1.5
Earthworks to be Kept Free of Water

The Contractor shall arrange for the rapid dispersal of water shed onto the earthworks
or completed formation, or which enters the earthworks from any source.
1.6
Setting Out
(i)
The Contractors calculations for setting out from established points shall be
available for inspection by the Engineer.
(ii)
The Contractor shall take all necessary precautions during the progress of the
Works to ensure that co-ordinated points are not damaged.
(iii)
All setting out is to be checked and approved by the Engineer.
(iv)
Setting out is also to be checked and agreed with the local statutory
body/authority, which for Works within the |Dubai Industrial City.
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2.0
VOLUME II A
EXCAVATION
FOR TENDER REV- 0

2.1
Extent of Excavation
Excavation shall be taken out in all material by whatever means necessary to the lines and
levels shown on the Drawings, or as ordered by the Engineer.
Slopes and
formation surfaces shall be trimmed true to the required profiles.
All excavations beyond the Contract limits, as shown on the Drawings, or the limits
otherwise ordered by the Engineer shall be made good with concrete Mix Ref A1
(Table D1 in Section D of this Specification) or with compacted approved suitable
material from excavations as ordered by the Engineer.
2.2
Stockpiles
Stockpiles of approved suitable materials from excavations shall be formed at
locations and in a manner agreed by the Engineer. Stockpile sites shall be cleaned up
after use and restored to their original condition.
2.3
Removal from Site

All excavated unsuitable material, other than that surplus to the requirements of the
Contract shall be removed from the Site to a tip provided by the Contractor, unless
otherwise authorized or directed by the Engineer.
No excavated suitable material, other than that surplus to the requirements of the
Contract, shall be removed from the Site, unless otherwise authorized or directed by
the Engineer. Should the Contractor be permitted to remove suitable material from
the site to suit his operational procedure, then he shall make good from his own
resources any consequential deficit of fill with sufficient suitable fill material to
occupy, after full compaction, a volume corresponding to that which the excavated
suitable material occupied.
2.4
Excavation for Trenches, Pits etc

When excavating pits and trenches the Contractor shall provide all necessary
timbering, sheet piles or other supports, and shall shore the sides of excavations,
trenches, pits etc. in such a way as to prevent any movement of the sides of the
excavation or damage to adjacent structures.
Unless shown otherwise or approved by the Engineer, the sides of excavations shall not
be battered. The spoil from deep excavations shall be deposited at a safe distance from
the edge of the excavation.
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2.5
Pipe and Cable Trenches

Trenches for pipes and cables shall be set-out in straight lines and to uniform falls
between inter-sections. Sight rails shall be set-up at all inter-sections. Trenches for
pipes and cables shall be so excavated as to allow the pipes or cables to be properly
laid, jointed, inspected and tested. In areas of filling, trenches for pipes and cables
shall be dug after the fill material has been fully compacted and approved by the
Engineer.
The method of supporting the excavations must be such that disturbance to the
bedding below the pipes and cables is minimised.
The trench bottom shall be hand finished to correct levels and free from unsuitable
material, stones or other sharp objects. Unsuitable material in trench inverts shall be
removed and replaced by approved bedding or suitable material. The trench bottom
shall be compacted by approved means to a density of not less that of the undisturbed
ground.
Where pipes are not required to be bedded on concrete or bedding material, the trench
bottom shall be formed so that each pipe is properly supported throughout its length
with recesses taken out at joints.
No pipes, cables or bedding material shall be placed in trenches until the trench
bottom has been approved.
2.6
Bottom of Pits and Trenches

In excavations for foundations, rock surfaces shall be thoroughly cleaned until sound
rock is exposed over the whole area. In material other than rock the last 150 mm of
excavation shall be carried out by hand, and only when concrete blinding is about to
be placed. Before blinding is placed, the material in the bottom of the excavation
shall be compacted by approved means to a density of not less than that of the
undisturbed ground.
Any pockets of 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 or with
concrete Mix Ref. A1 (Table D1 in Section D) as directed by the Engineer. After
placing of any blinding concrete, no trimming of the excavated side faces shall be
carried out for 24 hours.
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The Contractor shall notify the Engineer when excavations are ready for inspection.
VOLUME II A
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The placing of blinding concrete or any new work shall not commence without the
prior written consent of the Engineer. Blinding shall be placed in the bottom of
excavations as soon as consent is given, so that the bottom does not soften or become
unsuitable.
If the Contractor allows the bottom to become unsuitable due to flooding or other
causes, the Contractor shall remove the unsuitable material at or below the bottom of the
excavation and make good with suitable material or concrete Mix Ref A1, as
directed by the Engineer, at his own expense.
2.7
Minimum Pipe Trench Widths

Excavation for pipe trenches shall be carried out to give a minimum clear excavated
width of 150 mm on each side of the pipe collars, or of the extent of bedding and
haunching material where this is specified. Additional excavation to give ample
space for making pipe joints shall be carried out as necessary.
2.8
Maximum Pipe Trench Widths

Excavation for pipe trenches shall not exceed the width used in the structural design of
the pipeline. Where the excavated width exceeds the maximum permissible value it
shall be made up in concrete Mix Ref A1 (Table D1 in Section D) up to the level of the
crown of the pipe.
2.9
Minimum Cable Trench Widths

The side of any excavated cable trench shall be minimum of 150 mm from the side of the
cable.
3.0
3.1
FILLING
Approval to Commence Filling
The areas on which fill material is to be placed shall be cleared and no fill shall be
placed until the Engineer has given written approval for filling to begin.
3.2
Fill Material
Except where otherwise indicated, in the Drawings or instructed by the Engineer fill
material used anywhere in the Works shall be suitable material obtained from the
excavations on the Site. Where suitable materials from the excavations are
insufficient for the required filling the requirement shall be made up with imported
materials the quality and sources of which shall be to the approval of the Engineer.
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3.3
Method Statement
At least 7 days before starting the earthworks, the Contractor shall submit to the
Engineer his method statement for placing and compacting the fill material, without
segregation.
3.4
Mechanically Placed Fill and Compaction

Fill material shall be placed evenly in layers not exceeding 250 mm compacted
thickness. Each layer shall occupy the full width of the area to be filled including any
side slopes, and shall be compacted in a regular pattern so that all parts of the area
receive the full amount of compaction specified. The spreading of a layer shall be
carried out as soon as practicable after the previous layer has reached the degree of
compaction specified. The fill material shall be compacted at its optimum moisture
content to a tolerance of + 1% to - 3%, or such other value as may be agreed by the
Engineer. The insitu density shall be determined in accordance with BS 1377 : Part 4
(4.5 kg rammer method), and the dry density in accordance with BS 1377 : Part 9.
Fill placed in the dry shall when necessary be watered by spraying, but the Contractor shall
arrange his operations so as to make the best use of the natural moisture content of the fill
material to obtain the maximum insitu density.
Any side slopes of filled areas shall be slightly overfilled when placing and
compacting, and afterwards trimmed back to the correct profile in such a manner that fully
compacted material extends out to the face.
3.5
Fill near Structures

The soluble sulphate content of any fill material used within 500 mm of any concrete
structures shall not exceed 1.9 g of sulphate (expressed as SO 3 ) per litre, when tested in
accordance with BS 812 : Part 118.
The total sulphate content (expressed as SO 3 ) of any fill material used within 500 mm of
metallic items forming part of the Permanent Works shall not exceed 0.5% by mass when
tested in accordance with BS 1377 : Part 3.
When placing fill material adjacent to structures, the surface level of the fill material
around the perimeter shall at no stage vary by more than 0.5 m. The fill material shall
be carefully compacted right up to the structure, using a vibrating plate compactor or
other suitable compactor in places where the main equipment cannot operate.
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3.6
VOLUME II A
Compacting Near Formation level

FOR TENDER REV- 0

The insitu density of all fill placed under this Contract shall exceed 95% of the
maximum dry density.
A series of 5 insitu density tests shall be carried out daily, or for each 250 m3 of fill
material placed or at such other intervals as the Engineer may determine. At least 9 out
of the 10 test results shall be not less than the specified density, and no result shall be less
than 92% of the maximum dry density. If such tests disclose an insufficient degree of
compaction, the Contractor shall take all suitable measures to achieve the required
compaction and shall, if necessary, excavate the fill material in the defective areas and
replace it so that the specified compaction is achieved, or carry out such other
remedial action as the Engineer may instruct.
3.7
Filling and Compaction in Trenches and Pits

Unless a particular surround and backfilling sequence is specified for a pipe, backfill
to pipe trenches shall be carefully deposited and thoroughly consolidated by ramming
in layers not exceeding 150 mm thick around and over the pipes up to a height of 300
mm over the pipes using suitable material. Thereafter the fill shall be returned to the
trench and thoroughly consolidated by vibrating plate compactor in layers not
exceeding 150 mm.
Backfilling in pits and trenches other than pipe trenches shall be in suitable material
and consolidated by vibrating plate compactor or power operated rammers in layers not
exceeding 150 mm.
In pipe trenches the sheeting within the depth of the bedding must be carefully
withdrawn clear of the bedding (and concrete arch) before backfilling is commenced
and must be further withdrawn in stages as the backfilling is carried out. At no time
during the withdrawal of the sheeting shall the pipe be allowed to settle below the
required level and every care shall be taken to ensure the even distribution of the
bedding into the void left by the removal of the sheeting.
3.8
3.9
Settlement
The Contractor shall make good and compact in an approved manner, with fill
material or other suitable material as approved by the Engineer, all settlement that
may occur. Defects in the Permanent Works due to settlement shall be made good by the
Contractor.
Tolerances
Tolerances shall be in accordance with the particular requirements of Section P of this
Specification.
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3.10
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PRE - CONSTRUCTION TERMITE PROOFING

FOR TENDER REV- 0

The pre-construction treatment of filled/compacted ground for the prevention of

termite attack where identified on the Drawings, Authority, Industrial Operations
Control,
Health
&
Safety
Dept.,
(DIC,
H&S) shall be provided in all areas below building foundations and floor
slabs, expansion/contraction joints and structures in contact with the ground.
The material/chemical to be used shall comply fully with recognized Dubai and
DIC / Port Regulations concerning the use of Termiticides. (The material shall be
either Demon TC or Dursaban 4TC origin). The method of application and the Pest
Control Company applying the chemical must be approved by DIC, H&S. Under no
circumstances will Contractors be allowed to apply the Termiticide in-house unless
they are a registered and approved Pest Control Company.
Contractors are to submit the required Pest Control check list proforma to Authorities,
H&S Dept., for approval prior to carrying out any Termiticide spraying.
4.0
STANDARDS
4.1
Standards and Codes of Practice

Standards and other Codes referred to in this Section are as follows:
BS 812 : Part 118 : - Testing aggregates
content
BS 1377
- method for determination of sulphate
- Methods of test for soils for Civil Engineering purposes.
: Part 2 : 1990
- Classification Tests
: Part 3 : 1990
- Chemical and electro-chemical tests
: Part 4 : 1990
- Compaction related tests
: Part 9 : 1990
- In-situ tests
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SECTION D
CONCRETE WORKS
1.0
GENERAL
1.1
Codes of Practice
The provisions of BS 8110 and BS 5328 shall be generally applicable to the Works.
Concrete shall be to a designed mix unless specifically stated otherwise.
1.2
Designed Mixes
The Contractor shall calculate the mix proportions of the designed mix in order to
satisfy the strength and other requirements of the Contract. These requirements are
detailed in the Schedule of Mixes, Table E.1 of this Specification. Where stipulated
elsewhere in the Contract the Contractor shall ensure that the electrical resistivity and
other properties of the concrete complies with the requirements for any cathodic
protection.
The consistency, aggregate size and shape, and the placing method of the concrete
mixes shall be such that they do not cause any damage to any pre-placed anode
systems within either repair or new concrete containing new cathodic protection.
When required by the Contract or directed by the Engineer the Contractor shall carry out
electrical resistivity tests on proposed repair concrete and original concrete in
accordance with Concrete Society Report No. 36 Cathodic Protection of Reinforced
Concrete Clause 5.3.6.
1.3
Special Requirements for Mix D2M.

Concrete mix reference D2M as detailed in the Schedule of Mixes in Table E.1 shall
be designed to provide a dense impermeable concrete that is suitable for reinforced
concrete in a hot marine environment. The mix design shall be such that it minimizes
the ingress of external water and vapour borne chloride ions into the concrete cover
zone to the reinforcement.
The mix shall be resilient to any possible surface
degradation caused by frequent wetting and drying and any wave action of sea water.
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2.0
MATERIALS
2.1
Cement
2.1.1
Definition of Cement
Cement shall mean Portland Cement and other approved materials used as partial
replacement for Portland Cement.
2.1.2
British Standards for Cement

Cement shall comply with one of the following British Standards when tested in
accordance with BS 4550.
(i)
BS 12
Ordinary and Rapid Hardening Portland Cement.
(ii)
BS 146
Portland Blast Furnace Cement.
(iii)
BS 1370
Low Heat Portland Cement.
(iv)
BS 3892 Part 1
Pulverised Fuel Ash for use as a cementitious concrete.
(v)
BS 4246
High Slag Blast Furnace Cement.
(vi)
BS 6588
Portland Pulverised Fuel Ash Cement.
The cement shall be as specified in Table E.1, unless otherwise agreed in writing by the
Engineer.
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2.1.3 Portland Blast Furnace Cement

Where applicable the cement properties, supply, delivery and storage shall comply
with the requirements for cement in this Section of the Specification. Portland Blast
Furnace Cement shall comply with the requirements of BS 146 for slag content,
chloride content, loss on ignition soundness and setting time and other requirements.
The strength of the cement shall comply with BS 143 and be adequate to ensure the
required concrete design strengths are met. The Contractor shall submit evidence
demonstrating that the proposed cement supply has been used successfully in
concrete mix designs in a hot marine environment in the splash and tidal zone over a
period of at least 10 years. This evidence shall include both laboratory and field test
results for permeability and chloride ingress into concrete for a mix similar to that
now proposed. The tricalcium aluminate (C3A) content of the OPC element of the
blend shall comply with the relevant clause of this Section of the Specification. The
Contractor shall confirm in writing the proposed proportions of OPC and GGBFS to
be blended to form the Portland Blast Furnace Cement. Once approved the cement
shall be produced to this blend to a tolerance of + 5%.
2.1.4
Blend of OPC and Microsilica

Microsilica shall be supplied by a reputable established producer with a record of
having supplied the material for a minimum period of 15 years for use in concrete
mixes. Where applicable the cement properties, supply, delivery and storage shall
comply with the requirements for cement in this Section of the Specification. The
Contractor shall submit evidence demonstrating that the proposed microsilica supply
has been successfully used in concrete mix designs in a hot marine environment in the
splash and tidal zone over a period of at least 10 years. This evidence shall include
both laboratory and field test results for permeability and chloride ingress into
concrete for a mix similar to that now proposed. The microsilica shall be produced,
transported and stored, batched and mixed in accordance with the manufacturers
instructions.
The Contractor shall confirm the compatibility and suitability of any proposed
admixtures to be used with the microsilica. The microsilica shall either be mixed into
a slurry with water or dry batched and mixed with the cement. The Contractor shall
carry out trials to demonstrate that the cement and microsilica are thoroughly mixed.
The proportion of cement replaced by microsilica shall be between 5% and 20%. The
Contractor shall carry out trial mixes at different contents of microsilica and for a
control mix without microsilica for testing as directed by the Engineer. Based on the
results of these trials the Contractor shall propose for approval by the Engineer the
content of microsilica in the mix.
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2.1.5 High Alumina and Rapid Hardening Cements

High Alumina Cement and Extra Rapid Hardening Cement shall not be used.
2.1.6
OPC Cement C3A Content

The tricalcium aluminate (C3A) content of Ordinary Portland Cement (OPC) shall be
within the range minimum 4% and maximum 10% by weight.
2.1.7
PFA Cement Colour Requirements

The Pulverised Fuel Ash Cement (PFA) shall have a maximum colour index of 6
(Colour Comparator disc reference No. 296570) when using the Lovibond Colour
Comparator System as recommended in BS 3892.
2.1.8
Manufacturer and Brand

The Contractor shall inform the Engineer of the brand name and manufacturer of the
cement which he proposes to use in the Works. The Contractor shall not place the
order for the cement before the Engineers approval of the cement is obtained and
shall not use cement from a different source or of a different composition to that
approved.
2.1.9
Supply
All cement supplied for this Contract shall be certified as having been tested by an
approved laboratory to BS 4550.
2.1.10 Delivery
Cement shall be delivered to the Site either in bags or in suitable containers. Each
bag or container shall be sealed and marked with the name of the brand and
manufacturer and the number of the consignment. The Contractor shall make the
necessary arrangements for deliveries to be made with sufficient frequency to ensure
freshness. Delivery arrangements for bulk cement shall be to the Engineers approval.
When each consignment of cement is delivered to the Site the Contractor shall supply the
Engineer with a statement showing the quantity so delivered, the number of the
consignment, the name of the manufacturer, the date of grinding and the number and date
of the manufacturers test certificate relating to that consignment.
If a consignment of cement is delivered to the Site without a manufacturers
certificate then the cement shall be tested to ensure compliance with the Specification
by an approved laboratory in accordance with BS 4550 before being used in the
Works.
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2.1.11 Storage
Cement shall be delivered and stored in a clearly identifiable way. Cement shall be
kept dry, off the ground in covered and watertight stores and used in the sequence
order of delivery. Loose, split or air-set cement shall not be used in the Works.
2.2
Aggregates
2.2.1
Requirements
Aggregates shall comply with the requirements of and be tested in accordance with BS
812 unless specified otherwise in this Section.
2.2.2
Approval
Before commencing concrete trial mixes the Contractor shall submit, for approval by
the Engineer, a 50 Kg sample of each type of aggregate that he proposes to use
together with all the test results stating the source of supply. When approved the
samples shall be retained on Site by the Engineer for reference and comparison with
later deliveries.
If during the course of the Works the Contractor wishes to change the source or
nature of any aggregate which has been approved, he shall first submit a sample with all
the test results to the Engineer for his approval and retention.
2.2.3
Sampling and Testing

The Contractor shall carry out regular sampling and testing of the aggregate
stockpiles as directed by the Engineer. As well as meeting the requirements of BS 882
aggregates shall be sampled and tested in accordance with the additional
requirements of this Specification.
2.2.4
Alkali Reactivity
Aggregates shall be innocuous when tested chemically in accordance with ASTM
C289. If the test shows them to be deleteriously, or potentially deleteriously, reactive
with the alkalis in the cement then an alternative source of aggregate shall be used.
The Engineer may require aggregates to be tested in accordance with ASTM C 227
(mortar bar method), ASTM C 586 (potential alkali reactivity for carbonate rocks)
and ASTM C 342 (potential volume change of cement aggregate combinations).
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2.2.5 Additional Specific Requirements for Coarse Aggregate

The coarse aggregate shall be crushed natural stone or gravel and have the following
characteristics over and above the requirements of BS 882 when tested according to:
2.2.6
(a)
BS 812
Clay, silt, dust and other deleterious matter (by weight):
max
1%
Flakiness Index: BS 812: Part 105: Section 1
max
25%
Elongation Index: BS 812: Part 1
max
25%
Apparent Relative Density: BS 812: Part 2
min
2.6
Water Absorption : BS 812: Part 2
max
2.5%
Impact Value: BS 812: Part 3
max
30%
Crushing Value: BS 812: Part 3
max
30%
Drying Shrinkage: BS 812
max
0.05%
Acid Soluble Chloride ion: BS 812: Part 117
max
0.02%
Acid Soluble Sulphate ion: BS 812: Part 118
max
0.4%
(b)
-
ASTM C 88
Soundness : loss after 5 cycles of immersion and drying shall not exceed
10% using sodium sulphate, or
14% using magnesium
sulphate.
Additional Specific Requirements for Fine Aggregate

The fine aggregates shall have the following characteristics over and above the
requirements of BS 882 when tested according to:
(a)
BS 812
Apparent Relative Density: BS 812: Part 2

Acid Soluble Chloride ion: BS 812: Part 117
Acid Soluble Sulphate ionL BS 812: Part 118
min
max
max
2.5
0.03%
0.4%
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2.2.7
(b)
ASTM C 125
Fineness Module shall not be less than 2.3 nor more than 3.1
(c)
ASTM C 88
Soundness: loss after 5 cycles of immersion and drying shall not exceed
10% using sodium sulphate or 15% using magnesium sulphate.
Segregation
Aggregates shall be produced, delivered and stored in such a way that they do not
segregate and their size and cleanliness is ensured.
2.2.8
Wet Aggregate
Fine aggregate which is wet shall not be used until, in the opinion of the Engineer, it
has drained sufficiently to ensure proper control of the water/cement ratio.
2.2.9
Staining Impurities
Aggregates for exposed concrete shall only be supplied from sources known to be
free of staining impurities such as coal, lignite, iron pyrites, etc.
2.3
Water
2.3.1
Compliance
Water shall be clean, potable and free from deleterious matter in solution or
suspension and shall comply with the requirements of BS 3148.
2.4
Admixtures
2.4.1
Approval
The Contractor shall submit to the Engineer for approval full details of all admixtures
he proposes to use and the manner in which he proposes to add them to the mix.
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2.4.2 Standards
Admixtures shall comply with the requirements of BS 5075 where applicable
BS 5075:
2.4.3
Concrete Admixtures
Part 1
Accelerating admixtures, retarding admixtures and water

reducing admixtures
Part 2
Air-entraining admixtures
Part 3
Superplasticisers
Suitability
The Contractor shall be responsible for demonstrating the suitability of admixtures for
their intended purposes when the hydraulic binders and aggregates differ from those
used in the relevant British Standard compliance tests.
2.4.4
Chloride Content
The chloride content of any admixture shall not exceed 2% chloride ion by mass of
the admixture.
2.4.5
Required Details
The Contractor shall provide the Engineer with information relating to:(a)
detrimental effects of under and over dosage
(b)
the chemical names of the main active ingredients
(c)
whether or not the admixture leads to the entertainment of air in the absence
of an air entertainment agent.
(d)
side effects
(e)
the free water content of the admixture.
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3.0
REINFORCEMENT
3.1
Materials
Steel for reinforcement shall comply with the requirements of BS
reinforcing fabric shall comply with BS 4483.
4449. Steel
All steel for concrete reinforcement shall be entirely free from mill scale, surface rust,
pitting, oil, grease, paint and other deleterious matter before being used in reinforced
concrete work. If deemed necessary by the Engineer reinforcement shall be blast
cleaned with an approved sand grit immediately prior to concreting.
3.1.2
Test Certificates
The Contractor shall supply to the Engineer a manufacturers test certificate for each
consignment of reinforcement delivered to the Site, together with a delivery note
stating the weight, number, length, dimension and place of origin of the bars or fabric in
each consignment.
3.1.3
Samples for Testing

The Contractor shall, under the supervision of the Engineer, cut samples from any of
the reinforcing bars or fabric whenever directed and the Contractor shall despatch
such samples for testing as the Engineer may from time to time direct. Minimum
sample length shall be 600 mm or 20 times the bar diameter whichever is greater.
3.1.4
Binding Wire
All binding wire shall be galvanized steel wire No. 16 SWG (1.6 mm diameter).
3.2
Storage
All reinforcement shall be stored at least 300 mm off the ground. Bar or rod
reinforcement shall be stored in suitable racks. Fabric shall be stored level on bearers to
prevent distortion. Reinforcement shall be kept in a clean condition until it is
required to be used.
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3.3
Cutting and Bending
3.3.1
Bar Schedules
The preparation of any Bar Schedules necessary for the construction of the Works,
including any additional reinforcement required, will be the responsibility of the
Contractor. The Schedules shall be submitted to the Engineer for approval before
cutting or bending of the reinforcement commences.
3.3.2
Cutting & Bending

Bars shall be cut and bent to the dimensions shown on the Drawings and Schedules in
All bars shall be cold bent by the gradual and uniform application of pressure such
that the material is not damaged in any way. Heating of the bars will not be permitted
without the prior approval of the Engineer.
3.3.3
Tolerances
Tolerances shall be as specified in BS 4466.
3.3.4
Re-bending
Cold worked bars or hot rolled high yield bars shall not normally be straightened or
bent again once having been bent.
Where it is necessary to bend mild steel
reinforcement projecting from the concrete, the internal radius of bends shall not be less
than twice the diameter of the bar.
3.4
Fixing
3.4.1
Placing of Reinforcement
The size form, spacing and location of all steel reinforcement shall be in exact
accordance with the Drawings. The Contractor shall ensure that the reinforcement is
fixed and placed correctly in all respects, within a tolerance of + 5 mm of the correct
position, and that it shall not move in the forms during concreting. All ties, links,
stirrups, etc., shall be taut and the bars properly braced and tied.
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There shall be no direct connection between any reinforcement within a concrete

member and any metalwork on the surface of the member, except where required by
Cathodic Protection Systems.
The Contractor shall provide all spacer bars, chairs and distance pieces necessary to
retain the reinforcement in the correct position and to maintain a rigid reinforcement
cage during concreting.
3.4.2
Binding Wire
Binding wire shall be finished with the correct tools.
wire shall be bent inwards away from the formwork.
3.4.3
The free ends of the binding
Splices and Laps

No splices or overlapping of reinforcement shall be made except where shown on the
Drawings or approved by the Engineer. Unless otherwise shown on the Drawings, the
bars shall be provided with an overlap of not less than 40 diameters of the smaller bar.
The gap between pairs of lapped bars shall not be less than the diameter of the larger
bar or the maximum size of the concrete aggregate. Fabric reinforcement shall be fixed
in position with lapped joints of at least two meshes and shall be securely bound to
any supporting bars with binding wire.
3.4.4
Welding and Reinforcement

Reinforcement shall not be welded except with the written approval of the Engineer,
who will require detailed procedures to be submitted for his approval. Where
approval is given, welding shall be in accordance with BS 7123.
3.4.5
Cover
Cover to reinforcement shall be as specified on the Drawings with a tolerance of plus or
minus (+)5 mm. Cover is to be achieved by the methods described in the BCA
Report, (Spacers and Cover,1987).
Spacers and chairs shall be at least of the quality specified in the above report.
Cementitious spacers shall be of similar strength, durability, porosity and appearance to
the surrounding concrete. Where ties are provided for holding the spacer block in place
such ties shall be of strong nylon line, galvanised or plastic coated wire, and approved
by the Engineer.
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3.4.6
Starter Bars
Reinforcement which is temporarily exposed from the concrete, such as starter bars,
shall be continuously protected against corrosion before and after concreting in a
manner to be approved by the Engineer.
3.4.7
Dowel and Tie Bars

All reinforcement passing through a movement joint shall be protected with three
coats of approved bituminous paint, or be heavily galvanized, after cleaning and
preparing the bars. When painted the protection shall extend across the joint and a
minimum of 25 mm into the concrete.
For bars passing through expansion joints, the entire surface of the bar on one side of
the joint shall be treated or sleeved to promote debonding from the concrete.
3.4.8
Surface Preparation of Reinforcement in Broken Out Concrete

Any exposed reinforcement shall if directed by the Engineer be de-greased with
suitable solvent. Reinforcement shall then be grit-blasted to BS 4232 second quality.
The Contractor shall ensure that the reinforcement is cleaned as far as is practicable
over the full circumferential area of the bar and shall use needle guns, wire brushes or
other means to clean areas that are inaccessible for grit-blasting. All corrosion
products including magnetite shall be removed. The period between completing
cleaning of reinforcement and encasing in repair concrete shall be minimised and in
no case exceed 48 hours.
Anti-corrosion protective agents shall not be used to protect cleaned reinforcement.
3.4.9
Inspection of Reinforcement
No concreting shall be commenced until the Engineer has inspected the reinforcement
fixed and placed in position and given his written approval. Prior to concreting the
reinforcement shall be washed with fresh water to remove any surface contamination
and the formwork shall be free of surplus water before concrete is placed.
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3.5 Spacers and Cover

Unless otherwise indicated on the Drawings, the minimum cover to the reinforcing
bars is to be as listed below or equal to the diameter of the bar, whichever is greater.
Position
Minimum cover
(mm)
Main bars in internal faces of columns and beams

Main bars in external faces of columns and beams
Main bars in floor slabs and soffits of roof slabs
Main bars in top of roof slabs
Outermost bars in internal faces of walls
Outermost bars in external faces of walls
Main bars in external faces of walls
Bars in top of ground slabs
Bars near faces in contact with soil
30
40
30
30
30
40
35
40
75
Spacers to be used for maintaining the cover shall be of an approved material.

(See Clauses 3.4.1 and 3.4.5).
4.0
CONCRETE
4.1
Concrete Quality
4.1.1
Characteristic Strength
The specified minimum characteristic strength of a designed mix shall be the 28 day
compressive cube strength (N/mm) equal to the value in the Mix Reference
designation of the Schedule of Designed Concrete Mixes, Table E.1.
(The actual characteristic strength of any concrete mix approved for use in the Works
may, for quality control purposes, be fixed by the Engineer with reference to actual
cube strengths achieved from properly controlled and approved plant trial mixes. The
Engineer may request such plant trials to be repeated as required during the course of
the Works).
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4.1.2 Mix Reference

The Mix Reference of concrete shall define its characteristic strength, nominal
maximum size of aggregate, type of cement, type of aggregate, minimum cement
content, maximum water/cement ratio and rate of sampling for strength testing as
described in the Schedule of Designed Concrete Mixes, Table E.1.
4.1.3
Water/Cement Ratio
The Water/Cement content ratio of the concrete mix shall be the minimum value
required to give adequate workability of the concrete but shall not exceed the
maximum value stated in Table E.1, which is a free water/cement ratio.
It must be emphasized that water/cement ratio is closely related to the durability of the
concrete and that close control of this ratio is likely to take preference over the control of
strength alone.
4.1.4
Chloride Content of Concrete

The total chloride content of the concrete mix, expressed as a percentage of chloride
ion by mass of cement, shall not exceed 0.1% for concrete made with cement to BS
12, BS 1370 or BS 6588. The chloride content shall be measured in accordance with
BS 1881.
4.1.5
Sulphate Content of Concrete

The total sulphate content of the concrete mix, expressed as percentage of sulphur
trioxide by mass of cement, shall not exceed 4.0%. The sulphate content shall be
measured in accordance with BS 1881.
4.1.6
Alkali Content of Concrete

The total acid-soluble alkali content of the mix, expressed as equivalent sodium
oxide, shall not exceed 3 kg/m3 when measured as described in the BCA document
Minimizing the Risk of Alkali Aggregate Reaction.
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4.1.7 Drying Shrinkage

Drying shrinkage shall not exceed 0.05% when an expansion bar test is carried out in
4.1.8
Impermeability to Water
All concrete shall be designed to be dense, durable and have a high impermeability to
water. Where required in the Schedule of Designed Concrete Mixes, Table E.1.
concrete shall be tested at frequencies and locations as directed by the Engineer and
specimens shall meet the following criteria at an age of 28 days:(i)
Water Penetration to DIN 1048 - Maximum 20 mm
(ii)
Initial Surface Absorption of Concrete (ISAT) to BS 1881

Max Flow
(ml/m/S)
< 0.25
< 0.17
<0.10
< 0.07
(iii)
Time
(Minutes)
10
30
60
120
Capillary Rise to Concrete Society Report No. 31 1987 Section 4.2.2

(Taywood Sorption Test) - Max Rise in 4 hours < 10 mm.
The Engineer may require concrete to be tested in accordance with other test
procedures which shall include, but not be limited to:
-
Porosity as per Rilem CPC 11.3 Absorption of Water by Immersion under

Vacuum.
Rapid determination of the chloride permeability of concrete as per AASHTO

T277-83.
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4.2 Trial mixes

4.2.1 General
The Contractor shall prepare trial mixes using the approved aggregates and cement
and, where applicable, approved admixtures. He shall make, cure and test
specimens for strength and other tests in the Specification as directed by the Engineer.
Specimens for strength shall be 150 mm cubes for each class of concrete in
accordance with BS 1881, except that cubes shall be cured in water at the ambient
temperature. The Contractor shall give notice in writing to the Engineer to enable him
to be represented at the making of the trial mixes and compressive testing of all
cubes.
4.2.2
Mixing
Trial mixes shall be made at temperatures similar to those likely during construction
and preferably using the batching plant and transport to be employed in the Works.
The trial mixes shall be transported a representative distance before making the test
cubes.
4.2.3
Workability
Mix proportions shall be properly balanced without excess of any constituents. The
free water/cement ratio shall be the minimum possible having regard to proper
compaction by means specified. The slump and compacting factor when measured in
accordance with BS 1881 shall be within the range + 25 mm and + 0.03%
respectively of the optimum values shown in Table E.1. Where stiff concrete mixes
are specified which will have a low slump value, the Engineer may opt to measure
workability by the Compacting Factor method as specified in BS 1881. The Engineer
may request the Bleeding Test to ASTM C 232-92 to be carried out in order to satisfy
himself that excessive bleeding of the mix is avoided.
4.2.4
Test Cubes
Nine 150 mm test cubes shall be taken from three separate batches for each Mix
Reference of concrete. From each set of nine test cubes three cubes shall be tested at 7
days and three at 28 days. The three remaining cubes shall be available for further tests
should these be required by the Engineer.
The average crushing strength of the three sets of three cubes tested at the specified age
shall exceed the specified characteristic strength by at least twice the designed
standard deviation. Where there is no evidence of the standard deviation which may be
expected to be achieved under similar conditions the designed standard deviation shall
be assumed to be not less than 7 N/mm2.
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4.2.5
If the difference between the greatest and the least individual results for any set of
three cubes is more than 20 percent of the sum of the specified minimum crushing
strength plus twice the designed standard deviation the results for that set shall be
discarded. An additional set of three cubes shall be made and tested to provide a
replacement set of results.
Approval of Mixes
The Contractor shall submit to the Engineer for approval full details of the trial mixes
he proposes to adopt for the Works, including:
(i)
the grading of the coarse and fine aggregates;
(ii)
the ratio by weight of all constituents of the mix;
(iii)
the compacting factor and slump test results;
(iv)
the test cube results.
No concrete shall be used in the Permanent Works until the test cubes have attained
the required strengths at the age specified and the mix has been approved in writing
by the Engineer.
4.2.6
Calculations to be Provided
The Contractor shall supply copies in triplicate to the Engineer of all calculations
relevant to the determination of the proportions of each class of concrete, and shall
prove the sufficiency of such calculations to the satisfaction of the Engineer.
4.3
Batching and Mixing
4.3.1
Concreting Plant
All concrete shall be machine mixed unless otherwise approved in writing by the
Engineer. The type, capacity and design of the concreting plant shall be suitable for its
purpose.
Its performance and disposition shall be to the satisfaction of the
Engineer. The use of continuous mixers shall not be permitted.
4.3.2
Measuring Materials
All cement and aggregates shall be measured by weight. The amount of water added
shall be measured, due allowance being made for the water content of the aggregate
and any additive . The moisture content of the fine aggregate shall be measured
continuously in the hopper by an approved device. The amount of admixtures shall
also be measured.
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4.3.3
Accuracy of Measuring Equipment

Weight-batching machines shall be kept clean and in good condition and adjustment.
The Engineer shall require the Contractor, at reasonable intervals of time, to check the
accuracy of each weight-batching machine and each water measuring device in the
presence of the Engineer. The accuracy to be attained in each case shall be within + 2.5%
of the quantity of cement, water or total aggregates being measured.
4.3.4
Mixing
All concrete shall be machine mixed unless agreed otherwise by the Engineer.
Concrete shall be thoroughly mixed to a uniform consistency. Each batch of concrete
shall be mixed for a minimum of two minutes after all the materials have been added,
unless agreed otherwise by the Engineer.
The mixer shall be washed out with fresh water before mixing the first batch after any
stoppage or, alternatively, the first mix shall be discarded. After every stoppage the
mixer shall be thoroughly cleaned and washed out.
Concrete shall be discharged from the mixer or agitator onto a level, clean, watertight
platform or floor or into watertight receptacles.
Concrete which has commenced to set shall not be re-mixed and shall not be used in the
Permanent Works.
4.4
Quality Control and Testing
4.4.1
Quality Control
The Contractor shall provide full time on Site a fully qualified Concrete Supervisor
whose duties shall include day to day supervision of the concrete constituents and the
concrete mixing, placing, sampling, testing and record keeping operations.
The Contractor shall ensure that his Concrete Supervisor is aware of the importance of
maintaining a uniform quality of concrete and that he is experienced in detecting
variations in quality and workability and rapidly correcting the same
The Contractor shall carry out such tests as the Engineer may require to check the
proportions of the ingredients of any concrete being produced.
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4.4.2
Frequency of Testing Concrete

Six 150 mm test cubes shall be made from each sample of concrete taken from any
section of work as required by the Engineer. Samples of concrete shall be taken for
each mix reference at the frequency specified in BS 5328, or for each shift of work
where this is less than the rate specified. Cubes shall be made, transported, cured and
tested in accordance with BS 1881. The cubes shall be made at the point of placing and
at the time of placing.
Three cubes shall be tested at 7 days and three at 28 days.
cubes strengths shall be taken as the test result
The average of the three
The Engineer may very the number of cubes scheduled above for each mix reference in
Table E.1 if in his opinion either additional tests are required or consistently
satisfactory test results are being obtained.
4.4.3
Compliance with Characteristic Strength

Compliance with the characteristic strength as may be defined from plant trials as
described in Clause 4.1.1 shall be assumed if both the following conditions are met:
(i)
The average concrete strength at 28 days determined from any group of four
consecutive test results exceeds the characteristic strength by not less than
3 N/mm for concrete of grade 30 and above, and 2 N/mm for concrete of
lower grades. Where only two sets of results have been taken, the mean must
exceed the minimum characteristic strength by not less than 1 N/mm.
(ii)
Each test result at 28 days is not less than the characteristic strength minus 3
N/mm for concrete of minimum characteristic strength of 30 N/mm and
above and 2 N/mm for concrete of lower grades.
If only one test result fails to meet condition (ii) then that result will be
considered to represent only the particular batch of concrete from which the
set of three cubes was taken, provided the average strength of the group
satisfies condition (i).
If more than one test result in a group fails to meet condition (ii) or if the
average strength of any group of four consecutive test results fails to meet
condition (i) then all the concrete in all the batches represented by such cubes
shall be deemed not to comply with the strength requirements.
The flexural strength of concrete used in paving shall be tested in accordance
with BS 1881 and shall be not less than 10 N/mm at 28 days.
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4.4.4 Results of Tests

The results of all works tests carried out to control the quality of concrete and
concrete materials shall be recorded by the Contractor on suitable forms provided by
him which shall be subject to the approval of the Engineer. The Contractor shall
supply to the Engineer three copies of the results of each test.
4.4.5
Unsatisfactory Test Results

Should any of the results of the specified work tests on concrete or materials be
unsatisfactory the Engineer may take one of the following actions:
(i)
Reject the work and instruct that the section of the Works to which the
unsatisfactory test results relate be cut out and replaced in accordance with
Clauses 4.10 and 4.11.
(ii)
Instruct the Contractor to carry out additional tests and/or works to ensure the
soundness of the structure at the Contractors expense. Testing shall be
carried out in accordance with Clause 4.10.
(iii)
Accept the work. Any decision to do so shall be at the Engineers discretion

and with the Employers approval and a reduction in the rate of payment of the
appropriate items shall be made by the Engineer.
(iv)
In the case of any test result at 7 days being less than 55% of the minimum
characteristic strength, or an amended value based on test results for the trial
mixes, the Engineer may order that the work affected be stopped but that it
shall not be liable to rejection until the results of the 28 day tests are known.
Any delays to construction due to the test results at 7 days being
unsatisfactory shall be at the Contractors expense.
Following the failure of test cubes to reach the required standard, the Contractor shall, on
the instructions of the Engineer, take one or both of the following steps:
(a)
He shall alter his methods of making concrete and for controlling its quality so
as to reduce its variability.
(b)
He shall alter the proportions of the concrete mix so as to increase its

compressive strength.
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4.5 Ready Mixed Concrete

Ready-Mixed Concrete shall be used only with the agreement of the Engineer and
shall comply with all the requirements of this Specification for concrete unless
otherwise stated, and also the following special requirements.
The Contractor shall be entirely responsible for demonstrating to the Engineer that the
Ready Mix Concrete which he proposes to use will comply with the Specification, and
that the concrete actually used in the Works also fully complies.
The Ready Mix plant proposed by the Contractor for each Mix Reference shall be
subject to the approval of the Engineer and the plant used, once approved, shall not be
changed unless agreed in writing by the Engineer.
The concrete shall be carried in purpose-made agitators, operating continuously, or
truck mixers. The time of introduction of water to the mix shall be recorded on the
delivery note together with the weight of the constituents of each mix.
Readymix concrete shall, where applicable, comply with the requirements of BS
5328.
When truck-mixed concrete is used, water shall be added under supervision either at
the site or at the central batching plant as agreed by the Engineer, but in no
circumstances shall water be added in transit.
Truck mixer units and their mixing and discharge performance shall comply with BS
4251.
4.6
Casting of Concrete
4.6.1
Workability
The concrete shall be of only sufficient workability that it can be readily worked into
position and compacted taking into consideration the particular conditions under
which the concrete is being placed.
Workability shall be measured at a minimum frequency equal to the sampling rate
and at such times as directed by the Engineer.
Measurement shall be by one of the following tests in accordance with BS 1881 and
shall be within the following limits of the optimum values given in Table E.1.
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4.6.2
Slump:
+ 25 mm or + one third of the optimum value, whichever is the

greater.
Compacting factor:
+ 0.03 where the optimum value is 0.9 or more.
Construction Sequence
The sequence of construction shall be such as to satisfy the Specification and any
particular requirements for the Works under the Contract or as shown in the
Drawings. The Contractor shall prepare a detailed method statement covering all
major concreting works for approval by the Engineer.
4.6.3
Transportation of Concrete
All concrete shall be transported in bottom-opening skips or vehicles of a type and
size approved by the Engineer. Concrete shall be so transported and placed that
contamination, segregation or loss of the constituent materials does not occur.
4.6.4
Placing Concrete
Concrete shall not be placed in any part of the Works without the prior written
approval of the Engineer who shall be given a minimum of 24 hours notice by the
Contractor. No concrete shall be placed outside normal working hours.
The bottom of all ground formations which are to receive insitu concrete shall, unless
specified to the contrary, first be covered with a 50 mm minimum thickness blinding
layer of mass concrete Mix Ref. A1 to form a clean, dry, hard, working surface.
Concrete shall be placed in its final position and all compaction shall be completed
within 30 minutes from the time of water being added to the mix. Where a retarding
admixture has been used and hot weather concreting precautions are in place this time
may be extended up to a maximum of 2 hours after written approval by the Engineer.
Fresh concrete shall not be placed against previously placed concrete which has been in
position for more than 30 minutes or where the initial set has taken place.
Concrete shall be placed and compacted in such a way that previously placed and
compacted concrete is not disturbed. Concrete shall not be placed in a manner which in
the Engineers opinion precludes even distribution of constituents and full
compaction of the concrete.
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Concrete shall be placed and compacted uniformly in layers not exceeding 300 mm in
depth in its final position in the Works and shall not be caused to flow into position
by vibration or other means. The surface of the work shall be kept generally
horizontal. In deep sections the concrete profile shall advance in 300 mm stepped
layers to avoid placement against concrete where the initial set has taken place.
When the cement content of a mix exceeds 400 kg/m and the minimum dimension of
concrete to be placed in a single pour exceeds 600 mm special precautions shall be
taken to ensure temperature differentials exceeding 20C are not generated within the
concrete. When required the Contractor shall submit proposals for approval by the
Engineer for demonstrating compliance with this requirement prior to concreting.
Concrete shall be placed in such a way as to avoid any joints other than the joints
shown on the Drawings or approved by the Engineer.
No concrete shall be allowed to fall more than 2 metres during placing. For heights of
fall greater than 2 metres, chutes or pipes shall be used.
If the Contractor proposes to place concrete by pumping or pneumatic means, he shall
submit his proposals for the Engineers approval and shall not commence operations until
shall approval has been obtained.
Pumping procedures shall be in general
accordance with AC1-304-73.
4.6.5
Concrete Repairs
Repair concrete, if required, shall be poured in complete bays between consecutive
movement joints. Bays shall be poured on a hit-and-miss basis, with a minimum of 14
days to elapse between adjacent pours.
Each bay shall be sub-divided into panels so as to minimise the risk of formation of
cracks in the surface of the concrete. Panel size shall not exceed 2 metres in length or
width and shall be formed by the use of crack inducers and surface rebates. All
rebates shall be sealed with an approved joint sealant. The maximum permissible
crack width 28 days after completion of curing shall be 0.10 mm. The Contractor
shall provide the facilities to enable the full surface area of all exposed concrete to be
inspected and cracks to be measured at times to be agreed, and shall be responsible
for repairing or sealing, as agreed with the Engineer, all cracks which exceed this
value.
The repair concrete shall have a coefficient of thermal expansion similar to the
existing concrete.The Engineer may require tests to be carried out to check the
coefficient of thermal expansion of the existing concrete and proposed repair mix.
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4.6.6 Concreting During Wet Weather

