Part-5.1B (R01 Technical Specification For Civil Work) REV

380/110/13.
8kV Substations Tender no:
Table Of Content
5.1B.1.6 CIVIL WORKS

5.1.B.1.6.1 GENERAL
5.1B.1.7 BRIEF DESCRIPTION OF CIVIL REQUIREMENT
5.1B.1.7.1 SCOPE
5.1B.1.8 CONSTRUCTION FEATURES
5.1B.1.8.1 GENERAL
5.1B.1.8.2 SOIL INVESTIGATION AND SITE SURVEY
5.1B.1.8.3 SITE PREPERATION
5.1B.2 GEOTECHNICAL SUB-SURFACE EXPLORATION
5.1B.2.1 GENERAL
5.1B.2.1.1 DESCRIPTION
5.1B.2.1.2 REFERENCES
5.1B.2.1.3 QUALITY ASSURANCE
5.1B.2.1.4 SUBMITTALS
5.1B.2.2 PRODUCTS
5.1B.2. 3 EXECUTION
5.1B.2.3.01 PERFORMANCE
5.1B.2.3.02 FIELD SAMPLING AND TESTING
5.1B.2.3.03 DATA TABULATION
5.1B.2.3.04 LABROTARY TESTING
5.1B.2.3.05 INVESTIGATION REPORT
5.1B.3 CIVIL WORKS
5.1B.3.1 GENERAL
5.1B.3.1.1 BUILDING REGULATIONS
5.1B.3.1.2 DESIGN AND CONSTRUCTION OF SUBSTATION CIVIL WORKS
5.1B.3.1.3 STANDARS
5.1B.3.1.4 CLIMATIC CONSIDERATIONS
5.1B.3.1.5 ADDITIONAL TESTS
5.1B.3.2 SITE INFORMATION
5.1B.3.2.1 GENERAL
5.1B.3.2.2 INESPECTION AND EXAMINATION OF SITES
5.1B.3.2.3 SITE SURVEY
5.1B.3.2.4 INFORMATION SUPPLIED BY ENGINEER
5.1B.3.3 DESIGN REQUIREMENTS
5.1B.3.3.1 DESIGN BY TENDER
C:\SEC-WOA- SPECs Part 5

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380/110/13.8kV Substations Tender no:
5.1B.3.3.2 DESIGN BY CONTRACTOR

5.1B.3.3.3 QUALIFICATION OF DESIGNER
5.1B.3.3.4 CALCULATIONS
5.1B.3.3.5 CIVIL DRAWINGS
5.1B.3.3.6 LOADING FOR DESIGN
5.1B.3.3.7 BUILDINGS GENERALLY
5.1B.3.3.8 FOUNDATION DESIGN
5.1B.3.3.9 ROARD WORK
5.1B.3.3.10 BOUNDRY WORKS
5.1B.3.3.11 SANITARY FACILITIES
5.1B.3.3.12 WATER SUPPLY AND STORAGE
5.1B.3.3.13 WEATHER PROOFING AND THERMAL INSULATION
5.1B.3.3.14 ROOFS
5.1B.3.3.15 CONCRETE PROTECTION
5.1B.3.3.16 CRANES
5.1B.3.3.17 DOORS AND FRAMES
5.1B.3.3.18 FLOOR FINISHES
5.1B.3.3.19 WALL FINISHES
5.1B.3.3.20 CEILING FINISHES
5.1B.3.3.21 FIRE PROTECTION
5.1B.3.3.22 TRANSFORMER AND REACTOR FOUNDATIONS AND OIL PITS
5.1B.3.3.23 RAINWATER DRAINAGE
5.1B.3.3.24 PENETRATION THROUGH BUILDING ELEMENTS
5.1B.3.3.25 JOINTS IN BUILDING ELEMENTS
5.1B.3.3.26 PUMOS
5.1B.3.3.27 TEMPERORY WORKS
5.1B.3.4 SURVEYING
5.1B.3.5 EXCAVATION
5.1B.3.6 FILLING
5.1B.3.7 CONCRETE WORK
5.1B.3.7.0 GENERAL SUMMARY
5.1B.3.7.1 MATERIALS
5.1B.3.7.2 PRODUCTION OF CONCRETE
5.1B.3.7.3 WORKMANSHIP
5.1B.3.7.4 SAMPLING AND TESTING OF CONCRETE
5.1B.3.7.5 RECONSTRUCTION OF FACULTY WORK
5.1B.3.8 FINISHES FOR CONCRETE

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5.1B.3.8.1 FINISHES GENERALLY

5.1B.3.8.2 CLASSIFICATION OF FINISHES
5.1B.3.8.3 TOLERANCE
5.1B.3.9 FORMWORK FOR CONCRETE
5.1B.3.10 REINFORCEMENT FOR CONCRETE
5.1B.3.11 PRECAST CONCRETE
5.1B.3.12 STRUCTURAL STEELWORK
5.1B.3.13 METAL WORK
5.1B.3.14 ASPHALTIC CONCRETE
5.1B.3.15 BLOCKWORK
5.1B.3.16 INTERNAL AND EXTERNAL FINISHES
5.1B.3.17 DRAINS AND SEWERS
5.1B.3.18 RAINWATER GOODS
5.1B.3.19 PLUMBING AND SANITARY WORK
5.1B.3.20 CONCRETE TROUGHS AND DUCT BANKS
5.1B.3.21 SITE CLEARANCE
5.1B.3.22 SITE RESTORATION
5.1B.3.23 DRAWINGS AND INFORMATION
5.1B.4 SUBSTATION EARTHING AND LIGHTENING PROTECTION
5.1B.4.1 SUBSTATION EARTHING
5.1B.4.2 LIGHTNING PROTECTION
5.1B.5 MECHANICAL AND ELECTRICAL SERVICES
5.1B.5.1 SCOPE
5.1B.5.2 STANDARDS
5.1B.5.3 LIGHTING
5.1B.5.4 AIR CONDITIONING AND VENTILATION SYSTEM
5.1B.5.5 POWER FACILITIES
5.1B.5.6 OVERHEAD TRAVELLING CRANE
5.1B.5.7 MISCELLANEOUS EQUIPMENT
5.1B.5.8 ELECTRICAL WIRING
5.1B.6 FIRE PROTECTION
5.1B.6.1 DESIGN CONDITION
5.1B.6.2 STANDARD RULES AND EGULATIONS
5.1B.6.3 SCOPE OF SUPPLY
5.1B.6.4 LIMITS OF SUPPLY
5.1B.6.5 FIRE AND PREVENTIVE MEASURES

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5.1B.6.6 FIRE FIGHTING INSTALLATION

5.1B.6.7 WATER SPRAY FIXED SYSTEM
5.1B.6.8 FM 200 EXTINGUSHING SYSTEM
5.1B.6.9 FIRE ALARAM AND FIRE PROTECTION
5.1B.6.10 PORTABLE FIRE EXTINGUISHERS
5.1B.6.11 SPECIFIED SPARE PARTS FOR FIRE FIGHTING AND FIRE ALARAM

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5.1B.1.1 to 5.1B.1.5 Not applicable
5.1B.1.6 CIVIL WORKS
5.1.B.1.6.1 General
This section of the specification covers the civil works to complete various items of work defined in the
scope of works under Part-6. Contractor is responsible for all aspects of work to provide the facilities
included whether or not called for specifically in these specifications. Civil works shall be provided for
the new substation including all facilities for a complete installation.
The general requirements for soil exploration, design, manufacture, testing, supply and construction of
civil, structural steel and architectural works involved for the above works are covered in this
specification. The general arrangements for the above works are shown in tender drawings indicating
conceptual layout. The dimensions are subject to alternations if the electrical equipment necessitates this.
However, the design shall generally comply with the proposal and will meet all the stipulations of this
specification.
5.1B.1.7 BRIEF DESCRIPTION OF CIVIL REQUIREMENT
5.1B.1.7.1 Scope
The spacification cover the basic requirment for civil and structural work related to substation, which
shall include design, supply of all materials, labor, plant and equipment, fixtures, fittings, erection and all
temporary and permanent works necessary for the satisfactory completion of the job in all respects. The
contractor is responsible for the completion of all necessary civil works to the satisfaction of the
Purchaser/Engineer whether or not specifically stated herein.
The minimum specific work but not limited to the following shall be executed under this part of the
contract:
- General installation of site.
- Complete reinforced concrete/structural steel skeleton for substation buildings
as shown in drawings including masonry and finishing works related to the
building.
- Foundations for transformers/reactors.
- Isolated oil containment with separator.
- Cable channel to transformers and shunt reactors.
- Overhead travelling crane in 110kV switchgear hall .
- Concrete roads and pavements inside substation including access roads.
- Crushed rock yard surfacing.
- Boundary wall from reinforced concrete posts and wall panels with barbed
wire including main sliding gates.
- Drainage system to prevent flooding of substation.
- Other ancillary work, auxiliaries etc.
The major items of civil works involved are as follows: -
- General installation of the site including soil investigation, topographical

survey, sites grading.
- Earth and rock excavation including dewatering if necessary.
- Reinforced concrete in foundations and superstructures.
- Transformer foundations with rail.
- Piling, if required.
- Steel structures.
- Roads and pavements.
- Pipes/pipe ducts/tunnel for cables.

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- Doors and windows.

- Security building (only for 380kV substation )
- Finishing works including masonry, plastering, tiling and painting.
- Provide suspended ceiling in control, protection and office rooms.
- Crushed rock yard surfacing.
- Air conditioning, ventilation.
- Lighting (indoor, outdoor, security, emergency).
- Lightning protection of S/S building, outdoor equipment.
- Substation earthing with design, material, execution, testing and
commissioning.
- Fire protection.
- Furniture.
- Water supply and sanitary waste disposal.
All works to be complete in every respect and ready for use. Together with the tender, tenderer shall
submit drawings showing overall layout of the proposed site installation.
5.1B.1.8 CONSTRUCTION FEATURES
5.1B.1.8.1 General
The general construction features are outlined herein detailing the requirements. The execution of these
works shall be as per the requirements of this specification.
5.1B.1.8.2 Soil Investigation and Site Survey
The contractor shall conduct soil investigation necessary to establish soil parameters for the design of
foundation and earthwork as required by this specification. The contractor shall conduct a land and
topographic survey of substation site establishing all boundaries and dimensions, locating existing and
new bench marks, locating all existing above and below ground structures, utilities, roads and other
obstacles and showing the contours of the site.
5.1B.1.8.3 Site Preparation

Site preparation includes cleaning the site of all obstructions, constructing temporary roads, grading the
site including all earthwork cuts and fills either soft soil or hard rocks etc. The contractor shall clean the
site of all vegetation, roots, debris and topsoil within the limits of grading. Site grading plans and details
shall be developed to show the grade elevations of site and access roads, site cross sections, drainage
ditches for rainwater. The grading plan and details shall be developed from the site survey, soil
investigation reports and electrical layout.
5.1B.2 GEOTECHNICAL SUB-SURFACE EXPLORATION
5.1B.2.1 GENERAL
Normally Soil Investigation is under the scope of client but if as per PTS requirement it is contractor
responsibility to take care of the following:
5.1B.2.1.1 DESCRIPTION
 Definition
Work of this section comprises supplying all labour, materials, plant and performing all work necessary for
drilling bore holes. Performing standard and static cone penetration tests, soil sampling, laboratory testing of
soil samples to define soil parameters, analysis of test data, applying the results for foundation and fill
design, submittal of geotechnical reports.

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Geotechnical contractor should be approved by SAUDI ELECTRIC COMPANY (W). Geotechnical

contractor should prepare the geotechnical report.
5.1B.2.1.2 REFERENCES
Publications listed below form part of this specification:
 National Standard TESP-119.10, 119.13
 American Society for Testing and Materials (ASTM)
D422 Method for Particle Size Analysis of Soils

D1140 Test Method for Amount of Material in Soils finer Than the No. 200 Sieve
D4318 Test Method for Liquid Limit, Plastic Limit and Plasticity Index of Soils
D1194 Test Method for Bearing Capacity of Soil for Static Load on Spread Footings
D698 Test Methods for Moisture Density Relations of Soils Using 2.5 kg Hammer and 304.8 mm
drop
D1557 Test Methods for Moisture Density Relations of Soils and Soil Aggregate Mixtures Using 10
lb. (4.54 kg) Hammer and 18 inch (457 mm) drop
D1586 Method for Penetration Test and Split Barrel Sampling of Soils
D2922 Test Methods for Density of Soil and Soil Aggregate in Place by Nuclear Methods (Shallow
Depth)
D3441 Test Method for Deep, Quasi-Static, Cone and Friction Cone Penetration Tests of Soil
D2435 Test Method for One Dimensional Consolidation Properties of Soils
D2166 Test Methods for Unconfined Compressive Strength of Cohesive Soil
D2216 Method of Laboratory Determination of Water (Moisture) Content of Soil, Rock and Soil
Aggregate Mixtures
D2434 Test Method for Permeability of Granular Soils (Constant Head)
D2850 Test Method for Unconsolidated, Undrained Strength of Cohesive Soils in Triaxial
Compression
D3080 Method for Direct Shear Test of Soils under Consolidated Drained Conditions
D3370 Practices for Sampling Water
D596 Methods of Reporting Results of Analysis of Water
D1293 Test Methods for pH of Water
D1888 Test Methods for Particulate and Dissolved Matter in Water
D516 Test Methods for Sulphate Ion in Water
G51 Test Method for pH of Soil for Use in Corrosion Testing
D854 Specific gravity test for soil.
 British Standards (BS)
BS1377 Determination of Total Sulphate Contact of Soil Test 9
5.1B.2.1.3 QUALITY ASSURANCE
 Personnel
Contractor's and/or subcontractor's personnel carrying out geotechnical investigation shall be fully qualified
and experienced in their respective fields of drilling, sampling, testing and interpretation of results.
Well-reputed geotechnical consultants shall perform soil investigation. The Contractor shall submit the pre-
qualification of such consultant for Owner's review and approval.
5.1B.2.1.4 SUBMITTALS

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Submit with tender the name and experience of geotechnical engineering subcontractor intended to be used
for approval by Engineer.
Submit to Engineer three copies of all field logs, drillers' logs, laboratory test data and recommendations of
geotechnical engineer at the completion of geotechnical investigation but not later than 30 days before any
construction work commences.
5.1B.2.2 PRODUCTS
Space holes at 25 m for building foundations depending on the complexity of soil conditions. Number and
depth of bore holes for each heavily loaded structure, tunnel and road to be indicated clearly. Depth of
borehole shall be minimum 12 meter unless rock layer is found during boring.
5.1B.2. 3 EXECUTION
5.1B.2.3.1 PERFORMANCE
 Drilling Equipment
Advance bore holes by means of either auger boring, rotary drilling or wash boring equipment.
 Soil Sampling Equipment
Make available a full range of standard sampling equipment during investigation to deal with specific soil
conditions. Use split spoon equipment (5 cm outside diameter, 3.5 cm inside diameter and 46 to 61 cm long)
for recovering disturbed samples and for making standard penetration test, and "thin walled tube" (5 to 7.5
cm diameter, 16 gauge seamless steel) for recovering undisturbed samples of cohesive soil.
 Static Cone Penetration Test Equipment
Equipment for sounding in sediments shall be of approved design and shall meet the following requirements:
· Use penetration test cone of mechanical or electrical type to perform in situ testing as specified
herein and as required by Engineer.
· Steel cone shall have a base area of 1000 mm2 and a tip angle of 50 degrees.
· Hydraulic press furnished shall have a minimum capacity of 100 KN. Equipment shall be
capable of testing soil to a depth of 30 m.
· If mechanical or discontinuous sounding method is used, employ a measuring interval of 0.2
m.
· If continuous electrical sounding method is used, measure continuously during penetration at a

constant speed of approximately 10-20 mm/s.
 Soil Resistivity measurement.
Soil resistivity measurement shall be carried out using four point Wenner arrangements as per IEEE-81,
TES-P-119.10 and ASTM G57.
5.1B.2.3.2 FIELD SAMPLING AND TESTING
 Standard Penetration Test
Measure resistance of soil to a penetrometer by "standard penetration test" for estimating consistency of
cohesive soils and relative density of cohesion-less soils.

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Take samples with split spoon sampler at 1.5 metre intervals. At selected intervals, recover thin wall tube
samples of cohesive soils to determine in laboratory strength/deformation characteristics of soil.
Perform standard penetration test at 1.5 metre intervals except where thin wall tube samples are taken and at
change in soil strata in accordance with ASTM D1586.
 Static Cone Penetration Test
Static cone penetration tests shall be performed with applicable requirements of Clause 3.01C of this section
and in accordance with ASTM D3441.
 Vane Shear Test
Make direct in situ measurements of shearing resistance of clays using vane shear apparatus.
 Plate Bearing Test
Perform in situ plate bearing test in accordance with ASTM D1194 to estimate immediate settlement of
spread footings.
 Ground Water Measurement
Install piezometers wherever it is considered necessary to monitor ground water levels.
 Maximum Density
Maximum densities of each classification of backfill materials shall be determined in accordance with
ASTM D698 and ASTM D1557 Method D.
 Bulk Density
Bulk density shall be determined in field in accordance with ASTM D2922.
Adjusted bulk density of fraction of fill passing (19 mm) sieve shall be determined from bulk density by
laboratory test using procedures which are most appropriate in the opinion of the Engineer.
 Ground Water Analysis
Take samples of ground water in accordance with ASTM D3370. Report analysis in accordance with
ASTM D596. Analysis of ground water to include the following:
· PH value to ASTM D1293

· Sulphate content to ASTM D516
· Particulate and dissolved matter to ASTM D1888
 Soil Corrosiveness
Determine the pH value of soil in accordance with ASTM G51. Determine sulphate content of soil in
accordance with BS1377, Test 9.
 Collapsible or Liquefiable Soil
Identify soil, which is likely to collapse or liquefy due to static, dynamic or seismic effects, contact with
water, ground water pressure or other effects as appropriate.

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 Seismic Investigation
The contractor to ensure an adequate factor of safety against soil liquefaction shall carry out full seismic
risk analysis with computer modelling of ground motion and foundation interaction. It has been indicated
that plant system specified for dynamic analysis, UBC Zone 2A with an importance factor of 1.5 is
considered appropriate.
5.1B.2.3.03 DATA TABULATION
Make a continuous log of each borehole by a qualified soil engineer or a technician who will supervise all
drilling and sampling operations. Logs shall contain all pertinent information regarding soil strata, field
sampling and testing, and ground water levels.
During static cone penetration testing, measure and record both cone and friction sleeve resistance and Keep
complete records of all testing operations.
5.1B.2.3.04 LABORATORY TESTING
Perform the following laboratory tests on soil samples in accordance with respective ASTM standards. If
other internationally accepted standards are used, record appropriate standards on the test result.
Type of Test ASTM Standard
Unit weight -
Moisture content D2216
Atterberg limits D4318
Gradation D4318
Permeability D2434
Consolidation D2435
Compaction D698 and D1557
Shear strength properties
Unconfined D2166
Direct shear D3080 (consol. drained)
Triaxial D2850 (unconsol. undrained)
5.1B.2.3.05 INVESTIGATION REPORT:
The report shall clearly specify the net safe bearing capacity of soil, angle of response, modulus of sub grade
reaction, chemical analysis of soil, allowable settlement, type of cement to be used, depth of foundation,
position of ground water table, quality of ground water table, fill material, depth of fill material and sample
calculation for net bearing capacity of soil considering shear and settlement criteria separately. The report
shall also include all applicable curves mainly shear stress and settlement curves.
Beside furnishing all the pertinent data, the geotechnical agency’s report shall include:
5.1B.2.3.05.1 A “B” size Drawing in SEEDS-п format, showing the approved / actual location of
boreholes and soil resistivity measurement points.
5.1B.2.3.05.2 Any previous experience during soil investigation/foundation design and construction in
the nearby area of the site.
5.1B.2.3.05.3 List and Detail all the equipment employed for the soil investigation and soil resistivity
measurements.
5.1B.2.3.05.4 Photographs of soil boring, soil resistivity measurement and soil testing.

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5.1B.2.3.05.5 Findings of the trial pits.
5.1B.2.3.05.6 Identification and recommendation on potential problems, encountered or

expected, such as settlements, dewatering problem, rock excavation, etc,. and there
solution.
5.1B.2.3.05.7 Soil bearing capacity recommendations and expected foundation settlement with
calculations.
5.1B.2.3.05.8 Recommendations on the appropriate type of foundation suitable for the soil
Parameter of the soil l rock type encountered, with foundation placement levels.
5.1B.2.3.05.9 Ground water observation, elevation of the free water encountered & its level after
24 hours and recommended ground water elevation, if any, to be considered for design.
5.1B.2.3.05.10 Proposal for the protection of the basements and other structural components
Seasonal variation shall be fairly ascertained by the soil investigation agency based
on the previous experience and site vicinity and recommendations made.
5.1B.2.3.05.11 Engineering analysis of the soil / rock and recommendations. The report shall
include all engineering parameters; angle of internal friction, cohesion, adhesion,
modulus of elasticity of soil, modulus of sub-grade reaction, coefficient of active, at
rest and passive earth pressures, coefficient of horizontal earth pressure and specific
weight of soil at different layers.
5.1B.2.3.05.12 Suitability of the excavated material for the general or structural backfilling.
5.1B.2.3.05.13 Chemical analysis for sulphate and chloride and the recommendation on protection
against corrosion.
5.1B.2.3.05.14 Type of cement to be used in the sub and super structure.
5.1B.2.3.05.15 Electrical soil resistivity tests, calculations and recommendations for grounding
design purposes.
5.1B.2.3.05.16 The soil investigation agency shall use only recognized and well accepted references and
international codes for arriving at the value of soil parameters listed above. Soil
parameters adopted shall result in conservative design of foundations. Soil investigation
agency shall clearly specify and attach for company review all such references and
International codes that are used for soil parameters, which shall be reviewed by the
company.
5.1B.2.3.05.17 Final interpretation of soil parameters & earth resistivity recommendations and
approval is up to the COMPANY and the decision shall be final and binding on the
CONTRACTOR.
5.1B.2.3.05.18 The CONTRACTOR should not proceed with the designs of foundations and earthwork
until the soil investigation report is reviewed and approved by the company.
5.1B.2.3.05.19 The CONTRACTOR shall not start with the laying of the grounding until the earth
resistivity report and the design calculation / drawings of main grounding grid are
approved by the COMPANY.

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5.1B.3. CIVIL WORKS
5.1B.3.1 GENERAL
5.1B.3.1.1 Building Regulations
Tenderers are deemed to have full knowledge of the obligations and responsibilities of a Contractor
under the National Building Regulations. The Contractor shall provide the Engineer with all
documentation, which is required to obtain all necessary permissions for building.
5.1B.3.1.2 Design and Construction of Substation Civil Works
The Contractor shall be responsible for the design, detailing and construction of all the substation
building, auxiliary plant rooms, boundary wall/fences, Switchyard and equipment foundations,
transformer foundations, cable trenches and services required for the complete substations.
The works shall be constructed to the lines and levels shown on the drawings prepared by the Contractor
and approved by the Engineer or to such lines and levels as the Engineer may approve.
The appearance and architectural treatment of the buildings shall be to the approval of the Engineer. The
Tenderer shall submit full particulars of his proposals in this regard with his tender.
All buildings, transformer equipment & steel structure foundations, roads and other works at site and
their design and detailing shall meet the technical and operational requirements of the plant and
equipment to be accommodated.
5.1B.3.1.3 Standards
The civil engineering, building and structural works shall be designed and executed in accordance with
recognized Standards and Codes of Practice approved by the Engineer.
The attention of Tenderers is drawn to particular requirements regarding materials for fill, aggregates for
concrete works, building sands, aggregates for asphalt concrete, bitumen, cement, water and to the
requirements regarding workmanship for the concretor. These requirements have been adapted to meet
local conditions and the Contractor shall be required to comply strictly with it.
The Engineer may require the Contractor to comply with the requirements of the latest British /
Americans and Saudi Standards and Codes of Practices for any portion of the works.
The Standards and Codes of Practice referred to in this Specification shall be the latest editions of such
Standards and Codes of Practice.
5.1B.3.1.4 Climatic Considerations
The Contractor shall take full account of the climatic conditions at the sites in preparing his designs and
selecting materials for the works.
5.1B.3.1.5 Additional Tests

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The Engineer may require tests, in addition to those detailed in this Specification, as may be deemed
necessary to prove compliance with this Specification including tests on selected specimens and such
tests as required shall be carried out in accordance with the tender documents, and applicable code and
standard.
5.1B.3.2 SITE INFORMATION
5.1B.3.2.1 General
The location and dimensions of the site are as set out in the scope of work and tender drawings.
5.1B.3.2.2 Inspection and Examination of Sites
The Tenderer shall inspect and examine each site and its surroundings and satisfy himself before
submitting his Tender to the nature of the ground and sub-soil conditions, the quantities and nature of the
work, the materials necessary for the completion of the works and the means of access to the sites.
The Tenderer shall be deemed to have obtained all necessary information as to risks, contingencies and
other circumstances, which may influence or affect his Tender price. No claim for additional payment
shall be allowed on account of the failure of the Tenderer to obtain complete and correct information on
all matters relating to the sites. The Tenderer shall be responsible for any misunderstanding or incorrect
information however obtained, except information given in writing by the Engineer.
Any neglect, delay or failure on the part of the Tenderer to obtain reliable information upon the above or
any other matters shall not relieve him from any risks or liabilities or from the responsibility for the
completion of the Works included in the Contract.
5.1B.3.2.3 Site Survey
The Contractor shall, at his own expense, have carried out topographical and contour surveys of the sites.
The Contractor shall prepare for each site a comprehensive map giving the contours of the land, location
of existing bench marks, if any, location of new bench marks and base lines, location of existing
underground and above ground structures and utilities, roads and any other features that exist at the site.
The scale of the map shall be 1:250. Contours shall be plotted at O.5m intervals, which interval may be
revised if there are large variations in topography at the site.
5.1B.3.2.4 Information Supplied by the Engineer or Employer
Notwithstanding any information provided by the Employer and the Engineer, including Site
Investigation Reports, the Engineer and the Employer make no representations about and take no
responsibility for the actual ground conditions at the sites, for which the entire risk must be assumed by
the Contractor and no claim shall be made by the Contractor on account of any difference there may be
in the nature of any materials actually encountered during the execution of the works as compared with
any information provided.
5.1B.3.3 DESIGN REQUIREMENTS
5.1B.3.3.1 Design by Tenderer
The Tenderer shall submit with his Tender a design portfolio, which shall include at least the following
items:
(1) Outline civil, building and architectural drawings showing in plan, elevation and sections the
general arrangement of all the works together with a full descriptive specification. Drawings
shall show the main dimensions of all the rooms and structures, the levels of foundations, floors
and roofs, ducts, trenches and concrete protection in accordance with this Specification.

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(2) An account of the design method used for each part of the Works; design criteria used (loading,
permissible stresses and such like) assumptions in respect of foundations.
(3) A listing of the standards, codes of practice, textbooks and design data proposed for use in
respect of design and construction of the works and equipment to be supplied.
(4) A listing of materials to be used with brief technical descriptions. Where proprietary products or
materials are proposed, manufacturer brochures and technical literature shall be submitted.
Tenderer shall submit complete original brochures, photocopies of relevant sections will not be
acceptable and where these are not in the English language the Tenderer shall provide a
translation.
5.1B.3.3.2 Design by Contractor
All civil engineering and building work required for the completion of all works covered by this
Specification shall be designed and drawn in detail by the Contractor, in accordance with the provisions
of this Specification.
The Contractor shall be entirely responsible for the adequacy of the design of the Works,
notwithstanding any approvals given or comments made by the Engineer in respect of the designs,
drawings and calculations submitted by the Contractor.
Experienced and competent engineers shall carry out the design of the Works. The design shall be
consistent with professional standards of skill, care and diligence comparable with the work of first class
international firms carrying out design work of a similar nature.
The detailed design, including calculations and drawings, for all the works to be carried out shall be
submitted to the Engineer for approval. Such submissions shall be in accordance with an approved
program.
The Contractor shall not proceed with any work of construction until the Engineer has approved the
designs and drawings in respect of it.
5.1B.3.3.3 Qualifications of Designers
Tenderers shall submit with their Tenders details of the qualifications and experience of the senior staff
to be employed on the design. The Contractor shall notify the Engineer and obtain his approval of any
change of designer during the course of the Contract.
5.1B.3.3.4 Calculations
Submission of Calculations:
All design calculations shall be submitted to the Engineer for his approval and shall be accompanied, if
requested, by two English language copies of Standards and Codes of Practice approved by the Engineer.
Approval by the Engineer of any calculations shall not relieve the Contractor of responsibility for that
calculation or for the safety, suitability and adequacy of any part of the Works designed in accordance
with that calculation.
Presentation of Calculations:
All calculations, other than computer printout, shall be on A4 size paper and shall be bound into book
form with signature of authorized person and stamped. Each book of calculations shall have a title page.
The title page shall indicate clearly:
(1) The name of the project

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(2) The name of the substation

(3) Document number
(4) The element of the Works covered and the nature of the calculations
(5) The design office where the calculations were carried out and the names of the designer(s) and
checker(s)
(6) Date of issue.
The title page shall also provide for the recording of any revisions to the calculations.
Calculations shall be in English and in SI units, clearly legible, preferably typed. calculations
which are not easily legible or which present difficulty in comprehension will not be examined
by the Engineer and the Contractor shall be obliged to resubmit such calculations in legible /
comprehensible form.
Calculations shall be arranged in a logical sequence and shall include such sketches and
annotations as may be required to make them self-explanatory. Each section of the calculations
shall be prefaced by a Design Information Sheet, which shall include, for example, such
information as:
Standard and Codes of Practice used, Textbooks and Design Manuals used, Loading Conditions
assumed
- Dead
- Imposed
- Plant
- Dynamic, Seismic
- Wind
Subsoil Conditions,
Foundation Type,
Materials of Construction and Design Stresses,
Environmental Conditions assumed.
The Contractor is advised that calculations conforming generally to the following standard shall
be considered satisfactory by the Engineer:
"Model procedure for the presentation of calculations" Concrete Society Technical Report No. 5
(2nd Edition April, 1981) Published by:
The Concrete Society,

Terminal House,
Grosvenor Gardens,
London SW 1W OAJ.
The Contractor shall take particular care to ensure that the source of any item of data used in the
calculations is either immediately obvious or is given by reference to other calculation books or
documents.
Details of computer programs used by the Contractor for design shall be submitted to the Engineer for
approval. The Contractor shall submit flow diagrams, sample calculations or other acceptable means of
verification together with complete descriptions of the programmer. Calculations carried out by any
program rejected by the Engineer shall be re-calculated by the contractor by some other means and
re-submitted for approval. Program used in this design shall be standard program.
All printouts shall be accompanied by the information listed above for the Design Information Sheet of
each calculation book.

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If the Contractor engages a third party to carry out design and/or drawing work he shall check all such
work before submission for the Engineer's approval, to ensure that the design and/or drawings comply
fully with the requirements of the Contract Documents.
Checking of Calculations:
Before being submitted to the Engineer for approval all calculations, including computer printouts, shall
be checked by an engineer in the design office, who shall be of similar competence to the originator of
the calculations. The originator shall not act as the checker of his own work.
Where the Engineer is of the opinion that the checking has been inadequate the Contractor shall re-check
and re-submit the calculations.
The checker shall concern himself with the design assumptions and criteria, the reliability and
correctness of interpretation of the information on which the calculations are based as well as the
appropriateness and correctness of the design and its ability to conform to the requirements of this
Specification.
The checker shall initial each sheet of calculations and computer printout submitted for approval.
Revisions to Calculations by Contractor:
Any revisions required to calculations subsequent to the Engineer's approval shall be noted on the title
sheet in the revision box. The pages with the revisions shall be appended to the original calculations and
the original pages shall be struck out and boldly marked "SUPERSEDED".
Where the revision concerns only a minor part of the page, the revision shall be noted on the title page
and the original page marked up in a distinctive manner.
All revisions shall be carefully reviewed by the Contractor to determine what other parts of the
calculations are affected. Such other affected calculations shall be revised in turn.
All revisions shall be subjected to the same checking and submission for approval procedure as the
original calculation.
5.1B.3.3.5 Civil Drawings
The Contractor is advised that drawings conforming generally to the following standards would be
considered satisfactory by the Engineer.
Building Works: BS 1192 - Recommendations for Building Drawings

Practice/American/German/Saudi standards.
Reinforced ACT 381 Building Code Requirements for

Concrete Works: Reinforced Concrete.
ACI 315 - Manual of Standard Practice for Detailing Reinforced Concrete
Structures /BS/German/Saudi standards.
Standard Method of Detailing Reinforced Concrete (Published by the Concrete Society and Institution of
Structural Engineers, London).
Structural Steel: AISC Code of Standard Practice/BS/German/Saudi standards.
Welding: American Welding Society/BS/German/Saudi standards.

