Urgent Water Supply and Sanitation Rehabilitation Project (UWSSRP) Republic of Zimbabwe

Bidding Document for Procurement of: Rehabilitation of Water Supply and Sewage Systems in Mutare UWSSRP/004 Volume II of IV Part 2 Employers Requirements General and Particular Specifications

Issued on: 7th August 2012 ICB No: UWSSRP/004

Employer:

The Crown Agents for Oversea Governments and Administrations Limited for and on behalf of the Ministry of Finance, Government of the Republic of Zimbabwe

Section VI. Employers Requirements

PART 2 Employers Requirements

This Volume II of the Bidding Documents contain the Specifications and Supplementary Information which are included in Part 2 - Employers Requirements. The separate Volume IV of the Bidding Documents contain the Drawings which are also included in Part 2 - Employers Requirements.

Section VI. Employers Requirements

Section VI. Requirements

Table of Contents
Specifications...................................................................................................................... 1 Drawings.......................................................................................................................... 273 Supplementary Information............................................................................................ 274

Section VI. Employers Requirements General Specifications

2-1

Specifications

General Specifications
Table of Contents
1. 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 1.10 1.11 1.12 1.13 1.14 1.15 2 2.1 2.2 2.3 2.4 2.5 3 3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8 3.9 3.10 3.11 3.12 3.13 3.14 GENERAL PROVISIONS....................................................................... 6 Background .....................................................................................................................6 Establishment on Site ......................................................................................................6 Part of Site Available to Contractor ..................................................................................6 Water Supply and Electricity ............................................................................................7 Accommodation of Traffic, Deviations and Temporary Access Roads .............................7 Survey and Stand Pegs ...................................................................................................7 Levels ..............................................................................................................................7 Survey Equipment ...........................................................................................................7 Watching and Lighting .....................................................................................................7 Samples ..........................................................................................................................8 Protection of Existing Services and Structures ................................................................8 Programme .....................................................................................................................8 Sign Boards .....................................................................................................................8 Costs of Testing ..............................................................................................................8 Asbestos Warning ...........................................................................................................8 MATERIALS ........................................................................................................... 10 General .........................................................................................................................10 Samples ........................................................................................................................10 Packing .........................................................................................................................10 Unloading ......................................................................................................................10 Inspection at the Factory ...............................................................................................10 EARTHWORKS ...................................................................................................... 12 Definition of Earthworks .................................................................................................12 General Excavation .......................................................................................................12 Site Clearance ...............................................................................................................12 Soil Stripping .................................................................................................................12 Types of Excavation ......................................................................................................13 Classification for Excavation Material ............................................................................18 Excess Excavation ........................................................................................................20 Water in Excavation.......................................................................................................20 Blasting .........................................................................................................................20 Timbering and Supporting Excavations .........................................................................21 Cut to Spoil (Trenching and Structures Excavation).......................................................21 Working Space ..............................................................................................................21 Topsoiling and Grassing ................................................................................................21 Unsound Foundations ...................................................................................................22

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Section VII. General Specifications 3.15 3.16 3.17 3.18 4 4.1 4.2 4.3 4.4 4.5 4.6 4.7 4.8 4.9 4.10 4.11 4.12 4.13 4.14 5 5.1 5.2 5.3 5.4 5.5 5.6 5.7 5.8 6 6.1 6.2 6.3 6.4 6.5 6.6 6.7 6.8 6.9 6.10 7 7.1 7.2 7.3 7.4 7.5 7.6 Termites ........................................................................................................................22 Demolition Works ..........................................................................................................22 Tolerance ......................................................................................................................23 Measurement ................................................................................................................24 PIPE LAYING.......................................................................................................... 28 Pipe Materials................................................................................................................28 Codes of Practice ..........................................................................................................30 Construction Machinery .................................................................................................30 Laying Pipes to Gradients..............................................................................................30 Cut Pipe Lengths ...........................................................................................................31 Bedding of Pipes ...........................................................................................................32 Minimum Cover to Pipes ...............................................................................................35 Jointing of Pipes ............................................................................................................35 Pipe Laying Details and Procedures ..............................................................................37 Testing Pressure Mains .................................................................................................39 Testing of Sewers 900 mm Diameter and Below ...........................................................40 Major Road Crossings ...................................................................................................41 Railway Crossings .........................................................................................................42 Measurement for Pipelines ............................................................................................42 BUILDING WORKS ................................................................................................ 47 Plastering and Walling Linings .......................................................................................47 Brickwork .......................................................................................................................52 Joinery and Ironmongery ...............................................................................................58 Sheet Metal Work, Plumbing and Associated Services ..................................................63 Glazing ..........................................................................................................................68 Painting .........................................................................................................................71 Pavings, Floor Coverings and Plastic Linings ................................................................75 Butyl Rubber Roofing Membrane...................................................................................80 PLAIN AND REINFORCED IN-SITU CONCRETE .................................................. 82 General .........................................................................................................................82 Materials ........................................................................................................................82 Storage..........................................................................................................................82 Concrete Manufacture and Placing ................................................................................83 Formwork ......................................................................................................................90 Placing and Fixing Reinforcement, Bolts, Water Bars, etc. ............................................ 95 Construction Joints ........................................................................................................95 Finishes .........................................................................................................................96 Testing of Structures .....................................................................................................97 Measurement ................................................................................................................99 MANHOLES AND ANCILLARY CHAMBERS ...................................................... 108 Cement, Reinforcement, Aggregate and Water ........................................................... 108 Bricklaying and Plastering ...........................................................................................108 Covers .........................................................................................................................108 Manholes and Inspection Chamber Construction ........................................................ 108 Precast Concrete Specials ..........................................................................................110 Measurement ..............................................................................................................110
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Section VII. General Specifications 8 8.1 8.2 8.3 8.4 8.5 8.6 8.7 8.8 8.9 8.10 8.11 8.12 8.13 8.14 8.15 8.16 8.17 8.18 8.19 8.20 8.21 8.22 8.23 8.24 9 9.1 9.2 9.3 9.4 9.5 9.6 9.7 9.8 9.9 9.10 MECHANICAL WORKS ........................................................................................ 111 Introduction .................................................................................................................111 Materials and Workmanship ........................................................................................111 Design Life ..................................................................................................................111 Welding .......................................................................................................................112 Castings ......................................................................................................................112 Forgings ......................................................................................................................113 Fixings .........................................................................................................................113 Allowances for Wastage ..............................................................................................113 Lubrication ...................................................................................................................113 Machinery, Lifting, Dismantling, Guards, Noise and Vibration ...................................... 114 Bearings ......................................................................................................................115 Pumps .........................................................................................................................116 Flanges .......................................................................................................................118 Pipe Work ....................................................................................................................119 Valves and Penstocks .................................................................................................125 Instruments and Ancillaries..........................................................................................130 Chemical Dosing Plant ................................................................................................133 Horizontal, Single Suction-End, Centrifugal Pump ....................................................... 135 Submersible Centrifugal Pumps ..................................................................................136 Mixer Units ..................................................................................................................137 Surface Aerator Units ..................................................................................................138 Settlement Tank Bridge Scrapers ................................................................................ 138 Ancillary Mechanical Works .........................................................................................138 Painting and Protective Coatings ................................................................................. 139 ELECTRICAL WORKS ......................................................................................... 142 Introduction .................................................................................................................142 Electricity Supply .........................................................................................................142 Low Voltage Distribution Equipment ............................................................................ 142 Conduits and Accessories ...........................................................................................151 Metal Cable Trunking ..................................................................................................156 Cable Trays .................................................................................................................159 Luminaires and Lamps ................................................................................................160 Wiring Accessories ......................................................................................................161 Mounting Heights ........................................................................................................162 Cable Routing and Trenching ......................................................................................163

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Section VII. General Specifications Acronyms and Abbreviations A AASHTO AC AC pipes AfDB AGMA AWWA BNR BOD BS CBD D or dia. DB DC DE DIN DN DOL FST ft GOZ h Hg HP HRC Hz IE IEE IP ISO LCD m MCB MCC MOF NB NC NDE
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Amps American Association of State Highway and Transportation Officials Alternating current (when referring to electricity) Asbestos Cement pipes African Development Bank American Gear Manufacturers Association American Water Works Association Biological Nutrient Removal Biological Oxygen Demand British Standards Central Business District Diameter Distribution Board Direct Current Drive End Deutsches Institut fur Normung Diametre Nominal (French) = Nominal Diameter Direct On Line Final Sedimentation tank Foot Government of the Republic of Zimbabwe Hour Mercury Horse Power High Rupturing Capacity Hertz Implementing Entity Institution of Electrical Engineers (UK) now replaced by IET Institution of Engineering and technology (UK) Ingress Protection Rating International Standards Organisation Liquid Crystal Display Metre Miniature Circuit Breaker Motor Control Centre Ministry of Finance of Zimbabwe Nominal Bore Normally Closed Non Drive End
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Section VII. General Specifications

NO No. NTU kg O&M OD OMC PD PI PID PN ppm ppt PST PVC RAS RC pipes rpm rms SAZS SPS SPDP STW SWA SWG TDS uPVC UWSSRP V VFD vpm WAS WTW ZESA Zim-Fund

Normally Open Number Nephelometric Turbidity Unit Kilogram Operation and Maintenance Outside Diameter Optimum Moisture Content Permissible Deviation Plastic Index Proportional Integral Derivative Pressure Number = Pressure Rating in bar Parts per Million Parts per Trillion Primary Sedimentation Tanks Polyvinyl Chloride Return Activated Sludge Reinforced Concrete pipes Revolutions per Minute Root Mean Square Standards Association of Zimbabwe Standards Sewage Pump Station Screen Protected Drip Proof Sewage Treatment Works Steel Wire Armoured Standard Wire Gauge Total Dissolved Solids Unplasticised Polyvinyl Chloride Urgent Water Supply and Sanitation Rehabilitation Project Volt Variable Frequency Drive Vibrations per Minute Waste Activated Sludge Water Treatment Works Zimbabwe Electricity Supply Authority Zimbabwe Multi-Donor Trust Fund

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Section VII. General Specifications 1. 1.1 GENERAL PROVISIONS Background

The Urgent Water Supply and Sanitation Rehabilitation Project (Phase 1) (UWSSRP) refers to activities to further restore and stabilize the water supply and sanitation services in the six urban areas of Harare, Chitungwiza, Mutare, Masvingo, Kwekwe and Chegutu, of the Republic of Zimbabwe. UWSSRP is financed by the Zimbabwe Multi-Donor Trust Fund (the Zim-Fund), which was established in May 2010 by the African Development Bank (AfDB). The Zim-Fund was established to mobilise donor resources and promote donor coordination for the purpose of contributing to recovery and development efforts in Zimbabwe. AfDB is the administrator of the Zim-Fund and has set-up a Zimbabwe Multi-Donor Trust Fund Management Unit (MMU) in Harare, Zimbabwe, with responsibility for processing and overseeing projects and activities financed by the Zim-Fund. The Government of the Republic of Zimbabwe (GOZ) acting through its Ministry of Finance (MOF) is a nominal Recipient of a Grant from the Zim-Fund. This Grant is used to finance the UWSSRP. The Ministry of Finance has appointed The Crown Agents for Oversea Governments and Administrations Limited (Crown Agents) to act as its Procurement Agent., who will act as the Employer. The Ministry of Finance has also appointed an Implementing Entity, Lahmeyer GKW Consult GmbH (Lahmeyer GKW) (formerly Pyry Environment GmbH). Lahmeyer GKW has overall responsibility for implementation of the UWSSRP, as well as for all record-keeping and reporting of the project activities to the Zim-Fund and the GOZ. They will also act as the Employers Project Manager. Each End-User Municipality of the six project towns, through its Departments of Water and Sanitation and that of Health, will be closely involved in the implementation of the UWSSRP in its own area. In particular, the staff responsible for O&M would be attached to the Contractor for hands-on training and knowledge transfer. This Contract refers to Works for the rehabilitation of water supply and sewerage infrastructure of the City of Mutare as Beneficiary Municipality. 1.2 Establishment on Site The Contractor shall provide all necessary workshops and sheds for storage of materials etc., and clear away on completion and make good all works disturbed. The Contractor shall also provide an office for his own resident staff, foreman, etc., including lighting and sanitary accommodation and fittings, together with attendance and clear away on completion and make good all works disturbed. 1.3 Part of Site Available to Contractor The operations of the Contractor shall be confined to the area of land immediately adjoining the Works included in this Contract and the special areas designated to the Contractor. Clearance shall be to the satisfaction of the Project Manager, to permit the carrying out of any other work by other contractors, and the Contractor shall obtain the approval of the Project Manager for the siting of all dumps, temporary roads, paths, etc. necessary for the execution of the Contract. The Contractor shall also obtain the approval of the Project Manager for the siting of all camps, offices, workshops, deviations, paths etc.

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Section VII. General Specifications 1.4 Water Supply and Electricity

The Contractor shall be responsible for all necessary water and electricity applications and shall be required to make payment for all connections and for water and electricity used during the Contract at the current rates of the city or municipality. 1.5 Accommodation of Traffic, Deviations and Temporary Access Roads The Contractor shall carry out the Works in such a manner that the least possible inconvenience is caused to the public and to owners of land. Reasonable access shall be provided at all times to and on roads, tracks, etc., to ensure that obstruction to pedestrians and vehicular traffic is kept to a minimum. Where required by the Project Manager, the Contractor shall provide and maintain to a standard approved by the Project Manager, adequate detours or deviations to ensure full compliance with the Contract. The cost of detours or deviations as well as their maintenance and any necessary shall be deemed to be covered by the Contractor in the rates and prices of the Contract. 1.6 Survey and Stand Pegs Certain level pegs will be handed over to the Contractor. These are to be preserved and treated in the same way as land survey pegs. On taking over the site the Contractor shall be furnished with a plan of all survey pegs. In the absence of such a plan, known survey pegs shall be pointed out to him and the Contractor shall carefully protect and preserve all such survey pegs and any additional survey pegs which may be installed on the site from time to time. 1.7 Levels No work shall commence upon any portion of the Contract until such time as ground levels have been taken by the Contractor in an approved manner, and checked and accepted by the Project Manager to ensure that a firm basis has been established for measurement and setting out purposes. Should the Contractor fail to comply with this Clause the Project Manager reserves the right to base the final measurement on other survey data. 1.8 Survey Equipment The Contractor shall provide all survey and measuring instruments of every kind necessary for his use in the execution of the Works. The Contractor is also to provide service and maintain survey equipment listed in the the Contract for the Project Managers use if any. 1.9 Watching and Lighting The Contractor shall at all times provide and maintain adequate watching lighting, signposting, watchmen and protective fences or barricades to ensure the safety of road users and the works. Traffic signs barricades, lights etc., shall be of such quality and condition as to adequately perform under dusty conditions. Remote warning signs shall be erected a minimum of 100 metres from construction work and deviations. Flagmen shall be employed whenever required for safety. The cost of providing these shall be deemed to be covered by the Contractor by the rates and prices of the Contract.

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Section VII. General Specifications 1.10 Samples

The Contractor shall provide all samples required by the Project Manager. The cost of providing these shall be deemed to be covered by the Contractor in the rates and prices of the Contract. 1.11 Protection of Existing Services and Structures Before commencing any section of the work, the Contractor shall obtain at his own cost full information with regard to the position of all existing services and structures and shall exercise the utmost care when working in their vicinity. The Contractor must serve notice of his intention to work near the services or structure to the responsible authority, and obtain their written approval before commencing work, which must be carried out in accordance with the responsible authority's requirements. All costs arising out of the protection of existing services and structures shall be deemed to be covered by the Contractor in the rates and prices of the Contract. The Contractor shall also bear the full costs of remedial work to existing services, which are damaged by the Contractor when carrying out the Works. 1.12 Programme Contractor shall submit his Programme for performing the Works using Microsoft Project software of such version to be approved by the Project Manager. The Programme shall be subject to regular review throughout the period of the Contract and the Project Manager reserves the right to direct the sequence for performing the Works. 1.13 Sign Boards The Contractor shall arrange for the fabrication and installation of three sign boards, including the inscription of Zimfund, the Employer, Project Manager, Contractor and any subcontractor names on the sign boards. The sign boards shall comply as regards size, painting, decorating and detail with the requirements for the standard board, recommended by the Zimbabwe Association of Consulting Engineers. The description of the project and the names and titles of Zimfund, Employer, Project Manager, Contractor, and any subcontractors shall be included on the sign boards. The Project Manager will issue precise requirements upon contract commencement and approve the content and design of the sign board prior to fabrication. 1.14 Costs of Testing The costs of any testing shall be deemed to be covered by the Contractor in the rates and prices of the Contract. Laboratory testing shall be carried out by a laboratory nominated by the Contractor and approved by the Project Manager. 1.15 Asbestos Warning The use of asbestos materials is strictly prohibited. The safety hazards associated with asbestos have been well documented. Contractors are instructed that under no circumstances are materials containing asbestos to be supplied and installed under this Contract. The existing plant, equipment and buildings may contain asbestos, for example asbestos cement (AC) pipes and asbestos containing building materials. The Contractor shall take precautions to avoid disturbing or working on, or in close proximity to asbestos containing materials. The current best practice relating to asbestos shall apply including, but not limited to, the latest EU Directives, including Directive 2009/148/EC. Drawings may show AC pipes. Where these are existing pipes the Contractor shall take care not to disturb or work on, or near them. Where any new pipes are shown as AC on a
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Section VII. General Specifications Drawing then that is an error, and the Particular Specification shall take precedence over the Drawings. IN CASE OF ANY DOUBT ASK THE PROJECT MANAGER FOR GUIDANCE.

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Section VII. General Specifications

2 2.1

MATERIALS General

All goods and materials shall be of the best quality and obtained from an approved maker. The latest relevant Standard Association of Zimbabwe Specification or other approved National or International Standard Specification with current amendments shall apply. Materials are specified in detail under the section for which they are required. The Contractor shall be fully responsible for securing all necessary materials and shall bear all costs for any import of materials from other countries, if necessary, for him to adhere to the Contract. 2.2 Samples Fair and representative samples of all materials to be used in the Works shall be submitted to the Project Manager for his approval, wherever practicable, at least three weeks before it is proposed to use the materials. No materials shall be used until such approval in writing has been obtained. Any material which, in the opinion of the Project Manager, does not comply with the standard of the samples submitted and approved, shall be rejected and replaced by the Contractor at his own expense. 2.3 Packing All goods are to be carefully packed to prevent damage during transit. The costs for all packing and crating necessary to ensure safe transport shall deemed to be covered by the Contractor by the rates and prices of the Contract. All damage and breakages are to be made good by the Contractor. 2.4 Unloading The Contractor shall exercise care and be responsible for the loading and unloading of all materials and he shall make his own arrangements at his own expense for the safe storage of all materials on the site for which storage he alone will be responsible. In the transport and off- loading of materials the Contractor shall ensure that no stoppage or disorganization of traffic at any point shall occur by reason of negligence or carelessness on his part. Materials shall not be off-loaded in such positions as will cause a nuisance or danger to life or property. The Contractor will be responsible for taking delivery and for protecting and storing all materials, including those to be supplied by nominated sub-contractors (if any), at site, until such time as they are required for erection at the site 2.5 Inspection at the Factory The right is reserved by the Project Manager to appoint an Inspector to inspect the materials at the manufacturer's works, to attend to the official tests specified or otherwise agreed, and to satisfy himself that the material is in accordance with the Specifications. The Inspector shall be given a minimum of three days notice by the Contractor of tests to be carried out and he shall be afforded all reasonable facilities in his visits of inspection to inspect the manufacture and tests at all stages and to satisfy himself that the materials manufactured and tests performed comply with the Contract. All expenses in connection with the tests, except the Inspector's fees and traveling expenses, shall be borne by the Contractor. In the event of the Inspector not being present at the tests after the specified notice has been given to him, the Contractor, immediately after carrying out of such tests, shall submit to the Inspector a signed statement in triplicate that the tests have been carried out, together with the all test sheets and relevant data.
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Section VII. General Specifications Every article passed by the Inspector will be clearly marked with his stamp or pencil; the Inspector shall also be entitled to demand that all rejected material is distinctly marked as such. If no Inspector is appointed, the Contractor shall properly carry out the test in the manner specified and shall submit in duplicate to the Project Manager signed certificates setting out the details and results of the tests, and in such certificates shall guarantee that no material failing to comply with the Specifications will be or has been delivered under the Contract. Such certificate shall be mailed within three days of the carrying out of tests.

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Section VII. General Specifications

3 3.1

EARTHWORKS Definition of Earthworks

Earthworks shall include all excavations, filling, embankments and forming, whatever may be the materials and for whatever purpose they are required, and all other works contingent upon or relating to excavations as required by the nature of the Contract, as described in these Specifications and as shown on the approved Contractor's Documents. 3.2 General Excavation The whole of the excavation shown on the approved Contractor's Documents for the several parts of the work shall be carried out to the exact lines and levels, widths, lengths and depths indicated on the approved Contractor's Documents or to such other dimensions as may be directed. No excavation, for any purpose whatever, shall be made on site without the permission in writing of the Project Manager. 3.3 Site Clearance The areas to be occupied by permanent work should be cleared of all bushes, undergrowth, vegetation, trees and stumps up to 1 metre girth, hedges, fences, rubbish, debris and decayed vegetable matter outside these areas. Tree roots shall be grubbed up and trees or stumps exceeding 1 metre girth measured at a height 1 metre above ground level or at the top of the stump, whichever is the lesser shall be logged and stacked. All timber shall remain the property of the Employer, or alternatively land owner where the work is being carried out in a way-leave or easement. Where directed, the excavations left by the removal of trees shall be backfilled and consolidated to ground level. Such excavations, if they are below or contiguous to structural foundations shall be filled with concrete as directed. Concrete so used will be measured and paid for at rates given in the Bill of Quantities. All vegetable debris shall be disposed of by burning and other debris shall be disposed of as directed by the Project Manager. Care shall be taken in the control and lighting of fires to ensure that they do not spread. All surplus soil from site clearing operations shall be left in windrows or spread as directed by the Project Manager. Care shall be taken to remove all grass and roots etc.., which would, in the Project Managers opinion, adversely affect the consolidation and stability of completed earthworks. Where directed, pipe tracks shall be cleared to a minimum distance of 2 metres on each side of the centre line of the pipe, or to such other greater dimensions as the Contractor may require to gain access and to construct the Works. No clearance shall be carried out outside the limits of the way-leave or casement without written permission of the Project Manager. No ditches or natural drainage channels shall be filled in or blocked without the written permission of the Project Manager. 3.4 Soil Stripping Where directed by the Project Manager, or as shown on the approved Contractor's Documents, the Contractor shall remove all topsoil to an average depth of 150 mm as and where directed by the Project Manager, and deposit this separately from all other excavated materials in neat stock piles, where directed. Alternatively, the Project Manager may direct that this soil be spread evenly over the surrounding area.

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Section VII. General Specifications 3.5 Types of Excavation

Excavation is considered under the following two different headings, depending on the operational procedures involved: 3.5.1 Type 1 - Trench excavation and backfill for pipelines Type 2 - Excavation and backfill for structures Type 3 - Bulk Machine Excavation (Cut and Fill) Type 1 - Trench Excavation and Backfill for Pipelines

(a) Trench Excavation Unless otherwise specified or directed by the Project Manager in writing, pipeline trenches shall be excavated in any material to the following base widths: For pipes up to 150 mm diameter: 600 mm wide. For all other pipes: 500 mm in excess of the external diameter of the pipe, or as detailed in these Specifications or on the approved Contractor's Documents.