No concreting shall be carried out during periods of continuous heavy rain unless the
concrete is completely covered during mixing, transporting and placing to the
satisfaction of the Engineer. If rain should interrupt concreting the concrete shall be
adequately protected.
4.6.7
Concreting During Hot Weather

When the air temperature rises above 35C or the anticipated evaporation loss from
the freshly placed concrete, when calculated in accordance with ACI 305, exceeds
1 kg/m/hr, special precautions shall be taken in accordance with ACI 305 to the
satisfaction of the Engineer to cool aggregates, mixing water and other ingredients to
maintain the specified maximum water/cement ratio, and other special batching,
placing and curing techniques. Steel reinforcement and shuttering exposed to the sun
should be mist sprayed with cool fresh water immediately before placing the
concrete. Aggregate stock piles, batching plants, areas prepared for concreting and
areas of recently placed concrete shall be shaded and general good concreting
practice, as set out in CIRIA Special Publication 31 - The CIRIA Guide to concrete
construction in the Gulf region, shall be followed.
Concreting shall not be carried out if the temperature of the concrete mix at the point of
placing exceeds 30C.
Where concrete pours are greater than 1 metre thick the
temperature of the mix shall be further reduced as directed by the Engineer. Cooling
arrangements shall be to the approval of the Engineer.
In order to maintain lower mix temperatures concrete may be mixed and placed at night
subject to the written approval of the Engineer and provided that any lighting and other
arrangements are to his satisfaction
4.6.8
Compaction and Finish

Concrete shall be compacted into place by means of a sufficient number of approved
internal vibrators of adequate power with a frequency of not less than 100 hertz.
Mechanical vibrators shall only be operated by trained and experienced workmen.
Care shall be taken to avoid contact with reinforcement or formwork. An adequate
number of standby vibrators shall be available at each pour in case of breakdown.
Concrete shall be thoroughly worked around the reinforcement and against whatever
surface it adjoins so that a dense homogeneous mass is produced, all entrained air is
expelled and the concrete surface when exposed is free from air pockets,
honeycombing and other defects. Care shall be taken in compacting and finishing
concrete to avoid overworking and the bringing of excessive laitence to the surface.
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If vibrating screed boards are used for slab work they shall be of sufficient power to
compact the full depth of the slab being cast, over the full length and width of the
screed.
Should there be evidence of plastic settlement cracking, the affected concrete may be revibrated whilst the concrete is still plastic, by a method approved by the Engineer, to recompact the disturbed concrete. The Contractor shall take appropriate measures to reduce
the possibility of cracking in further pours.
4.6.9
Attendance of Steel Fixer

During concreting of all reinforced work a competent steel fixer shall be in
attendance throughout. It shall be his duty to ensure that the reinforcement and other
embedded items are kept in position as the work proceeds.
4.7
Joints
4.7.1
Movement Joints
Movement joints shall be formed in the positions and to the details shown on the
Drawings. Joint fillers, sealing compounds and water bars shall be incorporated in
these joints in strict accordance with the Drawings and the manufacturers
instructions.
The faces of movement joints shall have a formed Type B finished as defined in
Clause 6.0.
4.7.2
Joint Fillers
Compressible filler sheets of the thickness shown on the Drawings shall be made of
bitumen impregnated wood fibres to the approval of the Engineer. They shall not
extrude when compressed and must return to at least 80% of the original thickness after
compression. Water resistant joint filler board shall be made of preformed bitumen
bonded cork, from an approved manufacturer.
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4.7.3
Joint Sealants
All sealants shall be mixed and applied, strictly in acccordance with the
manufacturers recommendations, by properly trained staff who have been trained by
the supplier of the material. The manufacturer will be asked to confirm that proposed
sealants are suitable for their intended purpose, use and locations prior to approval.
Except where shown otherwise on the Drawings, sealants for horizontal joints shall be
either cold two part elastomeric sealant or hot applied pitch/liquid polymer. The cold
applied type shall be a two pack mix, such as Colpor 200E as manufactured by Fosroc
Ltd. or other equal/similar approved. The pitch/liquid polymer shall be Nitoseal
777, by Fosroc, or other similar approved.
Except where shown otherwise on the Drawings, sealants for vertical joints shall be two
part multi componenent liquid polysulphide polymer, which when mixed and applied
will cure to form a tough rubber like seal. Sealant for vertical joints shall be Thioflex
600 as manufactured by Fosroc or other similar approved.
The joint sealant is to be compatible with the joint filler and all other adjacent
surfaces.
4.7.4
Polythene Membranes
Polythene sheeting membranes shall be minimum 250 microns, laid flat without
trapping air. A lap of 300 mm shall be provided between sheets.
4.7.5
Construction Joints
Stoppages in concreting at the end of a period of work shall be made at properly
formed construction joints in positions of low shear stress and approved by the
Engineer. Recesses shall be made in construction joints in order to form a key with
adjacent concrete. A rebate at least 25 mm wide by 40 mm deep shall be formed on
the exposed face of any joint so that the finished work shows a clean straight line.
Formwork to provide stop ends for vertical joints in reinforced concrete shall be
firmly fixed and scribed around the reinforcement. Such concrete as passes through the
stops shall after setting be hacked off and removed. Retarding agents shall not be
permitted on formwork to stop ends.
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The surface of construction joints shall, when the concrete has set but not hardened,
be prepared by removing the outer mortar skin using a stiff brush and a fine spray of
water, to the extent that the large pieces of coarse aggregate are exposed but not
damaged or dislodged. Alternatively, expanded metal mesh can be used to form a
roughened surface, the mesh being removed with care within 24 hours of casting.
If this procedure is not possible, the laitence shall be removed with a combined jet of air
and water. If the concrete is too hard, sand blasting, wire brushing or scabbling may be
used with care with the approval of the Engineer.
The prepared joint surface is to be cured using only fresh water. It shall be
thoroughly cleaned with compressed air or other equally efficient method and then
jetted with clean water shortly before the adjacent concrete pour is placed. Special care
shall be taken to butt the new concrete thoroughly against the old.
Concreting beyond construction joints shall not take place for at least 24 hours after
forming the joint face.
4.8
Curing
4.8.2
Protecting Concrete
Immediately after compacting and finishing, and thereafter until the concrete has
achieved the strength specified, the concrete shall be protected from the harmful
effects of weather, including rain, sun, wind, rapid temperature changes and from
drying out.
The concrete shall also be protected from other work in progress. No equipment,
vehicles, workman or materials shall be permitted on recently placed concrete until
the Engineer considers the concrete to be sufficiently strong and hard not to be
damaged thereby.
4.8.2
Curing Method
Reinforced concrete shall not be allowed to come into contact with sea water for a
period of 28 days from the date of placing.
All concrete shall be wet cured for a minimum period of 14 days after casting.
Curing water shall be potable water free from deleterious salts. The temperature of
the curing water shall not be more than 10C below the temperature of the concrete.
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The methods for the provision of curing water and curing shall be to the approval of the
Engineer, and in principle as follows:
(i)
(ii)
Horizontal Surfaces
(a)
Polythene sheeting of minimum thickness 0.1 mm placed directly after

finishing.
(b)
Immediately after final set has taken place the polythene shall be
replaced with 2 layers of wet hessian, which is to be held in continuous
contact with the concrete surface, and re-covered by the polythene.
(c)
The hessian shall be kept continuously wet by sprinkled or sprayed

water as necessary.
Vertical or Inclined Surfaces

(a)
Polythene sheeting over 2 layers of wet hessian, which is to be held in

continuous contact with the concrete surface, shall be firmly secured to
all surfaces immediately after the removal of the formwork.
(b)
The hessian shall be kept continuously wet by sprinkled or sprayed

water as necessary. The use of curing compounds shall not be
permitted.
Polythene sheeting used for curing shall be well sealed and fastened at all stages.
4.9
Inspection and Records
4.9.1
Inspection of Concrete Surfaces

No concrete surface shall be worked on in any way after the removal of formwork, or
permanently covered up, until it has been inspected and approved by the Engineer.
4.9.2
Tolerances
Except where otherwise noted in the Specification or on the Drawings concrete
surfaces shall be cast within the tolerances set out in Table E.2, Clause 6.0, page
D/38.
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4.9.3
Records
Detailed records shall be kept by the Contractor of all batches of concrete, of their
mix reference, date and time of manufacture, position in the Works and of all
associated tests and measurements. Records shall also include actual casting
sequence and actual mix constituent quantities. During hot weather, the mix and
ambient temperatures and wind speeds shall be recorded. Three copies of all records
shall be supplied to the Engineer, within 24 hours of the recorded event.
4.10
Defective Concrete
4.10.1 Rejection and Reconstruction of Faulty Work

Concrete poured under this Contract which is defective form any cause whatsoever
shall, if so directed by the Engineer, be cut out and the work reconstructed at the
Contractors expense. (See Clause 4.4.5).
If there is any doubt concerning the strength or quality of previously placed and
hardened concrete, or the position of the reinforcement, the Engineer shall decide
whether the Contractor shall undertake core sampling or rebound testing or a cover
meter survey of the suspect concrete as follows:
(i)
150 mm diameter core samples shall be taken at locations directed by the

Engineer, following a cover meter survey if necessary. The cover meter shall
be used in accordance with BS 1881. The cores shall be tested in accordance
with BS 1881 and the equivalent cube strength shall be determined. Core
holes in concrete which is to remain in the Works shall be repaired by filling
with concrete or mortar of the same specification as the surrounding concrete,
or an approved proprietary non-shrink repair mortar to the satisfaction of the
Engineer.
(ii)
A series of rebound hammer tests shall be taken at locations directed by the

Engineer in accordance with BS 1881. Correlation between strength and
rebound number shall be carried out using 150 mm cubes of the same concrete
mix reference as the suspect concrete.
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4.11 Breaking out of Concrete

4.11.1 Removal of Concrete
The Contractors method of breaking out shall be designed to minimize further
damage to existing concrete. The Contractor shall submit details of his proposed
method, staff and equipment to be used and shall obtain the Engineers approval for such
prior to commencing work.
Feather edges shall not be accepted and the perimeter of the areas to be broken out shall
be saw cut to a depth of at least 20 mm.
Broken out concrete surfaces and exposed reinforcement shall be protected from salt
water splash and spray. The period between breaking out existing concrete and
placing new repair concrete shall be minimized and in no cases be longer than 7 days.
4.11.2 Surface Preparation of Concrete

Concrete surfaces which have been cut-back shall be prepared by grit-blasting or
scabbling and chipping out loose projecting coarse aggregate to expose a sound
matrix of rough profile. Marine and vegetable growth shall be removed by high
pressure water jetting or similar means to expose the concrete face and the Contractor
shall ensure that all oil or grease is removed by steam cleaning in conjunction with
suitable detergents. Surfaces shall be thoroughly cleaned by high pressure air-lance.
The parent concrete shall be soaked with fresh water for a period not less than 8 hours
prior to concreting such that the bonding surface is in a saturated surface dry
condition at the time of placing the repair concrete. Bonding agents shall not be
employed unless approved by the Engineer.
4.12
Concreting Underwater
Concreting underwater shall only be permitted with the approval of the Engineer.
Concreting underwater shall be carried out in accordance with Concrete Society
Report Underwater Concreting Ref.: TRCS3.
The Contractor shall prepare a detailed method statement for any underwater
concreting operations for approval by the Engineer.
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Table E.1 : Schedule of Designed Concrete Mixes
Mix Reference
A1
C1
D1
D2M
Reinforced
Concrete
40
Reinforced
Concrete
(Marine)
40
Use:
Lean Concrete
Min. Characteristic Strength N/mm
10
1. Mass concrete
2. Reinforced
Concrete
30
Nominal Max. Aggregate Size mm
20
20
20
20
Cement - Type Standard

146
OPC - BS 12
OPC - BS 12
OPC - BS 12
PBFC-BS
or blend of
OPC/Microsil
ica
- Min Cement Content (kg/m3)
- Max Cement Content (kg/m3)
100
N/A
330
500
400
500
400
500
Water/Cement Ratio- Absolute Max.

- Nominal Design
Type of Coarse Aggregate
N/A
Natural/Crushed
0.45
0.43
Natural/Crushed
0.40
0.38
Crushed
0.40
0.38
Crushed
Maximum Chloride Content by

Wt Cement % (Spec Clause 4.1.4)
N/A
0.1
0.1
0.1
N/A
75 + 25
75 + 25
75 + 25
N/A
32
30
30
N/A
Maximum Alkali Content of Mix

Kg/m3 (Spec Clause 4.1.6)
N/A
Maximum Drying Shrinkage %

(Spec Clause 4.1.7)
N/A
N/A
0.05
0.05
Impermeability to Water
(Refer Spec Clause.4.1.8)
- DIN Water Penetration
- ISAT BS 1881
- Capillary Rise
N/A
N/A
N/A
N/A
N/A
N/A
YES
N/A
N/A
YES
YES
YES
Workability - Slump (mm)

Maximum Temperature at
placing (C) (Spec Clause 4.6.7)
Maximum Sulphate Content by
Wt Cement % (Spec Clause 4.1.5)
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6.0
FORMWORK AND SURFACE FINISH
6.1
General
6.1.1
Formwork Generally
Formwork shall include all temporary or permanent forms required for forming the concrete,
together with all temporary construction required for their support. The provisions of BS
8110 shall be generally applicable to the Works.
The Contractor shall be entirely responsible for the sufficiency and stability of the
formwork and for the safe removal of the same so that, after hardening, the concrete
shall be in the position and of the shape, dimensions and surface finish described in
the Contract.
The Contractor shall, if required, submit Working Drawings and
supporting calculations for the formwork he proposes to use for the approval of the
Engineer before commencing the work.
Allowance shall be made for any loading
deflection to false work that will occur during concreting.
Such approval shall in no
way relieve the Contractor of his responsibilities under the Contract.
6.1.2
Formwork Construction
Formwork shall be constructed of metal, sound well-seasoned clean timber or other
approved materials, and shall be constructed so as to be rigid during the casting of
concrete.
All formwork shall be adequately propped, braced and fixed in the correct position and shall
be sufficiently strong to resist the pressure of wet concrete and disturbance due to flotation.
Formwork shall be strong enough to withstand the action of vibrators without
displacement, distortion or leakage and to carry the necessary constructional traffic.
6.1.3
Immersion in Sea Water

Where formwork is erected for concreting in tidal conditions it shall be suitable in
every respect for this use and resistant to immersion in sea water.
6.2
6.2.1
Finish, Fixing and Striking

Rough Finish
Formed concrete surfaces which are not visible in the finished work may, unless
specified otherwise, have a rough finish. A rough finish is defined as one which
meets the general requirements of this Specification without any extra requirements.
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6.2.2
Formed Finishes for Visible Surfaces

Formed concrete surfaces which will be visible in the finished work shall be formed to
one of the following two standards, and as shown on the Drawings.
Type A Small blemishes caused by entrapped air or water may be acceptable but
the surface shall be free from voids, honeycombing and other blemishes.
Type B All surfaces shall be true with clean arises. Only very minor surface
blemishes shall be permitted with no staining or discoloration from the
release agent.
6.2.3
Tolerances for Visible Formed Concrete Surfaces

Unless required by the Specification or Drawings to be otherwise, all visible formed
surfaces shall be within + 5 mm of the intended lines and levels. Differences in line
and level across joints in plane surfaces shall not exceed + 3 mm and all arrises and
chamfers shall be properly formed without significant defects. Weathered or sloping
surfaces shall be formed without hollows that allow ponding of surface water.
The Engineer may require the Contractor to carry out trials not forming part of the
permanent works to demonstrate the adequacy of his proposed formwork and
finishing procedures.
The following four parameters shall be used to determine the acceptability of the
quality of finish:
6.2.4
(i)
Deviation from plane
(ii)
Local deviation from plane
(iii)
Joints between panels
(iv)
Blow holes
The minimum allowable tolerances for each type of formed finish are shown in Table
E.2, but the tolerance shall also be within the limits required by any crane rail
installations. (i.e. Generally +0 mm to -5 mm unless stated otherwise on the
Drawings).
Chamfers and Fillets
Chamfers and fillets shall be formed on all external and internal corners to the sizes
shown on the Drawings or as agreed by the Engineer. Where no detail or instruction is
given the chamfer or fillet shall be 20 mm x 20 mm.
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6.2.5
Cambers
Formwork for soffits of suspended members shall be erected with an upward camber of
6 mm for each 3 metres of clear span.
6.2.6
Fixings, Holes, etc.

The Contractor shall be responsible for obtaining all necessary information from his
Sub-contractors and Suppliers in connection with holes, mortices, chases, ducts and
fixings of any description required for inclusion in the Works.
Holes, mortices, chases etc., shall be formed by the provision of the necessary inserts at
the time of casting the concrete. No holes, mortices, chases, etc., shall be cut in any
concrete without the approval of the Engineer.
Before placing concrete all devices for forming, holes, slots and other cavities shall be
securely fixed to the formwork, and all items to be embedded in the concrete shall be
firmly secured in position.
All pipes, bolts, steelwork and other fittings required to be built in or through the
concrete shall be firmly fixed in the formwork, which shall be neatly cut and fitted to
suit to prevent the escape of grout. Inserts into reinforced concrete shall be of an inert
material.
6.2.7
Use of Tie-bolts
Where internal metal tie-bolts are permitted, they or their removable parts shall be so
fixed that they can be easily removed when the formwork is dismantled without
damage to the concrete. The remaining holes shall be filled with mortar of the same
fine aggregate and cement as the concrete, mixed in the proportions of 1:2
cement/sand by weight, and shall provide a watertight seal, or an approve proprietary
non-shrink grout/repair mortar to the satisfaction of the Engineer. No permanently
embedded metal part shall have less concrete cover than that specified to the
reinforcement, or 75 mm whichever is greater.
Under no circumstances shall wire ties be used.
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6.2.8
Preparation of Formwork
The inside surfaces of formwork shall, except for permanent formwork, unless
otherwise agreed by the Engineer, be coated with an approved non-staining mould oil
to prevent adhesion of the concrete to the formwork. Release agents shall be applied
strictly in accordance with the manufacturers instructions and shall not come into
contact with the reinforcement or fixing devices. Different release agents shall not be
used in formwork to adjacent areas of concrete which will be visible in the finished
work.
6.2.9 Cleaning of Formwork
Before any concreting is commenced, all formwork shall be cleaned to remove dirt,
shavings, sawdust and other refuse. Formwork shall in general be cleaned out using oil
free compressed air. All formwork shall be subject to the written approval of the
Engineer before any concrete is placed.
Openings for inspection of the inside of the formwork and, where agreed, for the
removal of water used for washing out, shall be formed so that they can be
conveniently closed before concreting.
6.2.10 Striking of Formwork

Formwork shall be removed carefully at such a time and in such a manner that it does
not damage the concrete. All formwork shall be constructed so as to permit easing
and removal without jarring or damage to the concrete. The Engineer may direct that
additional concrete cubes are made to check the actual field strength of concrete prior to
giving approval for formwork removal.
The Contractor shall be responsible for properly supporting all concrete until it is
sufficiently strong for the formwork to be removed. No formwork shall be removed
without the prior approval of the Engineer but, notwithstanding such approval, the
Contractor shall retain complete responsibility for all formwork and any
consequences of the striking being premature or harmful. The minimum period of
time before striking vertical formwork shall be 24 hours from casting the concrete.
6.2.11 Temporary Loads
Materials shall not be stacked on, or construction loads applied to beams or slabs
without the approval of the Engineer.
6.2.12 Re-Use
Where it is intended that formwork is to be re-used it shall be thoroughly cleaned and
made good to the satisfaction of the Engineer.
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6.2.13 Unformed Surface Finish-Slabs

Unless otherwise directed in the Contract or by the Engineer the unformed surface
finish of concrete slabs (including angles making less than 15 degrees to the
horizontal) shall be uniformly levelled and screeded using a mechanical vibrating
screed to produce a tamped surface to the levels and falls shown on the Drawings.
Subsequent making up will not be allowed. All such unformed surfaces shall be
given a brush finish unless otherwise shown on the Drawings.
6.2.14 Trowelled Finish
Where a surface is to have a trowelled finish, the surface shall, after the moisture film
has disappeared and the concrete has hardened sufficiently to prevent laitence from
being worked to the surface, be trowelled (wood or steel) under firm pressure to
produce a dense, smooth uniform surface free from trowel marks.
6.2.15 Brush Finish
To achieve a brush finish, the surface shall be first wood trowel finished as specified
in Clause 6.2.14, then brushed in the direction of falls with a wire broom not less than
450 mm wide. The tufts of the broom shall be of 32 gauge tape wire, initially 100
mm long. The texture depth produced by brushing shall be to the approval of the
Engineer.
Brushing shall be carried out prior to the application of a curing
membrane.
Brushes made of other materials may provide an equally acceptable finish but their
suitability must be demonstrated to the satisfaction of the Engineer.
6.2.16 Sloping Surfaces
Formwork shall be provided for the top faces sloping work where the slope exceeds
15 degrees from the horizontal and shall be anchored to prevent flotation.
6.3
6.3.1
Remedial Treatment
Remedial Treatment of Surfaces
Any remedial treatment to surfaces shall be agreed with the Engineer following
inspection immediately after removing the formwork and shall be carried out without
delay.
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Honeycombed or otherwise defective concrete shall be cut out to ts full extent and
made good with concrete of the appropriate mix reference as directed by the
Engineer.
Any concrete whose surface has been treated before being inspected by the Engineer
shall be liable to rejection and replacement at no extra cost to the Contract.
6.3.2
Stains
The Contractor shall ensure that permanently exposed concrete surfaces are protected
from rust marks and stains of all kinds.
6.4
Suspended Formwork
Special care shall be taken to ensure that the design and construction of suspended
forms are capable of carrying imposed loads during placing and finishing concrete
without movement. Provision should also be made for access by labour to complete
finishing work without using the formwork for support and clearances should allow
for proper finishing of exposed surface below cross members, strutting and the like.
6.5
Standards
6.5.1

British and other Standards and Codes of Practice referred to in this sub-section are as
follows:
BS 8110:
Structural Use Of Concrete: Code Of Practice For

Design And Construction.
British Cement
Association
Specification For Formed Concrete Surfaces (W. Mark,

1987).
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Table E.2: Tolerances For Visible Formed Concrete Surfaces

Unless otherwise stated on the Drawings, all exposed concrete work shall be
constructed to the highest quality. The minimum acceptable finish shall be as the
specified Type B in Clause 6.2.2.
Characteristic
Limits for Type

A
10 mm or
0.002 L
whichever is the
greater
Deviation from Plane

Measured over a whole element
by reference to a straight line
(overall length L)
B
8mm or
0.0015L
whichever is
the greater
Local deviation from plane

Measured over 150 mm.
4mm
6mm
Joints between elements

measured width in (d max-d)
relation to the or
\design width (d) (d-d min)
12mm
16mm
Blow-holes
assessed by direct comparison between concrete
surface and figure (4) * Reference 1
* Note: * refers to Specification For Formed Concrete Finishes -W. Monk (1987)
7.0
7.1
7.1.1
PRECAST CONCRETE
General
Compliance
Areas for precasting concrete shall be situated away from exposed coastal locations where
contamination of concrete and materials is likely from chlorides.
Precast concrete shall comply with the requirements of Section Clauses 1 to 6 of the
Specification for Concrete Works in so far as they are applicable, except where varied
by the requirements of this sub-section. Members specified as cast insitu may be
precast (or vice versa) only after the written approval of the Engineer has been given.
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7.1.2 Method of Casting, Handling, Storage etc

The Contractor shall submit proposals to the Engineer for approval of the location of the
casting area and the method of casting, curing, handling and storage of precast concrete
units and for the erection sequence.
When the method statement has been approved no changes shall be made without the
written consent of the Engineer.
Prior to cutting and bending of reinforcement for production units, the Contractor
shall assemble a complete reinforcement cage for each type of unit, for inspection and
approval by the Engineer.
7.1.3
Surface Finish
Precast concrete units shall generally be formed with a finish as defined in
accordance with Clause 6.2.3 of the Specification.
The surfaces of precast units which will subsequently receive grout or concrete to
form a structural connection with insitu concrete shall be prepared by removing the
outer mortar skin when the concrete has set but not hardened, using a stiff brush and a
fine spray of water, to the extent that the larger pieces of coarse aggregate are
exposed but not damaged or dislodged.
7.1.4
Casting Tolerances
Tolerances for precast units shall be as recommended in BS 8110.
7.1.5
Marking and Serial Numbers

Units shall be clearly and indelibly marked to show the date of casting. The markings
shall be in such a position that they will not be seen in the completed work.
7.1.6
Handling
Precast units shall be lifted or supported only at points approved by the Engineer and shall
be handled and placed without impact or vibration. Care shall be taken not to distort any
reinforcement projecting from units.
7.1.7
Loading During Handling

Precast units shall at no time be subjected to loading, including their own weight,
which will induce a compressive stress in them exceeding 0.33 of their compressive
strength at the time of loading or of their specified minimum Characteristic Strength,
whichever is less.
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Embedded steel lifting hooks shall only be used if the recessed holes are reinstated
with non-shrink proprietary cementitious repair mortar to provide a minimum cover of
75 mm or that shown on the Drawings, whichever is greater.
For the purposes 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.
7.1.8
Support to Precast Units

The Contractor shall be responsible for providing all necessary support to precast
units during concrete operations.
7.1.9
Placing Tolerances
Precast units shall be placed in the Works to within + 5 mm of their specified plan
position and + 3 mm of the specified level.
8.0
STANDARDS
8.1

British and other Standards and Codes of Practice referred to in this Section are as
follows:
BS 12:
Specification for Ordinary and Rapid-Hardening Portland Cement.
BS 812:
Testing Aggregates
Methods for determination of particle size and shape.
Methods for determination of physical properties.
Methods for determination of mechanical properties.
Guide to sampling and testing aggregates.
Methods of sampling.
Methods for determination of particle size distribution.
Flakiness index.
Methods for determination of shell content in coarse aggregate.

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Methods for determination of water-soluble chloride salts.
Methods for determination of sulphate content.
Methods for determination of acid-soluble material in fine aggregate.
Methods for testing and classifying drying shrinking of aggregates in

concrete.
BS 882: Aggregates From Natural Sources Of Concrete.
BS 1370:
Low Heat Portland Cement.
BS 1881: Testing concrete

- Method for determination of initial surface absorption of concrete. (see
Clause 4.1.8)
VOLUME II A
Methods for testing hardened concrete for other than strength.
Method of sampling fresh concrete on site.
Method for determination of slump.
Method for determination for compacting factor.
Method for determination of Vebe time.
Method for making test cubes from fresh concrete.
Method of normal curing of test specimens.
Specification for compression testing machines for concrete.
Method for determination of compressive strength of concrete cubes.
Method for determination of flexural strength.
Method for determination of the compressive strength of concrete cores.
Methods for analysis of hardened concrete.
Recommendations for surface hardness testing by rebound hammer.
Recommendations on the use of electro-magnetic cover meters.

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BS 3148: Methods For Testing For Water For Making Concrete.

BS 3892
Pulverised Fuel Ash For Use As A Cementitious Component In Structural

Concrete.
BS 4246: Low Heat Portland Blast Furnace Slag Cement.
BS 4251: Truck Type Concrete Mixers.

BS 4254: Two-Part Polysulphide Based Sealants.
BS 4449: Carbon Steel bars For The Reinforcement Of Concrete
BS 4466: Bending Dimensions And Scheduling Of Reinforcement For Concrete
BS 4483: Steel fabric for the reinforcement of concrete BS 4550: Methods Of Testing Cement.
-
Sampling.
Chemical tests.
Physical tests.
BS. 5075: Concrete Admixtures.

-
Accelerating admixtures, retarding admixtures and water reducing

admixtures.
Air-entraining admixtures.
Superplasticizing admixtures.
BS 5328: Methods For Specifying Concrete, Including Ready-Mixed Concrete.

BS 6588: Portland Pulverised Fuel Ash Cement.
BS 7123: Metal Arc Welding Of Steel For Concrete Reinforcement
BS 8110: Structural Use Of Concrete:- Code Of Practice For Design And
Construction
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AASHTO T277-83
Rapid Determination Of The Chloride Permeability of

Concrete.
ACI 304-73
Recommended Practice For Measuring, Mixing, Transporting

And Placing Concrete.
ACI 305-91
Hot Weather Concreting.
ASTM C 88-91
Test Method For Soundness Of Aggregates By Use Of Sodium

Sulphate Or Magnesium Sulphate.
ASTM C 125-86
Definitions Of Terms Relating To Concrete And Concrete

Aggregates.
ASTM C 232-72
Test For Bleeding Of Concrete
ASTM C 289-87
Test Method For Potential Reactivity Of Aggregates.
DIN 1048:
Test Methods For Concrete.
UK Department of Transport, Manual of Contract Documents For Highway Works,

Volume 1.- Specification For Highway Works (December 1991)
British Cement Association: Minimising The Risk Of Alkali Aggregate Reaction.
British Cement Association: Spacers And Cover (Working Party Report, 1987)
UK Concrete Society Report No.31- Permeability Testing Of Site Concrete: A
Review Of Methods And Experience
UK Concrete Society Report Ref. TRCS3- Underwater Concreting
CIRIA: Special Publication 31- The CIRIA Guide To Concrete Construction In The
Gulf Region.
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SECTION E
BLOCKWORK
1.0
MATERIALS
All precast concrete blocks shall comply with the requirements of BS 6073 Part 1 and
2 , and Dubai Municipality Local Order No. 44 of the year 1990.
1.1
Cement
(i)
The cement used in the manufacture of precast concrete masonry blocks shall
comply with the requirements of BS 12 or BS 4027 as appropriate.
(ii)
Handling and storage shall be in accordance with the requirements of the
Concrete Specification.
(iii)
1.2
The cement content of manufactured blocks shall be not less than 200 kg/m.
Aggregate
(i)
Aggregate shall consist of naturally occurring crushed or uncrushed materials
which shall fully comply with BS 882.
(ii)
Handling and storage shall be in accordance with the requirements of the
Concrete Specification.
(iii)
The content of acid soluble chlorides (Cl) shall not exceed:

(a)
0.6% by weight of fine aggregate
(b)
0.2% by weight of coarse aggregate
(iv)
The content of acid soluble sulphate (SO3) shall not exceed 0.3% by weight of
coarse and fine aggregates.
(v)
Coarse aggregates used for the manufacture of concrete blocks shall be 10 mm

nominal size for standard blocks. Grading, when determined in accordance
with BS 882 shall be within the limits of Table 4 of BS 882.
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1.3
1.4
2.0
2.1
Water
(i)
Water shall be potable, clean and free of any organic and deleterious matter
having a pH value of 7 to 9.
(ii)
Organic impurities shall not exceed the following limits:
(a)
Total dissolved solids
2000 mg/litre
(b)
Chlorides
600 mg/litre
(c)
Sulphates
500 mg/litre
(d)
Alkalis, carbonates and bicarbonates 1000 mg/litre
Additives
(i)
All pigments shall comply with BS 1014.
(ii)
All admixtures shall comply with BS 5075.
(iii)
Admixtures shall not contain chlorides. They are preferred to be lignosulphate

based water reducing agents.
BLOCK MANUFACTURE
Dimensions and Tolerances
(i)
Standard co-ordinated block sizes for walls shall be 400 mm long, 200 mm
high and of width indicated on the Drawings.
Sizes shall be modular as specified in BS 6073 Part 2.
VOLUME II A
(ii)
Load bearing blocks shall have a thickness of not less than 200 mm.
(iii)
Hollow blocks shall have voids between 25% and 50% with a minimum
external shell of 35 mm or 1.75 times the nominal maximum size of aggregate,
whichever is greater.
(iv)
No overall dimension (length, width or height) shall differ by more than 3 mm

at any point.
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2.2
3.0
3.1
Testing
(i)
Ten blocks shall be drawn at random for testing from every designated 1000
blocks section or part thereof in a consignment. All samples shall be clearly
marked at the time of sampling in such a way that the designated section or
part thereof and the consignment represented by the sample are clearly
defined.
(ii)
Concrete blocks shall be as per BS 6073 Part 1 and 2 and Dubai Municipality.
(iii)
Sample specimens shall be tested in compression as specified in BS 6073.
(iv)
Unless otherwise specified on the Drawings the compressive strength shall be

as follows:
(a)
Load bearing blocks - average strength not less than 12.5 N/mm.
Minimum individual strength not less than 10.0 N/mm.
(b)
Non load bearing blocks - average strength not less than 7.5 N/mm.
Minimum individual strength not less than 6.0 N/mm.
(v)
A Certificate of Compliance from Dubai Municipality Laboratory Laboratory shall be

provided by the manufacturer with each delivery of material at site in
accordance with local order 44, 1990. Density of blocks shall not be less than
1500kg/m as per BS 6073 Type "A".
(vi)
Further tests by an approved independent laboratory may be requested by the

Engineer to verify compliance.
(vii)
The costs of all sampling and testing shall be borne by the Contractor.
MORTAR
Mortar Constituents
(i)
Mortar shall consist of cement and sand in the specified proportions.
(ii)
The Contractor may use a plasticiser or a retarder with the mortar, subject to
the approval of the Engineer and provided that it is used strictly in accordance
with the manufacturer's printed recommendations.
(Complying with
BS 4887).
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3.2
(iii)
The addition of mortar admixtures shall produce a 70% improvement in ISAT

water absorption values (BS 1881).
(iv)
Lime shall comply with BS 890.
Mortar Designations
(i)
Mortar designation shall be in accordance with BS 5628.
(ii)
For mortars containing admixtures the mortar designation

accordance with Table 1 of BS 4721 (I).
(iii)
All mortars shall be tested in accordance with BS 4551.
4.0
ANCILLARY ITEMS
4.1
Damp Proof Courses
shall be in
Damp proof courses to block walls shall consist of one layer of quality bitumised
fibre felt damp proof course complying with Type B of BS 743 and weighing not less
than 3.3 kg per square metre.
4.2
4.3
Wall Ties
(i)
Wall ties shall be galvanised iron generally, stainless steel where particularly
specified or shown on the Drawings, or other approved by the Engineer.
(ii)
Standard wall ties shall conform to the requirements of BS 1243.
Movement Joints
Movement joint filler shall be 10 mm thick (unless specified otherwise) cellular nonabsorbent low density joint filler sealed on both sides with an approved polysulphide
sealant complying with BS 4254.
4.4
Special Blocks
(i)
Special blocks for forming feature panels etc. shall be to details shown on the
Drawings and to the approval of the Engineer.
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(ii)
4.5
4.6
Reinforcement
(i)
Expanded steel mesh joint reinforcement shall comply with BS 2989.
(ii)
Bar reinforcement shall comply with the requirements of the Concrete Section
of this Specification.
Cavity Wall Insulation

(i)
Cavity wall insulation shall be preformed rigid boards of closed cell extruded
polystyrene to BS 3837.
(ii)
5.0
5.1
Claustra perforated blocks shall be constructed generally as for precast

concrete blocks but perforated as indicated on the Drawings. They shall be
formed in purpose made moulds to give faces finished fair to receive a paint
finish without plastering.
Insulation board fixings shall be approved purpose made proprietary wall ties
complete with polypropylene retaining clips and to the approval of the
Engineer.
WORKMANSHIP
Construction
(i)
Blockwork shall be constructed in accordance with BS
5628 and laid
in a workmanlike manner with true and regular horizontal courses and
staggered vertical joints with walls and partitions bonded to one another at
junctions and angles.
VOLUME II A
(ii)
All joints shall be of consistent thickness (average 10 mm); all horizontal

joints shall be properly level and vertical joints shall be properly lined and
quoins, jambs and other angles plumbed as the work proceeds.
(iii)
Not more than five courses of blocks should be laid in any one day within any
section of walling.
(iv)
Cut blocks shall only be used where required for bonding purposes or to
facilitate building in of other components but shall not be used as a lintel
bearing.
(v)
In hollow blocks, where required by the Engineer, hollows shall be filled with
concrete (min. grade 25N/mm) at ends of walls and jambs to openings below
lintels, beams and slabs which bear on the wall. Filling with mortar or
material other than that specified will not be accepted.
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(vi)
Walls shall be carried up regularly without leaving any part more than 4
courses lower than adjacent sections unless the permission of the Engineer is
first obtained and any work left at different levels shall be evenly stepped
back.
(vii)
In cavity wall construction one skin shall not be taken more than 3 courses
above the adjacent skin.
(viii) Blocks shall be soaked with water for 24 hours before being used and the tops
of walls left off shall be well wetted immediately prior to recommencement of
work.
5.2
(ix)
The faces of walls shall be kept clean and free from mortar droppings and
splashes.
(x)
Blockwork abutting concrete columns shall be tied with 32 x 6 mm galvanised

steel clamps or ties shot fired to the concrete and built in every third course of
blockwork and shall be debonded from the blockwork by painting with
bitumen.
Movement Joints
(i)
The movement joints material and thickness shall be as specified and
allowance shall be made for leaving temporarily open courses immediately
under all horizontal structural members and they shall be made good and
pointed up at the time when structural members have been fully loaded and
before the completion of that section of the works.
(ii)
The movement joint material shall be laid to the width appropriate to the
walling with clean, even butt joints and the joint shall be kept clean of any
material which may be detrimental to the operation of the joint.
(iii)
Movement joints shall be sealed on both faces with an approved polysulphide

sealant.
5.3 Cavity Walls
(i)
In cavity wall construction the cavity shall be maintained at the width shown
on the Drawings or as specified and shall be kept clean by efficient means
throughout the construction of the walls and any accidental mortar droppings
shall be prevented from adhering to cavity faces of walls, wall ties, cavity
trays or insulation.
(ii)
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Wall ties shall be bedded minimum 50 mm in to each skin of walling and

spaced 600 mm vertically and 900 mm horizontally with additional ties within
200 mm of sides of openings at 400 mm vertical centres.
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5.4
5.5
(iii)
Cavity wall insulation shall be installed in accordance with BS 6676 Part 2 (as
appropriate) and in accordance with the manufacturer's printed instructions.
(iv)
Insulation boards shall not, under any circumstances, be pushed into a cavity
but shall be fixed tightly against the insulating skin of walling which shall be
clean, using approved fixings.
(v)
Insulation boards shall be tongue and groove jointed with staggered vertical
joints and shall be evenly and cleanly cut where required.
(vi)
Spacing of wall ties with retaining clips shall suit sizes of insulation boards so
as to retain all edges but not be less than the requirements of Clause 5.3 (ii).
Damp Proof Courses

(i)
Where indicated on the Drawings approved damp proof courses shall be laid
on and bedded in mortar in continuous lengths as far as it practicable and in
accordance with the requirements of BS 743.
(ii)
Joints shall be lapped 200 mm in straight runs and for the full width at
junctions and angles with the meeting surfaces sealed with bituminous
waterproofing compound.
Joints
(i)
Walls which are to be rendered shall have the joints cleanly raked out to a
depth of 15 mm to form a key which shall be approved by the Engineer before
rendering commences.
(ii)
Where the blockwork is described as "with flush joints formed as the work
proceeds" the joints shall be "bagged" or similarly flushed up to ensure that
the mortar surface is finished flush between blocks.
(iii)
5.6
Where the block work is described as with weather struck joints formed as
the work proceeds the joints shall be formed on the same day as the blocks
are laid and be integral with the bedding mortar, and formed as per the details
shown on the Drawings.
Tolerances
(i)
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Permissible tolerances shall be within the limits shown in the Table on page
E/8 below.
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(ii)
(iii)
Permissible deviations shown are the maximum that will be accepted and any
work not in compliance shall, upon instruction from the Engineer be rebuilt.
The Contractor shall, should the nature of subsequent finishes or fittings
require, adopt closer tolerances.
TABLE OF PERMISSIBLE TOLERANCES

ITEM OF CONSTRUCTION
TYPE OF DIMENSION
Size and shape of wall

elements
Height up to 3.0 metres.

Straightness in 5.0 metres.
Vertically up to 2.0 metres.
Level of bed joints in 3.0 metres
Walls
Position in plan of any point or

Specified face relation to nearest
grid line on the same level
Door, window and other

openings
Note: a)
b)
Position in elevation from design

position
Level of sill or soffit
For each 1.0metre of width with
maximum of verticality.
Of any point for each 1.0 metre
of height with maximum of.
PERMISSIBLE DEVIATION
mm
15
5
15
15
15
15
5
15
15
Tolerances are not cumulative.