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Where the Contractor wishes to submit for approval drawings received from some third party which do
not comply with the requirements of this Specification he shall have same drawings re-drawn to comply
with this Specification and checked before submission.
5.1B.3.3.6 Loading for Design
Loading criteria shall be as per TES-P-119.09.
(1) Wind Loading:
The works shall be designed in accordance with CP 3: Chapter 5: Part 2: 1972 as issued by British
Standards Institution, 2 Park Street, London WIA2BS/American/German/Saudi standards.
. The basic wind speed as defined in Clause 5.2 shall be taken as 50 m/s. in calculating the resultant wind
pressure the following factors shall be used:
- Design of Building Structure:
Topography Factor - S1 = 1
Ground Roughness Factor - S2 ground roughness 1 i.e.
Open Country with no obstructions Class B

Statistical Factor - S3 = 1
- Designs of Cladding, Glazing, etc.

Topography Factor - S1 = 1
Ground Roughness Factor - S2 ground roughness 1 i.e.: -
Open Country with no obstructions Class A

Statistical Factor - S3 = 1
(2) Imposed Loads (Other than Plant Loads)
All floors and roofs shall be designed to carry the uniformly distributed load (U.D.L) or the concentrated
load on an area 300mm square, whichever produces the greater stresses.
The loads, other than self-weight, plant loads and special maintenance loads, which are to be applied to
floors and roofs, shall not be less than the following:
U.D.L kN/m² Concentrated Loads kN

Floors
Control and Relay Rooms 2.5 2.75
Store 10.0 40.0

Switchgear Halls/Transformer Room 4.0 See Note
Roofs
All roofs 1.5 1.0
Note: Suitable allowance shall be made for the putting down in such space of any item of plant during
erection and maintenance.
(3) Plant Loads:
Plant loads shall be determined by the weight of the manufacturer's equipment supplied and by
the dynamic or impact effects in the case of switchgear and rotating machinery.

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A full dynamic analysis shall be carried out for all structures subject to dynamic loading. The
support structures under circuit breakers and other outdoor equipment shall be designed for the
maximum dynamic loading resulting from all circuit breakers in a zone operating
simultaneously following a buszone fault.
(4) Temperature Effects:
Allowance shall be made for the stresses induced in any structure due to differences in
temperature between the surfaces of a member or between parts of the structure.
The temperature of a concrete or steel surface exposed to sunshine may be taken as 70 oC

maximum.
In long structures, expansion joints shall be provided for a temperature range of 60 oC. The
joints shall be located and spaced so as to minimize strains in the structure, cladding, finishes,
fixings or plant.
(5) Seismic loads: as per BS/American/German/Saudi standards and code of practice. For Seismic
analysis the minimum requirement to be fulfilled is Zone 2A and importance factor 1.25 as per
UBC standard.
(6) Other Loads:
Allowance shall be made for crane loads, shrinkage, creep and unequal settlement of supports.
(7) Combination of Loads:
All parts of a structure shall be designed for the worst combination of dead, imposed and plant
loads with temperature, wind, seismic and other effects.
5.1B.3.3.7 Buildings Generally
The buildings shall be entirely suitable for climatic conditions at the site and comply with the
requirements of this Specification.
The structure of the buildings shall be of reinforced concrete or structural steel construction. Reinforced
concrete slabs shall have a minimum thickness of 150mm; reinforced concrete walls shall have a
minimum thickness of 250mm and the minimum cross sectional dimension of beams and columns in any
direction shall be 250mm. All blockwork in the building shall be constructed using calcium silicate
blocks or equivalent except where the wall of the building is acting as a blast wall in which case the
building wall shall be constructed from reinforced concrete blockwork as specified.
The complete structure shall be capable of safely withstanding all the static and dynamic loading
imposed by the plant, equipment and wind loading. Due regard shall be taken to avoid excessive
deflection or movement of the structures, floors, etc. which could prejudice the proper operation of the
plant or cause permanent damage to the complete installation.
Particular attention shall be given to the design of wall and roof membranes and the positioning and
detailing of doors and louvers to exclude wind borne sand, dust and spray. The design of the steel
fabricated external doors shall take account of the need to provide adequate sealing against the ingress of
sand and dust.
The design of wall, roof membranes and doors shall take account of the need to provide adequate
protection from solar gain and glare.

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The design of buildings shall ensure that noise; vibration and temperature levels are maintained within
acceptable limits. The Tenderer shall give full details of the measures to be adopted and the materials he
proposes to use to achieve these requirements.
The dimensions of 110 & 13.8kV control buildings shall be such that adequate space is provided for the
safe installation and proper operation and maintenance of all plant and equipment. Rooms required shall
be as specified in the SCOPE OF SUPPLY.
Except for the battery room floor, the finished levels of all ground level floors shall be the same and the
levels of structural concrete in the various rooms shall be altered as necessary to comply with this
requirement.
All internal walls including the internal face of external walls shall be plastered for the full height of the
wall except in the switchgear hall where the plaster shall terminate 2 meters above the floor level.
Where a column is located in any external wall or in an internal wall of the switchgear hall the internal
column face shall be flush with the finished plaster.
The dimensions of the rooms have preliminary been fixed by the Engineer .the contractor should have to
coordinate with switchgear contractor for the size and shape of the equipment.
The buildings shall include the accommodation for 110, 13.8kV switchgear, control panels, relay panels,
communications equipment, batteries, auxiliary power supply equipment, and mechanical and electrical
services with adequate provision for any future extension or addition of equipment as indicated in the
SCOPE OF SUPPLY. Other rooms shall be provided if called for in the SCOPE OF SUPPLY. These
shall in the opinion of the Engineer, be of sufficient size to meet the requirements of the plant.
Ease and speed of construction are very important considerations in the execution of this Contract.
Tenderers shall have to give a clear and detailed specification of the building construction proposed and
tenders which are not sufficiently detailed for an accurate assessment by the Engineer will not be
considered.
A cable room (cable basement) shall be provided under the 110 & 13.8KV switchgear halls and other
room as required.
Access to the cable room shall be by a permanent stairs and stair wall in the switchgear hall floor slab
with handrail as specified.
Each cable room shall have an emergency exit remote from the access stairs & permanent exit with door
which come out side the Substation building. The cable room shall be designed and constructed to be
watertight. The room shall be provided with fire resistant doors as specified in the relevant section of this
specification.
Trough covers and manhole covers shall be provided over permanent cable and pipe trenches and
chambers. These covers shall be designed to accept the appropriate floor loading according to their
location. Similar covers shall be provided over all floor openings installed to cater for the full
development of the station. Lifting keys shall be provided for handling of removable covers.
Adequately designed noise and thermal insulation shall be incorporated in the buildings particularly in
the control and relay rooms. Where suspended ceilings are specified all wiring and fittings shall be
concealed above suspended ceilings.
The layout of the building shall be to the approval of the Engineer.
Entrance to the control and relay rooms shall be through a hallway. 380, 110, 13.8 kV Switchgear halls
shall have separate external emergency escape door adjacent to the main equipment door. A further
emergency escape door shall be provided at the end remote from the main equipment door. This escape
door may either be an internal door or an external door. All external emergency escape doors above the

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surrounding ground level shall be provided with an external concrete platform and stairs with protective
handrailing.
5.1B.3.3.8 Foundation Design
All foundation designs shall conform to the requirements of British Standards Institution BS 8004 or an
approved Code of Practice for Foundations and shall take full account of the soil conditions on site.
All foundations shall be capable of resisting all the design loading and shall be designed to keep
differential and total settlements or other movements within acceptable limits. The Contractor shall
demonstrate that the stability of buildings and structures as a whole or any part of them and calculated
factors of safety conform to the approved Code of Practice.
Foundations for plant shall be designed with due regard to deflections, settlement and vibration so that
proper functioning of the plant is unimpaired. The transmission of vibration shall be kept to a
satisfactory minimum and effective measures shall be taken to ensure this.
The design of foundations shall have regard to the requirements in respect of pipe and cable troughs and
trenches, building-in of holding down bolts for plant or structural components and concrete protection.
13.8kV building and transformer foundations in reclaimed material shall be founded on piles or ground
which has been subjected to ground improvement.
Two No 49Kg/m type S49 or equivalent rails shall be provided on each transformer foundation with
coordination of Transformer contractor or as directed by the Engineer.
Piling methods or ground improvement techniques used shall be entirely suitable to meet the
requirements of design and the nature of the particular site and shall be carried out by specialist
contractors approved by the Engineer.
Due account shall be taken of:
(1) The water-bearing nature and permeability of the strata.
(2) The presence of unstable sands and silts.
(3) The nature of the bedrock.
(4) The presence of contaminating chemicals in ground water.
(5) All other geological features.
Where piling is adopted the design of the piles and the foundations they support shall be to the approval
of the Engineer. Where foundations are supported on piles they shall be adequately and properly tied to
the pile heads.
Testing shall be required at each site, where piling methods or ground improvement techniques have
been applied. The extent and form of such testing shall be appropriate to the type of construction used
and shall be to the Engineer's approval. The cost of all such testing shall be borne by the Contractor and
included in his Tender.
5.1B.3.3.9 Roadwork
The design and construction of roadwork shall take full account of the information provided by the Site
Investigation.

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The layouts of roads shall be determined by the arrangement of buildings AIS high voltage equipment,
gantries and transformer foundations and shall be to the approval of the Engineer. Minimum Road width
shall be 5 meters or as agreed by the engineer.
The Contractor shall provide roads up to the off-loading bays of each switchgear room and main
HVequipment and any other access roads necessary for the proper movement and installation of all the
installed plant.
See Clause 5.1B.3.3.7 for requirements regarding roadway levels outside the off-loading bays. The
Contractor shall provide adequate access and facilities for the delivery and removal of transformers.
These shall be designed to safely withstand all jacking point loads, etc. and adequate haulage bollards or
rings shall be provided where necessary. Where roads or transformer access pass over cables or pipes
special designs shall be incorporated to prevent damage to the services.
The road construction shall be asphaltic concrete designed to withstand the loads to which the roads will
be subjected including the delivery and removal of the heaviest items of plant.
The entire width of the road shall be excavated to formation level and any material found to be
unsuitable should be further excavated until a sound road foundation is established. CBR (California
Bearing Ratio) tests must be carried out to establish the strength of the foundation layer. Unsuitable
material shall be replaced with Hardfill Type II compacted in accordance with Clause 5.1B.3.6.2 of this
Specification.
Before placing any sub-base course material the surface of the formation shall be well rolled and
compacted to the required lines and levels.
A layer of compacted Hardfill Type 1 sub-base of finished thickness required by the design but not less
than 300mm thick shall be graded and rolled to the required cross-section and profile in accordance with
Clause 5.1B.3.6.2 of this Specification.
The surface shall consist of a 50mm asphaltic concrete wearing course laid on 80mm asphaltic concrete
base course laid to falls and cross falls. The wearing course shall be laid as late as possible during the
contract period to avoid damage by construction plant. The thickens must be approved by the engineer.
The edges of all road surfacing shall be protected by a concrete edge strip 250mm wide flush with the
road surface and of at least the same depth as the road construction. The edge strip shall have nominal
reinforcement to resist vertical loads.
The concrete in road margins shall be in accordance with Clause 5.1B.3.7.2 and shall be finished with a
smooth trowelled surface accurate to line and level. Expansion joints shall be provided at intervals not
exceeding 4m and shall be an approved proprietary 15mm thick non-staining compressible bitumen
emulsion impregnated wood fibre board which recovers in excess of 80% after compression and will not
extrude when compressed.
A continuous soakaway shall be provided on the low side of all roads and paved areas and shall have
cross-sectional area of not less than 0.07m² for every square meter of paved area draining into it. The
depth shall be equal to or greater than the width. The soakaway shall be filled up to three-quarters of its
depth with 150-75mm crushed rock and the remaining quarter to ground level with 75-10mm crushed
rock.
5.1B.3.3.10 Boundary Works
General
Boundaries where required shall be in accordance with the directives contained in the document Security
and Safety Directives. The category of fences, gates etc. shall be as per SSD1. Boundry wall shall be
constructed as per Architectural appendix.
Perimeter fence shall be constructed as per company standard Drawing TB-801800 to 801808, TC-
801809 & TB-801812 Type 4 .

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5.1B.3.3.11 Sanitary Facilities

Where the SCOPE OF SUPPLY requires toilets at substations, toilets of both European and of Arabian
types shall be provided. They shall be complete with wash basin, mirror, electric hand dryer and low
level water tap (Arabian only) to the approval of the Engineer. A Water heater is to be provided for
toilets, and tearoom.
The toilets and wash basins shall, where possible, be connected to a public sewer or alternatively be
connected to a suitable septic tank designed to cater for 10 persons. It shall be watertight and constructed
to the approval of the Engineer. Suitable single seal inspection covers shall be fitted and the vent shall be
provided with a suitably shielded flap valve. The effluent discharged from the septic tank shall be piped
away to discharge in an approved soak pit. After completion and inspection of the septic tank and soil
drains the septic tank shall be filled and activated to the satisfaction of the Municipal Authority and the
Engineer.
5.1B.3.3.12 Water Supply and Storage
If sanitary facilities are to be provided, the following water supply facilities shall be included.
Where mains water supply is available an indoor cold water storage tank of adequate capacity shall be
provided. The underground (UG) and overhead (OH) water tank shall be min capacity of 10,000 and
2000 litres respectively. The tank shall be at an elevation sufficient to ensure an adequate supply to all
points of demand. The tank shall be of galvanized and painted steel or fiberglass construction and shall
comply with BS 417 Part 2 Grade "A" or BS 4994 respectively. A 25mm diameter supply pipe shall be
laid to a suitable point just outside the boundary wall chosen by the Engineer for present or future
connection to the main water supply. The pipe shall terminate with a proprietary approved valve and
valve box and a short length of pipe on the supply side to be jointed to the service facility of the main
water supply.
All tanks shall be supported so there is a fall to one end. A valved scour pipe shall be filled at the lowest
point of each tank and connected to waste. Tanks shall be provided with a valved discharge through a
take off 50mm above the bottom of the tank and located at the end remote from the scour
All tanks shall be fitted with an overflow pipe, which will allow water to be discharged outside the
building so as to be readily noticeable.
Tanks shall be tested and commissioned before acceptance and shall be designed for minimum
maintenance requirements.
5.1B.3.3.13 Weather-Proofing and Thermal Insulation
The roof and walls shall not allow the passage of rain or moisture into the building. The walls shall be
provided with all necessary horizontal and vertical damp-proof courses and flashing. The damp courses
and flashing shall be of bitumen impregnated asbestos fibre with a lead core, or similar approved
material.
The thermal insulation of the walls and roof shall be such that the temperature rise within the individual
rooms on failure of air conditioning/mechanical ventilation shall be within the limits determined in
accordance with the clause on Indo or Ambient Design Temperature in the section on GENERAL
REQUIREMENTS.
5.1B.3.3.14 Roofs
5.1B.3.3.14.1 General
As substation buildings having electrical equipment therefore it is essential that the roof provided shall
be weatherproof and leak-proof under all conditions. The successful tenderer shall guarantee the

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satisfactory performance of the roof for a period of ten years and shall undertake to make good any
defects, which may arise within that period.
The minimum pitch of the roof shall be 1 in 100. The roof structure of each of the control, relay and
communications rooms shall be designed to leave these areas free from internal columns and walls.
5.1B.3.3.14.2 Roof
The roof shall be of reinforced concrete or structural steel construction.
5.1B.3.3.14.3 Roof Covering
A cold-applied waterproof flexible laminate comprising 0.3mm PVC sheet and 1.5mm self-adhesive
rubber/bitumen compound, suitable for hot climates shall be laid on the concrete slab, in strict
conformity with the manufacturer's instructions. The roof slabs shall have been thoroughly inspected,
cleaned and made good as necessary to ensure a satisfactory surface before laying the membrane.
Roof insulation of thickness determined by the building thermal design but not less than 50mm in
thickness shall be laid on the waterproof membrane. The insulation shall be a rigid, stable, closed cell
insulation board, extruded polystyrene type with a five year aged thermal conductivity of 0.032 W/m°C
at 24°C, a density of 32-35kg/m, a compressive strength of 0.3 N/mm² and a water absorption of less
than 0.1% by volume. It shall be rot-proof, non-hygroscopic and shall not support vermin
A separation layer of synthetic fibre mesh of not less than 0.7mm thickness shall be laid on the insulation
in strict conformity with the manufacturer's instructions.
All roofing materials shall be proprietary and approved by the Engineer. All roofs shall be finished with
gravel screened 15mm to 30mm with no fines placed in a layer of thickness required to achieve a
sufficient degree of ultra-violet protection but not less than 50mm.
5.1B.3.3.14.4 Roof Drainage
The roof shall be drained to gutters and downpipes generally in accordance with
American/German/Saudi standards/British Standard Code of Practice CP 308.
5.1B.3.3.15 Concrete Protection
Concrete protection shall be provided for all concrete below ground level at all sites. Concrete protection
shall consist of a layer of polythene sheet 250 microns thick laid on foundation soil, a layer of Grade C
blinding concrete laid on the polythene sheet, a layer of proprietary approved self-adhesive, self-sealing
pre-formed bitumen/polythene waterproof protective impervious membrane not less than 1.5mm thick
laid on top of the blinding concrete and a second layer of Grade C blinding concrete laid on the
impervious membrane. A vertical layer of the approved membrane protected by 6mm plywood shall be
carried up the sides of the protected structure to a level of not less than 300mm above finished ground
level. This vertical membrane shall be lapped with the horizontal membrane and sealed at the highest
point with a hardwood strip secured to the vertical face of the structure with a countersunk brass screw
and an approved sealant. This entire detail shall be carried out strictly in accordance with Drawings
appended to this Specification.
Where concrete is in contact with ground water or soil with high salt content, high acidity or other
substance which would be harmful to the concrete, the concrete shall be protected on the bottom and all
sides with bitumastic coating.
Concrete protection of cable troughs and duct banks shall be as shown on Drawings appended to this
Specification.

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Concrete pile protection shall consist of a permanent Bitumen coated mild steel casing of 6mm wall
thickness from the top of the pile to bedrock surrounded by 75mm thickness of blinding concrete for its
entire length. The top of the protective steel casing shall have a minimum lap of 100mm with the
protective impervious membrane surrounding the concrete pile cap or footing as detailed in the above
'Concrete Protection'. This entire detail shall be carried out strictly in accordance with Drawings
appended to this Specification.
Where spaces are to be left between the underside of suspended ground floor slabs and the ground level
below, the underside of slabs and beams and the internal faces of walls enclosing this space shall be
painted with 2 coats of an approved bitumastic paint.
All traces of loose material, laitance, shutter oil, grease, wind blown deposits and other contaminants
which could prevent the proper adhesion of, or result in adverse reaction with, the protective system shall
be removed from the concrete surfaces to be protected.
Concrete surfaces to be protected shall be free from pinholes and other surface defects. The Engineer's
approval shall be obtained for any method of repairing surface defects. Any preparatory filling required
shall normally be carried out using an approved non-shrinking mortar.
Surfaces to be tanked with a bituminous/polymer sheet laminated membrane shall be wire brushed to
remove all dust and other loose material.
Blinding concrete prepared for receiving base slab protection shall be free from sharp edges and
projections. The surface shall be cleaned by an oil free air blast where practicable or as otherwise
directed by the Engineer.
Surfaces to be coated with bituminous-based coating shall be wire brushed, either by hand or with power
tools. All dust and other loose materials shall be removed.
5.1B.3.3.16 Cranes
An approved electrically operated overhead travelling crane capable of lifting the heaviest load during
erection or maintenance which will be handled with in 110 KV hall. The detailed requirements are given
in clause 5.1B.5.6 of this specification.
5.1B.3.3.17 Doors and Frames
5.1B.3.3.17.1 General
The doors used throughout the works shall be proprietary hollow steel in steel frames from a supplier
approved by the Engineer. Doors and frames shall be painted as specified for galvanized surfaces in
GENERAL REQUIREMENTS. All external doors shall be dust proof doors.
Exterior and Interior holllow metal doors shall be acoustically sealed, thermal insulated, honey combed
core construction and approved and labeled for 3 hr fire resistance rating as per Underwriters Laboratory
(UL).
All surfaces of Doors and frames shall be coated with two (2) coats of high gloss epoxy paint. The paint
shall be suitable for the application over the galvanized surfaces.Painting work to the door frames should
be in accordance with TES-H-107.01 and color shade shall be as per TES-H-107.02.
The size of the door shall be adequate for the easy movement of biggest equipment, while sizing the
door, the contractor shall provide the documents for biggest equipment that shall be moved in and out of
the door.
The contractor shall submit evidence to the satisfaction of the Engineer of the door manufacturer's
proven record in the manufacture, supply and erection of the type of door required by this Specification.
Complete shop drawings showing all dimensions, sections, materials, reinforcements, thickness, finish
hardware sets, anchors, hinges, and all other information necessary for proper evaluation shall be
submitted to the Engineer for approval.

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5.1B.3.3.17.2 Doors
All hollow metal doors and pressed metal frames shall be constructed of prime quality cold rolled steel.
Quality, weights and sizes specified herein are considered to be the minimum that will be acceptable.
Doors shall be 45mm minimum thickness flush type with face sheets of 1.5mm minimum thickness
stretcher leveled steel, all welded construction with perimeter stiles of not less than 1.2mm steel. Face
sheets shall be securely welded to interlocking vertical and horizontal frame members spaced no more
than 400mm on centers. Tops shall be flush closed. All exposed welds shall be ground smooth. All door
cavities shall be filled with suitable sound deadening and insulating material. Doors and frames shall be
reinforced for hardware e.g. hinges, door closer, etc. All hallow metal doors shall comply with the
requirement of TES-P-119.19 and TESP-119.21.
Doors and hinges shall be galvanized, bonderized and shop painted with one coat of rust-inhibitive
primer in preparation for finish painting on site.
Doors shall be erected plumb and true with all hardware left in proper working order. Erection shall be
by competent door erectors in accordance with the manufacturer's recommendations and to the
Engineer's satisfaction. Hardware of Hollow metal door shal be in accordance with the required Steel
Door Institute (SDI) specification SDI-105.
5.1B.3.3.17.3 Pressed Metal Frames

Pressed metal frames shall be wrap around or butted 1.9mm minimum thickness rolled steel, with
integral stops and rebates, to the sizes as noted on the final construction drawings. All frames shall have
all hardware cutouts reinforced with 3.2mm minimum plate welded to frame, and 4.8mm minimum plate
hinge reinforcement. Frames shall be mortised and reinforced, drilled and tapped for mortise type
hardware, reinforced for surface hardware. Frames used in masonry walls shall have tapped holes
protected by steel plaster boxes welded behind reinforcement. Heads and jambs shall be notched mitred,
welded and finished smooth. Not less than three adjustable wall anchors shall be provided at each jamb,
plus welded-on clip angles with two holes for anchoring to floor at bottom of each jamb. Frames shall
have removable angle spreaders securely fastened to bottom of jambs to ensure rigidity during shipping
and handling. All frames shall be galvanized, bonderized and shop painted with one coat of rust
inhibitive primer. Exterior door frame (header and jambs) and door bottom shall be provided with
neoprine compressible seal.
5.1B.3.3.17.4 Fire Resistance
The fire resistance rating of doors shall be in accordance with the requirements of this Specification.
Frames and thresholds shall be equal in rating to that of the door. Doors shall comply with the
requirement of NFPA 80, NFPA 101, and UL 63. Fire endurace tests of door asssembly shall be
performed in accordance with NFPA 252.
Tenderers shall clearly state their proposals for proprietary fire resisting door sets which shall include a
certificate of fire resistance from an internationally recognized testing laboratory e.g. Underwriters
Laboratory of U.S.A.
5.1B.3.3.17.5 Door Furniture
Door furniture shall be proprietary from an approved manufacturer of the best quality and suitable in all
respects for its location including adequate strength and resistance to corrosion. Samples of door
furniture shall be submitted to the Engineer for approval.
Main equipment doors in switchgear room:

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The equipment doors shall be fitted with an espagnolette type bolt system on the inside fitted with a
locking device. The internal bolt system shall be inaccessible from the outside of the door where an
approved fitted door handle only shall be provided.
Doors shall also be provided with an approved system for keeping doors fixed in the open position at
loading/unloading times.
Emergency escape doors from switchgear room:
The escape doors shall be provided with an approved panic bolt system on the inside.
An approved lock shall be fitted, operable with keys of the 'HVBR' system. This lock shall be
inaccessible from the inside of the door.
Other Doors:
The following doors shall be provided with locks operated with keys of the 'HVBR' system:
External door to entrance hall.
External and internal door of Workshop
Internal door to Communication Room
Internal door to Battery Room Toilet doors
Locks shall be to the approval of the Engineer. Personnel gate in boundary fence shall be fitted with
Employer's standard padlock.
All doors shall be provided with door handle sets, door closer and stops. Hinges on doors shall be "flag
type" to enable doors to be removed.
All internal doors and toilet doors shall be operable from within without the use of a key.
External doors shall be fitted with seals to prevent the ingress of dust and sand. Seals shall be of the
'compression' type. They shall be air filled with a high compression capability. Seals shall not be integral
with the doors or frames but shall be fitted after the erection of the doors and frames. The method of
fixing shall be with self-tapping screws or other fixing method approved by the Engineer. Fixing method
used shall be such that worn or damaged seals can be easily removed and replaced.
The design of the door seals and closer shall take into account the pressurization of the substation.
5.1B.3.3.17.6 Windows and Louvers:
Aluminum/steel windows and louvers can be provided with detailed specification with the approval of
SEC/Engineer.
5.1B.3.3.18 Floor Finishes
The floor finishes shall be as specified below:
The concrete floor finishes U1, U2 and U3 shall be as specified in Clause 5.1B.3.8.2.
Cable Room - The floor shall have a class U2 finish and be sloped to the sump (or sumps) to facilitate
the removal of water.
13.8kV Switchgear hall, Earthing Room, Charger Room office and store - The floors shall have
Class U3 finish and a pigmented surface hardener consisting of 3 coats of an approved two component
water dispersed epoxy resin floor sealing system applied strictly in accordance with the manufacturer's
instructions.

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Control and Relay Rooms - the floor shall have a Class U2 finish with dust proofing compound and be
provided with a free access (computer type) decking over the complete area of each room. The minimum
clearance between the floor and the decking shall be 600mm.
Entrance Hall, Toilets, and Kitchen - the floor shall have a Class U1 finish overlaid with terrazzo tiles
and with terrazzo skirting.
Battery Room - the floor shall have a Class U1 finish. The finished floor levels shall be lower than those
of adjoining rooms or passageways by an amount sufficient to prevent escape of electrolyte from the
room in the event of any spillage, leakage or rupture of tanks or containers. Any cable opening or duct
passing through the floor shall project above floor level by a similar amount to prevent any escape or
leakage through such opening or duct. The floor and skirting shall be finished in tiles resistant to
electrolyte and set in electrolyte resisting mortar.
5.1B.3.3.19 Wall Finishes
The wall finishes in the various rooms shall be as specified below:
The concrete wall finishes shall be as specified in Clause 5.1B.3.8.2. The paint systems shall be as
specified in Clause 5.1B.3.16.5.
Cable Room - subject to any repair work required, the concrete shall have a Class F2 finish and shall be
painted with paint System A.
Toilets - the walls shall be finished to ceiling height with glazed tiling.
13.8kV Switchgear hall, Earthing Room, Charger Room and Store - The walls shall be plastered up
to a height of 2 meters above floor level and shall have fair-faced blockwork above that level. All
surfaces shall be painted with paint System D.
Hallway, Office and Kitchen - walls shall be plastered for the full height of the wall. Plaster shall be
treated with paint system D to a height of 2m above floor level. Plaster above this level shall be treated
with paint system B.
All Other Rooms - blockwork shall be plastered for the full height of the wall and shall be painted with
paint system B.
All External Wall Surfaces - all blockwork shall be fairfaced and, subject to any repair work required,
concrete surfaces shall have a Class F3 finish. Concrete blockwork and concrete surfaces shall be painted
with paint system C. Calcium silicate blockwork shall be painted with paint system E or paint system C
as required by the Engineer.
5.1B.3.3.20 Ceiling Finishes
The ceiling finishes in the various rooms shall be as specified below:
Control Room, Relay Room, Entrance Hall, Kitchen and Toilets - suspended ceilings as specified in
Clause 5.1B.3.16.4.
All other Rooms - subject to any repair work required the concrete shall have a Class F2 finish as
described in Clause 5.1B.3.8.2 and shall be painted with paint System B as described in Clause
5.1B.3.16.5.
5.1B.3.3.21 Fire Protection

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The structural design and materials of each substation and room shall be such that the spread of fire is
retarded. Means of escape shall be provided to enable staff to go to safety. All doors shall open in the
direction of personnel escape routes and all doors shall have panic-handles and magnetic door-holders
The building shall be compartmented to the approval of the Engineer to restrict the spread of fire. Each
fire-protected zone shall have a self-holding abort button near the entrance.
Walls, floors and other barriers separating compartments shall be such as to give two hours or more fire
resistance. Where cable pipes or ducts pass through compartment walls a barrier of non- combustible
material shall be provided such that the fire resistance of the wall, floor, etc. is not reduced.
Doors shall be such as to provide the following resistance to fire:
- Doors which protect escape routes for safety of personnel - 1 hour.
- Doors which prevent the spread of fire between compartments - 2 hours.
The spread of fire or explosion from one transformer to another and to adjacent buildings shall be
prevented by blast wall provided between each transformer or as directed by the engineer. Blast walls
shall be of reinforced concrete or reinforced concrete blockwork or as directed by the Engineer.
Reinforced concrete blockwork blast walls shall be hollow block with concrete filling and a minimum
reinforcement of 8mm diameter high yield steel bars, two every second course horizontally and one
every block vertically. Where walls of a building are sufficiently close to be at risk and are not protected
by a blast wall, such walls shall be designed as blast walls.
An oil drainage pit with broken stone shall be provided to contain and extinguish fire in escaping oil.
5.1B.3.3.22 Transformer and Reactor Foundations and Oil Pits
Foundations shall be constructed in reinforced concrete. An oil collection system shall be provided to
contain all oil in the event of leakage. The system shall be by a common oil drainage pits away from
transformers and shunt reactors designed to collect leaking or drained oil from each equipment to
effectively remove away oil in case of a fire on any of the transformer or shunt reactors. Capacity of
common oil pit shall also take into consideration the quantity of water discharged by pressure water tank.
The oil drainage pits shall contain sufficient broken stone 50 to 75mm with 40% void to extinguish fire
in the escaping oil. Oil drainage pits shall be connected to common oil pit by stone ware pipe. The
complete system shall be submitted to the Engineer for approval during design stage.
Foundations and oil pits shall be of watertight monolithic reinforced concrete construction. They shall be
painted internally with an oil-resistant paint. Provision shall be made to separate oil from water and for
removal by pumping of oil/water from the pits.
Reinforced concrete troughs fitted with removable covers and pipe ducts as required shall be provided
for cables to the transformers. These shall be adequately sealed to prevent ingress and escape of oil or
water and should be subjected to the engineer approval.
5.1B.3.3.23 Rainwater Drainage
The Contractor shall ensure that adequate drainage is provided around the periphery of each site to
intercept and divert clear of the site any rainwater flows and to keep the site from being flooded by them.
All ground surfaces and roof areas shall be drained to prevent flooding. Drains shall be designed to
handle the maximum rainfall likely to be experienced, slope shall not be less then (1 in 250).
Rainwater drainage and the sewerage system shall be kept completely separate. No sewerage drainage
shall be allowed into the rainwater drainage system and rainwater shall not be permitted to enter sewers.