The specified trench widths measured at the crown on pipelines of internal diameter greater than 225 mm shall not be exceeded without the Project Managers approval. All trench excavations and related quantities, including rock, shall be based on the trench widths specified above, and the Contractor shall allow in his rates for any additional working space required for the making of joints, and for the trimming of trenches to the correct grades, all to the satisfaction of the Project Manager, and also for the provision of adequate bedding depths or specially shaped trench bottoms in accordance with these Specifications. (b) Trench Openings Not more than 1 km of trench shall be opened ahead of pipe laying, and the Project Manager may instruct that this length be reduced. (c) Excavation in Headings With the approval of the Project Manager the Contractor may, in certain cases, excavate for pipework on a cut and drive principle, using short lengths of heading. The size of the heading shall be outer diameter of pipe plus 750 mm with a minimum of 1.4 m height and 900 mm width. The greatest care shall be exercised in backfilling, which will be subject to close supervision by the Project Manager, and must be tightly packed in layers and well rammed by hand. Measurement for excavation for the lengths in heading shall be on the basis of normal excavation rates for full trench excavation to the inverts. The general liabilities with regard to dewatering, etc. remain. All other items shall be measured according to net measurement of work done on the dimensions given in these Specifications or on the approved Contractor's documents. The Project Manager reserves the right to instruct the Contractor to carry out trench excavations across roads or in other special circumstances by this method. (d) Backfilling Backfilling shall be carried out as soon as possible after the pipe work has successfully passed the tests and inspection specified, and has been approved in writing by the Project Manager. Specially selected material without stones or other substances that in the opinion

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Section VII. General Specifications of the Project Manager might cause damage to the permanent work shall be used for filling around the pipe work and to a height of at least 150 mm above it, or as shown on the approved Contractor's Documents. This material shall be thoroughly and evenly compacted to 90% Mod AASHTO to give the pipe work maximum support from the trench sides and shall be carried out in such a manner that the pipe work is not disturbed. Refilling of the trench shall be continued by replacing selected excavated material in 150 mm layers measured after compaction or as shown on the approved Contractor's Documents. Each layer shall be well rammed and consolidated to 90% Mod AASHTO before the succeeding layer is placed. Where ramming is done by hand, the proportion of rammers to fillers shall be three-to-one. If so directed by the Project Manager, water shall be used, which the Contractor shall supply at his own cost. Backfilling of the trench by mechanical excavator or bulldozer shall not be permitted. No vegetation and fibrous material shall be included in the backfilling. At the ground surface, the filling shall be banked to about 150 mm above the level of the adjacent ground surface and shall be maintained in this condition until the completion of the period of maintenance. Any excavated material which the Project Manager considers to be unsuitable for backfill shall be removed from site by the Contractor, and any subsequent lack of excavated backfill material shall be made good with material as ordered by the Project Manager in writing and paid for under the terms of the Contract. Where trenches cross tarred or gravelled roads or lanes, particular attention must be paid to compaction of the backfill, and the replacement of base materials to their original thickness in the order in which they were laid. All compacting of backfill under roadways must be carried out with mechanical rammers with the soil near optimum moisture to densities equal to or greater than the original material. Until permanent reinstatement is carried out, the trench surface shall be maintained in a sound condition slightly proud of the carriageway or other surface, in such a way to prevent any possible injury to persons or property. Loose material scuffed from the trench by wheels of traffic shall be broomed back into place and trench surfaces in carriageways shall be maintained in a neat and nuisance free manner to the satisfaction of the Project Manager. Permanent reinstatement shall be carried out by the Contractor. He will provide a finished road base and surface at least equal to that existing immediately before he entered the site, and must include in his rates for returning to site at regular intervals during the Defects Liability Period. (e) Stabilised Backfill Where instructed by the Project Manager, backfill shall be stabilised with 5% cement by weight. The material shall be dry mixed by either mixer or hand so that all aggregations of material are broken down into individual particles. The correct weight of cement shall then be added and the material dry mixed until a completely uniform tilth is obtained. Water shall be added to bring the material to within 1% of the optimum moisture content (OMC) at Modified AASHTO compaction effort, and the material thoroughly mixed to give uniform moisture content. The material shall then be compacted in-situ to a minimum density of 93% Modified AASHTO. The Contractor shall achieve a high degree of compaction by hand ramming or by vibrator or other mechanical compaction plant.

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Section VII. General Specifications (f) Cut-Off Walls Where directed the Project Manager on steep inclines and at major road crossings, concrete cut-off walls 200 mm thick of 15 MPa concrete, shall be constructed for the full height of the trench. The cut-off wall shall clear the pipe by 200 mm, extend down to the bed of the trench and cut into the trench 250 mm on either side. The cut-off wall shall be sited approximately 500 mm on either side of the tarred roadway, and constructed in such a way as to facilitate compaction of the backfill under the roadway and prevent any storm water or erosion of the backfill material under the roadway. 3.5.2 Type 2 - Excavation and Backfilling for Structures Excavation for foundations and structures shall be to the required dimensions and depths as detailed on the approved Contractor's Documents, together with any further excavation necessary for working space. Excavation will be classified as in "soft" excavation material and no measurement or payment for extra excavation for working space will be allowed. The work shall include for backfilling above base slabs and around foundation walls as specified in these Specifications or on the approved Contractor's Documents. 3.5.3 Type 3 - Bulk Machine Excavations (Cut and Fill) In general terms, this excavation shall be measured under two items. The first is a cut or borrow to fill and compact item, which will be measured as compacted fill, and the second is a cut to spoil item, which will be measured as an in-situ volume before excavation. (a) Cut and Borrow to Fill Fills shall be constructed on the lines, levels, side slopes, grades, densities, etc.., indicated and directed on the approved Contractor's Documents. The material used for fill construction shall be selected and approved as specified in these Specifications or shown on the approved Contractor's Documents, and shall be free from all deleterious matter. Fill shall be measured on a free haul of 1000 m for all fills measured. Overhaul instructed otherwise by the Project Manager, shall be measured separately. The Project Manager reserves the right to control excavation and to direct where materials arising from cut shall be deposited and how and where they shall be used, and also to direct where borrow materials which may be essential for fill, shall be obtained. This shall also include the control of the use of rock spoil in rock fill embankments. Before commencing work, the Contractor shall ensure that he has adequate instructions concerning the use of spoil from cut. No claims for double handling will be considered. Fill material shall be obtained from cut whenever it is reasonable in the Project Managers opinion to do so. (b) Cut to Spoil Where any inferior material is encountered in the construction of the earthwork, or where there is an excess of excavation over fill, the material concerned shall where directed, be cut to spoil in positions directed by the Project Manager. Anthill material shall generally be excavated to a depth of 0.60 m below sub-grade or foundation level, and replaced with selected fill, which shall be measured on a cubic metre basis. Before replacing the selected fill, anthill shall be poisoned with approved pesticide.

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Section VII. General Specifications (c) Method of Compaction Compaction shall be controlled to give the Modified AASHTO Field Dry Densities specified in these Specifications or on the approved Contractor's Documents. It will be the Contractors responsibility to achieve these densities and where applicable the procedures outlined below shall be complied with. Where the material is transported to bank in heavy pneumatic tyred vehicles, the required compaction will frequently be achieved by routing the equipment uniformly over the whole width of the fill, and if necessary making additional passes with loaded vehicles. Under the correct conditions this procedure shall give densities of approximately 93% Modified AASHTO. (i) The material to be compacted shall be thoroughly broken up over the full width and depth of the layer by means of scarifiers disc harrow, hand tools or other suitable equipment, and all stone, clods, and lumps with a maximum dimension larger than one-half the specified compacted thickness of layer concerned shall be broken down unless otherwise authorised by the Project Manager. Where deemed necessary by the Project Manager, the Contractor shall use heavy grid rollers, sheeps-foot rollers, cleat rollers, flat-wheel rollers, and hand tools for breaking down over-sized material. Processing by means of such equipment shall continue until the material so treated has been broken down sufficiently to ensure that after compaction the resulting layer shall be firm, well bonded and free from nests of segregated materials. During such processing, the layer shall be frequently scarified and bladed to ensure that over-size materials are brought to the surface of the layer. (ii) Any water required before the materials is compacted shall be added to the materials in successive applications by means of water sprinklers fitted with proper sprinkler bars, or by means of pressure distributors, all capable of applying the water evenly and uniformly over the area concerned. The water shall be thoroughly mixed with the material to be compacted by means of ploughs, disc harrows, rotary mixers, motor graders or other suitable equipment. Mixing shall continue until the required amount of water has been added, and until a uniform and homogenous mixture is obtained before compaction is commenced. The material shall be compacted at the optimum moisture of Modified AASHTO density with an allowable tolerance of plus one percent or minus two percent of moisture by weight of dry material. Should the mixture be too wet, due to rain or any other cause, it shall be harrowed and allowed to dry out to a moisture content conforming to the above requirements before compaction proceeds. (iii) Compaction shall be carried out in series of continuous operations over the full width of the layer concerned, and the length of any section of a layer being compacted shall, whenever possible, not be less than three hundred meters, unless otherwise authorised by the Project Manager. The thickness of any one layer after compaction, shall be in accordance with these Specifications or approved Contractor's Documents, and shall not exceed 150 mm unless so authorised by the Project Manager in writing. This will depend on the plant used and the material being compacted. Any new layer of less than 75 mm compacted thicknesses shall be bonded to the underlying materials by scarifying such material to a depth of not less than 50 mm. The total depth of loosened and added material shall not be less than 150 mm after compaction. The costs of such scarification shall be deemed to be covered by the Contractor by the rates and prices of the Contract. Compaction shall be carried out by means of grid rollers, vibratory rollers, and/or pneumatic rollers. The types of rollers to be used and the amount of rolling to be done
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Section VII. General Specifications shall be as such as to ensure that specified densities are obtained. During compaction, the layer shall be maintained to required shape and cross section, and all holes, ruts, and depressions corrected by frequent blading with motor graders. The formation shall be finished off by a flat wheeled roller to form a smooth base to the specified cross falls and levels and to the specified density. Rock fill embankments shall have all interstices filled with approved fill material, and shall be compacted to the maximum possible state of consolidation, with all rocks in contact with adjacent rocks on all faces. This shall normally be achieved by subjecting each layer to at least eight passes of a towed vibrating roller weighing not less than four tonnes, or by a grid roller weighing not less than 13 tonnes dead weight, or other plant approved by the Project Manager. Compaction in fills shall generally be controlled by making a specified number of passes of approved compaction plant over layers of prepared fill material at the correct moisture content, of loose layer thickness not exceeding 200 mm unless otherwise authorised by the Project Manager. The number of passes each item of the Contractor's compaction plant requires, to achieve the specified densities, shall be determined by means of full scale compaction trials. Notwithstanding such trials, no approval of the Project Manager for any method of compaction shall relieve the Contractor of any of his responsibilities for obtaining the compacted densities specified or for fulfilling all the conditions as required by these Specifications. (d) (i) Soil Testing General During the progress of the works, the Contractor shall have tests taken and results submitted to the Project Manager, on the materials and workmanship in order to ensure compliance with specification. The costs of such tests shall be deemed to be covered by the Contractor by the rates and prices of the Contract. (ii) Method of Testing All testing shall comply with CAS 185 part and A 43 Part 2 "Method of Testing Soils Civil Engineering Purposes". (iii) Testing of Earthworks, Subgrade, Sub-base Shoulders and Base After a visual acceptance of a completed of the works, a number of tests to ensure compliance with the frequency of these tests shall be as in the table following: LAYER Fill Subgrade Sub-base Shoulder Base Course NUMBER OF FIELD DENSITY TESTS PER AREA 3 tests per 750 m2 or part thereof 3 tests per 500 m2 or part thereof 3 tests per 500 m2 or part thereof 3 tests per 500 m2 or part thereof 3 tests per 500 m2 or part thereof

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Section VII. General Specifications The Project Manager may reduce or increase the number of testing at his discretion. Dry density determination of cement or stabilised layers shall be carried out between four to six hours after mixing of the stabilising agent. 3.6 3.6.1 Classification for Excavation Material Material in Trenches and Confined Spaces - Method of Classifying

The Contractor may use any method he chooses to excavate any class of material, but his chosen method of excavation shall not determine the classification of the excavation. The Project Manager will decide on the materials. In the first instance the classification will be based on inspection of the material to be excavated and on the criteria given in these Specifications. All equipment specified in these Specifications shall be in good mechanical condition. "Efficiently" as used in these Specifications shall be taken to mean "in a manner that can reasonably be expected of a Contractor, having regard to the production achieved". In the event of a disagreement between the Contractor and the Project Manager, it shall be the responsibility of the Contractor, if required to provided plant that is suitable to the site, to make available at his expense such mechanical equipment as is specified in these Specifications, in order to assess the reasonable removability or otherwise of the material. The decision of the Project Manager on the classification shall then, subject to the provisions of the Contract, be final and binding. 3.6.2 Classes of Excavation

Machine Excavation The excavation of material using back-acting excavators will be classified as follows for purposes of measurement. (a) Soft Excavation In restricted excavations, soft excavation will be excavation in material that can be efficiently removed by a back-acting excavator of flywheel power approximately 0.10 kW for each millimetre of bucket width, without the assistance of pneumatic tools such as paving breakers. (b) Intermediate Excavation In restricted excavation, intermediate excavation shall be excavation in material that requires a back-acting excavator of flywheel power exceeding 0.10 kW for each millimetre of bucket width and the use of pneumatic tools as an essential preparation to permit removal by equipment equivalent to that specified in (a) above. (c) Hard Excavation In restricted excavation, hard rock excavation shall be excavation in material that cannot be efficiently removed without blasting or without wedging and splitting. Hand Excavation The excavation of material using picks and shovels will be classified as follows for purposes of measurement and payment and will only be used where machine excavation is not practical. The Project Managers decision on this is final.

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Section VII. General Specifications (a) Soft Excavation In restricted excavations, soft excavation will be excavation in material which does not fall into the category of intermediate and hard excavation described below. (b) Intermediate Excavation Intermediate materials will be material other than hard material, the excavation of which would be uneconomical if executed by pick and shovel and thus requires the use of pneumatic tools. (c) Hard Excavation Hard excavation will be solid rock excavation occurring in bulk or in banks or ledges the practical excavation of which would normally necessitate the use of explosives. 3.6.3 Excavation in Bulk Machine Excavations

Method of Classifying The Contractor may use any method he wishes to excavate any Class of material but his chosen method of excavation shall not determine the classification of the excavation. The Project Manager will decide on the classification of the materials. In the first instance the classification will be based on inspection of the materials to be excavated and the criteria given in these Specifications. All equipment specified in these Specifications shall be in good mechanical condition. The expressions "efficiently removed" and "efficiently loaded" shall in this context be taken to mean: "removed or loaded (as the case may be) in a manner that a contractor can reasonably be expected to do having regard to the production achieved". In the event of disagreement between the Contractor and the Project Manager, it shall be the responsibility of the Contractor, if required, to make available at his expense such mechanical equipment as is specified in the Specifications in order to assess the reasonable removability or otherwise of the material. The decision of the Project Manager as to the classification shall then, subject to the provisions of the Contract, be final and binding. Classes of Excavation The excavation of material will be classified as follows for the purpose of measurement. (a) Soft Excavation Soft excavation shall be excavation in material that can be efficiently removed, without ripping, by a bulldozer of mass approximately 20 tonnes and flywheel power about 130 kW, or, without prior ripping by a tractor scraper unit of total mass about 28 tonnes and flywheel power about 250 kW or that can, without prior ripping or stockpiling, be efficiently loaded by a front-end loader of mass about 22 tonnes and flywheel power about 140 kW. (b) Intermediate Excavation Intermediate excavation shall be excavated in material that requires ripping or stockpiling or both as an essential operation to permit removal by equipment equivalent to that specified above.

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Section VII. General Specifications (c) Hard Rock Excavation Hard rock excavation shall be excavation in material that cannot be efficiently ripped by a bulldozer of mass about 30 tonnes and flywheel power about 200 kW and fitted with a single tine ripper suitable for heavy ripping. Note: Such excavation generally includes material as formations of fresh solid rock that can be only removed after blasting or wedging and splitting. Measurement of Intermediate and Hard Excavation In all cases, excavation in Intermediate and Hard Excavation shall be net volume to be removed only, and no payment will be made in respect of over-break. No excavation in Intermediate or Hard Material shall commence until the quantities to be removed have been measured and agreed by the Project Manager, and furthermore if this procedure is not followed, the Project Manager may then refuse to certify for payment any such work undertaken. 3.7 Excess Excavation In the event of any excavation being carried out wider or deeper than authorised, they shall be filled in by the Contractor at his own expense to the required dimensions or levels with approved fill, to a density of at least equal to the density of the surrounding soil. If the excess excavation occurs under structures, the backfill shall be in mass concrete, as directed by the Project Manager, all at the Contractor's expense. 3.8 Water in Excavation Water shall not be allowed to accumulate at any part of the workings. The Contractor shall take all risks from water, clear or foul, whatever the source or cause may be and shall at his own expense, effect drainage and keep dry all the works during construction and take due care to prevent surface water soaking in. All side channels, sumps or temporary excavations for de-watering shall also be formed, maintained and used, outside and clear of the main works, and shall be properly filled in when their use ceases. 3.9 Blasting Blasting may be resorted whenever required, strictly under Government or Municipal Regulations, but in no case so as to impair or injure any foundation, wall, pipeline or structure, completed or partly completed. If in any situation, blasting is considered dangerous, then blasting shall not be resorted. The Project Managers decision in this respect shall be final. Should any damage occur during blasting, the Contractor shall at his own expense, carry out such work of repair or restoration as the Project Manager may direct and shall be fully and solely responsible for such damage or any claims that may arise there from. Care shall be taken that no un-discharged cartridges are left in the excavation. Should blasting likely interfere with the operations of any other contractor, times will be set by the Project Manager for such blasting if authorised, and the Contractor shall give adequate warning to such other contractors or road users or any other persons in the neighbourhood that blasting is about to take place. Careless or indiscriminate use of explosives will result in the Project Manager withdrawing permission for their use, and under such circumstances, the Contractor shall resort to other methods of excavation.

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Section VII. General Specifications 3.10 Timbering and Supporting Excavations

The costs for excavation shall include for the use of all timber and for all labour in placing and withdrawing the timber required for properly supporting and timbering the works, in such a manner as to ensure the safety of workmen shall be complied with. The Contractor shall be held entirely responsible for any accident, subsidence, slip or damage caused by defective or insufficient timbering, careless workmanship or any other cause whatsoever and for all costs involved, including reinstatement. The Contractors attention is drawn to the relevant clauses in the Factorys Act. 3.11 Cut to Spoil (Trenching and Structures Excavation) Material from excavation shall be used or disposed of under the direction of the Project Manager. Surplus or unsuitable material from trench or other construction shall be disposed of by spreading locally, including the provision of extra cover over the pipes. No further payment will be made for the above operations and the cost thereof is to be included in the rates and prices of the Contract for the various excavations. Excavated material shall not be wasted indiscriminately and the Contractor shall first obtain the Project Managers approval before spoiling any material arising from the excavations. Should the Project Manager decide that local spreading of surplus spoil is not desirable, the Contractor shall load up, cart, haul up to 1,000 m, unload, spread and level to the approval of the Project Manager. In the case of trench excavations, the Project Manager reserves the right to direct the Contractor to stack spoil on one side of the trench only in existing business and residential areas and to provide gaps in the windrows so formed for pedestrians and vehicular crossings. Spoil heaps shall be such as to cause a minimum of inconvenience to the public and traffic and to disrupt kerb-line parking for as short a period as possible, and shall be of such a height as will not interfere with driver vision. 3.12 Working Space Where in the opinion of the Project Manager, it is not practicable or advisable to cast concrete directly against the faces of the excavation, the Project Manager shall direct the use of external shutters. Where the use of external shutters is made necessary through any action of the Contractor which is contrary to these Specifications, then no payment shall be made for either the working space or the outside shuttering. 3.13 Topsoiling and Grassing Where shown on the approved Contractor's Documents or as instructed by the Project Manager, topsoiling and grassing of earthworks shall be carried out by the Contractor. The Contractor shall ensure that the earthworks are correct as regards density, shape, line and level before starting topsoiling operations. Topsoil shall be taken from approved stockpiles and spread uniformly over the designated areas to a depth of 100 mm measured normal to the slope after light rolling. The layer of topsoil shall be rolled with a hand roller to seal the surface. Care shall be taken that no soil is allowed access into any embankment surface drain. Grass shall be planted in clumps or drills, according to the habit of the grass. Drills and lines of clumps shall be 200 mm apart measured down the slope of the bank and shall be located horizontally. Clumps shall not be more than 200 mm apart. The runners shall be staggered on lines normal to the top of the bank to prevent formation of erosion channels.
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Section VII. General Specifications The grass shall be of the runner variety, Starr No. 2 (Couch) or Kikuyu, of a type suited to local conditions capable of giving a dense and well-knit sward. The source and type of grass shall be to the approval of the Project Manager. Wherever possible, grass shall be planted just prior to or at the beginning of the rainy season and the Contractor shall arrange his grassing programme accordingly. The Contractor shall observe the growth of the grass during the rainy season and replant any areas where the grass has failed to root satisfactorily. The size of the clump used for all plantings shall be such that the growth of cover shall be as rapid as possible. Plantings shall be kept damp until such time as the grass is properly established. Should the bank be damaged by rain, wash-aways shall be repaired and the grass be replanted at the Contractor's expense. Providing that the topsoiling and grassing have been properly carried out in accordance with these Specifications and to the satisfaction of the Project Manager, the Contractor shall not be held responsible for any failure of the grass to grow, spread or cover the surface effectively after the end of the rainy season. Should the Project Manager then decide that any area requires replanting with grass, such replanting shall be measured as new work. The Contractor may be called upon to apply fertilizer to the embankment after planting grass if the rate of growth is unsatisfactory. The fertilizer to be used shall be an approved proprietary brand which promotes root development. Fertilizer shall be applied by placing carefully measured amounts in "dibble" holes punched into the topsoil. These holes shall be laid out in a square pattern with 300 mm sides. Fertilizer shall be applied in successive applications of approximately 220 kg per hectare. Surplus topsoil shall be loaded from stockpile carted and spread in an area within the site. This work must only be carried out on specific written instruction of the Project Manager. The maximum haul distance not to exceed 1000 m. 3.14 Unsound Foundations If any unsound material occurs in the bottom of any excavation, it shall be removed and disposed of and the resulting space shall be filled with concrete 10 MPa or as directed by the Project Manager. 3.15 Termites Where termite nests are encountered on the site, the Contractor may be directed to excavate and remove these and refill and consolidate the resulting hole with a suitable material. The termite poison shall consist of a 5% solution of pentachlorophenol in used engine oil or other approved solvent evenly spread at the rate of 4.2 litres per square metre and shall be applied if directed by the Project Manager. 3.16 Demolition Works Where the removal or demolition of existing structures is called for in the Contract or as directed by the Project Manager, such structures whether above or below ground shall be demolished completely and unless otherwise directed, all material resulting from demolition work shall be collected, stored and handed-over when directed. Structures to be demolished shall include buildings of whatever construction, foundations, floor slabs, fencing, water pipe lines, sewers and drains, manholes, inspection chambers, gullies, walls, piers, poles anchored in the ground, wires, cables, culverts, storm water drains, ditches, sumps, earth and retaining walls, buried ducts, septic tanks, soak-aways and any other structures or portions of structures which, for the purpose of this clause, shall be

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Section VII. General Specifications declared to be subject to demolition work. All structures below ground level shall be grubbed up and removed and the resulting holes filled with approved material. 3.17 Tolerance

Positions, Dimensions, Levels, Etc.. The degree of accuracy of the finished work shall be within the following limits. (Degree II accuracy shall apply if no degree of accuracy is specified.) Degree of accuracy Permissible deviation (PD) (a) Excavation for Structural Foundations (1) Position in Plan PD in plan of any point measured from the nearest grid line ...... (2) Dimensions in Plan PD from the design dimensions...... (3) Foundation level (i.e. level of underside of concrete except to floor slab) PD in level of surface of excavation trimmed to receive concrete (4) Level PD from designed level with reference to the nearest transferred bench mark (b) (1) Terraces and embankments Position of top edge of Terrance* PD from designated position of any point, measured from nearest grid line ............................. + 75 + 50 + 25 III mm II mm I mm

+ 50

+ 35

+ 25

+ 75

+ 50

+ 25

+ 20

+ 15

+ 10

+ 450

+ 300

+ 150

* Subject to the break-line between intersecting slopes being acceptably straight. (2) Alignment of top edge of Terrance PD from a line joining any two points 30m apart on top edge of Terrance... (3) Finished Levels PD from designated levels with
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+ 200

+ 100

+ 50

Section VII. General Specifications reference to nearest transferred bench mark ..................... (4) Slopes of Top Surface PD from direction of slope PD from rate of fall: 1 in 100 to 1 in 300 1 in 400 and flatter 3.18 Measurement nil % 20 10 nil % 10 5 nil % 5 2

+ 150

+ 50

+ 50

3.18.1 Site Clearance General site clearance shall be measured in square meters or hectares; pipe track clearance where directed shall be measured in lineal metres irrespective of the pipe diameter. Trees exceeding 1 metre girth measured 1 metre above ground shall be measured under separate items, and shall not be removed unless so directed. 3.18.2 Soil Stripping Soil stripping shall be measured in square meters and allow for 150 mm of topsoil. 3.18.3 Excavation for Pipe Trenches Excavation for pipe trenches shall be measured per lineal metre run for the particular diameter of pipe at the depths and shall include for excavation in "Soft Material" any extra working room over the trench widths or depths specified, return fill and ram, spread and level surplus, timbering, dewatering, working in half road widths and all other contingent items described or implied herein. The lineal measurement shall be continuous through manholes, etc., and additional excavation required for the manholes and boxes shall be allowed for by the Contractor for manholes, chambers, etc. An extra over payment will be made where the Project Manager requires surplus or unsuitable material to be loaded, hauled, dumped, spread and levelled. The depths indicated on the approved Contractor's Documents are from natural ground level to the invert level of the pipe and this depth will be used for measurement purposes. The Contractor shall allow for the extra excavation to the underside of the pipe and the underside of the bedding material where shown on the approved Contractor's Documents. The Contractor shall also allow for special shaped trench bottoms where specified and shown on the approved Contractor's Documents and for trimming to grade. Where the natural ground level has been lowered before trench excavation has commenced, the depth of the trench shall be measured from the reduced ground level. Where the trench passes through an anthill or other artificial embankment, the measurement shall be based per cubic metre for a trench 900 mm wide or 500 mm wider than the nominal diameter of the relevant pipe, whichever is the greater, for all excavation above ground level. The material so excavated is to be spread and levelled locally. When ordered in writing by the Project Manager, extra excavation in the trench 75 mm below trench or bedding bottom, in unsuitable material, and refilling with sand or approved granular soil or concrete, shall be measured and paid for on a square metre basis on the trench widths specified or detailed.
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Section VII. General Specifications An extra over payment measured in cubic metres will be made for excavations in "Intermediate" or "Hard" Excavation. The costs for excavation shall include for all necessary timbering, dewatering, storm water protection, protection of other services, also backfilling and consolidating where applicable and for any additional working space not elsewhere specifically allowed for. These costs shall be deemed to be covered by the Contractor by the rates and prices of the Contract. 3.18.4 Excavation for Structures All excavation in which concrete is to be placed shall be measured in cubic metres as "Soft Material" to the depth shown on the approved Contractor's Documents and to the greatest spread of the concrete to be placed therein, or as specified. An extra over payment will be made for "Intermediate" or "Hard excavation. Except as specified, all bases, footings and foundation slabs shall be poured against the excavations without outside formwork. The costs for excavation shall allow for all associated operations, precautions, dewatering etc.., for backfilling over footings and behind walls and for spreading or carting the surplus material to waste. These costs shall be deemed to be covered by the Contractor by the rates and prices of the Contract. 3.18.5 Bulk Excavation All measurements shall be net. Excavations or fill in excess of the authorised cross sections, as shown on the approved Contractor's Documents, or as directed by the Project Manager, shall not be paid for. The rates and prices of the Contract shall be deemed to include for all costs entailed in location, abstraction, and storage of water, haulage to site and application, wherever required, including trial pits, testing of materials etc., all as specified. The removal of materials in slips, slides or subsidence and over-breaks of rock extending beyond the lines or slopes, or below the levels shown on the approved Contractor's Documents, or required by the Project Manager, will not be paid for. The rates and prices of the Contract shall be deemed to cover any dewatering and all timbering necessary for the protection and safety of excavations. (a) Fills: (1000 m free haul) The units of measurement for fills arising from cut or borrow, shall be the cubic metre of material measured as Soft Excavation in fill after compaction, and computed by the method of average end areas from levelled cross sections taken before and after construction of the fill at 20 metre intervals on centre line. All measurement shall be net. The rates and prices of the Contract shall include for haulage up to 1000 m, unloading, spreading, application of water and mixing if necessary, compaction to 93% modified AASHT0 density and for trimming to 50 mm of the final level. Extra over payments measured in cubic metres will be made for excavation in "Intermediate", "Hard", and Boulder Class A or B excavation. (b) Cut to Spoil (1000 m free haul) The unit of measurement shall be the cubic metre of material, measured in place before excavation and computed by the method of average end areas from levelled cross sections taken before and after excavation at 20 m intervals on centre line. All measurement shall be net, and the rates and prices of the Contract shall include for all costs as in (a) above.