In general tolerances are to be maintained in accordance with BS 5606.
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SECTION
ROOFING
1.0
2.0
GENERAL DESCRIPTION
(i)
The roofing system shall be inverted "warm roof" type limestone chippings or
other protection as specified and shown on the Drawings, laid on thermal
insulation over single layer roofing membrane applied to screeded concrete.
(ii)
All roofing shall be in accordance with C.P. 144.
PREPARATION
(i)
Before commencing installation of the roof waterproofing and insulation

system all construction work and installations above roof level shall be
completed as far as practicable.
(ii)
Particular care shall be taken to ensure that :

(a)
All rainwater, plumbing, air conditioning and ventilation duct outlets

have been fixed in position and are protected against blockage or
accidental damage.
(b)
Supports to ductwork, pipework, cable tray and the like have been
installed.
(c)
All kerbs to rooflights, access doors, plant and water tanks have been
installed.
(d)
All chases for skirtings, etc., have been prepared.
(iii)
The surface of the substrate shall be clean and dry, free from ridges or
indentations, laid to falls as required and not contaminated with oil or other
deleterious matter.
(iv)
No surface primer or waterproof membrane shall be applied until the substrate

has been inspected and approved at each stage by the Engineer.
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3.0
3.1
3.2
VOLUME II A
MATERIALS AND APPLICATIONS

Roof Screed
(i)
Refer to Section D, Concrete Work, for materials specification.
(ii)
The roof screed shall be formed of cement and sand, mix proportions 1:3 or as
otherwise specified.
(iii)
The screed shall be laid in bays, square where possible to a maximum area of
10 m. Each bay shall be formed between stopboards of the correct height and
cut on each side to indicate the falls required.
(iv)
Unless indicated otherwise the minimum fall shall be 1 in 80 and the

minimum thickness of the screed shall be 50 mm.
(v)
The screed shall be trowelled with a wood float to true and accurate falls and
cross falls up to the stop boards.
(vi)
The screed shall be allowed to cure thoroughly to attain maximum shrinkage

and any cracks occurring, due to shrinkage, shall be made good to the
satisfaction of the Engineer.
(vii)
A gap of 10 mm shall be left between each screed bay for the depth of the
screed. All gaps shall be thoroughly cleaned by brushing or blowing and filled
with cold bitumen upon completion of curing.
Roofing Membrane
(i)
All surfaces to receive the roof membrane shall be primed prior to laying the
roof membrane.
(ii)
The roofing membrane shall be self adhesive or torch applied, impermeable,

bitumen polymer waterproofing membrane, distilled bitumen strengthened
with added plastomers and elastomers and reinforced with a continuous
extruded fibre non-woven spunbound polyester.
The membrane shall be
flexible at low temperature and have high melting temperature, resistance to
thermal ageing and to ultra violet rays, acids, inorganic salts. The membrane
shall remain impermeable until breaking of non-woven polyester fabric. The
total thickness of the roofing membrane shall not be less than 4 mm and
designed for single layer application.
(iii)
At all angles, kerbs, parapets, pipes, etc., the roofing shall be reinforced by
additional layers, to a minimum total thickness of 4 mm, with internal angle
fillets provided, all as detailed on the Drawings and in accordance with the
manufacturer's printed instructions and recommendations.
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3.3
(iv)
All joints shall be overlapped to a minimum of 150 mm and bonded in the

method suited to the membrane in accordance with the manufacturer's printed
instructions and recommendations.
(v)
No storage of materials or trafficking by other trades shall take place on areas

of exposed roofing membrane until subsequent finishing surface protection
materials have been laid.
Thermal Insulation
(i)
The thermal insulation shall be of rigid boards of extruded close cell

expanded polystyrene in accordance with BS
3837: Part 1, Grade SHD
(Special Heavy Duty) Type A, minimum density of 36 kg/m, of the thickness
as shown on the Drawings and with interlocking edges.
(ii)
The thermal conductivity (k value) shall not be greater than 0.03 watts/m K.
(iii)
The boards shall be laid with close butted and staggered joints and shall be
accurately cut and trimmed to fit kerbs, parapets, fillets, etc. Boards shall not
be bonded to the substrate.
(iv)
The boards shall be protected as work proceeds against prolonged exposure to

sunlight, damage and displacement before finished surface protection is
applied.
4.0
SURFACE PROTECTION
4.1
The insulation layer shall be protected by one or a combination of the following as

detailed on the Drawings or as instructed by the Engineer.
(i)
Mineral Chippings
Chippings shall be 12 mm limestone aggregate, to a depth in accordance with
Table 1 laid on an approved filter membrane of minimum weight 100 g/m.
Suitable guards shall be installed at rainwater outlets.
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Table 1 , DUBAI INDUSTRIAL CITY
PLOT 5330316,5330317,5330318,5338058
Thermal insulation thickness
Up to
(mm)
50
60
70
80
100
120
Depth of stone/gravel
protection (mm)
90
(ii)
(iii)
4.2
Up to
50
60
70
80
80
Precast Concrete Roofing Tiles

(a)
Constituent materials shall be as specified in Section D - Concrete

Works.
(b)
Tiles shall be cast under pressure and shall be 600 x 600 x 50 mm

overall and rounded or chamfered at all exposed joints.
(c)
Tiles shall have keyed backs and be cured for a period of seven days
after the initial set by being totally immersed in a tank of clean water
after which they shall be stacked on edge for a period of seven days
and be kept moist by spraying with water.
(d)
The finished surfaces of tiles shall be flat, smooth and plain, free from
projections or depressions and edges shall be sharp and true.
(e)
Samples of tiles shall be submitted to the Engineer for approval.
(f)
Tiles shall be laid on proprietary spacer pads as approved by the

Engineer and clean, open joints shall be maintained.
Solar Protection Membrane

(a)
On all surfaces where the roofing membrane is exposed without

insulation, or other protection, a self adhesive aluminium faced
membrane shall be applied.
(b)
The solar protection membrane shall be wholly compatible with the

roofing membrane and shall be installed in accordance with the
manufacturer's printed instructions.
Proprietary Waterproofing Systems

(i)
Where specified on the Drawings or approved by the Engineer a proprietary

waterproofing system may be used.
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(ii)
4.3
The work shall be carried out by skilled and experienced operatives, strictly in
accordance with the manufacturer's printed instructions and the system shall be
guaranteed by the licensee for a minimum period of ten years.
Aluminium Flashings
Aluminium flashings where required shall be formed from 22 gauge aluminium sheet cut
and bent to the required shape and screwed to and including softwood battens cast into
the concrete coping or upstand with and including aluminium screws.
4.4
White Cement Tiles

The tiles shall be of size 300 x 300 x 25 mm or as mentioned on Drawings and from
an approved supplier. The fixing details should be as for marble mosaic tiles
(Terrazzo) flooring and each panel size should not be more than 3.0 m x 3.0 m square.
The joint between the panels should be minimum 12 mm wide and should be filled
with bitumen impregnated fibreboard and approved mastic.
5.0
METAL SHEET ROOFING

Metal sheet roofing shall be profiled aluminium to comply with Section N.
6.0
TESTING
(i)
The Engineer will require all areas of roofing to be water tested by the
Contractor after the roofing has been laid.
(ii)
The Contractor shall allow for the roof to be flooded with water to a
prescribed level and left for a minimum of 72 hours, or allow for any other
suitable and approved method of testing and shall provide all facilities for
complying with such tests the cost of which shall be deemed to be included in
his tender rates.
(iii)
On completion roofs shall be left sound, watertight and in a neat and clean
condition before handing over and to a standard which is to the entire
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7.0
GUARANTEE
(i)
The Contractor shall provide the Engineer with an unconditional guarantee in

favour of the Client against failure of the roof waterproofing system whether
caused by defective materials or workmanship.
(ii)
The guarantee shall be valid for a period of (10) ten years commencing at
completion of the Period of Maintenance as defined in Clause 49 of the
Conditions of Contract.
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SECTION G
CARPENTRY, JOINERY AND IRONMONGERY
1.0
1.1
1.2
CARPENTRY
Timber Generally
(i)
All timber shall be clean, sound, of merchantable quality, properly seasoned
and free from wooly texture, soft heart, sapwood, splits, shakes, waney edges,
fungal and insect attack, faults caused by compression failure and any defect
or combination of defects, natural or otherwise.
(ii)
Sizes of timber shall be in accordance with BS 5450 (for Hardwood) and BS

4471 (for Softwood).
(iii)
Unless specifically stated otherwise, sizes shown on Drawings are finished

sizes and the Contractor must allow within his costs for forming wrought faces
from appropriate larger sizes.
Moisture Content
(i)
All timber (softwood and hardwood) shall be kiln dried to a moisture content
of 11% - 13% (12% average) before transportation.
(ii)
1.3
Each batch shipped shall have accompanying documentation verifying this

and any batch without such documentation will be rejected.
Preservatives
(i)
When stated on the Drawings/Schedules treated timber shall mean timber
treated with copper chrome arsenate (CCA) fixed water-borne preservatives
applied by vacuum pressure impregnation in accordance with BS 4072.
(ii)
All softwood shall be treated as in Clause 1.3(i) whether or not stated on

Drawings/Schedules.
(iii)
The Engineer shall be informed of details of the firm undertaking the timber
treatment and the Contractor shall obtain from the firm a certificate of
treatment for every consignment of timber treated which shall be re-submitted to
the Engineer.
(iv)
Treatment shall be carried out after machining of timber except that brush or
spray application of the manufacturer's preservative, in two applications, to
any cutting or boring subsequent to the initial treatment will be carried out to the
Engineer's approval.
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(v)
1.4
1.5
All water borne preservative treatment shall be undertaken in good time for
timber to dry out before allowing the treated timber to contact any other
materials or components.
Hardwood
(i)
All hardwood shall be in accordance with the requirements of BS 1186 : Part 1
and shall be of first quality, sorted and selected at time of fabrication for
suitability of purpose and to give a harmonious appearance to the approval of
the Engineer.
(ii)
The species of hardwood shall be as indicated on the Drawings/Schedules.
(iii)
In addition to the requirements of Clause 1.1(i) all hardwood shall show a

straight and regular grain throughout, shall have a consistent colour in all
locations and be free from knots on exposed faces.
(iv)
Any hardwood showing visible imperfections will be rejected.
Softwood
(i)
All softwood shall comply with the requirements of BS 1186 Part 1.
(ii)
In addition to the requirements of Clause 1.1(i) all softwood shall be free from
pith showing on the surface, sloping grain exceeding 1 in 8, checks and
shakes, knots exceeding 25mm diameter, arris and splay knots, decayed or
loose knots and knot holes.
(ii)
Softwood shall be one of the following:

Species
(BS 7539:1991)
Origin
Whitewood/European Spruce
(Picea abies)
Europe
Scots pine/Redwood
(Pinus sylvestris)
Europe
Douglas fir/British Columbian pine

(Pseudotsuga taxifolia)
Canada/USA
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1.6
1.7
VOLUME II A
Plywood
(i)
All plywood shall comply with the requirements of BS 6566 Grade II and B
on both faces and shall be of Canadian, Finnish or other equal and approved
origin obtained from a manufacturer to be approved by the Engineer.
(ii)
Except where stated otherwise plywood shall be Exterior Grade Bonding with
synthetic resin adhesives to BS 1203.
(iii)
Plywood shall be supplied by the manufacturer in the thicknesses as stated on

the Drawings/Schedules.
(iv)
Plywood shall be manufactured from hardwood and shall be free from end
joints, (including joints in veneers) overlaps in colour veneers, dead knots,
patches and plugs,open defects, depressions due to defects in cure, insect
attack (isolated pinwork holes through face veneers only) fungal attack and
from discolouration differing from that normally associated with the species of
timber used.
(v)
Face veneers shall be hard and durable and shall be capable of being finished
to a smooth surface to receive coatings.
(vi)
Marine plywood shall be to BS 1088 and 4079 and of balanced construction.
Mechanical Fastening and Fixings

(i)
Non-standard metal work used in cleats, brackets, straps etc. standard sections
as detailed in the Drawings shall be from mild steel in accordance with
Section J, Metalwork.
(ii)
All fastenings described below shall be of steel unless otherwise stated.
(iii)
All ferrous metalwork, nails, screws, bolts and other mechanical fastenings
shall be protected by galvanising after manufacture in accordance with Section
J, Metalwork, or, where appropriate, the relevant British Standard for the item.
(iv)
Nails shall be high grip nails with annular ringed shank or helical threaded
shank to BS 1202:Part 1.
(v)
Screws shall be to BS 1210.
(vi)
Plain hexagon bolts shall be to BS 4190.
(vii)
Washers, large diameter, shall be to BS 4320.

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1.8
1.9
(viii)
Expanding bolts shall be proprietary devices comprising corrosion resistant

expanding insert and removable bolt or threaded stud to suit work being fixed,
or of a pattern and make to the approval of the Engineer.
(ix)
Frame cramps shall be galvanised steel cramps of an approved pattern shaped

for building in.
(x)
Timber connectors, where indicated on the Drawings, shall be of the toothed

plate type to BS 1579.
(xi)
All mechanical fastenings and fittings shall be adequately protected from

corrosion and all exposed bolts are to be capped with an approved dome
headed nut.
Adhesives
(i)
Adhesives shall comply in all respects with BS 1204 and BS 5442 Part 3 and
shall be used in strict accordance with the manufacturer's printed instructions.
(ii)
For joints in non-bearing internal work and for joints in work where the
moisture content is always less than 16%, organic or casein glues may be
used.
(iii)
For work under damp conditions (moisture content normally 20%, or where
conditions are liable to fungal attack) resin type adhesives shall be used.
Packing, Delivery and Storage

(i)
All timber must be polythene wrapped at 12% moisture content prior to
transportation.
(ii)
Protection shall be such as to protect the timber against stain, discolouration

and other surface injuries during transportation and erection on site.
Protection shall be of such composition that it may be easily removed when
work is complete, without being harmful to the surface of the timber.
(iii)
Polythene shall be removed as soon as possible and the timber close stacked in
the shade, clear of the ground on levelled bearers in a manner that prevents
sagging and permits free air circulation.
(iv)
When stored externally timber shall be covered during wet weather and
uncovered during dry weather.
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(v)
(vi)
1.10
Temporary covers should be kept from close contact with the timber.
Unless otherwise approved by the Engineer, joinery that shall be finally fixed
in an air conditioned environment shall be stored, immediately prior to fixing,
in similar conditions to those designed for that location and for a period
sufficient to enable acclimatisation to that environment.
Workmanship
(i)
Timber shall be sorted and selected at time of fabrication for suitability, for
purpose and its function in the Works.
(ii)
The moisture content of timber shall be checked, before fixing, with a reliable,
properly calibrated meter and timber with a moisture content in excess of 2%
above that specified shall not be fixed.
(iii)
Timber shall be sawn truly square, straight and free from burrs.
(iv)
Joints shall be as shown on the Drawings but where not specifically shown
shall be the recognised form of joint with regard to its location and such that
they tighten under load, resist tension as appropriate to their function an are
without gaps or imperfections.
(v)
Loose joints shall be used where provision must be made for shrinkage or
other movements acting other than in the direction of the stresses of fixing or
loading.
(vi)
All joints, arrises, recesses, etc. shall be plumb, true and square.
(vii)
All units and members shall be installed such that they are truly plumb or
horizontal.
(viii)
The carpenter shall perform all necessary mortising, tenoning, grooving,

matching, tonguing, housing, rebating and all other works necessary for
correct jointing.
(ix)
All metal plates, screws and other fixings that may be required or necessary
for the proper execution of the carpentry works shall be provided.
(x)
The carpenter shall also carry out all works necessary for the proper
construction of all framing, linings, etc. and for their support and fixing in the
building.
Nails, sprigs, etc. shall be punched and puttied.
Screw heads in work to be painted shall be countersunk and stopped.
(xi)
(xii)
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(xiii)
Glued joints shall be used where provision need not be made for shrinkage or
other movements in the connections and where sealed joints are required.
(xiv)
Glued joints shall be cross tongued or otherwise reinforced so as not to wholly

depend upon the adhesive.
(xv)
Surfaces to be glued shall be clean, free from dirt, dust, sawdust, oil and other
contaminants and shall have a good sawn or planed finish.
(xvi)
Adequate pressure shall be applied to glued joints to ensure intimate contact

and pressure shall be maintained whilst the glue is setting.
(xvii) Unless specific sizes are stated on the Drawings/Schedules screws shall be of a
size and length to suit pre-drilled holes in metalwork and dimensions of timber
being fixed.
(xviii) Screws shall be fully driven home and timber shall be pre-drilled where
necessary.
(xix)
(xx)
Screws fixed into masonry, concrete and blockwork shall be plugged using
approved durable proprietary fibre composition or plastic plugs of suitable
size and length for the fixing and at centres necessary to provide adequate
support but not exceeding 600mm.
Masonry nails shall not be used for fixing timber to masonry, concrete or
blockwork unless approved by the Engineer.
(xxi) Approved proprietary expanding masonry bolts/resin anchor bolts shall be

used where shown on the Drawings as specified or instructed by the Engineer
and shall be of a type, size and strength suitable to their location and function
and fixed in strict accordance with the manufacturer's printed instructions.
2.0
JOINERY
2.1
Timber Generally
Comply with Clause 1.1.
2.2
Moisture Content
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2.3
2.4
Preservatives
(i)
(ii)
With regard to Clause 1.3(iii) specified treatment shall be carried out prior to
assembly of pieces.
Hardwood
2.5
Softwood
Comply with Clause 1.5 except all softwood shall be free from knots exceeding 6mm
diameter.
2.6
Plywood
(i)
2.7
(ii)
Face veneers shall closely match the general joinery timber unless described
otherwise and shall be approved by the Engineer prior to inclusion in the
Works.
(iii)
Plywood for joinery work shall be Grade 1 and A on both faces unless
otherwise shown, specified or approved.
Blockboard
(i)
Blockboard shall comply with BS 3444 and be manufactured by approved

process with hardwood veneers, minimum 3mm thick, to faces.
(ii)
Clause 2.6(ii) applies in respect of visible faces of blockboard.
(iii)
Full sheets shall have edges lipped with matching hardwood 6mm thick, the
full thickness of the sheet.
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2.8
Decorative Laminated Sheet

(i)
Decorative plastic sheet shall be amino plastic faced phenolic resin laminated
veneer to BS EN 438:1991 or a comparable alternative to the Engineer's
approval.
(ii)
2.9
2.10
The laminate shall be minimum 1.2mm thick with decorative finish on one
face only to the manufacturer's standard colour, pattern and texture as shown,
specified or approved by the Engineer.
Adhesives
Adhesives shall comply with Clause 1.8.
Doors
(i)
All timber doors shall be solid core type unless specified otherwise and to the
size, thickness and pattern as shown on the Drawings/Schedules.
(ii)
Timber for construction shall be as specified within this section.
(iii)
Plywood for door facing shall comply with Clause 2.6, and shall not be less
than 3mm thick.
(iv)
Plywood facing for painted finish shall be Grade 1 and A on one face.
(v)
Unless specified otherwise doors shall be hardwood lipped on all edges to the
full width between finished faces minimum 15mm thick.
(vi)
Glazed apertures shall be in accordance with Section L and as detailed on the

Drawings and shall be framed in hardwood to match edge lippings with
matching, screw fixed beading.
(vii)
Adhesives for facings and door construction shall comply in all respects with
BS 1203, BS 1204 or BS 5442 Part 3 as appropriate.
(viii)
When described as "fire check" or "fire resistant" doors and frame assemblies
shall be constructed to BS 8214 and pass the fire tests described in BS 476
Parts 8, 20 and 22:1987 for the periods stated on the Drawings/Schedules.
(ix)
Where indicated on the Drawings/Schedules approved intumescent seals shall

be let into grooves on all edges of fire doors/frames fixed in strict accordance
with the manufacturer's printed instructions and to comply with Clause
2.10(viii)
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2.11
Mechanical Fastenings
(i)
Mechanical fastenings shall comply with Clause 1.7(iii).
(ii)
Nails shall be to BS 1202 and shall be lost headed nails, suitable for stopping
when used for decorated work.
(iii)
Screws shall be to BS 1210 and shall be stainless steel or brass where

specified.
(iv)
Cups for screws shall be brass or stainless steel heavy pressed socket pattern.
2.12
Fittings
Materials and workmanship for metal, glass, etc. forming an integral part of joinery
items shall comply with the appropriate section of this specification.
2.13
Workmanship
(i)
Where Clause 1.10 is applicable to elements of joinery work the requirements
of that Clause shall be complied with.
(ii)
Joinery shall comply with the requirements of BS 1186 Part 2, and shall be
accurately, properly and soundly fabricated in a manufacturer's workshop.
(iii)
Fixing of all joinery work, including fillets, architraves, frames, glazing beads
and the like shall be by means of screws unless specifically approved by the
Engineer.
(iv)
The terms "frame", "framed" or "framing" shall mean work put together by
proper carpentry or joinery joints, such as morticing and tenoning, dovetailing,
dowelling, etc. and the joints are to be as shown, specified or directed.
(v)
Butted and screwed or nailed joints or halved joints and the like will not be
accepted for framed work.
(vi)
Cutting of plywood and blockboard shall be neatly and accurately performed

with fine tooth saws so as to avoid splitting the face veneers, or intermediate
ply.
(vii)
Where raw edges arise from cutting blockboard these shall be lipped with
hardwood to match factory produced edges.
Plastic laminates shall be fixed with an approved adhesive in accordance with
BS 1203 and BS 1204 Part 1.
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(ix)
Care shall be taken on fixing plastic laminates to eliminate all air from beneath
the laminate and if air is entrapped the portion and work so disfigured shall be
removed and replaced.
(x)
After complete setting of the adhesive the plastic laminate shall be neatly
bevelled along all arrises with a plane.
(xi)
Where plastic laminate is fixed to doors or shelves, etc. without laminate to

the outer edge, a raised lipping is to be provided and the laminate finished
flush against the lipping.
(xii)
Where blockboard and plywood are specified to have a laminated plastic

sheet, a balancing veneer of the same material and thickness shall be bonded to
the back.
(xiii)
Unless secret fixing is practicable or otherwise described, clear finished

hardwood shall be fixed using non-ferrous or plated screws with beads let in
and pelleted with grain matched pellets of minimum 6mm thickness cut from the
same timber.
(xiv)
Built in fittings, etc. are to be accurately constructed in accordance with

detailed Drawings and doors, drawers, etc. shall fit and open and close
smoothly and all work next to walls, floors and ceilings or other fixed items
shall be soundly fixed and scribed to fit snugly against same.
(xv)
Mouldings shall be worked on the solid unless otherwise stated and shall be
accurately worked to the Drawings.
(xvi)
When circular work is shown on the Drawings or specified it shall be built up

with an appropriate number of pieces, cut to the required shapes, which shall be
put together in two or three thicknesses so that they break joint, and shall be
secured with hardwood keys and wedges or with hardwood pins, whichever is
more appropriate.
(xvii) Skirtings, architraves, plates and other joinery works shall be accurately
scribed to fit the contour of any irregular surface against which they will be
required to form a close butt connection.
(xviii) Doors shall be properly hung within frames/linings to give a uniform
clearance.
(xix) Hardwood veneers shall be of the species described or specified and shall be
selected pieces free from splits, dots, stains, insect and fungal attack or any
other natural or man-made defects.
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(xx)
Glass or synthetic fibre stitching will not be permitted for jointing veneer
leaves together and filling or inlaying shall be avoided.
(xxi)
All wood veneers shall be bonded to the core material with the approved
adhesives such that no lifting or blistering shall occur.
(xxii) The method of construction must accommodate tolerances as shown on the

Drawings and allow for ensuring that repetitive units can be accurately located
in relation to grid lines or other setting out points and that tolerances do not
accumulate.
(xxiii) Reasonable tolerances shall be provided at all junctions between joinery and
the building carcasses, whether of masonry or frame construction so that any
irregularities or movement shall be adequately accommodated.
(xxiv) All joinery shall be left finished smooth and clean by rubbing down by hand
with fine glass paper.
(xxv) Should any joints or moving parts in joinery fit other than accurately and
evenly or without acceptable clearances or should any defect of timber
become apparent, the joinery shall be repaired or replaced as directed by the
Engineer.
3.0
IRONMONGERY
(i)
Ironmongery shall be of the pattern and finish as shown on the

Drawings/Schedules or as specified and obtained from approved
manufacturers, delivered in protective packing, clearly labelled and stored in a
secure store.
(ii)
Hinges and other items to be fixed flush with timber shall be located within
accurately formed housings.
(iii)
All ironmongery shall be fitted firmly into its housing or surface mounted as
appropriate with matching screws or other fixings in accordance with the
manufacturer's printed instructions and to enable its proper and easy operation.
(iv)
Where possible ironmongery shall be fixed as a final operation or shall be

removed and refixed as necessary to facilitate decoration or other work.
(v)
Where indicated on the Drawings/Schedules approved draught/dust seals shall

be removed and refixed as necessary to facilitate decoration or other work.
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(vi)
All ironmongery shall be properly eased, adjusted, lubricated and cleaned on

completion and left in good working order all to the Engineer's approval.
(vii)
Locks shall be suited as indicated on the Drawings/Schedules and all keys,

with two duplicates shall be adequately labelled and handed to the Engineer.
(viii) All ironmongery shall be coated as indicated on the Drawings and/or as

specified and approved by the Engineer and obtained from an approved
supplier.
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SECTION H
STRUCTURAL STEELWORK
1.0
STANDARDS
All structural steelwork shall be executed in accordance with the provisions of BS 5950 or other
National standards subject to approval of the Engineer.
1.1
DRAWINGS
Before the commencement of fabrication or erection of any steelwork, the relevant
drawings showing the details of fabrication, provisions for assembly of steelwork and
methods of erection shall be furnished by the Contractor to obtain the approval of the
Engineer.
Where welding is to be used, the Shop Drawings shall give full particulars of "weld
preparation" and procedure of carrying out the work. Three copies of each Drawing
shall be submitted before commencement of fabrication to enable the Engineer to
check the Drawings and no work shall be carried out before obtaining his approval. All
work shall be fabricated in accordance with the approved Drawings.
Fabrication Drawings bearing remark: "Approved with Comments" shall be duly
corrected by the Contractor and three copies of the same shall be re-submitted for the
final approval of the Engineer. One copy of each Drawing duly approved by the
Engineer will be returned to enable the Contractor to commence work.
The Engineer's approval shall not in any way be deemed to relieve the Contractor of his
obligations under the Contract.
Reproducible prints of all approved fabrication Drawings shall be sent to the Engineer
for distribution whenever requested. On completion of the work, the Contractor shall
supply the Engineer with reproducible prints of all "as-built" fabrication Drawings for
record purposes.
2.0
MATERIALS
Structural steelwork shall comply with the requirements of the following British
Standard Specifications:
Structural Steel Sections
Weldable Structural Steel
Welding Electrodes
Bolts & Nuts
Washers
Hot Rolled Angles
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BS 4 : Part 1
BS 4360
BS 639
BS 3692, 4190 & 4395
BS 4320
BS 4848 : Part 4
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In the event of the Contractor proposing an alternative National Standard, a chemical

analysis of the proposed material, together with the results of mechanical tests shall be
submitted to the Engineer for approval.
The Contractor shall, if requested, furnish the Engineer with copies of test certificates
showing that all the principal materials comply with the requirements of BS 4360 or
other applicable standards. If the Engineer requires further tests to be carried out, the
Contractor shall provide the necessary test-pieces or samples at his cost, and shall
transport them to an approved testing laboratory.
All steel shall be straight, sound, free from defects such as twists, segregation, cracks,
surface flaws, lamination, imperfect edges, and other defects.
2.1
All material shall be stored properly on raised platforms. It shall be kept clean and
properly drained. Structural steel shall be so stored and handled that members are not
subjected to excessive stresses and damage. Long members, such as columns shall be
supported so as to prevent deflection.
3.0
FABRICATION
All the steelwork shall be fabricated in shops, duly approved by the Engineer, and
assembled/bolted at site. Before commencement of fabrication of any steelwork, all
plates and sections shall be carefully examined for lamination and other defects likely to
affect the finished structure. Sections and plates shall be straightened and made true
by approved methods so that when assembled the adjacent surfaces at
connections will be in close contact throughout.
Accuracy shall be maintained during fabrication to ensure that all parts fit together
properly during erection. All corresponding parts shall be similar and
interchangeable.
All structural steelwork including beams, columns and other miscellaneous items
shall be clearly marked with an erection number. The Contractor shall show, on the
fabrication Drawings, the positions, where the erection number is to be found and the
method of marking it. Metal die-stamps shall not be used for making erection marks.
All fabricated members shall be inspected by the Engineer prior to erection.
Whenever the fabrication shop is located far away from the construction site, the
Contractor shall be responsible for informing the Engineer as soon as any structural
member is ready for inspection, and shall afford all the facilities necessary for
inspection by the Engineer. Any material or workmanship at any stage of construction
which in the opinion of the Engineer does not comply with the specified requirements
shall be rejected and not incorporated in the Works.
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The Contractor shall be responsible for any delay caused in the

programme by rejection of any such work.
4.0
WORKMANSHIP
4.1
General
The workmanship shall be equal to the standard practice followed in modern
structural shops. All similar parts shall be manufactured accurately so that the same
could be interchanged with other parts having the same identification marks.
4.2
Templates
Templates used shall be of steel or steel-bushed type wherever considered necessary. In
cases where actual parts have been used as templates for drilling similar pieces, the
Engineer shall decide whether they are fit to be used in the permanent works.
4.3
4.4
Straightening
All members shall be reasonably straight and free from twists.
necessary, the same shall be straightened and/or attended to by pressure.
If considered
Clearance
The erection clearance for cleated ends of members connecting steel to steel should
not be greater than 2 mm at each end. The erection clearance at ends of beams
without cleats should not be more than 3 mm at each end; but for practical reasons, if
greater clearance is considered necessary, suitably designed seatings or connections
shall be provided.
4.5
Shearing, Flame Cutting and Planing

Shearing or flame cutting may be used at the Contractor's discretion provided, a
mechanically controlled cutting torch is used for the flame-cutting and the resulting
edge is reasonably clean and straight. Sheared members shall be free from distortion
at sheared edges. Special care shall be taken to remove the burnt edges of high tensile
steel when flame-cutting methods are employed. When gas cutting is adopted, the
flame cut edges shall be machined to a depth of 3 mm to 5 mm depending on the
thickness of the member.
Chipping of angle flanges and edges of plates wherever necessary shall be done
without damaging the parent metal. Chipped edges shall be ground to a neat finish
and sharp corners and hammered rough faces shall be rounded off.
Edge preparation for welding may be done by machine controlled flame cutting with
edges free of burrs, clean and straight.
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The butting surfaces at all joints shall be planed so as to butt in close contact
throughout the finished joint.
The ends of all built-up girders and of all columns shall be faced in an end milling
machine after the members have been completely assembled. Column-caps, bases
and roof structure connections shall be machined.
All flame-cut edges shall be planed, unless they are clean, square and true to shape.
4.6
Holing
Holes for bolts shall be drilled. All holes, except as stated hereunder, shall be drilled
to the required size or sub-punched 3 mm less in diameter and reamed thereafter to
the required size. Thickness of the material for sub-punching shall not be greater than
16mm. All matching holes for bolts shall register with each other so that a gauge of
0.8 mm less diameter than the diameter of the hole can pass freely through the
members assembled for bolting in the direction at right angle to such members. All
holes for turned and fitted bolts shall be drilled undersize by 1 mm and after
assembly, reamed to a tolerance of +0.13 mm/-0.00 mm unless otherwise specified.
Holes in purlins, side sheeting runners, packing plates and lacing bars may be
punched full size, provided the thickness of the material does not exceed 12 mm.
All punching and sub-punching shall be clean and accurate and all drilling shall be
free from burrs.
No holes shall be made by gas cutting process.
4.7
Assembly
All parts assembled for bolting shall be in close contact over the whole surface and all bearing
stiffeners shall bear tightly, at both top and bottom surfaces without being drawn or caulked.
The component parts shall be so assembled that they are neither twisted nor otherwise
damaged. Specified cambers, if any, shall be provided.
All parts of bolted and welded members shall be held firmly in position by means of
jigs or clamps while bolting or welding. No drifting of holes shall be permitted
except to draw the parts together and no drift shall be larger than the nominal
diameter of bolts. Drifting carried out during assembly shall not distort the metal or
enlarge the holes.
Trial assemblies shall be carried out at the fabrication stage to ensure accuracy of
workmanship. These checks shall be witnessed by the Engineer.
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5.0
5.1
WELDING
General
Welding of structural steelwork shall be carried out by the metal arc process and shall be
in accordance with the following British Standards.
5.2
BS 5950
Structural use of steelwork in building.
BS 639
Covered electrodes for the manual metal-arc welding of carbon and

carbon manganese steels.
BS 709
Methods of testing fusion welded joints and weld metal in steel.
BS 4870
Approval testing of welding procedures.
BS 4871
Approval testing of welders working to approved welding procedures.
BS 4872
Approval testing of welders when welding procedure approval is not

required.
BS 5135
Metal-arc welding of carbon and carbon manganese steels.
Welding Electrodes
Welding electrodes shall comply with BS 639 and shall be chosen so as to produce
welds with mechanical properties which are at least equal to those required for the
base material. Welding electrodes shall be kept in a dry state in unbroken packets and
shall be accompanied by the manufacturer's certificate of date of manufacture and
guarantee of compliance with BS 639 and the same shall not be used in a damp or
damaged condition.
5.3
Welding Plant
Welding plant shall be capable of maintaining the voltage and current specified by the
manufacturer of the electrodes. The Contractor shall supply instruments for verifying the
voltage and current as and when required by the Engineer.
When an automatic process of welding is adopted, the deposited metal must have
mechanical properties equal to those obtained by the use of electrodes complying with
BS 639.
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5.4
Manual Welding
Manual welding shall be carried out by qualified welders equipped with plant suitable for
the purpose. All welders shall be qualified in accordance with BS 4871, BS 4872 and
BS 5950 and details of such qualification shall be submitted to the Engineer. When
instructed by the Engineer, the Contractor shall retest any welder and submit the results
of that test to the Engineer.
5.5
Machine Welding
Machine welding shall be carried out with approved machines sufficiently supervised by
qualified operators. Welding procedure qualification tests shall be carried out for the
operations which are to be executed with the automatic equipment.
Welding standards shall be prepared by the Contractor showing bead sequence, weld
sequence, electrode size and type, travel speed, voltage and amperage.
5.6
Welding Procedure and Trials

Before welding of any of the Permanent Works is carried out, the Contractor shall
furnish details of the welding procedure for each welding operation.
Welding trials shall be carried out and completed on representative samples of the
materials before the start of fabrication, as directed by the Engineer.
Welding trials are intended to establish welding procedure prior to the
commencement of fabrication and for this purpose assemblies shall be made from
plate or section cuttings large enough to simulate the joint selected for trial. The trial
shall be representative of actual fabrication conditions including:
(a)
(b)
(c)
(d)
(e)
(f)
Preparation and fit-up

Preheat
Welding position
Restraint (so far as is practicable)
Welding conditions either by manual or automatic process as the case may be
Grain of materials
Welding trials on material 20 mm thick will be taken to include all material under
20mm thick and trials on materials 40 mm thick to include material between 20 mm
and 40 mm thick. The trials shall include specimen weld details from the actual
construction which shall be welded in a manner simulating the most unfavourable
instances of fit-up and preparation which it is expected will occur in the particular
fabrication.
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After welding, the specimen shall be allowed to cool naturally to ambient

temperature. It shall be left for 72 hours and thereafter, it shall be sectioned and
examined for cracking.
Testing shall be carried out in accordance with BS 709 or as directed by the Engineer.
Approval of any welding procedure shall not relieve the Contractor of his
responsibility for correct welding procedure to be followed and shall cater for
minimising the distortion in the finished structure.
5.7
Workmanship of Welding
The general welding programme for shop and site welds, including particulars of the
preparation of fusion faces, pre-heating where required and method of making welds
shall be submitted in writing to the Engineer for approval before the work is put in
hand. No departure from the welding programme shall be made without the prior
approval of the Engineer.
In the fabrication of built up assemblies all butt welds in each component part shall be
completed before the final assembly.
Wherever practicable, clamps, magnets, holding devices or other setting-up fixtures
shall be used in assembling parts of the structures so as to avoid tack-welding as far as
possible.
In fit-ups where clamps cannot be used, spacer-strips shall be used to ensure the
correct root gap.
Where tack welds are used, they shall be of the same quality and size as the first run of
main weld. All tack welds shall be cleaned and ground to sound material prior to
welding of the root pass. The main weld shall fuse completely with the end of the
tack weld to form a regular profile. Where pre-heat is required for the main welds,
the tack welds shall be made under the same heat conditions. The indiscriminate use of
tack-welds during assembly shall be avoided.
All welds shall be visually inspected. Cracked or badly formed welds shall be cut out to
the approval of the Engineer before re-welding.
As far as practicable, all welding shall be carried out in the downhand position.
Where structural steelwork is painted before fabrication or erection, the metal surface
within 75 mm of any weld shall be coated with primer only.
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5.8 Supervision and Inspection of Welding

The Contractor shall appoint welding supervisors whose competence and
qualifications shall be subject to the approval of the Engineer and all welding work
shall be carried out under their direction.
The Contractor shall co-ordinate his activities so that all inspection work can be
carried out before the removal of scaffolding and before the welds are covered by
painting or field coating.
5.9
Testing of Welds
The whole of the total length of each full strength butt weld shall be examined by
radiography or other approved non-destructive testing method and approved by the
Engineer. Non-destructive tests are to be carried out on all other major welds by the
Contractor and he shall carry out radiographic examination if instructed by the
Engineer.
Defective welding revealed by testing shall be made good to the satisfaction of the
Engineer at the cost of the Contractor.
The Contractor shall provide qualified operators and suitable equipment for
radiographic inspection of welding as specified herein and shall submit the results to
the Engineer in an approved form. The rates in the Bills of Quantities shall be
deemed to be inclusive of all charges in respect of radiography and non-destructive
testing.
5.10
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Criteria for Tests

The Contractor shall conduct tests in accordance with the following norms:
(i)
Visual examinations - One hundred per cent (100%) of the welded joints.
(ii)
Ultrasonic or drilling method - one drill hole for 50 metres of welded joint and
not less than 50 mm for each 50 metres of welded joints.
(iii)
X-ray and Gamma-ray examination - Two per cent (2%) of the length of weld
made by manual or semi-automatic machine and One per cent (1%) of the
weld if made by automatic welding machines (flux welding, shielded arc
welding, electro-slag automatic welding). However, important joints such as
the joint between two tapering girders located near an inclined column-support
shall be tested beyond these limits - 10% of the length of the weld shall be
tested.
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6.0
6.1
ERECTION
General
Erection of structural steelwork shall be carried out in accordance with the relevant
BS Code in conformity with the Drawings and Specifications, in an expeditious
manner.
The suitability and capacity of all plant, equipment, etc. used for erection shall be to the
6.2
Scope of Erection Work
6.2.1
The Contractor shall provide all construction material and equipment, transport
facilities, tools, tackles, consumables, labour, supervision for erection, including
carrying out the following:
(i)
Receiving, unloading, checking and moving into the storage facility at site, as
outlined under General Conditions of Contract inclusive of attending to all
insurance matters in respect of materials arriving at site.
(ii)
Transporting from site, storage, handling, rigging, assembling, rivetting,

bolting, welding and installation of all fabricated materials in proper locations
according to Drawings or as directed by the Engineer.
(iii)
Checking centre lines, levels of all foundation blocks, including checking line
and level, position and plumb of all bolts and pockets. Any defect observed in
the foundation shall be brought to the notice of the Engineer. The Contractor
shall satisfy himself regarding correctness of the foundations before installing
the fabricated structures on the foundation blocks.
(iv)
Aligning, levelling, rivetting, bolting, welding, fixing in position fabricated

materials in accordance with Drawings or as directed by the Engineer.
(v)
Painting as per Specifications including supply of paint.
(vi)
Supply of all required consumables, construction and erection materials,

including but not limited to gauges, welding and brazing rods, electrodes and
wires, oxygen, acetylene, fuel, bolts, nuts, rivets, shims and temporary
supports, etc., as required for the incidental works and for the completion of
erection.
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6.2.2
Erection shall also include the following work:

(i)
All minor modifications such as:
(ii)
6.3
(a)
Removal of bends, kinks, twists, etc., of parts damaged during

transport and handling.
(b)
Cutting, chipping, filling, grinding, etc., for preparation and finishing

of site connections.
(c)
Reaming for use of the next higher size of rivet or bolt for holes which
do not register or which are found to be damaged.
(d)
Welding of connections in place of rivetting or bolting for which holes

are either not drilled or wrongly drilled during fabrication. Welding in
place of rivetting or bolting will be permitted only at the discretion of
the Engineer.
The following shall be considered as a legitimate part of erection work:

(a)
Re-fabrication work in respect of parts damaged beyond repair during

transport and handling or in respect of those that are incorrectly
fabricated.
(b)
Fabrication of parts omitted during fabrication due to an error, or

subsequently found to be essential.
(c)
Plug-welding and re-drilling of holes which do not register and which

cannot be reamed for the use of the next size of rivet or bolt.
(d)
Drilling of holes which are either not drilled at all or are drilled in
incorrect positions during foundation works.
Erection Drawings
The approved Erection Drawings and any approved Arrangement Drawings,
Specifications or Instructions accompanying them shall be followed while erecting the
structural steelwork. Erection Drawings for structural steelwork shall be prepared by the
Contractor and shall consist of line-diagrams showing every member in position with
the respective erection mark.
Erection marks shall appear on the structural steel members as detailed and all
steelwork shall be erected with the marks in the same relative position as shown on the
plan or elevation.
Any discrepancy between Drawings and Specifications shall be brought to the
attention of the Engineer for obtaining his decision.
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6.4 Storing and Handling of Material

The fabricated materials shall be carefully unloaded at site, examined for defects,
checked, sorted out for each building and stacked properly above the ground level,
and be kept clean and properly drained. The handling and storing of the component
parts of a structure shall involve the use of methods and appliances not likely to
produce injury by twisting, bending or otherwise deforming of the metal. No member
slightly bent or twisted shall be put in place until the defects are corrected. All small
bends or twists detected in members shall be rectified before such members are put in
place.
Any serious bends or defects shall be reported at once to the Engineer.
The
straightening of bent edges of plates, angles and other shapes shall be done by
methods not likely to produce fracture or other injury.
Following the completion of the straightening of a bend or buckle, the surface of the
metal shall be carefully inspected by the Contractor for evidence of incipient or any
other type of fractures. The Contractor shall report to the Engineer about the presence of
such evidence and act according to his instructions.
6.5
Setting Out
The Contractor shall be responsible for checking the alignment and levels of
foundations, correctness of foundation-bolt centres, their projected height above the
foundation tops, the length of threading provided and the provision and fitment of
nuts for the foundation bolts. These shall be checked well in advance of starting the
erection work and the Contractor shall be responsible for any consequences for
noncompliance thereof. Discrepancies, if any, shall immediately be brought to the notice
of the Engineer for his advice.
One set of reference axis and one bench mark level will be furnished to the
Contractor. These shall be used by him for the setting out operation.
The Contractor shall assume full responsibility for the correct setting out of all
steelwork and erecting it correctly as per the alignment and levels shown on the
Drawings and for the plumbing of vertical members.
Notwithstanding any assistance rendered to the Contractor by the Engineer, if at any
time during the progress of the work any error should appear or arise therein, the
Contractor shall remove and amend the work to the satisfaction of the Engineer, at his
own cost.
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6.6
Assembly and Erection

Before the commencement of structural steelwork, the Contractor shall submit a
Schedule of Operations, detailing the erection procedures to be followed.
The
Schedule shall include provisions for any temporary bracing that may be considered
necessary during the erection.
During the erection of a structure, the steelwork shall be securely bolted or otherwise
fastened and if necessary temporarily braced, so as to make adequate provision for all
erection stresses and conditions, including those due to erection equipment and its
operation. Such temporary bracing shall be maintained in position until the erection
work is sufficiently advanced, and it is ascertained that the bracing provided is no
longer required.
Connections for temporary bracing and additional holes, members or cleats used to
facilitate handling or erection, shall be provided in a manner which does not weaken the
steelwork already erected.
The alignment of each portion of the structure shall be carried out progressively, soon
after that portion is erected. Permanent connections shall not be made until proper
alignment has been obtained and a sufficiently large portion of the structure has been
erected and temporarily connected so as to ensure that the members thus connected
shall not be overstressed or displaced during the progressive alignment of the
remainder of the structure.
6.7
Tolerances
Erection tolerances shall be provided strictly in accordance with the requirements of
BS 5606 and the following clearances shall be provided for:
Clearance with cleated end of members
2 mm
Clearance for ends of beams without cleats
3 mm
Hole diameter of bolts
7.0
bolt dia +2 mm (bolt up to 24 mm dia)
bolt dia +3 mm (bolt over 24 mm dia)
GALVANISING
Galvanizing of steelwork if required shall be carried out after fabrication is complete.
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Steelwork required to be galvanised shall be pickled in diluted hydrochloric acid then

washed, fluxed and stoved, and coated with zinc by dipping in a bath of molten zinc.
Components shall be immersed in the bath only for a period sufficient to attain the
temperature of the bath and shall be withdrawn at a suitable speed so that a minimum
coating of 610 g/m surface (85 microns min. DFT) is achieved. Components shall be
covered evenly on all surfaces.
Items described as heavily galvanised shall be grit blasted prior to galvanising and
receive a minimum coating of 1000 g/m of surface (140 microns min. DFT).
Light weight gauge metal work shall be galvanised by the hot-dip process as specified in
BS 3083 or BS 2989.
Contact between galvanised steel members and aluminium surfaces shall be prevented by
means of an approved isolating layer or barrier.
Galvanised steelwork shall receive specified paint treatment and shall be cleaned,
degreased, abraded and etch-primed beforehand.
8.0
PREPARATION OF STEELWORK FOR PROTECTIVE TREATMENT