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Provision shall be made for removal by pumping of rainwater from transformer and reactor pits.
5.1B.3.3.24 Penetration through Building Elements
Where penetrations are required for cables and other equipment to pass through external building
elements including basement walls, the penetration detail proposed shall be watertight.
5.1B.3.3.25 Joints in Building Elements
Full joints shall be provided every 3 meters in reinforced concrete external walkways and upstand roof
parapets.
5.1B.3.3.26 Pumps
An approved electrically operated portable sump pump suitable for use in all sumps in the substation
shall be provided. The pump shall be suitable for use on both oil and water.
5.1B.3.3.27 Temporary Works

The Contractor shall submit to the Engineer for consideration completed drawings and calculations
relating to strength and anticipated deflection of all temporary works and stage he proposes to erect, not
less than six weeks before putting such work in hand. Any comments of the Engineer shall not diminish
the Contractor's full and entire responsibility for such temporary works or stage.
5.1B.3.4 SURVEYING
See clause 5.1B.1, GENERAL REQUIREMENTS.
5.1B.3.5 EXCAVATION
5.1B.3.5.1 Excavation near Existing Services
See clause 5.1B.1. GENERAL REQUIREMENTS.
5.1B.3.5.2Excavation Level
Foundations for structures not supported on piles shall be carried down to sound material and to level not
higher than shown on or inferred from the drawings.
The drawings for the various structures shall show, as near as it is possible and practicable to determine
beforehand, the depths for the proposed excavations, but such limits shall be finally determined during
construction.
5.1B.3.5.3Foundation on Rock
The excavated rock surface at foundation level shall be free of shattered or loose particles of rock and
shall be washed free of clay, silt and rock chipping, etc. with an air and water jet immediately before
concreting begins.
5.1B.3.5.4Foundation on Material other than Rock

When the depth of excavation has reached to not less than 150mm above the invert level shown on the
drawings, the approval of the Engineer shall be obtained as to the suitability of the material for the
foundation in question. Should the material be suitable, the excavation shall then be cleaned down to the
correct foundation level, the Engineer's approval obtained and concrete placed on the invert of the
excavation without delay No excavated material shall be filled in to the bottom of excavations. Any
material disturbed at the approved foundation level shall be removed and replaced by concrete. In the

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event of the approved invert being covered by water before concrete is placed, the excavation shall be
pumped out and the excavation carried down to sound undisturbed material.
5.1B.3.5.5Excavation of Foundation Pits and Trenches
Catch-pits with pumps in cable basements and common sump for all transformers and shunt reactors
situated away from the equipment should be provided before any particular excavation is commenced,
the contractor shall submit his proposals with regard to the outline thereof to the Engineer for approval.
The Contractor may carry out these excavations by any method he considers most suitable, subject to the
stipulations in the Contract.
The sides of pits, trenches and other excavations shall be adequately supported at all times to the
satisfaction of the Engineer until backfilling is complete. Sound and durable material shall be used for
supports and the Contractor shall ensure that the supports are installed, maintained, and removed by men
experienced in such work.
Exposed faces of the excavations shall be cleared of all material (including rock fragments) which are
liable to cause injury or damage by falling during the course of the work. The Contractor shall take all
precautions necessary for the safety of adjoining structures by shoring, opening in short lengths, or
otherwise. Excavations shall be kept free from water until, in the opinion of the Engineer, the works
therein (including backfilling) will not be damaged by water, and the Contractor shall construct any
sumps or temporary drains which the Engineer may deem necessary for this purpose. The excavations
shall be of sufficient size to enable the work therein to be properly executed, and shall allow for the
supports, drainage facilities, and other things required for this purpose.
In the event of excavations being carried out wider or deeper than approved they shall be filled in to the
required dimensions or levels with concrete or with other suitable material, to the satisfaction of the
Engineer.
Trenches for pipelines shall be excavated to the required levels and grades so that the pipes when laid are
to true alignment and grade and supported over their lengths. High spots shall be removed and additional
excavation shall be carried out under the ends of each pipe and fitting, as necessary to facilitate the
making of joints and to ensure that the pipes do not bear at the joints.
Where the trench passes through rocky or very stony ground, the trench shall be excavated to a depth of
100mm below the proposed invert level and backfilled with approved sandy material. The filling shall
be placed and compacted to finished level and the trenches for pipelines opened subsequently.
5.1B.3.5.6Disposal of Excavated Material
The disposal of all materials arising from excavations shall be to the approval of the Engineer. Material
which is suitable for re-use as filling or for other purposes required under the Contract shall not be
disposed of until it has been agreed by the Engineer that it is not required for re-use. The Contractor shall
not dispose of materials outside the site or to another person, organization, body or authority without the
approval of the Engineer.
Materials which, by agreement, are to be disposed to spoil shall be removed to approved spoil dumps or
otherwise as directed by the Engineer.
In all cases spoil dumps shall be filled in orderly sequence and kept free from standing water or pools or
areas dangerous to persons or animals. The cost of compliance with these requirements shall be deemed
to be included in the Tender Price.
5.1B.3.6 FILL

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5.1B.3.6.1 Fill Classification
Fill shall be obtained from areas previously used for winning such material. The Contractor shall inform
the Engineer about the source from which he proposes to obtain fill material. Prior to approval of the
source of material the Contractor shall carry out such tests on samples of the material as the Engineer
may require to ensure that the material is in accordance with this specification.
Fill shall be classified as follows:
(1)Soft Fill
(2)Rock Fill
(3) Rock Armoring
(4) Hard Fill Type I, Hard Fill Type II
(5) Hardcore
(6) Fill for Transformer Pits
(1) Soft fill shall be classified as plastic or non-plastic. Non- plastic materials shall be those
described as "coarse-grained non-cohesive" in BS 5930/American/ German standard. Plastic
materials shall be all other materials described as "fine-grained, cohesive" in the
above-mentioned table. Soft fill shall be placed at moisture content, which shall be to the
In the case of plastic material this moisture content shall be not more than 2 per cent above the
plastic limit for the material and in the case of non-plastic material, it shall be within 2 per cent
of that of the material as excavated above the water table.
(2) Rock fill shall be approved dense hard Grey rock, free from dirt, earth loam, clay or
organic matter, or alternatively obtained by blasting from a source approved by the
Engineer. Soundness of won rock shall be tested by water absorption test.
The stones shall not be more than 300mm or less than 50mm in any direction; 60% of the stone
shall be between 200mm and 300mm in size.
(3) Rock armoring shall be quarried and shall be hard dense stone of the best quality obtainable and
tested in accordance with slake durability test specified by the International Society for Rock
Mechanics and shall be obtained from quarry faces approved by the Engineer.
The stone shall be prismoidal in shape and the maximum dimension of any stone shall not be
more than three times the minimum dimension. Stone that has a tendency to fracture when
dropped onto stone shall be rejected.
(4) Hardfill Type I shall be selected hard well-graded material screened and crushed as necessary to
lie within the following grading of percentage by weight:
0 - 20% shall pass 75-micron aperture Sieve

8 - 45% shall pass 600-micron aperture Sieve
20 - 65% shall pass 5-mm aperture Sieve
45 - 100% shall pass 20-mm aperture Sieve
85 - 100% shall pass 37.5mm aperture Sieve
Free of stone over 75mm.
Hardfill Type II shall be selected hard granular material with not more than 7% by weight water
soluble and shall be within the following grading of percentage by weight:
Not more than 10% shall pass 90-micron aperture sieve.

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Not more than 28% shall pass 355-micron aperture sieve
Not more than 50% shall pass 4mm-aperture sieve.
Free of stone over 150mm gauge.
(5) Hardcore shall consist of broken stone, concrete brick or coral varying in size from 100 to
25mm. It shall be free of clay, soft material and deleterious matter and shall be chemically inert.
(6) Fill for transformer pits shall be broken stone graded 50 to 75mm with a minimum of 40%
voids when placed.
5.1B.3.6.2 Filling
Fill under all foundations, slabs and roads shall be mechanically compacted at the optimum moisture
content. The minimum degree of compaction shall be 95% of the maximum dry density at the optimum
moisture content. In situ density testing shall be carried out in accordance with BS 1377.
Backfilling of foundation pits and trenches shall be carried out only after the foundation and structural
works within the excavations have been inspected and approved by the Engineer. All filling shall consist
of approved materials, which shall be deposited and compacted, in layers not exceeding 250mm loose
depth.
Soft fill shall be placed at moisture content, which shall be to the approval of the Engineer. In the case of
plastic material this moisture content shall be not more than 2 per cent above the plastic limit for the
material and in the case of non-plastic material, it shall be within 2 per cent of that of the material as
excavated above the water table.
Soft fill shall be spread in layers of 200mm loose thickness and compacted by eight passes of a 10 ton
roller or such other approved plant and methods which will give 95% maximum dry density as
determined in accordance with BS 1377 Test No. 13 or 14.
Rock fill shall (except where otherwise required near formation level or at external surfaces) be of such
size that it can be spread and leveled in layers not exceeding 450mm loose depth by a tractor weighing
not less than 15 tones. Voids in each layer shall be filled with rock fragments before placing the next
layer. Each layer shall be compacted after spreading by at least 15 passes of a towed vibratory roller with
a static mass per meter width of roll of at least 1800kg or a grid roller with a mass per meter width of roll
of at least 8000kg or other equivalent plant approved by the Engineer.
Hardfill Type I and Type II shall be placed in layers not exceeding 150mm and 300mm respectively at
optimum moisture content and compacted to 90% maximum dry density as determined in accordance
with BS 1377 test no. 13 or 14.
Hardcore shall be compacted in layers not exceeding 200mm thick.
Where material consisting of a mixture of rock and soft fill is used as filling, the material shall contain
sufficient soft fill for satisfactory compaction of the filling.
Fill shall not be deposited in standing water without the Engineer's permission. This permission will not
normally be granted for soft fill or for fill of any kind where the standing water can, in the opinion of the
Engineer, be pumped out, drained or diverted.
Permission may be granted to place rock fill by random tipping in areas where the depth of water is
greater than 600mm but the methods and quality of the fill material shall be subject to approval. When
the fill level is 600mm above the water surface it shall be compacted until there is no discernible
movement under the plant placing or compacting fill, before normal filling and compacting is resumed.

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Pipe trenches shall be backfilled and compacted in layers 150mm thick, the filling to 300mm above the
crown of the pipe shall be approved sandy material free from stones, etc. well packed by hand evenly
around both sides of the pipe, care being taken not to disturb the pipe. Back filling over this level shall be
carried out using approved material and may be compacted by mechanical means.
The Contractor shall be responsible for making good all settlements, which may occur to the satisfaction
of the Engineer.
5.1B.3.7 CONCRETE WORK
5.1B.3.7.0 GENERAL SUMMARY
DESCRIPTION OF WORK INCLUDED:
Concrete shall confirm to the requirement of 70-TMSS-03.

Work of this section consists of supply and placing of reinforcement, formwork and cast-in-place
concrete and includes materials and measures to complete concrete work required for the Works.
REFERENCES:
Publications listed below form part of this specification:
American Concrete Institute (ACI):

- 301 Specifications for Structural Concrete for Buildings.
American Society for Testing and Materials (ASTM):

- C260 Specifications for Air Entraining Admixtures for Concrete.
- C494 Specifications for Chemical Admixtures for Concrete.
- D412 Specifications for Rubber Properties in Tension (Tests for).
- D2103 Specifications for Polyethylene Film and Sheeting.
British Standards Institute:
- CP110 The Structural Use of Concrete.
SUBMITTALS:
Submit cement certificates; water and aggregate samples and test results; batch plant and checking
procedures; mix designs and trial mix test results.
MATERIALS:
Materials for concrete work shall conform to all requirements of AC1 301 Specifications for Structural
Concrete for Buildings, except as modified by the following supplemental requirements:
1. Reinforcement shall be deformed steel, to ASTM A615. Reinforcement shall be type Grade 40
minimum.
2. The following admixtures may be used:

 Air Entraining admixtures to ASTM C260.
 Water Reducing Plasticizing admixtures, Chloride free conforming to ASTM C494 Type A or
D.
The use of all admixtures will be subject to Engineer’s approval.

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3. Type V cement or type I and II cement with cementious derivatives as per the geotechnical studies
and recommendations of the geotechnical consultants shall be used for all buried concrete and
concrete in contact with seawater. Other concrete shall be Type I or Type II.
4. Chloride content of aggregates shall be limited to 0.02% by dry weight.
5. Aggregates shall not contain harmful amounts of reactive minerals or other chemical compounds,
which may react with groundwater or chemicals present in the ground. Aggregates shall be suitable
for the production of sulfate resisting concrete.
6. The minimum cover to reinforcement shall be as follows:
 Concrete against ground - 76 mm (3 in)

 Concrete exposed to weather - 50 mm (2 in)
 Concrete not exposed to weather or in contact with ground:
a) Slabs, walls, joints:
# 14 and #18 bars - 38 mm (1-1/2 in)
# 11 bar and smaller - 19 mm (3/4 in)
b) Beams, columns:
Primary reinforcement,
Ties stirrups, spirals - 38 mm (1-1/2 in)
7. Continuous water stops shall be provided for all construction and expansion joints of water retaining
structures. Submit details and samples of water stops to Engineer for approval, prior to installation.
Only rubber, neoprene or PVC waterstops conforming to ASTM D412 shall be used.
8. Proprietary materials for repair of surface defects will only be permitted if proposed materials were
approved by Engineer.
9. When required damp proofing shall be installed below slabs and shall consist of 0.20 mm minimum
thickness polyethylene to ASTM D2103 or 20 kg (45 lb.) roll roofing.
10. Where concrete is in contact with ground water or soil with high salt content, high acidity or other
substances which would be harmful to the concrete, the concrete shall be protected on the bottom and
all sides with bitumastic coating.
11. Floor hardener shall be metallic type and shall be subject to Engineer’s Approval.
EXECUTION:
Concrete work shall conform to all requirements of AC1 301, Specifications for Structural Concrete for
Buildings, except as modified by the Supplemental requirements below:
1. The use of earth cuts for forms will be permitted, provided adequate cover is maintained for
reinforcement.
2. Provide a 40mm x 40m chamber on external corners and edges of concrete exposed to view.
3. Tolerances for formed surfaces of buildings shall be as specified in Table 4.3.1 of AC1 301.
4. Do not disturb formwork until concrete has hardened adequately. Reference may be made to AC1
347 for recommended times of removal of forms.
5. Welding of reinforcement will not be permitted.
6. Placement of concrete underwater will not be permitted.

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7. Finishing of formed surfaces shall be as specified in AC1 301 Chapter 10 for the following:
 Rough form finish
 Smooth form finish
8. Slab finishes shall be as specified in AC1 301 Chapter II for the following:
 Broom or belt finish
 Troweled finish
 Nonslip finish
9. The contractor shall perform all testing in accordance with ACI 301. Testing with the facilities
provided by the contractor. All testing be carried out by an independent local testing laboratory
appointed by the engineer.
10. Damp proofing below slabs shall be lapped not less than 200 mm at joints.
11. Concrete floor hardener shall be applied in accordance with the manufacturer’s written instructions.
5.1B.3.7.1 Materials
5.1B.3.7.1.1 Cement
All cement used on the Works shall be Portland cement of a brand approved by the Engineer and
complying in all respects with Clause 5.1B.3.7.2.2 of this Specification and it shall be low-alkali content
to Table 1A of ASTM C150 - 83a.
Certificates:
Each consignment of cement shall be delivered in sealed branded bags or barrels and shall be
accompanied by a certificate from the manufacturer, showing that the cement has been tested and
analyzed and the date of such tests and analysis and that such analysis complies in all respects with the
Standard and if required the bags from each consignment shall be given a distinctive seal.
Tests after Delivery:
After delivery of each consignment of cement to the site, the Contractor shall supply samples of the
cement for testing. The samples, in sufficient quantity for testing in accordance with the requirements of
the Standard and not less than 5kg in weight, shall be supplied and handled at the Contractor's expense.
Stock of Cement:
In order to ensure due progress of the Works the Contractor shall at all times maintain on the site a stock
of cement sufficient for the following months' work. No cement shall be used upon the Works until the
Engineer has accepted it as satisfactory.
Returns:
The Contractor shall make a monthly return to the Engineer showing the quantities of cement received
and used during the month and in stock at the end of the month.
Storage on the Site:

The Contractor shall arrange that cement imported for use on the Works is delivered to the site with a
minimum of delay and that it is stored under suitable conditions during transit. All cement kept upon the
site shall be a stored in well-ventilated covered shed on platforms clear of the ground. The Contractor
shall ensure that cement is used in order of delivery to site and that different brands of cement are kept in
entirely separate stores.

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The use of bulk cement shall be subject to the Engineer's approval of the source, methods of transport,
unloading and storage on site and arrangements for delivery to the mixer.
Rejection:
The Engineer may reject any cement as the result of any test thereof notwithstanding the manufacturer's
certificate. He will also reject cement, which has deteriorated owing to inadequate protection or other
causes or in any other case where the cement is not to his satisfaction.
The Contractor shall remove all rejected cement from the site without delay.
5.1B.3.7.1.2 Aggregates for Concrete Works
General:
Except as may be modified hereunder the aggregates (fine and coarse) for all types of concrete shall
comply in all respects with BS 882 "Concrete aggregates from natural sources". They shall be hard,
strong and durable and shall contain no harmful material in sufficient quantity to affect adversely the
strength or durability of the concrete or, in the case of reinforced concrete, to attack the reinforcement.
The maximum size of coarse aggregate shall be 20mm for all concrete mixes.
Source of Aggregates:
The Contractor is advised that otherwise suitable sources of naturally occurring fine aggregates can often
be contaminated by surface and other layers containing gypsum and of high salt content in zones within
range of capillary moisture. If the Contractor elects to win aggregates from such an area, subject to the
source being approved by the Engineer, he is strongly advised to obtain a sole concession over the area
required, to fence the area as necessary to prevent outside interference and to remove the contaminated
layers to spoil before commencing the winning of aggregates. This operation should be closely
supervised by the Contractor to ensure that no aggregates are obtained from the areas affected by
ground-water capillarity.
Similarly salts, gypsum, clay, cherts and other deleterious materials can be present in unacceptable
quantities in surface and other layers of bedrock. Bedrock within 1.5m of the original ground surface
shall not be used as a source of coarse aggregates.
Physical Requirements:
Fine and coarse aggregates shall comply with the following physical requirements:
(1) The weight of voided shells in fine aggregate shall not exceed 3%.
(2) The clay, fine salt and dust content shall not exceed the following limits:
-Coarse aggregates 1% by weight
-Natural sands 3% by weight
-Crushed stone sands 6% by weight
(3) The flakiness index and elongation index of coarse aggregates measured in accordance with BS
815 shall not exceed 25% and 35% respectively.
(4) The absorption of fine and coarse aggregates as measured in accordance with BS 815 shall not
exceed 2%.
(5) The aggregate impact value for coarse aggregates as measured in accordance with BS 815 shall
not exceed 30%.

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(6) Fine aggregates shall be clean, sharp, coarse sand and shall be within Zones 2, 3 and 4 only of
Table 2 of BS 882.
(7) Coarse aggregates shall be single sized aggregates obtained by mechanical crushing and
screening.
Chemical Requirements:
The maximum allowable level of chlorides and sulfates in concrete mixes shall be in accordance with the
following table:
Maximum allowable
Cement Type Property Level in Mix by
Weight of Cement
All Types Total acid soluble sulfate as sulfur 4%

trioxide (SO3)
Sulphate Resisting and Moderately Total acid soluble chloride as C1 0.2%

Sulphate Resisting Cement.
Ordinary Portland Cement. Total acid soluble chloride as C1 0.3%
Fine and coarse aggregates shall not be potentially reactive with alkalis.
Aggregates to be washed:
All aggregates, both fine and coarse, shall be washed mechanically by the Contractor to remove clay,
silt, dust and adherent coatings to the satisfaction of the Engineer.
Sampling and testing:
Sampling and testing of aggregates shall be carried out in accordance with BS 815 "Sampling and testing
of mineral aggregates, sands and fillers" where applicable. Chemical analysis shall be by normally
accepted methods. If required by the Engineer such sampling shall be carried out by the Engineer's
Representative, and samples delivered by him to the approved testing laboratory. The laboratory shall
forward a copy of the results of tests direct to both the Contractor and the Engineer.
Petrographic examination shall be carried out in accordance with the American Society for Testing
Materials Standard C295 "Recommended practice for petrographic examination of aggregates for
concrete".
An accelerated test for potential alkali reactivity shall be carried out in accordance with Research Paper
No. 25 Parts V and VI of the National Building Studies published by H.M.S.O., by an approved testing
laboratory. If this test indicates the possibility of alkali reactivity, further testing in accordance with the
following American Society for Testing Materials Standards will be necessary.
C227 Test for potential alkali reactivity of cement aggregate combinations (mortar bar method) (for
long term testing)

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C289 Standard method of test for potential reactivity of aggregates (chemical method)
C342 Standard method of test for potential volume change of cement aggregate combinations
C586 Standard method of test for potential alkali reactivity of carbonate rocks for concrete aggregates
(rock cylinder method).
Approval of Aggregates:
As soon as practicable after commencement of the Contract and well in advance of commencing
concreting, the Contractor shall, at the request of the Engineer, submit for testing samples of all
aggregates he proposes to use in the Works whether it is proposed to use in situ or ready mixed concrete.
The Engineer will require to inspect the sources of the proposed aggregates to be satisfied that the
proposed methods of working the sources and the arrangements for washing will produce aggregates of
regular quality complying with this Specification.
No aggregates for use in the Works shall be delivered to site until the Engineer has approved the
aggregates to be used and the arrangements for washing, storage and such like. Thereafter the Contractor
shall take samples from every 100 cubic meters of each type of aggregate delivered to the site and
handed to the Engineer for routine control tests.
Aggregates that fail to comply with this Specification or which have become contaminated, defective or
otherwise unsatisfactory shall be removed from site or otherwise disposed of to the Engineer's
satisfaction.
Storage of Aggregates:
The Contractor shall at all times maintain on the site such quantities of each type of aggregate as are
considered by the Engineer to be sufficient to ensure continuity of work.
Each type and grading of aggregate shall be stored separately bins, the floors of which shall be concrete
or other approved material having sufficient slope to ensure adequate drainage.
Wet aggregate delivered at the site shall be kept in storage for at least 24 hours to ensure adequate
drainage before being used for concreting.
Aggregates, which have been in storage for a long period, shall be removed from the bins and rewashed
by the Contractor if required by the Engineer to remove any accumulation of dust, silt and deleterious
substances.
5.1B.3.7.1.3 Water
The mixing water shall have a PH value of between 6.5 and 8. Water shall be tested in accordance with
BS 3148 - the following limits shall not be exceeded:
Total dissolved solids not greater than 2000 PPM

Suspended solids not greater than 2000 PPM
Chloride as NaC1 not greater than 800 PPM
Chloride as C1 not greater than 500 PPM
Sulfates as S03 not greater than 1000 PPM
Alkali HC03/C03 not greater than 1000 PPM
The methods of delivery and storing the water shall be to the approval of the Engineer.
5.1B.3.7.1.4 Admixtures

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(a) Where approved or specified, admixtures shall be used as a means of
(i) Increasing workability of the concrete without increasing water/cement contents,
(ii) Controlling and limiting retardation of setting,
(iii) Increasing concrete durability,

(iv) Reducing bleeding and associated settlement and cracking.
(b) Concrete admixtures and cements containing additives shall not be used unless specified or
approved by the Engineer in writing. Where not specified, approval will not be given unless the
Contractor can demonstrate that there is a clear technical advantage resulting from their use,
which cannot be obtained by reasonable variation of the constituents of the concrete mix.
(c) Only liquid admixtures shall be permitted. They shall comply with BS 5075, shall be chloride
free and shall not contain other substances, which adversely affect the durability and
performance of the concrete. Admixtures that excessively retard or accelerate the setting time of
concrete shall not be permitted.
(d) Water reducing admixtures shall normally be limited to those based on ligno-sulphonates or
salts of hydroxylated carboxylic acid.
(e) Air entraining agents shall be based on neutralized vinsol or other resin. The density of air
entrained concrete shall not be more than 5% less than the density of non air entrained concrete
manufactured with the same aggregates at the same water content.
(f) The following information shall be submitted to the Engineer for approval purposes.
(i) The detrimental effects, if any, of under-dosage and over-dosage.
(ii) The chemical name(s) of the main active ingredients in the admixture.
(iii) Confirmation that the admixture is chloride free.
(iv) Whether or not the admixture leads to the entertainment of air when used at the
manufacturer's recommended dosage.
(v) The length of time and conditions under which the admixtures should be stored.
(g) In addition, the suitability and effectiveness of any admixtures shall be verified by trial mixes
with the cements, aggregates and other materials to be used in the works.
(h) If two or more admixtures are to be used simultaneously in the same concrete mix, data shall be
provided to assess their interaction and to ensure their compatibility.
5.1B.3.7.2 Production of Concrete
5.1B.3.7.2.1 Concrete Grades
Grade A - All concrete above ground level

Grade B - All concrete below ground level
Grade C - All blinding and mass concrete
For the purposes of the above, the ground level in the concrete structure shall be as designated by the
Engineer.
5.1B.3.7.2.2 Concrete Grade Requirements

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Concrete Grade
(As defined) A B C
(cl. 15.7.2.1
Cement Type To ASTM C150-83a I V V

(Ordinary Portland) (Sulfate (Sulfate Resisting)
Resisting)
Minimum Cement Content 350kg/m³ 370kg/m³ 220kg/m³
Maximum Cement Content 500kg/m³ 500kg/m³ 500kg/m³
Nominal Maximum Size at aggregate 20mm 20mm 20mm
Maximum Water Cement Ratio 0.45 0.42 -
Characteristics Cube Strength At 28 days 35N/mm² 45N/mm² 20N/mm²
The concrete grades to be used in the various parts of the Works shall be as stated on the drawings and
approved by the Engineer.
5.1B.3.7.2.3 Mix Proportions & Trial Mixes
Unless he proposes to use ready-mixed concrete, the Contractor shall submit his proposals regarding mix
proportions with samples of cement and aggregate at least 28 days before any concrete incorporating
those materials is to be placed in the Works.
The requirements to perform trial mixes as described below may be relaxed by the Engineer on
production of satisfactory evidence of trial mixes previously approved using the same materials in the
same proportions.
When the proposed mixes have been approved they shall not be altered without the written permission
of the Engineer. If the Contractor shall apply for such permission, the Engineer may require a repetition
of the trial mix procedure.
The proportions of fine to coarse aggregate, cement to combined aggregate and the water/cement ratio
shall be determined by tests carried out in accordance with the recommendations set out in "Design of
Normal Concrete Mixes" published by HM Stationery Office, London, so as to give concrete of the
required strength and of the highest possible density. In all cases the water/cement ratio shall be the
minimum practical having regard to the conditions of handling and placing and the necessity of
achieving proper compaction.
The Contractor shall make trial mixes using the approved material, the plant used for these trials being, if
possible, the plant which will be used in the Works.
Three 150mm test cubes shall be made from each of three consecutive batches of each mix proposed for
the various grades of concrete and maximum sizes of aggregate. The cubes shall be made, stored and
tested at 28 days in accordance with BS 1881. A further 3 cubes shall be taken from each batch for tests

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at 7 days. The trial mix proportions shall be approved for strength if the average crushing strength of
each group of 9 cubes exceed the values for 7 day and 28 day (characteristic) strength given in Clause
5.1B.3.7.2.2.
The workability of the trial mixes shall be tested in accordance with BS 1881 using samples obtained
from the batches used for the test cubes. The slump of the concrete shall be not greater than 100mm or
less than 25mm unless otherwise approved by the Engineer. In addition, concrete from each trial mix,
taken from the batches used for the test cubes, shall be placed and compacted by the methods proposed
for the works in a trial section of form work having a capacity of not less than 0.5m 3 and representative
of the sections to be employed in the Works.
This procedure, together with the making of test cubes as described above, shall be repeated, if
necessary, until the appearance of the trial section of concrete is acceptable to the Engineer.
The Contractor shall submit full details of the trial mixes and test results and of the mixes proposed for
use in the Works, which must be based on the satisfactory results of these preliminary tests and on the
methods of mixing and placing the concrete in the Works.
The Contractor shall be responsible for ensuring that the concrete conforms in all respects with this
Specification Notwithstanding any approval given by the Engineer to any mix proportions. During the
progress of the Works the if Engineer is not satisfied with the strength, workability, or other properties of
the concrete he may order the Contractor to provide additional cement, and change the aggregates or
vary the grading. The Contractor shall have to comply immediately with such order and shall have no
claim against the Engineer for any expense or loss of time, occasioned by compliance with these
provisions.
The cost of all sampling and testing associated with this clause shall be borne by the Contractor.
5.1B.3.7.2.4 Mixing of Concrete
Aggregates shall be weighed in their separate sizes in accordance with the approved mix design and the
weights shall be corrected to allow for the free water contained in the aggregates. This shall be
determined by an approved method before mixing commences each day and more frequently if the
Engineer so requires. The water to be added to the mix shall be similarly corrected. Cement shall be
added as a number of whole bags or weighed separately in a separate weighing device. Details of the
equipment, which is to be used on the Works, shall be submitted for approval before construction
commences. Weighing and water dispensing equipment shall be maintained clean, properly lubricated,
and in good working order.
When checked by standard weights and volumes its accuracy shall be within ±3% of the quantity of
cement, water or total aggregates being measured and within ±5% of the quantity of any admixture being
used, and the approved mix proportions shall be accurate as an average over each day's work. The
Contractor shall make provision for regular checking of weighing and water dispensing equipment at
intervals not exceeding 1 month or as directed by the Engineer.
Concrete shall be mixed in a power driven batch mixer complying with the requirements of BS 1305
which has been approved by the Engineer and which shall be kept clean and in proper working order.
The mixing blades in the drum shall be replaced when worn by 10% of their dimensions. The quantity of
material in each batch shall not exceed the normal continuous rated capacity of the mixer and the speed
of rotation shall be within 1 r.p.m. of the manufacturer's recommended speed.
Ingredients shall be fed into the mixing drum so as to ensure the most efficient use of the mixing period
and to avoid the loss of material, particularly cement. The mixing time shall be not less than that used by
the manufacturer in assessing the mixer performance or otherwise as directed by the Engineer. Mixing
shall continue until the concrete is homogeneous and of uniform appearance. In the case of mixes of low

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workability or high cement content, a satisfactory mixing time shall be determined by comparing the
strength of samples mixed for different times.
Aggregates may be batched by volume with the approval of the Engineer, but this will not normally be
granted for grades 15 and above. The volume of the aggregates shall be adjusted to allow for the effect of
moisture content on the bulking of fine aggregates, and the ingredients shall be measured separately in
approved containers.
Mixing of concrete shall not commence without ensuring that the stocks of ingredients are adequate
(with a reasonable safety margin) for the completion of the particular pour of concrete. In the case of
pours, which cannot be interrupted once commenced, the Contractor shall provide adequate standby
plant and labor to the satisfaction of the Engineer.
The Contractor shall add approved retarding agents and workability agents to all concrete mixes.
Admixtures shall be used in accordance with the Manufacturer's recommendations and shall be dispersed
by approved automatic dosing equipment which feeds a fixed quantity of admixture into the mixing
water before it is discharged into the mixer; the equipment shall provide a visible means of checking
each dose.
When more than one admixture is to be used in a mix, the compatibility of the various admixtures shall
have been ascertained and certified by the manufacturers.
5.1B.3.7.2.5 Ready-Mixed Concrete
Subject to the approval of the Engineer the Contractor may elect to use ready-mixed concrete.
The name and address of the Works of the proposed Supplier shall be submitted to the Engineer at least
6 weeks before concrete is scheduled for delivery together with a copy of the agreement between the
Contractor and Supplier, details of the mixes proposed, specifications and all other documents relating to
the supply of concrete and details of alternative supply arrangements in the event of failure of supply
from the proposed supplier.
Details of the quality control procedures in operation at the ready mix depot shall be submitted to the
Engineer for approval at the time of stating the intention to use ready mixed concrete. Facilities shall be
provided at the ready mix depot for the Engineer to inspect the batching and mixing of the concrete, the
materials used, and samples of materials shall be provided for any tests which the Engineer may wish to
carry out. Any inspection or testing carried out by the Engineer shall not relieve the Contractor of his
obligation to provide concrete fully in accordance with this Specification.
Ready-mix concrete shall comply with all respects with BS 5328. The cement, aggregates, admixtures
and water shall comply with the requirements of this Specification and the Engineer may require the
Contractor to produce evidence of compliance. Notwithstanding any approval by the Engineer the
Contractor shall be responsible for ensuring that ready-mix concrete complies in all respects with the
requirements of this Specification.
In respect of each grade of concrete to be supplied, the Contractor shall provide the Engineer with a
statement, certified by the ready mixed concrete supplier, giving the following information:
- The nature and source of each constituent material.
- The proposed quantity of each constituent material per m3 of compacted concrete.
- Details of any proposed change in the source or nature of any constituent material and of any
proposed change in the cement content from that last declared and agreed. This information
shall be given not less than two weeks prior to the date of the proposed change, and the change
shall not be made without the Engineer's approval.