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Section VII. General Specifications Where measurement in place is not considered to be practicable by the Project Manager, spoil may be measured in vehicles on site, seventy per cent of volume in the truck being accepted as the equivalent volume of spoil and gravel in place before excavation, and fifty per cent of the measured volume in the truck being accepted as the equivalent volume of broken rock or stone in place before excavation. Extra over payments measured in cubic meters will be made for excavation in intermediate or rock excavation. (c) Overhaul Overhaul payment for haul distances greater than 1000 m will be paid on a m3-km measured basis. The volume of material will be measured as in (a) or (b) above and the distances will be the overhaul distance as assessed by the Project Manager to the nearest 100 m. The unit of payment is the product of the volume and distance. 3.18.6 Stabilised Backfill The unit of measurement for stabilised backfill shall be on the cubic metre compacted volume, and the rates and prices of the Contract shall include supply of cement and all contingent work, and shall be paid extra-over trench excavation and backfill based on the trench widths specified and detailed. 3.18.7 Working Space Excavation of working space for fixing, propping and removing external shutters shall be measured as part of the general excavation. The volume measured shall be measured either vertically above the outer limits of finished foundations or within a distance of 600 mm measured from the shuttered surface for all depths of excavation. The rates and prices of the Contract shall allow for any additional excavation. No excavation for working space shall be paid for except where external shuttering is directed by the Project Manager in substitution for casting concrete directly against the face of excavation. 3.18.8 Anthills Nothing shall entitle the Contractor to payment for anthill excavation unless the quantities are measured by the Project Manager before excavation is commenced. Volumes of anthills shall be measured under the Formula V = C2 x H /25.2 where V is the Volume in m3, C is the circumference in metres around the base taken at the point where the steep slope commenced, H is the average vertical height in metres measured from points on the circumference C to the top of the main body of the anthill (ignoring any stalagmite tip). 3.18.9 Topsoiling and Grassing The unit of measurement for topsoiling and grassing shall be the square metre of surface grassed, measured in the plane of the bank. The unit of measurement of fertilizing after planting shall be per 50 kilograms of fertilizer ordered and applied. This specification is irrespective of the number of times areas may be replanted, as well as for the provision of all supervision, labour, transport, plant, equipment, tools, water irrespective of haul, materials and incidentals necessary to complete, protect, and maintain the work prescribed in this these Specifications. If an application of super phosphate at the time of planting (1 kg/m2) is called for then this should be allowed for in the rates and prices of the Contract. Payment for each 50 kg of fertilizer shall include full compensation for procuring and making available on site approved fertilizer, for setting out and punching dibble holes, and filling such holes with the approved amounts of fertilizer, as well as for the provision of all

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Section VII. General Specifications supervision, labour, transport, storage, plant, equipment, tools, materials and incidentals necessary to complete the work in accordance with these Specifications.

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Section VII. General Specifications

4 4.1

PIPE LAYING Pipe Materials Earthenware Sewer Pipes and Fittings

4.1.1

All Earthenware Sewer Pipes and Fittings shall comply with BS 65 SABS 559 or SAZS 342. Pipes shall be supplied with an approved flexible rubber ring joint, or bonded plastic joint. 4.1.2 Concrete Pipes Concrete pipes shall comply with SAZS 315, 11005; SABS 677 or BS 5911. Pipes to be used for foul sewers or under hydraulic pressure are to have approved flexible joints sealed with a rubber ring. Concrete pipes for surface water drainage shall have a spigot and socket, OG, or other approved joint. Sewer pipes shall be capable of withstanding the air test specified, and shall be manufactured with an approved limestone aggregate. In terms of SAZS 315, 100 mm and 150 mm dia. pipes shall be Class C, 225 mm and 300 mm dia. pipes shall be Class S, and larger dia. pipes to the class required by bedding conditions and loading. Pipe ducts and gravity piping shall normally comply with Class X and Class S of SAZS 315 respectively, but the class must meet the design loadings under the bedding conditions encountered. Pipes are to be at least four weeks old before leaving the manufacturer's works. Where high pressure concrete pipes are required they shall be in accordance with SABS 676. 4.1.3 4.1.4 4.1.5 Cast Iron Pipes and Fittings Spun Iron Pipes Steel Pipes and Fittings Cast iron pipes and fittings shall be in accordance with BS No. 4622 and 4772 Centrifugally Cast (Spun) iron pipes shall comply with BS No. 4772. Steel pipes and fittings which are buried shall be generally in accordance with SABS 719 Grade B. The pipes shall have 3 mm thick internal spun bitumen or other approved lining, and a soluble external coating of bitumen and fibre glass material which shall not show any tendency to creep or flow at a temperature of 77C and one coat limewash. Unless otherwise stated, the pipes shall be plain ended and jointed by means of Viking and Johnson coupling or other equivalent approved couplings installed in accordance with the manufacturer's recommendations. Should specialist steel pipes be required they will be according these Specifications or the approved Contractor's Documents. All flanges shall be in accordance with BS 4504 and shall be coated with an approved protective composition to prevent the formation of rust. All flanges shall be drilled for working pressures as required by these Specifications or as required by the Project Manager. 4.1.6 Polythene Piping Low density polythene piping for cold water supplied up to 50 mm nominal bore shall be Class C and comply with BS 3284 or SABS 533 Type II.

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Section VII. General Specifications Where high density polythene piping is specified or offered, full details of the material used shall be submitted by the Contractor. All plastic joints or contact joints using special adhesive shall be subject to the approval of the Project Manager. 4.1.7 Alternative Pipes Alternative offers for the pipe work specified above will be considered, but in all cases the Contractor shall submit full details of the materials offered, the method of manufacture and the type of joints. Corresponding details of specials and fittings to mate with the pipe work shall also be given. The Project Manager reserves the right to approve the pipe supplier as nominated by the Contractor and to adjust the relevant rates of the Contract on the basis of the approved pipes. 4.1.8 Fire Hydrants Unless otherwise stated, these shall be of approved manufacture and conform to BS 750, Screw-Down type. The frost valve drain plug shall be blocked off. The outlet shall be 62 mm diameter, screwed with round thread to BS 336 or to the standard of the local fire authority where different to the above standard. Each fire hydrant shall be provided with a 75 mm diameter double flanged galvanised steel rising piece of such length that the outlet of the hydrant is not more than 300 mm below the cover of the surface box. The rising piece shall be painted black. An alternative is to install a horizontal hydrant tee double flanged 75 mm 90 degree bend, 75mm double flanged gate valve 75 mm 90 degree duck-foot bend with a brass screw round thread to suit the Local Fire Authority. 4.1.9 Special Valves Where special or proprietary valves are offered, full details with drawings shall be submitted by the Contractor. If such valves are specified, they shall be installed and tested in accordance with the manufacturers instructions. 4.1.10 Gate Valves Gate valves shall conform to SAZS 148, 149 and 289, and shall be of approved design and manufacture, and shall be solid wedge gate valves for cold water supplies. The primary service rating shall correspond with the designed working pressure of the valve. Drain plugs will not be required, nor will means for slinging for valves less than 450 mm diameter. Valves larger than 400 mm diameter shall be provided with renewable seats. Valves are to be provided with inside screws. Flanged valves are to be drilled to BS 4504 depending on the class of the valve. The testing of the gate valves, which shall be closed and tested unless otherwise stated, shall be carried out at 0.35 bars as well as at the specific maximum working pressure. Valves shall close anti-clockwise unless otherwise stated. Valves with hand-wheels shall be clockwise closing. 4.1.11 Step Irons Step irons shall be of malleable cast iron to BS 1247 and samples shall be provided to the Project Manager for his approval before being used on the works. 4.1.12 Jointing Materials The provisions of BS CP.310 shall be complied with.

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Section VII. General Specifications Flange Joints: Rubber insertion rings for flange joints shall comply with BS 5292. For pressures of 16 bars and over, compressed asbestos fibre (Klinkerite) shall be used. Where special or proprietary joints are specified, they shall comply with the approved manufacturers requirements. If special joints are offered by the Contractor then full details with drawings shall be submitted by him. An approved pipe jointing compound complying with BS 217 or 5292 and yarn shall be used on screwed joints. For sewer pipes shall be a continuous rubber ring and comply with BS 2494, Part 2, or SABS 974, with a nominal hardness of 45 IRHD.

Special Joints:

Screwed Joints: Rubber Joint Pipes:

4.1.13 Spare Jointing Material The Contractor is to ensure that adequate quantities of types and sizes of jointing materials are available on the site. In the case of bolts and nuts, this shall include not less than 5% spares and not less than 10% for rubber rings etc., required for jointing pipes, valves and specials for each day's work. 4.1.14 Damaged Pipes and Fittings No damaged or defective pipes or fittings shall be used, but these must be laid aside for inspection by the Project Manager, who shall determine and decide whether the damage is so extensive as to call for the rejection of the pipe or fitting or is sufficiently slight as to be capable of remedy at site. The Contractor shall replace the damaged pipe or fitting and thereafter shall submit the pipe or fitting for inspection and approval by the Project Manager, and the repaired pipe or fitting shall not be laid into the pipeline until so approved. The Project Manager shall have the right to order the removal from the pipeline of any defective or damaged pipe or fitting which has not been so rectified and approved by him, whether such pipe has or has not been laid and jointed in the pipeline, and the Contractor shall thereupon, at his own expense, effect its removal and replacement to the entire satisfaction of the Project Manager. 4.2 4.3 Codes of Practice Construction Machinery Where applicable, the provisions of SABS 0102 shall be complied with. The movement of construction machinery over any pipeline shall be at the Contractor's risk. Any pipe damaged thereby shall be repaired or replaced as directed by the Project Manager at the Contractor's full expense. 4.4 Laying Pipes to Gradients General excavation of trenches shall be carried out either manually or mechanically, and then with the aid of accurately made boning rods. Pegs shall be carefully driven into the trench bottoms so that the top of the peg shall coincide with the grade line of the pipe invert. After the trench has been inspected and approved by the Project Manager, the pipes, which shall have been previously distributed along the side of the trench, shall be carefully cleaned and lowered into place onto the prepared trench bottom and each pipe accurately laid to grade with a straight edge or other approved method. The preparation of the trench bottom depends on the type of bedding. The line of all drains shall be established by a string line laid alongside the pipe at half collar height. Particular care shall be taken to see that each pipe barrel is properly and firmly
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Section VII. General Specifications bedded onto the prepared trench bottom over its full length and that pipes are laid concentrically. Where sewer pipes are to be laid on concrete and haunched or surrounded, 20 MPa concrete mats to the thickness approved by the Project Manager will be laid, at least 300 mm wider than the OD of the pipe, to the gradient of the pipeline, the top of the mat being 75 mm below the underside of the pipe. The mat shall be broken at flexible pipe joints. The pipes will thereafter be bedded on 20 MPa concrete, 75 mm thick under the barrel of pipe, and the haunch or surround shall be added as soon as possible so as to form a homogeneous mass with the bedding. All pipes and fittings are to be laid true to line and level in accordance with the approved Contractor's Documents or as directed by the Project Manager. Pipe laying is to commence at the lowest point in the section and to work uphill. Where applicable, sockets are to face uphill or as approved by the Project Manager. Care shall be taken to ensure that no soil, stones or foreign matter enter the pipeline. Each pipe is to be carefully cleaned after laying. A plug or cap placed in the mouth of the last pipe when pipe laying is not actually proceeding. Laying, jointing and testing of pipes and backfilling of trenches shall proceed as expeditiously as possible. The Contractor shall be responsible for providing protection to the pipeline before backfilling, at his own full expense. Sight rails shall be provided when pipes are laid to gradients. Before the pipe trench is excavated, sight rails shall be erected at every manhole, or at lesser distances if directed by the Project Manager. These shall be made of substantial construction and shall be painted in black and white in such a manner as to indicate clearly the lines and levels, and for use in conjunction with them, suitable boning rods shall be provided. Each sight rail shall consist of a horizontal rail not less than 150 mm deep with the top edge planed true and smooth, firmly nailed to vertical posts. The posts shall be firmly planted, one on either side of the trench. The Contractor shall be held responsible for any errors which may occur in the execution of the work, through sight rails being disturbed, faulty setting-out there from or any other cause whatsoever and shall make good at his own full expense. The centre line of the sewer shall be indicated on each sight rail, both front and back. For water and other pressure mains, where pipeline sections are issued, sight rails shall be set up at all changes of grade, at fittings and at such other positions as will limit the distance between them to a maximum of 60 m. 4.5 Cut Pipe Lengths Cut pipes shall only be used where permitted by the Project Manager, and the ends which have been cut shall be dressed square and to a smooth even finish which shall not be inferior to that of the uncut pipe. Proper cutting tools must be used and in no circumstances will a hammer and chisel be allowed. The finished dimensions of spigot ends cut at site must be within the tolerances applicable to the spigot ends of the particular type of pipe to be laid. After cutting asbestos cement pipes, the cut ends shall be turned to the correct external diameter for the detachable joint by means of the special tool made by the pipe manufacturers and to be provided by the Contractor for performing the work.

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Section VII. General Specifications 4.6 4.6.1 Bedding of Pipes General

This section refers to all sewers, pressure mains, storm water and pipe ducts. 4.6.2 Definitions

Bedding The material in the bedding cradle and selected fill up to the underside of the main fill. Bedding Cradle The zone in which bedding is placed firmly and without voids under and up the sides of the pipe etc., in such a manner that for all practical purposes the pipe etc. cannot move or deflect. Even Graded Material Description of a particular material that is such that the size of about 90% by mass of the grains is evenly distributed. Expansion Joints The joint in the concrete structure in which two concrete surfaces are separated by resilient filler of thickness of at least 15 mm. Flexible Pipe A pipe of which the diameter is reduced by more than 1% under an external radial force before the appearance of cracks. Joint Holes A depression formed in the bedding cradle to accommodate a joint in a pipeline. Main Fill An approved filling material placed in a pipe trench after the pipe has been laid, bedded and surrounded by selected fill up to 150 mm or other specific cover above the top of the pipe. Rigid Pipe A pipe of which the diameter is reduced by not more than 1% under an external radial load before the appearance of cracks. 4.6.3 Material

Selected Granular Material Selected Granular material shall be material of a granular non-cohesive nature that is singularly graded between 0.6 mm and 19 mm, and is free draining. Selected Fill Material Selected fill material shall be material that has a Plastic Index (PI) not exceeding 6 and is free from vegetation, lumps, and rock of diameter exceeding 30 mm. Bedding

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Section VII. General Specifications 4.6.4

Bedding for rigid pipes shall be of Class A, B or C. Bedding for flexible pipes shall be selected granular material or selected fill material. The bedding cradle for Class A bedding shall be concrete. The Bedding cradle for Class B and C bedding shall be selected granular material. The material for selected fill shall be as described above. Excavation

The excavation of the pipe trench shall comply with these Specifications. During the bedding process, the Contractor will be allowed to use and screen approved selected material from the trench excavation. Should suitable material not be available, then the Contractor shall import the material subject to the Project Manager approving the material and its source. 4.6.5 Plant

The Contractor must supply adequate compaction plant for compacting the bedding as required by these Specifications. 4.6.6 Construction of Bedding

The width shall accord with these Specifications. The material in the trench bottom which the Project Manager considers to be unsuitable from the bottom of the trench shall be excavated to the depths and disposed of as shown on the approved Contractor's Documents or as directed by the Project Manager. The resultant space shall be refilled with approved material and compacted. The depth of the trench and the trimming and grading of the bottom shall be such that the barrel of each length of pipe can be uniformly supported for its full length, free at the joints and at the correct grade and levels. Except above the trench excavation is rock, hard objects and boulders that may obviously affect the uniformity of the excavation shall be removed to a depth of 100 mm below the hard bottom. Where the hard bottom has been loosened during excavation, it shall be compacted to 90% Modified ASSHTO density to OMC prior to bedding and pipe laying The bottom of the trench shall be sufficiently straight to enable the pipes to be laid without reduction in side allowance.

Details of Bedding Details of pipe bedding shall accord with these Specifications or the approved Contractor's Documents or where directed by the Project Manager.

Placing No bedding shall be laid until the Project Manager has approved the trench, checked levels and authorised pipe laying to proceed. Except in the case of Class A Bedding, joint holes shall be refilled with granular material. In placing the bedding, all voids under the overhang of the pipe shall be filled and compacted in a uniform manner on each side of the pipe so as not to cause any lateral or vertical movement. Bedding shall be carried out as the pipe laying proceeds and shall be completed before the acceptance tests.

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Section VII. General Specifications 4.6.7 Compaction Density

The degree of compaction allowed for on the bedding, other than concrete, shall be 90% Modified AASHTO. 4.6.8 Placing and Compacting of Rigid Pipes Class A Bedding The Contractor shall construct Class A Bedding to the following requirements. The pipes shall be supported on a continuous cradle of concrete having a compressive strength of 20 MPa. During pipe laying and before the placing of concrete bedding, the pipes shall be suitably supported as approved by the Project Manager. Care shall be taken during the placing of the concrete to prevent movement or flotation from the line and level. In the case of pipes with flexible joints, concrete shall not be allowed to enter the joints during construction of the bedding. A positive vertical expansion joint in the bedding cradle shall be form at each pipe joint. The selected fill shall not be placed in any section until a period of 24 hours has elapsed. The main fill shall not be placed on any section until the compressive strength of the bedding has reached at least 15 MPa.

Class B and C Bedding The Contractor shall construct the bedding to the following requirements: The pipes shall be bedded on a continuous bed of selected granular material. To ensure that each pipe will be fully supported throughout the length of its barrel joint, holes shall be formed in the trench bottom for pipe sockets or couplings.

Class D Bedding (Storm Water Pipes) The Contractor shall construct Class D Bedding in according to the following requirements: The pipe hall be placed directly on the hard bottom after it has been hand trimmed to ensure each pipe will be fully supported throughout the length of the barrel. Joint holes shall be formed in the hard bottom for pipe joints or couplings. 4.6.9 Placing and Compacting of Flexible Pipes The Contractor shall construct bedding for flexible pipes according to the following requirements. Bedding Cradle Flexible pipes shall be supported on a continuous bed of selected granular material of compacted depth of at least 100 mm and covering the full width of the trench and compacted to a density of 90% Modified ASSHTO. Additional selected granular material shall then be placed carefully and evenly between the sides of the trench and the pipeline, in layers of uncompacted thickness of not less than 100 mm. Each level shall be compacted to the

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Section VII. General Specifications density specified above. Particular attention shall be exercised to prevent damage, deflection or displacement of the pipeline. 200 mm Selected Fill After compaction of the bedding cradle, selected fill shall be placed carefully in layers of 100mm uncompacted thickness over the full width of the trench and shall be compacted to 90% Modified ASSHTO up to a height of at least 300 mm above the crown of the pipe. Special care shall be taken when compacting over the pipeline. Density Tests The Project Manager will order density tests to be carried out by the Contractor to determine the density and grading of the Bedding. The costs of such density tests shall be deemed covered by the rates and prices of the Contract. If the material grading does not comply with these Specifications or the density is below that specified, the Project Manager may order the removal and compaction of material. The permissible deviation from OMC and density shall be as follows: OMC Specified Density for Rigid Pipes Specified Density for Flexible Pipes - 2% + 1% - 0% + 5 % - 0% + 3%

4.6.10 Bedding of a Special Nature Where special bedding conditions or concrete surround to pipes are required, details will be shown on the approved Contractor's Documents or as required by the Project Manager. The rates and prices of the Contract for this work shall include for any rough shuttering. 4.7 Minimum Cover to Pipes The minimum allowable depth of cover over the top of any pipeline will depend on site conditions and the type and classification of pipe as specified below. 4.7.1 Pressure Mains The minimum depth of cover from the final finished ground level to the top of the pipe shall be not less than: 500 mm for 50 mm and smaller galvanised steel piping; and 500 mm for 50 mm and smaller black polythene piping.

Asbestos cement or concrete pressure mains shall not have less than 1,000 mm cover under roadway surface levels, or 750 mm below ground level elsewhere. Should this occur on site, the Project Manager may direct the use of Steel pipe for those works. 4.7.2 Sewers Unless otherwise directed, the minimum depth of cover from final finished ground level to top of pipe shall not be less than: 500 mm for 100 mm sewers; and 750 mm for 150 mm and larger sewers.

Where the minimum cover is less than specified, the Project Manager may order the pipe to be encased in 200 mm of 10 MPa concrete. 4.8 Jointing of Pipes Pipes shall generally be laid and jointed in accordance with the manufacturer's recommendations. In obtaining approval for any manufacturers products, specific details of the jointing techniques to be employed shall also be provided by the Contractor.

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Section VII. General Specifications Joint spaces (gaps between pipe barrels) shall generally be governed by the manufacturer's recommendations unless otherwise indicated on the approved Contractor's Documents. Before putting together, the ends of all pipes and fittings and all couplings and flanges are to be inspected and cleaned to ensure that all parts forming the joint are clean and undamaged. 4.8.1 Flanged Joints In jointing flanged pipework, valves, etc., the jointing material, cut properly to size and holed for bolts, is to be inserted immediately before bringing the two flanges together. Before closing the joints, the flanges must be parallel with each other in position evenly distributed over the circumference of the flange. After the fittings have thus been aligned and well supported, the joint shall then be closed by bolting up all bolts to a uniform tightness. 4.8.2 Asbestos Cement Pipes Note above sub-clause 1.15 Asbestos Warning. The use of asbestos material is strictly prohibited. Cast iron short collar or long collar detachable joints and asbestos cement sleeve joints shall all be jointed strictly in accordance with the manufacturer's instructions. Special Steel joints may be used if CISCJ are not available. 4.8.3 Plain Ended Steel Pipes Plain ended steel pipes are to be jointed by means of Viking Johnson flexible (or other similar approved) couplings. The pipe ends are to be thoroughly cleaned but in the case of coated pipes, no coating shall be removed. If the coating on the ends or end faces is damaged, it shall be reconditioned by coating with quick drying bituminous solution. The joints shall be made strictly in accordance with the manufacturer's recommendations. Where continuous internal lining of the joints is specified, the sleeve of the coupling shall be correctly positioned and the lining completed with the correct equipment, all in accordance with the manufacturer's specification. This also applies to external moulding of the joints, but this shall not be carried out until the pipes have passed the specified pressure test on site. 4.8.4 Steel / Asbestos Cement Joint Note above sub-clause 1.15 Asbestos Warning. The use of asbestos material is strictly prohibited. Unless otherwise specified, joints between Steel and asbestos cement pressure mains shall be made by building up the ends of the Steel main to the OD of the asbestos cement pipe. The joint shall then be made using normal cast iron short collar joints or Viking Johnson couplings. 4.8.5 Screwed and Socketed Pipes Before making screwed and socketed joints, the threads shall be thoroughly wiped clean and then treated with a thin layer of approved jointing compound and yarn. The pipes and fittings shall then be brought into correct alignment and the joints screwed up tightly. Tightening of the joints must be obtained by screwing only. Caulking of thread shall not be resorted to and care shall be taken to avoid damage to pipe surfaces as may be caused by the improper use of tools, etc. Polythene piping shall be threaded and screwed to galvanised steel pipes and fittings in a similar manner. 4.8.6 Concrete Sewer Pipes using Rubber O-Rings Care is to be taken to ensure that the pipes are drawn up concentrically in accordance with the pipe manufacturer's instructions, to avoid damage to the joint surfaces and the rubber rings, and to ensure the provision of a water-tight joint in accordance with the specification.