Surfaces shall be cleaned to BS 7079 before any protective treatment is commenced.
Steelwork shall be degreased and shot or grit blasted to SA 2 quality standard with a
surface amplitude of 40-50 microns to remove rust and millscale; dust and debris shall
be removed by vacuum cleaning, compressed air or brush. Site welds and adjacent
steelwork shall be blast cleaned and similarly prepared. Surface defects shall be
suitably removed.
The type of grit or shot to be used for blasting is to be to the approval of the Engineer.
Regular millscale detection tests shall be made using the Copper Sulphate method.
Blasting operations and painting processes shall be segregated.
9.0
PAINTING GENERALLY
Paint shall be applied by brushing or spraying in accordance with the manufacturer's
instructions. Thinners shall only be added to paint in strict accordance with the
manufacturer's permitted percentages. Brushes stored in thinners shall be worked out to
remove thinners before re-use.
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Painting shall not be carried out when the steelwork temperature is below 4C or
above 30C, or less than 3% above dew point, nor when the relative humidity is above
80%.
Stripe coats shall be applied to welds and steel edges before painting.
Strong paint films shall be achieved on all cleats, arrises, bolt holes, bolt heads and
the like.
Protective treatment other than site applied coatings shall be under factory conditions in an
enclosed shop. Completed coats shall be checked for continuity by a lowvoltage wetsponge holiday detector and for thickness by an Elcometer.
If a required film thickness is given it shall be the minimum dry film thickness (DFT) as
measured by an Elcometer; the Elcometer shall be calibrated for each coating by the
use of a shim of known thickness placed upon the shot-blasted blank or the
underlying coat, and the shim shall correspond with the theoretical film thickness of the
surface of coating to be measured.
Otherwise a full coating shall be applied in accordance with the rate of coverage
recommended by the paint manufacturer having regard to the surface profile of the
steel and the conditions of application.
Sample plates shall be prepared for approval and shall thereafter be adopted as the
standard to be achieved on the finished work.
The Contractor shall prevent dust and dirt coming into contact with freshly painted
surfaces.
Before the site painting coats are applied, the surfaces shall be washed with clean
water to remove salt and other impurities and abraded to provide a mechanical key.
Paint shall not be applied to the embedded portions of metal items except for the
portions within 75 mm of the finished concrete surface.
9.1
Application of Protective Layers

Blast-cleaned surfaces shall be kept dry and be over-coated within 4 hours of the start
of cleaning (2 hours for outdoor blasting cleaning). Surfaces shall be treated in
accordance with the protective treatment schedule, except faying surfaces for HSFG
connections.
9.2
Bolts
Bolts, including friction-grip bolts, nuts and washers shall be hot-dip spun-galvanised in
accordance with BS 7290. The threads of nuts may be re-tapped as provided for in that
standard.
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Faying surfaces of high-strength friction grip connections shall be blast cleaned to SA

2 quality standard, masked within 2 hours to exclude air and only exposed just
before bolting-up. Paint or contaminants shall not be allowed on faying surfaces.
9.3
Materials for Steelwork Protection

Materials for steelwork protection shall be as specified in the Particular Specification,
Section M Painting & Decoration section in this Specification or as indicated on the
Drawings.
9.4 Schedule of Protective Treatment
9.4.1 Following paint system (or equivalent to approval) shall be used for painting of
all steelwork.
1.
2.
3.
4.
Primer Coat
First Coat
Second Coat
Final Coat
Penuguard Primer ZP (DFT - 50 microns)

Penuguard HB Zinc Phosphate (DFT - 100 microns)
Penuguard HB Zinc Phosphate (DFT - 100 microns)
Polyurethane Paint - Futura II (DFT - 35 microns)
The second and final coat shall be applied on site after erection of steelwork.
(Life expectancy of all coating systems is to be 15 to 20 years)
Damaged paintwork shall be blast-cleaned if bare metal is exposed or corrosion is

present. If the primer is intact the surface shall be prepared by power wire-brushing.
to a mechanical cleaning standard of ST2 and the existing surface abraded. The
prepared surface shall then be protected with a repeat of coatings 2, 3 and 4 each to
the minimum DFT.
9.4.2
Galvanised plus alkyd finish paint system
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Treatment
1.
2
3.
4.
5.
6.
7.
8.
Degrease galvanised surfaces with G.500 water

rinsable
cleansing solution
Lightly abrade
Check for paint acceptability with mordant solution.
(Paint application shall not proceed until this check
indicates,by the development of a black conversion
coating, that the entire surface is suitably prepared to
receive paint)
Rinse with fresh water and dry - Apply Washprimer
Alkyd based primer
Micaceous iron oxide alkyd based undercoat
Modified alkyd undercoat
Modified alkyd high gloss finish (colour as directed)
Min. DFT
Microns
10
50
50
50
50
Damaged paintwork shall be blast-cleaned if bare metal is exposed or corrosion is

present. If the primer is intact the surface shall be prepared by power brushing and
abraded to ST2. The prepared surface shall be protected as follows:
(i)
Where primer is intact:

Touch up with coatings, 6, 7 & 8 each to the min. DFT.
(ii)
Where mechanical cleaning is necessary:

Apply the complete painting system to the affected area.
9.5
Painting of Galvanised Bolts, etc., after erection

Following erection galvanised boltheads, bolt ends, nuts and washers shall be
degreased with cleansing solution and abraded and painted to the specification of
adjacent steelwork.
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10.0
BEDDING OF STEELWORK
Bedding shall be carried out with non shrink cementitious grout having a
characteristic strength of minimum 60N/mm at 28 days.
Grout shall be used for voids under 25 mm in thickness and it shall be just sufficiently
fluid to flow and fill the voids completely.
Before grouting the steelwork bases shall be supported by steel wedges (suitably
galvanised) and immediately prior to grouting the voids to be grouted shall be
thoroughly cleaned out.
The grouting operations shall not be carried out until the steelwork has been finally
levelled and plumbed.
Grout is to be mixed, handled and applied strictly to the manufacturers instructions.
11.0
EARTH BONDING
11.1
Earthed Equipotential Bonding

In accordance with BS 7671, (IEE Wiring Regulations), Section 413-02, 417-08 and
547, all exposed conductive metalic parts in a building are to be connected to an
Earthed Equipotential Bonding System. This measure is generally applicable and is
intended to prevent the occurrence of a voltage of such magnitude and duration
between simultaneously accessible conductive parts that danger could arise.
The structural steelwork of a building shall therefore be earth bonded as per the
provisions of the above mentioned regulations as applicable and to the satisfaction of the
Engineer.
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H/18
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SECTION J
METALWORK
1.0
MATERIALS
1.1
General Provisions
1.2
1.3
(i)
When a precise grade or alloy of metal is not specified the Contractor shall
obtain the metal from an approved specialist supplier or fabricator who shall be
informed by the Contractor of the particular application of the metal within the
Works and it shall be the Contractor's responsibility to obtain the correct
material suited to its application in the Works.
(ii)
All materials and components shall be the best of their respective kind, to the
dimensions shown on the Drawings and where applicable sections shall be in
accordance with the relevant BSI, DIN or approved equivalent standard.
Steel
(i)
Where the terms "steel" or "mild steel" are used it shall mean steel to BS 4 :
Part 1, BS 1449, BS 4360 or BS 4848 and shall be Grade 43A unless specified
otherwise.
(ii)
Stainless steel shall be austenitic steel unless specified otherwise and shall be
in accordance with BS 1449 : Part 2 and finish shall be as specified (eg Dull
Polish, Mirror Polish, etc.).
Aluminium
(i)
The term "aluminium" shall mean "wrought aluminum alloys for general
engineering purposes" in accordance with the BS 1470 - 1475 series and "cast
aluminium" shall be aluminium cast by permanent mould or gravity die
techniques to BS 1490 using LM6 alloy.
(ii)
The Contractor shall submit samples of components to the Engineer for

approval together with test certificates which show that the components
possess the following characteristics: (See Tables on page J/2).
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(a)
Mechanical
Properties
Cupping test to DIN 53156

Bend test to DIN 53152
Reverse impact to ASTM 27944-69
Indentation hardness to DIN 53153
Cross cut test to DIN 53153
(c)
Continuous
Heat
Resistance
Corrosion
and
Weathering
Test
Less than 5mm

100-150 cm/kg
More than 100
2H
Pencil hardness
(b)
9mm
Gt. 0
After 1000 hours at 120C
Sligt yellowing
of white shades
Humidity test to DIN 50017 on

zinc phosphated steel sheet
No change
after 500 hours
Salt spray test to ASTM B 117 on

zinc phosphated steel sheet
No loss of
adhesion after
20 rounds
Weather in Florida (USA) and

Industrial climate
Excellent results
(d) Chemical Reaction

Test Medium
Premium petrol (gasoline)
Ethanol
Toluene
Butyl acetate
Trichloroethylene
Acetone
Hydrochloric acid, 10%
Sulphuric acid, 10%
Acetic acid, 10%
Soda solution, 1%
Nitric acid, 1%
Fuel oil
Ammonia, 10%
Caustic soda lye, 10%
VOLUME II A
Time
10 minutes
10 minutes
10 minutes
10 minutes
10 minutes
10 minutes
4 weeks
4 weeks
4 weeks
4 weeks
4 weeks
4 weeks
4 weeks
4 weeks
Result
No change
No change
No change
No change
Softening
Softening
No change
No change
No change
No change
No change
No change
No change
Detached
J/2
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1.4
1.5
Surface finish
(i)
In addition to specified surface finishes, the Contractor shall where

necessary adequately treat or seal the permanently hidden parts of metal work
from deterioration and corrosion (excluding standard hollow sections).
(ii)
Mill finish aluminium will not be accepted unless specified, or to the

Engineer's written approval, or if to be subsequently decorated.
Protective coatings and finishes

(i)
Primers
Section of primers shall be in accordance with BS 5493 and shall comply to BS
2523 and/or BS 4652.
(ii)
Galvanising
Where steel is referred to as "galvanised", galvanising shall be applied by Hot
Dip process to BS 729 and BS 2989 and unless otherwise indicated shall be 85 um
(6.0 g/m).
(iii)
Anodising
Where indicated on the Drawings or specified elsewhere aluminium shall be anodised in
accordance with BS 1615 Grade AA25 and BS 3987 to the colour and finish approved by the
Engineer.
Anodising shall be by the "Anoloc" process to give 25 micron minimum
depth.
Sections shall be anodised before cutting into length to suit the fitting
dimensions.
(iv)
Polyester Powder Coating

Powder coatings shall comply to BS 6496 or BS 6497 as applicable to the
material to be coated.
Polyester powder coating shall be to a minimum film thickness of 10 microns
and carried out by an approved specialist and to the specified colour.
Steel to receive polyester powder coating shall be first galvanised in
accordance with Clause 1.5 (ii) above.
Aluminium sections to receive polyester powder coating shall be first cleaned,
degreased and primed with two-pack etch primer.
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(v)
Painting
When described on the Drawings/Schedules the painting of metalwork shall be
in accordance with Section M of this specification.
2.0
2.1
2.2
COMPONENTS
General Requirements
(i)
All components shall be obtained from an approved supplier/fabricator and the

Contractor shall submit to the Engineer for his approval a complete set of shop
drawings indicating dimensions, materials, components, fixings etc. prior to
commencement of fabrication.
(ii)
The design of metal components shall comply with the requirements of BS

4479 in as much as they are applicable to the specific component, and where a
British Standard exists for the component it shall also be complied with.
(iii)
The shop drawings referred to in 2.1 (i) above shall conform to the design,
dimensions and general descriptions as shown on the Drawings/Schedules and as
specified.
(iv)
All fixing shall be of non-corroding materials compatible with the component

being fixed and where dissimilar metals are used adequate precautions, such as
coating, taping or sleeving, shall be taken to prevent electrolytic corrosion.
(v)
All nuts and bolts shall be adequately protected from corrosion to the
satisfaction of the Engineer, and all exposed bolts including Carpenters and
Joiners Metalwork are to be capped with an approved dome headed nut.
Aluminium Windows, Doors & Screens

(i)
Aluminium windows shall be manufactured to BS 4873 and tested to BS 4315

Part 1 to comply with severe exposure rating as defined in BS 6375 Part 1.
(ii)
The Contractor shall obtain from the window manufacturer all design
calculations in respect of wind loading for external windows and screens and
submit them to the Engineer for approval.
(iii)
Aluminium framed sliding glass doors shall be in accordance with BS 5286.
(iv)
Glazing shall be installed at the factory at the time of manufacture in

accordance with Section L of this specification.
J/4
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2.3
(v)
All fixings, ironmongery, locks and locking devices, fly-screens, glazing,

weatherstripping, etc. necessary for the proper and intended function of the
component shall be included with the component and shall be allowed for
within the Contractor's Tender.
(vi)
All aluminium windows and doors are to be constructed so as to provide

maximum security against break-in.
(vii)
Ironmongery to such fabricated components shall be comparable to the

ironmongery used elsewhere in the Works and suited to the proposed
operation of the component and the component shall be suitably strengthened,
lapped and modified to receive the ironmongery.
(viii)
Ironmongery shall be as specified on the Drawings, Schedules and

Specifications and any particular requirements for ironmongery and any other
integral parts of the components shall be included.
(ix)
All frames, angles, channels and the like shall be non-ferrous and fixed with
countersunk aluminium screws or as indicated on the Drawings/Schedules all
of which shall be finished to match exactly the colour and finish of the
adjacent aluminium components and sections or to the specified finish/colour.
(x)
Aluminium frames are to be fixed to approved grounds or spacers and/or a

pre-formed groove to facilitate the correct application of approved sealants
between frames and formed openings, to comply with clause 2.3 (vi).
(xi)
Aluminium roller doors are to be provided with weather proof EDPM sealing
pieces, including the bases of the roller track guide.
Workmanship
(i)
All metalwork shall be undertaken in accordance with sound engineering and

smithy practice and as much metalwork as possible shall be undertaken in
properly equipped workshops with site work restricted to fixing and other
operations that cannot be undertaken prior to delivery to site.
(ii)
All finished components shall be wrapped, taped or otherwise protected with

non absorbent coverings and delivered to site at a time to eliminate or reduce to a
minimum, storage on site prior to fixing.
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(iii)
Protective coverings shall be sufficiently removed for jointing, assembly and

fixing purposes and afterwards replaced.
(iv)
After erection all metalwork with applied finishes shall be adequately

protected from any damage and any such work which is scratched, marked or
damaged in any way shall be suitably repaired if appropriate, to the Engineer's
approval or, if so instructed by the Engineer, replaced at the Contractor's
expense.
(v)
The Contractor shall submit to the Engineer evidence that the thickness of
protective/decorative coatings are not less than as specified and in cases of
doubt the Engineer may instruct the Contractor to send sample pieces to
independent testing laboratories and the cost of all such testing shall be borne by
the Contractor.
(vi)
All window, door screen, and other like frames shall be made to allow a 5 mm
tolerance all round the opening in the structure and junctions shall be finished
off by applying an approved sealant onto a closed cell polystyrene foam
backing strip or as otherwise shown on the Drawings or as specified.
(vii)
Discrepancies in overall width or height exceeding 5 mm will not be allowed

and where such discrepancies occur the frame will be rejected.
(viii) Welding shall be undertaken in accordance with the appropriate British

Standard for the type of metal being joined.
(ix)
Aluminium fixed against or into cementitious materials or stone/brickwork

shall be adequately protected by plastic spacers/sheeting or two coats
bituminous paint applied to the fixed face of the component.
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SECTION K
FINISHES
1.0
1.1
GENERALLY
(i)
(ii)
(iii)
1.2
1.3
1.4
Wallboards shall be stored flat in dry conditions and shall always be carried on
edge.
Rolls of sheet material shall be stacked standing on end.
All materials are to be stored in accordance with the manufacturer's
recommendations.
Sample Panels and Control Samples

(i)
Sample panels minimum size 600 x 600mm shall be prepared for all finishes,
finishings and textured coatings to be used in the Works.
(ii)
If the Engineer so requires control samples of finishing materials shall be

prepared in an agreed location within the Works (e.g. the floor tiling to a
complete room). The area to be used as a control shall be completed and
approved to the standard of workmanship and appearance obtained before the
application of the material is proceeded with elsewhere in the Works.
Scaffolding
(i)
Scaffolding shall be erected to external facades and any other areas where it is
required before any work is commenced, so that good access is obtained to the
whole of the working area.
(ii)
The scaffolding shall be supported independent of the working area and shall
provide platforms at about 2 metre intervals. A gap of at least 250 mm shall
be left between the work face and the scaffolding to allow sufficient clearance
for working.
Test for Dryness

Moisture content of substrate shall be ascertained by use of a hygrometer or similar
approved instrument. A substrate will be considered "dry" in accordance with the
requirements of the Engineer when all readings taken in the corners, along edges and
at various points over the area being tested show 75% relative humidity or less.
K/1
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1.5
1.6
Uniformity
(i)
To ensure consistency of appearance all flexible sheet or tiles of the same

type, colour and pattern which will be visible together when laid shall be from
onebatch.
(ii)
In all cases and wherever possible, joints in tiling to walls, floors and ceiling
shall be aligned and matched to the satisfaction of the Engineer.
Recesses, Duct Covers and the Like

Floor finishes shall be fitted into recessed duct covers to finish flush with the
surrounding floor. Tiled finishes shall be located so as to continue the joint pattern of
the surrounding floor.
1.7
Changes in Finish at Doorways

Changes in colour or type of finish in doorways shall be situated under the centre line
of the door leaf.
1.8
Protection of Floors
(i)
During floor laying operations the area being treated shall only be accessible
to the floor layers.
(ii)
Completed tiled floors shall not be subject to traffic until the bedding has
stiffened and sufficient bond has developed between the bedding and the
finish to ensure that the tiles will not be disturbed.
(iii)
Light pedestrian traffic shall not be allowed over a finished floor until 4 days
after completion of the laying, traffic heavier than pedestrian shall be excluded
for 14 days after laying.
2.0
MATERIALS
2.1
Generally
The cement and water used for plastering or bedding shall be as described in Section D,
(Concrete Work) and the sand shall be as described in Section E, (Blockwork). Lime
shall be hydrated complying with BS 890, Class B. Any pigments used to colour
cement products shall be obtained from an approved manufacturer and shall meet the
requirements of BS 1014.
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2.2
2.3
Expanded Metal Lath

(i)
Expanded metal lath shall be manufactured from tight coat galvanised sheet
made in accordance with the requirements of BS 2989 Grade Z2, coating type
"C" and shall have a minimum aperture of 6mm measured the short way of the
mesh. It shall weigh not less that 1.22 kg/m where used as reinforcement
over different backgrounds and weigh not less than 1.90 kg/m where used as a
background for plastering or rendering.
(ii)
Wire ties shall be galvanised and be of a minimum 1.20 mm diameter.
Beads and Stops

Beads and stops shall be manufactured from tight coat galvanised steel to BS 2989,
Grade Z2, coating Type "C", profiled to suit the depth of plaster or render to be
applied.
2.4
Welded Fabric Mesh for Reinforced Rendering

Reinforcement for rendering shall consist of galvanised welded-fabric mesh with 50 x
50mm squares having wires not less than 2.5mm diameter.
2.5
2.6
VOLUME II A
Nails, Screws and Washers

(i)
Nails, screws and washers shall be galvanised, or stainless steel. Pins for shotfiring shall be of steel with a tight coating of cadmium or zinc to comply with
BS 1706.
(ii)
Clout nails shall be of galvanised steel and shall comply with BS 1494.
Movement Joint Filler and Sealant

(i)
Movement joint filler shall be approved impregnated fibreboard or cellular

polyethylene which is compatible with the sealant being used and which does not
give up bituminous or oily products.
(ii)
Sealants shall be two-part polysulphide type as recommended by the

manufacturer for the situation in which they will be used. Butyl mastic and
other forms of mastic shall not be used without specific approval by the
Engineer.
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2.7
Brass Dividing Strip
2.8
Brass dividing strip shall comply with BS DD 19.

Surface Hardener, etc.
(i)
Where specified the cement and sand screed shall be treated with surface
hardener manufactured by and applied in accordance with the printed
instructions of an approved manufacturer.
(ii)
2.9
Power floated concrete slabs shall be treated with dust-proofer manufactured

by and applied in accordance with the printed instructions of an approved
manufacturer
Adhesives
(i)
Adhesives used for fixing ceramic tiles shall comply with BS 5980, Class A.
ii)
Adhesives used for fixing carpet shall be of a waterproof, peel-up type

recommended for the purpose by the carpet manufacturer, complying with BS
5225.
Adhesives used for fixing flexible PVC, thermoplastic or similar material in
sheet or tile form shall be recommended for the purpose by the manufacturer.
(iii)
3.0
WALL FINISHINGS
3.1
Plastering and Rendering

(i)
The requirements for washed sand for finishing coats shall be in accordance
with the following:
BS SIEVE
PERCENTAGE BY MASS
PASSING BS SIEVES
mm
2.36
%
100
1.18
90 100
0.600 (600 micron)
55 100
0.300 (300 micron)
5 50
0.150 (150 micron)
0 10
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(ii)
The requirements of washed sand for undercoats and screeds shall be in

accordance with the following:
BS SIEVE
PERCENTAGE BY MASS
PASSING BS SIEVES
mm
3.2
5.00
%
100
2.36
90 100
0.600 (600 micron)
70 100
0.300 (300 micron)
40 80
0.300 (300 micron)
5 40
0.150 (150 micron)
0 - 10
Thickness of Plaster and Rendering

(i)
The methods of measuring and mixing plaster shall be as laid down under
Section D, (Concrete Work) and the proportion and minimum thickness of
finished plasterwork and rendering shall be in accordance with the following:
Plaster or rendering
Cement, lime, sand plaster
Internally
Cement and sand
rendering
finish internally and
externally
(ii)
Mix
1 part cement
part lime
4 parts sand
Minimum Thickness
Two coats: total finished
thickness 15mm to walls and ceilings.
1 part cement
5 parts sand with Wood or steel float finish Render coat,
15mm finished thickness
approved
plasticiser
All plasters and renders shall have a plasticising admixture complying with BS
4887 added at a rate of 0.3-0.6 litres/100 kg of cement
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3.3
3.4
The addition of this plasticising admixture shall impart greater workability and
cohesion and shall increase durability by reducing drying shrinkage and
thermal movement in the cured mortar as a direct result of decreasing the
amount of gauging water.
Mixing and Use
(i)
Plaster and rendering may be mixed either in a mechanical mixing machine or

by hand.
(ii)
Hand mixed plaster and rendering shall be first mixed in the dry state, being
turned over at least three times. The required amount of water should then be
added and the mix turned over until such time as the mass is uniform in colour and
homogenous.
(iii)
The plaster shall be completely used within thirty minutes of mixing and any
hardened plaster shall not be remixed but removed from the site.
Preparation of Surfaces for Plaster, etc.

(i)
Irregularities in the surfaces to be plastered or rendered shall be filled with

mortar, without lime, at least twenty-four hours before plastering is
commenced.
Joints in blockwork, etc. are to be well raked out before
plastering to form a good key. Smooth concrete surfaces to be plastered shall be
treated with an approved proprietary bonding agent, or scabbled to the
(ii)
All surfaces to be plastered or rendered shall be clean and free from dust,
loose mortar and all traces of salt.
(iii)
All surfaces shall be thoroughly sprayed with water and all free water allowed
to disappear before plaster is applied.
(iv)
As far as practical, plastering shall not be commenced until all mechanical and
electrical services, conduits, pipes and fixtures have been installed.
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(v)
3.5
3.6
Before plastering is commenced all junctions between differing materials shall

be reinforced.
This shall apply where walls join columns and beams,
particularly where flush, and similar situations where cracks are likely to
develop and as directed by the Engineer. The reinforcement shall consist of a
strip of galvanised wire mesh (10 to 15 mm hexagonal mesh) 450 mm wide
which shall be plugged, nailed or stapled as required at intervals not exceeding
450 mm at both edges.
Application of Plaster and Render

(i)
After preparation of the surfaces a key coat of cement slurry shall be applied
to the wetted surface to be plastered.
(ii)
When this coat is dry the plaster coat shall be applied, by means of trowel,
between stops, laid, ruled and plumbed as necessary. This coat shall be
allowed to set hard and then cured as described. Surfaces are to be finished
with a wood or steel float to a smooth flat surface free from all marks.
(iii)
Where wall or ceiling plaster is to stop with a clean edge to a line, the edge
shall be formed by means of proprietary plaster stops or stop beads and angle
beads as specified and shall be used as per manufacturer's recommendation.
Curing of Plaster
Each coat of plaster or rendering work is to be maintained in a moist condition for at
least three days after it has developed enough strength not to be damaged by water.
3.7
Tyrolean Rendering
(i)
Tyrolean rendering shall consist of white cement and coarse washed sand
complying with Clause 3.1 (i) in the proportions 1:1 or 1:2 if applied to a
rendered undercoat, or be of an approved proprietary pre-mixed brand.
(ii)
Sufficient supplies of sand from a single source shall be stockpiled on site to

ensure that the Tyrolean finish is of even texture and colour throughout the
Works.
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(iii)
The rendered undercoat shall be applied in accordance with Clause 3.4 and 3.5
except that the surface of the undercoat shall be finished smooth with a wood
float and not scratched.
(iv)
The Tyrolean finish coat shall be applied by an approved hand-operated

machine in layers to build up an average thickness of 6 mm and shall be
allowed to cure and dry in the same way as a final rendering coat.
3.8
Dry Linings
(i)
Gypsum wall board shall consist of either 9.5 mm or 12.7 mm thick gypsum
plasterboard complying with BS 1230, having one face finished for direct
decoration.
(ii)
Thermal wallboards shall consist of an insulation core having a thermal

conductivity of not less than 0.037 W/mC bonded on one side to gypsum
wallboard and on the reverse side with a water-vapour resistant membrane.
(iii)
The edge profiles of wallboard shall be:

(a)
(b)
(c)
(iv)
3.9
"Tapered" for smooth seamless jointing

"Beveled" for Vee-jointing
"Square" for stippled textured coatings, cornership jointing or plaster.
Accessories for installing wallboard shall be approved proprietary materials

recommended by the manufacturer of the board.
Ceramic Wall Tiles

(i)
Glazed ceramic wall tiles shall be first quality tiles to conform to BS 6431 and
shall be selected. Tiles shall be manufactured by an approved manufacturer and
subject to the approval of the Engineer.
(ii)
Tiles for external use must be only those recommended for the purpose by the
manufacturer. All tiles shall be glued to fully dried and cured plaster with an
approved adhesive especially made for the purpose with closely butted joints and
later pointed in white coloured cement.
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3.10
(iii)
Where tiling abuts against frames, or other tiling at angles and around pipes,
etc., it shall be carefully cut and fitted to form a close neat joint. Open
irregular joints filled with cement and sand or plaster will not be permitted.
(iv)
Movement beads in the face of wall tiling shall be positioned at internal

corners, at junctions between concrete blocks and concrete columns and at
maximum 4.50 metre vertical centres.
(v)
External corners shall be protected and provided with approved proprietary

PVC edge strips.
(vi)
A silicon rubber based sealant shall be inserted between tiles and all sanitary
fittings and shall be by an approved manufacturer and used strictly in
accordance with the manufacturer's printed instructions.
Wall Coating Schedules

(i)
All fair finished concrete, blockwork and render shall be treated/finished as
per the Drawings, Finishes Schedules and the Coating Schedules as defined in
Section M of this Specification.
(ii)
All fair finished blockworks, mortar, render and tyrolean finishes, as indicated
on the Drawings shall be treated with a single component, non-staining,
penetrating silane-siloxane which shall react to produce a bonded water
repellent lining.
This treatment while allowing water vapour to escape from the substrate shall
act as a barrier to significantly reduce the absorption of water borne chlorides.
The silane-siloxane shall have a solids content of not less than 10%.
All surface preparation, material storage and application shall be carried out in
strict accordance with the manufacturers instructions.
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4.0
FLOOR FINISHES
4.1
Cement and Sand Floor Screeds

(i)
The surface of the concrete base must be clean, firm and rough to ensure a
good bond. This shall be achieved by hacking thoroughly to remove all
laitence and to expose the aggregate over the whole area, followed by
sweeping clean and hosing down to remove all dust.
(ii)
The base shall be soaked with water for at least 12 hours and any surplus
water removed before any lathing commences.
(iii)
To obtain the required thickness of screed leveling battens shall be used,

carefully fixed to line and level and fully bedded. There shall be a minimum
thickness of screed of 20 mm over the top of any conduit or duct.
(iv)
The screed shall be laid in alternate bays maximum 15 m with plain butt
joints and length of the bay shall not exceed 1 times the width. Movement and
construction joints in the base shall be carried through the screed.
(v)
Immediately prior to laying the screed, (10 minutes maximum), a thick brush
coat of wet cement grout shall be applied to the dampened surface of the base
concrete and shall be properly scrubbed in.
(vi)
Screeds to receive thin flexible finishes (i.e. of vinyl and rubber sheet or tile)
shall consist of 1 part of cement to 3 parts of sand by weight and screeds to
receive strong rigid coverings (e.g. quarry and ceramic tile) shall consist of 1
part of cement to 4 parts of sand by weight. Sand shall comply with the
requirements of Clause 3.1 (ii) or as otherwise indicated on the Drawing or
recommended by the tile manufacturer.
(vii)
The mix shall only contain sufficient water that will allow full compaction and
shall be evenly spread to a thickness approximately 10mm greater than that
required. The screed shall then be thoroughly compacted by tamping and
drawing off to the required level with a screed board
(viii) If a smooth surface is required the final working up shall be done with a wood
float, steel trowel, power float or other finish as specified elsewhere in the
Contract Documentation or on the Drawings. Care shall be taken to avoid
excessive trowelling which may cause crazing.
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4.2
4.3
(ix)
Screeds to receive thin flexible finishes or screeds which are finished as

paving shall be laid to a tolerance such that localised variations do not exceed
plus or minus 2 mm under a 3 metre straightedge and plus or minus 10 mm
over large areas, measured from datum.
(x)
As soon as each bay is completed and has hardened sufficiently to prevent

damage to its surface it shall be covered with polythene or similar sheets
which shall be adequately lapped and held down. The screed shall not be
allowed to dry out for a minimum period of 7 days and no traffic shall be
permitted on the surface during this time.
PVC and Thermoplastic Floor Tiles

(i)
Thermoplastic floor tiles shall comply with BS 2592.
(ii)
PVC (Vinyl) floor tiles shall comply with BS 3260 and BS 3261 and be
supplied by a manufacturer approved by the Engineer and they shall be laid
strictly in accordance with the manufacturer's printed instructions and to BS
8203.
(iii)
A high standard of finish will be required and it is essential that the

preparatory screeds be put down accurately to thickness and level. Unless
otherwise stated the screeds will be 1:3, cement and sand trowelled smooth
and level. Tiles will be fixed to the prepared screed with approved adhesive and
treated on completion with approved liquid sealer applied strictly in
accordance with the manufacturer's instructions.
(iv)
Coved skirtings will be fixed to backing with adhesives. Brass division strips
are to be provided at junctions of different colours and against all other floor
finishes and are to be bedded into the screed and finished flush with the floor
finish.
Flexible Sheet Flooring

(i)
Unbacked PVC sheet flooring shall comply with BS 3261, Part 1, Type "A".
(ii)
PVC sheet flooring will be fixed to the prepared screed with approved
adhesive all as Clause 4.2.
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4.4
4.5
4.6
Ceramic Floor Tiles

(i)
Unglazed ceramic floor tiles and skirting tiling shall conform to BS 6431 and
shall be by an approved manufacturer.
(ii)
Tiles shall be delivered in unbroken packages bearing the brand and maker's
name. They shall be stored on raised platforms and properly covered to
protect them from moisture. Tiles must not be allowed to come into contact
with water during storage.
(iii)
Tiles are to be fully bedded with an applied cement slurry on a cement and
sand screed as described and to make up the total finished floor thickness with
perimeter and intermediate joints at maximum 4500 mm centres.
(iv)
Tiles shall be laid with continuous straight joints not wider than 2mm to true
lines without lipping and with a minimum of cutting. Work shall be so laid
out that no tiles less than half tile size shall occur.
(v)
Bedding joints shall be well filled and grouted at least twelve hours after
completion with a mortar mix tinted to match the colour of the tiles. All
surplus grouting and mortar shall be cleaned off immediately.
(vi)
Tiles shall be neatly cut around pipes or other obstructions. All work shall be
protected from damage during the Contract and shall be properly cleaned off
on completion.
Floor Tile Movement Joints

(i)
Floor tile movement joints shall be a minimum of 6mm wide at the tile face.
The joints shall be packed with silicon rubber sealant after priming. The joint
backing shall be 10 mm diameter foamed polyurethane strip to pass through the
full depth of tile and rendered backing.
(ii)
Silicon rubber sealant shall be by an approved manufacturer and used strictly

in accordance with the manufacturer's written instructions.
Floor Tile Expansion Joints

The expansion joint materials are to be supplied by an approved manufacturer and
used strictly in accordance with the manufacturer's written instructions.
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4.7
Adhesive
Ceramic floor tile adhesive and grouting material shall be by an approved
manufacturer and used strictly in accordance with the manufacturer's written
instructions.
4.8
4.9
Terrazzo Floor Tiles and Skirtings

(i)
Portland cement and aggregates for the base layers and pigments used in the
manufacture of the tiles shall comply with Clause 2.1 and BS 4131, 4357,
5385. Aggregates for the facing layer shall consist of good quality, hard
marble or other approved natural stone with similar characteristics. The
marble aggregates shall be graded, but shall not include a high fines or dust
content and shall be sharp and angular.
(ii)
The base layer shall consist of not less than 3 and not more than 3.5 parts of
aggregate to one part of cement, proportioned by weight. The facing layer
shall be such as to provide a minimum wearing surface of 6 mm after grinding
and shall consist of 2.5 parts of aggregate to one part of coloured cement.
(iii)
The tiles shall be vibrated to an extent which allows the entrapped air to
escape to the surface and compacts the aggregate at the wearing surface and
hydraulically pressed sufficient to mould the facing to the base layer.
(iv)
The surface of the facing layer shall be ground and slight imperfections shall
be filled by grouting with a neat cement paste coloured to match the original
mix and well worked into the surface before it is re-ground to a fine grit finish.
(v)
Skirting tiles shall have square or beveled, ground top edges. Cut floor tiles
shall not be used for skirtings.
(vi)
The tile faces shall be free from projections, depressions, flakes and crazes and
the aggregate shall be evenly distributed. The tiles shall be square and of
rectangular cross section with sharp and true arrises, shall comply with the
performance requirements of BS 4131 and shall be of the minimum thickness
shown on the Drawings.
Laying Terrazzo Tiles (to BS 8000 Sect. 11.1)

(i)
The areas of concrete substrate to be tiled shall be brushed clean and

dampened until absorption ceases and the finished floor level shall be
established by means of dots and rules.
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(ii)
The mortar for bedding the tiles shall be to the thickness shown elsewhere in
the Contract Documentation and shall consist of 1 part of cement to 4 parts of
sand by volume, mixed semi-dry in a mechanical mixer with only sufficient
water added to give a crumbly consistency which retains its shape when
squeezed in the hand.
(iii)
A stiff slurry consisting of cement and water shall be prepared and spread on
the back of the tiles about 2 mm thick before they are laid on the bed and the
tiles then tapped firmly into position with a rubber or wooden hammer. The
tiles shall then be vigorously beaten with a wooden bearer to ensure a true
surface and that contact between the tiles and bedding is complete.
(iv)
The tiles shall be laid with joints of about 3 mm and proper alignment shall be
maintained with continuous joints in both directions. The joints shall line-up
through doorways where possible.
(v)
At least 24 hours after laying the tiles, the joints shall be filled with neat
cement grout to a colour approved by the Engineer. Excess grout shall be
removed with a squeegee and shall be cleaned off the face of the tiling and
surrounding surfaces as the work proceeds.
(vi)
The tiles shall be laid with a minimum of cut tiles, but where it is necessary,
they shall be cut with a power driven saw and any rough edges shall be rubbed
smooth. Rough cutting by means of a chisel or axe shall not be permitted.
(vii)
Tiles shall be laid level or to 1% falls in "wet" areas as may be required.

Localised variations in level for a nominally flat floor shall be a maximum of
plus or minus 3 mm under a 3 metre straightedge. Particular care shall be
taken in "wet" areas to prevent low spots and the pooling or ponding of water.
(viii) Skirtings shall be fixed in such a manner that their vertical joints coincide with
horizontal joints of the floor tiles.
4.10
Precast Terrazzo Units

(i)
Precast terrazzo units shall comply with the requirements of BS 4131.
(ii)
Precast treads and risers shall also comply with Clause 4.8 except that the
facing layer of the treads shall be such as to provide a minimum wearing
surface of 12 mm after grinding.
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(iii)
4.11
Carpet and Underlays

(i)
All carpets of one type, colour and pattern which will be visible together when
laid shall be from the same batch to ensure consistency of appearance.
(ii)
All carpet, carpet tiles and underlays containing natural fibre shall be
mothproofed by the manufacturer.
Underlays shall comply with BS
5808 and unless specified otherwise
elsewhere in the Contract Documentation shall be of approved felt or cellular
rubber suitable for medium traffic, not less than 7 mm thick and weighing not
less than 1.40 kg/m.
(iii)
4.12
4.13
All exposed edges of the units shall be terrazzo faced.
Tapes and Trims for Carpet

(i)
Tape for seams shall be approved heat bonded type minimum 75 mm wide or
as recommended by the manufacturer of the carpet.
(ii)
Trims/fixing bars and carpet gripper shall be of the types recommended by the
manufacturer of the carpet and shall have an anodised aluminium finish to
exposed surfaces where applicable.
Entrance Matting
(i)
Entrance matting shall be of open construction allowing dirt to fall through

into a recessed well.
(ii)
Mats shall have an absorbent pile surface with alternative ridges of aluminium
and rubber and be fully reversible.
(iii)
Mats are to be set in recessed wells with 30 mm deep aluminium angle

skirtings which shall be set flush with adjacent floor finishes.
5.0
MINERAL SURFACE FLOOR HARDENER
5.1
Scope of Work
Supply of pre-mixed and ready to use surface floor hardener which is to be applied as a
dry screed onto fresh concrete.
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5.2
Concrete Compliance
ACI 201-2R-77 : ACI 302-1R-89 : ACI 305-R-77
5.3
Curing Compounds
ASTM C309-81
5.4
Products
The surface floor hardener shall be an approved, ready to use premixed blend of
chemically inert, synthetic mineral non oxidising aggregate, chemicals, pigments and
cements.
5.5
(i)
Application Rates
(a)
Light Duty
5-6 kg/m
Pedestrian foot traffic

Soft wheels (pneumatic)
Commercial Institutional Premises
(b)
Heavy Duty
7-8 kg/m
High density vehicular traffic (fork lifts with solid tyres/ small wheels)
High density abrasive pedestrian foot traffic
(ii)
5.6
Moving heavy abrasive loads

Curing
Floor surfaces shall be cured with an approved sealer coat, at a coverage rate
of 1 litre per 5 m per coat. Where additional protection against penetration of
mild chemicals and acids is required use 2 x coats of curing compound. Curing
should commence immediately following finish.
Finishing
The concrete surface should be finished with a power float to ensure a smooth and
dense finish.
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If surfaces are to be steel floated manually this should take place prior to concrete
stiffening (Refer Manufacturer's Technical Department).
5.7
Protection
Finished floors shall be protected against oil, grease and spillage of paint, thinners and
other debris.
In addition floors shall remain covered and not be subjected to traffic for at least
7 days.
5.8
Site Service
During the initial stages of application the Manufacturer / Supplier should be called
upon to supply an on-site service to offer recommendations on product application.
6.0
CEILING FINISHES
6.1
Suspended Ceilings Generally

(i)
The Contractor shall provide Shop Drawings to show the final layout and sizes
of members of all suspension systems, to co-ordinate the design and work on
the suspended ceilings with other trades, to provide for the reception and
installations of outlets, fixtures, access panels, etc. pertaining to mechanical
and electrical work, all for the Engineer's approval before any work is
commenced.
(ii)
Ceilings shall be erected in a rigid and secure manner by workmen skilled in

this work so that the final surface is free from waves, buckles or sags.
(iii)
The suspended ceiling shall not be installed until:

(a)
(b)
(c)
(d)
(e)
The building is weathertight.

The wet trades have finished their work.
All work above the ceilings such as ductwork, pipework and electrical
work has been installed, tested, inspected and approved.
The positions of light fittings, diffusers, etc., have been checked
relative to the ceiling grid.
The position of access panels have been confirmed with the Engineer.
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(iv)
The tiles shall be set out so that:

(a)
The soffits are level, free from undulations and lipping, with all lines
and joints straight and parallel to walls unless specified otherwise in
the Contract.
b)
They are symmetrical about the centre lines of the room or space,
beginning with a tile or joint line as required to avoid narrow tiles at
the perimeter.
(v)
The ceiling shall be finished at the junction with all walls and columns with
edge trim fixed at maximum 450 mm centres.
(vi)
Additional supports shall be provided above all access panels, light fittings,
diffusers, etc. and the tile shall be carefully cut to accommodate all such
fittings. Under no circumstances shall any fitting be supported by the tiles,
plank, grid or strip membrane material.
(vii)
Care shall be taken to ensure that the tiles are kept clean if subsequently
removed for access to services, for inspection or for remedial works.
(viii)
All suspended ceilings work shall be carried out in accordance with CP 290,
and to BS 8290.
(ix)
The tile, grid, plank or strip membrane material shall be a specified elsewhere
in the Contract and shall have a fire performance when tested in accordance
with BS 476 which satisfies the requirements of:
(a)
Class O - BS 476, Part 6
(b)
Class 1 - BS 476, Part 7
(x)
The suspension system shall be as recommended by the manufacturer of the

membrane material and shall be constructed from hot dipped galvanised steel
sections and galvanised wire or similar non-corrodible materials and fixings.
(xi)
The suspended ceiling system shall incorporate proprietary mineral fibre tiles
which shall be by an approved manufacturer and installed in accordance with
the manufacturer's written directions.
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5.2
Expanded Metal Lathing Ceilings

(i)
Unless otherwise approved, framework shall consist of 9 mm x 25 mm, 16g

galvanised steel channel sections at 600 mm centres wired to 11 mm x 38 mm,
16g galvanised steel channel sections hung on 3 mm x 25 mm straps. The
straps shall be bolted to concrete soffits with rawlbolts.
(ii)
Coving shall be ribbed galvanised expanded metal lathing fixed to underside

of suspension grid with 16 gauge soft galvanised tying wire or to underside of
timber framing at maximum 350 mm centres.
(iii)
The whole to form a suspension grid ready and of adequate strength to receive
plaster or other applied finish and with supports for lighting fittings where
required.
(iv)
The Contractor shall submit to the Engineer Shop Drawings as described

Part 4-Appindes VI: Method Statement of Thermal Images
A.
CONTENTS
Collection of Thermal Images
A. Collection of Thermal Images

1. The collection of thermal imaging data from equipment normally necessitates the plant being in a
working condition. Data will only be recorded from such positions as to keep personnel in a safe
position. Guards are not to be removed from moving machinery.
2. Thermal images are collected using a video type camera, personal positioning and awareness
must at all times be carried out with respect of the reduced visual capability of the user during
operation of the camera.
3. Survey areas which are behind electrical panel doors will be monitored in a controlled manner. A
qualified electrical member of the clients staff (authorised to open panel doors with the power on)
will supervise the opening, surveying of the panel, and the subsequent closure of the panel door.
Data will only be collected from outside the confines of the panel at a safe working distance from
any live connections (with consideration of the voltages within the panel).
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SECTION L
GLAZING
1.0
1.1
GENERALLY
Samples
Samples not less than 150mm square shall be submitted for approval by the Engineer for
all types of glass to be used in the Works.
1.2
Storage
Glass shall be stored in a shaded and ventilated area and shall be protected from dirt and
accidental damage.
Care shall be taken to prevent the accumulation of water
between the sheets and any glass stocks that show signs of dampness shall be
separated and dried.
1.3
Indicators
Painted or stuck on indicators shall not be used on solar control or coloured glass.
Whitewash may be used on ordinary glass but shall be restricted to small central areas
of the panes.
1.4
Cleaning
All glass shall be cleaned to remove smears, excess compound and sealant on
completion. Broken or damaged glass shall be replaced prior to handover of the
Works.
2.0
2.1
VOLUME II A
MATERIALS
Glass
(i)
Glass shall comply with BS 952.
(ii)
Transparent glass shall be clear float or polished plate glass not less than 4mm
nominal thickness. Sheet glass shall not be used in the Works.
(iii)
Wired glass shall be square pattern Georgian wired (13mm square).
(iv)
Patterned and rough cast (obscured) glass shall be to the approval of the
Engineer.
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(v)
Solar control glass shall be body tinted, surface modified or surface coated
float glass as specified elsewhere in the Contract Documentation or Drawings
and shall be of a thickness recommended by the manufacturer for the size of
pane.
(vi)
Hermetically sealed flat double glazing units shall comply with BS 5713.
(vii)
Toughened glass shall be processed float or polished plate glass satisfying the
impact requirements of BS 6206, Class B.
(viii) Glass bricks shall be hermetically sealed hollow transparent or translucent

glass blocks complying with BS 952, Part 1, of the sizes, surface patterns and
colours specified on the Drawings.
2.2
(ix)
Rooflights shall be of the types specified on the Drawings, constructed in

compliance with the requirements of CP 153, Part 2 and obtained from a
manufacturer to be approved by the Engineer.
(x)
All glass shall be of accurate size with clean, undamaged edges and surfaces
which are not disfigured.
Mirrors
Mirrors shall be manufactured from float or polished plate glass minimum 6mm thick
and shall have ground and polished edges. The silvering shall be protected by a
copper backing and protective paint coating.
2.2.1
Accessories
(i)
Distance pieces, setting and location blocks shall be plasticised polyvinyl

chloride complying with BS 2571 (softness number 35 to 45), rigid nylon or
sealed hardwood. PVC shall not be used for heavy glass panes, solar control
glasses or sealed double glazing units.
(ii)
Screws for fixing mirrors shall be brass with detachable, screw-on chrome
plated brass dome to BS 1494. Sleeves and washers shall be polyethylene.
3.0
WORKMANSHIP
3.1
Glazing - Generally
(i)
External glazing shall be wind and watertight on completion.