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Where a central or plant mixer is used it shall comply with BS 1305 in so far as this applies. Truck
mixers, used as mixers or as agitators, and their mixing and discharge performance shall comply with BS
4251. The Contractor shall consult with the Engineer if any ambient conditions such as high
temperatures, traffic congestion, etc., are likely to affect the quantity of the concrete as delivered.
Before discharging the concrete at the point of delivery, the supplier shall provide the Contractor with a
delivery note for each batch of concrete on which is printed, stamped or written the following minimum
information:
- Name of ready mixed concrete depot
- Series number of ticket
- Date
- Truck number
- Name of purchaser
- Name and location of job
- Specified grade of concrete including, where specified, minimum cement content per cubic
meter of concrete
- Specified workability
- Type of cement
- Type and weight of aggregate
- Maximum size of aggregate
- Type and name of admixture
- Amount of concrete in cubic meters
- Time of loading
- Extra water added at the request of the Contractor and his signature
The Contractor in respect of each delivery of concrete shall also record the following information:
- Position in the structure where the concrete is placed
- Results of workability tests, if any
- Detail of test cubes taken, if any
- Copy of Engineer's approvals of materials and mixes

The concrete shall be compacted and in its final position within 2 hours of the introduction of cement to
the aggregates, unless a longer time is agreed by the Engineer. The time of such introduction shall be
recorded on the delivery note. 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.

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Sampling and testing of ready mixed concrete after delivery to site shall be in accordance with this
Specification.
5.1B.3.7.3 Workmanship
5.1B.3.7.3.1 Commencement of Concreting
No concreting shall be commenced in any portion of the Works until the preparations have been
approved and written permission given by the Engineer that concreting in such portion of the Works may
commence.
24 hours notice shall be given to the Engineer when work is ready for concreting to enable him to attend
all tests, inspections, checks, etc., as may be necessary.
5.1B.3.7.3.2 Transporting of Concrete
Concrete shall be transported from the place of mixing to the place of final deposit as rapidly as
practicable by methods, which will prevent the segregation or loss of the ingredients. It shall be placed as
nearly as practicable in its final position to avoid re-handling or flowing.
5.1B.3.7.3.3 Placing of Concrete
The concrete shall be placed in uniform layers as soon as possible after mixing and before the initial set
has taken place. Vibrators shall not be used to spread the concrete in layers from heaps but shall be used
for compacting once the concrete is in layers. Once the initial set has taken place concrete shall not be
subsequently disturbed.
The depth of lift to be concreted shall be determined by the Contractor and to the approval of the
Engineer.
Concrete shall not be thrown or deposited from a height greater than two meters. Where chutes are used
in the placing of concrete they shall be of a design and used at slopes approved by the Engineer.
The time elapsing between concrete leaving the mixer and being placed in position shall not exceed 15
minutes.
The timetable for the depositing of concrete between construction joints shall be so arranged that no face
of concrete shall be left more than 15 to 20 minutes before fresh concrete is deposited against it. Pauses
for meals, changes of shifts, etc. and the distribution of the concrete among the positions where work
may be proceeding simultaneously must therefore be carefully organized to ensure that the above
mentioned interval shall not be exceeded.
The method of depositing concrete underwater shall be to the approval of the Engineer. Concrete shall
not be dropped from any height through water. Where bottom-opening skips are used they shall be of
such a design that the bottom doors open as the skip is lifted from the surface on which the concrete is
being deposited. The skips shall be full and covered with a woven canvas cover.
Concrete shall be placed evenly over the whole area enclosed by the shattering and the order of placing
shall be approved by the Engineer. The size of shutters for underwater concreting shall be such that a
pour of concrete finishes level with the top of the shutter
Once placed, the concrete shall not be subsequently disturbed and shall not be vibrated or rammed.
All pours of concrete between tide levels shall be carried out in the dry and with such celerity and in
such a manner that the top may be blanketed to the approval of the Engineer before being covered by the
rising tide. In the case of construction joints the blanketing shall be replaced immediately after the joint

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has been cleaned and roughened as specified unless depositing of further concrete follows on the same
low tide.
Notwithstanding the need for speed, all projecting reinforcement, shattering and joint faces shall be
cleaned as specified and the concrete thoroughly compacted.
The maximum advantage shall be taken of neap tides to avoid tidal pours.
5.1B.3.7.3.4 Compaction
All concrete shall be thoroughly compacted by vibrators during the operation of placing to ensure that is
it homogeneous. It shall be thoroughly worked around the reinforcement, around embedded fixtures and
into the corners of the shattering. The method of carrying out this work and the number of vibrators to be
employed on any particular section of the work shall be to the satisfaction of the Engineer.
All vibrating shall be carried out under the direction of specialists and to a plan approved by the
Engineer. No workman shall be allowed to operate a vibrating tool without having received instructions
and training in its use. Vibrators shall be immersion-type of approved pattern; they may be electrically or
pneumatically driven. Care shall be taken to avoid segregation and excessive vibrating.
Sufficient vibrators shall be provided at each pour location to ensure that the concrete is fully compacted
without delay.
At least one reserve vibrator and power source shall be provided on site and not less than one reserve for
every two in use at one time. Immediately before the mixing and pouring of concrete each day the
necessary vibrators shall be started and tested to the satisfaction of the Engineer. Undue difficulty in
starting a vibrator shall be sufficient grounds for rejection.
5.1B.3.7.3.5 Screeding
All surfaces of slabs or other members not requiring to be shuttered shall be screeded in an approved
manner to a smooth and dense finish by means of a wood float or steel shod tamp, unless otherwise
specified.
5.1B.3.7.3.6 Construction Joints
Construction joints shall be as shown on the drawings or as approved by the Engineer. No additional
construction joints shall be provided without the approval of the Engineer which approval will only be
granted in special circumstances.
Kickers and nibs, 150mm deep, shall be formed upon horizontal and vertical surfaces respectively where
subsequent lifts and bays of walls or columns are required.
On exposed surfaces construction joints shall be carefully formed to produce a neat straight flush line or
where indicated on the drawings shall be formed with a recessed joint feature. Grout checks 25mm wide
and 40mm deep shall be provided at all horizontal construction joints where recessed joint features are
not specified.
Suitable bonding chases shall be formed in the ends of other surfaces of sections exceeding 200mm thick
for the purpose of keying such sections to those adjoining. The chases shall be formed over the full
length of the joint and shall have sloping sides.
Unless otherwise specified no slopes will be allowed in connection with the deposition of concrete.
Where it is necessary for any reason to terminate a bed, such termination must be against vertical timber
shutter stepped as requisite and as approved by the Engineer.

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At construction joints the shutters shall whenever practicable be stripped as soon as possible after
pouring subject to the approval of the Engineer and any skin or laitance removed and the tops of the
larger stones exposed by means of brushing and washing.
At horizontal construction joints removal of laitance and exposure of the larger stones shall be
accomplished whenever practicable by means of washing and brushing shortly after pouring, care being
taken to obviate undue erosion of the mortar. After cleaning, excess water shall be removed immediately
to limit absorption by the concrete. In cases where the concrete has set but not set hard the removal of
the laitance and roughening shall be accomplished by wire brushing and washing or by compressed air,
care being taken not to damage the underlying mass.
Where at either vertical or horizontal joints the concrete has set hard any skin or laitance shall be
removed and the surface roughened by hammering with an approved power-operated "bush" hammer
followed by wire brushing to remove all loose particles. When using this procedure, care shall be taken
to avoid breaking off the arises of the joint face and loosening the stones from the mortar matrix.
Whichever of the above treatments has been given to the exposed surface, it shall be cleaned from
foreign matter by further wire-brushing if necessary and shall then be thoroughly washed with clean
fresh water and the surplus water blown off immediately before depositing the fresh concrete.
Fresh concrete shall be forced hard onto the set faces. To this end the compacting tools and vibrators
where appropriate shall be worked right up to the old faces and into angles and corners formed between
them and the shutters.
5.1B.3.7.3.7 Movement Joints
Where it is calculated that movement joints are required in a structural reinforced concrete frame, these
shall be continuous across the entire cross-section of the frame. That is, wherever the plane of the joint
intersects with a member of the frame, a space for movement shall be created.
The space shall be formed by attaching an expanded polystyrene sheet of the appropriate thickness for
the required movement of the face of the concrete on the side of the joint cast first and then casting the
other side in contact with the polystyrene. The sheet shall fully cover the whole surface of the cast
concrete and shall not be penetrated by reinforcement, concrete or anything else.
Where possible, the frame on either side of the joint will rest on separate foundations. If this provision
brings about a situation where twin columns have a space between them, horizontal members of the
frame shall be cantilevered across this space.
The joint shall be continued through any element of the building which might otherwise bridge it,
including masonry walls, floor and roof slab and internal walls, partitions or slabs. The purpose of this
shall be firstly to ensure that free movement at the joint is not impaired and secondly to prevent any
damage to these elements caused by movement of the joint, which might impair the function, or
aesthetics of the building.
Where the joint cuts the external weathering of the building, either walls or roof, an approved special
treatment shall be devised to ensure that the external skin is completely weather tight and shall remain so
for the life of the building. In walls this may mean cutting back the polystyrene to leave a groove to be
filled with an elastic sealant which will adhere to both concrete surfaces. In roofs the treatment shall
ensure that felt or other waterproof membrane shall not be either torn or crumpled by movement at the
joint. This may also involve the introduction of an upstand at the joint.
Where the joint cuts tiled flooring or plastered walls, it shall be covered with an approved decorative
masking strip which shall be fixed to the floor or wall at one side of the joint only so as to be undamaged
by joint movement.
The Contractor may propose an alternative material for the joint filler for approval.

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5.1B.3.7.3.8 Stand-by Plant
At all times when concreting is being carried out, the Contractor shall have readily available on site
sufficient stand-by plant to cover the operations of mixing, transporting, placing and compaction of
concrete in the event of breakdown of plant.
5.1B.3.7.3.9 Precautions during Increment Weather
When the air temperature rises above +30°C special precautions shall be taken to the satisfaction of the
Engineer to cool aggregates and mixing water and to maintain the correct water/cement ratio; e.g.
shading aggregate stockpiles, laying water supply main underground, adding crushed ice to mixing
water. Reinforcement and shattering shall be cooled by shading from the direct rays of the sun and by
spraying with water, care being taken to remove surplus water before commencing concreting.
Concreting shall not be carried out when the air temperature rises above +38°C, or if the temperature of
the concrete mix rises above +30°C.
During windy weather approved protection shall be provided to prevent the cement from being blown
away during the process of apportioning and mixing.
During wet weather approved precautions shall be taken to protect the cement and to ensure proper
mixing. No concreting shall be carried out during periods of continuous heavy rain.
5.1B.3.7.3.10 Curing
(a) Method statements for the curing of all concrete shall normally comply with the following
minimum requirements and shall propose effective means of preventing premature drying and
the resulting effects of plastic shrinkage.
Where small quantities of concrete are being used, the Engineer may relax the requirements of
the following clauses. The Contractor's intentions in this instance shall be clearly indicated in
his method statements and approved by the Engineer.
(b) Exposed Surfaces
(i) Exposed surfaces of concrete shall be completely covered with polythene sheeting with substantial
close fitting laps within 20 minutes of placing and compaction, and within two or three hours of this
shall quickly be replaced by wet hessian covered with polythene. Polythene sheeting may be
temporarily removed for surface finishing where required.
(ii) The Hessian shall be kept damp continuously using water of the quality specified for concreting for a
period of at least seven days or such longer period as the Engineer may direct.
(iii) Approved curing compounds may be applied to supplement the use of wet hessian and polythene.
(iv) In addition to the above measures, shading from direct sunlight and windbreaks may be proposed or
may be required by the Engineer to give added protection.
(c) Formed Surfaces
(i) Formed surfaces shall be completely covered by wet Hessian and polythene within half an hour of
stripping the formwork and shall then be treated in accordance with the requirements for exposed
surfaces.
(ii) Formwork shall be shaded and/or continuously wetted to prevent high temperature accelerating cure.

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(iii) For formed surfaces which are to be exposed, effective approved measures shall be taken to prevent
concrete surfaces from drying out and to ensure adequate curing whilst rubbing down is taking place
and before application of any approved curing membranes or other curing methods.
(d) When shade temperatures exceed 30°C in any part of the day or when lower temperatures in combination w
high wind speeds are likely to lead to premature drying, the Engineer may instruct any combination of
foregoing methods to be used.
(e) Curing compounds
(i) Curing compounds shall be stored and used strictly in accordance with the manufacturer's instructions.
(ii) Curing compounds shall not be applied to surfaces to which further concrete or a surface finish is
subsequently to be bonded.
5.1B.3.7.4 Sampling and testing of Concrete

5.1B.3.7.4.1 General
The preparation, curing, transport and testing of concrete cubes to ascertain the minimum crushing
strengths at 7 days and 28 days shall be carried out in accordance with BS 1881; "Methods of Testing
Concrete".
5.1B.3.7.4.2 Works Cube Tests
The Contractor will be held responsible for ensuring that the crushing strength of the concrete is not less
than that specified for the respective qualities.
Samples of concrete shall be taken by the Contractor during each major pour where and when directed
by the Engineer and six 150mm cubes made therefrom. The cubes shall be cured by the Contractor and
then transported by him to the site laboratory for testing, 3 cubes at 7 days and 3 cubes at 28 days. The
cubes shall be indelibly marked with the contract identification, serial numbers and the date cast. The
cost of preparation, curing, marking, handling and transport of cubes will be deemed to be included in
the Contract Price. The cubes will be tested at the expense of the Contractor.
Should the crushing strength prove to be below the figures specified the Contractor shall make such
changes in the proportions or in the method of mixing or in the materials as the Engineer may approve so
as to bring the concrete up to the required strength.
5.1B.3.7.4.3 Concrete Cores
Where the quality of the finished concrete is considered by the Engineer to be suspect, he may order 100
or 150mm nominal diameter cores to be cut from the hardened concrete for the purpose of examination
and testing. The coring equipment and method of executing the work shall be to the approval of the
Engineer.
If the estimated cube strength of any core as determined in accordance with BS 1881 is less than the
appropriate specified minimum crushing strength or if in the opinion of the Engineer the concrete fails to
meet the specified requirements in other respects, the concrete in that part of the Works will be deemed
not to comply with the Specification.
The cost of cutting of the core specimen, preparing if for testing and making good the cored hole will be
borne by the Contractor irrespective of the result of the test.
5.1B.3.7.5 Reconstruction of Faulty Work
The Contractor on the written instruction of the Engineer shall remove and reconstruct at his own cost
any portion of the work which in the opinion of the Engineer gives evidence of any fault, defect or injury
from any cause whatsoever, which in the opinion of the Engineer may prejudice the strength or

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durability of the construction. No repairing of any concrete shall be done without the permission in
writing of the Engineer and then only in such a manner as he shall direct or approve.
Treatment of Minor Surface Blemishes
All concrete surfaces shall be smooth and true. All fins, which may occur between boards or panels, shall
be removed and air holes filled with mortar of approved composition and color. Any area requiring
treatment after stripping as outlined above shall afterwards be rubbed down with a Carborundum block
and washed perfectly clean. No surface treatment shall be carried out until the surface has been inspected
by the Engineer.
5.1B.3.8 FINISHES FOR CONCRETE
5.1B.3.8.1 Finishes Generally
Where uniformity of color is required in the surface finish of concrete, each material shall be obtained
from a single consistent source. Where surfaces are to be formed using large formwork panels made up
from individual plywood or timber sheets the individual sheets shall have uniform properties of
absorption and surface texture.
Where a concrete surface is to be permanently exposed only one release agent for the formwork shall be
used throughout the entire area. Release agents shall be applied evenly and contact with reinforcement
avoided. Where the surface is to receive an applied finish, care shall be taken to ensure the compatibility
of the release agent with the finish.
If the Engineer so requires, a trial pour shall be made to test the suitability of the materials and
techniques to be used.
5.1B.3.8.2 Classification of Finishes
Finished concrete surfaces shall be classified in accordance with the classes listed below. The class of
finish required shall be shown on the drawings.
Class F1 - Formed Finish:
This finish shall be required for surfaces against which backfill, further concrete or grout will be placed,
including recesses for bolts and other build-in parts, or for surfaces which will otherwise be concealed
from view.
Class F2 - Formed Finish: ("Wrot")
This finish shall be required for structural surfaces permanently exposed to view except where otherwise
indicated.
Class F3 - Formed Finish: ("Precast Quality")
This finish shall be required for prominent or important architectural features, or for precast concrete
units. It shall be free from boardmarks, surface pitting or discoloration.
Class Ul - Unformed Finish: ("Screeded")
This finish shall be required for the surface of roads, foundations, bases, slabs and structural units to be
covered by backfill, subsequent stages of construction, bonded concrete toppings or mortar beds, and
also for exposed surfaces of paving where a superior finish is not required and as the first stage for
finishes U2 or U3. It shall be obtained by leveling and screeding the concrete to produce an even,

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uniform, plain or slightly ridged surface without laitance, surplus concrete being struck off by a straight
edge immediately after compaction.
Class U2 - Unformed Finish: ("Floated")
This finish shall be required for the surface of beds and slabs intended to receive further finishes or for
exposed surfaces where a steel-trowelled finish is not required. Floating shall be done only after the
concrete has hardened sufficiently and shall not be continued to the extent of bringing excessive fine
material to the surface, but only so as to produce a uniform surface free from screed marks, and within
any tolerance stated or implied for the thickness of bedding or bonding material.
Class U3 - Unformed Finish: ("Steel Trowelled")
This is a hard smooth finish which shall be required for surfaces of high quality concrete pavings, tops of
walls, coping and unformed surfaces of architectural features (including precast units), for surfaces of
beds and slabs to receive thin flexible sheet and tile pavings bedded in adhesive, and seating for metal
items where the metal is in direct contact with the concrete. Trowelling shall not commence until the
moisture film has disappeared and the concrete is sufficiently hard to prevent the working of excessive
laitance to the surface. The surface shall be trowelled firmly and left free from trowel marks.
Class US finish may be produced by power floating of concrete subject to the requirement that such
work is carried out by experienced and skilled workmen.
5.1B.3.8.3 Tolerances
All unformed surfaces of concrete works shall be located as shown on the drawings within the following
tolerances:
(a) Setting out dimensions + or - 6mm
(b) Sections of concrete members ± 3mm
(c) Surface level of slabs, floors ± 5mm
(d) Surface level of switchgear room floor ± 2mm
(e) Surface level of tops of walls and beams ± 3mm
(f) Location of sleeves and openings ± 6mm
(g) Flatness of surfaces other than those to be cambered measured from a line stretched between
any two points of the surface: -
Up to 3 meters long ±1.5mm.
Up to 15meters long ±7.5mm.
5.1B.3.9 FORMWORK FOR CONCRETE
5.1B.3.9.1 Formwork Generally

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Formwork shall include all temporary or permanent moulds, and shutters for forming the concrete,
together with all construction required for their support.
5.1B.3.9.2 Design and Construction
Formwork shall comply with the requirements of BS 5975 "Code of Practice for Falsework".
The Contractor shall provide such details of the Formwork and supports as the Engineer may require in
sufficient time to permit the design to be checked before the formwork is used.
The use of proprietary type shattering systems shall be subject to the Engineer's approval. Full details of
the proposed use of such systems shall be submitted to the Engineer. All plywood shattering used shall
be waterproof.
Formwork (including supports) shall be sufficiently rigid to maintain the forms in their correct position
and to correct shape and profile so that the final concrete structure is within the limits of the dimensional
tolerances specified in Clause 5.1B.3.8.3. Formwork shall be designed and constructed so that concrete
can be properly placed and compacted by vibration or otherwise without loss of material and so that the
concrete shall set and hardened without injury.
The supports shall be designed to withstand the worst combination of self-weight, formwork weight,
Formwork forces, reinforcement weight, wet concrete weight, construction, wind loads and uplift due to
immersion in wet concrete or water, together with all incidental dynamic effects caused by placing
vibrating and compacting the concrete. Formwork shall be cambered where this is necessary to maintain
the required accuracy of finished work.
Struts supporting formwork shall incorporate seasoned hardwood wedges or jacks, and these shall be
used if required to take up settlement during the placing of concrete and to ease the struts during
removal. The struts shall rest on adequate supports, which shall be safeguarded against interference by
plant, personnel, or construction operations and deterioration due to erosion, softening or movement of
the supporting ground, or from other causes.
Formwork shall be so arranged that side shutters can be removed without disturbing the soffit shutters. If
it is required to leave struts in place after removal of soffit shutters, the struts shall not be disturbed when
the shutters are being removed.
Internal Formwork supports and ties shall be to the approval of the Engineer as to material, location and
design. The whole or part of such supports and ties shall be removed without damage to the concrete so
as to leave no part embedded nearer the surface of the concrete than the designed cover of the
reinforcement or 50mm in the case of unreinforced concrete. Holes left after the removal of supports and
ties shall be filled with concrete or mortar of approved composition and color after being roughened and
cleaned to ensure a bond, and shall be finished off neatly to the standard of the concrete surface. Such
filling mortar shall contain the minimum amount of water and shall be adequately cured.
Formwork containing water bars, water stops, anti-seepage membranes, puddle flanges, pipes and similar
items shall be so arranged that the built-in element is prevented from developing seepage paths caused
by relative movement during concreting.
In all classes of formwork special care shall be taken at the tops of walls or piers which are to be left
exposed or which are to carry superimposed structures so as to produce a neat even level or graded line,
as may be required, to which the upper surface of the concrete shall be screeded.
Chamfer, fillets, rounded arises and solid timbers shall form similar features where possible, and
integrated structurally with the formwork.
The quality of the surface finish produced by the formwork shall be appropriate to the classification as
described in Clause 5.1B.3.8.2. Generally, it shall be free from areas of honeycombing, segregation, loss
of cement or fine material, from damage due to stripping of forms, from bolt-holes, abrupt inequalities
caused by movement of shutter or components, loose knots and similar features, and from bulges or

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depressions in the general plane of the surface. Surfaces produced by wrot (Class F2) Formwork shall be
free from discoloration, fins and pitting.
5.1B.3.9.3 Preparation
Formwork shall be cleaned before each use. Form release agents shall be to the approval of the Engineer.
They shall be applied carefully and sparingly and shall not be allowed to come in contact with concrete
surfaces or with items (including reinforcement) which are to become bonded to the concrete
Formwork with damaged edges or faces shall not be used until repaired to the approval of the Engineer.
Open joints in timber forms shall be sealed. Plywood surfaces and cut edges shall be sealed to prevent
the absorption of moisture.
Immediately before concreting the forms and all other surfaces which will be in contact with the fresh
concrete shall be cleaned of all loose material and debris. Adequate clean-out holes shall be provided for
this purpose and subsequently securely closed so as to restore the required formwork quality.
Reinforcement shall be cleaned with compressed air and water jet. The use of compressed air for
cleaning will be subject to approval of precautions to avoid the deposition of suspended oil on
construction joint surfaces, reinforcement, or other items, which are to be bonded to concrete.
5.1B.3.9.4 Striking and Removal
The removal of formwork shall be subject to the permission of the Engineer. Striking of formwork shall
be in accordance with BS 8110.
5.1B.3.9.5 Holding-Down Bolts and Embedded Parts
Holding down bolts and holding down bolt assemblies shall be provided with bottom nut welded to bolt
shank and fixed to anchor plate, channel or angle as shown on the drawings or as otherwise indicated.
Bolts, anchor plates, etc. shall be of Grade 43 steel to BS4360 with nuts of strength grade 4 or higher.
Bolts obtained from bolt manufacturers shall comply with the requirements of BS 4190 as regards
threads and tolerances. The material, manufacture and mechanical properties shall comply with the
requirements of BS 3692 or BS 4190 as appropriate.
Where bolts are fabricated from plain round bar the threads shall be ISO metric, coarse pitch series, free
fit as specified in BS 3643. Both ends shall be threaded and the nut at the bottom end shall be welded in
place to prevent it from turning The diameters used shall be as given in BS 6722.
Nuts shall comply with the requirements of BS 3692 or BS 4190 as appropriate. Nuts shall be of normal
standard thickness; thin nuts shall only be used as Locknuts.
Threads of holding down bolts shall be protected with a proprietary protective adhesive tape approved by
the Engineer, during delivery and storage. After concreting the bolt projections with attached nuts and
washers shall be protected against corrosion with this tape and protected against mechanical damage
with a timber shield or as otherwise approved until the erection of the steelwork or other plant
commences.
All embedded parts for mounting of switchgear based on loading, panel supports for raised flooring in
relay and control room and any other fabricated base frame if required for panel mounting shall be
supplied and installed by civil contractor with the coordination of switchgear, transformer, LDC and
cable contractor.
Holding down bolts, embedded fixtures and recesses shall be located in the correct position by means of
timber templates or as otherwise approved and shall be held rigidly in position during concreting.

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Particular attention shall be directed to the placing of reinforcement around bolt assemblies and
embedded fixtures to ensure that the arrangement shown on the drawings is adhered to and to the
Holding down bolts, and holding down bolt assemblies shall be located in the positions shown on the
drawings, and in the absence of locating tolerances on the drawings, shall be located to the following
accuracy:
Bolt Dia. Tolerances
Up to 15mm ± 5mm
13mm to 32mm ± 7mm
33mm and over ± 10mm
Difficulty can be anticipated with the use of sand/cement mortar for grouting in holding down bolts and
other embedded items which require a thin layer of grout to be in contact with fully dried concrete. For
this reason proprietary non-shrink grout mixtures with the capacity to cure and strengthen in the
prevailing conditions shall be used.
In using these grouts the Contractor shall have careful regard to the manufacturer's instructions
particularly in respect of the temperature of the grout and the temperature of the concrete in contact with
the grout
5.1B.3.10 REINFORCEMENT FOR CONCRETE
5.1B.3.10.1 Reinforcement Steel
All reinforcement shall comply with BS 4449, 4461, 4482 and 4483 or other approved specifications,
and shall be tested as required by the Engineer. Type of Reinforcement will be denoted by suffix in
accordance with BS 4466 and as detailed on the drawings.
5.1B.3.10.2 Storage
Reinforcement shall be stacked on the site, separated into the various sizes on timbers so that the steel is
kept clear of the ground and free from mud, oil, grease and other contamination. Stacks of steel are to be
covered to protect steel from contamination with wind blown sand and dust.
5.1B.3.10.3 Bending
Reinforcement shall be bent in accordance with BS 4466 "Bending Dimensions and Scheduling of Bars
for the Reinforcement of Concrete". Bars shall be bent cold in such a manner that the material is not
injured in any way.
Bent bars ready for fixing shall be stored in bundles marked with a number corresponding to the bar list
on the bending schedule. Bars shall be bent accurately and checked from time to time. Temporary
bending and subsequent straightening of reinforcement shall be avoided where possible. When permitted
by the Engineer this shall be carried out at the ambient temperature and the internal radius of such bends
shall be in accordance with BS 4466. Reshaped steel shall be inspected for signs of fracture. Steel
showing signs of fracture shall be rejected and removed from site.
5.1B.3.10.4 Fixing
Minimum concrete cover to reinforcement shall be as follows:

Piles, Pilecaps, Pad Footings
Columns below ground - 75mm
Groundbeams, Earth face of walls - 50mm

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Columns, Beams, Walls - 40mm

Solid and Ribbed Slabs, Stairs - 24mm
The soffit of all ground floor slabs, whether or not in contact with the ground, shall be deemed an
external surface and cover to reinforcement shall be 40mm.
In no case shall the cover be less than or exceed the specified cover by more than 5mm for concrete up to
300mm thick, or not more than 15mm for concrete over 300mm thick.
Bars, which intersect or pass over each other shall be securely wired together at a point of intersection
with 18 or 20 S.W.G. soft iron wire.
Small concrete blocks specially precast to give the correct cover shall be used to ensure cover on ground
centering and slab shattering and elsewhere as considered necessary. They shall be made of mortar not
leaner than 1 part of cement to 2 parts sand. Other suitable methods approved by the Engineer may be
permitted.
Support chairs for reinforcement shall be designed by the Contractor and approved by the Engineer. The
use of proprietary type spacers or couplers shall be subject to the Engineer's approval, and full details of
proposals for their use shall be submitted at least 4 weeks in advance.
Welding of reinforcement shall be subject to the Engineer's approval. The Contractor shall submit to the
Engineer complete details of proposals to weld reinforcement at least eight weeks in advance. All
reinforcement shall be cleaned free of salt depositions, loose mill scale and rust, grease, set mortar or
other harmful matter, by power brushing or acid dipping if necessary. Particularly the Contractor shall
ensure that such reinforcement is protected against chemical deposits at all stages of the work until the
concrete is poured.
Placed reinforcement shall be checked against the relevant drawings before concreting is permitted.
5.1B.3.11 PRECAST CONCRETE
Units shall be provided by an approved supplier who shall submit details of the design and manufacture
for approval by the Engineer. The finish shall comply with specifications or as required by the Engineer.
Precast concrete kerbs and blocks shall comply with BS 340 and 6073 Part 1 respectively.
Other precast items shall be constructed to the details, dimensions and tolerances given on the
drawings.
The concrete ingredients, grades, mixes, strengths, general quality, testing, mixing, placing and curing
shall be generally as described in the Specification and as detailed on the drawings. The surface of the
finished units shall be smooth, dense and hard with clean sharp arises (except where otherwise
indicated), and shall be free from cracks, crazing, discoloration, holes, fins, honey-combing,
water-marks, dusting or shuttermarks.
Units shall be manufactured and cured in a properly equipped casting yard or shop and the arrangements
shall be subject to the inspection and approval of the Engineer. The Contractor shall give adequate notice
to the Engineer before dispatching precast units to the site, and if the Engineer so requires, shall provide
facilities for inspection, test-loading and dimensional checking of the units before they are dispatched.
In the case of units constructed in a factory or yard remote from the site, details of the concrete
ingredients, mix design, and compression test cube results shall be made available to the Engineer.
5.1B.12 STRUCTURAL STEELWORK

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5.1B.3.12.1 Material
All material shall, in general, comply with Grade 43DD to BS 4360 for rolled sections, Grade 43EE for
plate and grade 43C for hollow sections. The dimensions of rolled steel sections shall comply with BS 4:
Part 1 or BS 4848. The dimensional tolerances for plates and flats shall be as specified in BS 4360. The
tolerance over or under the nominal thickness shall be equal to half the total thickness tolerance.
Only new steel shall be used; steel, which in the Engineer’s opinion is heavily pitted or badly rusted,
shall not be used.
Structural hollow sections shall be hot rolled structural hollow sections to BS 4848 Part 2 in steel to BS
4360. Welded cold formed steel structural hollow sections to BS 6363 shall not be substituted unless
agreed to by the Engineer in writing.
Cold rolled sections shall comply with BS 2994.
5.1B.3.12.2 Design and Drawings
The design shall be in accordance with the requirements of BS 5950 or AISC Manual 52 of Steel
Construction.
The Contractor shall prepare the necessary general arrangement drawings and shop drawings for
fabrication and shall be fully responsible for checking and accuracy of these drawings. The general
arrangement drawings shall be to such a scale that identifying numbers for each member are clearly
shown. Before fabrication, three copies of these drawings shall be submitted to the Engineer for
approval.
Such approval shall not relieve the Contractor of the responsibility for the accurate detailing and
fabrication of members and for proper assembly at the time of erection.
5.1B.3.12.3 Fabrication
5.1B.3.12.3.1 Fabrication Generally
Construction and fabrication shall be in accordance with the requirements of BS 449 or AISC Manual of
Steel Construction.
As much fabrication as possible shall be carried out in the shops and shall be supervised by a competent
engineer. The Contractor shall be fully responsible for checking the accuracy of the shop drawings.
Careful attention shall be given during fabrication to ensure that members can be placed in position to
comply with a practical sequence of erection. Any constructional details, which would hinder this, shall
be modified. Drainage holes shall be provided in members where water could collect during and after
erection.
5.1B.3.12.3.2 Straightening
All plates, bars and sections shall be flat, straight and free from twist within the tolerances specified in
the relevant British Standard, unless more stringent tolerances are specified on the Engineer's drawings.
Any flattening or straightening required to achieve the required tolerances or to satisfy fit-up
requirements shall be carried out before any other work is done on that item. The method adopted for
such work shall be as such as not to deface or weaken the material.
5.1B.3.12.3.3 Cutting and machining
Steel may be sawn, sheared, cropped or machine flame cut. Where it is impractical to use machine flame
cutting, the use of hand cutting shall be subject to the approval of the Engineer, who may require
dressing or other treatment of the cut edges, depending on the details of the joint or member.