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Section VII. General Specifications The position of the rubber O-ring shall be checked carefully by the use of feeler gauges as soon as the joint is made secure, and before the next pipe is brought into position. The filling and sealing of the inner peripheral joint space may be called for on large diameter sewers as directed by the Project Manager. 4.8.7 Cement Filled Spigot and Socket Pipes The pipe ends shall be thoroughly cleaned and wetted with water before the joint is made. Stiff 1:2 cement mortar shall then be placed in the lower half of the socket of the pipe section already laid. The spigot of the next pipe to be laid shall be inserted in the socket of the pipe already laid, the joint pulled or pushed up tight, taking care to see that the inner surfaces of the abutting pipe sections are flush and even. The socket all around the pipe shall then be packed full with 1:2 cement mortar, as dry as can be reasonably worked, well rammed home with a proper caulking tool, and finished off outside the pipe with a 45 degree level. All surplus mortar shall be removed from the inside of the pipe after jointing and the joints shall be properly cured by covering with damp sacking. The pipeline shall not be tested for at least 24 hours after the last joint has been made. 4.8.8 Special Joints Special joints shall be made strictly in accordance with the manufacturer's recommendations and with any special materials which may be required. 4.9 Pipe Laying Details and Procedures Pipeline details shall conform to these Specifications or approved Contractor's Documents. Pipe laying procedures shall comply with the following sub-sections. 4.9.1 Pressure Mains

(a) Asbestos Cement Joints At joints, a gap of 9.5 mm shall be left between pipes. All specials shall be jointed with Cast Iron short collar joints, and Fluid-tight joints used elsewhere. (b) Pipe Saddles Pipe saddles for water mains shall be installed strictly in accordance with the manufacturer's specification. (c) Bends On all pressure mains, bends shall be provided for curves and changes of direction and the Contractor shall lay them accurately to avoid any "cramping". Thrust blocks shall be constructed in accordance with these Specifications or approved Contractor's Documents at all bends, tee pieces and where directed by the Project Manager. No flexible joint will be permitted if any pipe deviates more than 3 degrees (250 mm in a length of 4 metres) from the line of the pipe to which it is jointed. Generally with pipes 375 mm diameter and over, the maximum deviation per joint will be two degrees for flexible joints. With the written authority of the Project Manager, the deviation at any one joint may be increased within the maximum deflection laid down by the manufacturers, but in this case special concrete supports of the pipes shall be carried out.

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Section VII. General Specifications (d) Scour Branches Level invert scour branches shall be provided to points as directed by the Project Manager. They shall be brought to ground level and provided with outlet boxes as indicated on the approved Contractor's Documents and as directed by the Project Manager. Wherever possible, the scour outlet should be above known flood levels. Washout hydrants shall be provided at points indicated or directed, and shall be finished off in the normal way in a hydrant box. (e) Disinfection of Water Mains Where mains to carry potable water have been laid and tested, and before they are commissioned to be put into service, they shall disinfected in the following manner. The pipes shall be thoroughly flushed out, and then filled with chlorinated water containing not less than 150 milligrams per litre of "Calcium Hypochlorite" or similar approved disinfectant, care being taken to eliminate all air from the main. This chlorinated water shall remain in the mains for at least 24 hours, after which the pipes shall again be thoroughly flushed out and refilled with pure water, care being taken to eliminate all air from the main. The Contractor must then notify the local Health Authority, who will arrange a bacteriological test at the Contractor's full expense. If this test proves unsatisfactory the Contractor must disinfect again the mains at his own full expense. (f) Tolerances (Permissible Deviation) Lateral Vertical (i) Control Points +75mm - 75mm Open Area +75mm -75mm 20% of NB Boundary +20mm -20mm +20mm -20mm

(ii) Alignment (Plan & Level) +10% of NB along centre line of pipe 4.9.2 Sewers

(a) Ventilation Ventilation columns in accordance with the approved Contractor's Documents or as directed by the Project Manager shall be installed where shown on the approved Contractor's Documents and as directed by the Project Manager. (b) Saddles When directed by the Project Manager, saddles shall be fitted to sewers. Saddles shall be fitted over the top of the sewers, and particular care shall be exercised when cutting into the sewer to prevent broken pieces of pipe barrel from dropping into the sewer. The saddle shall be bedded on a 1:2 cement mortar, and the whole unit encased in 100 mm of 15 MPa concrete.

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Section VII. General Specifications (c) House Connections These shall be constructed in accordance with the approved Contractor's Documents from manholes and inspection chambers on the main sewer. The end of the connection shall be plugged, using a 1:3 cement mortar water 20 mm thick of suitable diameter fixed into the pipe socket with 1:12 cement caulking or approved clay. (d) Ramps and Backdrops These shall be constructed as detailed on the approved Contractor's Documents and care must be taken when positioning them in the manhole to facilitate rodding. (e) Tolerances (Permissible Deviation) Lateral Open Area +150mm +150 mm 1/2 pipe length -----------------

Vertical (IL) (i) Centreline Control +5mm -5mm (ii) Manhole Location at +5mm -5mm Control Points (iii) Manhole not located at +5mm -5mm Control Points (iv) House Connections +5mm -5mm 4.10 Testing Pressure Mains

Boundary +75mm -75mm +75 mm -75mm +75mm -75 mm +300mm -300mm

4.10.1 General Pipelines shall be tested in convenient lengths as the work proceeds, by means of test equipment supplied by the Contractor at his own cost. Each test shall be carried out in the presence of the Project Manager. The Contractor shall be responsible for carrying out all tests and for all expenses incurred in this work. When carrying out the hydraulic test, the Contractor shall ensure that all valves, tees, and bends are properly secured and shored to prevent movement of pipes and fittings. Should any such movement occur, the Contractor shall, at his own full expense, reposition and, if necessary, repair the pipes and fittings and the securing means. Until each section of the pipeline has been subjected to the pressure test and has complied with the applicable requirement for leakage rate given in these Specifications, the pipeline will not be accepted. The test shall be repeated until the Project Manager is satisfied that the section under test complies with the said requirement. 4.10.2 Standard Hydraulic Pipe Test Unless otherwise ordered, hydraulic testing shall be commenced only after permanent anchor blocks have attained their specified strength, i.e. after 28 days. After the pipe trench has been partially backfilled and before the trench is filled in at the pipe joints and the fittings, the pipeline shall be tested in sections between isolating valves and/or end caps, blank flanges, or other isolating devices, at the pressure given below appropriate to the type and, when relevant, class of pipe in the pipeline under test. Where mixed types or classes of pipe occur, and where the pipeline traverses a wide range of altitudes, the Project Manager may require that temporary valves or blank flanges be inserted and that the pipeline be tested in reduced lengths and, in addition, at the point of maximum pressure. The test pressure applied over any section of pipeline under test, taking any difference in elevation along the pipeline into account, shall be such that the pressure at any point along

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Section VII. General Specifications the section is not less than the design pressure or greater than 1.5 times the design maximum working pressure of the pipe at these points. The field test pressure shall not exceed the appropriate of the following values: Asbestos Mild Steel Reinforced Concrete Prestressed Concrete Flanged cast iron Black polyethylene UPVC 75% (of the test pressure for pipe class) 75% (of minimum specified yield stress) 75% (of the test pressure for pipe class) 75% (of the test pressure for pipe class) 67% (of works test pressure) 100% (of working pressure of pipe class) 150% (of working pressure of pipe class)

Where circumstances permit, in the case of asbestos cement and concrete pipes, each section shall be filled 24 hours before the test pressure is applied to ensure saturation of the pipeline. Care shall be taken to ensure that all air is expelled from the line to be tested after it has been filled and before the test commences. 4.10.3 Visible Leaks The specified test pressure shall be maintained for a period of at least three hours (or such longer period as is necessary for inspection of the pipeline) by means of a suitable pump, during which period all pipes, specials, joints, and fittings shall be carefully inspected for leaks. All visible leaks shall be made good and any pipe, special, or fitting found to be defective shall be removed and replaced at the expense of the Contractor and such replacement material shall, after installation, be tested at the full expense of the Contractor. In the case of pipes of nominal diameter under 400 mm, the test period may be reduced proportionally to the nominal diameter of the pipe, provided that in no case shall the test period be less than one hour. 4.10.4 Permissible Leakage Rates The test pressure shall be maintained for a further period of one hour after the completion of the procedure given above, during which time the volume of water required to be pumped into the pipeline for maintenance of the pressure shall be measured. No additional water shall be required in the case of continuously welded Steel pipes, and in other cases the volume shall not exceed the value, in liters, calculated from the applicable of the following formulae: (a) Asbestos cement and concrete pipes and concrete lined steel pipes: x diameter of pipe in millimetres x length of test section in kilometres x square root of the test pressure in mega-pascals Jointed pipes in steel, cast iron, black polythene, and UPVC: x diameter of pipe in millimetres x length of test section in kilometres x square root of the test pressure in mega-pascals Testing of Sewers 900 mm Diameter and Below

(b)

4.11

In the presence of the Project Manager, the Contractor shall test all pipe drains, sewers and associated house connections by means of an air test before the pipe trench is filled. The Project Manager shall carry out a line and level test on the main at the same time. The Contractor shall carry out the testing as the work progresses between manholes or as directed by the Project Manager and he shall provide all necessary testing apparatus, including expanding plugs, flexible bag stoppers, suitable air testing machine, etc..
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Section VII. General Specifications The length of pipe to be tested shall be properly plugged and air pumped in by suitable means until a pressure of 100 mm of water is indicated in a glass U-tube and the pressure indicated by the U- tube be observed. Should the pressure fall below 75 mm of water within a period of 5 minutes, the length under test shall be deemed to have failed and the Contractor shall make good, at his own expense, any defects in materials or workmanship until the test is satisfactory to the Project Manager. The Contractor shall also carry out such test in a like manner on approximately 10% of all sewers laid, between one and two months after back-filling and man-hole construction has been completed. This post backfilling test will not be an acceptance test. The results will be recorded by the Project Manager as the time taken for the pressure to drop from 50 mm to 25mm of water. Sewers of 1050 mm diameter and above will be concrete and are not required to be tested, but all internal joints shall be sealed as specified in these Specifications. In the event that the air test on concrete pipes as specified fails the Contractor may, at no additional cost to the Employer, carry out a water test as follows: The length under test shall be stopped at each end, with adequately designed plugs to allow the filling of the main with water and to allow all air to escape. The plugs must be suitably propped to prevent movement during the test. After filling, the pipe shall be kept at a slight pressure for five days in order to allow the concrete to absorb the water. During this period all joints and the plug shall be inspected for leaks. The test shall be carried out over a period of three hours and shall be at a head of 1.5 m. The loss in the pipeline shall not exceed 0.5 litres/mm (dia.)/km (length)/hour. Major Road Crossings

4.12

Where a trench or pipe crossing passes underneath a major road, the following procedures shall be adopted by the Contractor. The minimum cover over any pipe shall be one metre beneath the carriageway. The trench shall be backfilled in layers not exceeding 150 mm in thickness with selected material moistened and mechanically compacted layer-by-layer. The trench shall be completely back-filled in this manner and maintained for a period of not less than three months so that the level of the trench surface remains as nearly as possible level with the bituminous road surface adjoining it. At the end of that period, the backfilled material shall be excavated to a depth of 250 mm below the adjoining road surface and replaced with selected base gravel stabilised with 5% of cement to restore the trench to the level of the adjoining road surface. Road crossings shall be carried out in such a manner as to cause the minimum obstruction to the free passage of road traffic, and where possible in half widths. The Contractor shall provide adequate watching, lighting, signposting, barricading and control of traffic to ensure the safety of the road user and of the works. Traffic signs, barricades, and lights shall be in a satisfactory condition to perform the required duty. Advance warning signs between 150 m and 250 m from the construction work or deviation may be required by the Project Manager. Flag men shall be employed whenever required for safety. The cost of providing watching, lighting, signposting, barricading and flagmen shall be deemed covered in the rates and prices of the Contract.

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Section VII. General Specifications The Contractor shall accept responsibility at his own expense for any repairs to the road surface arising from poor workmanship in the backfilling of the trench until the end of the Defects Liability Period. 4.13 Railway Crossings Where a pipeline crosses beneath a railway line, the Contractor shall be responsible for ensuring that the work is carried out in such a manner as to cause no obstruction to any railway traffic on the line. The Contractor shall notify the Railway Authorities a minimum of two weeks before any work is done, informing the Authorities of the date of proposed works, in order that railway attendance may be provided for the purpose of warning traffic on the line that work is in progress. Any pipe crossing beneath the railway line shall be sleeved in a Steel pipe of suitable diameter with welded joints extending for a minimum distance of three metres either side of the centreline of the railway line or such other distance as may be directed by the Project Manager. When a pipe crossing is in heading, the Contractor shall be responsible for ensuring that the backfilling of the heading is carried out in a thoroughly competent manner. If such backfilling is not carried out in a satisfactory manner, the Project Manager may order that the backfilling be done using 10 MPa mass concrete at the Contractor's own full expense. The rates and prices of the Contract for the excavation of a pipe crossing beneath a railway line shall include for all risks and work involved in construction the crossing and for the cost of the attendance supplied by the Railway Authorities. 4.14 Measurement for Pipelines 4.14.1 Scheduled Items (a) Supply, Lay, and Bed Pipes Complete with Couplings Unit Pipelines shall be measured by length over all lengths as laid. No deduction will be made for specials and valves. Separate items will be scheduled for each diameter and each type and class of pipe laid. The rates of the Contract shall cover to cost of the provision of the pipes complete with couplings, and the costs of the handling, inspecting, transporting, bedding, laying, jointing, cutting, testing and, when relevant, disinfecting of the pipes and the joints. (b) Extra over (a) above for the Supplying, Laying, Unit and Bedding of Specials complete with Couplings Extra over (a) above for the Supplying, Fixing, and Bedding of Valves Unit Specials and valves shall be measured by the number of each type, class, and size. The rates and prices of the Contract shall cover the cost of the provision of each special or valve, complete with couplings, and the cost of the handling, fixing, bedding and testing of the special or valve, as applicable, and the cutting of the pipes. No extra payment over and above the rates will be made in respect of any additional cutting, turning, and jointing of pipes required for the location of valves, specials, etc., exactly in the positions given on the approved Contractor's Documents or as directed by the Project Manager. Unless specified provision is made in the Contract, no separate payment will be made for the supply and fitting of any additional joints and jointing materials which may be required for the connection of shortened pipe lengths.

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Section VII. General Specifications (c) Extra for the Cutting of the Pipe and the Supplying and Fixing of the Extra Coupling Measurement shall be according to the quantities of scheduled items. The rates and prices of the Contract shall cover the cost of the cutting of the pipe and of the supplying and fitting of the additional coupling. (d) Supply and Place Pipes, Valves and Specials (Short Pipe Runs) Short pipe runs that include frequent bends or other specials, or both (as, for instance, in a pump station, reservoir, or a deviation of a major water main under a road or round a bridge) shall be measured in terms of the quantities of scheduled items such as bends, tees, reducers, valves and stated lengths (or lengths stated to be approximate) of straight pipe. The rates and prices of the Contract shall cover the provision of each pipe, special, and valve and, as applicable, the fixing, anchoring, or bedding of them in the manner shown on the approved Contractor's Documents or required by the Project Manager. (e) Extra over for Encasing Joints Where wrapping or protection of joints etc. in corrosive soils is ordered by the Project Manager, payment will be made as an extra over per joint. Measurement shall be according to the quantities of scheduled items. The rates and prices of the Contract shall cover the cost of the material, plant, and labour necessary for the completion of the joint. (f) Recover Old Pipeline

The total length of the pipeline ordered to be recovered will be measured by length for each stated depth range. No deduction will be made for valves, specials, and the like. The rates and prices of the Contract shall cover the cost of the excavation and removal of the pipes, valves, and fittings from the trench, the handling and transporting to the Contractor's store on site, the cleaning and listing of the salvaged recovered materials, and the backfilling of the trench. (g) Test Recovered Pipes on Site before Relaying Measurement shall be according to the quantities of scheduled items. The rates of the and prices of the Contract shall cover the cost of the provision of suitable testing equipment and the carrying out of the specified test. (h) Relay Pipeline The rates and prices of the Contract shall cover the cost of the transporting, handling, laying and bedding, as well as the provision of new rubber rings or insertions, as the case may be. (i) Joints and Couplings for Recovered Pipeline

Measurement shall be according to the quantities of scheduled items. The rates and prices of the Contract shall cover the provision of complete sets, each comprising a new rubber ring or insertion, as the case may be, as well as all elements of the coupling and bolts that need replacement. (j) Temporary Valves and Fittings

Payment for the supply or loan of temporary valves, end caps, blank flanges, or other isolating devices required shall be included in this item. Measurement shall be according to the quantities of scheduled items.

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Section VII. General Specifications No pipe end during construction will be allowed to be left open until the final connection is made and the Contractor shall allow in his rates for the supply and installation of end caps or flanges on a temporary basis. Failure to comply with this will result in all pipe work being thoroughly flush out to ensure no animals etc. are in the pipe before chlorination takes place, in which case the Contractor shall bear the full expense to comply. (k) Anchor/Thrust Blocks and Pedestals Concrete Formwork Reinforcement Unit m3 Unit m2 Unit kg

Anchor/thrust blocks and pedestals shall be measured as the volume of concrete, area of formwork, and mass of reinforcement, as relevant, placed to dimensions specified or shown on the approved Contractor's Documents or as directed by the Project Manager. (l) Concrete Casing

Concrete will be measured net by volume to the specified width and depth in excess of the external volume of the pipe (i.e. the volume of the pipe will be deducted.) The rates and prices of the Contract shall cover the cost of formwork (including stop ends at flexible joints) and concrete. (m) Valve and Hydrant Chambers Valve and hydrant chambers, manholes etc. shall be measured as complete units. Measurement shall be according to the quantities of scheduled items. The rates and prices of the Contract shall cover additional excavation, materials, plant, and labour necessary for the complete construction, including the installation of the surface boxes or covers. (n) Special Wrapping in Corrosive Soil Measurement shall be according to the length of pipe to be wrapped. The rates and prices of the Contract shall cover the cost of the provision and fixing of the wrapping and the cost of any delay and inconvenience caused by the requirement to wrap. 4.14.2 Measurement (Sewer and Storm Water Pipes) The operation of constructing the bedding cradle and selected fill blanket around and over the top of the pipeline shall be regarded as part of the pipe laying operation. 4.14.3 Scheduled Items (a) Supply, Lay, Joint, Bed, and Test Pipeline The pipeline shall be measured linearly on slopes overall as laid. No deductions will be made for specials, but deductions will be made for the internal length of manholes. (b) Extra over Item for Specials Measurement shall be according to the quantities of scheduled items. The rates and prices of the Contract shall cover the cost of supplying, laying, bedding, jointing and testing each special. (c) Encasing of Pipes in Concrete to Prescribed Mix The volume will be computed from the amount as encased in the actual works according to the dimensions shown on the approved Contractor's Documents.
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Section VII. General Specifications The rates and prices of the Contract shall cover the cost of dealing with any excavation (in all materials including disposal of surplus) that is additional to that measured under the item for pipe trench excavation, the cost of encasing the pipe in concrete, the cost of formwork, if any, for encasing the pipe, and the cost of formwork to form flexible joints at 4-metre centres. (d) Anchor Blocks The rates and prices of the Contract shall cover the cost of all work necessary to complete the construction of an anchor block. (e) Marker Posts The rates and prices of the Contract shall cover the cost of manufacturing, installing, painting the identification marks, and submitting to the Project Manager the records of all marker posts. (f) Permanent Plug Stoppers

The rates and prices of the Contract shall cover the cost of supplying and fitting plug stoppers at the ends of pipes, where so ordered by the Project Manager. (g) The Raising or Lowering of Existing Manholes The rates and prices of the Contract shall cover the cost of removing the cover and frame, demolishing the top of the manhole if required, providing materials and labour for rebuilding the manhole to the designated new level, and setting and grouting the cover and frame to the correct level as approved by the Project Manager. 4.14.4 Measurement and Payment of Bedding for Water, Sewers and Storm Water. The rates and prices of the Contract shall include the cost of acquiring approved bedding material not exceeding 500 m distance, and which complies with these Specifications and the costs of delivering the material points alongside the trench spaced to suit the Contractor's method of working and of disposing of displaced material within a free haul of 500 metres as approved by the Project Manager. Provision of Bedding from Trench Excavation (a) Selected granular material (b) Selected fill material Unit : Lineal m per pipe dia. Unit : Lineal m per pipe dia.

Provision of Bedding from Borrow Pits (a) Selected granular material (b) Selected fill material Unit : Lineal m per pipe dia. Unit : Lineal m per pipe dia.

Provision of Bedding from Commercial Sources (a) Selected granular material (b) Selected fill material Concrete for Bedding Cradle Unit: Lineal metre per pipe dia . The rates and prices of the Contract shall cover the costs of providing and placing the concrete screed and cradle and forming. Unit : Lineal m per pipe dia. Unit : Lineal m per pipe dia.

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Section VII. General Specifications Flexible Joints Unit: Number per pipe dia. Flexible joints shall include for all formwork and filler material 15 mm wide using a kaylite or similar approved material. Overhaul of Imported Material for Bedding Cradle and Selected Backfill Unit: m3-km This item is applicable to material hauled for a distance in access of 0.5 km with the written approval of the Project Manager. The volume shall be compacted as specified in these Specifications. The distance shall be determined on the basis of the shortest practical route in one direction measured to the nearest 0.1 km.

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Section VII. General Specifications

5 5.1

BUILDING WORKS Plastering and Walling Linings General DO NOT BEGIN coating work until all: 1. Required openings, chases or other apertures have been cut. 2. Pipes, fixtures and fixing pads have been fixed. 3. Making good of structure has been completed.