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(ii)
All rebates and grooves shall be clean, dry, free from burrs and other
projections, smooth and undistorted.
(iii)
The minimum thickness of glass other than fully toughened glass shall be
6mm when situated in the following locations:
(a)
Any hinged fully or partly glazed door and any adjacent side panel.
(b)
Any sliding fully or partly glazed door and any adjacent fixed light.
(c)
Any glass wholly or partially within a zone between floor level and
800mm above floor level.
(iv)
Glazing to internal wood doors and screens shall be bedded in self-adhesive

black velvet or approved proprietary tape and secured with hardwood glazing
beads fixed with brass cups and screws.
(v)
Glazing to external wood doors and screens shall be bedded in approved

polymer mastic preformed tape and secured with hardwood glazing beads
fixed with brass cups and screws.
(vi)
All rebates to wood doors and screens shall be primed and sealed.
(vii)
Wire glass shall be fixed with the wires parallel to the surround and aligned in
adjacent panels in single and double doors.
(viii) Fire resistant glazing channel shall be butt jointed at corners and fixed with
38mm countersunk brass screws at not more than 200mm centres and not
more than 50mm from each end. The butt joints of glazing channels for onehour fire resisting doors shall be sealed with intumescent mastic.
3.2
(i)
(ii)
VOLUME II A
Glazing Aluminium Windows externally

Generally the glazing system shall utilise snap-in beads and neoprene glazing
gaskets. Other glazing techniques involving the use of glazing compounds,
sealants, etc. shall be submitted to the Engineer for approval together with
details of similar installations successfully employed elsewhere in the Gulf
Region.
Unless otherwise indicated on the Drawings the maximum permitted size of an
external glass pane with all four edges fully supported in a low rise building
(maximum 10 metre high) shall not exceed the areas given in Table 1, on page
L/5.
L/3
FOR TENDER REV- 0

(iii)
The recommendations of the glass manufacturer shall apply in all situations

not covered by Table 1 and where the information is not provided in the
Drawings. The recommendations shall be based on a 3 second gust of wind
exceeding 46 metres/second at 10 metres above ground level occurring in
U.A.E. on average only once in 50 years and a ground roughness category of
1.
(iv)
The depth of rebates for bead glazing shall not be less than that shown in
Table 2, on page L/5 and the minimum edge clearance (distance between the
edge of the glass and the surround) shall not be less than 3mm for any glass up to
and including 12mm nominal thickness. The recommendations of the glass
manufacturer shall apply for all glass over 12mm nominal thickness.
(v)
The minimum edge cover to single glazing shall be as recommended by the

manufacturer of the units.
(vi)
Setting blocks shall be used between the bottom edge of the glass and the
frame or surround, to support and centralise the glass in the opening. The
minimum length of each block shall be equal to 30mm per square metre of
glass area and the width shall be equal to the thickness of the glass (or glass
insulating unit) plus the back clearance.
(vii)
Location blocks shall be used in opening windows and doors between the
edges of the glass, other than the bottom edge, to prevent movement when
they are opened. Each block shall be at least 25mm long and the width shall
be equal to the thickness of the glass (or glass insulating unit) plus the back
clearance.
(viii) Setting and location blocks shall be positioned as near to the quarter points of
each side as possible.
(ix)
3.3
The glazing gaskets shall be positioned on both sides of the glass and shall be
correctly sized so that when forced into the space between the glass and
surround sufficient pressure is provided to support the glass structurally and to
form an effective seal against the weather. Care shall be taken to ensure that
the gasket is correctly located in the grooves and that the glass is completely
bedded.
Fixing Mirrors
Mirrors shall be fixed with spacer washers to compensate for irregularities in the wall
surface and with sleeves and washers to prevent contact between the mirror and the
fixings.
L/4
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4.0
STANDARDS AND TABLES
4.1
Standards
The standards referred to in this Section are:
BS 952
Glass for glazing
BS 1494
Fixing accessories for building purposes
BS 2571
Flexible PVC compound
BS 5713
Hermetically sealed flat double glazing units
BS 6206
Impact performance requirements for flat safety glass and safety

plastics for use in buildings.
Table 1
BS 6262 Code of Practice for glazing for buildings
MAXIMUM AREAS FOR GLASS PANES SITUATED EXTERNALLY

NOMINAL THICKNESS IN mm
TYPES OF GLASS
4 m
Transparent Float or
Polished Plate
5 m
6 m
7 m
10 m
12 m
1.30
2.00
3.00
4.00
5.50
8.00
Wire cast
1.25
Wired Polished
1.80
Rough cast and patterenred
0.70
1.20
1.75
Fully toughened
1.80
2.90
4.20
1.00
2.80
4.00
5.50
Transparent laminated
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NOTES:
(i)
The table is based on a 3-second mean wind loading of 1600 N/m.
(ii)
The table does not apply where the building exceeds 10 metres high or where
the length/breadth ratio of the pane is greater than
3:1 and is therefore
considered as two-edge supported.
Table 2
MINIMUM REBATE DEPTHS FOR BEAD GLAZING

NOMINAL GLASS THICKNESS
mm
MINIMUM REBATE DEPTH

mm
10
12
12
10
15
12
15
L/6
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SECTION M
PAINTING, DECORATING & PROTECTIVE COATINGS
1.0
GENERALLY
1.1
Marking of Containers
(i)
(ii)
Materials shall be delivered in sealed containers clearly labelled with the

following information:
(a)
Manufacturer's name, initials or recognised trade mark.
(b)
Title and specification number.
(c)
Whether primer, undercoat or finishing coat.
(d)
Colour reference from BS 4800.
(e)
Batch number and date of manufacture or re-test.
No paint shall be used more than 18 months after manufacture or re-test.
(iii)
Coating materials other than spray paints, bituminous paints and fine textured
masonry paints shall be in containers not exceeding 5 litres capacity.
1.2
Samples
(i)
Sample panels of minimum two square metres in area shall be prepared for
each type and colour of coating material to be used in the Works for the approval of
the Engineer.
(ii)
Sample pieces of each paper/fabric material of minimum size 500 x 500 mm
showing at least the pattern repeat where applicable shall be submitted for the
1.3
Manufacturer
The Contractor shall state the name and address of the manufacturer whose materials
he proposes to use. Once approval has been given the Contractor shall not obtain
materials from other sources without the prior written agreement of the Engineer.
M/1
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2.0
MATERIALS
2.1
Preparatory Materials
2.2
(i)
Paint removers, abrasive papers and blocks, cleaning agents, etching solutions,
stopping, knotting, fillers and other commodities shall be of the types
recommended by the manufacturer of the coating to be applied.
(ii)
White spirit shall comply with BS 245.
(iii)
Knotting shall comply with BS 1336.
(iv)
Stopping and filler for woodwork shall be approved proprietary leadless, oil
based type recommended for internal or external work as appropriate.
Stopping for woodwork to receive a clear finish shall be tinted to match with
the surrounding woodwork.
(v)
Filler for plaster and rendering shall be of an approved proprietary type.
Primers, Paints and Coatings

(i)
All brands of primers, paints and coatings shall be approved and shall comply
with the relevant BS where one exists.
(ii)
Primers for plaster and rendering shall be alkali resistant. Primers for other
surfaces shall comply with Clause 4.2.
(iii)
Undercoats on wood and metal surfaces shall be of the drying-oil/resin binder

type pigmented with titanium dioxide and/or coloured pigments providing a
matt or low-sheen finish suitable for subsequent application of a drying-oil
finish.
(iv)
Water thinned priming paints and undercoats shall only be used with the
specific approval of the Engineer and compliance with BS 5082 will need to be
demonstrated in order to obtain such approval.
(v)
Finish coats on wood and metal surfaces shall be of the drying-oil/alkyd resin
binder type pigmented with titanium dioxide and/or light fast, coloured
pigments, or any other coating system approved by the Engineer.
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2.3
Adhesives
Adhesives for wallpaper/fabrics shall be of a type recommended by the manufacturer
of the material to be fixed, and in the absence of such recommendation shall be of an
approved type.
3.0
WORKMANSHIP
3.1
General
(i)
Before painting commences all floors shall be washed over and every possible
precaution taken to keep down dust. No paint shall be applied to surfaces
structurally or superficially damp and all surfaces must be ascertained to be
free from condensation, efflorescence, etc., before the application of each coat.
(ii)
Workmanship generally shall be carried out in accordance with BS 6150

unless otherwise specified.
(iii)
No primed or undercoated woodwork and metalwork shall be left in an

exposed or unsuitable situation for any undue period before completion of the
painting process. No exterior or exposed painting shall be carried out under
adverse weather conditions, such as rain, extreme humidity, etc.
(iv)
All items not required to be painted (e.g. ironmongery) shall first be fitted and
then removed before any painting preparation commences. The fittings shall be
refixed in position when all painting is completed.
(v)
Brushes, pails, kettles, etc., used in carrying out the work shall be clean and
free from foreign matter. They shall be thoroughly cleaned before being used for
different types or classes of material.
(vi)
All materials shall be used strictly in accordance with the manufacturer's

printed instructions and paints of different brands shall not be mixed or used in
the same coating system. No dilution of painting material shall be allowed
except strictly as detailed by the manufacturers and as approved by the
Engineer.
(vii)
Concrete, blockwork, plaster and timber surfaces which are to be painted shall
be washed down prior to painting. The surfaces shall then be allowed to dry
out completely before application of paint.
M/3
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3.2
3.3
Preparation of Plastered and Rendered Surfaces for Painting

(i)
The surface shall first be scraped to remove mortar splashes, etc., and then
made good, cutting out all defective work and repairing with plaster or render of
the same type as previously used.
(ii)
The surface shall then be rubbed down with fine glass paper to remove loose
particles and to smooth irregularities before the application of the filler coat
which shall be spread evenly with a scraper over all surfaces and allowed to
dry.
(iii)
The first application of filler coat shall be rubbed down and a second
application of filler coat shall be made as before.
(iv)
The surface shall then be sanded using progressively finer grades of paper
until perfectly smooth and approved by the Engineer.
(v)
New concrete shall be allowed to age a minimum of 28 days prior to coating

application. The surface must then be chemically treated or sweep blasted to
remove the laitance layer. The pH of the concrete surface should be within the
6.8 - 8.0 range for safe coating application. If the surface pH is outside this
range, the fresh water rinse should be repeated until pH is within the required
range. The drying of the concrete can be accelerated by applying isopropanol
ethanol to the surface. The first priming paint coat shall be thinned and
applied with a paint brush to obtain maximum penetration.
(vi)
All rendered surfaces shall receive one full coat of alkali resistant primer
before the application of oil based paints.
(vii)
Screeds to receive an epoxy or similar floor coating shall be brushed down, all
cracks and holes filled and all projections removed to leave a suitable dust free
surface. When the cleaned surface has been approved apply two coats of two
pack epoxy floor coating as manufactured by an approved manufacturer and as
approved by the Engineer.
Preparation of Wood Surfaces for Painting

(i)
All large, loose or resinous knots shall be cut out and the holes plugged with
sound wood. Nails shall be punched well below surfaces, especially
externally.
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(ii)
All surfaces shall be rubbed down with fine glass paper in the direction of the
grain to give a smooth even finish with arrises rounded or eased.
(iii)
After dusting off all oily woods such as teak and afromosia shall be washed
with white spirit.
(iv)
Two thin coats of knotting shall be applied to all knots and any other resinous
parts of softwood.
(v)
A full coat of primer shall be vigorously brushed in, particular care being
taken to fill end grain. Backs of members shall receive two coats of primer.
(vii)
After priming all nail, screw holes and similar depressions shall be filled with
stopping, pressed well and finished off flush with surface. Screw heads shall be
countersunk sufficiently to hold the stopping.
(vi)
After priming and stopping is completed, pore and grain irregularities shall be
treated with a coat of brush or knife applied filler, and the surface rubbed
down smooth and even.
(viii)
Woodwork delivered primed shall be highly rubbed down with abrasive paper,
and dusted off. Touch up of bare areas with a similar priming including open
grained ends. After touch up priming of all joints, holes, cracks and open
grained ends the woodwork shall be stopped and filled, rubbed down and
dusted off.
(ix)
Edges of exterior plywood and blockboard, shall be sealed with two coats of
aluminium primer and the backs treated with a suitable approved primer.
(x)
All woodwork scheduled to receive a clear finish shall be well sanded (with
the grain) removing all dirt, etc., to give as smooth a surface as possible.
Resinous timber shall be swabbed down with white spirit and dried
thoroughly. Split or end grain shall be filled with suitable filler recommended by
the clear lacquer manufacturer, in accordance with their instructions, and of the
appropriate shade.
M/5
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FOR TENDER REV- 0

3.4
3.5
Preparation of Metal Surface for Painting

(i)
Bare metal work shall be thoroughly cleaned of all dirt, grease, rust and scale
by means of chipping, scraping and wire brushing, particular attention should
be given to the cleaning of welded, brazed and soldered joints. Wash down
with white spirit and wipe dry with clean rags. Apply one coat of metal
primer immediately the cleaned surfaces have been approved by the Engineer.
Iron and steel surfaces shall receive two coats of primer of 50 microns
thickness.
(ii)
Galvanised metalwork scheduled for painting shall be thoroughly cleaned of

dirt, grease, dusted and washed down with white spirit and wiped dry with
clean rag. Any minor areas of rust shall be removed by wire brushing and spot
primed with a zinc rich primer. Apply at least one coat of a two pack high
build epoxy undercoat, pigmented with zinc phosphate to all surfaces
subsequently to be painted
(iii)
If the priming coat of pre-primed metalwork has suffered damage in transit, or

during erection on site, the affected areas shall be cleaned off by wire
brushing, abrading and dusting off, the bared patches touched up with a primer of
a similar type to that already applied.
(iv)
Copper scheduled for painting shall be lightly abraded with emery cloth,
washed with white spirit and wiped dry with clean rag. When the cleaned
surfaces have been approved apply:
- One coat of etch primer of copper pigmented primer
- One coat of alkyd gloss paint or other approved coating system.
(v)
Aluminium scheduled for painting shall be lightly abraded with emery cloth,
washed with white spirit and wiped dry with clean rag. Apply a coat of etch
primer and zinc chromate primer immediately the cleaned surfaces have been
approved.
(vi)
Priming shall follow manual preparation as quickly as possible and not later
than on the same day. With blast cleaned surfaces priming should follow
within 1 hour and under no circumstance later than after 3 hours after blasting.
Paint Application
(i)
VOLUME II A
Coatings shall be applied in accordance with the manufacturer's printed

instructions to clean, dry surfaces, in dust free and dry atmospheric conditions
and after any previous coats have hardened.
M/6
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(ii)
Priming coats shall be applied by brush unless other methods are approved
taking care to work the primer into the surface, joints, angles and end grain.
(iii)
Any primed surfaces which have deteriorated on site or in transit shall be

touched up.
(iv)
All surfaces of joinery which have not been primed in the workshop shall be
primed immediately on arrival at site and before fixing.
(v)
Care shall be taken to ensure that finish coats applied over calcium plumbate
primer are compatible with the primer.
(vi)
Undercoats shall be applied as an even film over all exposed surfaces avoiding
an uneven thickness at edges and angles.
(vii)
All priming and undercoats shall be rubbed down to a smooth surface with
fine abrasive paper and cleaned of all dust before the application of the next
coat.
(viii) Finishing coats shall be applied as an even film over exposed surfaces,
avoiding brush marks, sags, runs and other defects. Where two gloss finishing
coats are specified the second coat shall be applied within 48 hours of the first.
(ix)
The application of paint systems for iron and steel shall result in a minimum
total dry film thickness of 270 microns internally or externally
not with standing the number of coats specified.
(x)
Unless otherwise indicated in the Specification or Drawings the minimum

number of coats for drying-oil/resin based paint systems shall be as per the
manufacturer's recommendations.
(xi)
The permission of the Engineer must be obtained if it is necessary to proceed

with painting generally if the temperature is less than 40F (5C) and relative
humidity in the building is greater than 80% or when such temperatures and
humidity may be expected. Polyurethane wood finishes shall not be applied
when the temperature is less than 50F (10C) and humidity of the timber is
above 18%.
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(xii)
In the event that the Engineer is not satisfied that the quality of finish complies
with the required standards and/or the sample panel the Contractor will be
required to repaint at his own expense such work to the satisfaction of the
Engineer. If in the opinion of the Engineer it is necessary to remove the
unsatisfactory paintwork completely this shall also be done under the direction of
the Engineer at the expense of the Contractor.
(xiii)
If, while the work is in progress, the paint appears to be faulty, such as
in consistency of colour, drying time, or quality of finish, the work shall be
stopped at once and the manufacturer consulted.
(xiv)
The manufacturers of the material shall be given every facility for inspecting
the work during the progress in order to ascertain that the materials are being used
in accordance with their directions, and to take samples of their products from the
site if they so desire for testing.
(xv) The finishing coats of the various paints or surface finishing shall be free from
sags, brush marks, runs, wrinkling, dust, bare or "starved" patches, variation in
colour and texture and other blemishes.
(xvi) When the work has been completed, the finished surfaces shall not be inferior
in quality, colour and finishes to the samples approved by the Engineer, and
imperfections in manufacture shall not be apparent through these finished
surfaces.
(xvii) Refer to clauses 5.0 and 6.0 for Coating Application Schedules.
3.6
Preparation of New Surfaces for Decorative Papers/Fabrics

(i)
Rendered surfaces shall be scraped to remove mortar splashes and all

irregularities, cracks and blow holes shall be filled and rubbed down when dry
to a smooth surface removing all nibs and loose material.
(ii)
Rendering, proprietary external quality board and other alkaline surfaces shall
receive on coat of alkali resistant primer.
(iii)
All nail and screw heads to rigid sheet surfaces shall be below the surface,
touched in with metal primer and allowed to dry before filling.
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3.7
3.8
(iv)
Paperfaced plasterboard, hardboard, chipboard and the like shall receive one
coat of general purpose primer.
(v)
Surfaces which have not been primed and other surfaces, as recommended by
the adhesive manufacturer, shall receive one coat of size which shall be
allowed to dry.
Preparation of Previously Papered/Painted Surfaces for Decorative

Papers/Fabrics
(i)
All existing paper or fabric shall be removed and the surface washed down
with warm water to remove old adhesive and size. All existing painted
surfaces shall be scraped to remove any loose material and washed with a
detergent solution to remove any dirt and grease.
(ii)
All irregularities and cracks shall be filled and rubbed down when dry to a
smooth surface.
(iii)
Bare and filled areas shall be touched in with general purpose primer.
Hanging Decorative Paper and Fabrics

(i)
Hanging shall not commence until:

(a)
All work affecting the surfaces to be covered is complete.
(b)
The surfaces to be covered are dry and free from dust.
(c)
The painting of adjacent surfaces is finished and dry.
(ii)
Switch plates, grilles, etc., shall be removed before hanging commences and
replaced when the surfaces are dry.
(iii)
The Engineer's instructions shall be obtained where the specified covering will
allow minor blemishes in the surfaces to show.
(iv)
Only rolls with the same shade number shall be used in any one area. Before
hanging, the rolls shall be carefully matched for colour.
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(v)
The manufacturer's recommendations for hanging the coverings and to which

surface adhesive is best applied shall be followed. Great care shall be taken to
avoid staining the face of the paper or fabric.
(vi)
All lengths shall be in one piece unless greater than roll length.
(vii)
Patterned paper or fabric shall be correctly aligned and accurately matched.

Where mismatching is unavoidable the Engineer's approval shall be obtained to
clarify the position allocated.
(viii)
Wallpaper shall be accurately butt jointed. Where incomplete widths are

required or where materials do not have straight edges the joints shall be
overlapped and cut through using a straight edge to form a butt joint. Edges
shall be neatly trimmed to a true line at junctions with other finishes.
(ix)
When finished, papers and fabrics shall be free from air bubbles, wrinkles,
gaps, tears, adhesive marks and stains and shall be secure and smooth.
4.0
STANDARDS AND TABLES
4.1
Standards
The Standards referred to in this Section are:BS 245Specification for mineral solvents
BS 1336
Knotting
BS 2523
Lead based priming paint for iron and steel
BS 3698
Calcium plumbate priming paints
BS 4652
Metallic zinc-rich priming paint (organic media)
BS 4756
Ready-mixed aluminium priming paints for woodwork
BS 4800
Paint colours for building purposes
BS 5082
Water thinned priming paints for wood
BS 5358
Low-lead solvent-thinned priming paint for woodwork
BS 6150
Code of Practice for painting of Building
BS 6952
Exterior wood coating systems
M/10
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4.2
SUITABLE PRIMERS FOR BACKGROUNDS
SURFACE
PRIMER
Non resinous wood
Low lead oil based primer BS 5358, or

Aluminium wood primer to BS 4756
Resinous woods
Alkyd based primer to BS 4756
Iron and Steel
Red lead primer to BS 2523, Type "B"
Galvanised steel
Two pack high build epoxy undercoat on zinc

primer
Zinc-rich primer to BS 4652, Types 1, 2 and 3
Blast cleaned iron and steel or touching-up

damaged zinc coatings
Aluminium and aluminium alloys
Etch primer plus zinc phosphate primer
Copper and copper alloys
Externally: Etch or aluminium

pigmented primer internally: Alkyd gloss paint
direct
Plastics
High build two pack epoxy, thinned 20%
5.0
PAINTING & COATING SCHEDULES
5.1
Application Thickness & Characteristics

The following materials are required to a high standard and the Contractor shall
provide full details of such materials, including test results and samples, to the
Engineer for approval. Until approved, the paints and coatings shall not be delivered,
stored or used at site, except for the provision of samples.
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(I)
5.2
General
Type A : PVA PRIMER (Internal)
Copolymer based, alkali resistant

Primer/sealer,
containing
fungicide.
Single pack.
DFT/Coat :- 50 microns.
Type B : PRIMER (External)
High-Build, two pack, epoxy coating

based on a high molecular weight epoxy
resin.
Type P : PRIMER
(Metal Work)
Epoxy Zinc phosphate primer conforming

to BS 5493.
Type Q : UNDERCOAT
(Metal Work)
Two pack, epoxy based high build semigloss undercoat, for use as an intermediate
coat in an epoxy/polyurethane.
Type R : TOPCOAT
(Metal Work)
Twin pack, Polyurethane topcoat giving a

gloss finish.
Coat Applications And Locations

NOTE: Where protective coatings required for E&M Equipment are required to have
decorative coats such decorative coats, shall be applied as specified in this Section.
(i)
Fair Face Concrete and

Rendered Blockwork Walls
(External)
Preparation of surface
Type B 1No coats
Type E 1No coats
Type F 2 No coats
Surface will appear lightly textured.
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(ii)
Rendered Blockwork and

Rendered
Concrete Type A 1No coats
(Internal)
Type C 1 No coats
Type D 2 No coats
(iii)
Woodwork
(Internal) (i.e. Skirting)
Type H 1 No coats
Type J 2 No coats
(iv)
Timber Doors
(Internal)
Type H 1 No coats
Type K 2 No coats
(v)
Timber Doors
(External)
(vi)
Pipework
(Plastic) (Internal)
(vii)
Pipework
(Copper, Steel) (Internal)
(viii)
Mild Steel, Aluminium &

Steel Metal Work
(Internal & External)
Type H 1 No coats
Type K 2 No coats
Preparation of surface and adequate

sanding for key
Type L 1 No coats
Type M 1 No coats
Type N 1 No coats
Type Q 1 No coats
Type R 1 No coats
Degrease surface
Type N 1 No coats
Type P 1 No coats
Type Q 1 No coats
Type R 1 No coats
6.0
PROTECTIVE COATING SCHEDULES :
6.1
Protective Coating Schedule - Concrete

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6.1.1
Surface Preparation of Concrete

Concrete surfaces which have been cut-back shall be prepared by grit-blasting or
scabbling and chipping out loose projecting coarse aggregate to expose a sound
matrix of rough profile. Marine and vegetable growth shall be removed by high
pressure water jetting or similar means to expose the concrete face and the Contractor
shall ensure that all oil or grease is removed by steam cleaning in conjunction with
suitable detergents. Surfaces shall be thoroughly cleaned by high pressure air-lance.
The parent concrete shall be soaked with fresh water for a period not less than 24
hours prior to concreting such that the bonding surface is in a saturated surface dry
condition at the time of placing the repair concrete. Bonding agents shall not be
employed unless approved by the Engineer.
6.1.2
Protective Coatings Generally

All protective coating systems to be used shall be applied strictly in accordance with the
manufacturers recommendations.
The Contractor shall provide evidence that the protective coating systems have
performed successfully in similar conditions and environments. The Engineer may
request submission of test data on the performance of the coating system, which shall
include but not be limited to : resistance to water, chloride ion and sulphate ion
ingress.
Prior to applying the coating system to the permanent works the Contractor shall carry out
a small trial of the coating system for review and approval by the Engineer.
The Contractor shall take all necessary precautions to avoid damage to protective
coatings during the Contract period. Any damage to protective coating systems shall be
made good.
6.1.3
Protective Coating Type C1 : Waterproof Membrane Below Ground

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.
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The bituminous material shall be a minimum of 1.5 mm thick and the membrane shall be
capable of bridging crack widths in the substrate up to 0.6 mm wide.
Membranes shall be protected during backfilling by hardboard or similar.
The
membrane shall extend 300 mm above finished ground level unless shown otherwise on
the Drawings.
6.1.4
Protective Coating Type C2 : Impregnative Silane-Siloxane Coating

Where indicated on the Drawings or directed by the Engineer concrete exposed to the
atmosphere shall be protected by 2 coats of an impregnative silane-siloxane primer
applied to ensure maximum penetration into the concrete.
The material shall be formulated to provide maximum protection against the ingress
of water or vapour borne chlorides and shall be suitable for the climatic condition in
Dubai.
Unless directed otherwise by the Engineer the treatment shall be applied approx. 24
hours after the wet curing period.
Any concrete finishing required shall be
completed before the application of the treatment.
The Contractor shall carry out tests to verify the depth of penetration of the material.
Where there are fine cracks in the concrete at a width acceptable within the Contract an
additional 2 stripe coats of the treatment shall be applied prior to the main
treatment. A further 2 stripe coats of material shall be applied to all visible cracks in the
concrete shortly before the end of the defects maintenance period.
The material shall be applied strictly in accordance with the manufacturers
instructions and as follows:
(i)
The material shall be applied by fine nozzle spray.
(ii)
The application shall be such as to minimise loss by evaporation. Application

will not be permitted when the ambient air temperature is above 35oC or in
windy conditions.
(iii)
The surface shall be cleaned by a stiff brush or compressed air to remove all
loose deposits.
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(iv)
Concrete to be treated shall be surface dry for a minimum period of 24 hours

before impregnation.
(v)
Membranes, joint sealers and cast in concrete ancillaries shall be masked off
prior to treatment.
(vi)
Application shall be made by saturation flooding.

application shall be at least six hours.
(vii)
Treated areas shall be protected from seawater and rain for six hours after
treatment.
The interval between
6.1.5 Protective Coating Type C3 : Flexible Cementitious Coating

Where indicated on the Drawings or directed by the Engineer concrete exposed to the
atmosphere shall be protected by a flexible two component acrylic modified
cementitious coating.
The material shall be applied strictly in accordance with the manufacturers
instructions and as follows:
(i)
The material shall be applied immediately on completion of the curing period.
(ii)
The material shall be applied as two coats to give a total thickness of not less
than 1.0 mm.
(iii)
Shallow blowholes and imperfections in the concrete shall be initially filled

with the same material but mixed to a stiffer consistency.
(iv)
The surface shall be free from oil, greases and any loose deleterious material.
(v)
The surface shall be damp prior to treatment.
(vi)
Application shall be by stiff brush or roller.
The final colour of the treatment shall be to the approval of the Engineer.
The material shall be flexible enough to bridge a 0.6 mm surface width crack in the
substrate.
The material shall be capable of resisting daily cyclic variations in
substrate crack width of between 0.3 mm and 0.6 mm.
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6.1.6
Protective Coating System Type C4

Use
Rendered Blockwork
Preparation :
Surfaces shall be brushed down to remove loose

material and dust, prior to the surface being thoroughly
washed, with a minimum of warm water and detergent,
to remove all dirt and grease and allowed to dry. Minor
defects, cracks and holes, after cutting out as necessary,
shall be made good as appropriate and rubbed down
flush with the surrounding surface. All make up and
repairs must be allowed to cure before over-painting.
Generally all preparation must as a minimum, conform
to the paint manufacturers instructions.
It may be
necessary to check the proposed paint system for
compatibility before overcoating existing paitwork.
Painting
2 Coats Exterior quality waterproof paint. Finish to be textured

as existing. Colour to match existing or as detailed on
the Drawings or instructed by the Engineer.
6.2
PROTECTIVE COATING SCHEDULE - STEELWORK
6.2.1
Coating System P1
Use
IN SHOP
Preparation :
Painting
Abrasive blast clean to S1S 05590 SA 2.5
1 Coat
Epoxy zinc phosphate holding primer to a minimum

DFT of 20 microns.
1 Coat
Epoxy zinc phosphate paint to a minimum DFT of

75 microns.
AT SITE
Preparation :
Painting
VOLUME II A
Structural Steelwork. (General)
Repair and touch up of any mechanical damage.

1 Coat
Intermediate coat, coal tar epoxy to a minimum DFT of

125 microns, pigmented brown.
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1 Coat
Method of Application:
6.2.2
Airless spray.
Coating System P2
Use
Structural Steelwork. (High quality/above ground)
IN SHOP
Preparation :
Painting
Abrasive blast clean to S1S 05590 SA 2.5
1 Coat
Epoxy zinc phosphate primer conforming to BS 5493

type KP1A to a minimum DFT of 75 microns.
2 Coats
Epoxy micaceous iron oxide paint to a minimum DFT

of 125 microns per coat.
Method of Application:
6.2.3
Finish coat, as above but pigmented black.
Airless spray.
Coating System G1
Use
Galvanised and Painted Steelwork.
GALVANISING
Preparation
Galvanising :
Following removal of burrs, slag, oil and grease, abrasive

blast clean to S1S 05590 SA 2.5
The hot dip galvanising process shall be carried out generally in
accordance with BS 729, except that the minimum
DFT for the zinc coating shall be increased to 210 microns.
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PAINTWORK
Preparation :
Remove dirt and debris and clean thoroughly with and

emulsifying degreasing agent to remove all grease and
foreign matter.
The surface shall then be washed with
clean fresh water and allowed to dry before overcoating.
Alternatively the articles may be lightly sweep blasted after
cleaning and degreasing.
Apply a two-pack etch primer confirming to BS 5493 type
AP3A, care being taken to obtain a DFT between 8
microns and 15 microns. Excessive film build up must be
avoided.
Painting : 1 Coat
: 1 Coat
: 1 Coat
High build epoxy consisting of a two-pack epoxy

undercoat to give a minimum DFT of 100 microns
(normal solids content 75% by volume), pigmented brown
High build epoxy as coat 2 above except pigmented black.
6.3
PROTECTIVE COATING SCHEDULE - ALUMINIUM
6.3.1
Painting System : A1
Use
Preparation :
Where aluminium is in direct contact with cement

mortars or concrete.
Remove dirt and debris and wash thoroughly with a
solvent based emulsifying cleansing solution which
should be then rinsed off with clean fresh water and
allowed to dry.
The surface shall then be lightly
abraded.
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Painting
1 Coat
Single pack high build bituminous paint to give a

minimum DFT of 125 microns. The paint shall be of
the reinforced bituminous type with a minimum solids
content of 50%.
6.3.2 Painting System : A2

Use
Wherever Aluminium is required to be painted.
Preparation :
Aluminium surfaces to be painted shall be washed down

with a suitable solvent to remove dirt and grease.
Painting
Surfaces are to be treated to prevent oxidation and one

coat chromate primer applied or one coat of self etch
primer.
1 Coat
Zinc phosphate compatible with future coats.
2 Coats
Alkyd based undercoat to a minimum DFT of

40 microns each coat.
1 Coat
Alkyd based gloss finish to a minimum DFT of

40 microns.
6.4
PROTECTIVE COATING SCHEDULE - E & M EQUIPMENT
6.4.1
Painting System P1
Use
Exposed external E&M Equipment and lighting

columns which have not been galvanised.(Except
where noted otherwise in this Schedule)
Preparation :
Abrasive blast clean to SA 2.5
Painting
Painting shall correspond to BS 5493 SL5
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: 2 coats
Two-pack epoxy zinc phosphate primer to total

minimum DFT of 140 microns.
: 2 Coats
Two-pack epoxy undercoat to total

minimum DFT of 200 microns.
Polyurethane finishing coat to a minimum
of 50 microns DFT.
: 1 Coat
6.4.2
Painting System P2
Use
E&M Equipment and other items that have been

galvanised, including galvanised lighting columns.
Preparation :
Painting
Wash and degrease surface.
Painting shall correspond to BS 4593 SF8 after suitable

pre-treatment.
Pre-treatment using primer in accordance with Clause
11.3.2 of BS 5394
1 Coat
Alkyd Primer to a minimum of 50 microns DFT.
1 Coat
Alkyd undercoat to a minimum of 50 microns DFT.
2 Coats Alkyd finishing coat to a minimum of 100 microns total DFT,

50 microns each coat.
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6.4.4
Painting System P4
Use
:
Buried steel LPG pipework with or without pipewrap
(in trenches, ducts etc., and above ground)
Abrasive blast clean to SA 2.5
Two-pack epoxy zinc phosphate primer to a minimum of
70 microns DFT.
Two-pack coal tar epoxy to a minimum of 100 microns
DFT.
Preparation :
Painting
1 Coat
1 Coat
Apply approved pipewrap as specified elsewhere in the

Specification.
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SECTION N
METAL SHEET ROOFING, CLADDING & CURTAIN WALLING

1.0
MATERIALS
1.1
General Provisions
2.0
2.1
VOLUME II A
(i)
Materials shall be inorganic, resistant to rodents, vermin, mildew, fungus and

algae, as necessary to obtain design and performance requirements as
specified.
(ii)
All materials and components shall be the best of their respective kind, to the
dimensions shown on the Drawings and where applicable sections shall be in
accordance with the relevant BSI, ASTM, DIN or approved equivalent
standard.
(iii)
When a precise grade or alloy of metal is not specified the Contractor shall
obtain the metal from an approved specialist supplier or fabricator who shall be
informed by the Contractor of the particular application of the metal within the
Works and it shall be the Contractors responsibility to obtain the correct material
suited to its application in the Works.
(iv)
Unless specified elsewhere or identified in Section N below, all base

metalwork and material shall comply with Section J of this Specification.
(v)
The Contractor shall submit samples of all components and materials to the
Engineer for approval together with test certificates which show that they
possess specified characteristics.
GENERAL
Scope of Work
The scope of Works is to include the following:
(i)
The details as shown and indicated on the Drawings.
(ii)
The design and detailing of the roof sheeting, cladding or curtain wall
systems.
(iii)
The supply of all components, materials and accessories necessary to

complete the installation.
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2.2
(iv)
The fabrication of all necessary assemblies, and
(v)
The erection of all components and assemblies to complete the installation.
Shop Drawings
The Contractor shall provide 3 sets of Shop Drawings and Details for approval by the
Engineer prior to manufacture of any and all components.
2.3
Erection and Fixing

The sub-contractors employed for the supply, erection and fixing of all components
and assemblies are to be approved by the Engineer.
3.0
ROOF AND WALL SHEETING
3.1
Aluminium Sheets
The outer or external sheets for roofs shall have a base metal thickness of 0.7 mm or
0.55 mm aluminium sheeting as indicated on the Drawings of a quality not less than the
requirements of BS EN 485, BS EN 515 and BS EN 573.
Wall sheets and cladding external sheets shall be
aluminium sheeting and as indicated on the Drawings.
0.7 mm or 0.55 mm thick
The sheeting shall be profiled as shown in the Drawings and shall be of trapezoidal
type with a minimum depth of 45 mm and maximum pitch of 150 mm unless
otherwise specified.
The sheet profile shall have a fully supported side lap or an approved side overlap as per
the manufacturers recommendations.
Sheets shall conform to the requirements for material and finishes as laid down in BS
4868 Profiled Aluminium Sheet for Building.
Aluminium pre-coated coil shall be manufactured using computer controlled,
continuous on-line paint technology and the process must be quality controlled and
certified to QAQC requirements of BS EN ISO standard.
N/2
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The Sheet will be externally finished with a factory applied polyester coating,
minimum thickness of 20 microns plus 3-5 microns primer coat, or as otherwise
indicated on the Drawings. The internal will be finished with an epoxy or polyester
lacquer or paint.
The colour of finishing coats shall be as follows and in accordance with BS 4904.
a)
External faces- as defined by the Client, or as defined in the Schedules or

Drawings.
b)
Internal faces- as defined by the Client, Schedules and Drawings or as

provided as standard by the manufacturer.
The finish shall be uniform with no variation in colour or sheen.

3.2
Aluminium Composite Panels

Composite or sandwich panels should consist of an outer/external 0.5 mm thick
aluminium sheet of trapezoidal type (min. 45 mm deep and max. 150 mm pitch unless
otherwise specified or indicated on Drawings), an internal liner sheet of 0.5 mm
thickness with a factory injected fire retardent, CFC Free, polyurethane core bond
between.
The polyurethane core bond thickness shall be suitable to meet the specified
insulation and overall heat transfer co-efficient and is to have a minimum density of
35 kg/m.
Thermal insulation values shall be as follows:
POLYURETHANE CORE-THICKNESS (MM)

OVERALL HEAT
W.M C
TRANSFER
KCAL/mh C
COEFFICIENT
BTU/Fth C
T=30
0.63
0.52
0.11
T=40
0.48
0.40
0.08
T=50
0.38
0.34
0.069
T=80
0.24
0.22
0.046
T=100
0.19
0.18
0.037
60%
45%
36%
22.5%
18%
ADDITIONAL VALUE OF INSULATION IN

CORRUGATED AREA
The above values are based upon a thermal conductivity () = 0.019 W/m Deg.
Celsius.
For colours and finishes refer to paragraph 3.1 a) and b).
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3.3
Durability
The sheeting, roof and cladding shall be considered for a life span of 10-20 years as
classified by BS 5427 (Coastal Environment External Wet (possibly polluted) Internal
Environment).
3.4
Side And End laps

Side laps are to be a minimum of one pitch overlap and be sealed with a
non-hardening, permanently elastic, self adhesive polybutyl sealant strip
9 mm x 3 mm and riveted at centres as per the Table in Clause 3.10 using aluminium
rivets. Sealing is not required on the verticals, but should be riveted at 400 mm
centres.
End laps are to be as per the Table in Clause 3.10 and sealed with two runs of sealant.
3.5
Flashings
Trims and flashing shall be manufactured from 0.9 mm thick aluminium to match the
sheeting.
3.6
Fixing Accessories
Sheeting to be fixed to steel purlins and sheeting rails with stainless steel, (Series 304
austenstic to BS 5427), self tapping screws complete with stainless steel (or
aluminium) washer incorporating neoprene sealing washer and PVC colour cap.
Roof sheets are to be fixed through the profile crown and utilise a matching colour
coated aluminium trapezoidal saddle washer.
Wall sheets and cladding shall be fixed through the profile trough.
Purlin and sheeting rails shall be covered by PVC barrier tape.
Flashings and side laps will be fastened with an all aluminium water tight rivet
including mandril and pin.
Profile filler blocks should be used in conjunction with flashings to adequately seal
ridge, eaves, gable and drips where applicable. Filler blocks will be black synthetic
rubber.
N/4
All fixing shall be in accordance with manufacturers recommendations.

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3.7
Installation
Installation must always be carried out in accordance with manufacturers
recommendations and with particular reference to British Standards and Codes Of
Practice.
All damaged, dented or scratched sheeting will be removed and replaced at the
Contractors expense and to the satisfaction of the Engineer.
3.8
Cutting
Sheets should be cut either with powered circular saw or nibbler machine (Fein or
similar).
Care must be taken to avoid distortion of the profile and it is a requirement that
site-cut ends are covered by flashings or laps. Damaged and dented sheets will not be
accepted.
3.9
Drilling
Correct size and depth of hole is of prime importance and must be to the
manufacturers recommendations.
Fastener holes should always be drilled and not punched.
Swarf, should be removed as completely as possible before fasteners are tightened.
Swarf, cuttings, rivet mandrills and other debris should be cleared from the roof and
gutters after each working day, and adjacent areas swept clean.
3.10
Fastenings
All fastenings shall be stainless steel series
BS 5427.
304 austenstic in accordance with
It is important that all fasteners and fastenings are fixed at right angles to the plane of
fixing.
N/5
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Correct fastener tightness is of prime importance as over or under tightening may

ultimately lead to leakage. Overtightening of fasteners may lead to deformation of
the sealing washers, sheet damage, and in the worst case, damage to the fastener
thread.
Fasteners should be tightened just enough to compress the sealing washer but not to
distort it.
Power screw drivers are available with magnetic drive sockets and
adjustable depth sensing clutch to ensure correct driving of screws. It is essential this
type of fixing gun is utilised for installation.
All sheets and fastenings damaged by incorrect installation techniques are to be
removed and replaced at the Contractors expense and to the satisfaction of the
Engineer.
Fasteners shall be fixed strictly at the centres detailed in the table below for severe
exposure.
Roof Pitch
Over 15
10-15
Upto 10
Exposure
Moderate
Severe
Side lap
End lap
Sealant
Side lap
End lap
Fastener
mm (min) side and
fastener
Mm
Centres
ends
centre
(min)
mm (max)
mm (max)
450
450
450
Translucent (roof lights)

Over 10
300
Up to 10
Sealant
side
and
ends
150
150
225
No
Yes
Yes
300
300
300
150
150
225
No
Yes
Yes
300
300
Yes
Yes*
350
300
300
300
Yes
Yes*
100
No
300
150
No
Walls
450
* Provide 2 rows of sealant

N/6
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3.11
GRP/PVC Translucent Sheeting:

Sheets shall be manufactured to and comply with BS 4203 & BS 4154.
Sheets shall match the main roof sheeting profile and be suitable for fixing to the
purlin support system.
Sheets shall be of sufficient thickness and strength to equal the main sheet roof
cladding properties.
Primary fastenings shall be fixed to steel purlins using self tapping screws complete
with stainless steel or aluminium washers, incorporating a neoprene sealing washer, and
PVC colour cap.
Primary fastenings shall be fixed through the profile crown and to the manufacturers
recommendations using a matching colour coated aluminium trapezoidal saddle
washer.
Primary fastenings shall be provided through alternate crown profiles in general roof
areas of translucent sheeting and through every profile crown at end laps.
Secondary fastenings shall be of an approved proprietary type incorporating stainless steel
screw and rubber/neoprene shank insert and two piece rubber/neoprene cap, to the
Secondary fastenings shall be provided at all side laps, at a maximum of
centres, and fixed through the crown profile, as per Clause 3.10 Table.
300 mm
Aluminium rivets are not to be used for fixings on translucent sheeting.