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Where notches are necessary they shall have smooth radiuses internal corners, produced by drilling holes
not less than 20mm diameter before cutting the rest of the notch or by carefully controlled flame cutting.
All burrs left by sawing, cropping or shearing shall be removed before fabrication or assembly. All sharp
arises shall be removed by light grinding.
The Contractor shall inform the Engineer of members on which he will be using shearing or flame
cutting and in cases where steel so cut is specified as being subject to dynamic or fatigue loading or
liable to brittle fracture, the sheared or flame cut edges shall be machined to a depth to be agreed by the
Engineer.
The ends of compression members at splices, caps or bases, dependent on contact for the transmission of
compressive stress. shall be prepared so that the butting faces are in contact over at least 50% of the
bearing area except for small clearances not exceeding 0.25mm. Over the remaining area the gap shall
not exceed 0.50mm. Base and cap plates and other bearing surfaces shall also be prepared to the same
standard.
Members shall be adequately supported in both the vertical and horizontal planes during cutting or
machining to ensure that the prepared ends are square to the axis of the member.
All plates 25mm thick and over which are to be connected using H.S.F.G. fasteners shall be checked for
"bowing" or "ripples"; if these defects are present they shall be eliminated before dispatch to site.
In H.S.F.G. connections all surfaces which have been machined shall be grit blasted in such a way as to
provide a slip factor of not less than 0.33.
5.1B.3.12.3.4 Fitted Plates and Stiffeners
The ends of fitted plates and stiffeners shall be accurately sawn or sheared and ground to fit tightly
between the flanges or parts to be stiffened. The maximum gap shall not exceed 0.25mm.
5.1B.3.12.3.5 Smith Work
All forging shall be performed in such a manner as not to impair the strength of the metal. The metal
shall not be worked after it has fallen to a 'blue heat'.
5.1B.3.12.3.6 Holes
Holing shall be in accordance with BS 5950 Part 2 (or BS 4606: Part 1 in the case of holes for friction
grip bolts). All 'burrs' and 'rags' shall be removed.
Slotted holes shall either be punched in one operation or else formed by punching or drilling two round
holes and completed by high quality flame cutting and dressing, to ensure that the bolt can travel the full
length of the slot freely.
Circular holes for bolts shall not be flame cut.
5.1B.3.123.7 Surfaces
(a) Any minor surface defects such as surface laminations, blow holes and crevices exposed by
blast cleaning shall, subject to the approval of the Engineer, be made good as specified in BS
4360.
(b) Any major surface defects shall be reported to the Engineer and his instructions followed.

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(c) Surfaces which become inaccessible after fabrication or assembly;, such as the inside of
structural hollow sections and other box sections, shall be sealed off from the outside
atmosphere by continuous welds unless specified otherwise.
(d) Hollow members, which are to be galvanized, shall have vent holes. These shall be large
enough to ensure internal galvanizing or if so specified shall be sealed after the member has
been galvanized.
5.1B.3.12.4 Protective Treatment
See Section 1 of this Specification - GENERAL REQUIREMENTS.
5.1B.3.12.5 Bolting
All bolts other than High Strength Friction grip bolts shall be in accordance with BS 4190 (metric) or BS
3692 (metric) and shall have a steel washer in accordance with BS 4320 under each nut, flat or tapered as
required. All bolts, nuts and washers shall be spun galvanized to BS 729 with a thickness of 75 microns
and only the manufacturer of these items shall carry out galvanizing. Bolts, nuts and washers shall be of
Grade 8.8.
High Strength Friction grip bolts, nuts and washers shall comply with the requirements of BS 4395
(metric). The allowable slip factor shall be 0.33. Where site joints are to be made using these bolts, they
shall comply with the requirements of BS 4604 (metric). Particular attention shall be directed to the
correct sequence of tightening bolts in large connections. Bolts provided with load indicating devices
should be tightened in accordance with the manufacturers instructions using power operated spanners,
equipped with torque limiters. Any H.S.F.G. bolts, which have to be loosened, shall in no circumstances
be re-used.
Care shall be taken to ensure that all H.S.F.G. bolts, nuts, washers etc. are maintained in good condition.
Particular care shall be taken to ensure that the threads of bolts and nuts are free from damage, grit,
corrosion or any condition necessitating excessive torque to obtain the required tension.
H.S.F.G. bolts shall not be used in temporary connections bolted in the Contractor's yard. Where it is
necessary to have a temporary connection which subsequently requires permanent H.S.F.G. bolts on site,
treated 4.6 Grade bolts of a smaller diameter than the H.S.F.G. bolts shall be used in the Contractor's
yard. The 4.6 Grade bolt shall be replaced on site by treated H.S.F.G. bolts of the correct size.
High Strength Friction grip bolts of 22mm diameter and above require one hard steel nut faced washer,
one hardened steel washer and load indicating device.
The bolt manufacturer shall supply spun galvanized High Strength Friction grip bolts.
Any bolts passing through members with a taper greater than 3 degrees shall be fitted with tapered
washers. Bolts 22mm diameter and above passing through members with a taper of 2°52' shall also be
fitted with tapered washers.
Slotted holes for movement connections shall be provided with shouldered bolts, spring washers and flat
washers to be approved by the Engineer.
The supplier in accordance with these standards shall furnish manufacturer’s tests certificates.
5.1B.3.12.6 Welding
5.1B.3.12.6.1 Welding Generally
Welding shall be carried out in accordance with the requirements of BS 5135; "Metal Arc Welding of
Carbon and Carbon Manganese Steels". Electrodes and fluxes shall be in accordance with BS 639.

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All electrodes shall have yield strength, tensile strength, toughness and ductility not less than those
specified for the grade of steel being welded.
When weathering steel is to be welded the welding electrodes shall be of matching composition to the
parent material.
Where the steelwork is to be blasted and metal sprayed or galvanized after fabrication, cleats and other
solid attachments welded to the member shall be welded all round to seal the unprotected surface.
The Contractor shall submit his proposals for all main welds, arrangement of welded assemblies and
welding procedure for the prior approval of the Engineer.
Approval of the welding procedure shall not relieve the Contractor of his responsibility for correct
welding and for minimizing distortion in the finished structure.
Shop welding shall be carried out in workshops under the specified conditions of temperature,
workmanship, welding operations, supervision and inspection. Machine welding will be allowed where
approved machines are in use correctly controlled by qualified operators.
Site welding shall not be permitted except where prior approval of the Engineer has been obtained before
fabrication has commenced and then only if proper site conditions can be assured as required.
The Contractor shall employ competent and experienced welding supervisors who shall be approved by
the Engineer.
5.1B.3.12.6.2 Welding Plant

The welding plant shall be capable of maintaining at the weld the voltage and current specified by the
manufacturer of the electrode used. The Contractor shall provide instruments for verifying voltage and
current as and when required by the Engineer.
5.1B.3.12.6.3 Butt Welds
All main butt welds shall have complete penetration and where possible shall be welded from both sides.
Unless otherwise specified, T-butt welds shall be reinforced by equal-leg fillet welds of leg length equal
to a quarter of the thickness of the thinner plate joined, but not less than 3mm nor greater than 10mm.
The root edges or root faces of butt welds shall not be out of alignment by more than 15 per cent of the
thickness of the thinner material but not greater than 3mm.
5.1B.3.12.6.4 Testing of Welders
The qualifications of each welder to be employed on the works, on site or at the fabrication shops, shall
be submitted to the Engineer for his approval.
The Engineer shall, if he so wishes required any welder to be tested before that welder can be employed
on the works.
All tests for welders shall be carried out in accordance with B.S. 4872 Part 1 1972. The above test shall,
if required by the Engineer be a procedure test for a welding procedure submitted by the Contractor in
accordance with BS 4870, Part 1 1974 on similar welding equipment to that which the welder will use in
the works.
After a minimum period of 72 hours of the test piece being completed, a test in accordance with B.S.
4870 Part 1 1974 or B.S. 4872 shall be carried out as applicable. Certified copies of all test results shall
be submitted to the Engineer for inspection and approval.

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5.1B.3.12.6.5 Testing and Inspection of Welds
The Contractor shall provide all necessary material, labor and equipment for, and shall carry out
non-destructive tests as approved by the Engineer on all welds in moment connections, or as directed by
the Engineer. The costs of such tests shall be carried by the Contractor irrespective of the test results.
All such tests are to be carried out by suitably qualified testing personnel, that is persons qualified to
C.S.W.I.P. (Certified Scheme of Weldmen Inspection Personnel) or its equivalent.
Any defective welds shall be put right in accordance with this specification, and at the Contractor's own
expense. However, prior to the repair of any defective weld, the Contractor shall submit to the Engineer
for his approval a welding procedure for that weld.
All defective welds shall be re-tested and re-inspected in accordance with the requirements set down in
B.S. 5135. The Contractor is to allow for the cost of all materials, labor and equipment required for the
testing and re-testing of welders, welds, test pieces and procedure tests as required by the Engineer.
5.1B.3.12.6.6 Stress Relieving
Fabricated components on which accurate bearing or locating surfaces are required should be stress
relieved before finish machining. Particular units may require to be normalized according to their
application.
5.1B.3.12.7 Marking
The steelwork delivered to the site shall be clearly marked with the appropriate erection reference marks,
which in the case of stanchions with baseplate, shall show these marks on both the side and the base.
Beams, which are drilled asymmetrically, shall have each end separately identified.
Fabricated units of steelwork in excess of 3 tons weight shall have the weight clearly marked on them.
The method of marking shall be to the approval of the Engineer and shall not damage the protective
coating.
The location of marks on members shall be consistent and shall be such that the marks are clearly visible
both before and after erection.
5.1B.3.12.8 Delivery
Delivery of the steelwork to the site shall be carried out according to a schedule to be agreed with the
Engineer and this schedule must be strictly adhered to. The supplier shall furnish shop material lists of
each consignment before the delivery of the consignment to the Site.
Steelwork shall be transported, handled and stacked in an approved manner so as not to overstress or in
any way damage the members.
Damage to any part of the structure either before or during erection shall immediately be brought to the
notice of the Engineer. Damaged material shall be rectified or replaced. No part that has been damaged
shall be assembled into the structure without the written approval of the Engineer.
Steelwork to be stored shall not be placed directly on the ground. It shall be stored in such a manner as to
avoid water retention.
Particular care shall be taken when transporting, handling or storing parts, which have been metal,
sprayed, galvanized or painted. If this coating is damaged it shall be restored to the satisfaction of the
Engineer.

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A set of marked erection and detail drawings together with a complete set of bolt lists shall be supplied
to the Engineer.
The bolt lists shall give the working drawing number, location, number off, diameter, type, grip length,
bevel or flat washer and weight in Kg.
2.5.12.9 Erection
Erection shall be carried out in accordance with AISC Manual of Steel Construction.
The steelwork shall be erected to the lines and levels as shown on the approved drawings to the
satisfaction of the Engineer.
The Contractor shall be entirely responsible for the correct setting out of the steelwork.
The tolerances for position and level of the steelwork shall be plus or minus 5mm and the steel
framework shall not be out of plumb by more than 1 in 1000 of the height.
The Contractor shall employ on erection only such persons as are skilled and experienced in steelwork
erection. A competent engineer shall supervise them on site.
The Contractor shall supply adequate plant, tools, service bolts, drifts, bolt tightening devices and other
equipment to ensure that the steelwork is correctly erected.
The Contractor shall submit to the Engineer for approval his proposals for correction of any fabrication
errors. Burning out of misaligned boltholes will not be permitted in any circumstances, and in heavily
loaded connections such holes shall be plugged by welding and re-drilled.
Steelwork in course of erection shall be securely bolted or otherwise connected together and if necessary
provided with temporary bracing or effectively anchored steel guy ropes to resist all dead loads, loads
due to erection equipment and the operation thereof, and all lateral loads including wind.
Temporary bracing and guy ropes shall be left in position and maintained for as long as is necessary to
ensure the safety of the structure.
No permanent bolting or welding shall be permitted until as much of the structure as will be stiffened
thereby has been brought into correct alignment. No straining into position will be allowed after the
permanent connections have been made.
Stanchions shall be erected on the bases provided; they shall be adjusted to line and level and supported
on steel packing pieces provided by the fabricator. When in the opinion of the Engineer sufficient steel
has been erected, braced, bolted, lined, leveled and plumbed the holding down bolts shall be grouted and
the base plates bedded or grouted in accordance with Clause 76 of BS 449. Ten days after the bases have
been grouted the Contractor shall tighten down the holding down bolts.
5.1B.3.12.10 Inspection
Erected steelwork will be inspected by the Engineer and the tender price shall be deemed to include for
providing the necessary access ladders, facilities and attendance on the Engineer when engaged in
inspection work.
5.1B.3.13 METALWORK
5.1B.3.13.1 Crane and Transformer foundation Rails
The crane rails shall comply with BS 105 Light and Heavy Bridge Type Railway Rails or be to other
approved profile and shall also comply with the general requirements of BS ll - Flat Bottom Railway
Rails. Rails shall be cold straightened and free from twist. They shall be substantially free from pitting,
laminations and other defects.

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The supplier in accordance with these standards shall furnish manufacturers test certificates.
Insofar as they are not overruled by this Clause, crane rails shall conform to the requirements of Clause
15.5.1B.3 herein. Rails shall receive the same protective paint treatment as specified in Clause
15.5.1B.3.4.
After erection of the crane girders the rails shall be accurately aligned on the girders and fixed in position
using proprietary expansion type clips approved by the Engineer. The clips shall be bolted down with
high tensile bolts tightened in accordance with the manufacturer specification. Crane rails shall be
aligned within the tolerances set out in:
Federation European de la Manutention

Section 1: Heavy Lifting Equipment Appliances,
Additive Sheet, Tolerances of Cranes and Tracks.
Location of rail joints shall be shown on the Contractor's drawings and shall be positioned to avoid joints
in crane girders and be located between pairs of clips.
5.1B.3.13.2 Checker Plate
Checker Plate flooring shall be galvanized raised pattern, self-draining type to BS 4360 Class 43A.
5.1B.3.13.3 Handrailing
Handrailing shall consist of galvanized tubular steel standards and tubular steel railing cut and beveled
where necessary. Blisters or uneven portion of welds shall be ground off. The tubing shall be in
accordance with BS 1387 or BS 1775.
5.1B.3.14 ASPHALTIC CONCRETE
Asphalt concrete paving works shall be as per the requirement of TCS-Q-113.01. Min thickness of
combined binder and wearing course shall be 102 mm (64 mm thick Class A Asphat binder course and
38 mm thick class C asphalt wearing course).
5.1B.3.14.1 Materials for Asphaltic Concrete
5.1B.3.14.1.1 Aggregates for Asphaltic Concrete
Aggregates shall consist of coarse aggregate, fine aggregate and mineral filler. The portion retained on
the 4.75 sieve shall be known as coarse aggregate, and the portion passing the 4.75 sieve shall be known
as fine aggregate. Mineral filler shall be as specified in (3) below. Aggregates shall conform to the
following requirements
(1) Coarse Aggregate:
Coarse aggregate shall be obtained from an approved source and shall consist of crushed rock
complying with the following requirements:
- It shall be clean, hard, durable and sound, of uniform quality and shall not contain
decomposed particles, clay lumps, organic matter, salts or other deleterious matter in
such quantities as will adversely affect its performance. It shall be as free as is
practicable from flat, elongated, soft and weatherable pieces. In no case shall the
proportion of soft weatherable particles exceed 2% and particular care shall be taken to
achieve a lower percentage for the surfacing course.
- It shall have test results not exceeding the following maxima - (x) being applicable to
90% of the material and (y) being an absolute maximum:
(x) (y)

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Aggregate crushing value (BS 815) 20% 25%
Abrasion loss (ASTM-C131) 25% 30%
Na SO soundness loss (ASTM C88) 10% 15%
Flakiness index (BS 815) 30%
Water absorption (BS 815) 2%
- It shall be produced in at least two sizes by the secondary crushing of the product of
primary crushing which is retained on a screen with openings at least twice the
maximum size of the aggregate being produced. The coarse or the coarsest of these
sizes shall not contain any particles exceeding 37.5mm size and the fine or finest of
these sizes shall not contain more than 2% of particles smaller than 3mm. When the
coarse aggregate is produced in two sizes they shall be divided on a screen with 15mm
openings or when the coarse aggregate is produced in three sizes they shall be divided
on screens with 16mm and 10mm openings.
(2) Fine Aggregate:
The fine aggregate shall comply with ASTM D1073 and shall consist of:
- Screenings from the production of the coarse aggregate by secondary crushing, as free as is
practicable from soft or weatherable particles but in no case containing more than 1% of such
particles for the surfacing course or 2% for the base course, or,
- Natural pit or beach sand which does not contain clay, loam, organic or other foreign matter in
such quantities as will adversely affect its performance. The grains shall be hard, sound and
durable, or,
- A mixture of screenings and natural sand all as specified above.
Screenings for use in the surface course, except those which have been wetted in the production
of coarse aggregate for the same course, shall be thoroughly wetted daily for at least four days
and allowed to stand until at least seven days after the first wetting in order to soften any soft or
weatherable particles. The grading of the fine aggregate shall be corrected if necessary to
correct any degradation, which occurs in this process or subsequently in the drier or the mixer.
The fine aggregate, comprising screenings, sand or a mixture of screenings and sand shall pass
the 6.7mm sieve and shall be graded such that when combined with the coarse aggregate,
grading within the limits given in Clause 5.1B.3.14.2 of this Specification can be achieved.
Natural sands from different sources, or natural sand from stone screenings, shall be combined
in suitable proportions to obtain a mix with a grading within the above limits if one material
graded within the above limits cannot be obtained or produced.
The percentage passing the BS Sieve 75 micron shall not vary by more than + or - 3% during
each day's working.
(3) Mineral Filler:
Mineral filler shall consist of cement or hydrated lime. It shall be thoroughly dry and free from
lumps. It shall have particle size grading within the following limits:
BS Sieve Size Passing (% by weight)
600 micron 100
75 micron 65 - 100
If the fine aggregate is sand, cement filler shall be used.

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(4) Stripping Test for Aggregates:
Aggregate passing the 9.5mm sieve and retained on the 6.7mm sieve shall be used for this test.
94 grams shall be heated to 135°C and thoroughly mixed with 6 grams of bitumen at 151°C.
After allowing the mixture to cool at room temperature for two hours, it shall be placed in a
beaker of distilled water covered with a watch glass and placed in a 60°C oven for twenty-four
hours. The amount of bitumen coating retained on the aggregate shall then be determined
visually. If there is less than 75% of bitumen retention, the aggregate shall be rejected, or an
approved method of treating shall be used to change the materials from a hydrophilic to a
hydrophobic state Anti-stripping and mixtures to improve adhesion of asphaltic cement to
aggregate shall be used in all asphalt concrete mixtures.
5.1B.3.14.1.2 Bitumen for Asphaltic Concrete
60 - 70 penetration bitumen meeting the requirements of ASTM D946 shall be used and, when tested in
accordance with the appropriate AASHO Standard methods, shall conform to the following
requirements.
Min. Max.
Penetration at 25°C, l00g 5 sees. 60 70
Flash point, Cleveland open cup, (°C) 232
Solubility in carbon-tetrachloride (%) 99
Ash (%) 1.00
Thin Film over test, 1/8", 163°C, 5 hours
Loss of heating (%) 0.80
Penetration of residue (% of original) 54
Spot Test Negative
It shall not foam when heated to 175 C. Cut back bitumen shall comply with ASTM D2027
(Medium-curing type) and ASTM D2028 (Rapid- curing type).
5.1B.3.14.2 Mix Proportions:
(1) The coarse and fine aggregates and the filler shall after mixing have particle size grading
between the following limits
BS Sieve Percentage Passing

Wearing Course Base Course
25 100 100
19.5 80-100 80-100
15.5 70-90 60-80

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BS Sieve Percentage Passing

Wearing Course Base Course
9.5 54-72 50-75

4.75 54-72 36-66
1.18 (No. 14) 34-48 20-34
0.42 (No. 36) 22-32 15-23
0.15 (No. 100) 15-20 5-13
0.075 (No. 200) 6-15 2-6
The proportion of the added filler shall be as required to fulfil the Marshall requirements specified
below.
The aggregates as finally used in the work shall not vary from the low limit on one sieve to the high limit
on the adjacent sieve, but shall be uniformly graded. Adjustment of the aggregate gradation and/or
bitumen content within the specified limits may be made as directed by the Engineer.
(2) The proportion of the bitumen shall be determined so that the asphaltic concrete, when
compacted by 50 blows of a standard marshall hammer, shall have the following test properties:
Base Course Wearing Course
Marshall stability, min. kg 500 1000
Marshall flow mm 1-4 L-4
% void in mix 3-8 3-5
% voids in aggregate filled

with bitumen 65-70 75-82
Marshall tests shall be carried out in accordance with ASTM D 1559.
The proportion of the bitumen, expressed as a % by weight of the combined aggregates and filler, shall,
unless the Engineer approves a variation of them be between 5.0 and 6.5 for the base course and 6.0 and
7.5 for the wearing course.
The proportion of bitumen in the surface course shall, within the limits tabulated in above and either in
addition to or in variation of the above requirements be related to the proportion of aggregate plus filler
passing the No. 75 micron BS sieve to obtain good surface durability properties to the approval of the
Engineer.
The Engineer shall have authority to reduce by written instruction the minimum stability of mixes if,
after the Contractor's trial mixes have been done, the Engineer considers that the higher stability could be
obtained only at the expense of loss of the durability characteristics of the surfacing.
In order to ensure the specified minimum stability, each mix shall be designed to have an average
stability exceeding the specified minimum 2.33 times the standard deviation of the stabilities obtained in
tests on the mix. Until at least 30 results have been obtained from a particular Job-Mix, the standard
deviation shall be assumed to be 135kg.
Job-Mix Formula:

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As soon as possible after commencement of aggregate production and well in advance of commencing
work, the Contractor shall carry out Marshall tests on trial mixes within the Specification limits and he
shall submit the results to the Engineer together with his proposals for the precise proportions of bitumen
and filler to be used. The Engineer shall then either approve these proposals or give instructions for the
other quantities to be used. The Contractor shall likewise propose and the Engineer approves or instructs
differently regarding the temperatures of stone and bitumen for mixing. In the event of any difficulty
arising in fulfilling the requirements the Engineer shall have power to amend the aggregate grading
limits. The precise proportions of bitumen and filler, the mix temperature and the aggregate grading, all
approved or instructed by the Engineer, shall constitute the Job-Mix Formula and the Contractor shall
manufacture the base course and surface course mix to the appropriate formulae within the following
limits of tolerance:
Particle size grading excluding % passing BS Sieve No. 75 : Up to limits specified in this Clause
micron as amended by Engineer
Proportion passing BS Sieve : ± 1.5%

No . 7 5 micron
Bitumen : ± 0.3%
Mix temperature : ± 14°C
The Contractor shall control the manufacture of the mix by tests as detailed in Clause 5.1B.3.14.1. He
shall submit the results thereof to the Engineer and he shall propose any variations of the Job-Mix
Formula, which may be necessary to comply with the requirements of this Clause. The Engineer shall
either approve such proposals or issue contrary instructions varying the Job-Mix Formula and the
Contractor shall manufacture the mix to this Formula within the limits of tolerance given above
The Engineer's approval of, or instruction on, the Job-Mix Formula shall not relieve the Contractor of
any responsibility to comply with the requirements of this Clause. The Engineer's approval of both the
mixes and the finished work will depend on fulfillment of all specification requirements as evidenced by
tests carried out by both the Engineer and the Contractor.
5.1B.3.14.3 Batching and mixing
Materials storage, mixing, plant equipment and operation shall comply with ASTM D995.
Aggregates shall be batched and mixed with the bitumen in an approved plant of the hot-mix
weight-batch type of a design, which will produce the mix within the Job-Mix Formula.
Aggregate shall be provided in at least three sizes. Each size and/or type of aggregate as delivered shall
be stockpiled separately. Where cold feeder bins are used each fine aggregate shall be placed in a
separate bin, or, should the number of aggregate sizes or types being used make this impossible, the fine
aggregate shall be thoroughly blended in such a manner and in such proportions as directed by the
Engineer prior to being placed in the feeder bin. Aggregates shall be handled and
transported between the crushing and screening plant and the stockpiles or cold-feed bins of the dryer
and mixer, and between stockpiles and the dryer, by plant and methods which shall ensure that
segregation does not occur and that moisture content variations are not large enough to affect the
uniformity of the temperature of heated aggregate at entry to the mixer. Aggregate shall not be permitted
to roll down the slopes of hot-bins.
The temperature of the aggregate, determined as it enters the mixer, shall be such that the temperature of
the finished mixture will be within the tolerance specified by the Job-Mix Formula. The heated and dried
aggregates shall be screened and conveyed to separate bins ready for mixing with the bitumen. The

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heated aggregate shall be separated into at least three sizes as designated or approved by the Engineer.
Mineral filler may be batched without heating
The aggregate without filler, prepared as specified above, shall be accurately weighed or measured and
conveyed into the mixer in the proportionate amounts of each aggregate size required to meet the
Job-Mix Formula. The required amount of bitumen for each batch, or calibrated amount for continuous
mixing, shall be introduced into the mixer. In batching mixing, the bitumen shall be added after the
aggregates have been introduced into the mixer and mixed for 5 to 10 seconds. In both types of plant the
filler shall be added after the bitumen and mixing shall continue for at least a minute after the addition of
the filler, and as much longer as may be required to obtain a homogeneous mixture.
Aggregate and bitumen shall each be heated to enter the mixing chamber at temperatures selected within
the range 150°C-175°C excepting as provided below and the temperature of the stone at entry to the
mixing chamber shall not be more than 14°C higher than that of the bitumen. The temperature of the
aggregate and bitumen at entry into the mixing chamber shall be chosen within the above limits and
having regard to the prevailing air temperature and haulage distance to ensure that the temperature of the
mix is between 135°C and 175°C when it is laid and not less than 150°C when rolling is commenced.
Aggregate and bitumen may be heated to enter the mixing chamber at temperatures between 175°C and
180° when this is necessary to fulfil the latter laying and rolling temperature requirements.
Thermometers reading between 150°C and 200°C shall be provided in the bitumen-heating tank and for
use in the mixing chamber or at its discharge point. Thermometers for observing air and surface
temperatures between -1°C and 66°C and for observing mix temperatures between 93°C and 180°C shall
be provided at each laying point
The volume of the aggregate and bitumen shall not be so great as to extend above the line of the mixer
blades when the blades are in a vertical position. All overheated and carbonized mixtures, or mixtures,
which foam or show indication of moisture will be rejected. When moisture is detected in the finished
mixture all aggregates in the bins shall be removed and returned to the stockpiles.
5.1B.3.14.4 Transporting
Asphaltic concrete shall be transported from the mixing plant to the spreader in trucks having tight,
clean, smooth beds 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 solvent shall not be used for this purpose. Loads shall be covered by waterproof canvas or metal
sheets during wet weather or when the temperature is below 10°C, or when the haul exceeds 3km.
Vehicles shall be insulated when the air temperature, and/or length of haul make this necessary to
maintain the temperature, between the specified limits. Deliveries shall be made so that spreading and
rolling of all the mixtures prepared for a day's run can be complete during daylight, unless artificial light
approved by the Engineer is provided. Any loads wet excessively by rain will be rejected. Hauling over
freshly laid material will not be permitted.
5.1B.3.14.5 Laying Equipment
(1) Mechanical Spreaders and Finishers:
The spreader and finisher shall be self-propelled, equipped with hopper, distributing screws,
heated adjustable screed on a frame supported at one end within the wheel-base or track length
and arranged to reduce the effect of an uneven laying surface. They shall be capable of laying to
the required width and profile without causing segregation, dragging, burning, irregularities or
other surface defects and of being operated at a speed consistent with the character of the mix
and the thickness of the course being laid, so as to produce a surface having a uniform density
and surface texture.
(2) Power Rollers:

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The roller to be used for commencing compaction shall be 6-8 ton tandem roller with a drive
roll pressure variable between 2200/2500 and 3600/4000kg/m of roller or an 8-10 ton tandem
roller with a drive roll pressure variable between 3200/3600 and 4000/4900kg/m of roller.
The roller to be used for completing compaction shall be a 10-15 ton tandem or three-wheel
roller with a rear roller pressure variable up to at least 5300kg per meter.
Roller wheels shall be equipped with adjustable scrapers, water tanks, and sprinkling apparatus,
which shall be used to keep the wheels wet for the purpose of preventing the asphaltic concrete
from sticking to the wheels, the rollers shall be otherwise suitable for rolling hot-mix surfacing
and shall be capable of reversing without backlash.
(3) Small Tools:
The small tools shall consist of rakes, shovels, tampers, pavement cutters, wood sandals and
stilt sandals of standard type, and other small tools as may be required.
5.1B.3.14.6 Laying
All loose material shall be removed immediately before applying prime and tack coats. The removal of
loose material shall be accomplished by the use of hand brooms or other acceptable means without using
water. The cleaning operation shall not displace or damage the surface.
Prime Coat:
The cutback asphalt prime coat shall be applied uniformly at designated temperature distributed evenly
at a rate of 0.65 to 1.75 1/m2 on prepared surfaces and as determined by field trials, in accordance with
ASTM D2995. Sufficient material shall be applied to penetrate and seal but not flood the surface.
Allowance shall be made to cure and volatilize as long as required to attain required penetration and in
no case less than 24 hours. Excess asphalt shall be blotted with just enough sand to prevent pick-up
under traffic. Loose sand shall be removed before paving.
Tack Coat:
The cutback asphalt tack coat shall be applied uniformly at designated temperature distributed at a rate
within 0.20 and 0.50 1/m2 on prepared surface of the asphalt concrete binder course. The appropriate
application rate in accordance with ASTM D2995 shall be determined by field trials. Tack coat shall be
applied by brush to contact surfaces of curbs, gutters, manholes and other structures projecting into the
abutting asphalt concrete pavement. Surfaces shall be allowed to volatilize until tack coat is at condition
of tackiness to receive overlaying course.
All permanently exposed curb surfaces shall be protected to prevent contamination by prime and tack
coats during application.
Frames shall be set for manholes, chambers and other such units within areas to be paved. Frames shall
be adjusted and fixed to proper position to comply with grade tolerances before paving. If permanent
covers are not in place, temporary covers shall be provided over openings until completion of road
construction. These covers shall be paved over, marked and removed after saw cutting and on
completion of permanent construction. Frame covers shall be set to grade, flush ( ± 3mm) with surface of
adjacent pavement.
Asphaltic concrete shall not be laid when the course prepared to receive it is damp, or when it has pools
of water, or during rainfall or a sandstorm. It shall not be laid when the atmospheric temperature is below
10°C and falling, or when the temperature of the course prepared to receive it is less than 5°C but it may
be carried out when atmospheric temperature is at least 5°C and rising, unless otherwise directed by the
Engineer.