5.1.1 a)

b) c) d) e)

PROTECT: All existing work and approaches with boards, dust sheets, etc.. All droppings onto finished work to be cleaned off immediately. PROTECT: All concrete surfaces from contamination by gypsum plaster. CLEANLINESS: Ensure that all plant and tools are kept clean and free from previous mixes. MECHANICAL APPLICATION: Where necessary, adjust type and grading of sand and consistency of mix to Project Manager's approval. Ensure that the standard of coating is not less than that applied by normal manual methods. MECHANICAL APPLICATION OF GYPSUM PLASTERS: Do not use mechanical coating methods for the application of gypsum plaster. DRYING OUT: Prevent excessively rapid or localised drying out. MAKE GOOD: Defective or damaged coating before decoration. SAMPLE PANEL: Provide a one m2 sample panel of any coating required by the Project Manager and obtain his approval of colour and texture before starting work. Materials CEMENT shall conform to SAZS 307. LIME shall conform to SAZS A.15. SAND FOR PLASTERING shall conform to BS 1191 for gypsum plasters and BS 1198 for external rendering and internal plastering with lime and Portland Cement. WATER: Unless drawn from a public source of supply shall, if required by the Project Manager, water shall be treated and approved in conformity with BS 3148. RETARDED SEMIHYDRATE GYPSUM PLASTER shall conform to the relevant Clauses BS 1191: Part 1. Use with sand for undercoats in wet areas. ANHYDROUS GYPSUM PLASTER shall conform to the relevant Clauses of BS 1191: Part 1. Use for finishing coasts except in wet areas. METAL LATHING for plastering shall conform to BS 1369. Fix in accordance with manufacturer's instructions. PACKAGING: Branded materials shall be delivered to site in their original packages, bearing the trade name of the material concerned. GYPSUM PLASTERBOARD OR LATH: Shall conform to SAZS A42. Fix in accordance with manufacturers instructions. Preparation of Backgrounds: Trims and Joints METAL BEADS, STOPS AND LATHING: Protect cut edges with bitumen coating solution.

f) g) h) i) 5.1.2 a) b) c) d) e) f) g) h) i) 5.1.3 a)

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Section VII. General Specifications b) DISSIMILAR BACKGROUNDS: Where specified, at junctions between dissimilar backgrounds in the same plane and with the same coating, fix steel lathing with 38 mm clout nails or with staples. Fix into drilled and plugged holes or into fixing bricks or plugs built in or cast in: 1. At single junction, lathing to be not less than 300 mm wide, fixed each edge at 100mm centres. 2. At columns, lathing to extend not less than 150 mm beyond each junction, fixed each edge and central at 100 mm centres. c) SCRIM: Where specified bed 90 mm wide jute scrim centrally over joints in neat plaster similar to first coat. Do not lap ends. Press well in, trowel flat and smooth and allow drying before applying coating. SCRIM TAPE: Fix gauze anti-rust scrim to joints between gypsum plaster-boards or plaster-lathes in accordance with manufacturer's instructions. Preparation of Backgrounds: Surfaces PROJECTIONS: Hack off projections and concrete feathers. VOIDS: Before applying single coat thin-wall plasters of less than 2 mm thickness, prepare surfaces by filling holes, scratches and voids with finishing plaster. BRUSHING: Remove afflorescence, laitance, dirt and other loose material by thoroughly dry brushing. SCRUBBING: Remove all traces of mould oil, paint, grease, dirt and other materials incompatible with plaster work by scrubbing. HACK SURFACES: Where directed by Project Manager, hack back surfaces thoroughly and evenly to depth of 3 mm keying approximately a third of the area. SOLID BACKGROUNDS: Before coating, adjust porosity to give uniform suction. PROPRIETARY BONDING AGENTS: May be used with approval of Project Manager. Use in accordance with manufacturer's instructions. Plaster Mixes LIME-SAND MIXES: Mix in the following proportions :

d) 5.1.4 a) b) c) d) e) f) g) 5.1.5 a)

TABLE 1 COAT UNDER COAT FINISHING COAT b) c) BY VOLUME lime putty, hydrated lime or sand slaked lime 1 part 2 - 3 parts 1 part up to 3 parts

CEMENT - LIME - SAND MIXES: In the above proportions. GYPSUM PLASTER - SAND MIXES: Mix in the following proportions:

TABLE 2 BY VOLUME retarded hemihydrate sand gypsum plaster and 1 part 1 3 part

1st & 2nd finishing coat

undercoats

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Section VII. General Specifications d) 5.1.6 a) b) SKIM COATS ON PLASTER BOARD: Use only gypsum plaster as instructed by the manufacturer. Applying Plaster/Internal Rendering MANUFACTURER'S INSTRUCTIONS: Apply all proprietary special-purpose plasters in accordance with their manufacturer's instructions. ACCURACY: Finish surfaces to a true plane to correct line and level, with all angles and corners to a right angle unless otherwise specified, and with walls and reveals plumb and square. DUBBING OUT: If necessary to correct in accuracies, dub out in thicknesses of not more than 10 mm in same mix as first coat. Allow to dry out before next coat is applied. Cross scratch surface of each coat immediately after set. METAL MESH: Work undercoat well into interstices to obtain maximum key. APPLY each coat firmly to achieve good adhesion, rule to even surface. CONDUITS AND PIPES bedded in undercoat are to be covered with 90 mm wide jute scrim bedded in finishing coat mix, pressed flat and trowelled in. Do not lap ends of scrim. SETTING: Apply subsequent coats of gypsum and light-weight plasters as soon as undercoat has set, is firmly bonded to background, and has developed reasonable suction. DRYING : 1. Allow cement based undercoats to dry out thoroughly to ensure that drying shrinkage is substantially completed before applying subsequent coat. 2. DO NOT allow coats of anhydrous gypsum plaster to dry out before setting is complete. Do not damp coats before or after setting. i) j) k) l) 5.1.7 a) b) c) d) ARRISES: Round arises to be formed with suitable arising trowel. INTERNAL ANGLES to be formed with angle trowel. DISSIMILAR BACKGROUNDS: Where specified, form neat straight V-joints at junction of different solid background materials. EXPANSION JOINTS: Ensure that V-joints in plaster are over structural joints beneath. Finishes to Plaster/Internal Rendering SMOOTH FINISH: Finish to a smooth steel trowelled surface, free from blemish, do not use water brush or excessive trowelling. WOOD FLOAT FINISH: Finish with a dry wood float as soon as wet sheen has disappeared from surface to give an even overall texture. ROUGH TEXTURED STRIPPLED FINISH: Finish with a cork, carpet or other float to provide a rough but even open-textured surface to approval BLOCK BRUSH BAGGING: Where specified to fair-face brickwork or concrete; to be applied by dipping a block brush into a cement-lime-sand mix and rubbing well into the backing to fill all holes and cracks and bring to an even texture. Fibrous Plaster Works MANUFACTURE: Fibrous plaster mouldings or sheets to be manufactured by an approved firm of specialists.

c)

d) e) f) g)

h)

5.1.8 a)

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Section VII. General Specifications b) FIX prefabricated gypsum plaster mouldings or sheets to solid background by drilling, plugging and nailing with suitable galvanised clout nails at centres as directed by the Project Manager. MITRE prefabricated gypsum plaster mouldings to required angles using a fine-toothed saw. Finish cut edges by lightly sandpapering to a smooth finish. DO NOT PLASTER over pre-fabricated gypsum plaster mouldings or sheets. VENTILATOR GRILLES: Bed levels and flush to as directed, 230 mm x 150 mm ventilator grilles in finish coat and fix true to line. All grilles to be copper or aluminum gauzed backed. Design to be approved by the Project Manager before fixing. External Rendering ACCURACY: Finish surfaces to a true plane to correct line and level, with all corners and angles to a right angle unless otherwise specified, and with walls and openings finished plumb and square. DUBBING OUT: If necessary to correct inaccuracies, dub out in thicknesses of not more than 10 mm in same mix as first coat. Allow to set before next coat is applied. Cross scratch surface of each coat immediately after set. UNDERCOATS FOR HAND FINISHING: Apply with trowel either by laying on or throwing. Leave rough and cross scratch without penetrating through the coat, to provide key for hand applied finishing coat. UNDERCOATS FOR MACHINE FINISHING: Level with straight edge and rub lightly with wood float to receive machine applied finishes. Do not scratch. WET undercoat thoroughly to maintain plasticity while applying textured or dry dashed finishes. DRYING: Prevent each coat from drying out too rapidly. If necessary, spray with water in hot weather. BRUSH DOWN each undercoat to remove dust and loose particles and wet thoroughly before application of next coat. FINISHES: Apply from top to bottom to give surfaces without joints. If joints are unavoidable, position to approval of the Project Manager. WOOD FLOAT FINISH 1. Apply to a uniform thickness 2. Finish with wood or other suitable faced float to give an even texture. 3. Do not overwork surface or use steel trowel to finish. j) k) TYROLEAN FINISH: Apply top coat with an approved hand operated Tyrol machine to give an even finish. BLOCK BRUSH BAGGING: Where specified to fair-face brickwork or concrete; to be applied by dipping a block brush into a cement-lime-sand and rubbing well into the backing to fill all holes and cracks and bring to an even texture. TILES: Glazed ceramic wall tiles are to be of first quality, from an approved manufacturer and shall confirm to SAZS 103 CEMENT RENDER: Ensure that rendering is at least 14 days old, firmly bonded to its background, free from dust with surfaces plumb and true to +/- 3 mm in any 2000 m.
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c) d) e)

5.1.9 a)

b)

c)

d) e) f) g) h) i)

5.1.10 Glazed Ceramic Wall Tiling a) b)

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Section VII. General Specifications c) d) e) f) g) h) i) j) k) PAINTED SURFACES: Remove soft or flaking paint be mechanical means. Do not use paint strippers. FIX tiles with adhesive in accordance with instructions of adhesive manufacturer. THICK BED: Butter each dry tile evenly and tap firmly into position ensuring that bed is solid under whole tile, and not more than 12 mm thick. ADJUSTMENT: Make any necessary adjustment to tiles immediately after bedding. CLEAN OFF tiles as soon as bedding is complete. JOINTS to be even and not more than 2 mm wide, as required by the Project Manager. ACCURACY: Fix tiles to a finished surface that is plumb and true to +/- 2 mm in any 2000 mm. MOVEMENT JOINTS: Provide not less than 6 mm wide, as required by the Project Manager. GROUT by pressing white or tinted cement mix firmly into joints, working in areas of not more than 1 m2. Clean off surplus grout as work proceeds. Water soluble grout will not be permitted. FINISHING: Clean off and polish tiles at completion. WATER: Do not allow water on new tiling until bedding and grouting are completely set. MOSAICS: To be glass or ceramic of shape, colour, pattern and manufacture, as approved by the Project Manager. CEMENT RENDER: Ensure that render is at least 14 days old, firmly bonded to its background, free from dust, with surfaces plumb and true to +/- 3 mm in any 2000 m. ACCURACY: Fix mosaics to a finished surface that is plumb and true to +/- 2 mm in any 2000 m. PAPER BACKING: If paper backed, soak off paper backing not less than three days after fixing. Leave on for protection as long as possible. GROUT by pressing white or tinted cement mix firmly into joints working in areas of not more than 1 m2. Clean off surplus grout as work proceeds. Water soluble grout will not be permitted. FINISHING: Clean off and polish mosaics at completion. PROTECT external mosaics from inclement weather until grouting has completely set. WATER: Do not allow water on to new mosaics until bedding and grouting are completely set. APPLICATION shall be by a specialist approved by the Project Manager. SAMPLE: Prepare 1 m2 sample panels of the finish for the approval of the Project Manager and retain until completion of the works. UNDERCOAT: Apply the undercoat 15 mm thick with a cement and sand mix 3:1 and bring to a fine wood float finish. MIX: In-situ terrazzo to be composed of one part by weight of white cement tinted to an colour and two parts of marble chippings of size and colour, all as approved by the Project Manager.

l) m) a) b) c) d) e)

5.1.11 Mosaic Linings

f) g) h)

5.1.12 In-Situ Terrazzo a) b) c) d)

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Section VII. General Specifications e) f) g) h) i) COMPACTION: Lay top coat immediately after undercoat and compact until all excess water is expelled to give a finished thickness of 15 mm. TROWEL to a smooth surface until about 85% of the marble chips are exposed. CURING: Keep the terrazzo moist for at least three days with clean wet hessian. POLISHED FINISH: Wash and polish with grinders to a lightly polished surface to show an even pattern of stone and cement. ACCURACY: Finish surfaces to a true plane to correct line and level, with all corners and angles to a right angle unless otherwise specified by the Project Manager, and with walls and openings finished plumb and square. SAMPLES: Samples shall be approved before placing bulk orders. SHAPE shall be straight, without twist and sag and to correct profile and finish. DAMAGE: Shipped, cracked or otherwise defective items shall be rejected. JOINTS IN PRECAST CILLS/SLABS: Positions of joints to be approved by Project Manager. BEDDING: Bed cills/slabs solid in cement-sand bed not less than 15 mm thick. POINTING: Point by pressing mix approved by the Project Manager firmly into joints to approved profile. Clean off surplus as work proceeds. FINISHING: Clean off and polish at completion. Building Limes Gypsum Plaster Board Portland Cement Glazed Ceramic Wall Tiles and Fittings Gypsum Building Plasters Part 1: Excluding Premixed Lightweight Plasters Building Sands from Natural Sources. Building Sands from Natural Sources. Metal Lathing (Steel) for Plastering. Tests for Water for Making Concrete.

5.1.13 Cills/Slabs a) b) c) d) e) f) g)

5.1.14 List of Codes and Standards SAZS A.15 SAZS A.42 SAZS 307 SAZS 103 BS 1191 BS 1198 BS 1199 BS 1369 BS 3148 5.2 5.2.1 a) b) c) d) e) f) g)

Brickwork Bricks/Blocks SAMPLES: Submit samples of each type of brick and block and obtain approval from the Project Manager before placing orders with suppliers. FACING BRICK SAMPLES: Deliver to site first load of facing bricks for approval from the Project Manager before bulk delivery starts. HANDLING: Unload and handle bricks and blocks without soiling, chipping and other damage. STORING: Stack bricks and blocks on level hard-standings. SAND-LIME BRICKS shall conform to SAZS 319. CONCRETE BLOCKS: Solid, hollow and aerated shall conform to SAZS 119. PRECAST SAND CEMENT BLOCKS shall conform to SAZS 119.
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Section VII. General Specifications h) i) j) k) 5.2.2 a) b) c) d) 5.2.3 a) b) c) CLAY BRICKS shall conform to SAZS 221 with the provision that the maximum absorption in accordance with Section 9 of SAZS 221 shall not exceed 15%. CLAY BLOCKS shall conform to SAZS 221 with the provision that the maximum absorption in accordance with Section 9 of SAZS 221 shall not exceed 15%. SAND CEMENT BRICKS shall conform to SAZS 306. FIRE BRICKS shall conform to the tests in BS 2972. Materials for Mortars CEMENT shall conform to SAZS 307. BUILDING LIME shall conform to SAZS A.15. MASONRY CEMENT shall conform to SAZS A.22. SANDS for mortars shall conform to BS 1199 and 1200 using Table 1 for General Purpose Mortars and Table 2 for Reinforced Brickwork Mortars. Making Mortars MORTARS GENERALLY: Mix constituents to proportions specified in Table 1 of BS 1199 and 1200 SAND: Proportions of mixes given are for dry sand. Allow for bulking. GAUGE BOXES: Measure mortar constituents by volume, using clean gauge boxes made to suit volumes required. Over-full gauge boxes and strike-off excess material with straight edge. PLASTICISER may be added as instructed by the manufacturer. Do not over-mix mortars containing plasticisers. ADMIXTURES: Do not use admixtures, other than plasticisers or pigments, without prior approval from the Project Manager. DRY ADMIXTURES: Dissolve in mixing water for each batch of mortar. MIX MORTAR: By mechanical mixer or by hand on a clean level banker board or other impervious surface as approved by the Project Manager. Mix thoroughly so that all individual constituents are incorporated evenly. KEEP MIXER CLEAN at all times and discharge mortar on to a clean level banker board or other impervious surface as approved by the Project Manager. USE MORTAR within two hours of discharge from mixer at normal temperatures. In no case must mortar be used after the initial set has taken place. Reconstitution of mortar will not be permitted. Mortars for Brickwork

d) e) f) g)

h) i)

5.2.4

TABLE 1 Grade Limited Proportions Measured by Volume Cement (2) 1 1 Lime (3) 0- 0 - 1 Sand (4) Not exceeding 4 Not exceeding 6 Minimum Required Compressive Strength MPa (at 28 days) (5) 10 5

(1) 10 5

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Section VII. General Specifications a) b) MORTARS to be one of the Grades shown in Table 1 of Section 5.2.4 above and shall achieve the minimum compressive Strength shown in Column (5). MASONRY CEMENT may be used in lieu of cement and lime and shall where Grade 5 mortar is permitted but mixed in accordance with the manufacturers instructions. The same strength shall be obtained. USE OF MORTARS: Use the mortars specified in Table 1 of Section 5.2.4 above in the following locations unless directed otherwise by the Project Manager: 1. Grade 10 mortars in all work below CPC level and in any brickwork above roof level and in arches and reinforced brick lintels and flues. 2. Grade 5 mortars in all situations except those specified for Grade 10. 3. Masonry cement mortar may be used in all situations where Grade 5 mortar is permitted. d) e) 5.2.5 a) MORTAR FOR DESIGNED BRICKWORK shall be specially specified for each situation by the Project Manager. BLAST FURNACE CEMENT: Where blast furnace cement is used in mortar, keep brickwork damp for seven days after laying. General SAMPLE PANELS: Prepare sample panels 1 m x 1 m approximately of each type of face brickwork including jointing or pointing and obtain approval of Project Manager before proceeding. WET BRICKS: Wet clay bricks and clay blocks as necessary to prevent mortar drying out prematurely. PROTECTION: Protect freshly laid brickwork / blockwork during rain and at the completion of each day's work. PROTECT FACEWORK: Protect with PVC or other waterproof sheet and keep clean during construction until practical completion. Turn back scaffold boards at night and during heavy rain. Protect salient angles with boards. Laying COLOUR MIXING: Distribute facing bricks of varying colour evenly throughout the work so that no patches appear. Mix different deliveries which vary in colour to avoid horizontal stripes. FROGS: In all load bearing walls lay single frog bricks with frog upper-most, double frog bricks with deeper frog uppermost, and fill all frogs with mortar. UNIFORMITY: Carry up work including both skins of cavity work, with no portion more than 1500 m above another at any time, raking back between levels. Block bonding will not be permitted. GAUGE of bricks to be approved by Project Manager before laying. BED BRICKS: Lay bricks on a full bed of mortar and fill all joints. Make bed joints of equal and consistent thickness but not more than 12 mm. BED SOLID BLOCKS: Lay solid blocks on a full bed of mortar with joints filled solid to a consistent thickness but not more than 12 mm. BED HOLLOW BLOCKS: Lay hollow blocks on a full bed of mortar and fill perpends, but do not fill hollows in blocks above DPC level unless directed by Project Manager. Joints

c)

b) c) d)

5.2.6 a)

b) c)

d) e) f) g)

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Section VII. General Specifications to be of a consistent thickness but not more than 12 mm. Hollow blocks below DPC level to be filled with Grade 10 concrete. h) i) j) k) l) ACCURACY: Keep courses level and perpends vertical and in line. Plumb quoins and other angles as the work proceeds. OPENINGS: Use templates for forming openings in face work where doors and windows are not to be built in. HONEYCOMB SLEEPER WALLS: Build with one third of area void to support plates below ground floors where specified by the Project Manager. BEAM FILLING: Fill between joints and rafters at floor levels and eaves. FAIR FACED WORK: Select bricks and blocks with good arises and flat surfaces and lay with faces in line. Where fair face brickwork is required to both faces in 230 mm walls, build in stretcher bond with brick reinforcement every fourth course in accordance with local authority bye-laws. Bonding BONDING: Lay bricks throughout the work with the perpends in any course not less than a quarter of a brick from those in the course below. ENGLISH GARDEN WILL BOND: Unless otherwise specified, all brickwork to be laid with three courses of stretchers with a half-brick lap and one course of headers. STRETCHER BOND: Lay half-brick walls, including cavity walls, with stretchers only in each course with a half-brick lap. Finishing of Joints JOINTS which are not to be emphasized in the finished work to be struck off with the trowel as the work proceeds. FLUSH JOINTS: Finish joints as the work proceeds with all voids filled to provide a smooth surface flush with the brick or block face. ROUNDED OR SQUARE JOINTS: Finish joints as the work proceeds with all voids filled and iron with an approved pointing tool. WEATHERED JOINTS: Finish mortar to a trowelled weathered joint as the work proceeds. FLUSH POINTING: Rake out joints to a depth of 15 mm as the work proceeds. Point to a flush finish with mortar of colour as approved by the Project Manager in a continuous operation as scaffolding is taken down. WEATHERED POINTING: Rake out joints to a depth of 20 mm as the work proceeds. Point to a weathered profile with mortar of colour as approved by the Project Manager in a continuous operation as scaffolding is taken down. BRICKWORK FOR PLASTER: Rake out mortar joints to a depth of 20 mm in brickwork to be plastered. BLOCKWORK FOR PLASTER: Strike off and leave rough joints in blockwork to be plastered. BAGGING: Where specified to fair-face brickwork or concrete; to be applied by dipping a block bust into a cement-lime-sand mix and rubbing well into the backing to fill all holes and cracks and bring to an even texture.

5.2.7 a) b) c) 5.2.8 a) b) c) d) e)

f)

g) h) i)

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Section VII. General Specifications 5.2.9 a) b) c) d) e) Cavity Work GENERALLY: Keep cavity and ties free from mortar and debris. Clean the bottom of the cavity through holes as necessary. Make good to holes. CAVITY BRIDGES: Seal cavities which are to be spanned with in-situ concrete with flat asbestos sheet. FILL cavities with concrete up to levels approved by the Project Manager and with top sloping towards exterior. WEEP HOLES: Leave every third perpendicular immediately above cavity fillings and lintels free of mortar for drainage. WALL TIES: For cavity walls to be galvanised "Vertical Twist" or "Butterfly" type to BS 1243 to the following lengths and spacings. Stagger in alternate courses. Horizontally 1. 200 mm for cavities up to 75 mm. 2. 250 mm for cavities 75 - 125 mm. 3. 300 mm for cavities 125 - 175 mm. f) g) a) b) c) d) e) f) a) Vertically Every 5 courses

900 mm

750 mm

Every 5 courses

450 mm

Every 5 courses

ADDITIONAL WALL TIES: Provide one additional intermediate tie at sides of openings between the ties specified previously. JAMBS: Build solid jambs in cavity walls. FLEXIBLE DAMP PROOFING STRIPS to walls to conform to SAZS 276 unless otherwise directed by the Project Manager. SCREED: Bed flexible damp proof course on a screed of cement mortar conforming to SAZS 276 trowelled smooth. FACING WORK: Keep leading edge of flexible damp proof course 10 mm back from face of brickwork. OPENINGS: Provide flexible damp proof course, extending 100 mm beyond end of lintels and sloping to weep holes over all openings in cavity walls. CILLS: Provide flexible damp proof course in one length under jointed cills turned up at back and ends. CAVITY WALLS: Damp proof courses to cavity walls to be separate under each leaf. BRICK REINFORCEMENT: To be used accord to Table 2 below

5.2.10 Damp Proof Course

5.2.11 Reinforced Brickwork

TABLE 2 Thickness of Wall 75 mm ) all walls every 115 mm ) fourth course 230 mm ) where specified 345 mm
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Equal to Cott No. CO C1 C2 C3

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Section VII. General Specifications b) c) d) e) f) CLEANING: All reinforcement to be cleaned of oils, paint, millrust, loose rust, etc.. LAPS: Joints to be lapped a minimum of 300 mm and locked together. ANGLES: Lap at corners and junctions equal to full width of walls and lock together. CILLS: Bed reinforcement in walls in the two courses immediately below window cill level projecting 300 mm each side of opening. REINFORCED BRICK LINTELS: Form over window and door openings exceeding 900mm but not exceeding 1700 m wide: 1. Bed reinforcement in Grade 10 mortar. 2. Brick reinforcement to be in accordance with Table 2 of Section 5.2.11 above. 3. Extend the reinforcement 300 mm each side of opening. 5.2.12 Ancillary Work a) WOOD DOOR AND WINDOW FRAMES: Build brickwork hard against jambs on both sides. Secure 300 mm long hoop iron lugs to both sides at 6-course intervals and bed lugs solid in mortar. Set 125 mm x 12 mm MS dowels into feet at door frames, projecting 50mm into frame and 75 mm into concrete floor. PRESSED WINDOW AND DOOR FRAMES: Build in hard against brickwork. Provide lugs in accordance with manufacturer's instructions and fill solid with mortar as the wall rises. Bed base tie bars of door linings into floor screed. METAL WINDOW AND DOOR FRAMES: Build in hard against brickwork. Provide lugs in accordance with manufacturer's instructions and fill solid with mortar as the wall rises. HOOP IRON TIES: Build into 230 mm and 345 mm thick brickwork 25 mm x 1.25 mm galvanised hoop iron ties for securing wall plates at not exceeding 1500 m centres, positioned immediately below trusses to slabs where applicable: 1. Ties in brickwork to extend downwards in centre joint of walls at least seven courses and be turned into brick joint at bottom. 2. Ties in concrete to be embedded at least 150 mm and cranked or fish-tailed at ends. 3. Length projecting above top of wall to be sufficient to allow wrapping over truss or rafter feet where applicable. e) GALVANISED WIRE TIES: Build into 115 mm and 280 mm cavity brickwork 3 mm galvanised wire ties for securing wall plates at not exceeding 1500 m centres. Positioned immediately below trusses. Wire to extend downwards at least seven courses and pass through joint and carried up each face of 115 mm wall and extend above top of wall sufficient to allow wrapping over truss or rafter feet and two ends windlassed together. WALL PLATE: Screed top of wall with level bed of cement mortar to receive wall plate and lay when wet where applicable. FLASHINGS: Rake out joints of brickwork 25 mm deep and securely wedge flashing into brickwork and point in cement mortar. AIR BRICKS to be precast cement, terra cotta or clay with copper or aluminum mosquito gauze backing, of approved type and manufacture. Set immediately below concrete ring beam or minimum of three courses below ceiling level. 1. Render openings in solid walls with mortar with steel trowel finish. 2. Line opening through cavity walls with asbestos slate or sheet.

b)

c) d)

f) g) h)

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Section VII. General Specifications 3. No air brick to be within 300 mm if the sides of any opening with reinforced brick lintels. i) j) k) PARTITIONS THROUGH CEILINGS: Build up all brick partition walls to a height of not less than 150 mm above ceiling level where applicable. FIXING BRICKS: Build in necessary fixing bricks or blocks for trims. COMPONENTS: Build in cills, copings, lintels, steps and other components using mortar similar to that in adjacent walls. Sandlime Bricks Precast Concrete Blocks Precast Sand-Cement Blocks Building Limes Masonry Cement Damp-proofing Materials Burnt Clay Building Bricks and Blocks Cement Bricks Portland Cement Building Sand from Natural Sources Metal Ties for Cavity Wall Methods of Test for Thermal Insulating Materials