3.12
Samples
The Contractor shall provide samples of all materials, fixings, fastenings and profiles of
the specified colour to the satisfaction of the Engineer and as required.
3.13
Gutters
Gutters are to be fabricated to the Design Drawing Details from 1.0 mm gauge
aluminium, colour to be as roof sheet. Joint sections to be 200 mm wide fabricated
from the same material.
N/7
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Joint gaskets are to be self adhesive neoprene strip 100 mm

x 3 mm thick. Joints should be fastened with M8 x 30 mm aluminium bolts and nuts
with aluminium and neoprene washer at 75 mm centres. 2 Nos. neoprene joint
gaskets are required for each joint. Gutter outlet nozzles shall be conical shape in
section and may be manufactured in GRP.
Gutters shall be isolated from support steelwork using PVC purlin barrier tape.
Gutters are to be sized in accordance with the relevant standards (BS 6367) to suit
75 mm per hour rainfall intensity design. Rainwater downpipes and outlets are to be
similarly designed. (Calculations are to be provided for the approval of the
Engineer).
3.14
Roof Ventilators
Roof ventilators shall be natural draught ridge mounted type.
aerodynamic design to utilise wind suction effect.
Vents should be of
Units shall have 300 mm fixed throat opening and total length shall be 300 mm.
Frame construction shall be of 25 x 25 x 2 mm welded aluminium angles. Fabricated
covers shall be 1.0 mm gauge aluminium sheet of alloy 3105 to BS EN 485,
BS EN 515 and BS EN 573. The sheet will be plain mill finish. Ventilators shall be
post painted after fabrication. Primer 30 microns D.F.T., Top coat Epoxy 20 microns
D.F.T. Colour to BS 5252 to Engineers satisfaction. Colour to match the main
roof/cladding sheets.
3.15
Materials for sheeting and cladding should be stored under cover and in the original
packing in a dry, well-ventilated position.
Sheets must not be allowed to come into contact with cement based products to
prevent staining.
Sheets are to be kept flat, supported on timber battens, off the ground and generally
covered to prevent damage to edges and coatings.
N/8
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3.16
Testing
The whole of the sheeting and cladding shall be tested for drainage and leaks by
flushing with water where directed by and in the presence of the Engineer.
All cladding and sheeting shall have test results showing compliance with the relevant
standards for the type concerned.
The contractor shall allow for having considered the list of tests below and for
providing evidence of tests having been performed on their proposed suppliers sheets,
materials and coatings as a requirement of the Contract. In the absence of bonafide
technical literature some or all of the tests, will be chosen by the Engineer from the
following:List of standards related to coated metal cladding
ASTM B117
Standard test method of salt spray testing
ASTM D522
Standard test method for mandrel bend test of attached organic

coatings
ASTM D523
Standard test method for specular gloss
ASTM D660
Standard test method for evaluating degree of checking of

exterior paints
ASTM D661
Standard test method for evaluating degree of cracking of

exterior paints
ASTM D714
Standard test method for evaluating degree of blistering of

paints
ASTM D772
Standard test method for evaluating degree of flaking (sealing)

of exterior paints
ASTM D870
Test Procedure For Water Soak
ASTM D968
Standard test method for abrasion resistance of organic

coatings by falling abrasive
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ASTM D1400
Standard test method for non-destructive measurement of dry

film thickness of non-conductive coatings applied to non
ferrous metal base
ASTM D2244
Standard test method for calculations of colour differences

from instrumentally measured colour co-ordinates
ASTM D2247
Condensation Testing
ASTM D2248
Standard practice for detergent resistance of organic finishes
ASTM D2794
Standard test method for resistance for organic coatings to the

effects of rapid deformation (impact)
ASTM D3363
Standard test method for film hardness by pencil test
ASTM D 4060
Standard test method for abrasion resistance of organic

coatings by the Taber abraser
ASTMG53-84
Procedure For Exposing Paint Systems To Q.U.V.
ASTM G85-94
Practice for modified salt spray test (acetic acid)
BS 476
Fire tests on building materials and structures
BS EN 485
Specification aluminium and aluminium alloys. Sheet strip and

plate
BS EN 515
Aluminium and aluminium alloys. Wrought products.
BS EN 573
Aluminium and aluminium alloys.
BS 1494
Specification for fixing accessories for building purposes
BS 2782
Methods of testing plastics
BS 3900
Methods of test for paints
BS 4154
Corrugated plastic translucent sheets
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BS 4203
Extruded rigid PVC corrugated sheeting
BS 4315
Methods of test for resistance to air and water penetration
BS 4800
Schedule of paint colours for building purpose
BS 4868
Specification for profiled aluminium sheet for building
BS 4904
Specification for external cladding colours for building

purposes
BS 5250
Code of practice for control of condensation in buildings
BS 5427
Code of practice for performance and loading criteria for

profiled sheeting in building
BS 6150
Code of practice for painting of buildings
BS 6262
Code of practice for glazing of buildings
BS 6496
Specification for powder organic coatings for application and

stoving to aluminium alloy extrusion, sheet and pre-formed
sections for external architectural purposes, and for the finish on
aluminium alloy extrusion, sheet and pre-formed sections coated
with powder organic coatings
BS 6497
Specification for powder organic coatings for application and

stoving hot-dip galvanised hot-rolled steel sections and preformed steel sheet for windows and associated external
architectural purposes, and for the finish on galvanised steel
sections and pre-formed sheet coated with powder organic
coatings
BS 8200
Code of practice for design of non-loadbearing external vertical

enclosures of buildings
CP 143
Code of practice for sheet roof and wall coverings
DIN 4102
Fire behaviour of building materials and building components
N/11
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DIN 16937
(PVC-P) waterproofing sheet compatible with bitumen

requirements
BS EN 10002
Tensile testing of metallic materials
ISO 174
Plastics: Determination of viscosity number of PVC resins in

dilute solution
ISO 6361
Wrought aluminium and aluminium alloy sheets strips and

plates - technical conditions for inspection and delivery
ISO 6892
Metallic materials - tensile testing
ISO 8618
Plastics - Liquid phenolic resins -Determination of non-volatile

matter
4.0
CURTAIN WALLING
4.1
Materials
See Specification clause 1.1 for General Provisions.
(i)
VOLUME II A
Framing, Trim and Flashings shall be as follows:

a)
Aluminium Extrusions: 6063 alloy, TS temper, or AI mgsi 0.5 F22

anodising quality.
b)
Aluminium Sheet & Plates: 1100-H14 alloy, anodising quality, and for
spandrels, controlled stretcher levelled optimum flat, stress relieved, to
commercial tolerances.
(ii)
Steel: to BS 5950
(iii)
Screws, Bolts, Washers, Nuts and other Fastening Devices:

200 or 300 series austenstic grade stainless steel.
(iv)
Slip Washers: Nylon
(v)
Thermal Separator (thermal break): Use polythermid insulator sizes to

conform to extruded aluminium members.
N/12
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(iv)
Dielectric Separator: Bituminous paint, tape or dielectric coating.
(vii)
Bituminous Paint: to BS 6949
(viii)
Insulation for packing in frames and between frames and adjacent

construction: Lightweight, inorganic mineral wool of
50 Kg/m nominal
density.
(ix)
Firestopping:
(x)
a)
Mineral fibre safing insulation: Complete with galvanised steel.

Firestopping shall be 25% wider than the space to be filled.
b)
Firestopping sealant: Dymeric 240 (manufactured by Tremco) or one

component silicone (manufactured by Dow Corning Ltd.) (General
Electric Ltd.) or Rhodorsil silicon (manufactured by Rhone-Poulene
Inc.) or similar equal approved.
Sealants:
a)
General: Non-bleeding, non-drying, capable of supporting their own

weight.
b)
For concealed non-moving static joints and fixing device penetrations:

One component butyl rubber.
c)
For moving working joints and exposed locations: One component

silicone, UV resistant, non-discolouring, formulated not to attract
airborne dirt and pollutants, (manufactured by Dow Corning Ltd., or
general Electric) or similar equal approved.
d)
Sealants: Sealants, cleaning solvents, fillers and primers shall be

compatible with each other.
e)
Colours for Sealants: As detailed on the Drawings or approved from

the sealant manufacturers standard colour range.
f)
Primers: As recommended by the sealant manufacturer to suit

conditions.
N/13
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(xi)
g)
Cleaning Material: Xylol, Methyl-ethyl-ketone, Toluol or as

recommended by the sealant manufacturer.
h)
Filler strips for back-up of sealants: Chemically compatible rod stock

of butyl or neoprene, or white non-absorbent closed cell foam
polyethylene of a diameter sized 25% greater than the joint width
before application.
Glazing:
a)
Float Glass: Annealed, clear to ASTM C-1036-85 or CAN2-12.

3-M76.
b)
Tempered Glass: To ASTM C-1036-85 or CAN2-12. 1-M76, tong

free. Tempered glass shall bear a factory applied permanently
stamped impression in one corner and be visible when glass is
installed, which identifies the glass as being tempered.
c)
Heat Strengthened Glass: As specified for tempered glass it shall be of

strength mid-way between annealed glass and fully tempered glass.
Heat strengthened glass shall bear a factory applied permanently
stamped impression in one corner and be visible when glass is
installed which identifies the glass as being heat-strengthened.
d)
Insulating Glass Units: To CAN2-12.8-M76 or BS 5713 or IGCC to

ASTM E -774 and ASTM E -773, dehydrated air-space, pressure
equalised to suit position on building to prevent bowing, glass edges
straight cut, free of nicks and other imperfections conducive to
breakage. The air spacers should be continuous at the corners.
e)
Labels: Identify glass panes and insulating glass units with labels,
showing thickness, glass type and manufacturers name. The labels on
insulating glass units shall also show orientation and location of outer
light.
f)
Vision through glass: Distortion free.
g)
Shims: Pressure sensitive, resilient, extruded synthetic rubber as

recommended by glass manufacturer.
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(xii)
h)
Spacers and setting blocks: 50 to 70 Durometer A hardness plus or

minus 5 respectively, neoprene rubber, resistant to sunlight,
weathering, oxidation, and permanent deformation under load.
i)
Glazing compound: Use two component polysulphide as secondary

seal, primary seal should be polyisobutylene.
j)
Glazing tapes: Extruded, ribbon shaped, non-drying, non-skinning,

non-oxidising, UV blocked, reinforced with internal shim rod, of
sufficient width and thickness to permit continuous void-free seal
between metal and glass.
k)
Glazing gaskets: Shall be made from high performance quality EPDM.

At corners use single piece vulcanised gaskets. Use special sealing
adhesive to join the gasket and to fill grooves below the corner
vulcanised gasket.
l)
Colour of glazing compounds, gaskets: As approved by the Engineer

or as detailed on the Drawings and from the manufacturers standard
colour range
Aluminium Glazing Systems

Glazing systems should be from Schuco, Couples, or Gartner or other equal
approved.
4.2
Design requirements:
(i)
Follow profiles, perimeter sizes and arrangements of components and

assemblies indicated to obtain the required appearance to the Engineers
approval.
(ii)
All glass units of each type shall be the same and shall have a consistent
uniform colour and appearance.
(iii)
Installed glass components shall be free of oil canning and pillowing.
(iv)
Exposed metal components shall be of uniform colour, sheen and appearance,

within components and from component to component and shall match
approved samples and mock-ups.
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(v)
Exposed metal sheets, plates and extrusions shall be visually flat under all
lighting conditions.
(vi)
Grain and rolling direction of non-painted metal sheets and plates when
installed on the building faces shall run in the same direction.
(vii)
Grain and rolling direction of non-painted braked formed trims, sills and
reveals and the extruded direction of non painted metal reveals, trims, sills,
when installed on the building faces shall run in the same direction
(viii) Engineer and install glass units so each glass unit can be removed without
removing adjacent units and metal panels.
(ix)
Engineer and install metal panels so each panel can be removed without
removing adjacent metal panels and glass units.
(x)
Break pressure plate dimensions are to be to the dimensions of glass panes.
(xi)
Accurately sized mullions at intersecting joints to obtain minimal joints, just

wide enough to permit thermal expansion and contractions so that no damages
and distortions to the work occur due to thermally induced movements.
(xii)
Concealed securement devices. Should it be demonstrated satisfactorily to the

Engineers approval that some exposed securement devices are necessary,
they shall be the same finish and colour of the members in which they occur.
(xiii) Provide a continuous fire and smoke seal at junctions between edges of
suspended concrete slabs and building envelope to prevent passage of fire and
smoke from floor to floor and from floor to roof.
(xiv)
Ensure components and assemblies drain to building exterior.
(xv)
Ensure components are designed, fabricated and installed to prevent build-up

of sand within the cladding cavities and glazing pockets which could cause
blockages to air pressure equalisation and to drainage of water.
(xvi)
Engineer the work to resist forces imposed by window washing stages and
buckets.
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(xvii) The vertical aluminium profile shall be drained and ventilated to the outside
before the profile expansion joint.
(xviii) The expansion joint of the vertical aluminium profile shall be sealed to
prevent any leakage of water from the profile drainage groove to the inside
section.
(xix) The transom mullion joint shall be overlapped and sealed.
(xx) All gasket joints shall be welded or sealed by a glue compatible to the gasket
material.
(xxi) The system shall comply with the rain screen principle.
4.3
Design Submission
4.3.1
General
Proposals and submission shall be accompanied by three sets of drawings and data
details which shall show the manufacturers intent to comply with the requirements of
this Specification Section for the extension elements as follows and shall show:
(i)
Typical head, sill jamb and corner details and typical intermediate mullions.
(ii)
Junctions with and anchorage to the building structure.
(iii)
Air barriers and vapour barriers.
(iv)
Dielectric separator details.
(v)
Thermal separator details.
(vi)
Provisions for thermally induced expansion and contraction of members.
(vii)
Provisions for the absorption of the building structure movements.
(viii) Water drainage system.

(ix)
Detail at parapet condition.
(x)
Pressure equalisation system and air ventilation to the glass rebate.

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(xi)
4.3.2
4.3.3
Method of erection.
Products Data
(i)
Submit manufacturers specifications, fabrication requirements, and

installation instructions, with amendments to fulfil requirements of this
section of the specification.
(ii)
Include erection and glazing details and maintenance and cleaning

instructions.
(iii)
Furnish data clearly describing reglazing techniques.
(iv)
Furnish maintenance and cleaning techniques.
Calculations
(i)
(ii)
Submit calculations, under seal and signature of a professional Engineer,

showing the following:
a)
Design load assumptions.
b)
Detailed engineering of mullions.
c)
Moment of inertia of mullions.
d)
Detailed engineering of anchorage hardware, clip angles, washers,

anchor bolts, welds, torque pressures.
e)
Materials proposed and their allowable shear and bending stresses.
f)
Deflections, expansions and contractions.
Prepare calculations in a clear, comprehensive manner to permit easy review.
Incomplete or haphazard calculations will be rejected unreviewed.
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4.3.4
Shop Drawings
(i)
Submit Shop Drawings as specified.
(ii)
Each Shop Drawing shall bear the signature of the professional Engineer.
(iii)
Show:
a)
Elevations.
b)
Detailed design, dimensions, members, profiles, joint location and
sizes, arrangement of units, horizontal to vertical connections,
thickness, details of special shapes, reinforcing, drainage details, and
flow diagrams, pressure equalisation system and air barrier system,
baffles, flashings, insulation, anchorage system interfacing with
building structure, connections and joints and seals to adjacent
building envelope systems, provisions for thermally induced expansion
and contraction, provisions for absorption of building structure
movements and creep, thermal break details and locations.
4.3.5
c)
Location of exposed fasteners and joints.
d)
Glazing details, methods, if done in field, in shop, locations of various

types and thicknesses of glass.
e)
Panels, related reinforcements and securement methods.
Samples
(i)
Submit samples as specified.
(ii)
Submit three samples of each material with respective finishes as follows:

a)
Extrusions: 300 mm long.
b)
Sheets: 300 mm x 300 mm.
c)
Gaskets and tapes: 900 mm long section of each type.
d)
Sealants: 150 mm bead strips applied to metal sheet, showing colours.
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(ii)
4.3.6
Fasteners: Three of each type.
f)
Glass: 300 mm x 300 mm of each type.
Samples shall represent physical and chemical properties, finishes and colours
to be applied.
Glass Stress Analysis Reports:

(i)
4.3.7
e)
Submit glass stress analysis performed by glass manufacturer/supplier of all

glass. Identify locations of each glass unit on building, stress factors and a
statement whether glass unit is to be annealed, heat strengthened or tempered.
Certifications:
(i)
Submit statements certified by the professional Engineer stating that:

a)
(ii)
Work of this section is engineered, supplied and installed as specified

herein.
Submit statements certified by the sealant manufacturer attesting that:

a)
Sealants selected are suitable for purposes intended.
b) Sealants will not deteriorate due to exposure to ultraviolet radiation

(sunlight).
4.4
c)
Joint designs are correct.
d)
Sealants are compatible with other materials with which they come in
contact.
e)
Sealants are suitable for temperature and humidity conditions at time

of application.
f)
Surfaces are properly prepared and primed to accept sealants.
Performance requirements:
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4.4.1
Application
(i)
4.4.2
Performance requirements apply to work of this section and to connections,

seals, joints, between work of this section to adjacent components/assemblies
provided under other sections of the Specification.
Pressure Equalisation (Exterior Walls):

(i)
Provide pressure equalisation to glazing pockets, to exterior components of

frames, to spandrel panels, to column covers, to infill panels.
(ii)
Provide baffles to prevent air flow within components and spaces as they may
be induced by stack effect and by wind forces.
Locate baffles:
4.4.3
a)
Vertically orientated at every building corner and at every mullion

(Spandrel areas).
b)
Horizontally orientated within extruded mullions at every 2nd floor.
c)
Horizontally orientated at window (vision areas) sills and heads.
d)
Provide baffles to prevent excessive rain entry into the components

which could lead to water ponding and the prevention of pressure
equalisation.
e)
Provide baffles to prevent excessive sand entry into the components

which could lead to blockages, build-up which could cause damaging
expansion stresses and which could prevent pressure equalisation.
Mechanical Design (Exterior Walls):

(i)
Engineer cladding to maintain the mechanical design performance of 22 deg.

C interior atmosphere when building exterior atmospheric temperatures cycle
between a low of 10 deg. C to a high of 60 deg. C.
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4.4.4
4.4 5
4.4.6
Thermal Criteria (Exterior Walls)

(i)
Engineer the work to accommodate within its components and to

accommodate between the work and the building structure and other
constructions, expansion and contractions due to cyclic temperature changes
described under mechanical design conditions to prevent damages and
distortions.
(ii)
Engineer the work to accommodate within its components and to

accommodate between the work and the building structure and all other
constructions, expansion and contractions due to cyclic heat gain and loss
from the absorption of the components of heat which caused the components
to get hotter than the temperatures described under mechanical design
temperatures.
(iii)
Thermal conductance of the work, U-Value shall be less than 2.8 w/cmK.
(iv)
Provide thermal breaks between interior and exterior components to prevent

thermal bridges by using polythermid insulators.
Water and Moisture (Exterior Walls):

(i)
Engineer the work to quickly drain any water and condensate moisture which
may enter within the cladding components to the building exterior.
(ii)
Engineer the work to prevent entry of water and moisture to the building
interior side of the work.
Air Infiltration and Exfiltration (Exterior Walls):

(i)
Air movement through the work, building interior to building exterior and
building exterior to building interior shall not exceed:
a)
For fixed elements: 1.08 m/hr/sqm under static pressure difference of

75 pa.
b)
For openable elements when closed: 0.55 (m/hr) per metre of crack
length under static pressure difference of 75 pa.
(ii)
Allow for mechanically induced air pressure at the building interior.
(iii)
No detectable draughts permitted.

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4.4.7
4.4.8
Glazing:
(i)
Engineer the glazing systems to allow for characteristics of framing and

effects of connections, sealant and frame connections.
(ii)
Engineer the work of metal, glass, glazing to ensure no more than 8 glass units
per 1000 will break during the buildings life.
(iii)
Glazing, gaskets, sealant on building exterior side of glass in exterior walls

shall be non-conductive. Gaskets used in exterior shall be fused or sealed at
corners and shall be of high performance EPDM quality.
(iv)
Pressure plates and other glass retaining devices shall apply uniform,
continuous pressure to glass to prevent:
Distortion, oil canning and pillowing of glass.
b)
Pressure points on the glass which could contribute to stress breakage.
(v)
Metal in direct contact with glass is not permitted.
(vi)
Insulating glass units must not have their seals in contact with water.
Acoustics:
(i)
4.4.9
a)
Provide completed installation free of rattles, wind whistles and other noise
due to thermal and structural movements and due to differential atmospheric
pressure.
UV and Heat Resistance:

(i)
All materials provided which are exposed to atmospheric heat and which are
exposed to sunlight including materials exposed through glass shall be
formulated not to lose their properties due to exposure to heat or ultra-violet
radiation.
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4.4.10 Structural:
(i)
Base design pressure, and negative as created by wind on a minimum velocity

of 45 m/sec (162 Km/hr). Allow for impact, suction, uplift and gusting of
wind and take into account the building height and the proximity of adjacent
buildings which could cause an increase to the forces due to venturi effect.
(ii)
Engineer the work to withstand within acceptable deflection limits, its own
weight, forces applied by building structure movements, forces applied by
adjacent components, and design loads due to wind, stack effect and rain.
(iii)
Engineer the work to accommodate:

a)
Movements within components.
b)
Movements applied due to attached adjacent constructions.
c)
Movements applied due to the building structure, long and short term
creep, column shortening, deflections, torsion, sway and racking.
d)
Movements due to vibration.
(iv)
Provisions shall ensure that no damages, distortions, misalignments occur to

the work and that integrity of thermal, air infiltration/exfiltration, weather and
water tightness barriers are maintained and aesthetic considerations are
maintained.
(v)
Engineer the work not to exceed the following deflections under full design
loads:
a)
Framing members of curtain wall, the lesser of 12 mm or L/240 per

span between anchorages to building structure.
Ensure deflection
limits of glass are not exceeded.
b)
Metal air barriers, maximum 3 mm positive and maximum 3 mm

negative and avoidance of contact with adjacent members and
constructions due to movements.
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c)
Engineer elastic deflections to prevent reduction of glass bite under

full load from exceeding 2.5 mm.
d)
Engineer deflection limits to ensure integrity of seals and glazing are

maintained under full load, dynamically applied.
e)
Permanent deformation of members due to applied loads are not

permitted.
f)
Engineer components in contact with firestopping to ensure

compression on firestopping is not less than
25% under all load
conditions.
g)
Engineer work to keep stresses on components, assemblies and

materials within working range of components, assemblies and
materials.
(vi)
Expansion joints in the vertical aluminium profile shall be provided every

second floor and shall be sealed to the inside with special accessories and
mastic that will allow movement and keep the air and water tightness below the
specified limits.
(vii)
The joint between the transom and the mullions shall be sealed with EPDM
sealing strips.
(viii)
Transoms and mullions shall be assembled by using spigot sleeve connection.

Visible screws or connectors will not be acceptable.
4.5
Tolerances:
4.5.1
Tolerances shall be:

(i)
Vertical position: plus/minus 2 mm
(ii)
Horizontal position: plus/minus 2 mm
(iii)
Racking in elevation: Nil
(v)
Deviation from the true plumb over full height: Maximum 6 mm.
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(v)
Deviation from true straight in plane over full length of each building face:
Maximum 6 mm.
4.5.2
Tolerances shall not be accumulative
4.6
Quality Assurance
4.6.1
Engineering:
4.6.2
4.6.3
(i)
All work shall be engineered by a licensed Professional Engineer.
(ii)
All submittals, proposals, samples, shop drawings, certifications, proposed

substitutions shall bear the seal and signature of a Professional Engineer.
(iii)
All fabrication and installation of work shall be inspected and certified

approved by the Professional Engineer.
Fabricators Qualifications Must Show:
(i)
Regular engagement in engineering, manufacturing, fabricating, finishing,

installing, glazing and sealing of the type of work specified in this section for
minimum of five years.
(ii)
Able to demonstrate satisfactory completion of work of minimum size as this

project.
(iii)
Able to demonstrate thorough understanding of the principles of rain screen,

stack effect, air seals, dynamic forces, behaviour of cast-in-place concrete
structures, water and weather controls as affecting building cladding systems.
Prototype for Laboratory Testing:

(i)
Provide prototype of curtain wall for inspection and testing. Modify prototype
as necessary to pass inspection and testing.
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(ii)
Prototype shall be 2 floors high and about 5 metres wide and shall include
framing, glass, spandrels, metal air/vapour barrier, insulation, seals, gaskets,
flashings, anchorages on to structure, baffles, moving joints and all
accessories necessary to provide a complete curtain wall system.
(iii)
Install prototype components in same sequence and utilising same methods

and personnel as will be used for actual building installations.
(iv)
Connect prototypes air-tight to test chambers.
(v)
Should prototype fail to meet performance requirements, make corrections

and modifications for further testing at no cost to the Client. Costs of further tests
shall be paid for by the Contractor.
(vi)
Tests to be carried out:
(vii)
a)
Air infiltration test according to ASTM E 283 & AAMA
b)
Water penetration test according to ASTM E 331 & AAMA
c)
Structural performance test according to ASTM E 330 & AAMA.
d)
Water test according to ASTM E 331 & AAMA.
e)
Structural performance test at 1.5 times the design load.
There should be no failure or permanent deformation when applying a load of

1.5 times the design load.
4.7
Fabrication
4.7.1
General
(i)
Insofar as practical, execute fitting and assembly in the shop with the various
parts or assemblies ready for erection at the building site.
(ii)
Take field measurements and levels required to verify or supplement those

shown on the Drawings for the proper layout and installation of the Work.
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(iii)
Co-ordinate dimensional tolerances in adjacent building elements and confirm

prior to the commencement of the Work. Commencement of installation of
floor by floor shall be construed as acceptance of building conditions. Work
shall not deviate from tolerances specified.
(iv)
Accurately machine, file, fit and securely frame together all joints, corners,
mitres.
(v)
Locations of exposed joints to approval.
(vi)
Make exposed work free of machine marks and dimpling.
(vii)
Fabricate components to avoid force fitting to obtain alignment with adjacent

components.
(viii)
Weld aluminium with inert metal arc equipment. Make exposed welds
continuous and flush with adjacent surface. Do not mar surface finishes with
welds in back of exposed aluminium. Do not deform the exposed metal and
finish in any way by welding.
(ix)
Welding joints of steel members shall be of adequate strength and durability

with joints tight and flush. Where it is necessary to weld components already
galvanised, remove galvanising for 50 mm around weld and paint as specified
over welds where galvanising is removed, as specified hereinafter.
(x)
Reinforce all the frames by concealed means as necessary to meet the

specified design requirements.
(xi)
Provide steel brackets and support framing to fasten frames in place in

openings. Provide slotted connections as required to accommodated
deflection of opening components.
(xii)
Seal hairline joints at junctions of frame members. Gun inject sealant from
inside ensuring a continuous seal of the joint. Ensure that bead in the glazing
space does not impair sealing of glazing materials. Remove excess sealant
which is forced on to face of frame assembly.
(xiii)
Where frame members are lapped, the faces exposed to the weather shall be in
full, tight contact. Allow minimal clearance for snap-on components.
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4.7.3
4.7.3
(xiv)
Where mullions are extended and connected to the underside of the building
structure above, provide slotted connections to accommodate structure
deflection.
(xv)
Fabricate corner pieces and filler pieces of thick plate aluminium to the
profiles shown, by welding prior to application of finish.
(xvi)
Provide concealed clips for fastening plate assemblies in place.
Firestops:
(i)
Supply and install firestopping material at all suspended slabs, between edges
of slabs and exterior cladding. Place firestop material under permanent 25%
compression. Use impaling clips or metal trims to hold insulation in place.
(ii)
Install fire/smoke barrier sealant continuous to top of firestopping. Make

upper surface flush with floor.
Finishes
(i)
Steel at building interior and steel which is not exposed to exterior

environmental conditions shall be primed with primer.
(ii)
Steel at building exterior or in exterior assemblies shall be galvanised.
(iii)
Paint all welded, galvanised items where galvanising has been removed for
welding. Make good corrosion protection using two coats of touch-up primer for
galvanised steel. Make good corrosion protection on prime painted steel using
the same primer.
(iv)
All exposed aluminium shall have Fluropolymer thermal setting UV blocked.

Duranar XL (manufactured by PPG Ltd) or other equal approved and be
applied by an applicator approved by the coating manufacturer and under the
coating manufacturers direction. Pre-treat aluminium to obtain primer bond,
apply prime coat, finish coat and clear protective coat. Colours and sheen
shall be uniform with no variations detectable by the naked eye at a 3 metre
distance.
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(v)
4.7.4
Exposed fastenings if occurring shall be finished and coloured to match the

finish and colour of the material in which they appear. The finish provided
shall be permanent and durable.
Preparation
(i)
Take field measurements from actual structure and verify prior to

commencement of fabrication.
(ii)
Remove dust and other loose materials from openings.
4.8
Installation
4.8.1
General
(i)
Erect all work plumb and true and in proper alignment and relationship to
established lines and grades and to specified tolerances.
(ii)
All devices for anchoring the frame assemblies to the building structure shall
have sufficient adjustment to permit correct accurate alignment.
After
alignment, rivet, weld or positively lock anchorage devices to prevent
movement other than those designed for expansion and contraction.
(iii)
Site fixing to the inside structure shall be of an approved material. Perform

drilling of concrete as required to install fixings. Contractor to bear the cost
of repair satisfactory to the Engineer of concrete chipped by drilling or fixing
operations.
(iv)
Supply and install aluminium parapets, copings, flashings, cap flashings and
base.
(v)
Provide continuity of thermal and air barriers with adjacent thermal and
air/vapour barrier systems by:a)
Gun application of a continuous 6 mm bead of sealant to all joints and

barrier junctions with adjacent construction. Liberally butter all screw
fastenings with sealant.
b)
Apply insulation to the building interior side (metal on warm side) of

the metal air barriers erected. Cut insulation slightly over-size as
required to ensure tight butt joints.
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(vi)
Ensure airtight seal at air barrier penetrations for mechanical and electrical
services.
4.8.2 Sealants:
(i)
Make surfaces to be sealed, sound, dry, free from dirt, water, frost, loose
scale, corrosion, asphalt, paints or other contaminants which may adversely
affect the performance of the sealing materials.
(ii)
Perform cleaning to the extent required to achieve acceptable joint surfaces.
(iii)
Joints and spaces which are to receive sealing compound shall in no case be
less than 6 mm; nor shall they be more than 15 mm wide.
(iv)
Fill joints to within 5 mm of the surface with backup material.
(v)
Mask areas adjacent to the joints as required. Prevent contamination of

adjacent surfaces. Remove masking promptly after the joint has been
completed.
(vi)
Perform priming immediately before installation of sealant.
(vii)
Before any sealing is commenced, test the materials for indications of staining
or poor adhesion.
(viii)
Use sufficient pressure to fill all voids and joints. Sealants shall bond to all
sides of joint except where backup material is used, sealant shall bond to both
sides of joint and shall not adhere to the backup materials.
(ix)
Sealant installations shall be a full bead free from air pockets and embedded
impurities and having smooth surfaces, free from ridges, wrinkles, sags, and
imbedded impurities.
(x)
After joints have been completely filled, tool them neatly to a slight concave
profile.
(xi)
Cover all fasteners penetrating the air seal with sealant.
(xii)
Seal all gasketing at sills.

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4.8.3
4.8.4
(xiii)
Immediately clean adjacent surfaces which have been soiled and leave work
in a neat, clean condition. Remove excess materials and droppings using
recommended cleaners and solvents.
(xiv)
The fact that the Drawings do not show all locations to be sealed does not
limit the responsibility of the Contractor to seal all locations required to create
and secure a continuous enclosure.
Adjustments:
(i)
Upon Completion of the project and just prior to the handing over of the
building to the Client or at a time as directed, inspect and make good
installation.
(ii)
Adjust all operating devices, windows and doors to proper and trouble free
operating condition.
(iii)
Inspect all units for damage and correct same immediately.
Cleaning:
(i)
5.0
When the building is completed, clean metal and glass thoroughly.
PROTECTION
(i)
Protect all work from damage.
(ii)
Do not apply snap-on caps and spandrels until the building is closed in, until
the roofing is installed and until no possibility of alkaline substances can be
washed from the building and building structure onto the work.
(iii)
Should work be prefabricated into assembled units complete with glazing,

spandrel panels, insulated metal air barrier, in the factory and installed on the
building as complete units, precautions shall be taken to protect units and
glass from damage due to alkaline bearing water.
(iv)
Clean glass as necessary to prevent etching due to alkaline bearing water.
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6.0
WARRANTIES
6.0.1
Submit written warranty in a form acceptable to the client, jointly signed by the
Contractor and the Subcontractor for the Work, warranting against defective
materials, products, workmanship, watertightness, design, performance and glass
breakage, due to defective engineering fabrication and installation for a five year
period following date of Substantial Completion of the work.
6.0.2
Five year warranty shall include but not necessarily be limited to :

(i)
Completely watertight and air tight work within specified tolerances.
(ii)
Structural soundness and freedom from distortion, and within elastic

deflection limits specified.
(iii)
Glass or snap-on mullion covers will not break or pop from frames due to
design wind loads, expansion or contraction movements, or structural loading.
(vi)
Metal finish will not crack, peel, pit, corrode, or discolour.
(v)
All sealants and gaskets shall remain free from any deterioration, oxidation or
dislocation due to sunlight and weather conditions.
(vi)
Completed installation shall remain free from rattles, wind whistles, and noise
due to thermal and structural movements and wind pressure.
6.0.3
Warrant the seals on insulated glass units for ten years. Units shall be free from
condensation, fogging and obstruction of vision due to film on internal surfaces.
6.0.4
Warrant that painted coatings will be free from peeling, cracking, pitting, corroding,
or non-uniformity of colour, or gloss deterioration beyond manufacturers descriptive
standards.
6.0.5
Warrant for five years, the metallic oxide coating on light and heat reflecting glass.
Coating shall be free of oxidation, delamination, colour change, streaks,
disintegration and:
(i)
Scratches, except those of maximum 75 mm in length and visible at a distance

of maximum 3000 mm.
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(ii)
Pinholes except those up to 1.2 mm in size. Large clusters of pinholes, as

assessed by the Engineer are not permitted.
6.0.6
Provide Data Books, Operation and Maintenance Manuals and Preventative

Maintenance Schedules for work of this section and as specified.
7.0
ROOF GUARANTEE:
In the case of Section N Works and materials which form part of a roof structure
covering, or waterproofing system the following shall apply.
(i)
The Contractor shall provide the Engineer with an unconditional guarantee in

favour of the Client against failure of the roof waterproofing system whether
caused by defective materials or workmanship.
(ii)
The guarantee shall be valid for a period of (10) ten years commencing at
completion of the Period of Maintenance as defined in Clause 49 of the
Conditions of Contract.
(See also paragraph 7.0 of section F)
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SECTION P
ROADWORKS, BLOCK PAVING & KERBS
1.0
GENERAL
1.1
Scope
The details shown on the Drawings giving the names and thicknesses of the various
layers which make up the pavements.
1.2
Underground Services to be Completed

Drains, sewers, gullies, manholes, cable ducts and other such work shall be
completed, inspected and approved by the Engineer's Representative before paving is
laid.
1.3
Drainage of Construction Surfaces

All pavement construction surfaces shall be kept in such a condition that they will
drain quickly and effectively at all times.
1.4
Contamination
All construction surfaces shall be kept clean of mud, slurry, deleterious matter and all
other contaminants. If the construction becomes contaminated, the Contractor shall
make good by cleaning it to the satisfaction of the Engineer and, if cleaning is
impracticable by removing that part of the construction and replacing it to
Specification.
1.5
Traffic on Construction Surfaces

(i)
Traffic on construction surfaces shall be restricted to that required for

compaction and for overlying construction.
(ii)
The equipment used shall be suitable in relation to the material, condition and
thickness of the courses it traverses so that damage is not caused to the
subgrade or pavement construction.
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1.6
Excavation
Refer to Section C.
1.7
Filling
Refer to Section C.
2.0
FORMATION & SUB-GRADE
2.1
Formation
The formation shall be compacted as specified in Section C. Before offering up the
formation for inspection by the Engineer the Contractor shall prepare formation as
follows:(i)
trim to level within the tolerances specified in Table 1 on page P/41.
(ii)
make up to level and test in accordance with Section C and as specified in the
following clause.
Formation which is outside the lower tolerance in level shall be corrected by

excavating and refilling with suitable granular material compacted in layers of not
more than 200mm. Alternatively the Contractor shall be permitted to increase the
thickness of the first pavement layer to suit.
The Contractor shall remain responsible for maintaining the completed formation.
Formation which is allowed to deteriorate by effects of rain or traffic or other cause
prior to laying of sub-base shall be subject to re-test as described above and making
good as required, all at the Contractor's expense.
2.2
Weak Sub-Grade and Replacement