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Asphaltic concrete course shall be constructed to the approved surface levels and the minimum
compacted thickness specified in Clause 5.1B.3.3.9. Where the compacted thickness of the first layer of
base course would exceed 80mm on account of irregularity in the surface of the formation the base
course shall be laid between 50mm and 60mm thick on a leveling course of a mix identical with it
excepting for any necessary limitation of aggregate maximum size and this leveling course shall be
between 20mm and 50mm thick.
Mixtures, which have a temperature of less than 135°C when, dumped into the spreader, will be rejected.
The spreader shall be adjusted and the speed regulated so that the surface of the course will be smooth
and the course of such depth, that when compacted, it will conform to the cross-section shown on the
drawings. Lanes shall be parallel to the road centerline. Joints in adjacent courses shall be staggered by
at least 60 ems. The length of any lane laid before placing the adjacent lane shall not be greater than will
permit a satisfactory hot longitudinal joint between lanes. When forming a hot longitudinal joint the 15
cm strip along the edge against which additional material is to be laid shall not be rolled until such
additional material is placed, except when the work is to be discontinued. After the first lane has been
placed and rolled, the adjacent lane shall be placed while the unrolled 15 cm is hot and in a readily
compactable condition. Cold joints shall not be made along the center of a road unless a stoppage of
laying necessitates changing a hot joint to a cold joint. Cold joints shall be formed on a vertical edge cut
in from the edge of the rolled mix and thinly coated with hot bitumen.
Initially rolling of the adjacent lane shall begin along the joint. A sufficient number of experienced
shovellers and rakes shall follow the spreader machine, dressing the surface as required to produce a
course of uniform surface texture and the required smoothness. In areas where the use of machine
spreading is impractical, the mixture may be spread by hand, and dressed with rakes. The loads shall not
be dumped any faster than can be properly handled by the shovellers and rakes. Rakes not equipped with
stilt sandals shall not be permitted to stand in the hot mixture. Contact surface of previously constructed
concrete pavement, kerbs, manholes and similar structures shall be painted with a thin coat of M.C. 800
or M.C. 3000 bitumen prior to placing the asphaltic concrete. Each layer shall be kept clean until the
succeeding layer is placed and the latter shall be laid as soon as possible after the former.
5.1B.3.14.7 Compacting
The mix shall be rolled immediately after laying and before its temperature has fallen below 150°C by a
tandem roller as specified in above and such rolling shall be continued only for so long as it is effective
and does not have any detrimental effect. The above 150°C minimum rolling temperature may be
lowered at the sole discretion of the Engineer, if this is necessary to ensure the best results in this initial
rolling. Compaction of the mix shall if necessary, be continued by heavier tandem rollers and it shall be
completed by a tandem roller or three wheel roller imposing at least 5300kg/meter of roller length. This
further and final compaction shall be carried out when the temperature of the mix is low enough to avoid
any detrimental effect but still high enough for the rollers to work effectively and compact the mix to the
density specified below. Such rolling shall, if necessary, be deferred until after sunset and night work
will be permitted for this purpose.
Final rolling shall be carried out parallel to the lanes and shall start at the extreme sides of the lanes and
proceed toward the center of the surfacing, over-lapping on successive trips by one-third of the width of
the rear wheel of the three-wheel roller. On superelevated curves rolling shall begin at the low side and
progress toward the high side. Alternate trips of the roller shall be slightly different lengths. Tests for
conformity with the smoothness specified in Clause 5.1B.3.3.9 shall be made by the Contractor
immediately after initial compaction, and any deviations in excess of the specified tolerances shall be
corrected by loosening the hot surface with rakes and removing or adding material as directed before
continuing the rolling. The speed of the rollers shall not exceed 5km per hour and shall at all times be
slow enough to avoid displacement of the hot mixture. Any displacement of the mixture occurring as
the result of reversing the direction of the roller, or from any other cause shall be corrected at once by
loosening the surface with rakes and re-rolling. Rolling of the surfacing shall be continued until all roller
marks are eliminated and a density of at least 98% of the laboratory density has been obtained. The
laboratory density shall be determined by the standard Marshall test method.

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During rolling, the wheels of the rollers shall be moistened to prevent adhesion of the material to the
wheels but an excess of water will not be permitted. Competent and experienced roller men shall operate
the rollers. In all places not accessible to the roller, the mixture shall be thoroughly compacted with hot
hand tampers weighing not less than 11 kg with a tamping face of not less than 300cm2. 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, replaced with fresh, and compacted as specified.
The rollers shall not be permitted to stand on asphaltic concrete, which has not been fully compacted.
Necessary precautions shall be taken to prevent the dropping of oil, grease, gasoline or other foreign
matter on any asphaltic concrete course. The Contractor shall provide competent workmen who are
capable of performing all work incidental to the correction of all surfacing irregularities.
5.1B.3.14.8 Level Tolerance
Each course of the compacted work shall be true to required levels and profiles.
After the completion of the final rolling, the smoothness of each course will be checked and any
irregularities or areas that retain water on the surface shall be corrected by removing the defective area
and replacing with new material without additional cost to the Employer.
5.1B.3.14.9 Thickness
The completed thickness of each asphaltic concrete course shall conform to the requirements of this
specification. Lanes shall be tested for thickness at intervals of 100 meters or at such closer intervals and
at such places as the Engineer may direct and the Contractor shall make and repair holes at his own
expense. If any surfacing or base course is found to be less than the thickness shown for it on the
drawings, the Contractor shall replace the asphaltic surfacing between such limits and to such levels as
the Engineer directs for the purpose of complying with Clause 5.1B.3.3.9 of this specification.
5.1B.3.14.10 Joints
All joints shall present the same texture, density and smoothness as other areas of the asphaltic concrete.
The joints between old and any new lanes or sections, shall be carefully made in such manner as to
ensure a continuous bond between the old and new pavement.
(1) Transverse:
The roller shall pass over the unprotected end of the freshly laid mixture only when laying of
the asphaltic concrete is to be discontinued for such length of time as to permit the mixture to
become cold. The end of the previously laid section shall be trimmed to expose an even, vertical
surface for the full thickness of the course. The fresh mixture shall be raked uniformly against
the joint and initial compaction secured with the tandem roller, followed by the regular rolling.
(2) Longitudinal:
When the edges of the longitudinal joints are irregular, honeycombed, or poorly compacted, all
unsatisfactory sections of joint shall be trimmed to expose an even, vertical or sharply sloping
surface for the full thickness of the course. Fresh mixture shall be raked uniformly against the
joint, followed by rolling.
5.1B.3.14.11 Protection of Asphaltic Concrete
After final rolling, no vehicular traffic of any kind shall be permitted on any course for at least 24 hours
or such longer time as shall be instructed by the Engineer.
5.1B.3.14.12 Sampling and testing

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The Contractor shall be responsible for tests to select his aggregate source and control its output. He
shall also be responsible for carrying out the following tests during all times mixing and laying work is
in operation:
(1) The grading of aggregate in each bin or stockpile extraction point and the grading of the
combined aggregates shall be determined at intervals not exceeding two hours during mixing.
(2) The stability, flow value and voids shall be determined by the Marshall Test Procedure at
intervals not exceeding two hours during mixing initially and not exceeding four hours
thereafter.
(3) The bitumen content and particle size grading of the aggregate in the mix shall be determined at
least twice daily, or once daily where the hours worked per day are 60% less than the normal
working hours.
In addition the Contractor shall submit to the Engineer suitable sized samples of all aggregates and
bitumen required for tests (1) and (2) above at least 20 days before surfacing is commenced, and of each
days production of aggregate, and of each batch delivery of bitumen. The Engineer will from time to
time carry out the tests involved in (3) above, and the Contractor shall facilitate the taking of samples.
Suitably sized samples for the determination of the density and composition of the completed asphaltic
concrete shall be removed and tests made by the Contractor at his expense at not less than 3 points in
each day's work and at intervals not exceeding 300 meters in each lane or as deemed necessary by the
Engineer. The Contractor shall repair the asphaltic concrete where samples have been removed. at his
expense.
If the deficiency in composition and/or density exceeds the limits specified no payment will be made for
such areas of asphaltic concrete until they are removed and replaced by the Contractor.
The Contractor shall allow for the cost of complying with all the above in his rates for asphaltic concrete.
5.1B.3.14.13 Inspection of Plant
The Engineer shall have access at all times to all parts of the mixing plant for checking the adequacy of
the equipment in use, inspecting the operation of the plant, verifying weights proportions, and character
of materials and checking temperatures being maintained in each portion and of the mixture.
5.1B.3.15 BLOCKWORK
5.1B.3.15.1Standards for Design and Workmanship
Design workmanship of all blockwork shall comply with BS 5268.
5.1B.3.15.2 Concrete Blocks
Concrete blocks shall comply with BS 6073, Part 1 - Precast Concrete Masonry Units. Blocks shall be
made with sulfate resisting cement below ground level.
The average compressive strength of the blocks and the lowest compressive strength of any individual
block tested in accordance with BS 6073 shall not be less than the values given below:
Average of 10 blocks : 5.0 N/mm2

Lowest individual block : 3.7 N/mm
5.1B.3.15.3 Calcium Silicate Blocks
Calcium silicate blocks, excluding size, shall comply with BS

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187 : Specification for Calcium Silicate brick.
The average compressive strength of the blocks and the lowest compressive strength of any individual
block tested in accordance with BS 187 shall not be less than the values given below:
Average of 10 blocks : 5.0 N/mm2

Lowest individual block : 3.7 N/mm
5.1B.3.15.4 Blockwork Sizes
Blocks shall be 390mm long and 190mm high and 100mm, 150mm or 200mm thick. Block 100mm thick
shall be solid and other blocks shall normally be hollow. Where blocks are to be used in work to be
plastered or rendered the faces shall be scored whilst the blocks are still "green" to provide a key. Block
sizes may be nominal allowing for a 10mm joint or actual, in either case structural dimensions shall be
co-ordinate to minimize cutting of blocks.
5.1B.3.15.5 Mortar
The mortar shall be composed of 1:5 cement: send or 1:1:4 cement: lime:sand. Cement shall be sulfate
resisting below ground level. Sand shall be clean, sharp, natural sand, well graded and entirely free from
loam, clay, dust or organic matter to the requirements of BS 1199, Table 1.
Water shall comply with Clause 5.1B.3.7.1.3 of this specification.

Plasticisers shall be in accordance with BS 4887 and shall be free from calcium chloride or similar salts
and shall be to the Engineer's approval.
5.1B.3.15.6 Laying Blockwork
All blockwork shall be set out and built to the dimensions shown on the drawings. Where a dimension
cannot be normal block sizes, special blocks shall be made or blocks cut from solid blocks.
Blocks shall be thoroughly soaked in clean fresh water immediately before use and unfinished work shall
be wetted immediately before block laying recommences.
All walls shall be laid in stretcher bond unless otherwise indicated. Blockwork shall be fully and
carefully bedded and all joints filled with mortar, the walls being carried up in a regular manner with
level courses and perpends strictly kept, no portion being more than one meter higher than another.
Blockwork left at different levels shall be racked back by at least one clear block per course.
Blocks shall be laid with cross-joints and beds averaging 10mm thick so that courses are kept to a
multiple of 200mm (or 210 if actual size blocks are used).
Where specified, blockwork shall be laid so that a fair face is produced on one or both sides.
Joints in faces to be plastered or rendered shall be raked to a depth of 10mm, other face joints shall be
approved by the Engineer.
The top courses of hollow concrete blockwork walls shall be laid in solid blocks unless otherwise
indicated.
All blockwork shall be tied to framing concrete columns by approved proprietary dovetail slots and
anchors.
Where blockwork frames into steelwork, blocks shall be cut and built securely and grouted into faces of
all structural steel columns with mortar. Blocks shall be well built and grouted up to the underside of
horizontal steelwork, which is to be bedded in the walls.

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5.1B.3.15.7 Reinforcement of Blockwork
Unless required to be specially reinforced all blockwork shall be nominally reinforced with minimum
8mm dia bars with approved proprietary galvanized masonry reinforcement complying with BS
405 - Expanded Metal (Steel) for General Purposes or approved alternative. Such reinforcement shall be
laid in every second horizontal joint.
5.1B.3.16 INTERNAL AND EXTERNAL FINISHES
5.1B.3.16.1 General
Unless otherwise stated, internal and external finishes shall be in accordance with this specification. If
the Contractor proposes to deviate from this specification he shall submit details of such proposals to the
Engineer for approval.
5.1B.3.16.2 Floors
5.1B.3.16.2.1 Power Floating
Where power floating is specified for concrete floors it shall be applied in two stages (i) Initial power
floating to even out any slight irregularities and (ii) Power-trowelling to close the surface, making it
smooth and dense.
Initial power floating shall not be started until surface moisture has evaporated and the concrete is stiff
enough to take the weight of machine and operator. A simple foot test leaving footprints no more than
3mm deep will assist timing. Concrete, which cannot be reached with the power-float, shall be hand
trowelled before power- floating starts.
Power trowelling shall not be started until excess moisture brought to the surface by initial power
floating has largely evaporated and the concrete has lost its stickiness. If mortar sticks to the palm of the
hand the slab is not ready to take trowelling.
5.1B.3.16.2.2 Concrete Surface Hardeners
Where surface hardeners are specified to be applied to concrete floors, the floor shall have a pigmented
surface hardener consisting of 3 coats of an approved two component water dispersed epoxy resin floor
sealing system applied strictly in accordance with the manufacturer's recommendations.
5.1B.3.16.2.3 Computer Flooring
Flooring in the control and communications rooms shall be an approved, proprietary system of modular
elevated free access type floor with a PVC tile finish, minimum 3mm thick complying with BS 3261.
The proposed system shall not have any supporting members between the adjustable floor jacks. Floor
panels shall be constructed of weather and boil proof non-hygroscopic plywood or approved equivalent
panel with a PVC tile finish pressure bonded to the upper surface with an agent that is waterproof,
cleaning detergent proof and will not support the growth of fungus.
The edges of the panels shall be protected with a PVC beading fitted into a machined groove in the panel
with a barbed tongue.
A number of spare tiles and suction pads for handling tiles shall be provided.
The Contractor shall submit samples for approval and selection of color and pattern.
5.1B.3.16.2.4 Terrazzo Tiles

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Terrazzo tiles shall comply with BS 4131, samples of the tiles shall be submitted to the Engineer for
approval and for selection of color and pattern.
Terrazzo tiles shall be laid on a 38mm thick 1:3 cement and sand screed. While the screed is still green
the tiles, which shall have been thoroughly soaked in clean, fresh water, shall be laid true to line and
level and with a joint width of 3mm on a 5mm thick bed of 1:3 cement and sand and leveled with a
wooden beater.
The joints shall be pointed with neat white cement and the floor cleaned immediately with sand or
sawdust and then polished mechanically and washed with hot water and pure soft soap.
Terrazzo tile skirting shall match the pavings and shall have rounded top edges and be coved at junctions
with floorings and shall be bedded on cement and sand screed to all vertical edges around pavings. All
required angles shall be provided to skirting, neatly cut and fitted to all abutments.
5.1B.3.16.2.5 Tiles for Battery Room
The tiles for the battery room shall be tiles complying with BS 6431 and shall be electrolyte resisting.
The Contractor shall submit samples for the Engineer's approval and for selection of color. The
Contractor shall also furnish a manufacturer's certificate in respect of the electrolyte resistance of the tile.
Tiles shall be laid on a 38mm thick 1:3 cement and sand screed. While the screed is still green the quarry
tiles, which shall have been thoroughly soaked in clean fresh water, shall be laid true to line and level
with a joint width of 3mm on a 5mm thick bed of 1:3 cement and sand and leveled with a wooden beater.
The joints shall be filled with 1:1 cement sand mortar and the floor cleaned immediately with sand or
sawdust.
Tile skirting shall match the pavings and shall have rounded top edges and be coved at junctions with
floorings and shall be bedded on cement and sand screed to all vertical edges around pavings. All
required angles shall be provided to skirting, neatly cut and fitted to all abutments.
An approved electrolyte resisting cement shall be used in screeds and jointing.
5.1B.3.16.2.6 Non-Slip Concrete
Where a non-slip finish is specified to floors or threads of stairs Carborundum shall be sprinkled on the
floors in the proportion of 3kg per sq. meter trowelled in before the concrete has set and proprietary
purpose made ceramic nosing tiles shall be used for stairs.
5.1B.3.16.3 Walls
5.1B.3.16.3.1 Plastering
Internal and external rendering shall be carried out in accordance with BS 5492 and BS 5262 and as
modified by this Specification.
The mortar for internal and external rendering shall be composed of one part of Portland cement and six
parts sand by volume. Water shall comply with Clause 5.1B.3.7.1.3 of this Specification.
The sand for internal plaster finishing coats shall be natural sand to comply with BS 1199 and BS
5.1B.300.
During hot weather an approved mortar plasticizer shall be used. Further measures to prevent cracking
such as keeping the wall moist, shading the wall and curing shall take place as necessary. The Engineer
may require that an approved Plastic Binder be applied to the newly plastered surface within one day of
plastering to aid curing.

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The mortars for the various types of rendering shall be mixed on a clean-boarded platform or in an
approved mechanical mixer. The materials shall be carefully proportioned by volume using approved
gauge boxes. Mortar for rendering which has taken its initial set before placing shall not be used.
Retempering will not be permitted.
All concrete or blockwork surfaces to be rendered or tiled shall be hacked or roughened by an approved
means as necessary to form an adequate key. Where work is to blockwork the joints shall be raked out to
a depth of 10mm.
Immediately before applying rendering the surfaces shall be wetted by brushing with clean fresh water.
Unless otherwise directed rendering shall be in two coats, the undercoat shall finish 15mm thick and the
setting coat shall finish 4mm thick. The undercoat shall be properly scored to receive the next coat and
shall be properly dry before the next coat is applied.
The undercoat shall be accurately executed to form the true surfaces required and the setting coat shall
be finished to a fine smooth surface with a wood float.
Galvanized plaster beads and laths shall be used at all corners. All arrisses and angles shall be finished
straight and true and all external angles and arrisses to reveals or openings shall be "pencil" rounded.
Rendering shall be kept damp for at least seven days after being applied.
5.1B.3.16.3.2 Tiling
Glazed wall tiles shall be 152 x 152mm cushion edged tiles 6mm thick to BS 6431, "Glazed ceramic tiles
and tile fittings for internal walls"; external and internal angles shall be formed with angle bead fittings.
Samples shall be submitted to the Engineer for approval and selection of color.
Internal tiling shall be executed in accordance with the recommendations of BS 5385.
Surfaces to be tiled shall be keyed and rendered in two coats as specified in the preceding clauses, the
second coat being finished plumb, true and level with a steel float.
Tiles shall be fixed with an approved mastic adhesive used in strict accordance with the mastic
manufacturer's instructions, the mastic being applied to the back of the tile. Joints shall be pointed in neat
white cement.
5.1B.3.16.3.3 Tyrolean Rendering
Tyrolean rendering shall consist of an undercoat as specified in Clause 5.1B.3.16.3.1 above and a
finishing coat of one part of white or colored cement to four parts of sand by volume applied with a
"Tyrol" dash machine in three applications to a total finished thickness of 16mm.
5.1B.3.16.4 Ceilings
Suspended ceilings shall conform to the requirements of British Standard CP 290 and to the approval of
the Engineer.
Panels for suspended ceilings shall be non-combustible felted mineral wool fiberboard panels 15mm
thick, 600 X 600mm nominal size with square cut edges and a factory applied matt white emulsion paint
finish.

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The panels shall be sound absorbing, with minimum 80% light reflectance and a thermal conductivity K
of 0.056 watt/meter C°.
The panels shall have a 2 hour fire resistance period and a Class O resistance to spread of flame and shall
be non-combustible Class O to Parts 1 and 4 of B.S. 476; "Fire tests on building materials and
structures".
Suspended ceiling panels shall be laid in an approved proprietary grid system of acrylic-coated
aluminum tees and angles suspended from the structure and fixed to true line and level. Each panel shall
be adequately clipped down and perimeter panels suitably supported.
5.1B.3.16.5 Painting of Buildings (Excluding Structural Steelwork)
Painting shall comply with the requirements of BS 6150 "Painting of Buildings" except insofar as
modified by this Specification.
This clause shall be read in conjunction with Clause on Protective Treatment of Metalwork in Section on
GENERAL REQUIREMENTS.
Sample boards showing tints of all paints and coatings proposed to be used shall be submitted to the
Engineer and no painting shall be commenced until such samples have been approved.
Where a paint system is to be applied to surfaces, which have been coated with a bituminous solution,
the surfaces shall be first given a coating of a knotting to prevent "bleeding".
External and internal concrete and blockwork surfaces shall be treated as follows:
The properties listed below for each paint are minimum solids by volume (%) and minimum specific
gravity.
Paint System A:
One coat of a PVA emulsion; 1.4 37%, 1.4
Paint B:
One coat of an alkali resistant primer; 32%, 1.2
Two coats of a PVA emulsion ; 37%, 1.4
Paint System C:
Two coats of chlorinated rubber based
high build coating ; 39%, 1.3
Paint System D:
Two coats of acrylic resin based enamel
with chlorinated plasticizer ; 31%, 1.0
Paint System E:
Two coats of a clear water repellent
silicone; 5%, 0.81
The materials specified in the above paint systems shall be proprietary and approved by the Engineer.
5.1B.3.17 DRAINS AND SEWERS
5.1B.3.17.1 Pipes and Fittings

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Pipes and fittings shall be in accordance with the following standards:
Clayware sewer and drain pipes - BS 65

C.I. S & S Pipes - BS 437
Clay drain pipes and fittings - BS 65
Unplasticised PVC pipes and fittings - BS 5481, BS4660
GRP pipes and fittings - BS 5480
All pipes and fittings shall be checked for soundness before laying.
Pipes shall be delivered, handled and stored in accordance with manufacturers' recommendations or, in
the absence of any recommendations, in such a manner as to protect them from damage, distortion or
deterioration.
5.1B.3.17.2 Excavation
Excavation for pipe trenches shall be in accordance with this Specification.
Excavations for sewers, drains, gullies and manholes shall be carried out to the lines and levels shown
the drawings or otherwise approved by the Engineer. In areas of general excavation or filling, these
excavations, and the subsequent construction shall not be commenced until the areas are completed to
grade unless the Engineer permits otherwise.
The Contractor shall maintain pipe trenches pumped out protected with safety barriers and well
supported where necessary and shall not open up trenches and leave them to fill with water without the
written permission of the Engineer.
Where solid rock is encountered at invert level it shall be removed to a depth of 150mm below the
bottom of the pipes and replaced with 150mm of compacted granular fill to approval of the Engineer.
5.1B.3.17.3 Laying and jointing
Earthenware pipes shall be laid true to line and level with the sockets leading uphill and each pipe shall
be separately boned between sight rails in accordance with BS 8301. Pipes shall be jointed in accordance
with BS 8301. The use of special joints shall be subject to the approval of the Engineer.
Cast iron pipes shall be laid and jointed in accordance with BS 8301. The use of special joints shall be
subject to the approval of the Engineer
PVC pipes shall be laid and jointed in accordance with BS 8301. Other types of pipes shall be laid and
jointed in accordance with the manufacturer's recommendations or as approved by the Engineer.
Connections to existing sewers and manholes shall be carried out in accordance with BS 8301.
5.1B.3.17.4 Testing
No work shall be covered or surrounded with concrete until it has been inspected and approved by the
Engineer. All sewers and drains (other than open-jointed subsoil drains) shall be tested for
water- tightness by means of water pressure maintained for not less than ten minutes in accordance with
BS 8301. Care shall be taken to avoid damage due to unequal temperature of the pipes and the test water;
for example, pipes exposed to hot sun shall not be tested with cold water.
Sewers and drains may be tested by air pressure and for straightness and obstruction in accordance with
BS 8301 if the Engineer so directs. Pressure tests shall be repeated when backfilling is completed. All
testing shall be carried out under the supervision of the Engineer
5.1B.3.17.5 Protection

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Where in the opinion of the Engineer, pipes require mechanical protection they shall be bedded,
haunched, or surrounded with concrete. The concrete shall be mixed and placed in accordance with the
provisions of the clauses of this specification dealing with concrete. Concrete shall not be thrown
directly on the pipes. The upper surface shall be struck off with a template or screed and neatly finished.
Flexible pipes shall be bedded or surrounded by approved granular material in accordance with the
manufacturers instructions, or as approved by the Engineer.
5.1B.3.17.6 Manholes and Catchpits
Manholes, catchpits, gullies and similar items shall be constructed and inspected in accordance with BS
8301. Concrete manholes, inspection chambers and gullies shall comply with BS 5911. Cast-iron
manhole cover, road gulley gratings, and frames shall comply with BS 497. They shall be galvanized
when shown on the drawings or as approved by the Engineer. Cast iron manhole step irons shall comply
with BS 1547. They shall be checked for soundness before building into manhole walls.
5.1B.3.17.7 Backfilling
Filling of trenches and other excavations shall not commence until the permission of the Engineer has
been obtained. The filling shall consist of approved excavated materials. For pipes which are not
completely surrounded with concrete, the material up to a level 300mm over the top of the pipe (or over
the top of any granular backfill shown on the drawings) shall be selected fill free from stones over 25mm
size, clay lumps over 75mm size, vegetable matter, or other material likely to damage the pipes, and it
shall be carefully placed and packed around (or over) the pipes to a density not less than that of the
surrounding soil. No filling shall be tipped into the trenches until this material has been completely
placed and compacted.
The general body of the filling shall be placed in layers not exceeding 200mm loose depth and
compacted with approved equipment to a density not less than that of the surrounding soil. Fragments of
rock not exceeding 200mm in any dimension will be permitted in the fill, provided that they are
surrounded by fine material graded so as to ensure the compaction of the fill without voids.
5.1B.3.17.8 Cleaning
On completion of the works, all drains, manholes, gullies, etc. shall be flushed from end to end with
water, left clean and free from obstructions.
5.1B.3.18 RAINWATER GOODS
Gutters, downpipes and fittings shall be in accordance with the following standards.
Aluminum rainwater goods - BS 2997

Cast iron rainwater goods - BS 460
Unplasticised PVC rainwater goods - BS 4576
Pressed steel rainwater goods - BS 1091
Wrought copper and zinc rainwater goods - BS 1431
All materials shall be checked for soundness before erection.
5.1B.3.18.2 Erection
Gutters, downpipes and fittings shall be erected in accordance with British Standard BS 6367. During
erection, care shall be taken to ensure that no damage is caused to existing buildings and structures. The

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Contractor shall ensure that his work does not interfere with other building work, which may be
proceeding during erection of rainwater goods.
5.1B.3.18.3 Protection
Steel and iron shall be protected from corrosion in accordance with BS 5493. Any protective coatings,
which may have been damaged before or during erection, shall be made good immediately to the
5.1B.3.18.4 Inspection and Testing
All materials shall be inspected after erection and those parts of the work, which will be concealed, shall
be tested before being finally enclosed in accordance with BS 6367.
5.1B.3.19 PLUMBING AND SANITARY WORK
Plumbing and Sanitary System shall be in accordance with SEC Standard TES-P-119.19 requirement,
except for others items as specialised below:
All materials shall be checked for soundness before installation. Materials shall be in accordance with
the following standards:
Copper pipes - BS 2871
Sanitary appliances - BS 6465
Code of Practice for sanitary pipework - BS 5572
C.I. soil waste and ventilating pipes - BS 416
Cold water uPVC pipes - BS 3505
UPVC soil and ventilating pipes - BS 4514
and fittings
A)Plumbing Piping: Piping shall confirm to the requirements of SEC standard 75-TMSS-01
B)Plumbing Fixtures:
1. Western Water Closet: Vitreous China, floor mounted, close coupled, siphon-jet flush action
water closet with trims and complete insulated tank supply assembly as per SEC standard 75-
TMSS-2.
2. Flush Tank: Wall mounted high level plastic flush tank with side inlet connection and stop
valve, complete with float assembly, concealed brackets or stainless steel screws, plastic flush
pipe and rubber connector.
3. Lavatory: Vitreous china, counter top lavatory as per SEC standard 75-SMSS-2 complete with
mounting kit, lavatory faucet with spout with aerator metal pop up drain and handle stops. It
shall be furnished with 32mm dia adjustable P-trap made of chrome plated cast brass with
cleanout plug and arm with escutcheon. Stainer shall be made of copper alloy or corrosion
resistant steel.
4. Plumbed Eyewash with Auxillary Trench Hose:

a. Unit shall meet ANSI Standard and/or OSHO rules and regulations.
b. Eyewash: Easy cleaning non clogging eyewash with stainless steel receptor, twin soft
PVC covered ABS plastic anti surge heads, stainless steel spray rings, dual automatic
pressure compensating devices, chrome plated brass ball valve easily activated by
stainless steel push flag, stailless steel dust cover, 40mm dia supply and waste pipe
fittings.

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c. Drench Hose: Eye/face and body spray with ABS plastic spray head, sqeeze lever handle
valve and 2.4 meters heavy duty yellow rubber hose.Hose spray assembly shall be
provided along with eyewash and should operate at maximum pressure of 276 kPa.
C)Plumbing Equipment:
1. Submursable Sump Pump:

The pump shall confirm to the requirements of dewatering pump on SEC standard 83-TMSS-
01. The sump pump shall be installed at each pit of basement. Discharge rate and discharge pipe
diameter shall be 4 litres per second and 50 mm respectively. The pump motor shall operate on
220V, 60Hz, single phase power supply.The pump shall be provided with control panel
(auto/manual) operation complete with control switch and other available pump moter
protection. The control panel shall be mounted on wall near the pump not less than 1.0 meter
high from the finished floor level.
2. Water Transfer pump:

The pump shall be closed coupled and designed for horizontal installation parts material and
specifcation as follows:
Casing : Cast Iran
Case Wearing ring: Bronze.
Impeller : Bronze.
Shaft: Stainless steel.
Mechanical Seal: Buna N Bellows, Stainless steel metal parts, Ni-Resist seat and Carbon
Washer.
The pump shall be designed to deliver 1.58 litre per second (25gpm) of water. Pump motor shall
have TEFC encloser and operable at 220 volts/ 1 phase/60 Hz.
The pump shall be equipped with complete safety and manual operational controls and shall be
provided with a galvanized steel sun shed.
3. Booster Pump :
The pump shall be closed coupled and designed for horizontal installation. Pump parts material
specification shall b as follows:
Casing : Cat iron
Case wearing ring : Bronze
Impeller : Bronze
Shaft : Stainless steel
Mechanical seal : Buna N Bellows, stainless steel metal parts , Ni resistant seat and carbon
washer.
The pump shall be designed to deliver water as required by the system, including the
emergency eyewash and hand spray equipment with an inlet supply pressuere of 276 kPa.
Pump motor shall have TEFC enclosure and operable at 220 volts/1-phasel60 Hz.
The booster system shall be skid mounted and provided with shed when installed outside the
building. The skid shall include control panel, pressure tank, pressuere gauge and pressure
switch..
4. Transformer Pit Pump:

The pump shall be self priming type designed for horizontal installation. Pump parst material
specifacation as follows:
Casing : Ductile Iron
Impeller : Ductile iron
Shaft : SAE 4140
Mechanical Seal : Silicon/silicon
Painting/Coating : refer to SES-H-001 requirement.
The pump shall be equipped with a complete safety operational controls and shall be provided
with galvanised steel sun shade.

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5. Electric water Heater: The water heater shall confirm to the requirement of SEC standard 94-
SMSS-1.
5.1B.3.19.2 Installation
Installation shall be in accordance with BS 5572 and BS 6465. During installation, care shall be taken to
ensure that no damage is caused to existing buildings and structures. Where possible, all necessary apes
and boxouts for services shall be formed during construction of the structures and buildings. Any apes,
chases, boxcuts or fixings subsequently needed shall only be provided with the Engineer's approval, and
the Contractor shall do all necessary making good and repairs.
5.1B.3.19.3 Testing
Testing of all materials after installation shall be in accordance with BS 5572 and BS 6465. Testing of
services, which will be subsequently concealed, shall be done before finally enclosed.
5.1B.3.20 CONCRETE TROUGHS AND DUCT BANKS
5.1B.3.20.1 General
Concrete cable troughs or duct banks shall be provided in accordance with the SCOPE OF SUPPLY.
5.1B.3.20.2 Concrete Troughs
The minimum thickness of reinforced concrete trough walls and floors shall be 150mm and covers shall
be a minimum of 75mm. Proprietary troughs or alternative proposals shall be submitted for approval.
Concrete protection shall be in accordance with clause 5.1B.3.3.15 of this Specification.
5.1B.3.20.3 Duct Banks
5.1B.3.20.3.1 Materials
Pipes shall be in accordance with the following standards:
PVC Pipes BS 3505, BS 4660
Where vitrified clay ducting is used samples of the pipes and jointing system shall be submitted to the
Engineer for approval. Other materials may only be used with the written approval of the Engineer.
5.1B.3.20.3.2 Installation
Ducting shall be 150mm dia. pipes Min. class3 encased in concrete. Separation between the pipes shall
be 80mm minimum. They shall be laid true to line and level, and all joints shall be accurately formed in
accordance with manufacturer's instructions. After installation, each duct shall be thoroughly cleaned by
water, air, rodding or other approved method. The duct shall also be proved by drawing a mandrel
through the duct. The diameter of the mandrel shall be 95% of the internal diameter of the duct.
5.1B.3.20.3.3 Inspection and Testing
All ducting systems shall be inspected before being finally enclosed. They shall be inspected for
accuracy of line and level, adequacy of jointing and resistance to ingress of water. The form of test will
be decided by the Engineer. Installations which have failed the tests shall be relaid to the Engineer's
satisfaction and shall be re-tested. Before being finally enclosed, all ducts shall be inspected to ensure
that they are entirely free from obstructions. The ends shall then be temporarily sealed until the ducts are
required for use.