5.2.13 List of Codes and Standards SAZS 319 SAZS 119 SAZS 119 SAZS A.15 SAZS A.22 SAZS 276 SAZS 221 SAZS 306 SAZS 307 BS 1119 & 1200 BS 1243 BS 2972 5.3 5.3.1 a) b) c) 5.3.2 a) b) c) Materials SOFTWOOD for joinery to be selected as joiner's quality clear Oregon Pine, or dark Meranti. SOFTWOOD MOISTURE CONTENT for joinery and strip flooring/boarding to be not more than 12% or less than 9% at time of machining. HARDWOOD MOISTURE CONTENT for joinery and hardwood strip flooring/boarding to be not more than 10% or less than 6% at time of machining. Machining Timber CORNERS to be arrised. NOMINAL DIMENSIONS: For "nominal" dimensions as shown for wrote timber, an allowance of 3 mm will be permitted for each face. EXPOSED SURFACES: Timber that is to be exposed in the finished surfaces of joinery works shall be wrote on the appropriate faces, unless otherwise specified by the Project Manager. PRESERVATIVES: Treat timber as specified by the Project Manager after machining but before assembly. Liberally apply preservative to all new surfaces exposed by minor cutting excluding those joints to be glued or finished. Assembling/Finishing Components EDGE SEALING: Before fixing, apply same sealer or varnish as specified for final coating to all edges. Lapped faces of boards to be sealed or varnished, so that uncoated areas will not be exposed by movement of the timber. TOLERANCES shall be: 1. Straightness in 8 mm (not cumulative): + 5 mm
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Joinery and Ironmongery

d)

5.3.3 a)

b)

Section VII. General Specifications 2. Length: + 5 mm 3. Height: + 5 mm c) CLEARANCE: Clearance shall be provided at all connections between joinery work and the building carcass, whether of masonry or frame construction, so that any irregularities, settlements or other movements shall be adequately compensated. LABOURS: Perform all labour necessary for correct jointing. FASTENINGS: Provide all fastenings and fixings necessary for the proper execution of the joinery works. DIMENSIONS: Do not make components until all site dimensions have been checked unless otherwise approved by the Project Manager. SCREWING SOFTWOOD & CHIPBOARD: Provide matching clearance holes for all sizes of screw and matching pilot holes for screws of 6 gauge or greater. SCREWING HARDWOOD AND HARDWOOD: Provide clearance and pilot holes to match screw sizes. All screws in hardboard to be brass unless otherwise directed. Screws in removable sections to be brass cupped. PUNCH all nail heads, which will be visible in completed work, to be below timber surfaces. COUNTERSINK SCREW HEADS: Screw heads which will be visible in completed work are to finish flush with timber surfaces. SINK SCREW HEADS: Screw heads which will be filled are to finish not less than 5 mm below timber surfaces. PELLETING: All exposed screws, except to removable panels, in hardwood to be pelleted unless otherwise directed. Sink screw heads which are to be clear finished 10 mm below timber surfaces. Glue in grain matched pellets not less than 10 mm thick cut from matching timber. Finish off flush with face. LOOSE JOINTS: To be used where provision must be made for shrinkage or other movement. BENT WORK: Perform bent work where specified by saw-kerfing, keying, laminating or steaming as appropriate. CIRCULAR WORK: Build up with appropriate number of pieces cut to the required shape and put together in two or three thicknesses to break joint. Secure with hardwood keys and wedges or with hardwood pins. SCRIBING: Scribe skirting without quadrants, architraves and other joinery works to fit the contour of any surface against which they may be required to form a close connection. SKIRTINGS WITH QUADRANTS: Keep skirting 3 mm clear of finished floor surface and fix quadrant as directed by Project Manager. NATURAL FINISH: Match pieces specified for staining, clear polishing or varnishing to present a uniform colour and grain. PRIMING SOFTWOOD JOINERY: All joinery for painting to be primed before leaving workshop. OILING HARDWOOD JOINERY: All hardwood for oiling to be treated with a coat of raw linseed oil before leaving workshop.

d) e) f) g) h)

i) j) k) l)

m) n) o)

p)

q) r) s) t)

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Section VII. General Specifications 5.3.4 a) b) Veneering/Sheet Surfacing ADHESIVES: Use in accordance with manufacturer's instructions. When using an adhesive other than a contact type, bond in presses. TIMBER VENEERS: When not otherwise specified by the Project Manager, apply to back face a sheet of similar material and thickness as the face veneer. Ensure that moisture content of veneers is equal. LAMINATED PLASTIC VENEERING: When not framed or otherwise specified by the Project Manager, apply to back face of baseboard a sheet of similar material and thickness to the face sheet. Condition material before fixing in accordance with manufacturer's instructions. GLUED JOINTS: Use glued joints where provision need not be made for shrinkage or other movements in connections, and where sealed joints are required. Cross-tongue all glued joints or otherwise reinforce. Surfaces in contact are to have good planed finish. GLUED SURFACES: Members in construction to be joined by glueing are to be of similar conversions. Keep all surfaces to be glued clean and free from any contamination. Apply adequate pressure to glued joints to ensure intimate contact and maintain whilst the glue is setting. LAMINATED PLASTIC EDGING: Finely chamfer edges at all external angles. Shelving EDGING STRIPS: Edge all exposed edges and ends with a 10 mm hardwood strip, full thickness of shelf, glued and pined. Flush Doors STANDARD: Flush doors shall be "solid core" framed-core ("semi-solid") or "hollow core" as specified by the Project Manager and shall conform to SAZS 184 and carry the Mark of the Standards Association of Central Africa. GRADES: Supply and fit "Internal" or "External" grade flush doors as specified by the Project Manager for the particular locations. The grade shall be clearly stamped on the door. LIPPINGS: All flush doors shall be supplied by the manufacturer with hardwood lippings to both vertical edges to conform to SAZS 184 paragraph 23. Lippings shall be square, rounded or rebated as required. PAINTING: Doors taken for painting shall be "Paint Doors" to conform to SAZS 184. VARNISH OR STAINING: Doors taken for varnishing or staining shall be "No. 1 Grade" to conform to SAZS 184. Flush Doors to Fittings RESTRICTION: This specification shall not be allowed for doors of a surface area greater than 1.5 m2. STANDARD: Flush doors shall be hollow core and shall conform to SAZS 184 except that the overall sizes shall be as detailed and the thickness shall be not less than 32 mm. LIPPINGS: All flush doors shall be supplied by the manufacturer with hardwood lippings to both vertical edges to conform to SAZS 184 paragraph 23. Lippings shall be square, rounded or rebated as required by the Project Manager. PAINTING: Doors taken for painting shall be "Paint Doors" to conform to SAZS 184.

c)

d)

e)

f) 5.3.5 a) 5.3.6 a)

b)

c)

d) e) 5.3.7 a) b) c)

d)

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Section VII. General Specifications e) 5.3.8 a) b) VARNISH OR STAINING: Doors taken for varnishing or staining shall be "No. 1 Grade" to conform to SAZS 184. Ledged and Braced Doors STANDARD: Ledged and braced doors shall conform to SAZS 184 and carry the Mark of the Standards Association of Central Africa. BOARDING: Construct with 22 mm thick boards not less than 75 mm or more than 100mm wide, excluding the tongues. Boards to be tongued, grooved and V-jointed. Screw each board to bottom, lock rails and once to brace. RAILS: Top, back and bottom rails to be 22 mm x 150 mm. The top and bottom rails to be set 75 mm from top and bottom of boarding respectively. BRACES to be 22 mm x 105 mm, set to rise from the hanging edge to the lock edge. Framed, Ledged and Braced Doors STANDARD: Framed, ledged and braced doors shall conform to SAZS 184 and carry the Mark of the Standards Association of Central Africa. BOARDING: Construct with 22 mm thick boards not less than 75 mm or more than 100mm wide, excluding the tongues. Boards to be tongued, grooved and V-jointed. Tongue and grooved ends of boarding into top rail and styles. Screw each board twice to bottom, lock rails and once to brace. SCREWS: painting. Brass screws to be used in hardwood doors; steel screws in doors for

c) d) 5.3.9 a) b)

c) d) e) f) g) a)

STYLES AND TOP RAIL to be 44 mm x 105 mm morticed and tenoned together. Tenons to carry through full width of styles and wedged both sides of tenon. BOTTOM RAIL to be 22 mm x 205 mm morticed and tenoned to styles. Tenons to carry through full width of styles and wedged both sides of tenon. LOCK RAIL to be 22 mm x 105 mm morticed and double tenon. BRACES to be 22 mm x 105 mm set to rise from the hanging style to the lock style. SOFTWOOD SKIRTINGS: Scribe skirtings to floor level in single lengths where possible, mitre angles and steel nail at 300 mm centres to wall. Punch nails to 2 mm below face of timber and fill. No hammer marks will be accepted. HARDWOOD SKIRTINGS: Scribe skirtings to floor level in single lengths where possible and mitre angles. Counter-sink screws 10 mm at 300 mm centres and screw to fixing blocks. Pellet with matching timber, retaining direction of grain. PELMETS: Unless otherwise specified by the Project Manager, construct pelmets from 22mm x 100mm softwood tops and ends and with 6 mm tempered hardboard face 150mm deep. Screw to 50 mm x 22 mm softwood batten securely fixed to wall. Provide and fix anodised aluminium VS 57 single soffit mounted curtain track with nylon runners and stopped ends in accordance with the manufacturer's instructions. Provide 10 runners per metre length. MIRRORS shall be fixed 3 mm clear of backing to approval of Project Manager. MATERIALS shall comply with these Specifications. Discrepancies to be reported to the Project Manager for decision.

5.3.10 Miscellaneous Joinery

b)

c)

d) a)

5.3.11 Ironmongery

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Section VII. General Specifications b) ALTERNATIVES to the specified article will be permitted if samples are submitted and prior approval obtained from the Project Manager. PACKAGING: Deliver ironmongery to the site as packed by the manufacturer where appropriate, otherwise adequately protected. ATTACHMENTS: Deliver ironmongery complete with all correct fittings, screws, etc.. DAMAGE: Replace damaged or defective ironmongery. INSTALL ironmongery as instructed by the manufacturers. SERVICING: Adjust, ease, free and oil as necessary and leave ironmongery operating correctly and freely. DOOR CHECKS: Fill oil controlled mechanisms with oil and leave all door checks, springs, etc. operating satisfactorily. CLEANING: Leave all furniture and fittings clean. GENERALLY: Provide two keys to each lock and place them in the relevant lock when the building is handed-over. DIFFERS: All locks to differ except when otherwise specified by the Project Manager. SECURITY LOCKS: Arrange for delivery of keys to safes, strong rooms, cells and other security areas having special security locks, direct from the supplier to the Project Manager in sealed packages. MASTER KEYS: Deliver master keys direct from the supplier to the Project Manager in sealed packages. KEY TAGS: Supply every key with a numbered plastic identification tag a minimum of 40 mm diameter and 3 mm thick and secure to the key with a small key ring. ENGRAVING: Numbers or names to be engraved on key tags as directed by Project Manager. BRASS LOCKS: Fit to cupboards/drawers, 4-lever, solid brass locks. SCREWS: Secure furniture and fittings with suitable screws. FINISH OF SCREWS: The finish of the screws is to be appropriated to the furniture or fitting secured. SCREW SLOTS: Screws are to be tightened and left with all slots matching. Wooden Doors Plywood and Composite Board Softwood Flooring Boards.

5.3.12 General a) b) c) a) b) c) d) a) b) c)

5.3.13 Installation

5.3.14 Keys

d) e) f)

5.3.15 Cupboard/Drawer Locks a) a) b) c) 5.3.16 Screws

5.3.17 List of Codes and Standards SAZS 184 SAZS 130 SAZS 114

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Section VII. General Specifications 5.4 5.4.1 a) b) c) d) 5.4.2 a) b) c) d) e) f) 5.4.3 a) b) Sheet Metal Work, Plumbing and Associated Services Sheet Metal Work GALVANISES SHEET IRON shall conform to BS 2989 and shall be of manufacture as approved by the Project Manager. REGALVANISE fabricated articles after manufacture where size permits, otherwise refer to Project Manager. MOVEMENT: Allow for expansion and contraction of long lengths and joint accordingly. Movement joints must coincide with those in the structure. FASTENERS: Use only suitable fasteners where in contact with various metals. Flashings GENERALLY: Pre-orm from separate strips of 0.46 mm galvanised sheet iron not more than 2400 m long. CLIPS: Restrain flashings over 100 mm deep with galvanised clips at 600 mm centres. WEDGES: Form from 20 mm wide x 20 mm pieces of galvanised sheet iron, folded and hammered into wedge shape. Drive full depth into groove. COVER FLASHING: Welt top edge 100 mm, turn 20 mm into groove and wedge at 60mm centres. Welt or bead bottom edge. APRON FLASHINGS: All joints to be lapped, riveted and soldered. STEPPED FLASHINGS: Welt top edge 10 mm, turn 20 mm into groove and wedge at each step. Welt or bead bottom edge. Saddle at ridge. Down-Pipes RAIN WATER PIPES: To be of the size and section specified by the Project Manager in PVC, 100 mm dia. Prefabricate in separate lengths to overlap 25 mm and seal joint. HOLDERBATS for rainwater pipes to be 20 mm x 3 mm galvanised iron strip with 25mm flanges, holed for and bolted together with two 20 mm x 6 mm galvanised gutter bolts and lock-nuts. Weld to a 100 mm x 8 mm dia. Anchor fishtailed 75 m into wall, retaining RWP 25 mm minimum clear of wall. Galvanise after bending and drilling. Plumbing Drainage and Water Supply Pipe Work INSPECTION: Inspect all pipes and pipe fittings carefully before fixing. Any pipes and pipe fittings which are defective as determined by the Project Manager shall be rejected. COUPLINGS: Jointing rings, couplings and adaptors to be of types instructed by the manufacturer of the pipes being jointed. Rubber joint rings must conform to BS 2494, Part 1 or 2, as appropriate. STORAGE: Store rubber jointing rings in their delivery bags. Do not expose to the sunlight. DAMAGE: Make good damage to coatings or re-coat as instructed by pipe manufacturer. STACKING PIPES GENERALLY: Stack pipes on level surface. Do not rest pipes on their sockets. Securely chock end pipes in bottom row to prevent collapse of stack. Do not stack more than two metres high. SLEEVES: Use sleeve pieces for total thickness of walls and suspended slabs through which pipes pass. Where pipes pass through holes or notches, do not subject them to pressures or friction.

5.4.4 a) b)

c) d) e)

f)

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Section VII. General Specifications g) h) CUTTING of pipe ends to be clean and square, using equipment appropriate to the material unless otherwise directed by the Project Manager. SEALING OFF: Prevent entry of foreign matter into any part of storm water and soil system by sealing openings during construction. Fit all access covers and cleaning eyes as the work proceeds. JOINTING material must not project into bore of pipes, fittings or appliances. OPERATIVES must be skilled in jointing the pipes and fittings as specified by the Project Manager. FIXINGS: Fix pipes and fittings securely with fixings and fastenings appropriate to the location and materials. CLEARANCE FOR SMALL DIAMETER PIPES: (up to 50 mm dia). Fix pipes with a minimum clearance of 35 mm from the face of the structure. CLEARANCE OF LARGE DIAMETER PIPES: (over 50 mm dia). Fix pipes with a minimum clearance of 50 mm from the face of the structure. THERMAL MOVEMENT: Obtain directions from the Project Manager regarding provision for thermal movement in the length of pipes. PLUMB PIPES: Vertical pipes to be fixed plumb. CHASES: Make adequate provision during construction, as directed by the Project Manager. PIPE RUNS: Discuss and obtain approval of pipe runs with Project Manager before starting work. CUTTING: Obtain permission of Project Manager before cutting into other work. GALVANIC ACTION: Do not use plumbing materials in combinations which will permit galvanic action. DEBRIS: Remove all debris from cisterns and tanks. Jointing, Plumbing and Drainage Pipes and Fittings GENERALLY: Flexible joints are to be used unless otherwise directed by Project Manager. FLEXIBLE SPIGOT AND SOCKET JOINTS (for use with concrete/clay UPVC pipes): Make joint in accordance with manufacturer's instructions. All jointing surfaces to be clean before jointing. FLEXIBLE SLEEVE JOINTS (for use with cast iron pipes): Joint plain ends of pipes with asbestos-cement coupling and rubber sealing ring to manufacturer's instructions. FLEXIBLE SLEEVE JOINTS (for use with asbestos-cement pipes): Joint plain ends of pipes with asbestos-cement coupling and rubber sealing ring to manufacturer's instructions. STEEL PIPES WITH SCREWED SOCKETS: Screw together, using jointing compound or pipe thread tape as instructed by pipe manufacturer. Paint threads exposed above ground. Coat thickly with bitumen or similar material for below-ground use. CAST IRON PIPES with spigots and sockets: Pack joint with gasket of firmly caulked tarred yarn and caulk with molten lead or fibrous lead yarn and finish with splayed fillet of non-setting compound or mechanical joint to approval of Project Manager. STEEL TO CAST IRON PIPES with spigots and sockets: Joint with cold caulking compound and finish with a splayed fillet of non-setting compound; or Pack joint with
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i) j) k) l) m) n) o) p) q) r) s) t) 5.4.5 a) b)

c) d)

e)

f)

g)

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Section VII. General Specifications gasket of firmly caulked tarred yarn, caulk with molten lead or fibrous lead yarn and finish with a splayed fillet of non-setting compound. h) CAST IRON to EARTHENWARE PIPES with spigots and sockets, to be jointed with: 1. An approved flexible mechanical joint, or 2. A cold caulking compound and finish with a splayed fillet of non-setting compound. i) j) k) COPPER PIPES: Joint with manipulative compression or capillary fittings in accordance with manufacturer's instructions. COPPER PIPES TO STEEL PIPES: Joint with approved brass connector. COPPER PIPES TO CAST IRON SOCKETS: Joint with manipulative compression or capillary fittings to copper alloy caulking bushes. Caulk with yarn and lead or cold caulking compound. COPPER PIPES TO EARTHENWARE SOCKETS: Braze or solder copper alloy sleeves to copper pipes. Joint with: 1. An approved flexible mechanical joint. or 2. A cold caulking compound and finish with splayed fillet ornon-setting compound. m) UNPLASTICISED POLYVINYL CHLORIDE (RIGID PVC) PIPES: Joint with: 1. A synthetic rubber ring or push-fit system in accordance with manufacturer's instructions. or 2. A solvent adhesive in accordance with manufacturers instructions. n) RUN LEAD SPIGOT AND SOCKET JOINTS: 1. Spigots and sockets to be perfectly dry. 2. Centre spigot into socket and caulk tightly with tarred gaskin or lead strip. 3. Pour molten pig lead to fill remainder of socket. 4. Caulk lead with plumbers' caulking irons and finish flush with socket. o) RIGID SPIGOT AND SOCKET CEMENT JOINTS (for use with clay/concrete pipes where directed by Project Manager). 1. 2. 3. 4. 5. p) 5.4.6 a) Wet ends of pipes thoroughly before jointing. Caulk with ring of tarred gaskin or proprietary rubber gasket. Fill joint and form neat 45 degree fillet with approved non-setting compound. Do not pressure test joints within 48 hours. Protect from direct sun until covered.

l)

JOINTING DIFFERING PIPES/FITTINGS: Joint with adaptors as instructed by pipe manufacturers. Testing and Inspection AIR TEST ABOVE GROUND: 1. Fully charge water seals of all sanitary appliances.

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Section VII. General Specifications 2. Insert test plugs into open ends of pipe work being tested. 3. Fit one testing plug with a tee-piece, with a cock on each branch. 4. Connect on branch to U-tube manometer gauge using a flexible tube. or Pass a flexible tube from a tee-piece attached to a U-tube manometer gauge through water seal of trap of sanitary appliance. 5. Introduce air or smoke through other branch until a pressure, equal to 40 mm water gauge, registers on the manometer scale. 6. Maintain pressure for not less than 10 minutes. 5.4.7 a) b) c) Jointing Water Supply Pipes and Fittings GENERALLY: Make all joints airtight and watertight. RED LEAD: Do not use compounds containing red lead. STEEL PIPES WITH SCREWED SOCKETS: Screw together using jointing compound or pipe thread tape as instructed by manufacturer. Oil paint threads exposed above ground. Coat thickly with bitumen or similar material for below-ground use. FLANGED STEEL PIPES: Flanges to be bolted together with asbestos fibre washers in the joint. COPPER PIPES: Joint with manipulative compression or capillary fittings in accordance with manufacturer's instructions. UNPLASTICISED POLYVINYL CHLORIDE (RIGID PVC) PIPES: Joint with synthetic rubber ring or push-fit system or solvent solution in accordance with manufacturer's instructions. POLYTHENE PIPES: Joint with synthetic rubber ring or push-fit system, or thermo-weld joints in accordance with manufacturer's instructions. ASBESTOS CEMENT PRESSURE PIPES: Joint with loose flange and rubber ring joints or patent fluid type joints, in accordance with manufacturer's instructions. Workmanship CONNECTION: Connect into new supply works. PURE WATER: Only potable water must be connected into pipe runs. INSTALLATION of all pipes to be in accordance with the manufacturer's instructions. SLEEVES: Pipe under roads to be sleeved as directed by Project Manager. TEMPORARY SEALING OF OPEN ENDS: During construction seal all open ends of pipes with suitable plugs and maintain until completion to prevent ingress of debris. PROTECTION OF LEAD COPPER AND GALVANISING: Where lead, copper or galvanised pipes are to be buried under the structure or where otherwise directed, wrap with bitumen felt or polythene sheet or strip wired or taped on, or other approved material as required by the Project Manager. TANKS: All tanks in roof spaces to be constructed of glass fibre of approved manufacture. TRAYS: Provide and fit fibre-glass trays under all tanks as directed by the Project Manager.

d) e) f)

g) h) 5.4.8 a) b) c) d) e) f)

g) h)

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Section VII. General Specifications i) 5.4.9 a) SUPPORT TANK AND CISTERN TRAYS: Adequately support all trays to tanks and cisterns on solid platform. Testing GENERALLY: 1. Inform Project Manager before carrying out tests. 2. Provide clean, potable water, and apparatus for testing as required for testing. b) c) OBSTRUCTIONS: Before testing, ensure that all pipe lines are clear. SERVICE PIPES (MAINS): Fill slowly with potable water to exclude all air. Apply test pressure equal to maximum working pressure plus 50%. There must be no measurable loss of pressure for at least 30 minutes. DISTRIBUTING PIPES FROM HEADER TANKS: Fill slowly with potable water to exclude all air. Close all draw-off taps. The system must be watertight. TAPS: Open each tap and check satisfactory rate of flow. DEFECTS: Locate and make good all defects. Retest to satisfaction of Project Manager. Leave system sound and perfect. LEVEL STORAGE: Store metal appliances on a level surface to prevent twisting. Prevent contact with cement and lime. PROTECTION AND DAMAGE: 1. Retain protective coverings, when practical, during and after fixing. 2. Replace any appliances which are damaged. 3. Do not sand in or on any appliances. 4. Do not use appliances. c) d) e) f) g) h) FIX APPLIANCES in accordance with manufacturer's instructions. Use fastenings supplied by manufacturer wherever possible. FLOOR FIXING: Where screws are used they must be brass. Bed floor-standing appliances in cement mortar unless otherwise specified by the Project Manager. CORBELLED APPLIANCES: Rigidly support built-in and cast-in appliances until wall is complete. SHOWER TRAYS: Bed solid to concrete screed on a continuous layer of cement-sand mortar 1:5. WATER CISTERNS: Use only glass-fibre cisterns. Fix at the height as approved by the Project Manager. TRAYS: Glass-fibre trays to be provided and fitted under all tanks and cisterns 100 mm larger than tank and 75 mm deep with 50 mm waste pipe to discharge to outside, to approval of the Project Manager. FLUSH PIPES: Position and fix to ensure complete emptying after each flush. TAPS: Fix in accordance with manufacturer's instructions, making a watertight seal to the appliance with non-setting mastic. Place hot tap to left as viewed by user of appliance.

d) e) f)

5.4.10 Sanitary Appliances a) b)

i) j)

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Section VII. General Specifications k) l) WASTES: Bed in waterproof jointing compound and fix with resilient washer between appliance and back-nut. WC PAN AND SIMILAR APPLIANCES: Bed solid to concrete screed on a continuous layer of cement-sand mortar 1:5. Connect to soil pipe spigots with plastic or rubber connector in accordance with manufacturer's instructions. or m) n) WC PANS: Connect to clay soil pipes with well caulked tarred gaskin and bituminous compound. Form 45 degree fillet. WC AND SIMILAR CISTERNS: Fix securely to wall with bolts cast into or screwed to brickwork in accordance with manufacturer's instructions. Cisterns to be fitted with 20mm overflow taken immediately through wall and projecting 75 mm beyond face. If cistern abuts an inside wall or duct, fix overflow as directed by Project Manager. PLUGS: Fix CP captive plugs to all relevant fittings. Chains and rubber/plastic plugs will not be permitted. OVERFLOWS: Fix overflows to all fittings and discharge as directed by Project Manager. STAINLESS STEEL SINKS: To be of approved design and manufacture in 1.0 mm Type 430 stainless steel and adequately supported and sound- deadened. Glazed Earthenware Drain and Sewer Pipes and Fittings. Concrete Pipes (Non-Pressure). Concrete Pipe Fittings including Manholes and Inspection Cover. Rubber Joint Ring for Drainage Purposes (metric units). Un-plasticised Polyvinyl Chloride Pressure Pipes. Un-plasticised Polyvinyl Chloride (UPVC) Sewer and Drain Pipes and Fittings (metric units). Un-plasticised Polyvinyl Chloride (UPVC) Soil, Waste and Vent Pipes and Fittings (metric units). Asbestos-Cement Pressure Pipes. Black Polyethylene Pipes for Cold Water Services and Drains. Cast Iron Spigot and Socket Soil, Waste and Ventilating Pipes sand cast and spun) and Fittings. Steel Pipes, and joints for Hydraulic Purposes. Light Gauge Copper Tubes (Light Drawn). Capillary and Compression Fittings of Copper and Copper Alloy for use with Copper Tube complying with BS 659, BS 3931 Part 2, Metric Units. Steel Tubes and Tubulars suitable for screwing to BS 21 Pipe Threads. Rubber Joint Rings for Gas Mains, Water Mains and Drainage Part 1. Rubber Joint Rings for Gas Mains and Water Mains. Part 2. Rubber Joint Rings for Drainage Purposes. Asbestos Cement Pipes and Fittings for Sewerage and Drainage. Hot-Dip Galvanised Plain Steel Sheet and Coil.