Treatment of weak areas shall only be carried out under the direction of the Engineer
who shall be notified by the Contractor immediately such weak areas are encountered.
Weak areas of subgrade shall be excavated and taken off site and replaced with
suitable material placed and compacted in accordance with Section C. The depth of
replacement shall be determined by the Engineer.
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Following replacement of weak subgrade the formation shall be prepared for

inspection and re-tested as described in the preceding clauses.
3.0
SUB-BASE
If the subgrade cannot achieve the required CBR value (30% at 95% MDD), a
sub-base layer shall be provided. The thickness of the layer shall be as shown in the
Drawings.
Unless stated otherwise, testing of subgrade, sub-base and roadbase materials and
workmanship shall be carried out in accordance with BS 812 and BS 1377, using
4.5kg rammer methods where applicable. In-situ CBR testing shall be in accordance
with ASTM D 4429-84.
Sub-base shall consist of approved granular material compacted to 95% of the

laboratory maximum dry density. The CBR value shall not be less than 30%.
Sub-base material shall be crushed rock or similar hard material or naturally occurring
gravel. The material shall comply with the following grading:
BS sieve size
Percentage by weight
mm
passing square mesh
75
100
37.5
8 to 100
10
40 to 70
25 to 45
0.600
8 to 22
0.075
0 to 10
The total sulphate content (as SO3) shall not exceed 2% by weight. The total chloride
content (as NaCl) shall not exceed 2% by weight. The material passing a 0.600mm
sieve shall have a plasticity index not exceeding 6.
The Laboratory CBR value shall be a minimum of 30% at 95% of the laboratory
maximum dry density (or higher approved density) after soaking for 96 hours.
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Sub-base material shall be spread evenly and compacted in layers not exceeding
150 mm compacted thickness to obtain a well bound surface finish. Loose or
segregated areas shall be made good by addition of fines or by removal and
replacement of the material as directed.
The sub-base shall be laid to the levels shown on the Drawings within a tolerance of +20
mm.
4.0
ROADBASE
4.1
Aggregate Roadbase
4.1.1
Aggregate material for roadbase shall consist of hard, durable screened gravel or
crushed stone and shall be free from organic matter or other deleterious substances.
Gradation of roadbase material shall conform to any of the following gradings:
Sieve Size
50.8 mm
38.1 mm
25.4 mm
19.1 mm
12.7 mm
9.52 mm
4.76 mm
A
100
75 - 100
60 - 90
45 - 80
40 - 70
30 65*
Percentage Passing
B
100
70 - 100
55 - 85
50 - 80
40 - 70
30 60*
C
100
70 - 100
50 - 80
35 65*
A
20 - 40
8 - 20
5 - 10
Percentage Passing
B
20 - 50
10 - 30
5 - 15
C
25 - 50
15 - 30
5 - 15
Sieve Size
2.00 mm
0.42 mm
0.074 mm
*
The grading of test samples taken from the Works is to be such that the
percentage passing the 4.76mm sieve shall not vary by more than 7% from the
sample originally submitted and approved.
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4.1.2
Aggregate for road base shall be delivered to the road bed as uniform mixtures and
shall be spread in layers or windrows. Segregation shall be avoided and the base shall be
free from pockets of coarse or fine materials.
4.1.3
The road base shall be spread by finisher and/or grader, watered, shaped and
compacted to the required grade and cross-section. The finished surfaces of the
roadbase shall not vary at any point more than 1 cm above or below the grade
established by the Engineer. The aggregate base shall be compacted to not less than
98% of the maximum density determined in accordance with the latest AASHTO T180 or ASTM D1557 and shall have a CBR value of not less than 80%.
4.1.4
Particle size analysis of soils for sieve analysis of fine and coarse aggregate shall be
carried out in accordance with AASHTO T-88 and T-27. The road base shall be
maintained in a condition satisfactory to receive any subsequent base or surfacing
material. Aggregate road base which does not conform to the above requirements
shall be reshaped or reworked, watered and thoroughly recompacted to conform to the
specified requirements.
4.1.5
The compaction procedure and plant shall be proven by trials at the commencement
of the works to the satisfaction of the Engineer. Compaction trials shall be carried out at
varying moisture contents. The weights, types and number of passes of compaction plant
shall also be varied to determine the optimum compaction effort.
4.1.6
Where directed by the Engineer a sieve analysis shall be carried out on the material
recovered from 5 consecutive field density tests. Where this sieve analysis shows an
oversize material content of 10% or greater, the area of construction will be removed
and the source of the material rejected until further notice.
Where considered necessary other areas of work which were carried out using
material from the same source shall be tested in a similar manner.
4.1.7
Frequency of test shall be one set of test per 500m.
4.2
Lean Concrete Roadbase
4.2.1
Lean concrete for roadbase shall be made from crushed rock or natural aggregate with
an aggregate : cement ratio of not greater than 18:1 by weight.
The aggregate shall consist of either coarse and fine aggregate batched separately or an
all-in aggregate. The materials shall comply with the requirements of Section D and
this Section.
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The nominal maximum size of the coarse aggregates shall be 40mm or 20mm. The
grading of the resulting aggregate mix shall lie within the relevant limits for all-in
aggregate in Table 6 of BS 882. In addition, the aggregate passing the 5mm sieve
shall be within the limits for fine aggregate in Table 5 of BS 882.
In all cases the resulting material must be able to be constructed with the intended
equipment and its approval shall be subject to the results of a trial as specified in this
Section.
4.2.2
Roadbase material shall be mixed mechanically in a machine capable of producing

mixes which contain the correct proportions of constituent materials. The Contractor
shall provide means by which the Engineer can check the measuring and
proportioning mechanisms of the mixer.
4.2.3
Transport vehicles carrying plant mixed material shall have a capacity suited to the
output of the mixing plant and the site conditions and be capable of discharging
cleanly. Material when mixed shall be removed at once from the mixer, transported
directly to the point where it is to be laid and protected from the weather both during
transit from the mixer to the laying site and whilst awaiting tipping. Care shall be
taken to prevent segregation during transporting.
4.2.4
Five random samples shall be taken at the point of placing from different deliveries,
for each 1,000 m or part thereof laid each day including trial areas. From each
sample a pair of 150 mm test cubes shall be prepared, for testing at 7 days and 28
days.
The making, curing and testing of all cubes shall be in accordance with BS 1881
except that the cubes may be compacted with an electric or pneumatic hammer. The
hammer foot shall be square or rectangular with an area between 10,000 mm and
15,000 mm. The cubes shall be compacted in 3 layers, each layer being compacted
until refusal.
4.2.5
VOLUME II A
The 28 day crushing strengths of sets of three 150 mm cubes shall be such that not
more than one in any five consecutive sets of averages is not less than 10 N/mm nor
greater than 20 N/mm. The Engineer shall require alterations of the mix if:(i)
the overall average of five consecutive sets of 3 cubes falls outside the range
of 11 - 20.5 N/mm, or
(ii)
the average range of 5 consecutive sets of 3 cubes exceeds 50% of the overall
range of the 15 cubes.
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In addition the average 7 day crushing strength of sets of 3 cubes must lie within the
range 8 - 14 N/mm. Where more than one set in five consecutive sets falls outside this
range the mix will be subject to alteration.
4.2.7
All roadbase material shall be placed and spread evenly, without segregation and
without varying degrees of pre-compaction. Spreading shall be undertaken either
concurrently with placing or without delay. The material shall be spread using a
spreaderbox approved by the Engineer and which levels off the material to an even
depth.
The maximum thickness of any layer shall be 300 mm subject to the Contractor
demonstrating by trial that adequate compaction can be achieved. Courses thicker
than 300 mm shall be made up from two or more layers of equal thickness. After
compaction the total thickness shall be as specified.
4.2.8
Unless the material is compacted against forms or haunches, the edge of all material
which has been laid for more than one hour shall be cut back to a square, vertical face
over the full layer depth before additional material is laid alongside.
4.2.9
Compaction shall be carried out until the surface is closed and the specified density
has been achieved.
The maximum period of time between mixing of the materials and final compaction
shall be 2 hours. Where required by the Engineer compaction shall be carried out
both longitudinally and transversely and the surface finished by rolling without
vibration.
4.2.10 Five determinations shall be made in accordance with BS 1377 of the dry density of
the compacted material for each 1,000 m or part thereof laid each day including trial
areas. Testing shall be such that the results are representative of the full depth of the
material placed under this Contract. Measurements shall be made between 4 hours
and 24 hours following the completion of compaction.
The average dry density obtained from sets of 5 tests shall not be less than 95% of the
theoretical dry density with zero air content calculated in accordance with BS 1377.
Failure of more than one set of five consecutive results will result in the Contractor
having to remove and replace the affected area.
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4.2.11 All completed roadbases shall have a close even finish with surface tolerances as
specified. High spots shall be ground off to achieve an even surface.
4.2.12 All layers of roadbase material not covered within 2 hours either by another layer of
such material, or by another pavement course, shall immediately on completion of
compaction, be cured for a period which shall be not less than 7 days unless the
Engineer agrees otherwise. Curing of the surface of the layers shall be achieved by
covering, until the next pavement layer is laid, with impermeable plastic sheeting,
adequately secured from being blown off the surface and with joints overlapped at
least 300 mm and set to prohibit egress of moisture. The final layer shall be cured
for a minimum period of 7 days before commencing the next layer of construction.
4.3
Wet Mix Macadam Roadbase
4.3.1
Coarse and fine aggregate shall consist of crushed rock (each particle shall have a
minimum of one crushed face - DM CQC & RS Test Methods DM 301) and shall
consist of naturally occurring material. The aggregate shall be graded as follows:-
BS 410
% by mass passing
Sieve Size
50 mm
100 1000
37.5 mm
985 - 100
20 mm
60 - 80
10 mm
40 - 60
5 mm
25 - 40
2.6 mm
15 - 30
600 micron
5 - 18
75 micron
2-7
The particle size shall be determined in accordance with the requirements of BS 1377
Test 7A.
The grading may be adjusted as required or as directed by the Engineer within the
above limits to ensure the mix has adequate binding properties.
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Physical properties of wet mix roadbase material shall not exceed the following
values:Liquid limit
Linear shrinkage
Plasticity index
Aggregate crushing value
Water absorption
Water soluble salts
Sodium Sulphate (Soundness loss)
(BS1377 Test 2)
(BS1377 Test 5)
(BS1377 Test 4)
(BS812)
(BS812)
(BS812 & BS 1377)
(AASHTO T104)
25%
3%
6%
25%
2%
1%
12%
Flakiness Index
Elongation Index
Loss Angeles (Abrasion Loss)
(BS812)
(BS812)
(AASHTO T96)
30%
30%
40%
The sand equivalent shall not be less than 45
(AASHTO T-176)
The moisture content of the wet-mix macadam roadbase at the time of compaction
shall be the optimum 0.5%. Water required to achieve this moisture content shall be
added at the mixing plant.
4.3.2
Vehicles carrying plant mixed materials shall have a capacity suited to the output of
the mixing plant and the site conditions and be capable of discharging cleanly.
Material when mixed shall be protected from the weather at all times and transported
without delay to the laying site.
Maximum distance between the mixing plant and the work site shall be 15 km.
The material shall be placed and spread evenly using a paving machine or spreader
box operated with a mechanism which levels off the material at an even depth and
without delay. Except where otherwise specified, the material shall be laid and
compacted in layers of maximum thickness of 150 mm.
Before placing the next construction layer or applying prime coat, the wet-mix
roadbase shall be mechanically swept then cleaned with compressed air to remove
loose material. As soon as possible after cleaning of the surface, the wet-mix
roadbase shall be sealed by the application of a prime coat as specified. Should the
surface of the material be allowed to dry out before the seal is applied, it shall be
lightly watered and recompacted immediately prior to spraying with prime coat.
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Should the full depth of layer be allowed to dry out, it shall be removed and replaced,
at the Contractor's expense, with fresh material.
Watering
not be permitted.
4.3.4
and
remixing
in
place
will
The material shall be compacted to a field density equal to or greater than 100% of the
maximum dry density obtained when tested in accordance with AASHTO T-180
Method D and shall have a minimum CBR of 80% at 100% compaction after 96 hours
soaking.
Compaction shall be completed as soon as possible after the material has been spread.
Special care shall be taken to obtain full compaction in the vicinity of both
longitudinal and transverse joints.
The surface of any layer of material shall on completion of compaction be well
closed, free from movement under compaction plant and free from compaction
planes, ridges, cracks or loose material. All loose, segregated or otherwise defective
areas shall be made good to the full thickness of layer and recompacted.
4.3.5
When directed by the Engineer, prior to the commencement of the Wet-mix Macadam
Roadbase operations, the Contractor shall construct trial lengths, not to exceed 1000
sq.m. The materials used in the trials shall be those approved for use as Wet-mix
Macadam Roadbase and the equipment used shall be that according to the
Contractor's approved detailed programme of work.
Trial areas may not form part of the permanent works but may be permitted to form
some areas of temporary works.
The object of these trials is to determine the adequacy of the Contractor's equipment, the
loose depth measurements necessary to result in the specified compacted layer
depths, the field moisture content, and the relationship between the number of
compaction passes and the resulting density of the material.
The Contractor may proceed with the Wet-mix Macadam Roadbase Work only after the
methods and procedures established in the compaction trials have been approved by the
Engineer.
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4.3.6
Immediately prior to the placing of the first layer of the next pavement course on to
the Wet-mix base course the final layer of Wet-mix base course shall be at the
specified density and to the required grade and section. In order to maintain these
requirements while placing the next course it may be necessary to water and reshape the
surfaceis work shall be at the Contractor's expense.
The true line and level of any point on the surface of the base shall not be greater than 10
mm above or below that shown on the Drawings. In addition when tested with a three
metre straight edge the variations of the surface from the testing edge of the straight
edge shall at no point exceed 6 mm. Areas requiring rectification shall be scarified to
a minimum depth of 80 mm, reshaped with material added or removed as necessary and
recompacted all to specification. The area treated shall be not less than 30 m long by 2 m
wide or as determined by the Engineer.
4.3.7
One test per 1,000 Cu.m. shall be carried out for Grading Plasticity Index, Sand
Equivalent C.B.R. and Loss by Abrasion. Two tests per 500 sq.m. shall be carried out for
compaction and moisture content. Field Density tests shall be carried out at a
frequency of 2 tests per 500 sq.m. of each layer.
The surface of any layer of material shall on completion of compaction be well closed
from movement under compaction plant, and free from compaction planes, ridges,
cracks or loose material. All loose, segregated or otherwise defective areas shall be
made good to the full thickness of layer and re-compacted.
5.0
BITUMINOUS PAVEMENTS
5.1
BITUMEN STORAGE AND HEATING
5.1.1
Bitumen Storage
For storage of bitumen, the temperature shall be kept as low as possible, consistent
with reasonable pumpability, and the bitumen shall not be stored at temperatures
exceeding approximately 60C above softening point.
The bitumen storage area and the heating station shall be kept neat and tidy and the
access road shall be bituminised. The whole area shall be cleared of vegetation and the
drums stacked on their sides only in small quantities with gaps between each stack to
reduce the fire risk.
Bitumen distributors and boilers shall at all times be kept clean.
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The flushing from boilers and distributors shall not be poured over the area
indiscriminately, but shall be led by drain channels to disposal pits, care being taken that
none finds its way into stormwater ditches or water courses.
All boilers, pre-heating pits, tools and plant shall be kept clean. When filling the
bitumen distributors from the boiler or bulk containers, the bitumen shall be passed
through a filter of fine wire gauze.
On completion of the Works, the disposal pits and drainage channels shall be filled in and
the Site left clean and tidy.
5.1.2
Heating of Bitumen
Bitumen shall be heated in approved boilers or bulk storage containers equipped with
adequate and accurate thermometers, to the temperatures within the limits given in the
table below or the maximum temperature as determined by Viscosity - Temperature
relationships when measured according to ASTM D2170.
Material
Straight-run bitumen
60/70 penetration
MC 30 or MC 70
RC 250
Min
140
Temperature (deg C)
Max
Correction Factor
177
0.907
35
40
65
75
0.978
0.958
No bitumen shall be heated over the maximum temperature given above, and any that is
accidentally over-heated shall be removed from the Site and disposed of by the
Contractor at his own expense.
No bitumen shall be heated in a boiler when the thermometer is broken or inaccurate.
The volume correction factor given is for reducing the volume of bitumen heated in
the boiler or distributor at mean spraying temperature to the standard temperature of
15.6C as used for specification, purchasing and payment purposes.
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5.1.3
Safety Precautions
The Contractor shall take every reasonable precaution to avoid fire or health hazards.
He should always ensure that :-
5.2
(a)
Bitumen is heated only to the temperature required for the particular

application.
(b)
Hot bitumen never comes into contact with water.
(c)
Suitable protective clothing and gloves are used by workmen when using
bitumen on the Works.
PRIME COAT
The surface of a granular layer upon which an asphaltic layer is to be provided shall be
first brushed completely free from all loose articles and dust by a mechanical
broom so as to expose a closely knit, compact mosaic. A light sprinkling of water
may be required to lay dust prior to priming.
The granular layer shall be sealed with a prime coat of MC 30 or MC 70 cutback
bitumen applied at a rate of approximately 1.0 Kg/sq.m. The rate of application may be
varied by the Engineer and only the actual quantity ordered shall be paid for. The area
to be primed shall extend 150 mm outside the area to be covered by the asphaltic base
course or up to the kerbs.
The prime coat may only be applied after the Engineer has approved the layer. The
asphalt course shall not be laid less than 24 hours after the completion of the prime
coat, and, if the prime coat contains solvents, not until the prime coat is dry.
If the prime coat becomes contaminated or for some reason loses its tacking
properties, a tack coat will be ordered by the Engineer at the Contractor's expense.
5.2.1
Protection of Other Works

During spraying, all kerbs, road furniture, culvert headwalls and the like which are
liable to be disfigured by splashing of bitumen shall be protected, and any such
feature which is accidentally marred by bitumen shall be cleaned off with a suitable
solvent or otherwise made good at the Contractor's expense.
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5.2.2
Curing Prime Coat

The prime coat shall be allowed to dry out before anything is allowed to pass over the
surface. Where the primer puddles, the surplus shall be blinded with sand or quarry
dust until the free bitumen is absorbed.
Twenty-four hours after priming, the Engineer may permit pneumatic-tyred vehicles
to run over it, provided the surface is lightly sanded or dusted where necessary to
prevent adhesion of the bitumen to the tyres. Such use of the surface is to be
discouraged and may only be undertaken on the written permission of the Engineer.
5.2.3
Repairs
5.3
Any repairing or other reinstatement that becomes necessary as a result of the

Contractor allowing traffic to run over the primed surface, shall be carried out at the
Contractor's own expense.
Tack Coat
A tack coat shall be applied between successive asphaltic layers where ordered by the
Engineer.
The surface to receive a tack coat shall be swept clean of all loose particles and dust
with a mechanical broom immediately prior to the application.
Tack coat shall comprise RC 250 cut back bitumen applied at the rate of between 0.3
and 0.5 kg/sq.m. of residual bitumen, or SSIH diluted emulsion at a rate between 0.25 to
0.35 kg/sq.m.
5.4
AGGREGATE
5.4.1
Aggregate Pre-Screening Requirement

Crushed rock or gravel for use as coarse or fine aggregate shall consist of the product
obtained by crushing material that has first been screened in such a manner that not
less than 90% of the material to be crushed is retained on a standard AASHTO 9.52
mm sieve.
5.4.2
Coarse Aggregate
Coarse aggregate is that portion of the mineral aggregates retained on BS Sieve
3.35 mm. Where an aggregate is produced by blending, the requirements given below
shall be satisfied by each fraction of the mix.
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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 fractions in proper proportions, the resultant mixture
will meet the required gradation. Sampling of coarse aggregate shall be in accordance
with AASHTO T-2. Sieve analysis shall be in accordance with AASHTO T-27 and
AASHTO T-11.
Coarse aggregate shall be clean and free from organic matter, clay, cemented particles
and other extraneous or detrimental material. The degree of crushing shall be such
that all material retained on the ASTM No. 8 Sieve has at least one fractured face and
at least 85% of the material retained on the same sieve shall have all faces crushed.
Coarse aggregate shall not exceed the following test values:
Wearing Course
Base Course
Aggregate Crushing Value
20%
25%
Flakiness Index
25%
30%
Elongation Index
25%
30%
Water Absorption
2.0%
2.0%
Coarse aggregate shall have a maximum Sodium Sulphate or Magnesium Sulphate

Soundness Loss of 12% when tested in accordance with AASHTO T-104. For
wearing course the figure shall be 8%.
The abrasion loss AASHTO T-96 for coarse aggregate used in asphalt mixtures shall
not exceed 25% except that a maximum abrasion loss of 35% will be allowed for
asphaltic road base and base courses when the surface of these courses is not to be
subjected to traffic.
5.4.3
Fine Aggregate
Fine aggregate is that portion of the mineral aggregate passing BS Sieve 3.35mm.
Fine aggregate shall consist of crushed sandstone or gravel or a combination thereof. If
produced by blending the requirements given below shall be satisfied by each
fraction of the mix. Crushed sand 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 AASHTO T-2.
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Sieve analysis shall be in accordance with AASHTO T-27 and AASHTO T-11.
Fine aggregate shall be clean and free from organic matter, clay, cemented particles
and other extraneous or detrimental material preventing adhesion of bitumen with the
aggregates. The content of acid soluble chlorides and sulphates shall not exceed
0.06% and 0.4% by weight of aggregate respectively.
Fine aggregate shall have a maximum Sodium Sulphate or Magnesium Sulphate
Soundness of 15% when tested in accordance with AASHTO T-104.
The sand equivalent for fine aggregate shall be minimum of 45% when tested in
accordance with AASHTO T-176.
5.4.3
Aggregate Storage
Aggregates shall be handled and stored so as to maintain their quality. Stockpiles
shall be placed only on cleared and compacted ground and spaced so that different
sizes are adequately separated.
Stockpiles shall be low and rounded to avoid
segregation and high stockpiles may be constructed only with terraces at vertical
intervals not exceeding 3 metres so as to avoid continuous slopes.
5.5
MINERAL FILLER
Filler is defined as the fraction of the total aggregates and "added filler' which passes the
75 micron BS sieve.
For road base the filler may comprise either rock dust or a combination of rock dust
and mineral filler. For wearing course, the rock dust filler shall not exceed 2% by
mass of the total aggregate including filler. The remainder shall be mineral filler.
The proportions of rock dust and mineral filler shall not be varied, once the design
mix has been approved, without the consent of the Engineer.
Rock dust is defined as fines originating from the crushing of gravel or rock.
Added filler is material added to the mix to comply with the above requirements.
It shall be added at the mixing drum and shall fulfill the following requirements:(a)
It shall consist of Ordinary Portland Cement to BS 12 or milled limestone.
(b)
It shall be thoroughly dry and free from lumps.

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(c)
It shall have the following grading when tested in accordance with AASHTO
T11 and T27 with that part retained on a 75 micron sieve regarded as Fine
Aggregate:
BS Sieve Size
600 micron
300 micron
150 micron
75 micron
U.S. Sieve Size

No. 30
No. 50
No. 100
No. 200
Percentage by Weight Passing

100
95-100
90-100
70-100
All filler shall have a bulk density in toluene of not less than 0.9 g/ml measured in
Filler shall be stored in silos with a capacity at least equal to one days requirements.
5.6
BITUMINOUS BINDER
Bitumen shall be 60-70 penetration, tested in accordance with the appropriate
AASHTO or ASTM standard method, and shall conform with the following
requirements:
Test AASHTO
Limits
Min
60
47
232
54%
99.0
100 cm
50 cm
Penetration at 25C, 100g, 5 sec (0.1mm)

Softening Point, Ring and Ball (C)
Flash Point (C)
Loss on heating 163C, 5 hr (% weight)
Penetration of residue from rolling thin film
Solubility in Trichloroethylene
Spot Test (*)
Ductility at 25C, 50mm per min
Ductility of residue at 25C, 50mm per min
Max
70
56
0.8
Negative
-
Test Method
T49
ASTM D36
T48
T47
T179
T44
T102
T51
T51
* The standard test method may be modified to permit the use of a solvent distilled
from the crude oil from which the bitumen was produced in lieu of the standard
solvent, provided it conforms with all the physical requirements of the standard
solvent.
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5.7
DENSE BITUMEN MACADAM (DBM)
5.7.1
Dense Bitumen Macadam Gradings

The gradings of the combined aggregate and filler shall be a smooth curve within and
approximately parallel to the appropriate envelope limit as follows:Aggregate Gradation for Dense Bitumen Macadam Base Course
B.S. Test Sieve

mm
50
37.5
28
20
14
10
6.3
3.35
300 micron
75 micron
Aggregate, Crushed Rock or Gravel

Percentage by mass passing for finished thickness of base
course
65-80mm
50-60mm
53-45mm
100
95 - 100
100
70 - 94
90 - 100
100
71 - 95
95 - 100
56 76
58 - 82
65 -85
52 - 72
44 60
44 - 60
39 - 55
32 -46
32 - 46
32 - 46
7 -21
71 - 95
7 - 21
2 -8
58 - 82
2 -8
Aggregate Gradation for Dense Bitumen Macadam Base Course

B.S. Test Sieve
mm
28
20
14
10
6.3
3.35
1.18
0.075
VOLUME II A
Aggregate, Crushed Rock or Gravel

Percentage by mass passing for finished thickness of base
course
35-50mm
25-30mm
20mm
100
95 - 100
100
70 - 90
95 - 100
100
55 - 75
70 - 90
95 - 100
40 - 60
45 - 65
55 - 75
24 - 40
30 - 45
30 - 45
15 - 30
15 - 30
15 - 30
2-6
2-6
2-6
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If in the opinion of the Engineer the available aggregate is such that adherence to one or
all of the grading envelopes detailed in this clause means that the specified mix
properties cannot be satisfactorily obtained, then the Engineer shall issue revised
gradings to replace those given above.
5.7.2
Mix Requirements
The working mixes for base and wearing courses shall comply with the following
requirements from the Marshall Stability test ASTM D 1558, based on 75 blow
compacted specimens. For base course tests aggregate greater than 25mm shall be
replaced by an equivalent weight of materials of size 10-19mm.
Mix Requirements
Marshall Stability at 60C, 75 blows (KN)
Flow (mm)
Marshall Quotient (Stability/flow KN/mm)
at 60C
Immersion Comp. Specimen AASHTO T165 Index of retained strength (%)
Voids in total mix (%)
Voids filled with bitumen (%)
Voids in mineral aggregates (%)
Voids at refusal (%) (400 to 600 blows in
50 blow increments)
Bitumen Content (% of total mix)
Base Course
7.5 (min)
2-4
Wearing Course
10 (min)
2-4
2.7 (min)
3.2 (min)
70
7-11
50-65
14-20
70
6-9
50-65
14-20
3 min
3.2-4.0
3 min
3.5-4.1
Notes:
1.
Void properties shall be calculated by the method described in the Asphalt

Institute Manual MS-2, Chapter V. The voids filled with bitumen shall be
calculated from the following formula:
VFB
2.
(VMA - VIM) x 100%

VMA
The optimum bitumen content, determined by the Marshall Method, shall be

used when preparing specimens for the AASHTO T-165 test.
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3.
5.7.3
Loss of Marshall Stability by submerging specimens in water at 60C for

twenty four (24) hours as compared to stability measured after submersion in
water at 60C for twenty (20) minutes shall not exceed 25%.
Preparation of Design Mix

At least one month prior to commencing work on each layer and whenever changes
occur in the nature or source of the material the Contractor shall submit to the
Engineer full details of his proposed aggregate grading and bitumen content together
with details of the Marshall mix design showing compliance with all of the above
requirements. The Engineer will then either approve in writing or order changes to the
submitted laboratory design mix.
The approved laboratory design mix shall be confirmed by full scale plant trials using the
full range of bitumen contents. The approved trial mix shall be termed the Job
Standard Mix.
5.7.4
Working Mix
When the Job Standard Mix is approved by the Engineer, the Contractor shall
maintain the composition of the working mix within the following tolerances from the Job
Standard Mix:(i)
Bituminous binder:
Design mix + 0.1 to -0.2% by mass of total mix, except that the running
average shall not be below the Job Standard Mix bitumen content.
(ii)
Aggregate retained on 5.00mm B.S. Sieve:

Design mix plus or minus 4% by mass of total mix.
(iii)
Aggregate passing 5.00mm B.S. Sieve but retained on 75 micron B.S. Sieve:
Design mix plus or minus 3% by mass of total mix.
(iv)
Aggregate passing 75 micron B.S. Sieve:

Design mix plus or minus 1.0% by mass of total mix.
The application of the above tolerances shall not result in values falling outside those
specified elsewhere.
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5.7.5
Mixing and Laying

Asphalt shall be prepared in a central mixing plant conforming to the requirements of
ASTM designation D995. The mixing time shall not be less than that recommended by
the plant manufacturer, or much longer time as may be required to ensure adequate
coating of aggregate and uniform distribution of the bitumen through the mix. The mix
time is to be approved by the Engineer.
The plant shall not be operated at a higher capacity than that of the manufacturer's
rated capacity. The plant shall be such that the mineral filler shall be kept dry and be
separately stored and weighed.
It shall be possible to introduce the filler separately into the mixer if required by the
Engineer. All aggregate on leaving the drier shall have a moisture content of less than
1% by mass.
The mixing temperature of the bitumen shall be such that its kinematic viscosity is in
the range of 150 to 190 centistokes (ASTM D1559). At no time shall bitumen be
heated in excess of 170C and any that is so heated shall be removed from site at the
Contractor's expense. The temperature of the aggregate excluding the filler which
shall not be heated before entering the mixer shall be within the same range as for the
bitumen but at no time shall its temperature vary by more than 15C from that of the
bitumen.
The base and wearing courses shall be constructed in the layers or thickness shown on the
Drawings.
Any overlay course shall be constructed to an overall average thickness as indicated on
the Drawings.
Where overlays comprise two courses, the first course shall
comprise a layer of base course material and the second course shall comprise a layer of
wearing course material.
In areas where the surface of the existing road pavement is uneven or contains low
spots, the Engineer may instruct a regulating layer prior to final overlay operations.
The mixture shall be laid by an approved mechanical paver with automatic level
control and the temperature of the mix at the time of laying shall be between 140C and
170C.
The paver shall at all times be adjusted and operated to eliminate
segregation of the mix and to provide an even flow of mix across the full width of
screed. Where layers are laid in half width, the longitudinal joints shall be treated
similarly to the transverse joints, if so directed by the Engineer.
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The vibrating tamper or screed of the paver is to be arranged to apply the same degree of
compaction across the full width of paving. Tamper bars shall be checked
regularly for wear and adjustment in accordance with manufacturer's details.
The paver shall not be operated to lay material unless there is a sufficient supply of
asphalt either immediately available, or a definite assured supply, to complete the
laying of an absolute minimum length of 250 metres, where the laying of such
minimum length is feasible. If any doubt exists as to the maintenance of an assured
supply then sufficient stock in transporters must be immediately available to complete the
stated length in a continuous operation. The paver shall be operated to move up to the
trucks transporting the mix, which shall either be stationary or moving in the same
direction as the paver at the time of contact. When laying on gradients steeper than 4%,
the paver shall be operated in an up-hill direction.
Handlaying will only be permitted with the written permission of the Engineer for
particular areas which are impossible or impracticable to cover satisfactorily by
machine.
5.7.6
Compaction
Prior to commencing the permanent works a compaction trial shall be carried out to
determine a suitable rolling pattern and to confirm that the specified density can be
achieved.
The mix shall be rolled immediately after laying and before its temperature has fallen
below 120C by tandem and pneumatic rollers and such rolling shall be continued
only for so long as it is effective and does not have any detrimental effect. The above
minimum rolling temperatures may be lowered at the discretion of the Engineer.
Vibrating rollers may be used only with the written permission of the Engineer. This
permission may be withheld if vibration is observed to result in damage to stone in the
surface.
Rolling of the surface shall be continued until all roller marks are eliminated and a
density has been obtained of at least 98% of the density achieved on laboratory
samples made from the plant mix used for the layer concerned and conforming to the
design formula approved by the Engineer.
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Should the material fail to achieve the specified density, re-rolling may be allowed at
the discretion of the Engineer subject to the following conditions:
a.
The densification to be achieved shall be 1% or less.
b.
Only P.T.R.'s to be used weighing no greater than 18 tonnes.
c.
Re-rolling to take place within 72 hours from the time of the initial rolling.
d.
Re-rolling to take place at the time of the day when the surfacing has attained
the maximum natural temperature.
e.
Re-rolling to be applied for a maximum of 2 hours.
f.
Re-rolling to be carried out in the presence of the Resident Engineer.
g.
The section of the works in question to be cored for density determination

immediately after the completion of re-rolling.
h.
If, after re-testing, the density achieved is 0.5% or less below the specified
density, the material will be accepted in the works subject to a 20% reduction
to the Billed Rates. If, on the other hand, the density achieved is greater than
0.5% below the specified density, the material shall be removed and new
material to the correct specification shall be laid at the Contractor's expense.
5.7.7. Joints
Transverse joints in the wearing course shall be offset at least 500 mm from those in the
base course. Longitudinal joints shall be offset at least 150 mm.
At transverse joints between existing compacted asphalt and newly laid asphalt, the
edge of the existing asphalt along the joint shall be neatly cut away in straight lines
over a sufficient width to ensure that the full specified thickness of new asphalt is
placed. The exposed edge of the existing work shall be painted with hot bitumen
immediately in advance of placing of the new work.
Where the asphaltic layers are laid in half widths, the longitudinal joints between
them shall be treated similarly to the transverse joints.
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Longitudinal or transverse joints that are formed with existing old asphalt surfaces
shall be constructed in accordance with the details shown on the Drawings.
5.7.8
Testing
Routine testing shall be carried out as specified in Section A of the Specification.
Sampling of materials shall be carried out in accordance with ASTM D-75, ASTM D979, and AASHTO T-2.
5.7.9
Tolerances
The thickness of layers except overlays will be determined by average caliper
measurement of cores. Samples shall be obtained at intervals and locations
determined by the Engineer.
The running average of three consecutive compacted thicknesses of each layer shall
not be less than 95% of that specified, except that individual results may be less than the
nominal specified as follows:
For base course, if the thickness is inadequate but not less than 75% of the specified
thickness the deficient material may either be made up to the specified thickness in
wearing course material or may be removed and relaid to the correct thickness. If the
thickness laid is less than 75% of the specified thickness the layer shall be removed.
For wearing course, if the thickness is less but not less than 75% of the specified
thickness the layer may be retained but payment shall be made pro rata to the
thickness laid. If the thickness of wearing course laid is less than 75% of the
specified thickness the layer shall be removed.
For base course, the finished surface level shall nowhere be higher than required but
may be up to 10 mm lower. The surface shall be checked with a 4 metre straight edge
and there shall be no gaps between the asphalt base surface and the straight edge
exceeding 8 mm.
For the wearing course, the final surface shall be of a uniform texture and shall
conform to the required grade, camber, or crossfall, within a tolerance of plus or
minus 5 mm. The surface of the finished road shall be checked with a 4 metre straight
edge and there shall be no gaps between the finished surface and the straight edge
exceeding 4 mm.
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5.7.10 Weather Limitations
Bituminous pavement materials shall not be mixed when the moisture content of the
aggregate is such as to interfere with the uniformity of the mixing temperatures or
with continuous plant operations. It shall not be laid when the underlying layer is
damp or dusty.
5.7.11 Defects
Any defects in the work, caused by faulty workmanship, shall be corrected and made
good at the Contractor's expense. Care shall be taken when starting and stopping the
paver to prevent the formation of humps and depressions.
Skin patching of an area that has been rolled will not be permitted. Any mixture that
becomes mixed with foreign material, or is in any way defective, shall be removed
and replaced in fresh material and compacted as specified.
5.7.12 Transport of Mixed Asphalt
The bituminous material shall be transported from the mixing plant to the spreader in
trucks having tight, clean smooth beds and sides which have been treated to prevent
adhesion of the mixture to the truck bodies. A thin film of soapy water or lubricating
oil may be used to prevent adhesion, but gasoline, kerosene or other solvents shall not
be used for this purpose. Deliveries shall be made so that the spreading can be
completed during daylight, unless artificial lighting is approved by the Engineer and
is provided.
Hauling over fresh laid material will not be permitted.
5.7.13 Protection
After final rolling no vehicular traffic of any kind shall be permitted on the surfacing for
at least 24 hours or such time as may be ordered or agreed by the Engineer. No rollers
or other plant shall be left standing on completed work.
5.8
ASPHALTIC CONCRETE
The materials used in asphaltic concrete mixes shall meet the following requirements:
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5.8.1
Fine aggregate
Fine aggregate is that portion of the mineral aggregate passing U.S. Sieve No. 8. Fine
aggregate shall consist of crushed sand, stone or gravel or a combination thereof. The
source of natural fine aggregate is considered to be the pit from which it is excavated
and the source of crushed fine aggregate is considered as the crusher site at which it is
produced. Crushed sand 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 AASHTO T-2. Sieve analysis shall be in accordance with AASHTO
T-27 and AASHTO T-11.
Fine aggregate shall be clean and free from organic matter, clay, cemented particles and
other extraneous or detrimental materials preventing adhesion of bitumen with the
aggregates. The use of dune sand shall not be permitted. The content of water
soluble salts shall not exceed 1% by weight of aggregate.
Fine aggregates shall have a maximum Sodium Sulphate Soundness loss of 10% when
tested in accordance with AASHTO T-104. Soundness when tested by the
Magnesium Sulphate method shall not exceed a loss of 14%.
The sand equivalent for fine aggregate shall be minimum of 45% when tested in
accordance with AASHTO T-176.
5.8.2
Coarse Aggregate
Coarse aggregate is that portion of the mineral aggregates retained on U.S. Sieve
No. 8. 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 fractions 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 AASHTO T-2. Sieve
analysis shall be in accordance with AASHTO T-27 and AASHTO T-11.
Coarse aggregate shall be clean and free from organic matter, clay, cement particles
and other extraneous or detrimental material. The degree of crushing shall be such
that at least 100% by weight of the material retained on the ASTM No. 8. Sieve has at
least one fractured face and at least 85% of the material retained on the same sieve
shall have all faces crushed. The flakiness of each individual stockpile shall not
exceed 30% and the aggregate crushing value shall not exceed 25% and the
elongation index shall not exceed 30% when tested in accordance with BS 812.
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Coarse aggregate shall have a maximum Sodium Sulphate Soundness Loss of 10%
when tested in accordance with AASHTO T-104. Soundness when tested by the
Magnesium Sulphate method shall not exceed a loss of 14%. For surface or wearing
courses, the figures shall be 6% and 10% respectively.
The abrasion loss AASHTO T-96 for coarse aggregate used in asphalt mixtures shall
not exceed 25% except that a maximum abrasion loss of 35% will be allowed for
asphaltic roadbase and basecourses when the surface of these courses is not to be
subjected to traffic.
The combined gradation of the coarse and fine aggregate shall be within the limit
given below:-
Aggregate Gradation for Asphaltic Concrete

Sieve Sizes
percentage by weight passing
Wearing Courses or Basecourse
B.S.
U.S.
30mm
40mm(min)
37.5
1.5
25mm
1.0
100
20mm
0.75
80-100
12.5mm
0.50
100
67-87
10mm
3/8
80-100
60-80
5mm
No. 4
55-75
48-65
2.36mm
No. 8
35-50
35-50
1.18mm
No. 16
22-35
22-35
600mm
No. 30
12-23
12-23
300 um
No. 50
6-15
6-15
150 um
No. 100
2-8
2-8
75 um
No. 200
0-5
0-5
Asphalt Cement
3.8-5.0
3.6-4.6
5.8.3
Mineral Filler
When separately supplied, from external sources, mineral filler material shall consist of
finely ground materials of limestone or cement or such other material which the
Contractor can show to the Engineer's satisfaction to produce asphalt mixes of at least
equal quality. It shall be thoroughly dry, free from organic substances and clay and
shall meet the following gradation requirements.
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5.8.4
Gradation of Mineral
B.S. Sieve Size
U.S. Sieve Size Percentage by Weight Passing
600 um
No. 30
100
300 um
No. 50
95-100
150 um
No. 100
90-100
75 um
No. 200
70-100
Asphalt Cement
The asphalt cement shall be prepared by the refining of petroleum. It shall be uniform
in character and shall not foam when heated to 175C. Blending of asphalt cement
materials from different refineries will be permitted only with the written approval of
the Engineer.
The asphalt cement specified for use in the asphalt mixes shall be 60 - 70 Penetration
Grade in accordance with AASHTO M-20 and as shown below in the table which
follows:.
60/70 Penetration Grade Asphalt Cement
Method
Type of Test
AASHO
Penetration at 77F (25C) 100g. 5 sec
T43
ASTM
Test result
Min.
D5
Max
70
232
Flash Point, Cleveland Open Cup C (F)
T48
D32
(450)
Ductility, cm @ 77 F (25C)
T51
D113
100
Thin Film Oven Test _ in (3.2mm) 325F
T44
D2042
0.80
(162C) 5 hr
54
Loss on Heating %
50
Penetration of Residue % of original
99
Ductility of Residue @ 75 (25C) 5cm

per minute cm
Solubility in Trichloroethylene, %
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The Contractor shall provide a certificate from an independent laboratory giving full
details of the properties of the asphalt cement being used on the Contract at one
month intervals or at such time as the Engineer may direct. Shipping certificates from
the supplier will not be considered being from an independent laboratory.
5.8.5
Liquid Asphalt
Liquid asphalt for use in asphalt works shall be either MC-70 medium curing cut-back
asphalt in accordance with AASHTO M-82 or RC250 rapid curing cut-back asphalt
consisting of an asphalt base with suitable petroleum distillates. The produce shall be
free of water, showing no separation prior to use.
5.8.6
Design Criteria
The Marshall Method of Mix Design (AASHTO T-245) shall be used in designing the
asphaltic concrete mixes. All of the criteria given in the Table below, not stability
alone, shall be considered in designing and evaluating each type of mix. The
optimum bitumen content determined by the Marshall Method shall be used in
preparing specimens for the Immersion Compression (AASHTO T-165) test.
Table: Design Criteria for Asphalt Concrete Mixes
Description
Wearing Course
MIN
Marshall Specimens No. of Comp blows

each end of specimen
Min. stability (Kn)
Flow (mm)
Stability Flow Quotient (Kn/mm)
*Voids in Mix(Air Voids) %
Voids in Mineral Aggregate %
Voids filled with bitumen %
Filler Bitumen Ratio
Immersion Comp. Specimen ASHTO
T-165 Index of Retained Strength %
Voids in Marshall specimen at refusal%
75
14
2
4.5
5
15
55
1.4
70
2
Base Course
MAX
MIN
MAX
75
14
2
4.5
5
9
75
9
14
55
1.4
70
2
75
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5.8.7
Laboratory Design of Mixture

Laboratory asphaltic concrete mixtures shall be prepared in accordance with the
design criteria and procedures given in AASHTO T-245. Mixes shall be made not
only at but also above and below the binder contents shown.
Compacted samples bulk specific gravities shall be determined in accordance with
AASHTO T-166. Aggregate specific gravities shall be determined in accordance with
ASTM C-127/128 and T84 in order that Void contents of the samples may be
calculated. After immersion in a water bath thermostatically controlled at 60C for 45
minutes, the samples shall be placed in the machine for measurement of the Marshall
Stability and Flow Value.
Curves shall be plotted of Marshall Stability, Compacted Density Voids in Mineral
Aggregate and Flow Value all against binder contents. It may be necessary to adjust the
grading until the requirements are met.
Additional Marshall samples shall be compacted to refusal and the voids in the mix
determined. Should the voids in the mix be below the minimum of 2% then the
design procedure shall be repeated until compliance is achieved.
The following principles may be used for adjusting mixes:
1.
Voids in mix low and stability satisfactory - reduce bitumen content or filler
content, modify aggregate grading to give more voids.
2.
Voids in mix low and stability low - increase filler content, reduce bitumen
content, increase stone content and angularity of stone. The Contractor shall
compact Marshall cylinders to refusal and demonstrate that in this condition a
Voids in mix of 2% is present.
3.
Voids in mix satisfactory and stability low - increase filler content, reduce
bitumen content, increase stone content or angularity of stone.
4.
Voids in mix high and stability satisfactory - increase bitumen content or filler
content, modify grading to give less voids.
5.
Voids in mix high and stability low - increase filler content, increase bitumen
content, modify grading to give less voids.
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6.
5.8.8
The Contractor shall submit a proposed "Laboratory Design Mixture" together

with all applicable design data at least one month prior to the commencement
of asphalt works. The Engineer will take samples of the materials proposed
for use in order to check their quality and to check the proposed mix design or
go to a new mix design. The Engineer will then issue an approval of the
"Laboratory Design Mixture" which shall be used for agreeing the approved
"Job Standard mixture".
Job Standard Mixture and Allowable Tolerances

If the "Laboratory Design Mixture" after passing the mixing plant and being laid and
compacted with approved plant fails to produce a satisfactory trial area the grading
mixture proportions may be modified by agreement with the Engineer, as necessary
and within the requirements of the previous tables, to produce a mixture of
satisfactory workability and acceptable surface finish. After approval of the trial area by
the Engineer this mixture shall be designated the "Job Standard Mixture" and shall
thereafter be the approved mixture.
The contractor shall report in writing to the Engineer before general mixing or laying
proceeds, the combined aggregate grading (showing a single definite percentage
passing each sieve), the mixture proportions and the values for stability, flow, unit
weight and voids (mean values from four specimens) of the "Job Standard Mixture"
which shall not be changed thereafter without the Engineer's approval. The "Job
Standard Mixture" will also establish the mixing temperature and a compaction
reference density.
Approval by the Engineer of the "Job Standard Mixture' shall in no way relieve the
Contractor of his responsibilities and obligations stipulated in 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.
After the "Job Standard Mixture' formula has been established and approved, all
mixtures from the mixing plant shall be designated "Plant Mixtures" and shall
conform thereof within the following tolerances:
Retained on 5mm sieve
5%
Passing 5mm sieve and retained on 600um sieve
4%
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Passing 600um sieve and retained on 75um sieve
2%
Passing 75um sieve
1%
Asphalt cement
0.2%
Temperature of Mix when emptied from the mixer
10C
Throughout the Contract any variations outside these limits shall be investigated and
corrected. If for any reason for quality, grading or supply, the source of aggregates is
changed, or if at any time the cause of variations outside the permissible limits cannot be
corrected for reasons beyond the control of the Contractor, the Engineer may
request a new "Laboratory Design Mixture" or "Job Standard Mixture" depending on the
extent of change or variations.
5.8.9
Job Standard Mixture Density

The density of the compacted mixes shall be related to the "Job Standard Mixture
Density". The "Job Standard Mixture Density" shall be determined by making, from
samples of the approved "Job Standard Mixture" six standard Marshall specimens and
by determining the compacted 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 gms/cc shall be rejected and provided not more than two results are so
rejected, the mean of the remaining results shall be designated the "Job Standard
Mixture Density". Manufacture of the samples to determine the "Job Standard
Mixture Density" will be carried out in the presence of the Engineer. Where in the
opinion of the Engineer anomalies are appearing the test shall be repeated up to and
including a daily basis. For control of site compaction and acceptance of work the
greater of the densities obtained from the JSM samples and the Daily Marshall
samples shall apply.
5.8.10 Sampling and Testing

Samples of the mixed materials shall be taken from the first two hundred tonnes and
from every two hundred tonnes thereafter to determine aggregate grading and binder
content. Samples of loose asphaltic concrete mix shall be taken behind the paver
before compaction and shall be obtained in accordance with AASHTO T-168.
Samples of compacted asphaltic concrete shall be obtained by coring in accordance
with Method B of AASHTO T-230.
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Determination of bitumen content and extraction

gradation may be performed on either loose or compacted samples in accordance with
AASHTO T-164 and AASHTO T-30 except that the mass of mineral matter in the
total volume of the extract shall be determined by using a bitumenometer or other
equipment and procedures which give equally satisfactory results. The specific
gravity of compacted asphalt cores shall be measured in accordance with
AASHTO T-230.
If any of these tests show results which are not in accordance with approved Job
Standard Mix or within permissible variations, suitable adjustments shall immediately be
made to ensure compliance therewith. Samples of the mixed material shall be taken
at least twice a day or as determined by the Engineer for making Marshall
specimens to determine stability, flow and unit weight. For the taking of daily
Marshall specimens the mixing pugmill temperature shall be set to the mixing
temperature as specified in T-245 and the compaction temperature of the moulds shall
also be in accordance with T-245. Should for practical reasons the pugmill
temperature be different from that used in T-245 then the Engineer shall set the
compaction temperatures for the moulds to so compensate.
All approved sampling and testing required under the sub-clause of this Clause shall be
undertaken by the Engineer. Sampling and testing by the Engineer in no way
relieves the Contractor of his responsibility for regular quality control testing in order to
ensure compliance with the Specification.
After rolling to the specified compaction, if the compacted material in permanent
works yields air voids below 5% out of twenty samples this is to be considered an
early indication of a fault in the mix design. The mix shall be subsequently adjusted
or redesigned.
5.8.11 Weather Limitations
Production and spreading of asphaltic concrete mix shall not be permitted when the
ambient temperature is less than 8C nor during rain, fog, dust-storms or other
unsuitable weather.
5.8.12 Equipment and Plant
The equipment and plant required for construction of the asphalt concrete courses
shall include all necessary major equipment and plant which the Engineer considers
necessary for the satisfactory preparation and performance of the work.
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All equipment and plant shall be checked and/or calibrated and plant shall
be satisfactorily maintained and shall be used in an approved manner to produce
asphaltic concrete pavements in accordance with these Specifications. Adequate
equipment, plant and labour shall be used so that there is continual production and
distribution of the asphalt course being constructed. Intermittent (Stop-Go) type of
operations will not be permitted.
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
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 or labour and to instruct suitable replacement thereof at any time he
deems such action is necessary.
5.8.13 Preparation of Asphalt Mixes
a.
Preparation of Asphalt Cement