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5.1B.3.21 SITE CLEARANCE
The Contractor shall be responsible for all clearance and other work required for preparation of the site.
Existing buildings, walls, fences, gates, piers and other structures and obstructions shall be completely
removed, together with their foundations, to the extent required by the Engineer. Suitable material from
such walls, piers, etc. may be incorporated in the works with the approval of the Engineer, but all other
materials arising from the clearance shall be disposed of to spoil as directed by the Engineer.
Underground chambers including cellars, tanks, cesspools and wells shall be excavated to formation
level, or as otherwise directed. The remainder of the chambers shall be cleaned of all loose or
unconsolidated material and pumped clear of water if the Engineer so requires before filling as
hereinafter described. Brushwood, scrub, or similar material shall be uprooted completely and burnt or
otherwise disposed of as directed by the Engineer.
Excavation resulting from the operations described above including all chambers below ground level
shall be filled with approved material in layers not more than 250mm loose thickness and each layer
shall be compacted to the same density as that of the adjoining ground. Existing services, including
sewers, surface-water and subsoil drains, water, gas, telephone and electricity mains shall be severed,
sealed off, backfilled, diverted or reconnected, as directed by the Engineer and to the satisfaction of the
appropriate authorities and owners. Temporary arrangements to maintain services during construction
shall be made as directed by the Engineer.
5.1B.3.22 SITE RESTORATION
Any part of the site not occupied by buildings, foundations, cable ducts, roads, soakaway or by other
structures or equipment shall be surfaced with 100mm of 25-50mm broken stone.
5.1B.3.23.1 To be submitted with Tender
(1) Items listed in Sub-clause 5.1B.3.3.1 of this Section.

(2) With reference to Sub-clause 5.1B.3.3.1.1 item (4) the name and addresses of
manufacturers/suppliers and full technical literature shall be provided for the items listed
hereunder. The technical literature shall be sufficiently comprehensive to enable the Tenders
proposals to be assessed for compliance with the Specification. Original brochures shall be
submitted.
Copies of parts of brochures are not acceptable. Documents not written in the English language
shall be accompanied by an English translation. This information is required for:
(a) Roof insulation board

(b) Roof mechanical protection membrane
(c) Concrete protection membrane
(d) Doors and door frames
(e) Door furniture
(f) Floor surface hardner
(g) Raised flooring
(h) Floor tiles
(i) Paint systems
(j) Suspended ceilings
(k) Septic tanks
5.1B.3.23.2 To be submitted after Award of Contract

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Design calculations, working drawing details of computer programs used in designs and other
information shall be submitted in accordance with the programming requirements of Sub-clause on
Design Submissions in the section on GENERAL REQUIREMENTS.
5.1B.4 SUBSTATION EARTHING AND LIGHTENING PROTECTION
5.1B.4.1 SUBSTATION EARTHING
5.1B.4.1.1 SCOPE
This section specifies the earthing system and bonding to earth of equipment housing structures
etc.
 Measurement of electrical resistivity of soil at substation site.
 Design of Substation earth electrode & mesh system.
 Installation of grounding system with coordination of switchgear contractor

to obtain the specified values.
 Supply and installation of earthing material & bonding to earth point of

equipment, cubicles, doors, structures etc with the coordination of contractors at substation site.
 Measurement of touch, step potential with the coordination of switchgear

contractor.
 Coordinate with switchgear contractor until the final installation &

measurement of touch, step voltages & earthing resistance.
5.1B.4.1.2 GENERAL REQUIREMENTS
The earth electrode systems together with all earth connections shall be designed and installed in accordance
with the recommendations contained in “IEEE Guide for Safety in Substation Grounding” IEEE Std 80-1986.
The bidder is also required to measure the touch and step voltage by the SGM and also the transfer voltages at
the nearest distribution package substation outside the 110 KV substation. The test method should be approved
by the engineer.
Each electrode system shall consists of a grid of copper conductor with mesh size designed to limit touch and
step voltages to safe values as recommended in IEEE Std. 80. If safe values of touch and step voltages cannot
be achieved by a conductor grid alone, earth rods shall be added as necessary.
In designing the earth electrode systems the following levels of earth fault currents shall be used :
380kV 50kA 1sec
110kV 40kA, 1 sec
13.8kV 21kA, 1sec
The resistance of the earth electrode system shall not exceed 0.5ohm during the summer period.
Earthing equipment:
The earthing equipment shall meet the requirements of IEEE. The earthing grid shall be of copper and its size
shall be based on the system fault current.
An earthing grid of Min.40X5mm steel shall be cast into the surface concrete of the floor in all switching hall
rooms and in the floor below these, if such exists; the connection point shall be welded. The mesh size shall not
be greater than (8X3.4). Suitable point shall be brought at every alternate column out of the concrete to allow
the connection of those parts of the building, which must be earthed. The part of these connection points which

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Saudi Electricity Company
110/13.8(11)kV Substation Tender no:
protrudes 20cm from the concrete for connection to the earthing to the earthing system shall be galvanized.
Further similar connection points shall be provided at a number of places in every bay for the connection of
portable earthing equipment when working in the station.
All iron parts of the building and reinforcement shall be connected to this earthing installation. Safety earthing
shall be provided for all electromechanical equipment under this contract by adequate size earth conductor.
An earthing grid of copper conductor if required by switchgear contractor, with a maximum mesh size of
(8x3.4) M shall also be provided under the transformer. Material for the mesh under transformer shall be
supplied by switchgear contractor but to be installed by civil contractor. Civil contractor will coordinate with
switchgear contractor for laying of earthing conductors in ground outside the substation building by switchgear
contractor as per earthing system design.
5.1B.4.1.3 TESTS
Prior to drawing up designs the Contractor shall carry out a series of soil resistivity measurements at each site.
The Engineer’s representative shall witness these measurements. The measurements shall be made using the
Wenner four-electrode method. Readings shall be taken for variations in probe separation in steps of 1-meter
upto 5 meters and continuing in steps of 10 meters upto 60 meters.
Position for probes shall be chosen on the basis that they are the most likely to give accurate results. At least
two series of measurements shall be made at each site, the directions of measurements being approximately at
90°C to one another.
Probe positions adjacent to existing earth systems or other buried metal objects shall be avoided as far as
possible. Ground resistivities and earth electrode resistances shall be derived from the measured data.
On completion of each installation the following tests shall be performed to verify that the earth system
resistance is within specification and that touch and step voltages are within tolerable limits:
- earth resistance test
- voltage gradient test
- step voltage test
- touch voltage test
The test methods shall be subject to the Engineer’s approval.
The Engineer’s representative shall witness the test.
In the event of these limits being exceeded the Contractor shall modify the earthing system at his expense to
attain values within the specified limits.
5.1B.4.1.4 EARTH CONDUCTORS
All earth conductors shall be copper.

A continuous conductor shall be laid 1m outside the boundary fence/wall of the new substation. The earth
electrode mesh shall be formed by interconnecting various points of the perimeter conductor.
Buried earth loops shall consist of stranded copper cable. The conductor shall have a minimum cross-section of
120 mm².
Loops within switchyard and buildings and the connections between these internal loops and the buried loops
shall consist of stranded copper conductor of a minimum cross-section of 120mm².
The requirements for earth connections within switchgear assemblies are detailed in the sections of this
specification covering switchgear. The number and disposition of earth connections between switchgear
assemblies and the earth loops shall be subject to the Engineer’s approval.
The minimum earth conductor size connecting various items of equipment to the earth electrode system shall be
as follows but during design of conductor, actual size of the conductor is more then as specified below then
contractor has to provide the designed size conductor with in the same quoted price:
C:\Projects for transmittal\AL Thager-2 Bulk Purchase Final\Part 5\Part-5.1B (R01 Technical specification for Civil work) REV.docx/ 83
1) Equipment and steel structures located within the substation area – two fully rated
stranded conductors of a minimum cross - section of 120 mm².
2) Equipment enclosures with can become live at high voltage during earth fault - one fully rated stranded
conductor of a minimum cross-section of 120 mm².
3) Miscellaneous other structures and steelwork, relay and control panel etc. - one stranded conductor of a
minimum cross-section of 50 mm².
4) Cubicle mounted low-voltage switchgear - two fully rated stranded conductors of a minimum cross-
section of 120 mm². one connected to each end of an internally mounted earthing bar.
5) Transformer and reactor neutral points, transformer and reactor tank - two fully rated stranded
conductors of a minimum cross – section of 120 mm².
(6) Transformer and reactor marshalling boxes - one fully rated stranded conductor of a
minimum cross - section of 120 mm².
(7) Cable sheaths - one fully rated conductor in accordance with the requirements of the
cable manufacturer and to the Engineer’s approval.
(8) Surge arresters - outdoor - a direct run of fully rated conductor from the arrester earth
terminal to an earth rod. At each location the rods associated with the three phase arresters shall be
connected together and shall also be connected to the earth electrode system at two points. In order to
get minimum surge impedance the earth conductor shall be kept short and free from bends. The
conductor shall be fastened to its supporting surface in order to withstand any electrodynamic forces and
shall be protected against mechanical damage.
Surge arresters - indoor - as for outdoor surge arresters and in addition the direct run of fully rated
conductor shall be bonded to the earthing bar and/or earth loop.
(9) Neutral resistors and reactors - two fully rated stranded conductors.
(10) VT primary windings - a direct run to the earth loop fully rated.
(11) Earth switches and devices - a direct run to the earth loop fully rated.
(12) The first transmission tower (if applicable) outside the substation area - two fully rated
stranded conductors of minimum cross-section of 120 mm².
5.1B.4.1.5 EARTH RODS
If earth rods are proposed they shall be copper clad rods of 16mm diameter and 2.4 meters in length. The
copper cladding shall be bonded to the steel electrolytically or by a molten welding process. If it is necessary to
form extended lengths of rods, standard sections shall be welded together. Rods shall be fitted with hardened
steel tips, caps and coupling pieces to facilitate driving by power hammer.
5.1B.4.1.6 MAINTENANCE EARTHING POINTS
If it is necessary to connect normally live parts to earth for maintenance purposes by means of temporary
flexible earth leads, fixed earthing points shall be provided close to the equipment. Such earthing points shall be
connected to the earth electrode system by means of fully rated earth conductor. The precise arrangement shall
be subject to the Engineer’s approval.
5.1B.4.1.7 FENCES
Exposed metallic parts of fences shall be bonded together and connected to the earth grid. Each strain section
shall have a connection to earth.
5.1B.4.1.8 OVERHEAD GROUND WIRES
Overhead ground wires, if they exist, shall be connected to the station earth grid via the line and gantries.
5.1B.4.1.9 POTENTIAL DANGER POINTS
In order to ensure the safety of personnel the earthing arrangements for the following items shall be drawn up
with special care :
- entrance gate frames, metal doors and handrails
- water supplies
- operating handles
- building steelwork and cladding
- fences
Care shall be taken also to minimize potential dangers from voltages which may be transferred along buried
pipes, telephone cables etc.
5.1B.4.1.10 INSTALLATION
The earth electrodes systems and bonding of equipment enclosures, structures etc. to earth shall be installed
with the utmost care to ensure that, during the life of the substation, all components shall be capable of carrying
the prescribed earth fault currents.
Where joints are buried the preferred method of jointing is by crimped connector or by thermo welding process
(Cadweld or equivalent). Bolted connections shall not be used below ground.
Connections between exposed earth conductors shall be made using crimped connectors.
Connections to the earth terminals of equipment, structures etc. shall be made using a bolted connection, two
bolts per connection shall be used.
Surfaces of current carrying connection and joints shall be thoroughly cleaned immediately before connection /
jointing. Paint, scale and other deleterious materials shall be removed.
All joints and connections shall be low resistance, fully rated, mechanically sound, secured against loosening
and protected against electrolytic action.
The earthing grid in switchgear buildings shall be cast in the concrete floors, with suitable connection points
brought out for equipment grounding.
Exposed earth conductors shall be installed inconspicuously in vertical or horizontal formation and shall be
securely fastened to supporting surfaces.
Earth conductors in proximity of control cables, sheaths and other buried services shall be PVC insulated and
there shall be adequate physical separation of the earth conductor from these services.
Where earth conductors are being led through walls and floors suitably sized PVC tubes shall be grouted in
during the construction of the building.
All miscellaneous steelwork including cable trays, support brackets, corner angles on the cable ducts etc. shall
be bonded to earth.
Where thermo welded joints are proposed they shall executed in accordance with an approved process. The
manufacturer’s instructions shall be followed in every detail. Welds shall not be porous or deformed. Worn,
damaged or incorrectly sized moulds shall not be used.
The earth electrode mesh shall be arranged so that connections between the earth terminals of equipment and
the earth electrode system are kept short. The number of splices in the earth conductor shall not be excessive.
Earth conductors which are buried in the ground shall be laid at a depth of 600mm below graded level.
5.1B.4.1.11 DRAWINGS AND INFORMATION
The following items shall be submitted to the Engineer for approval :
(1) Layout drawings of earth system (each system).
(2) Details of earthing system design calculations, including soil resistivity values.
(3) Details of all materials used, including method of jointing.
5.1B.4.2 LIGHTNING PROTECTION
5.1B.4.2.1 General
This section of the Tender provides the requirements for the design, installation and testing of complete
substation (building and outdoor equipment) shielding against lightning strokes. The combination of static poles
and shielding wire shall be coordinated with the transmission line shielding (if applicable) to provide the
required shielding protection of the substation. The Lightning and Lighting protection shall be as per Standard
TESP-119.19.
5.1B.4.2.2 Codes and Standards
Lightning protection system design shall conform to relevant IEC specification and also recommendation of
VDE DIN 0101.
5.1B.5 MECHANICAL AND ELECTRICAL SERVICES
5.1B.5.1 SCOPE
This section specifies the requirements for substations in regard to lighting, pressurization, ventilation and air
conditioning, fire protection, power facilities, overhead travailing cranes and miscellaneous equipment.
The design of these services shall be such that the associated equipment shall be fully integrated into the overall
design of the substation. All cabinets, panels, racks, boards shall have the same architectural features (height,
kicking strip, color, method of manufacture, labeling, etc.) as other cabinets and equipment within the room.
5.1B.5.2 STANDARDS
The latest revisions of the following standards shall apply:

BS 4533 Luminaries
BS 5266 Emergency lighting
BS 6207 Mineral insulated cables
IEC 309 Plugs, socket-outlets and couplers for industrial purposes
CIBS (UK) Code for interior lighting
ASHRAE & ARI Air conditioning, ventilation, air filtration, cooling/heating apparatus
BS 6540 Air filters used in air conditioning and general ventilation
BS 466 Power driven overhead travelling cranes, semi-goliath and goliath
Cranes for general use.
BS 5499 Fire safety signs, notices and graphic symbols
BS 5445 (Pt7) Point type smoke detectors
ANSI/NFPA 12 Carbon Dioxide Extinguishing Systems
ANSI/NFPA 15 Water Spray Fixed Systems
NFPA2001 Clean agent fire extinguishing systems.
In the case of conflict between this specification and any of the listed standards, this specification shall take
precedence.
5.1B.5.3 LIGHTING
5.1B.5.3.1General
The lighting system shall be such that all parts of a substation can be adequately illuminated. All lights shall
give good visual performance and shall be free from excessive glare, stroboscopic effects and flicker from
discharge lamps. Safety and amenity shall be important considerations of the lighting design. The system shall
be designed to ensure satisfactory operation and service life under all variations of voltage, frequency and
temperature.
Outdoor lighting shall be switched from the gate or relay/control room respectively by main switch and by
photocell automatically.
For indoor lighting, main fluorescent lamps to be used and switches shall be used for maximum four fluorescent
lamps. Rooms with more than four light fittings shall be operated by impulse current relays. An impulse switch
shall be provided at each door. All lighting switches shall have illuminating LED’s for easy location in the dark.
5.1B.5.3.2 Indoor Lighting
Levels of illumination for particular areas shall be designed to the following values, and shall be generally in
accordance with CIBS (U.K.). Code for Interior Lighting.
Average Illuminance
 Control and Relay Room, office 350 lux (min.)
 Mosaic Control Board in Control Room 450 lux (min.)
These values apply to the vertical face of cabinets and kiosks and shall have a uniformity factor based on the
minimum/average Illuminance of not less than 0.7 measured on a horizontal line 1.5m above floor level.
Average Illuminance
 Switchgear Hall 250 lux (min.)
In GIS switchgear halls the light sources shall be wall mounted and easily accessible for maintenance. Top of
GIS equipment shall be illuminated by floodlights on walls/ceiling.
Average Illuminance
 Battery Room, Ventilation Plant Room,

and Diesel Generator Plant Room, Fire Water
Pump Room, NGR Room, Store 250 lux (min.)
 Workshop 350 lux (min.)
 Cable Basement 150 lux (min.)
These values shall be measured at floor level except for the workshop where measurements shall be taken on a
horizontal plane 0.7m above floor level. A uniformity factor of not less than 0.7 shall apply.
Average Illuminance
 Corridors, Stairways, Entrance Halls, Toilets 200 lux
This value shall be measured at floor level and have a uniformity factor of 0.5 min.
All luminaries shall comply with BS 4533.
5.1B.5.3.3Outdoor Lighting
The levels of illumination shall be designed to the values indicated hereunder.
 Transformer and Reactor Bays, Average Illuminance 100 lux
 Outdoor Switchyard 30 lux
5.1B.5.3.4Lighting Switches
Lighting switches shall generally be metalclad 15 amp., "AC only" type capable of operating at their full rated
capacity.
Switches shall be one way, two way or intermediate as required and where mounted together they shall be fitted
in a common box. For surface installations they shall be fitted with fixed grids and in flush installations the
grids shall be adjustable.
Switches mounted externally shall be of weatherproof pattern fitted with machined box and cover joint, brass
operating handles, neoprene weather-tight seals and external fixing feet.
Switches shall be mounted 1.4m above finished floor level.
Switches controlling battery room lighting shall be mounted outside the room, adjacent to the access door.
Sockets
3 phase and 1 phase switched sockets are to be provided at relay / control room, switchgear hall, basement and
at outdoor substation area. Outdoor socket shall be of weatherproof and dust proof type. Location and number of
socket outlets will be decided by the Purchaser/Engineer.
All rooms shall be equipped and wired wih duplicate telephone socker
125 Amp. Triple pole and neutral switched socket shall be provided near transformer for oil treatment. These
sockets shall be weatherproof design and suitable for outdoor installation. These switched sockets shall be
supplied from AC distribution panel.
Emergency lighting shall permit survey in the operating rooms, in the relay/control room, outdoor switchyard
area etc. These emergency lights shall be positioned, to the approval of the Purchaser/Engineer.
The lighting distribution board shall be of cubicle type sheet metal enclosed and free standing or wall mounted
type. The distribution board shall be of front access only, dead front design and be furnished with hinged door
and lock. The distribution board shall be sized to house all future circuits for expansion. Each distribution board
shall be furnished with the necessary circuit breaker for incomer supply and with miniature circuit breaker for
outgoing feeders. In addition 20% spare outgoing feeders of each capacity shall be provided over and above the
present and future extension requirement. All spare feeders shall be complete in all respect and shall be wired
upto the terminal block.
5.1B.5.3.5Emergency Lighting
Emergency lighting shall comply with BS 5266 where not in conflict with the Specification, and shall be
operated at 110V DC. It shall provide sufficient illumination not less than 10 lux in all areas to ensure the safe
movement of personnel, safe access to and exit from any part of the substation.
On failure of the AC supply the emergency lighting shall be automatically illuminated from the 110V DC
supply. The control system shall be such that the emergency lighting is switched off after 10 minutes, unless
over-ridden. At the end of the 10-minute period, an indicating lamp shall be illuminated. An over-ride switch
shall be provided to extend the period of operation, either during the initial 10 minute period or subsequently. A
sensitive voltage relay shall be provided to monitor the battery voltage, set to operate when the voltage falls to a
value corresponding to a remaining battery capacity of the normal standby load for the remainder of the
discharge period, plus the emergency lights for ten minutes, plus the instantaneous discharge requirements, as
set out in the Clause on Batteries in the Section on AUXILIARY POWER SUPPLIES. On operation of the
voltage relay, a warning buzzer shall be sounded, and after a 10-minute delay, the emergency lights shall be
extinguished, and shall remain so until the battery voltage has recovered. If the AC supply returns during the
period of operation of the emergency lighting then the latter shall be switched off and re-set automatically.
Self-contained illuminated "Exit" signs complying with BS 5499 shall be provided in each room over the doors
of emergency escape routes. These units shall provide sustained lighting of the legend and of the door threshold
while AC supply is present and for a minimum of 1 hour after its failure.
Test facilities shall be provided for checking that the emergency lighting system is in working order.
Portable rechargeable emergency lights shall be provided one each in switchgear halls, relay room, sprinkler
room and entrance areas.
All wiring for the emergency lighting system shall be mineral insulated copper-sheathed cable (MICC) or
locally manufactured Flame retardant 750°C for 3 hours as per IEC.
5.1B.5.3.6Security Lighting System
Security lighting on periphery wall and on the building shall be provided in accordance with the Security and
Safety Directive SSD-13, Security Lighting Systems and as directed by the Engineer.
5.1B.5.3.7 Drawings and Information
The following drawings and information shall be submitted to the Engineer for approval.
(a) Physical layout of equipment in indoor lighting scheme. Flush mounted fittings shall be shown integral
with the ceiling tile arrangement.
(b) Physical layout of equipment in outdoor lighting scheme.
(c) Physical layout of equipment in emergency lighting scheme.
(d) Electrical schematic diagrams of all lighting schemes showing operation and control.
(e) A description of the lighting schemes involved and their operation and control.
(f) Equipment schedule to cover all items of equipment and giving complete information on each item
including manufacture, type rating etc.
Before putting into service and taking over by the Employer, detailed instructions on operation and maintenance
shall be submitted to the Engineer.
5.1B.5.4 AIR CONDITIONING AND VENTILATION SYSTEM
5.1B.5.4.1 General
1. The HVAC systems shall be designed to meet the specified indoor conditions in consideration of the
maximum outdoor ambient conditions described in the clause on Service Conditions in the Section on
GENERAL REQUIREMENTS and NGSA Standard TES-K-100.01,Rev.0. All necessary HVAC
System and accessories for their safe and efficient operation shall be provided. The HVAC System
and accessories shall be subject to the Engineer's approval.
2. The units to be provided shall be of direct expansion type, single packaged air conditioning units
(PACU) with 2 x 100% identical cooling capacity per system for duty and standby units, conforming
to the applicable requirement of SEC Standard 73-TMSS-01. Rev.01.Control facilities shall include
automatic selection of the Standby unit in the event of failure of On duty unit and planned
changeover.
3. PACUs shall be ground or roof mounted on reinforced concrete pads with all necessary vibration
isolators.
4. System and equipment shall be installed in accordance with TCS-K-100, TES-P-119.19 Rev.01 and
manufacturer’s instructions.
5. Telescopic type, wheel mounted lifting crane shall be provided for the unloading and Installation of
PACU Units at site whose crane capacity is 5 times capacity of the heaviest PACU unit to be lifted &
installed.
5.1B.5.4.2 Design Parameters
The following basic parameters shall be used in the design of HVAC systems.
(i) Pressurization
- Control and Relay Rooms: A minimum positive pressure of 50 Pa with respect to atmosphere
- All Other Rooms: minimum positive pressure of 40 Pa with respect to atmosphere except Battery
Room, Toilet and Kitchen to be maintained in a negative pressure.
(ii) Ventilation
- Occupancy of each
Control Room - 3 people
Relay Room - 6 people
Switchgear hall - 3 people
Battery Room - 1 person
Workshop & store - 2 people
Cable Basement - 2 people
NGR room, fire pump room - 2 person
- Fresh air ventilation rate per person -45CMH
(iii) HVAC Control System

- The Direct Digital Control (DDC) system shall be compact module type and shall contain digital
analog for input and output points as specified below:
a. All alarms and indications (such as pre-filter, bag filter, exhaust fan, etc.) shall be considered as
input points in DDC system.
b. Compact module DDC, shall be at least 16 points input and 16 points output.
c. DDC shall be ready to communicate with computer system to build Building Management
System (BMS) in the future.
d. DDC compact module shall be at least 20% free points spare.
e. Other requirements are:
i) Portable operator terminal shall be mounted on the panel door 1.50 meter high above the
finished floor level.
ii) Two communication interface ports shall be provided for future Building Management
System (BMS) connections.
iii) The DDC shall have an alarm history log and capable of storing at least 20 last events.
The latest events shall succeed the previous events and shall have dates and times of
occurrences. During normal operation, the DDC shall display the substation name,
month, day, year and time. Numeric display i.e. temperature and hours shall have one
decimal point.
iv) Submit proposed control diagram for review and approval prior to fabrication by control
specialist.
5.1B.5.4.3 Requirements for each room
5.1B.5.4.3.1 All Rooms
The complete substation building shall be pressurized to maintain each room at a positive pressure with
respect to outside atmosphere, to prevent the ingress of sand and dust. The pressurization/ventilation
system(s) shall deliver sufficient fresh air to each room to maintain the conditions set out in 5.1B.5.4.2.
To avoid over pressurization, Pressure Relief Damper (PRD) shall be provided in all clean agent
protected areas with Motorized Fire / Smoke Damper (MFSD).
- In the event of the internal pressure becoming negative with respect to atmosphere for any reason, an
alarm shall activate on the HVAC control panel system.
5.1B.5.4.3.2 Control, Relay and Battery Charger Rooms, Offices
These rooms shall be air-conditioned to maintain the temperature in the range 22-25°C and relative
humidity in range 45-55%.
5.1B.5.4.3.3 Switchgear Hall
110KV, 13.8KV rooms shall be air conditioned to maintain the temperature below 27°C and the
relative humidity below 50%.
5.1B.5.4.3.4 Battery Room
- This room shall be provided with continuously operating extraction fan(s) at three levels to prevent
the build-up of inflammable gases. This ventilation shall be sustained in the event of failure of the AC
supply. This fan & motor shall have a corrosion and explosion proof enclosure with Class B insulation
ideal for 24 hours continuous operation.
5.1B.5.4.3.5 Cable Rooms and Basements
- These rooms shall be air-conditioned to maintain the temperature below 30°C and the relative
humidity below 70%.
- Where these rooms like basements are below switchgear rooms containing SF6 insulated switchgear,
extraction fans shall be provided with two sets of louvers, one to remove SF6 gas at low level, and
the other to remove other gases and products of combustion at a higher level.
5.1B.5.4.4 HVAC System and Accessories
5.1B.5.4.4.1 General
- All Air conditioning Units shall be of the air-cooled type and shall be quiet and vibration free in
operation.
- Exhaust Fan / Smoke purging fans shall be of Centrifugal type complying with SEC Standard
73-TMSS-05 & TES-P-119.21.and shall be suitable for outdoor use.
- Noise levels in all systems shall be kept to a minimum. External noise levels measured at distance of
3m from suction or discharge grilles shall not exceed 60 dB (A).
- All exposed moving parts of plant shall be enclosed by a wire mesh screen. Protection shall be
according to IF 20, IEC 529.
- All electrical equipment, motors, wiring etc. shall comply with the appropriate regulations.
- All motors shall have an isolating switch-fuse unit or stop button within two meters of them together
with facilities for locking the control switch or circuit breaker in the 'off' position at the point of
control.
- The condensate from the air conditioning units shall be piped outside the building to a soak away, a
trap being installed in the pipework for pressure equalization purposes.
- The air conditioning plant, which operates intermittently, shall have a notice affixed nearby, in
English and Arabic, indicating that it may start up without notice.
5.1B.5.4.4.2 Packaged Air Conditioning Units
- Manufactured Units: Self-contained, single packaged, pre-wired units and pre-charged with
refrigerant complying with SEC Material Standard 73-TMSS-01. Rev.01, suitable for outdoor
installation consisting of cabinet, refrigerant compressors, condensing coil and fans, cooling coil and
fan, control wiring and piping, all factory assembled in a weather proof enclosure mounted on a
pressed steel base ready for field connections to utilities and ducts. Each unit shall be equipped with
hot gas bypass system.
- Constructions and Ratings: In accordance with ARI 340/360. Testing shall be in accordance with
ASHRAE 16.
- Performance Ratings: Energy Efficiency Rating (EER) and Coefficient of Performance (COP) shall
not be less than as prescribed in SEC Material Standard 73-TMSS-01. Rev.01.
- Electrical and Components
i) Motor: NEMA MG-1 and MG-2.

ii) Wiring Termination: Provide terminal lugs to match branch circuit conductor quantities,
sizes and materials indicated. Enclosure terminal lugs in terminal box sized to NFPA 70.
iii) Electric Duct Heater shall be Flanged-type mounted in a duct section with heater control
access door on the side of the unit.
5.1B.5.4.4.3 Filtration System
- Filtration shall be according to TES-K-100.01 Revision.0 Clause 12.0.