o) p) q)

5.4.11 Lists of Codes and Standards SAZS 342 SAZS 315 SAZS A29 SAZS 196 SAZS 327 SAZS 219 SAZS 220 SAZS 113 SABS 533 BS 416 BS 778 BS 659 BS 864 BS 1387 BS 2494

BS 3656 BS 2989 5.5 5.5.1 a) b) Glass

Glazing ACCURACY: All glass to be of accurate size with clean, undamaged, edges and surfaces which are not disfigured. SAMPLES: Submit samples, not less than 150 mm square, of decorative and obscure glass and obtain approval of Project Manager before cutting panes.
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Section VII. General Specifications c) d) e) CLEAR SHEET GLASS shall conform to BS 952, ordinary glazing quality, unless otherwise specified by the Project Manager. CLEAR FLOAT/POLISHED PLATE GLASS shall conform to BS 952, ordinary glazing quality, unless otherwise specified by the Project Manager. GLASS IN LOUVRES: Clear glass shall be the full width and depth of the clips, not less than 5 mm thick with both exposed edges ground. Decorative and obscure glasses shall be of thickness elsewhere specified and approved by Project Manager. Glazing Compounds SAMPLES: Submit samples of compounds which are not to be painted. Obtain approval from the Project Manager of colour before ordering. COMPATABILITY: Check with manufacturers that compounds, sealants, and paints to be used together are compatible. LINSEED OIL PUTTY for use in wooden frames shall conform to BS 544. METAL CASEMENT PUTTY to be of type as approved by the Project Manager, as instructed by the manufacturer for the particular application and with setting properties and unpainted to suit the construction programme. Preparation GENERALLY: All rebates and grooves to be clean, dry and unobstructed at time of priming, sealing and glazing. PAINTED TIMBER SURROUNDS: Ensure that suitable priming paint has been applied before glazing with linseed oil putty. CLEAR FINISH TIMBER SURROUNDS: Ensure that rebates have been sealed with undiluted exterior varnish before glazing. TIMBER BEADS: Ensure that timber beads are sealed all round to match timber surround. METAL SURROUNDS: Follow manufacturer's instructions of compound and surround to ensure that, if required, a suitable primer has been applied and suitable prepared. STONE/BRICK/CONCRETE surround: Ensure that rebates or grooves are sealed with at least two coats of alkali resistant sealer, as instructed by the compound and sealer manufacturers. Fixing WEATHERTIGHT: All external glazing to be wind and watertight on completion. DIRECTIONALLY PATTERNED OR WIRED GLASS: Align in adjacent panes. EDGE CLEARANCE: To be equal all round each pane, and not less than 3 mm for single glazing. SETTING AND LOCATION BLOCKS: Use for all panes exceeding 0.2 m2. Locate as instructed by window manufacturer, but never more than 75 mm from the corner of the surround. BEDDING: Ensure that no voids or spaces are left in back or bedding compounds. STRIP surplus backing or bedding compound flush with top of rebate, bead or groove. STAINING: Protect etched, sand-blasted or ground glass from staining by masking before fixing, and cleaning surfaces after fixing, as instructed by glass manufacturer.

5.5.2 a) b) c) d)

5.5.3 a) b) c) d) e) f)

5.5.4 a) b) c) d)

e) f) g)

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Section VII. General Specifications h) i) 5.5.5 a) b) c) d) 5.5.6 a) b) c) d) 5.5.7 a) DOUBLE GLAZING UNITS/LAMINATED GLASSES: Fix strictly in accordance with the manufacturer's instructions, which are to over-ride other clauses if in conflict. PRE-GLAZING of components will not be permitted. Putty Fronting TIMBER SURROUNDS: Secure glass less than 0.2 m2 with Glazier's sprigs or cleats not more than 450 mm apart. METAL SURROUNDS: Secure glass with spring clips or cleats as provided for or instructed by the surround manufacturer. BACK PUTTY to be of regular thickness, not less than 2 mm. FRONTING: Form neat triangular fillet to coincide with sight line. Lightly brush surface to seal putty to glass. Bead Fixing BEAD FIXING: Unless otherwise specified by the Project Manager, beads and screw fixings will be supplied by the surround manufacturer. CUP AND SCREW FIXING: Secure timber beads by countersunk screws and cups of centres predetermined by surround manufacturer. PROPRIETARY FIXING: Secure beads by the surround manufacturer's specialist method, as approved by the Project Manager. WASH LEATHER: Bed glass in wash leather or approved polymer tape and trim flush with sight line. Protecting and Cleaning of Finished Work INDICATORS: Do not use painted or stuck-on indicators on solar control or coloured glass. Whitewash may be used on ordinary glass but must be restricted to small central areas of panes. CLEAN SMEARS: Remove all smears and excess compound and sealant. Leave clean inside and out, and free from scratches. CLEANING MORTAR: Remove all mortar, plaster or concrete spillage whilst wet. PROTECTION OF PUTTY: Linseed oil putty and conventional metal casement putty to be sealed as soon as sufficiently hard and in any case within the times instructed by their manufacturers. Sealing to be painted or varnished, according to the finish specified by the Project Manager, and either: 1. 2. e) f) 5.5.8 The full final finish, suitably protected until completion and cleaned down and made good as necessary, or Two additional coats applied locally to the compound, to be followed nearer practical completion, with the full specified finish.

b) c) d)

PUTTY FRONTING: Leave all opening lights in closed position until putty has set sufficiently to prevent displacement of glass. REPLACE all glass and fixing materials broken or damaged before practical completion and re-decorate. List of Codes and Standards Glazing Putty for Wood and Steel Sashes Classification of Glass for Glazing and Terminology for Work on Glass

SAZS A24: BS 952:

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Section VII. General Specifications 5.6 5.6.1 a) b) Painting Materials APPROVED BRANDS: All brands of paints, distempers and other coating materials to be approved by the Project Manager. CONTAINERS: Coating materials are to be delivered in sealed containers, clearly labelled with the brand name, type of material, intended use and manufacturer's batch numbers. Paints other than water-based and bituminous paints to be delivered in containers of not more than 5 litres capacity. STORAGE: Store materials in a clean, dry area, protected from extreme temperatures. PAINT SYSTEMS: Priming coats, undercoats and finishing coats for any one surface must be compatible and obtained from the same manufacturer. WHITE SPIRIT shall conform to BS 245. GLUE SIZE shall conform to BS 3357, Type A. KNOTTING shall conform to BS 1336. FILLERS: Do not use water soluble fillers in potentially wet areas. PRIMERS FOR WOOD shall conform to SABS 678. As a primer to hardwoods or where moisture seepage is prevalent, an aluminium-base primer in conformity with SABS 436 shall be used. PRIMERS FOR METALS shall conform to SABS 904 or SABS 697. As a primer to hardwoods or where moisture seepage is prevalent, an aluminium-base primer in conformity with SABS 436 shall be used. UNDERCOATING (ALKYD TYPE) shall conform to SABS 681 or SAZS 355 HIGH GLOSS SYNTHETIC ENAMEL PAINTS shall conform to SABS 630 and 631 or SAZS 356 ROOF PAINTS shall conform to SABS 683 and 940 applied as directed. DIPPING PRIMERS shall conform to SABS 620. EMULSION PAINTS shall conform to SABS 633 and 634. ALUMINIUM PAINTS shall conform to SABS 436 and 682. Filling / Stopping / Cleaning Materials USE OF MATERIALS: Paint strippers, abrasive papers and blocks, cleaning agents, etching solutions, mould inhibitors, rust inhibitors, size, stopping, knotting, fillers and other commodities to be of the types instructed by the decorative coating manufacturer for the surfaces being prepared. STOPPING/CLEAR FINISH: Stopping for woodwork to receive clear finish to be plastic wood, tinted to match surrounding woodwork to approval of Project Manager. STOPPING/INTERNAL PAINTING: Stopping for woodwork, plywood, hardboard and fibre-board to be linseed oil putty which shall conform to BS 544. Preparation for Painting, Varnishing and Sealing PREPARE: Surfaces in accordance with decorative coating manufacturer's instructions, ensuring that all holes, cracks, defective joints and other defects in surfaces have been made good.

c) d) e) f) g) h) i)

j)

k) l) m) n) o) p) 5.6.2 a)

b) c) 5.6.3 a)

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Section VII. General Specifications b) c) d) 5.6.4 a) b) 5.6.5 a) 5.6.6 a) b) c) d) e) f) g) h) i) PRE-PRIMED SURFACES: Ensure that surfaces have been properly prepared and that primer is of suitable type, firmly adhering and in good condition. DRYING OUT: Before decorating, allow surfaces to dry thoroughly and brush down to remove dust, dirt and loose material. SAMPLE AREAS: Before applying coatings, prepare representative areas of each type of surface, to approval if required by Project Manager. Concrete / Brick / Plaster Surfaces REMOVE release agents, mortar and plaster splashes, loose and flaking material and surface salts. FILLING: Stop all minor holes, cracks and imperfections to match base, and size or seal surfaces of uneven porosity. Iron / Steel Surfaces REMOVE rust and loose scale, welding slag and spatter defective primer and reinstate where required. Clean out crevices and quirks. Remove oil, grease and dirt. Timber / Plywood Surfaces MOISTURE CONTENT: Ensure that at time of decorating timber has a moisture content appropriate to its use in the building. LOOSE KNOTS: Ensure that large and dead knots are removed and made good with sound timber. Rub down flush before priming. SMOOTHNESS: Ensure that surfaces have a smooth, even finish with arises rounded to 1.5 m radius. NAIL AND SCREW HEADS: Ensure that heads are counter-sunk. STOPPING FOR PAINTING: After priming, stop nail holes and similar depressions with stopping pressed well in to remove trapped air. Finish off flush with surface. STOPPING FOR CLEAR COSTINGS: To match the colour of the timber. KNOTTING: Remove resin and apply knotting to resinous timber and all knots and allow to dry. DEGREASING: Wash down immediately before priming hardwoods containing an excess of natural oil. FILLING FOR PAINTING: After stopping and priming, fill pore and grain irregularities with filler to match the colour of the timber. Remove surplus and rub down to leave a smooth, even surface. FILLING FOR CLEAR FINISHES: After stopping and sealing, fill pore and grain irregularities with filler to match the colour of the timber. Remove surplus and rub down to leave a smooth, even surface. PRE-PRIMED SURFACES: Ensure that any areas of defective primer are removed and patch-primed. Remove dirt and grease from satisfactorily primed surfaces and rub down lightly. Building Board Surfaces DEGREASING: Clean off surface oils and roughen surface with fine abrasive paper. Dust off surface before decorating. NAIL AND SCREW HEADS: Ensure that heads are punched or countersunk. GALVANISED CLOUT NAILS: Do not punch. Prime on coat oil paint to head.
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k)

5.6.7 a) b) c)

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Section VII. General Specifications 5.6.8 a) b) Painting / Varnishing / Sealing COLOUR RANGE: Carry out decoration in colours in conformity with BS 4800 as selected by the Project Manager. PERMIT PAINT MANUFACTURERS TO: 1. Inspect the work in progress. 2. Take samples of their products from site if requested by Project Manager. c) d) OBTAIN APPROVAL of representative sample areas of each type of coating before carrying out the remainder of the work, if requested by the Project Manager. CLEANLINESS: Keep all surfaces clean and free from dust during coating and drying. Provide all necessary dust sheets and protection. Remove all paint splashes immediately. Keep the works free of paint stains. Preparation of Materials GENERAL: Prepare coating materials as instructed by their manufacturer. REMOVE FROM SITE any coating materials showing "bittiness" in application. DO NOT INTER-MIX different coating materials. STIR coating materials to attain an even consistency before and during use unless otherwise instructed by manufacturers. PROTECT FROM DAMAGE: Protect freshly applied surface coating from damage. SIGNS: Exhibit "WET PAINT" signs and provide protective barriers where necessary. ADJACENT SURFACES: Protect surfaces adjacent to those being coated. GLAZING: Protect etched, sand-blasted or ground glass from staining by masking or as instructed by glass manufacturers. FITTINGS: Remove ironmongery and electrical fittings from surfaces to be coated where possible, and replace on completion. GENERAL: Apply coating in accordance with their manufacturer's instructions to clean dry surfaces in suitable atmospheric conditions, and after any previous coats have hardened. TINTS: Apply successive coats of different tints, except white. PRIMING: Apply priming coats by brush, working into the surface, joints, angles and end grain. Ensure that priming coats are of adequate thickness and suit surface porosity and that any primed surfaces which have deteriorated on site or in transit are touched up with primer or re-primed. PRIMING JOINERY: Prime all joinery surfaces before components leave joinery shop. PRIMING AFTER PRESERVATIVES: Where timber has been treated with preservative, check with preservative manufacturer that coating materials are compatible with the preservative. PRIME METAL: Prime metal surfaces on same day as they have been cleaned. PRIME FLAME-CLEANED METAL: Prime flame-cleaned iron and steel surfaces while still "hand-warm".

5.6.9 a) b) c) d)

5.6.10 Protection a) b) c) d) e)

5.6.11 Application a)

b) c)

d) e)

f) g)

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Section VII. General Specifications h) i) j) k) l) m) n) o) p) q) PRIME ETCH-CLEANED METAL: Allow "wash" or "etch" pre-priming coat to harden before applying subsequent priming coat. UNDERCOATS AND FINISHING COATS: Apply in a wet, even film over all surfaces, avoiding uneven thickness at edges, angles, brush marks, sags, runs and other defects. SECOND FINISHING COAT: Apply second coat within 48 hours of first coat, avoiding brush marks, sags, and other defects. DOORS: Prime and paint bottom edges before hanging. PRIMING REBATES: Apply priming coating to rebates and beads before glazing. PAINTING PUTTY: Extend painting adjacent to glazing across putty and 2 mm onto glass. RUB DOWN: All priming and undercoats to a smooth surface with abrasive paper and remove all dust before applying next coat. CUTTING IN: Cut in neatly and cleanly. Do not splash or mark adjacent surfaces. ROLLER PAINTING will not be permitted in the application of gloss paints. SPRAY PAINTING will be permitted with prior approval. Mask all adjoining surfaces. Spray perforated acoustic surfaces at an angle of 30 degrees to the surface. EMULSION PAINTS TO PLASTER / BUILDING BOARDS / CONCRETE / BRICKWORK: 1 b) c) d) White and light colours: Apply three coats or until cover is achieved. 2. Medium and dark colours: Apply two coats. PVA GLOSS ENAMELS: Apply strictly in accordance with manufacturer's instructions. SAND-BASED PAINTS: Advise manufacturer of intention to commence painting, request manufacturer's demonstrator to attend and follow his instructions. HIGH GLOSS/SIMI-GLOSS PAINTS TO TIMBER: 1. Apply one coat primer. 2. Apply one undercoat. 3. Apply two coats high gloss/semi-gloss as directed by the Project Manager. e) HIGH GLOSS/SEMI-GLOSS PAINTS TO PLASTER: 1. Apply one coat emulsion. 2. Apply two coats high gloss/semi-gloss as directed by the Project Manager. f) HIGH GLOSS/SEMI-GLOSS PAINTS TO IRONWORK: 1. Apply one coat metal primer. 2. Apply one undercoat. 3. Apply two coats high gloss/semi-gloss as directed by the Project Manager. g) HIGH GLOSS/SEMI-GLOSS SURFACES: PAINTS TO GALVANISED AND ZINC-COATED

5.6.12 Surface Treatments a)

1. Treat with approved pre-cleaner. 2. Apply one coat calcium plumbate.

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Section VII. General Specifications 3. Apply one undercoat. 4. Apply two coats high gloss/semi-gloss as directed by the Project Manager. h) i) j) SPECIAL PURPOSE PAINTS: Prepare surface and apply paints strictly in accordance with manufacturer's instructions. OIL TO HARDWOODS: Apply two coats raw linseed oil. Rub in first coat at joinery workshop. Apply second coat in-situ. WAX POLISHING TO HARDWOODS: 1. Apply two coats sanding-sealer. 2. Rub down with fine sandpaper or wire wool before and after each coat. 3. Apply two coats clear white polish, allow to dry and buff up. k) l) POLYURETHANE TO HARDWOODS: Apply two coats one-pack polyurethane in accordance with manufacturer's instructions. Allow four hours minimum between coats. COLOUR IDENTIFICATION: Paint pipes, conduits, ducts and cables in colours in conformity with SAZS 186 as specified by the Project Manager. ADHESIVES: 1. 2. 3. 4. (b) 1. 2. (c) Mix and keep in clean containers. Use only within manufacturers instructed open time. Use only types specified by manufacturers of materials being fixed. In the absence of such specifications, type to be approved by Project Manager. When specified by adhesive manufacturer: a dilute solution of adhesive. In other cases: glue size shall conform to BS 3357.

5.6.13 Adhesives / Primers (a)

SIZE: either:

FILLER: To be suitable for particular backgrounds and compatible with other materials being used. Linseed Oil Putty for use in Wooden Frames. White Spirit. Knotting. Glue Size for Decorators' Use. Paint Colours for Building Purposes.

5.6.14 List of Codes and Standards BS 544 BS 245 BS 1336 BS 3357 BS 4800 5.7 5.7.1 a) b) c) 5.7.2 a)

Pavings, Floor Coverings and Plastic Linings Screeds CEMENT shall conform to SAZ5 307. SAND shall conform to BS 1199 & 1200. WATER shall conform to BS 3148. General PROTECT all existing work and approaches with boards, dust sheets, or other suitable means.

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Section VII. General Specifications b) c) 5.7.3 a) b) HOT WEATHER: Ensure that full compaction is not prevented by premature stiffening or drying out of mix. After compaction prevent rapid drying out. WET WEATHER: Protect freshly laid screeds. Preparation of Base Surfaces CLEAN thoroughly to remove all dirt, dust, rust and oil. IN-SITU CONCRETE: 1. Hack concrete base thoroughly to remove all laitance, expose coarse aggregate and leave clean. 2. Wet base 24 hours before laying screed and remove surplus water. 3. Brush neat cement slurry into surface 20 minutes before laying screed, or apply bonding agent in accordance with manufacturer's instructions. c) PRECAST CONCRETE UNITS 1. Wet base 24 hours before laying screed and remove surplus water. Keep damp. 2. Brush neat cement slurry into surface 20 minutes before laying screed, or apply bonding agent in accordance with manufacturer's instructions. d) FRESH CONCRETE 1. As soon as concrete has set, spray surface with water. 2. While still green, brush base with stiff broom to remove all laitance and loose aggregate and to provide a key. 5.7.4 a) b) c) d) e) 5.7.5 a) Laying Screeds AERATED OR SPECIAL manufacturer's instructions. CONCRETE SCREEDS: Lay in accordance with

BAYS: Lay concrete screeds in bays of not more than 20 m2 in chequer-board pattern to Project Managers approval. Allow at least 24 hours between placing adjacent bays. JOINTS: Form movement joints with a trowel cut in screed exactly over movement joints in base. COMPACT material thoroughly for full depth. Do not wet surface. LAP REINFORCEMENTS: Where directed by the Project Manager, lap reinforcement 75mm in concrete screeds. Finishes TOLERANCES for floor screeds shall be: 1. +/- 10 mm overall each floor level of the works. 2. +/- 3 mm under a 3000 m straight edge.

b) c) d) e)

LOW SPOTS: Do not leave low spots between drainage outlets. STEEL FLOAT: Where thin sheets or tiles are specified by the Project Manager, finish surface of screed with steel hand trowel or power float. WEED FLOAT: Where required by the Project Manager, finish surface of screed with wood or other suitably faced float to give an even texture. MAKE GOOD all defective work in screeds before applying finishes.

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Section VII. General Specifications 5.7.6 a) 5.7.7 a) b) c) d) 5.7.8 a) b) Curing PROTECTION: Immediately after laying, protect surface from wind and sunlight, by covering and leaving for not less than 7 days with 25 mm of water, ponded to edges. Granolithic Finishing Coatings TIMING: Lay finishes when all other internal work is completed. PROTECT all existing work and approaches with boards, dust sheets or other suitable means. HOT WEATHER: Ensure that full compaction is not prevented by premature stiffening or drying out of mix. After compaction, prevent rapid drying out. WET WEATHER: Protect freshly laid finishes. Preparation of Base Surfaces As for cement/sand screeds. AGGREGATE FOR GRANOLITHIC: Use approved clean washed granite chippings or other approved stone to conform to BS 882 graded in size from 5 mm down with not more than 20% fine material passing a 200 mesh sieve to conform to BS 410. GRANOLITHIC FINISH: Mix to comprise one part Portland cement to two parts aggregate. Use the smallest quantity of mixing water needed to give adequate workability. Lay to a finished thickness of not less than 25 mm. NON-SLIP GRANOLITHIC where specified by the Project Manager, sprinkle surface of granolithic before setting with carborundum dust at the rate of 1 kg/m2, and trowel well in. TINTED GRANOLITHIC where specified, add one part by volume of colouring compound to six parts of cement and mix before adding to aggregate. Do not sprinkle colouring compound onto surface of screed. JOINTS BETWEEN BAYS: Agree locations with Project Manager before starting work. COMPACT MATERIAL thoroughly for full depth. Do not bring excessive laitance to the surface, and remove any which appears. Do not wet surface during compaction. Finishes LOW SPOTS: Do not leave low spots between drainage outlets. CEMENT: Do not sprinkle cement onto surface. FINISH surface with a steel trowel or steel float shortly after compaction is completed. Do not bring excessive laitance to the surface, and remove any which appears. Do not wet surface during finishing process. SKIRTING, Granolithic skirtings, unless otherwise specified by the Project Manager, to be 100 mm high, finished flush with and v-jointed to plaster above. Form skirting and cove in one operation with appropriate trowel. Form 230 mm margin with v-joint to floor surface. PROTECTION: Immediately after laying, protect surface from wind and sunlight by covering as soon as it is sufficiently hardened with 25 mm water, ponded to edges, for seven days. CLEAN surface of finish. Where surface hardening is specified, clean surface before application. SURFACE HARDENER: Apply sodium silicate as follows:
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d) e)

f) g) 5.7.9 a) b) c)

d)

5.7.10 Curing and Surface Treatment a)

b) c)

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Section VII. General Specifications 1. 2. d) Apply in solution one part to four parts water with mop or brush. Wipe-off excess, allow to dry, then wash with clean water. Apply second coat, or if necessary third coat, if directed by Project Manager, in solution one part to three parts water. Allow to dry, then wash with clean hot water.

PROPRIETARY surface hardeners, where specified by the Project Manager, to be applied in accordance with manufacturer's instructions. SEMI-FLEXIBLE VINYL FLOOR TILES shall conform to SAZS 272. FLEXIBLE VINYL FLOORING shall conform to SAZS A45. MANUFACTURE: All materials shall be manufactured by a manufacturer to be approved by the Project Manager. SHEET SAMPLES: Provide samples of each type of sheet, minimum size 230 mm x 230m, for approval of colour and pattern by Project Manager. TILE SAMPLES: Provide not less than three tiles of each type for approval of colour and pattern by Project Manager. PACKAGING: Deliver sheets and tiles to site in original packing each clearly marked with its batch number. UNIFORMITY: All sheets or tiles or the same type, colour and pattern which will be visible together when laid, are to be from one batch to ensure consistency of appearance. STORAGE: Store rolls standing on end. APPROVED FIRMS: Sheet laying is to be carried out by firms of specialists as approved by the Project Manager. DIMENSIONS: Take site dimensions before ordering and making up materials. FIXTURES: Do not start work until socket outlets, duct covers and other fixtures, around which materials will have to be cut, have been fixed. SURFACE CONDITION: Carrying out repairs of a minor nature requires approval of Project Manager before attempting repairs of badly damaged surfaces. EXISTING OVERINGS: Strip off existing coverings. Remove adhesive and any loose materials. CONCRETE AND PLASTER SURFACES: Apply suitable primer, if instructed by manufacturer of covering material or manufacturer of adhesive. CONDITIONS: Do not lay materials before building is weather tight, wet trades have finished their work, and the building is well dried out. MOISTURE: Where materials are to be stuck to wet laid screeds. 1. Test for moisture content, using a hygrometer as in CP 203: Part 2. 2. Take readings in all corners, along edges, and at various points over the area being tested. 3. Do not lay until all readings show 75% RH or less.