The 60/70 penetration grade asphalt cement shall be heated to a temperature to
yield viscosities in the range of 150-300 centistokes (75-150 seconds
SayboltFurol) when delivered to the mixer as determined from Temperature
Viscosity Chart of the product used. Asphalt cement shall not be used if foaming
occurs nor shall it be heated above 177C at any time.
b.
Preparation and Handling of Mineral Aggregate

Coarse and fine aggregate shall be stored at the asphalt plant in such a manner
that the separate stockpiles will not become intermixed. The stockpiles shall be
of sufficient size to provide a minimum quantity of one week's continuous
production of asphalt mix.
Aggregates brought to the asphalt plant to
supplement stocks should be tested and approved prior to placing in the
existing approved stockpiles.
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The cold bins shall be calibrated with the materials to be used and the settings
shall be such as to produce a combined gradation in accordance with the job
mix. The proportioning shall be such that surpluses and shortages in the hot
bins will not cause breaks in the continuous operation. All the above shall be as
approved by the Engineer.
The materials shall be thoroughly dried and heated so that their temperature is
within 8C of the temperature needed to satisfy the viscosity requirements of
the asphalt cement. In no case shall the materials be introduced into the
pugmill with a temperature, including the 8C tolerance permitted, of more
than that at which the asphalt cement has a viscosity of 75 seconds SayboltFurol. The moisture content of the heated and dried materials shall not exceed
0.5%. 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 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 minimize segregation and loss of
temperature of aggregate. Hot bins shall be drawn and cleaned of material at the
end of each day's operation.
c.
Proportioning and Mixing

The heated ingredients together with the mineral filler and asphalt cement
shall be combined in such a manner so as to produce a mixture which, when
emptied from the pugmill, complies with the requirements of the job mix
formula. Plant settings, once established, shall not be changed without the
The temperature of the aggregate immediately prior to mixing shall be within
8C of the temperature of the asphalt cement and the temperature of the
aggregate and asphalt prior to mixing shall be approximately that of completed
mix as defined in the Job Mix formula approved by the Engineer. The mix
temperature shall be within the limits set out in the Job Mix formula when
emptied from the mixer but in no case shall it exceed 170C.
Mineral filler, in a cold dry state shall be proportioned into the mixer either
with the aggregate or after the introduction of the asphalt cement to avoid loss
of fines that may occur in dry mixing as a result of turbulence in the mixer.
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d.
Control of Mixing Time

In batch type plant, the Engineer will designate the length of time of both dry
and wet mixing period to ensure a uniformly and completely coated mix.
Mixing period time shall not be altered unless so ordered by the Engineer. A
dry mixing period of not less than four seconds shall precede the addition of
the asphalt cement to the mix. Excess wet mixing shall be avoided. Wet
mixing shall continue as long as is necessary to obtain a thoroughly blended
mix but shall not exceed 75 seconds, nor be less than 30 seconds.
In continuous type plants, the weights shall be determined for the job from
tests made under the supervision of the Engineer and determination of mixing
time shall be by weight method under the following formula unless otherwise
required:
Mixing time, sec
Pugmill Dead Capacity kg

Pugmill rated output, kg per sec
The maximum mixing time in batch or continuous type plants shall be limited as
directed by the Engineer to avoid undue changes in the characteristics of the
asphalt material.
5.8.14 Transporting, Laying and Compacting
Asphaltic concrete mixes shall be transported, laid and compacted in accordance with the
following requirements:
a.
General Requirements
The base or subgrade, upon which the asphaltic concrete is to be placed shall be
prepared and maintained smooth, firm and in accordance with the
specification.
If necessary to obtain the required base or subgrade surface condition, and if
ordered, a base material of asphaltic concrete shall be spread and compacted as
directed to fill and level low areas, and high areas shall be removed by
cutting and levelling.
When a bituminous tack coat is not applied in advance of the placement of an
asphaltic concrete course, and the course is being placed on a primed or paved
surface, the surface to be paved shall be swept clean of loose dirt and other
objectionable material, using compressed air power brooms along with hand
brooms and other means as necessary.
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A light coat of bituminous material shall be applied as directed to edges or

vertical surface against which asphaltic concrete is to be placed.
The handling of asphaltic concrete shall at all times be such as to prevent
segregation.
Asphaltic concrete for finishing course shall be placed only when the
temperature of the surface on which the asphaltic concrete is to be placed is at
least 18C.
The temperature of the asphaltic concrete, just prior to the dumping of
material from the hauling vehicle, shall be at least 140 but not to exceed
165.
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 thin tack coat thereon if he
so deems necessary.
b.
Delivery of Asphaltic Concrete Mixture

The dispatching of the hauling vehicles to the job site shall be so scheduled
that all materials delivered may be placed in daylight, unless the Engineer
approves 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.
The mix shall be delivered to the job site at a temperature between 140 and
165C.
All precautions shall be taken to protect the mix from the weather.
Haulage trucks shall be equipped with a suitable box which shall be lightly
sprayed with a thin film of lubricant to prevent the mixture from sticking in
the truck. The truck box shall contain no dirt, dust, screenings, petroleum oil,
or other volatile mineral spirits, or any other foreign materials which may
affect the material being laid. All loaded trucks shall proceed immediately to
the works and shall discharge the load without delay. Any loads which are not
satisfactory for any reason whatsoever, including loss of heat, shall be
rejected. Where payment of the asphaltic concrete is by the tonne each truck
shall be weighed and a valid weight certificate shall accompany the load for
delivery at the paver. Trucks transporting asphaltic concrete shall be covered
when so directed.
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c.
Loading Material into the Paving Machine

The mixed material shall be dumped from the hauling vehicles directly into
the paving machine. It may be dumped onto the surface being paved when
being laid by hand in small areas inaccessible to the paving machine.
When dumping directly into the paving machine from trucks, care shall be
taken to avoid jarring the machine or moving it out of alignment. Trucks shall be
securely attached to the paving machine while dumping.
d.
Placing and Finishing by Means of Self-Propelled Paving Machine

All courses of asphaltic concrete shall be placed and finished by means of
selfpropelled paving machines equipped with an automatic control system or other
approved type paving machine. The temperature of the material taken at the
back of the paver after laying shall not be less than 130.
The use of motor graders 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. This shall be to avoid
segregation of the asphalt mix and shall comply with all conditions regarding
trueness of level, thickness and homogeneity of the mix.
The self propelled paving machine shall be equipped with an automatic
control system which will control the elevation of the screed at each end and
which is automatically actuated by a system of sensor-operated devices which
sense and follow reference lines or surfaces on one or on both sides of the
machine as required.
Failure of the automatic control system to function properly will be cause for
the suspension of the asphaltic concrete operations until such time as the
automatic control system has been made operative and is functioning properly.
The screed shall be maintained at the proper elevation at each end by
controlling the elevation of one end directly and the other end indirectly
through controlling the transverse slope and alternately, when directed, by
controlling the elevation of each end independently.
The control line shall be set by the Contractor and shall be maintained at and to
the grade and alignment established.
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The asphaltic concrete shall be deposited in the paving machine from the
hauling vehicle or from loading equipment and spread, compacted and
screeded or struck off in a dense layer with a smooth surface. The screed
assembly shall be heated when required to facilitate finishing the surface.
e.
Joints
Longitudinal joints in asphalt courses shall be offset at least 150 mm in
relation to the longitudinal joints in asphalt courses of the underlying course.
Longitudinal joints of the final course, whether surface or finishing course,
shall be located at the centre of a lane or at the joints between two adjacent
lanes.
Transverse joints in succeeding layers shall be offset at least 2 m.
Before a surface course is placed in contact with a cold transverse construction
joint, the cold material shall be trimmed to a vertical face by cutting the
material back for its full depth and exposing a fresh face. After placement and
finishing of the new material, the material on both sides of the joint shall be
dense and the joint shall be well sealed. The minimum cut back is to be
150 mm.
f.
Trial Area to Establish Rolling Method

After the approval of the "Job Standard Mixture" a further trial area shall be
laid outside the permanent works using this mixture to establish the rolling
method required to produce the specified field density. Three pairs of samples
shall be taken from the compacted trial area and the mean density of each pair
shall be not less than 99% of the "Job Standard Mixture Density". If the
required field density is not obtained the rolling procedure shall be adjusted
and further trial areas shall be laid and tested until satisfactory results are
obtained. These shall be submitted to the Engineer and the rolling method
agreed before mixing or laying is continued. Trial areas will not be permitted
for inclusion in the permanent work.
g.
Compaction
Unless otherwise directed by the Engineer at least two self-propelled smooth
steel wheeled rollers following closely one behind the other shall be used in
conjunction with each spreader and each roller shall weigh no less than 8
Tonnes nor more than 12 Tonnes and shall have a weight per centimetre width of
roll between 35 kg and 70 kg.
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A self-propelled pneumatic tyred smooth roller with a minimum dead weight of

25 Tonnes and tyre pressures of 6-6.3g/cm shall be used between the two steel
wheel rollers.
Breakdown rolling shall follow immediately behind the laydown machine and
the temperature of the mix at the commencement and end of rolling shall be
145C and 125C respectively unless otherwise directed by the Engineer.
To prevent pick up of asphaltic concrete the tyres of pneumatic rollers shall be
thoroughly heated before commencing rolling; wiping lightly with lubricant
may also be used as necessary. Breakdown rolling shall begin at the low side
and progress to the high side by overlapping of longitudinal strips parallel to
the centreline.
Finish rolling shall begin a soon as the stability of the asphaltic concrete will
prevent the shoving, displacing or cracking of the material as it is being
compacted and shall continue until the surface requirements and tolerances
specified herein have been met. Finish rolling shall be accomplished by
means of a tandem power roller.
The pavement shall not at any stage be opened to traffic until it shall have
been satisfactorily compacted and until such further times has elapsed as the
Engineer shall decide.
5.8.15 Field Compaction Control
Single or Twin samples as specified by the Engineer (from within 1metre of each
other) shall be taken by core cutter between 24 and 48 hours after paving from each
asphalt layer at the following frequencies:
Not less than one pair from every 850 sq.m. of surface.
Not less than one pair from every 2 hours of continuous paver operations, and
Not less than five pairs from each continuous paving operation.
Pavement corings shall not be cut later than 10.30 a.m. in the morning without the
Engineer's approval.
The mean value obtained from the twin samples from the same area shall be taken as
the field density of the compacted course.
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The field density is to be such that out of

20 consecutive mean values, not more than 3 results are to be below 98% for wearing
course, 96% for roadbase and 97% for basecourse of the "Job Standard Mixture
Density" and in no case shall the densities be below 96% for wearing course, and 95%
for base course and 94% for road base. Should the daily Marshall densities exceed
the "Job Standard Mix Design" by 1.8% then the mixture should be checked for
compliance with the Job Mix formula. Material which does not meet this requirement
shall be cut out and replaced. The samples may also be used to determine the course
thicknesses.
5.8.16 Surface Texture
The surface finish of the pavement shall be free from dragging cracks or other surface
blemishes. Back casting will not be permitted but where dragging occurs under the
screed of the spreader, fine bituminous material may be cast over the surface to fill the
dragging cracks, providing that this is carried out at the specified temperature. Should
dragging occur frequently the cause shall be investigated without delay and rectified.
5.8.17 Protection of Pavement Layers
Prevention of damage to newly laid asphaltic concrete and to underlaying
construction will be by enforcement of the following rules together with any further
requirements imposed by the Engineer during the Contract period.
Primed wet mix macadam: No vehicle with an axle load greater than 2 tonnes, other
than base course construction vehicles and plant, shall be permitted on the surface.
Asphaltic base course: No vehicle with an axle load greater than 4 tonnes, other than
wearing course construction vehicles and plant, shall be permitted on the surface.
Asphaltic wearing course: The finished surface may be opened to normal traffic 24
hours after paving or after such time determined by the Engineer.
Bituminous surface treatment (hardshoulder): The finished surface may be opened to
normal traffic on completion of brooming and rolling provided a speed limit of 30 kph is
observed for the first 24 hours.
The Contractor's rates shall include for all traffic control measures necessary for
enforcement of these rules.
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5.8.18 Bituminous Prime Coat

Bituminous prime coat shall consist of furnishing and applying liquid asphalt and
blotter material, if required, to a previously prepared and approved subgrade or
granular sub-base/road base course in accordance with these Specifications.
5.8.19 Liquid Asphalt
Liquid asphalt shall be of the medium curing type MC-70 grade and shall conform to
the requirements of Clause 5.8.5. The application rate shall be determined by a site
trial but will generally be between 1.20 to 1.50 kgs per sq.m. but may differ as
directed by the Engineer.
5.8.20 Blotter Material
Blotter material, if required, shall be clean natural sand.
5.8.21 Preparation of Surface
The surface on which the bituminous prime coat is to be placed shall be uniformly
smooth and firm and reasonably true to grades and cross sections as shown on the
Drawings, and shall be so maintained throughout the period of placing the prime coat.
In no event shall a prime coat be place on a soft, uneven base.
Any holes, depressions or irregularities shall be repaired by the removal of all loose and
unsuitable material and replacement by suitable material, which shall be compacted to
produce a dense surface conforming to the adjacent area.
Uniformity of surface texture is of the utmost importance.
When required, the surface on which the prime coat is to be placed shall be lightly
bladed and rolled immediately prior to the application of bituminous material.
The Engineer may direct that a light application of water be made just prior to the
application of liquid asphalt to facilitate penetration. Priming will not be permitted
when there is free water present on the surface.
5.8.22 Application of Prime Coat Material
The prime coat shall be applied only when the surface is either slightly damp or dry.
Prime coat shall not be applied when the ambient temperature is less than 13C nor
during rain, fog, dust storms or other unsuitable weather.
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The application temperature for the MC-70 liquid asphalt shall be between 60C and
85C as directed by the Engineer.
The prime coat shall be applied by means of an asphalt distributor. Hand spraying of
restricted inaccessible areas is permitted, subject to the approval of the Engineer.
The Engineer may direct that a light application of water be made just prior to the
application of liquid asphalt to facilitate penetration. Priming will not be permitted
when there is free water present on the surface.
5.8.22 Application of Prime Coat Material
The prime coat shall be applied only when the surface is either slightly damp or dry.
Prime coat shall not be applied when the ambient temperature is less than 13C nor
The application temperature for the MC-70 liquid asphalt shall be between 60C and
85C as directed by the Engineer.
The prime coat shall be applied by means of an asphalt distributor. Hand spraying of
The prime coat shall be applied to 1 / 3 to 1/ 2 of carriageway 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 will be permitted
at 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 satisfactorily disposed off by the Contractor after use. All areas of
excess bituminous material shall be blotted and removed to the Engineer's
satisfaction.
5.8.23 Maintenance of Surface
Traffic shall be kept off the bituminous material until it has penetrated the subgrade,
sub-base or roadbase and cured sufficiently. If it becomes necessary to permit traffic
prior to the primed surface having dried, but in no case sooner than 24 hours after the
application of the asphaltic material, blotter material shall be applied as directed by
the Engineer and traffic shall be permitted to use the lanes so treated. When applying
blotter material to an asphalt treated lane that adjoins a lane that has not been treated,
a strip of at least 200mm wide along the adjoining edge shall be left devoid of blotter
material.
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The primed surface shall be maintained in a good clean condition at all times until the
next course is placed. Any surface irregularities or holes in the primed surface,
however caused, shall be repaired and corrected by the Contractor.
5.8.24 Bituminous Tack Coat
Bituminous tack coat shall consist of furnishing and applying diluted emulsified
asphalt to a previously prepared bituminous road base/base course, or to an existing
bituminous surface, in accordance with these Specifications.
The material used for tack coat shall be emulsified asphalt and shall be of the rapid
setting Cationic or Anionic type of the CRS-1 or RS-1 grades respectively or be of the
slow setting Cationic or Anionic type of the CSS-1h or SS-1h grades respectively and
shall conform to the requirements of Clause 5.3. The approved emulsion if required
shall be diluted with approximately an equal quantity of water and thoroughly mixed
as directed by the Engineer. The diluted emulsion shall be applied at a rate between
0.25 and 0.35 kgs per sq.m.
The surface on which the bituminous tack coat is to be placed shall be clean and free
from dust, dirt or other unsuitable materials. The full width of the surface to be
treated shall be cleaned with a power-broom or power-blower immediately prior to
applying the overlaying bituminous course. All fatty or unsuitable patches, excess
cracks or joint filler, and all surplus bituminous material shall be corrected in
accordance with the requirements of the Engineer. The surface shall be dry when
treated.
The tack coat shall not be applied when the ambient temperature is less than 13C nor
The application temperature for the diluted emulsified asphalt shall be between 10C
and 60C as directed by the Engineer.
The tack coat shall be applied by means of an asphalt distributor. Hand spraying of
The surface of structures, kerb faces and similar objects adjacent to areas being
treated shall be protected in such a manner as to prevent them from being splattered or
marred.
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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 coat applied to the surface. No
additional payment shall be made for this work.
Where, in the opinion of the Engineer, a tack coat is not necessary between layers of
freshly placed courses, he may eliminate the tack coat in writing, in which case there
shall be no payment for tack coat for the areas concerned. Any cleaning required in
these areas shall be considered to be included in the overlaying asphaltic concrete
course and no separate payment will be made.
6.0
CONCRETE BLOCK PAVING
6.1
Sand Bedding For Paving Blocks

The paving blocks shall be laid over 50 mm thick sand bedding consisting of crushed
sand conforming to the requirements of BS 6717 part 3.
Silt/sand contents of the bedding material shall not exceed 3% by weight. Sulphate and
Chloride contents shall not exceed 0.3% and 0.5% by weight respectively. Tests shall
be carried out to confirm achievement of these requirements at the rate of one set of tests
for each 500 m.
The profile of the bedding sand before compaction shall be similar to that of the
finished surface. The maximum deviation from the design levels shall be 5mm.
The laying course shall be placed to a level which takes into account the compaction
which occurs during vibration of the blocks; the amount of this compaction shall be
determined by trials prior to commencement of surfacting.
The laying course material and joining material shall be clean sharp sand graded as in the
following table:-
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BS 410 Sieve Size

5 mm
2.36 mm
1.18 mm
600 micron
300 micron
150 micron
75 micron
% by mass passing
Laying course sand
Jointing sand
90-100
100
75-100
95-100
55- 90
90-100
35- 70
55-100
8- 35
15- 50
0- 10
0- 15
0- 3
0- 3
Stock piles of laying course material shall be covered to maintain the material at its
optimum moisture content.
The laying course material shall be spread on the base only after the latter has been
approved by the Engineer's Representative.
The material shall be spread at its
optimum moisture content, +1 to -3%, as determined by BS 1377: Part 4 (4.5 kg
rammer method).
The material should be spread loose and screeded with a surcharge of approximately
30% of the finished thickness prior to laying the blocks, in preference to laying the
blocks on pre-compacted material. The Contractor, shall, however, demonstrate both
these methods during the laying of the trial area specified in this Section.
Purpose-made screeding templates shall be used for screeding the laying course
material. Areas of laying course material screeded shall be limited to the area which can
be subsequently covered by blocks in a single laying session. When the laying course
material has been screeded to level, it shall not be walked on.
The laying course material shall have a final compacted thickness of 40mm, to a
tolerance of 6mm.
6.2
Paving Blocks
6.2.1
Materials
The paving shall consist of approved precast concrete blocks. The concrete
constituents shall comply with the requirements of the concrete specification given
elsewhere; cement shall be SRPC.
Additional requirements are contained in the following Clauses of this specification.
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Fine aggregate shall not contain more than 25% by weight of soluble calcium
carbonate in either the fraction retained on or the fraction passing a 600 micron BS
sieve.
Coarse aggregate shall be material retained on a 4.75mm BS sieve; the nominal
maximum size shall be 10mm. The grading shall comply with BS 882, Table 1, so
that when mixed with sand and cement a high density concrete is produced.
6.2.2
Testing
From each consignment of up to 10,000 blocks, 20 samples will be selected which the
Contractor shall test for characteristic strength and dimensional accuracy.
If the parameters of the specification are consistently met over the first three months of
full production, the frequency of block testing will subsequently be relaxed to 20
random blocks from each consignment of up to 20,000 blocks.
If any of the 20 test blocks do not comply with the requirements for dimensional
accuracy the whole consignment may be rejected.
The testing machine shall be of suitable capacity and capable of applying the required
load at the rate specified. It shall comply with the relevant requirements of BS 1610
and BS 1881.
The average compressive strength of the 20 blocks on delivery when sampled and
tested in the manner described below shall not be less than 49 N/mm in wet
condition. No individual block strength shall fall below 40 N/mm in wet condition.
The sample specimen shall be tested in a wet condition after being stored for at least 24
hours in water maintained at a temperature of 20C 5C. Before the specimens are
submerged in water, the necessary area shall be determined as follows:
The plan area shall be calculated by cutting out shapes of cardboard and weighing it to
the nearest 0.01 gm.
As
Where As
ms
20,000 ms
m
Area of block (mm)
Mass of cardboard shape matching test block (gm); the block

shall be placed wearing surface uppermost on the cardboard.
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Mass of 200 x 100 mm cardboard rectangle (gm) cut from the

same cardboard.
Plywood, nominally 4mm thick, shall be used as packing between the upper and
lower faces of the specimen and the machine platens, and boards shall oversail the
specimen by a margin of at least 5mm at all points. Fresh packing shall be used for
each specimen tested.
The load shall be applied without shock and increased continuously at a rate of
approximately 15 N/mm per minute until no greater load can be sustained. The
maximum load applied to the specimen shall be recorded. The strength shall be
expressed to the nearest 0.1 N/mm.
Block dimensions shall be measured using steel calipers and a steel rule capable of
measuring up to 300mm to an accuracy of 1mm.
The thickness of each sample shall be measured to the nearest 1mm at four different
points using steel calipers.
The value of the thickness measured shall have a
maximum deviation of 2mm from the specified thickness.
The length and width shall be measured to the nearest 1mm across two opposite faces
using steel calipers. The values of length and width measured shall have a maximum
deviation of 2mm from the specified dimensions, or the manufacturer's theoretical
dimensions.
Blocks may be required to be tested for water absorption. The test shall be based on
that specified in BS 1881, and the maximum acceptable limits for water absorption
shall be:
2.5% absorbed after 10 minutes
5.0% absorbed after 24 hours
The acceptable limits for water absorption may be required to be varied to achieve the
minimum absorption compatible with the aggregate approved for use in the paving
blocks.
The colour of blocks shall be uniform and as detailed on the Drawings or as directed.
Samples of each different colour shall be submitted for approval.
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6.2.3
Laying
Block laying shall commence at right angles to the main pavement axis starting at one end
of the area. Interlocking blocks shall be laid in a herringbone pattern at 45 to the main
pavement axis, or other pattern as approved or directed. Rectangular blocks shall be
laid in patterns, as directed, using different colours, if directed.
Blocks shall be laid on the sand bedding course so that blocks already laid are not
disturbed. Blocks shall be placed to fit closely together; the width of joints shall not
exceed 3mm.
Dimensional accuracy, uniformity of joint gaps, alignment and squareness shall be
checked after laying the first three rows of blocks and thereafter at regular intervals.
If joints begin to open, the blocks shall be knocked together using a hide mallet.
Special edge blocks shall be used on all edges of interlocking block paving which are
parallel to or perpendicular to the main pavement axis. Where the shape of or
dimensions of paved areas precludes the use of special or standard blocks on all
edges, cut blocks shall be used. Blocks shall be cut to suit, using a mechanical block
splitter or bolster chisel. In-situ concrete shall not be used to make up to edge
restraints.
The blocks shall be compacted to the required levels using a plate vibrator as each
area of 20 m is laid.
The plate vibrator shall have a plate area of 0.2 to 0.3 m and a compaction force of 9 to
16 kn. Two passes of the plate vibrator shall be made in two directions at 90.
Joints shall be filled by brushing in fine dry sand with a particle size of 0 to 2 mm and a
maximum sulphate content (as SO3) of 0.4% by weight. A further pass of the plate
vibrator shall be made in each direction.
The vibrator shall not be used within 1m of an unrestrained edge.
otherwise be left uncompleted overnight.
paving shall not
The finished surface level shall be within 5mm of the design level and the maximum
deviation within the compacted surface, measured by a 3m straight edge, shall not
exceed 5mm. The level of any two adjacent blocks shall not differ by more than
2mm.
P/49
VOLUME II A
FOR TENDER REV- 0

The laying of blocks shall comply with the requirements of the 'Code of Practice for
Laying Precast Concrete Block Pavements', published by the Cement and Concrete
Association/County Surveyor's Society/Interpave, U.K., and BS 6717: Part 3 except
where modified by the provisions of this Specification.
The working site shall be clear of all obstructions, to permit a satisfactory continuity of
work. The direction and shape of the laying face shall be carefully selected so that the
maximum output can be achieved.
Blocks shall be laid to match any existing adjacent block laying patterns.
Blocks shall not be laid so tightly that sand fails to penetrate the block joints from the
laying course or sand subsequently applied to the top surface.
The repair and reinstatement of any unacceptable and rejected block paving areas
shall be carried out following BS 6717.
7.0
STANDARDS
Surface levels to be checked on a 5m square grid:
Surface of Course
Table 1 : Tolerances for Paving Surfaces

Tolerance
from true
surface level
+20, -30
+8, -8
Maximum Depression
Tested with
3m
straight edge placed
on surfacing at right
angles to the cross fall
(ii)
6
+6, -6
(i)
Formation/Sub-base
Road-base
Beneath
concrete
blocks
Concrete Blocks
P/50
VOLUME II A
FOR TENDER REV- 0

Type of
compaction
equipment
Smooth-wheeled
roller or Vibratory
roller operating
without vibration
Pneumatic-tyred
roller
Vibratory roller
Vibrating plate
compactor
Vibro-tamper
Power rammer
Table 2 : Compaction Requirements

Category
Number of passes for layers not
exceedingthe following compacted
thicknesses:
Mass per metre width of
110 mm
150 mm
225 mm
roll:
over 2700kg up to 5400kg 16
unsuitable
unsuitable
over 5400kg
8
16
unsuitable
Mass per wheel
over 4000kg up to 6000kg
over 8000kg up to12000kg
over 12000kg
Mass per metre width of
vibrating roll:
over 5000kg
Mass per square metre of
base plate
over 1400kg/m up to
1800kg/m
over 1800kg/m up to
2100kg/m
over 2100kg/m
Mass:
over 75kg
Mass:
over 500kg
100kg - 500kg
BS 1377:
VOLUME II A
12
12
10
8
unsuitable
unsuitable
16
12
unsuitable
unsuitable
unsuitable
unsuitable
16
6
4
3
3
2
2
2
unsuitable
16
6
5
5
4
4
3
unsuitable
unsuitable
10
9
8
7
6
5
unsuitable
8
6
unsuitable
unsuitable
10
4
3
2
8
6
4
unsuitable
10
8
5
5
8
8
unsuitable
12
5
3
Methods of test for soils for civil engineering purposes

P/51
FOR TENDER REV- 0

Compaction - related tests

In-situ tests
8.0
BS 1881:
Methods of testing concrete

Method for making test cubes from fresh concrete
Method for determination of compressive strength of concrete cubes
BS 6717:
Specification for paving blocks

Code of practice for laying precast concrete paving blocks
Cement and Concrete Association/County Surveyors Society/Interpave
"Code of Practice for Laying Precast Concrete Block Paving",
February 1983
PRECAST CONCRETE KERBS, CHANNEL BLOCKS AND EDGINGS

Precast concrete kerbs, channel blocks, edgings and quadrants shall conform with and
be laid to the requirements of BS 7263, Parts 1 & 2, and to the details shown on the
Drawings.
All sections required shall be constructed in hydraulically pressed class 30/10
concrete. Concrete bedding and haunching for kerbing shall comprise class 30/20
concrete.
Mortar for bedding and jointing of kerb sections shall comprise a
1:3 cement: sand mixture, and in the case of bedding shall have a minimum thickness
of 15mm.
Excavation for kerb bedding shall be limited to a neat, even trench of sufficient width to
accommodate the concrete bedding. When kerbs are laid to levels higher than the
surrounding ground level, shuttering of concrete bedding may be necessary.
Foundations shall be thoroughly cleaned prior to placing bedding concrete.
Kerbs shall be laid to a smooth line and profile to the layouts as indicated on the
Drawings. Prior to placing any backing concrete, the lines, levels and jointing of all
kerbs shall be approved by the Engineer.
All kerbs shall be butt jointed with joints left open. Joints between kerbstones shall
not be less than 3mm nor greater than 5mm in width and shall be uniform from top to
bottom. Expansion joints shall be provided in kerb runs at a frequency of every
9 metres, and shall be formed from a suitable flexible material to the approval of the
Engineer. The expansion joint shall also extend through the kerb bedding and
haunching.
P/52
VOLUME II A
FOR TENDER REV- 0

On completion of all kerbing, the lines and levels shall be checked for accuracy. Any
units deviating by more than 3mm shall be immediately taken up and the work
repeated.
Where any filling placed adjacent to the kerb is likely to have a harmful effect on the
concrete due to aggressive chemical composition, then the kerbs shall be protected
from the fill material by a method agreed with the Engineer, or as shown on the
Drawings.
Kerbs shall be painted if required by the Engineer, using two coats of an approved
concrete paint.
9.0
MISCELLANEOUS ROADWORKS
9.1
TRAFFIC PAINT AND ROAD MARKINGS
9.1.1
General
Pavement marking shall consist of supplying road marking paint and marking of the
pavement as outlined herein. It shall include the marking of the centreline, the edge,
the barrier lines, the cross walk and any other markings required on the pavement for the
control and direction of traffic.
9.1.2
Materials, Application and Performance

Material for pavement markings shall consist of an approved hot applied sprayed or
screeded thermoplastic material complying generally with BS 3262 with the following
amendments and additions:
(i)
Reflectorised markings are required
(ii)
The approximate composition of the material as laid shall be:

Constituent
% by Weight
Aggregate
40
Solid glass beads (in the mix)
10
P/53
VOLUME II A
FOR TENDER REV- 0

Solid glass beads (sprayed on the surface)
10
Pigments and Extender
20
Binder
20
(iii)
Solid glass beads incorporated in the mixture shall comply with the Class A
Category of BS 6088. Solid glass beads sprayed onto the surface of the line
shall comply with the Class B Category of BS 6088.
(iv)
The softening point shall be at least 95C.
(v)
In the flow resistance test the specimen shall be maintained at a temperature of

40C plus or minus 2C for 48 hours.
The application of the material shall be in accordance with BS 3262 and the
manufacturer's instructions. Markings shall be free from raggedness at the edges,
uniform and free from streaks. The performance of the material shall be as given in
BS 3262.
9.1.3. Traffic Control and Protection of Work
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 if so required. Any
lines, strips or markings which become blurred or smeared by the traffic shall be
corrected by the Contractor at his own expense.
9.1.4
Measurement and Payment

The quantity of both solid and broken traffic lines to be measured for payment shall be
the number of linear metres of painted single line; for the broken lines only the
stretches actually painted shall be measured.
The quantity of road markings (striped zones, directional arrows, writing, etc.) to be
measured for payment shall be the number of square metres of surface actually
painted according to instructions and accepted.
P/54
VOLUME II A
FOR TENDER REV- 0

The quantities of traffic lines and road markings measured as provided above shall be
paid at the Bid Prices per unit of measurement entered in the Bills of Quantities for
each of the particular pay items listed, which prices and payment shall be full
compensation for furnishing and placing all materials, sampling and packing, for the
preparation of the surface, for protection of and from traffic, for all the costs indicated
in the Specification and all other costs necessary or usual to the proper completion of
the work.
9.2
PERMANENT TRAFFIC SIGNS

Permanent traffic signs, direction signs and place identification signs shall be located
where directed by the Engineer and shall conform to the Dubai Municipality
standards, Dubai Police Traffic Department Standards and the relevant parts of BS
873. The manufacturer's name and date of manufacture shall be stamped onto the rear
face of the sign.
Sign panels shall be panels of one piece construction made from sheet aluminium and
which have the face side reflectorised.
All sheets and plates shall conform to the requirement of ASTM B209, alloy 6061-T6.
All stiffeners, whether plates or extrusions, shall be of a similar material to the sign
plate and shall be bonded to the sign plate by either rivets or a manufacturer supplied
adhesive film.
Posts may be either aluminium or steel at the option of the Contractor. Steel posts
shall conform to the requirements of ASTM A499, galvanized in accordance with
ASTM A123.
Aluminium posts shall be standard shapes as specified and shall be aluminium alloy
6061-T6 of 6351 T5 conforming to ASTM B221.
Lag screws, washers, clip angles, shear plates, U-bolts, clamps, bolts, nuts and other
fasteners shall be galvanised steel or aluminium alloy, shall be compatible both
galvanically and physically to the sign material and shall be non-corrodible. All
exposed surfaces shall be painted the same colour as the area surrounding the part
exposed.
Galvanising of steel hardware shall be in accordance with ASTM A153. High
strength steel bolts, nuts and washers shall conform to ASTM A325, except as noted on
the Drawings.
P/55
VOLUME II A
FOR TENDER REV- 0

The lettering and the location of the signs shall be as directed by the Engineer. The
lettering of permanent traffic signs, direction signs and place name signs shall be in the
Arabic and English languages.
The sign posts shall be painted in alternate bands, black and white reflective paint of
300mm each. The reverse side of signs shall be painted in a matt finish grey colour
paint. Painting shall consist of a suitable self etching primer, two undercoats and one top
(gloss, matt or reflective) coat.
Traffic signs will be measured by the type and number installed and the rates shall be
deemed to include for all works specified herein and shown on the Drawings.
9.3
ROAD CROSSINGS AND DUCTS

Road crossing ducts and pipes shall be installed as shown on the Drawings or as
required by the relevant statutory Services Authority requirements subject to the
Conditions of the Contract regarding changes to the scope of Works.
All ducts, pipes and crossing are to be tested in accordance with the relevant Sections in
Volume IIA Specifications for M & E Services, and provided with all necessary drawwires, end caps and markers etc.
All earthworks, excavation, trenching, backfilling, compaction and the like is to be
carried out to the satisfaction of the Engineer and to the relevant Sections of the
Specifications.
P/56
VOLUME II A
FOR TENDER REV- 0

SECTION Q
PARTICULAR SPECIFICATION
1.0
GENERAL
1.1
The Particular Specification is meant only to give an indication of the standard of

materials and workmanship required and no manufacturer, supplier, specialist,
subcontractor or other agents are considered as nominated for the purposes of Clause 59
of the Conditions of Contract. Tenderers should note that materials similar and
equivalent in performance and quality to those specified may be approved, subject to the
conditions of Substitutions in Clause 2.0 of this Section.
1.2
All materials shall comply with the performance, standards and qualities mentioned in
Particular/General Specifications and as detailed on the Drawings.
1.3
Whether mentioned or not in the Specifications, Documents or Drawings, Tenderers

shall conform to all the manufacturers recommendations on the methods and
technicalities for the application of all specified materials and shall include all costs
involved in complying with the manufacturers recommendations for the supply and
application of the specified materials. (Any claim for time or cost in relation to
compliance with these requirements will not be considered by the Engineer).
2.0
SUBSTITUTIONS
2.1
No substitutions will be permitted without prior application to and obtaining of the

written approval of the Engineer.
2.2
Substitutions cannot form part of a Tender Offer except in the case of a fully
detailed Alternative Tender being submitted in line with Tender Instruction No.9.
On page A3 of Instructions to Tenderers, Vol. I Tendering & Contract Conditions.
2.3
Substitutions submitted on Shop Drawings without following the requirements of this

Section, prior to submission of the drawings, will cause the Shop Drawings to be
rejected at any time. Review of Shop Drawings shall not be construed as approval of
substitutions.
Q/1
VOLUME II A
FOR TENDER REV- 0

2.4
2.5
2.6
Requests for substitutions must include statements of:

(a)
Precise reasons for the substitution. i.e., An explanation as to why the

specified material is not being considered.
(b)
Description of the proposed substitution.
(c)
Respective costs of items originally specified and the proposed substitution.
(d)
Compliance with applicable Building Codes/Standards and requirements of

authorities having jurisdiction.
(e)
Effects concerning compatibility and interfacing with adjacent building

materials and components.
(f)
Compliance with the intent of the Contract Documents.
(g)
Comparative technical and financial analysis statement between the item/s

originally specified and the proposed substitution/s.
Substitution proposals will only be considered by the Engineer if:

(a)
The specified materials and products can be demonstrated as being not

available.
(b)
The delivery date of the specified material/product would unduly delay

Completion of the Contract through no fault of the Contractor.
(c)
The proposed substitute materials or products are considered by the Engineer

to be equivalent to or better than the specified material/product and
subsequently may result in a credit to the Employer. However, any additional
cost resulting from the substitution shall be borne by the Contractor.
Should a proposed substitution be accepted either in part or in whole, the Contractor

shall bear full responsibility and meet the costs of substitution effects on other work of
the Project. The Contractor shall also be liable to pay for any additional Design and
Contract Document changes required as a result of the substitution.
Q/2
VOLUME II A
FOR TENDER REV- 0

2.7
Amounts of any credits arising from the acceptance of the substitutions will be
determined by the Engineer in line with the requirements of Clause 52.1 of the
Conditions of Contract and the Effective Contract Price adjusted accordingly.
Notes:
1.
This list in no way infers nominated status on any of the suppliers listed.
2.
This list is to be read in conjunction with Volume II: Specifications For Building
And Civil Works and Volume IIA: Specifications For Mechanical & Electrical
Services.
SCHEDULE OF APPROVED SUB-CONTRACTORS
1.
Sanitary, Plumbing and Drainage
2.
Emirates Trading Agency

Lunar Drake & Scull
Sensaire
Remco
Bilt Middle East
Trans-Gulf Elec. Mech
Scientechnic
Penguin
Thermo LLC
B K Gulf
Emirates Voltas LLC
Al Hani Const & Trading Bureau
Juma Al Majid
International Electro-Mechanical
Trinity
Thermo LLC
B K Gulf
Emirates Voltas LLC
Remco
Bilt Middle East
Murad Electromec Company

Scientechnic
Link Middle East Limited
Electrical Works

Lunar Drake & Scull
Sensaire
Zener Steward
Al Hani Const & Trading
Bureau
Juma Al Majid
Roxby
Trinity
Penguin
Q/3
VOLUME II A
FOR TENDER REV- 0

3.
A/C Works
Lunar Drake & Scull
B K Gulf
Emirates Voltas LLC
Al Hani Const & Trading Bureau
Juma Al Majid
Scientechnic
Al Shirawi
4.
Al Abbar
Thomas Bennett
Bartawi
Sedam Aluminium
Alico
Thani Industries
Hamarain
Arabian Aluminium
ETA
Modern Decoration
J C Mclean International
Romea
Carpentry Works
Superfab
Bartawi
Al Habtoor
7.
Tiger Steel Corporation

ETA Steel Work and Fabrication
Aluminium Works
6.
Thermo LLC
Eros Electricals
Sensaire
Remco
Bilt Middle East
Al Futtaim Engineering
Trinity
Penguin
Structural Steel Works

Cleveland bridge
Galadari Engineering
Johnsonco Steel Fabrication
5.
Kitchen Cabinets
Al Maidoor
Gulf Precision Metals
J C Maclean International
Shafiq Dagher
Armital Metal Industries
Q/4
VOLUME II A
FOR TENDER REV- 0

8.
Partition Works
Al Shirawi
9.
Intex
Prefabricated Structures, GRP Canopies and Cover

Nitco
Speed House
Dufab
10. Readymix Concrete Supplier

Topmix
Arabian Readymix
Conmix
Unimix
Readymix Beton
11. Precast Concrete Works

Emirates Precast Construction
Est.
UPC
Juma Al Majid (E.M. Div.)
12. Water Proofing Works

Al Nahda
G.I.T.
Al Shafar
Beam Engineering
Desert Roofing
13. Earthworks and Road Works
Al Mulla Construction
National Wheel J & P Co.
Dutco
Al Naboodah Contg. Co.
Khansaheb Civil Engineering

Bartawi
U.T.C.C. Wade Adams
Q/5
VOLUME II A
FOR TENDER REV- 0

14. Antitermite Treatment Works

Al Bajaa Building Cleaning and
Pest Control
East Coast Pest Control Services
Middle East Agri Pest Co.
Target Pest Control
Arabian Agricultural Engineering Est.

Dubai Pest Co.
Ridapest Pest Control
15. Irrigation and Landscaping Works
Mirak
Orient Irrigation
Irrigation Trade M.E.
Al-Bayder
Greenscapes
Environs
Akar Technical Services
16. Sports Facilities and Equipment

G.I.T.
Al Kamda
Schelde Intern. Belgium
Bel Hasa Anthony Pools

STS Dubai
17. Testing Laboratories

Foundation Engineering
Fugro
Al Futtaim Tarmac Laboratories

Al Hoty Stanger
Q/6
VOLUME II A
FOR TENDER REV- 0

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PT-164 WAREHOUSE PHASE III

PLOT 5330316,5330317,5330318,5338058 , DUBAI INDUSTRIAL CITY

DESIGN & SUPERVISION

FOR TENDER REV- 0

PT-164 WAREHOUSE PHASE III

VOLUME II - SPECIFICATIONS FOR BUILDING & CIVIL WORKS

DEMOLITION & SITE CLEARANCE

EXCAVATION & EARTHWORKS

CARPENTRY, JOINERY & IRONMONGERY

PAINTING, DECORATING &

METAL SHEET ROOFING, CLADDING

ROADWORKS, BLOCK PAVING

FOR TENDER REV- 0

PT-164 WAREHOUSE PHASE III

This Specification shall be read in conjunction with the Conditions of Contract

The order of precedence of the various documents comprising the Contract

The Contract Agreement

The Tender and Letter of Acceptance

Part II of the General and Particular Conditions of Contract

Part I of the General Conditions of Contract

Drawings and Specifications

Any other document forming part of the Contract.

FOR TENDER REV- 0

PT-164 WAREHOUSE PHASE III

"BS" shall mean British Standard

"CP" shall mean British Standard Code of Practice

"PD" shall mean British Standard Provisional Document

"DD" shall mean British Standard Draft for Development

"Approved" or "Approval" shall mean approved by or approval of the

"Submitted" or "submit" shall mean submitted to or submit to the Engineer in

"Accepted" or "acceptance" shall mean accepted by or acceptance of the

"Inspected" or "inspection" shall mean inspected by or inspection of the

"Directed" shall mean directed by the Engineer in writing.

"Authorized" or "authority" shall mean authorized by authority of the Engineer

"Required" shall mean required by the Engineer in writing.

"Rejected" shall mean rejected by the Engineer in writing.

"In writing" shall also mean verbally, later confirmed in writing.

"O.O.E.A.A." shall mean Or Other Equal And Approved.

FOR TENDER REV- 0

PT-164 WAREHOUSE PHASE III

Scope of Work to be Priced

Items not Priced

FOR TENDER REV- 0

PT-164 WAREHOUSE PHASE III

Discrepancies, Errors or Omissions

No dimensions shall be scaled from the

USE AND PROTECTION OF THE SITE

Care and Protection

FOR TENDER REV- 0

PT-164 WAREHOUSE PHASE III

In pursuance of his obligations under the Conditions of Contract, the

Temporary Work Areas

FOR TENDER REV- 0

PT-164 WAREHOUSE PHASE III

Existing Services and Diversions

FOR TENDER REV- 0

PT-164 WAREHOUSE PHASE III

Where, in the Engineer's opinion, the convenience or amenity of an owner or

All proposed sub-contractors shall be to the approval of the Engineer.

sub-contractors who are registered, licensed and based in Dubai

PT-164 WAREHOUSE PHASE III

3.1.2 Co-ordination of Builder's Work

The Contractor shall co-ordinate the requirements of all builder's work. No

3.1.3 Verification of Site Measurements

Volume II-A Buildings & Civil Works

Volume II-A Buildings & Civil Works