- Fresh air make up shall be through the openings provided in the PACU’s equipped with sand trap
louvers with air filtration, motorized volume damper, removable 13 mm wire mesh bird screen and
access door for maintenance followed by two stages of filtration.
- The combination of sand trap and first "coarse" stage filter shall have a gravimetric efficiency of not
less than 95% for all dust 5 microns or greater. Its dust holding capacity shall be 2kg for every cubic
meter/second of air intake to the air conditioning system under design operating conditions.
- The second "fine" stage filter shall have a gravimetric efficiency of not less than 95%.Its dust holding
capacity shall be 0.75 kg for every cubic meter/second of air intake to the air conditioning system
under design operating conditions.
- Another combination of gravimetric efficiencies and dust holding capacities for the coarse and fine
filters may also be considered if it can be shown to perform to at least the standard described in the
last two paragraphs.
- Attention is drawn to the fact that the maximum wet bulb temperature may attain 35°C for prolonged
periods and any filter medium used must be designed to function satisfactorily under these
conditions.
- The filtration system is vital for the proper functioning of the entire HVAC system. Because of this,
particular care shall be taken in the selection of the types of filters employed, in the design and
installation of the filtration system and in ensuring that leakage around the filters shall be avoided.
- Install filter gage static pressure tips upstream and downstream of filters. Mount filter gages on
outside of filter housing or filter plenum, in accessible position. Adjust and level.
5.1B.5.4.4 Ductwork and Pipework
- The Contractor shall provide all necessary ductwork, Motorized Volume Dampers, control dampers,
motorized fire & smoke dampers, grilles, diffusers, louvers and all pipework, fittings and valves. The
layout and details shall comply with this Specification and with good engineering practice.
Fabrication & Installation shall be in accordance with NFPA 90A, UMC and SMACNA HVAC Duct
Construction Standards. Fire rating shall be as per clause 3.5.3 of TES-P-119.21.
- Ductwork shall be of ASTM A653 hot dipped galvanized steel sheet, lock-forming quality, having
G60 zinc coating in conformance with ASTM A90.
- Return Air Duct shall be provided for every enclosure where Supply Air Duct is provided.
- Ductwork air leak tests shall be carried out before applying insulation materials.
- Air distribution system shall be through externally insulated rectangular ductwork. Ducts shall be
provided with 56 kg/m3 density, rigid glass fiber board. Thick shall be 50mm insulation for the ducts
installed outside the building, with 0.80 aluminum sheet cladding and 25mm for ducts installed
inside the building. Internal exposed duct shall also be provided with 0.80 aluminum sheet cladding.
Adhesive to be use shall be of Waterproof and fire retardant type.
- In addition to the externally insulated duct workman inside duct insulation of 25mm thick Black
Glass Tissue (BGT) shall be provided in the main supply and main return duct that are three meters
length from the PACU,s. These are to be factory installed.
- Airflow direction shall be marked-up on all the exposed ducts for easy identification.
- The layout of ductwork and pipework shall be such as not to hinder access to any part of the
substation or to obstruct the operation and maintenance of any equipment in the substation e.g.
passageways shall not be obstructed. The layout of the ductwork and the lighting, fire detection and
ceiling tile arrangement shall be designed on an integrated basis.
- Ductwork and pipework in the Entrance hall, Control and communications rooms shall be concealed.
Exposed ductwork and pipework will be acceptable in other locations, subject to adequate
mechanical protection being provided. Ductwork shall be treated with galvanizing paint or similar.
The procedure and color finish shall be to the Engineer's approval.
- Control dampers shall be provided in air supply duct to each room and in return air duct these shall be
provided where necessary to achieve the designed air quantities and pressures, and elsewhere as
required.
- Provide balancing dampers on duct take-off to diffusers, grilles and registers, despite whether
dampers are specified as part of the grille and registers assembly.
- Reheating and dehumidification shall be through duct-mounted electric heaters.
- Except for toilet, temperature and humidity indicators (hygrometers) shall be conveniently installed in
all other rooms including one outside the building.
- Motorized Fire and Smoke Dampers (MFSD) of three-hour fire resistance shall be provided for all
ducts passing through walls separating building compartments.
- All raised floor shall be provided with direct ducted supply and return air.
- Provision shall be made to conduct inspection and maintenance for air ducts near bus bar and
energized equipment without power outage.
- No external ductworks installation shall be allowed at the side of a substation wall adjacent to the
Main Power Transformers.
- The Contractor shall adjust the control dampers, grilles, diffusers and louvers to design air quantities,
pressures & air distribution patterns.
- Fresh air intake and exhaust air discharges shall be provided with specially formed weather proof
louvers and insect screens. Automatically operating intake or exhaust louvers shall be effectively
sealed, permitting no airflow when in the closed position. Care shall be taken in selecting locations
for air intake and exhaust to ensure that the possibility of ingress of sand and dust particles is
reduced to a minimum. Fresh air intake louvers shall not be located close to plant liable to radiate
heat, e.g. transformers, or opposite boundary wall gates or other apertures as these are likely leading
to increase dust ingress.
- The lowest point of the air inlet to the air conditioning system shall be located at least 8 m above
finished ground level and shall be hooded to prevent direct ingress of large dust or sand particles. It
shall be located in a sheltered side of the building.
- Flexible copper braiding shall be used to bond adjacent sections of ductwork where non-metallic
flexible joints are used.
- Duct access doors shall be provided for inspection and cleaning, before and after filters, coils fans,
motorized dampers, combination fire and smoke dampers, electric duct heater and elsewhere as
required.
5.1B.5.4.5 Control and Supervision
- Control system shall include all the necessary pressure and temperature control protective devices as
well as control relays, consisting of, but not limited to the applicable requirements defined in SEC
standards 73-TMSS-01 Rev.01 and in TES-P-119.19, Rev.01.
- Controls shall be Direct Digital Control (DDC). Interlock controls shall be provided with SCADA
and FACP to remotely monitor status of the HVAC system, modification of set points and
parameters and to trip the duty A/C unit and exhaust fan in case of smoke/fire detection respectively,
except Battery room exhaust fans.
- Identify control panels and major control components outside panels with plastic nameplates.
- A copy of the DDC software shall be provided for future use.
- Filter condition indicators, suitably calibrated and equipped with test facilities, shall be provided on
all filters. The position at which the filters require cleaning or changing shall be clearly marked.
Indication shall be displayed on the control panel. In addition, HVAC instrumentation shall be
provided like Pressure Gage, Temperature and Humidity Indicators (Combined), Thermostat,
Humidistat and etc.
- Signal warnings of building HVAC System failure shall be displayed on the control panel.
- Two potential free contacts shall be provided on each of the above signals to facilitate supervision of
the equipment by local and remote signal monitoring systems.
- HVAC along with all motorized fire & smoke dampers shall automatically close within 10 seconds
during first stage alarm.
- HVAC System shall also be shutdown in case of activation of firefighting system through Mechanical
Manual Pull Station.
5.1B.5.4.6 Tests
5.1B.5.4.6.1 Testing of HVAC System
- Testing and commissioning work required herein shall be in accordance with the applicable
requirement of TCS-K-100.01.
- Name of Testing and Commissioning Agency shall be submitted for approval within thirty (30) days
after award of CONTRACT.
- Testing and Commissioning Agency shall be specialized in Testing and Commissioning of HVAC
systems with minimum three (3) years documented experience. Perform WORK under supervision
of National Environmental Balancing Bureau (NEBB) or any other Certified T&C Supervisor
acceptable to the COMPANY.
- Prior to commencing WORK, testing and commissioning procedures shall be submitted for NGSA
Approval.
- Upon completion of individual component testing, all systems shall be tested and balanced and the
correct air quantities, pressures and temperatures obtained. Each system shall be tested and adjusted
thermally over a period of not less than one month. The Contractor shall adjust, balance and regulate
each system as necessary, until the required conditions are obtained.
- Duct Test Holes must be provided in every main supply duct. Drill test holes about 6 to 10 diameter
of straight duct upstream from its location. Required number of holes and size shall be in conjunction
with TAB CONTRACTOR’S requirements. Cap with neat patches, neoprene plugs, threaded plugs,
or threaded or twist on metal caps.
- On completion of the system adjustment and balancing, the Contractor shall carry out tests to
demonstrate that each part of the installation is adjusted and regulated correctly to fulfill the function
for which it has been designed, e.g. room temperatures and pressures to be maintained, air quantity
to be handled, etc.
- The ability of the HVAC system to function satisfactorily under both normal and storm conditions
must be clearly demonstrated. This shall be achieved by running the HVAC systems in their normal
mode in one substation for a period of three months during the dust storm period, which shall be
taken to be March to mid-July inclusive. Both substation and test period to be nominated by the
Engineer. If no significant dust storm occurs during the test period the tests shall be extended until
one does occur.
- At the conclusion of the test, dust fall-out in the nominated substation shall not exceed one-half g/m2
of floor area and the design pressure difference between rooms and atmosphere shall be within ±20%
of nominal. Subject to the approval of the Engineer, the Contractor shall arrange a schedule for dust
collection and measurement.
5.1B.5.4.7 Drawings and Information
The following drawings and information shall be submitted to the Engineer for approval:
(a) Detailed design calculations for all systems, including design temperatures, pressures and airflow for
each room, capacities of plant and ductwork dimensions.
(b) Detailed drawings showing the physical arrangement of plant and layouts of pipe work and ductwork.
(c) Electrical schematic diagram of all systems showing operation, controls supervision etc.
(d) A description of the systems involved and their operation, control and supervision.
(e) Equipment schedule to cover all items of equipment and giving complete information on each item;
including manufacturer's name, type, rating etc.
(f) Detailed description of the filter system proposed, including the gravimetric efficiencies and dust
holding capacities of the coarse and fine filters.
(g) Detailed schedule listing thermostats and humidistat giving their location and recommended settings.
Before putting into service and taking over by the Employer, detailed instructions on operation and maintenance
shall be submitted to the Engineer.
5.1B.5.5 POWER FACILITIES
Single-phase socket outlets shall be rated 16A, 127(230) V 60Hz and shall be 3 pin-shuttered type fitted with
stainless steel or satin chrome front plates, to IEC 309.
A minimum of two single-phase socket outlets per room/switchgear hall shall be provided except in the case of
the battery room where one shall suffice. The socket outlet for the battery room shall be located in the corridor
immediately outside the battery room.
A 3-phase socket outlet shall also be provided in each room/ switchgear hall. The indoor socket outlets shall be
rated for 16A and shall be 3 pole, neutral and earth to IEC 309.
Socket outlets required for any other voltage or frequency shall be IEC 309 with color coding and clock position
appropriate to their use. Socket outlets mounted externally shall be protected to IF 44.
Socket outlets shall be mounted at 0.4m above floor level in all rooms except workshop and cable room, in these
rooms socket outlets shall be 1.0m above floor level.
One 3 phase outlet rated at 125A, 220/127(400/230) V, 60Hz shall be provided at each transformer and reactor
location for the connection of oil filtering equipment.
5.1B.5.6 OVERHEAD TRAVELLING CRANE
An electrically operated overhead travelling crane shall be provided in the 110 KV switchgear room to facilitate
the removal of any item of plant for maintenance or replacement. The complete crane and gantry shall comply
with and be tested in accordance with BS 466, DIN15018, FEM and VDE.
Electrical connections and power supply shall be totally enclosed. Fast and slow motor speeds shall be provided
and they shall be as follows:
Fast Slow
Hoisting Speed 4-6 M/min. 0.5-0.7 M/min.
Cross Travel Speed 25-25M/min. 4.0-6.0 M/min.
Down Shop Speed 15-20M/min. 5.0-8.0 M/min.
The alternate speed can be offered but will be subject to the fulfilment of technical rquirment and engineer
approval. The capacity of the crane shall be such that it is capable of lifting the heaviest element, which may be
removed for maintenance.
Access facilities to the crane for maintenance purposes shall be provided.
Tenderers shall clearly indicate their proposals regarding the design of the crane gantry girders including the
allowance to be made for vibration, shock, deflection, temperature change, etc.
5.1B.5.7 MISCELLANEOUS EQUIPMENT
An electrical clock with digital twenty-four hour reading shall be installed in the control room at the top of the
mosaic control board This clock shall have a spring reserve enabling it to continue operating for two hours in
the event of a failure of AC supply to it.
5.1B.5.8 ELECTRICAL WIRING
Electrical wiring shall be in accordance with the IEE REGULATIONS FOR ELECTRICAL INSTALLATIONS
OF BUILDINGS.
Internal fittings (sockets, switches, isolators, etc.) shall be surface mounted and all wiring including that to
switch and socket positions shall be run in surface mounted trunking.
The following items shall be submitted to the Engineer for approval:
(1) Detail lighting design calculations.
(2) HVAC design calculations.
(3) Details of fire alarm systems.
(4) Details of fire fighting systems.
(5) Details of overhead travelling cranes.
5.1B.6 FIRE PROTECTION
Fire Preventive Measures and Fire Fighting shall be as per attached Appendix.
5.1B.6.1 Design Conditions
A comprehensive fire protection installation shall be designed, supplied, installed and commissioned in view of
a layout which will offer protection where needed. The fire fighting installation shall be supplemented by a fire
detection and fire alarm system.
The design of automatic fire fighting installation shall incorporate features to prevent inadvertent operation of
fire fighting equipment especially in closed areas e.g. control room, cable basement, switchgear halls when
operation and maintenance staff are working in these fire zones.
The building shall be designed to minimize the possibility of fire spread internally and also with respect to the
surrounding. This in particular pertains to exposure protection.
Escape routes and emergency exits shall be easily noticeable. coloured signs and lights shall be selected to the
Engineer’s approval. Design features for all fire preventive measures shall be coordinated to suit the system of
the buildings and allow proper integration.
The fire fighting installation must, in any case, be ready for operation before commissioning of the substation.
Only companies experienced in design and creation of fire fighting equipment will be approved as
Subcontractors by the owner/engineer.
The contractor shall coordinate the fire fighting system with the requirements of the Air--conditioning and
ventilation system design and supply as specified in Article 5.1B.5.11 and 5.1B.5.12.
5.1B.6.2 Standards, Rules and Regulations
The design, installation and tests shall be accomplished in accordance with the NFPA Codes and Standards,
latest edition (National Fire Protection Association. Batterymarch Park, Quincy, MA 02269. USA) as well as
Saudi Standards.
Warning signs and all equipment, which is to be operated by the Fire Brigade and / or other local personnel,
shall bear inscriptions in English and Arabic.
5.1B.6.3 Scope of Supply
The system shall be complete and functional in every respect, whether mentioned or not in this specification.
The General Scope of Supply and work shall comprise mainly all equipment needed for fire protection and
fighting purposes and, in addition, such equipment as is deemed necessary for safe and reliable operation of the
different system.
Scope of work shall comprise the following, whereby alternative proposals are invited.
- Complete water supply installation including pressure tank and water storage tank of
sufficient size to extinguish the most extensive fire.
- Water spray fixed systems
- Drawings for pipe penetration through all civil work (walls, floors, roofs, tunnels)
- Covers, if any fire protection pipes penetrate cable tunnels and pipe trenches
- Fire detection installation.
- Fire alarm systems with manual alarm pull stations/alarm buttons
- Portable fire extinguishers
- Drawings for pipe penetration through all civil work (walls, floors, roofs, tunnels)
- All cables entering the switchgear &control cabinet shall be coated with flame
retardant material to stop the propagation of fire.

- Entry of cables in the switchgear hall shall be sealed with fire resistant putty that can withstand for two
hours.
- All lighting fixtures in both protection room, 110 halls shall be completely metallic, to avoid the spread
of fire.
- All electrical wiring in switchgear halls shall be of flame retarding properties which can with
stand for two hours.
- Area to be protected with FM200 shall be by total flooding system except HV switchgear halls which
shall be protected by local applications.
- local panel of HV switchgear hall and the control rooms shall have reserve quantity of clean agent.
Reserve quantity shall be as many as the primary, that shall be permanently connected to the distribution
piping and arrange for easy change over as per latest NFPA2001
The fixed fire fighting installations and the detection systems to be applied indicated in the following table:
Building/Area/Equipment Fire Fighting Detection System:
Power Transformers & Automatic water Heat/Ionization/Photoelectric
spray system
Shunt reactors detectors or other suitable device of
deluge valves
MV switchgear hall Automatic FM200 Total smoke/heat/ionization detectors
flood extinguish system
LV distribution rooms Automatic FM200 Total smoke/heat/ionization detectors
flood extinguish system
HV switchgear hall Automatic FM200 for local smoke/heat/ionization detectors
application for LCK
control panels (local control) FM200 cabinet protection smoke/heat/ionization detectors
Control and relay rooms including Automatic FM200 total
raised floors, flood extinguishing system smoke/heat/ionization detectors
Electronic equipment rooms Automatic FM200 total smoke/heat/ionization detectors
(e.g. data processing equipment) flood extinguishing system
Office, storage rooms, air Portable extinguishing smoke/heat/ionization detectors
conditioning rooms and workshops, system
auxiliary transformers upto
1000KVA (indoor and out-door),
NGR room
All plant sections Co2 fire extinguishers for manual fire alarm stations
manual fire fighting of small
fires at an early stage (within
buildings).
5.1B.6.4 Limits of Supply
The fire fighting equipment shall be supplied as specified here under. Electric power for the fire-fighting pump
shall be supplied to the terminal box of the pump controller.
The limit of supply for all other electrical consumers within the entire fire fighting pump installation as well as
the detection and alarm systems are the respective terminal boxes of rooms and /or equipment.
All fire alarm and detection lines shall be supplied up to the fire alarm panel located at the substation entrance
or as otherwise agreed upon.
Sufficient spare parts shall be supplied for a trouble free operational period of four years after issue of the Final
Acceptance Certificate. The list of spare parts and required tools shall be subject to the approval of the
owner/engineer. The costs of the spare parts and tools shall be included in the erection price.
5.1B.6.5 Fire Preventive Measures
Non-combustible and Fire Resistant Building Structure

The parts of the building to be newly erected shall be of non-combustible or fire resistant construction.
If exposed steel structure is used. A fire resistance of 90 minutes is to be accomplished, preferably by concrete
application.
Fire Zones
The building shall be sub-divided into various fire zones separated by fire resistant walls/ceilings/doors
providing 60. 90 or 120 minutes fire resistance depending on building construction features and combustible
loading. The following areas shall form an independent fire zone:
-each floor, except for stairways
-each staircase, defined as emergency exit and escape route
-each switchgear room-
-each control room
-each basement
-each Transformer
All electrical and ventilation ducts shall be provided with fire dampers equipped with magnetic release via
smoke detectors, controlled by the alarm system, limit switches for central indications and manually initiated,
electrically operated reopening system. The motor operated fir dampers shall be of a type provided with a
release via fusible link.
Fire zones shall have adequately designed smoke outlets when so required due to operation conditions and/or
occupancy.
Transformer bays and boxes shall be built with fire extenguishing facilities(sprinkler system)
Drainage.
Adequate drainage piping shall be provided throughout the rooms and all other areas sensitive to water damage
in case of fire. Pumps of suitable type and capacity shall be provided for rapid evacuation of flooded areas.
Stairs and Escape Routes
Stair walls shall be constructed fire resistant in all directions in a manner to serve as escape routes, and shall be
provided with a separate, over pressurizing ventilating system.
5.1B.6.6 Fire Fighting Installations
General Design Features
Equipment and material to be supplied must be useful to the ends of property conservation by preventing,
limiting or not causing damage under the worst conditions and must be identifiable and available on the local
market to the maximum extent.
The fire fighting installation shall be reliable and designed in accordance with international standards as
specified.
5.1B.6.7 Water Spray Fixed Systems
Water spray systems shall be designed, installed and tested in accordance with NFPA NO. 15, latest edition. All
components shall be coordinated to provide a complete system, fully automatically operated.
The pipes shall be of seamless steel, hot-dipped zinc-coated (galvanized). The treated ends of galvanized pipes
shall be properly protected against corrosion after installation.
The systems shall be designed to discharge effective water spray from all nozzles within 30 seconds following
operation of the detection system. The automatic detection equipment shall assure proper operation and guard
against premature operation of the system due to common pressure fluctuation.
Particular care must be taken to compensate for normal temperature fluctuations in installations such as
transformer protection. Detection equipment requiring weather protection shall be provided with a canopy, hood
or other suitable feature. Automatic detection equipment shall be of a type listed be a recognized laboratory as
the intended usage; location and adjustment shall guarantee reliable operation.
Each transformer shall be provided with a separate system.
Each system shall be provided with shutoff vales so located as to be readily accessible during a fire in the area
the system protects or adjacent areas.
System piping shall be adequately supported. All supports in the fire areas should be protected by the system. In
any area possibility of explosion may be recognized, special care shall be taken to support the piping from
portions of the structure least liable to disruption.
Installation of fire fighting equipment shall not interfere in any way with the operation and maintenance of the
equipment that it is intended to protect, e.g. the layout of piping etc.
Should permit easy access to substation equipment without dismantling the fire protection systems.
For protection of piping against damage where subject to earthquakes, reference is made to applicable sections
of NFPA 13.
Tapping or drilling of load-bearing structural members is not permitted unless the design of the structural
members contemplates this feature or their design is such that the additional load can be safely tolerated, and no
other arrangement is feasible. Attachments may be made to existing steel or concrete structures and in some
cases to equipment and its supports. Where welding of supports directly to vessels or equipment is necessary, it
shall be done in a safe manner in conformance with the provisions of all safety, and fire codes and standards.
Pressure Tank
For the transformer water spray system a pressure tank shall be provided at the plot of the substation at a
suitable location. This pressure tank shall have a capacity to water spray the biggest transformer at 10 bar
working pressure for a period of at least 10 minutes. An air compressor shall maintain the working pressure and
an automatic refilling of water must be guaranteed at all times.
5.1B.6.8 FM 200 Extinguishing Systems
FM 200 extinguishing systems shall be applied in extinguishing fires in switchrooms and in occupancies where
electrically non-conducting medium is essential or desirable, and where clean-up of other media may present
problems. The FM 200 systems shall be designed in accordance with NFPA Standards, latest edition.
FM 200 Total Flooding System
For this installation the amount of FM 200 stored in the system shall be at least sufficient for the largest single
hazard protected or group of hazards which are to be protected simultaneously. The storage containers for total
flooding systems shall be so located and arranged that inspection, testing, recharging and other maintenance
shall be facilitated, and that interruption to protection is held to a minimum.
Piping shall be of non-combustible corrosion-resistant materials.
FM 200 System for local application on control and switch panels (FM200
cabinet protection
FM 200 extinguishing units shall be provided for all switch and control panels where room application is not
justified.
The FM 200 gas shall be released by an ionization smoke detector to be installed inside the panels.
The control unit for the particular systems shall contain all plugs for detector, release equipment and two
potential free switchover contacts for alarm at the fire alarm and control panel..
The FM 200 supply pipes shall be made of non-combustible, corrosion resistant material.
5.1B.6.9 Fire Alarm and Fire Protection System
A fire alarm system for the substation shall be designed, delivered and installed with all conduits, wires, outlet
boxes, junction boxes and all accessories to erect a zoned, electrically supervised fire alarm system as specified.
The system shall be complete and operational to the extent indicated in these Specifications. The system shall
consist of the necessary numbers of alarm initiating circuits provided by automatic detectors, fixed fire fighting
installations and manual alarm pull stations. The central fire alarm panel shall allow audible and visible alarm
indication from any part of the substation. The central fire alarm panel shall be located at the substation
entrance.
The system shall be in accordance with NFPA or VDE/VDS standards. A collective fire alarm must be sent to
the substation alarm panel and to LDC.
The main functions of the fire alarm system shall be as follows: -
 The actuation of any signal-initiating device shall sound the alarm horns throughout the fire zone, initiate
the appropriate fire zone and stationary fire fighting system indicator at the fire alarm panel.
 Fire damper operation shall be indicated locally, using signaling lamps near the initiating device.
 Fire damper operation shall be indicated on the local air conditioning panel and the central fire annunciation
panel.
 Local alarm annunciation for relevant equipment.
 The horns may be silenced by pushing the silence button on the central fire alarm panel. Any subsequent
alarm shall again sound the horns utilities also acknowledged.
 All horns shall be switched off by a time relay, which is to be adjustable between 0.1 and 10 minutes.
 Upon restoration of the alarmed device to its normal condition, the system shall be returned to normal
stand-by condition by the use of the reset button on the alarm panel.
 The fire alarm system shall also release fire doors, fire dampers and other systems as required.
 Air handling units shall be shut down as required.
 The fire alarm system shall be capable of transmitting an alarm signal to the Campus Fire Control Center
for signal annunciation.
 Fire damper should be moterised for opening with the switch suitably placed at man hight.
 Each zone should have an abort switch and should be self holding type with indication facility.
Technical Requirements and Manual Fire Alarm Stations
Manual stations shall be of the non-coded type. Surface-mounted boxes shall have an integral or matching back
box.
The manual station shall be operated by pulling down on the lever. When operated, the lever shall remain down
with the alarm contacts closed until the station is reset. For resetting the glass rod shall be replaced.
The manual fire alarm boxes shall be distributed throughout the station so that they do not obstruct but are
readily accessible and are located in the normal exit path. At least one box shall be provided on each door.
Additional boxes shall be provided if the floor area is more than 1000 m and the horizontal travel distance more
than 60 m to the nearest box.
An additional set of contacts SPDT or NC shall provide a means of annunciation. The manual station shall be
reset by opening the front. The station shall close only after the switch is reset. The manual station shall be
tested by opening the station and operating a toggle switch. A glass rod in the station front will indicate which
station has been operated and the glass rod must be replaced when the station is reset.
Horns and Bells

Horns and bells shall have a minimum noise level of 100 dB(A) at a distance of 3 m and shall be different in
sound from other horns and bells installed in the area for other purposes.
Automatic Fire Detectors

Automatic detectors shall be of the fixed temperature, infrared, rate-of-rise, or ionization type. The detector
circuit shall be fully supervised to indicate the alarm or trouble signal upon malfunction.
The detector assembly shall be designed for flush or surface ceiling mounting, attached to a standard 100-mm
outlet box. It shall be possible to surface mount outlet or rigidly suspend it when necessary.
The detector spacing on smooth surfaces shall not exceed the distance recommended by the approving authority.
In areas where irregularities occur, the detector spacing shall be reduced in such a way as to obtain approved
spacing.
Detectors shall in general be connected in groups to the central fire alarm panel. The number of detectors
installed on any one line shall be limited as recommended by the manufacturer. Wiring shall have 600-volt
insulation and be enclosed in conduits.
Ionization Detectors
Opening D.C. voltage shall be equal to the one defined for the substation.
The detector shall detect products of combustion without being dependent upon the presence of either near
smoke or flame. It shall function on the ionization chamber principle and shall include radioactive tons and cold
cathode tube. The detector head shall have no moving parts. It shall be possible to check or adjust the sensitivity
of each individual head to satisfy the local conditions.
Fire Alarm Cubicle
Fire alarm cubicle capable to receive alarms, activate equipment and transfer alarms to the central fire
annunciation panel shall be part of this specification. The fire alarm cubicle may be installed behind the panels
of the control room or in an adjacent equipment room.
Solid state modules shall be as follows:
Alarm Receiver Module: Provide zone alarm receiving circuits for rooms and sections. The wiring for the
alarm initiating device upto and including the alarm receiver module shall be supervised against an open circuit
and a short circuit fault condition. Operation of an initiating device shall cause an individual red enunciated
flashing and supervised alarm. Zone annunciation to clock on shall provide an alarm output to the other
sections. An individual yellow trouble annunciation shall be provided for each alarm receiver zone to indicate
the location of any faults in the wiring to initiating devices. Enunciator test and reset function may be combined
on push buttons.
Cabling: Fire resistant Cables shall be provided according to IEC recommendations. The minimum diameter of
the cores shall be 0.8 mm laid in rigid steel conduits. The conduits are to be painted in red color at regular
intervals of 3 m for identifications.
Audible Signal Module: Provide audible signal devices per circuit. The wiring for the audible signal upto and
including the individual circuit breakers shall be supervised both against an open circuit and a short circuit fault
condition. Either fault condition shall immediately cause all trouble signals to sound without causing the signal
breaker to open while the panel is in the normal supervisory state. An individual zone amber trouble LED shall
be provided for each signal circuit to indicate the location of any faults in the wiring to the audible signals or
signal circuit breaker open condition.
Common Control Module: Provide the following functions.
LED Supervision: Failure of an alarm LED of the control unit or remote supervised enunciator LED shall
cause the trouble signals to sound. The amber “remote lamp failure” LED on the panel shall indicate which
remote enunciator has a LED failure.
LED Test: The control unit alarms and trouble LED may be tested to locate an LED failure by depressing the
LED push button.
Reset: When the alarm initiating devices have been restored, the system control shall be reset by depressing a
single reset push button.
Subsequent Alarms: An alarm from any receiving circuit shall cause the audible signals to sound for a full
period, whether or not a previous alarm has been initiated or reset manually. Resetting by any means shall cause
a green “signal reset” and LED on the panel to illuminate.
Manual Signal Silencing: Push button shall be provided to silence all audible alarm signals.
Master Power Supply Module: Provision of D.C. power for all system supervisory and control functions is
required. A red “Power-on” indication on the panel for each separate source of A.C. input power shall be
present. This is to be coordinated with already determined features and voltages.
Trouble Indication: A yellow trouble LED and distinctive audible signal shall operate when any of the
specified supervised trouble conditions exist. The audible portion of the trouble signal shall be silenced with a
“trouble-silence” push button.
The trouble signal and indication shall automatically reset to normal when a trouble condition is corrected. To
eliminate any confusion, all visual and audible trouble signals shall remain off during the progress of a true
alarm. Terminals shall be provided for connection of remote trouble lamps and audible signals.
Ground Detection: Local annunciators shall be flush-mounted with wired zone position an space only for spare
positions. Anunciators shall have red zone indicator lamps, red steel cabinet, stainless steel cover and trim. Each
zone lamp shall have a film label with a designation as shown in drawings. Local annunciators shall be installed
at the main entrance of the buildings and shall be subject to approval. A yellow flashlight outside the entrance
shall be activated if an alarm occurs.
5.1B.6.10 Portable Fire Extinguishers
The extinguishers shall be designed installed and tested in accordance with NFPA No. 10, and SASO standard,
latest edition. Extinguishers shall be distributed in all staircases and corridors in a manner that traffic will not be
obstructed. As a further condition, extinguishers shall be located at easily visible and accessible locations
considering the event of fire.
Preferably dry chemical extinguishers, multi-purpose type, shall be supplied. As a rule, powder units, containing
12 kg shall be supplied which combine all of the extinguishing effects and are permitted for fires of class A to C
in the presence of electrical voltage up to 1000 V. For class D fires involving combustible metals dry compound
extinguishers shall be introduced. The portable fire extinguishers shall be fitted with spring headed
interchangeable safety valves.
Rooms and areas where a voltage above 1000 V may be present and /or housing relays, control and computer
units shall be equipped with portable carbon dioxide extinguishers in addition. Suitable masks to prevent injury
to personnel shall also be supplied.
All extinguishers shall be designed to service over a period of 20 years taking the conditions at the site into
account.
The finally supplied extinguishers must be provided as early as possible, however, at the latest on
commencement of the commissioning preparation of new buildings and/or equipment.
Reference shall be made to fire protection during the construction period.
After completion of the installation random tests of 5% of the portable extinguishers supplied shall be
performed in connection with the training programs. The necessary refills shall be provided by the
CONTRACTOR.
The following arrangement criteria shall be met:
Maximum travel distance to an extinguisher 15 m
Maximum area to be protected per extinguisher 150 m²
Several extinguishers at lower ratings than 12 kg may fulfill the protection requirements.
5.1B.6.11 Specified Spare Parts for Fire Fighting and Fire Alarm System
The CONTRACTOR shall supply latest at the time of PAC spare parts related to the fire fighting and fire alarm
system in sufficient quantities to operate and maintain the complete system for a period of 4 years after issue of
the FAC. The relevant list of spare parts shall be submitted alongwith a price breakdown a the tender stage for
review. Even if not particularly mentioned in Section 6, Scope of Work/Scope of Supply or in Section 8, Price
Tabulation sheets, the required spare parts shall be deemed to be included in the total price of the fire fighting
system. Subcontractors shall be bound to supply the required spare parts and submit to the main
CONTRACTOR (Tenderer) the relevant information and lists.

Part-5.1B (R01 Technical Specification For Civil Work) REV

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380/110/13.

8kV Substations Tender no:

5.1B.1.6 CIVIL WORKS

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5.1B.3.3.2 DESIGN BY CONTRACTOR

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5.1B.3.8.1 FINISHES GENERALLY

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5.1B.6.6 FIRE FIGHTING INSTALLATION

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5.1B.1.1 to 5.1B.1.5 Not applicable

5.1B.1.6 CIVIL WORKS

5.1B.1.7 BRIEF DESCRIPTION OF CIVIL REQUIREMENT

The major items of civil works involved are as follows: -

- General installation of the site including soil investigation, topographical

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- Doors and windows.

5.1B.1.8 CONSTRUCTION FEATURES

5.1B.1.8.2 Soil Investigation and Site Survey

5.1B.1.8.3 Site Preparation

5.1B.2 GEOTECHNICAL SUB-SURFACE EXPLORATION

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Geotechnical contractor should be approved by SAUDI ELECTRIC COMPANY (W). Geotechnical

Publications listed below form part of this specification:

 National Standard TESP-119.10, 119.13

 American Society for Testing and Materials (ASTM)

D422 Method for Particle Size Analysis of Soils

BS1377 Determination of Total Sulphate Contact of Soil Test 9

5.1B.2.1.3 QUALITY ASSURANCE

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 Soil Sampling Equipment

 Static Cone Penetration Test Equipment

· If continuous electrical sounding method is used, measure continuously during penetration at a

 Soil Resistivity measurement.

5.1B.2.3.2 FIELD SAMPLING AND TESTING

 Standard Penetration Test

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 Static Cone Penetration Test

 Vane Shear Test

 Plate Bearing Test

 Ground Water Measurement

Install piezometers wherever it is considered necessary to monitor ground water levels.

Bulk density shall be determined in field in accordance with ASTM D2922.

 Ground Water Analysis

· PH value to ASTM D1293

 Collapsible or Liquefiable Soil

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5.1B.2.3.04 LABORATORY TESTING

Type of Test ASTM Standard

5.1B.2.3.05 INVESTIGATION REPORT:

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5.1B.2.3.05.5 Findings of the trial pits.

5.1B.2.3.05.6 Identification and recommendation on potential problems, encountered or

5.1B.2.3.05.14 Type of cement to be used in the sub and super structure.

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5.1B.3. CIVIL WORKS

5.1B.3.1.1 Building Regulations

5.1B.3.1.2 Design and Construction of Substation Civil Works

5.1B.3.1.4 Climatic Considerations

5.1B.3.1.5 Additional Tests

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5.1B.3.2 SITE INFORMATION

5.1B.3.2.2 Inspection and Examination of Sites