5.7.11 Plastic Sheeting / Tiling a) b) c) d) e) f) g) h) a) b) c) d) e) f) g) h)

5.7.12 General and Preparatory Works

5.7.13 Laying Sheets and Tiles a) ACCLIMATISATION, Store sheets and tiles in similar conditions they are to be laid for at least 48 hours immediately beforehand.
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Section VII. General Specifications b) c) d) e) f) g) ADHESIVE, Use in accordance with manufacturer's instructions. RIDGES AND HIGH SPOTS caused by particles on screed with not be accepted. REMOVE SURPLUS ADHESIVE from face of materials being laid, and any other surfaces, as the wood work proceeds. SETTING OUT: Lay tiles with sides parallel to room axis and with grain of adjacent tiles at right angles. PATTERN must match when repeated motif occurs. EDGE TILES whenever possible to be: 1. Equal width at opposite side of each area. 2. Not less than 75 mm wide. h) i) j) k) l) m) n) o) p) q) r) s) a) b) c) d) a) b) c) JOINTS: Overlap sheets and cut into a straight edge. Fix tiles with tight joints. HEAT-WELD joints in PVC sheet floor and wall coverings, using welded cable. WELDING CABLE: Trim off all proud material to finish flush with adjacent surfaces. FLOORS: Roll thoroughly in two directions. STAIRS: Fix sheet treads in one piece and ensure proper adhesion. WALLS: Align joints with those on floor. MIXTURES: Cut and fit materials to all socket outlets, duct covers and other fixtures. MANUFACTURER'S instructions. INSTRUCTIONS: Fix in accordance with manufacturer`s

TRIMS AND EDGINGS: If levels do not align, use bevelled edging strips at exposed edges of materials. FEATURE STRIPS: Scribe and fix flush with surface of adjacent material. DOORWAYS: Cut sheets and tiles to a straight edge under centre line of door when there is a change of material or colour. STAIR NOSINGS: Screw-fixed nosings on adhesive and screw securely. GENERALLY: Remove all scrap and clean surfaces in accordance with their manufacturer's instructions. FINISHING PVC: Apply two coats of emulsion polish or cleaner, in accordance with manufacturer's instructions. ANTI-STATIC FLOORING: Do not apply any polishes, sealers, or other materials to surfaces of anti-static flooring. PROTECTION: Cover floor as necessary to prevent damage from dirt and traffic. APPLICATION shall be by a specialist approved by the Project Manager. SAMPLE: Prepare one m2 sample panels of the finish for the approval of the Project Manager and retain until completion of the work. UNDERCOAT: Apply the undercoat 15 mm thick with a cement and sand mix 1:2.1/2, and bring to a fine wood float finish.

5.7.14 Cleaning and Polishing

5.7.15 In-Situ Terrazzo

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Section VII. General Specifications d) e) f) g) h) i) MIX: In-situ terrazzo to be composed of one part by weight of white cement tinted to an approved colour, and two parts of marble chippings of approved size and colour. COMPACTION: Lay top coat immediately after undercoat and compact until all excess water is expelled to give a finished thickness of 15 mm. TROWEL to a smooth surface until approximately 85% of the marble chips are exposed. CURING: Keep the terrazzo moist for at least three days with clean, wet, hessian. POLISHED FINISH: Wash and polish with grinders to a lightly polished surface to show an even pattern of stone and cement ACCURACY: Finish surfaces to a true plane to correct line and level, with all corners and angles to a right angle unless otherwise specified by the Project Manager, and with walls and openings finished plumb and square. LOW SPOTS: Do not leave low spots between drainage outlets. DIVIDING STRIPS: Positions of dividing strips to be agreed with the Project Manager. PROFILE WORK: Form profiles strictly in accordance with details. DIMENSIONS: Take site dimensions before ordering and making up materials. FIXTURES: Do not start work until socket outlets, duct covers and other fixtures, around which materials will have to be cut, have been fixed. SURFACE CONDITION: Carry out repairs of a minor nature require approval of the Project Manager before attempting repairs of badly damaged surfaces. CONDITIONS: Do not lay materials before building is weather tight, wet trades have finished their work, and the building is well dried out. MOISTURE: Where materials are to be stuck to new, wet-laid screeds, test to standard. POLISH: Apply two coats of clear white polish, allow to dry and buff up. TRAFFIC: Protect floor from damage, marking or scratching, after completion. Semi-Flexible Vinyl Floor Tiles. Flexible Vinyl Flooring. Portland Cement. Test Sieves. Aggregates from Natural Sources for Concrete (including Granolithic). Tests for Water for Making Concrete. Building Sands from Natural Sources. Sheet and Tile Flooring (Linoleum, Plastics and Rubber).

j) k) l) a) b) c) d) e) a) b)

5.7.16 General and Preparatory Works

5.7.17 Cleaning and Polishing

5.7.18 List of Codes and Standards SAZS 272 SAZS A45 SAZS 307 BS 410 BS 882 BS 3148 BS 1199 & 1200 CP 203, Part 2 5.8 5.8.1 a) General DO NOT BEGIN laying until: 1. Required openings, chases or other apertures have been cut, services installed, and the structure has been completed. 2. All contact services are free of defects, dirt and any other extraneous matter.

Butyl Rubber Roofing Membrane

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Section VII. General Specifications 3. All protrusions and hollows have been removed or filled, to give a smooth surface suitable for application of membrane. b) c) 5.8.2 a) b) c) d) ADHESIVES are to manufacturer's instructions. SPECIALIST FIRMS as approved by the Project Manager only are to lay the membrane. Laying ADHESIVES to be applied to contact surfaces to manufacturer's instructions. LAY in continuous sheets, free of bubbles, cuts or abrasions. JOINTING to be carried out by providing 100 mm side and 150 mm end laps. VERTICAL DRESSING to be carried up vertical faces by 150 mm and the ends covered by a separate strip flashing tucked into or over the structure of the same material. Tucks are sealed with a suitable plastic putty filler. OVERLAPS are to be bonded by a special compound provided by the manufacturer. OPENINGS, Membrane to be dressed into openings with one under-layer having been previously fixed to suit opening and general roof layer laid over to prevent leakage at joint. Finish MEMBRANE surfaces to be cleaned and free of all extraneous material before painting commences. TWO COATS of rubberised Aluminium paint to be applied to the surface. PROTECT painting surfaces to prevent damage of any kind for at least three days.

e) f)

5.8.3 a) b) c)

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Section VII. General Specifications

6 6.1

PLAIN AND REINFORCED IN-SITU CONCRETE General

The following codes of Practice and British Standards are deemed to form part of these Specifications: (a) SAZS Code of Practice 170: 1978 The Structural use of Concrete Part 1 - Design Materials and Workmanship (b) BS 8007: 1987 - The Design of Concrete Structures for retaining Aqueous Liquids and all their latest amendments. 6.2 6.2.1 Materials Cement ) ) ) ) ) ) Where items are not specifically covered by these Specifications of this Contract

All types of cements shall conform with SAZS 307 except as noted in SAZS 170. It shall not have deteriorated due to exposure to the elements. Different types of cement shall not be mixed. 6.2.2 Aggregates The aggregates used shall comply with SAZS 190. The cleanliness of the aggregates shall be to the Project Manager's approval. Different aggregates shall be kept separate. 6.2.3 Reinforcement Reinforcement shall conform to BS 4449, BS 4482, BS 4483 and ZISCO specification RSK 2075 and twisted to comply with BS 4461. The reinforcement shall be cut and bent in accordance with BS 4466. 6.2.4 Water All water used for concrete shall be taken from approved sources and shall comply with the requirements of BS 3/48. 6.3 6.3.1 Storage Cement

All cement shall be stored in a weather-proof building clear of the ground or in a suitable silo. The cement shall be used within six weeks of manufacture. Each batch of cement delivered shall be stacked separate from the previous batches. A record of date of manufacture of each batch shall be kept. Each stack shall be no higher than twelve sacks and shall be used on a first delivered, first used basis. 6.3.2 Aggregate Each type of aggregate shall be stockpiled on a hard smooth surface and kept separate from the other aggregates.

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Section VII. General Specifications 6.3.3 Reinforcement

Reinforcement shall be stored in racks clear of the ground. Steel fabric shall be delivered in flat sheets. Each bundle of bars shall be clearly marked with their schedule and mark number. 6.4 6.4.1 Concrete Manufacture and Placing Concrete

Concrete Mixes The Contractor may elect to use either a prescribed or designed mix subject to the approval of the Project Manager. Prescribed Mixes A prescribed mix shall be proportioned as set out in these Specifications to reach the required strengths and durability as stated in these Specifications. Designed Mixes The proportion of a designed mix shall be calculated by a recognised testing laboratory nominated by the Contractor and approved by the Project Manager to reach the required strengths and durability as stated in these Specifications. Trial Mixes The Contractor shall produce laboratory designed mixes for the various concrete grades. He shall submit results obtained from tests on trial cubes and aggregates, together with the mix proportions, the origins of the aggregate and other requirements made by the laboratory for approval of the Project Manager all before any concrete works commence. 6.4.2 Proportion of Mixes The proportions of aggregates and water to be used with the cement shall be accurately measured by weight or volume and all measuring equipment shall be kept in good working order. Allowance is to be made for the moisture content of the aggregate and for the bulking of the sand. The minimum amounts of cement in the grades of "designed" concrete mixes shall be determined by using the following data: Structures containing Liquid: BS 8007. Other Structures: SAZS CP 170 Table 48, Moderate Degree of Exposure.

Ready mixed concrete must be obtained from a plant which holds a current Certificate of Accreditation under the Quality Scheme for Ready Mixed Concrete. Each mix must be obtained from only one source unless otherwise approved by the Project Manager. The name and address of depot(s) must be approved by the Project Manager before any concrete is delivered. The Contractor shall retain all delivery notes for inspection and recordkeeping. 6.4.3 Method of Mixing All mixing shall be done by mechanical mixer. The mixers shall be kept in good working order and be thoroughly cleaned at the end of each pour. When a rotating drum mixer is used it shall be rotated between 30 and 50 revolutions after water is added. When a paddle mixer is used it shall be rotated between 20 and 40

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Section VII. General Specifications revolutions after water is added. Each batch of concrete shall be completely discharged before the mixer is recharged. 6.4.4 Slump Tests Slump tests shall be carried out in accordance with BS 1881 at regular intervals during mixing and at the request of the Project Manager. The test results shall comply with these Specifications. 6.4.5 Cube Crushing Tests At least one set of six test cubes shall be made by the Contractor from each 20 m3 pour, or part thereof in the presence of the Project Manager. The cubes and their curing shall be in accordance with BS 1881. Two cubes of each set shall be crushed at an age of seven days and the remaining at an age of 28 days. The crushing tests are to be carried out by an approved laboratory. The results shall comply with these Specifications. The average strength of four cubes shall constitute one test result. Concrete for cubes must be taken from the point of discharge from the mixer or delivery vehicle before any vibration has taken place. NOTE: The number of cubes per set may be reduced to four sets if in the opinion of the Project Manager sufficient consistency of quality in concrete mixing has been obtained by the Contractor. The results of compressive strength test carried out after seven days shall be recorded on a control chart and the values used: As an indication of what can be expected from the results of the 28 day tests. To decide whether immediate adjustment should be made to the concrete mix design.

The results of the compressive strength tests carried out after 28 days will be recorded on the control chart and the values will be used to assess whether the concrete from which the test cubes were taken shall be considered to comply with the requirements for compressive strength as required in these Specifications. The cost for making and testing of cubes shall be borne entirely by the Contractor and shall be deemed to be included in the rates and prices of the Contract. Notwithstanding the control excised by the Contractor and tests done by the Contractor as instructed, the Project Manager may require check tests and arrange for 150 mm cubes to be taken, stored and tested in accordance with the BS 1881. These check tests shall be taken at the point of deposition of the concrete. The results of these tests will be recorded and will form part of the criteria for assessment of failure. The Contractor shall arrange that the results of the tests, in certificate form, endorsed by the laboratory, be forwarded to the Project Manager within 24 hours of the test. 6.4.6 Transporting Runs or gangways for concrete transporters and main runs for foot traffic shall not be supported or allowed to bear on the fixed reinforcement. 6.4.7 Placing of Concrete General The Contractor shall ensure the use of the correct placing equipment such as cranes, dumpers, and mixing trucks so that there is no double handling of the mixed concrete.

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Section VII. General Specifications Project Managers Right to Stop Concreting Operations The Project Manager shall be empowered to stop any concreting operations if the method or plant used does not comply with these Specifications. Segregation Concrete shall be placed in such a manner that no segregation takes place, that no ingredients are lost and that the quality of the concrete is not impaired in any way. The concrete shall be placed so that the mortar is intimately in contact with the coarse aggregate and the reinforcement and other embedded parts, such as pipes and ducts. Placing methods which allow or cause the concrete to flow in the forms will not be permitted. Concrete shall not be dropped through reinforcement or embedded pipes and ducts so that segregation can be brought about by impact. Correcting of segregated concrete by means of remixing will not be permitted. Time between Mixing and Placing Concrete shall be placed in its final position with as little delay as possible. Unless concrete is kept in an agitator, the time between addition of water to the mix and placing shall not exceed thirty minutes. Concrete which is kept in an agitator which imparts a mild mixing action to it shall be placed in its final position within 120 minutes of adding water to the mix. Check slump tests will be taken and concrete which becomes unworkable will be rejected by the Project Manager. Placing Methods and Compaction Concrete shall be placed in horizontal layers of 300 mm to 500 mm deep (or as directed by the Project Manager). Each layer shall be soft when a new layer is placed on it. Entrapment of air in partially enclosed spaces to be filled with concrete shall be avoided. The height through which concrete may be dropped will not be limited, and unconfined fall will be permitted, with the provision in both cases that groups and/or clusters of segregated aggregate are not produced. Wherever possible the concrete shall be deposited vertically into its final position in the structure, but in any case the lateral movement of concrete shall be restricted to two metres and shall be effected by shovelling only. Permission to place concrete using a chute must be obtained from the Project Manager. The chute slope must be uniform throughout its length and must not be flatter than 1 in 3 nor steeper than 1 in 2. The flow of concrete must be maintained at a steady rate and baffles must be provided at the discharge ends. The transport of concrete in dumpers must not exceed 300 m. Wheelbarrows may be used provided each wheelbarrow carries a full load and the distance does not exceed 50 m. Wheelbarrows shall be full to minimise segregation. Half loads and less will not be allowed. Concrete shall be placed and compacted in all corners of the forms and around the reinforcement without segregation. The placing and compaction shall be continued without delay or interruption until a construction joint or stopping point is reached as authorised by the Project Manager.

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Section VII. General Specifications The rate of placing shall be controlled so that the compacting operations for each batch can be completed before the next batch is deposited in the forms or spaces to be filled, and shall not be so rapid as to result in movement or failure of the forms. The concrete shall be worked by vibration or, if the permission of the Project Manager is obtained, by other effective means, to ensure thorough compaction, and to remove all voids. After vibration, the concrete shall be spaded in the corners, angles and against the forms to release air bubbles with may have been trapped in these positions. Once concrete has been placed and compacted it shall not be disturbed. In general, adequate measures shall be taken to ensure that the finished hardened concrete is a dense, homogeneous material free from voids, air-holes, and honeycombing, and that the exposed surface is even and uniform. Re-Tempering of Concrete Concrete shall not be re-tempered by the addition of water or other materials. The practice of adding water to concrete after it has been discharged from the mixer will not be permitted. If this does occur, then the Project Manager will reject the concrete as unacceptable. Adequate precautions shall be taken to prevent outside water such as rain-water, groundwater, storm-water or waste-water from entering the concrete before it has hardened. Plums Displacers or plums may be placed in un-reinforced concrete sub-foundations or in other concrete members where agreed to in writing by the Project Manager. Where plums are permitted, they shall be deposited by hand. In no case will plums be permitted in sections of which the thickness is less than 0.5 m. Plums shall not displace more than 20 per cent of volume of the concrete member. The plums shall generally have a minimum dimension of 150 mm and a maximum dimension of 300 mm provided this maximum dimension shall not exceed one third of the minimum width of the member in which the plums are being placed. Each plum shall be surrounded by not less than 150 mm of concrete. The stones used as plums shall have a truly crystalline structure throughout, shall show no signs of fracture, and shall not show any signs of decomposition or weathering on the surface. Placing in Water The Contractor shall not be permitted to place concrete in water except by written permission of the Project Manager. Permission to place concrete in water will only be given if the Project Manager is satisfied that the method to be used and the precautions to be taken will ensure concrete which is free from segregation and of the required strength and quality. Precaution in Excavation Particular care shall be taken when pouring concrete against the side of an excavation, to avoid contamination of the concrete by loose material. Placing on Slope When it is necessary to place concrete on a slope by hand methods, the consistency shall be such as to exhibit no slump.
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Section VII. General Specifications Placing, vibration, and strokes of finishing operations shall be performed in an upward direction on the slope. 6.4.8 Plant The apparatus and method of vibration employed during concrete placing shall be subject to the approval of the Project Manager. Vibrators may be of the external, surface or internal type. The vibrators shall conform to the following requirements: Table and/or surface vibrators: Frequency at least 3,000 vpm with variable acceleration of 4 g and upwards. Form vibrators: Frequency 3,000 to 6,000 vpm at an acceleration of 4 g. Internal vibrators: Frequency 6,000 to 7,000 vpm with acceleration 4 g to 10 g. Vibration of Concrete

Table vibrators may be used for small precast pre-stressed or precast reinforced concrete work. Surface vibrators may be used wherever the concrete has a large surface area. Form vibrators may be used for precast or pre-stressed members and for all structural members where in the opinion of the Project Manager heavy reinforcement excludes the use of internal type vibrators. Where form vibrators are used, the forms shall be so constructed as to be sufficiently strong to permit such vibration without deformation of leakage. Internal vibrators may be used for all types of precast and cast in-situ concrete. The size and number of vibrators on hand for any concreting operation shall be sufficient to cope with the concrete to be placed. Sufficient stand-by vibrators shall be available for immediate use if required. Use of Vibrators All concrete shall be compacted by means of vibration, unless permission to use other methods is given by the Project Manager. In general the period of vibration shall be not less than 10 seconds or more than 20 seconds per 0.1 m2 of surface area over which the vibration is visibly effective. The intensity and period of vibration shall be sufficient to ensure complete consolidation of the concrete, as indicated by the cessation of air bubbles which rise to the surface and the appearance of a lime of cement paste at the forms and the attainment of a level top surface with just sufficient mortar for finishing. Care shall be taken to avoid over-vibration and bringing excess mortar to the surface. Internal vibrators shall be inserted vertically and withdrawn slowly. Vibrators shall not be used to push concrete, or to transport concrete laterally. The distance between insertions shall not exceed 0.5 m or a distance equal to the radius over which vibration is visibly effective. Internal vibrators shall not be allowed to touch the formwork, and shall not be allowed to damage or deform the formwork, neither shall the vibrators be deliberately held against the reinforcing steel. When concrete is placed in layers, the vibrators shall be inserted near the bottom of the layer close to previously placed concrete.

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Section VII. General Specifications Where surface vibrators in the form of vibrating screeds are used, they are to be moved by positive means such as cranking or by winch and cables. Pulling by hand may be approved by the Project Manager when he has determined that the method will produce satisfactory results. Vibrating screeds shall be moved slowly at a uniform rate along rails or screed guides which have been accurately set and securely supported. A uniform amount of concrete shall be kept in front of the screed at all times for the full width of the screed. Vibrators may not be attached to the reinforcement 6.4.9 Protection and Curing of Concrete

Protection on Concrete during Placing Walking on unset concrete during placing operations will not be permitted unless, in the opinion of the Project Manager, it is absolutely necessary in order to carry out the placing operations. Wheelbarrows and other vehicles shall not be permitted on concrete which is still soft. Special movable platforms or bridges shall be provided for the purpose. Protection of Concrete during Setting and Hardening All newly placed concrete shall be protected against any process which is likely to interfere with the setting and shall be protected from the harmful effects of the sun, wind, cold weather and running or surface water. While concrete is setting, it shall not be subjected to vibrations of any nature, which in the opinion of the Project Manager, are avoidable. Formwork shall not be jarred and no stress shall be placed on the ends of protruding reinforcement. Unsupported reinforced concrete members shall not be subjected to any superimposed load before the permission of the Project Manager is obtained. All other concrete shall be kept free of any load for at least 24 hours after casting. Notwithstanding the above provisions, no vehicles, pedestrians or loads or any form shall be permitted on any of the concrete work without the permission of the Project Manager. Curing of Concrete - Duration The concrete shall be protected from loss of moisture from any exposed surface for a period after is has been placed. This curing period shall vary as follows. Where atmospheric temperatures do not fall below 15C, the curing period for concrete made with normal Portland cement shall be seven days and the curing period for concrete made with rapid hardening Portland cement shall be three days. Where at any time during the curing period the atmospheric temperature falls below 15C, the above curing periods shall be extended to ten days and four days for normal and rapid hardening Portland cement respectively. Where at any time within the periods specified below the atmospheric temperature falls, or in the opinion of the Project Manager is likely to fall below 5C, effective measures shall be taken to maintain the concrete at a temperature of not less than 10C nor more than 25C for the remainder of these periods: In the case of concrete made with normal Portland cement, 72 hours from the time of placing. In the case of concrete made with rapid hardening Portland cement, 24 hours from the time of placing.

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Section VII. General Specifications Curing and protection of un-shuttered surfaces shall commence immediately after any portion of the surface has been completed and not at the end of the day's work. Curing of Concrete - Methods Protection against the loss of moisture shall be brought about by one or more of the following methods. Retaining forms in place, provided the forms are made of material suitable for the purpose, and provided the forms are kept wet. Ponding of water on exposed surfaces. Covering and suitable moisture retaining materials kept continuously wet. Sand, earth, straw, cotton mats and jute mats are considered to be suitable moisture retaining materials. Sprinkling or spraying with water to keep the exposed surfaces continuously wet. Covering with waterproof or other curing paper or other acceptable waterproof membranes held firmly at the edges. Re-use of curing paper or other membranes will not be permitted without prior approval by the Project Manager for every proposed re-use. Application of liquid curing compounds. Where formwork to vertical faces is removed before the specified curing period has elapsed, the application of liquid curing compound shall be carried out immediately.

Prevention of Staining when Curing The Contractor shall ensure that the concrete is not stained, marked, contaminated, or otherwise damaged as a result of the curing operations. Any staining or other blemish which does occur, shall be immediately removed. 6.4.10 Failure of Concrete Definition of Failure Concrete from which test cubes have been taken shall be considered to have failed to meet the requirements of these Specifications if: Any one cube result falls more than 10% below the specified compressive strength for that particular class of concrete. The result of any one test is less than the specified compressive strength for that particular class of concrete.

Procedure in the Event of Failure Should the strength of test specimens fail to meet the requirements of the above Definition of Failure, the Project Manager shall have the right to instruct the Contractor to remove and replace the portion of the structure affected. In this event the Contractor shall carry out the removal and replacement to the satisfaction of the Project Manager. Before taking the action mentioned above, the Project Manager, at his discretion, may require the Contractor to adopt any combination of the following actions: Drill and test cores, from portions of structure represented by the particular test cubes as indicated by the Project Manager and according to the manner of BS 8110.
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Section VII. General Specifications The corrected equivalent cube strengths, as specified in BS 8110, shall be recorded for assessment of the strength of the concrete in question. Conduct full scale load test on the portion of the structure under consideration according to the manner of BS 8110. Effect remedial measure to the satisfaction of the Project Manager.

In all events, the Contract shall effect improvements in the concrete for the remainder of the Contract period. 6.4.11 Costs in the Event of Failure All costs which may be incurred by reason of failure of the concrete to meet the strength requirements of these Specifications, including any costs of testing which may be required, shall be borne completely by the Contractor and no extra payment on account of such costs shall be made. 6.4.12 Quality of Cast Concrete Treatment of Cast Concrete Unless the Project Manager directs otherwise, no treatment of any kind other than that required for curing, shall be applied to the concrete after removal of the forms until it has been inspected by the Project Manager. The Contractor's methods of making good any defects are to be to the prior approval of the Project Manager in each case before such work commences. Protection Surfaces which will be exposed in the finished works shall be protected from spillage, stains and any other damage. Quality of Exposed Concrete Surfaces Any finished work which the Project Manager judges to be inferior in any respect to the approved sample or to be different in appearance from parts of the works already constructed or which is subsequently stained or damaged, will be determined as defective work. 6.4.13 Concrete in Hot Weather On exposed concrete surfaces in high sun temperatures and/or strong drying wind conditions, the Contractor shall use a curing method which also shades the concrete and this shall be placed in position no later than half an hour after final tamping. If the surface exhibits cracking while the concrete is still plastic, then it shall be re-tamped to close the cracks. Any formwork made of metal, concrete or other material of high thermal capacity shall be cooled by water before the concrete is placed on it. 6.5 6.5.1 Formwork General

Formwork shall be designed to have adequate strength to support the wet concrete. All joints shall be of adequate tightness to stop undue leakage of concrete fines during vibration. The inside of formwork shall be clean to the satisfaction of the Project Manager.

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Section VII. General Specifications All circular surfaces shall be true circular shape unless agreed otherwise with the Project Manager previously. Formwork panels shall be stiff enough to prevent damage to the concrete surface during vibration. 6.5.2 Damaged Formwork Damaged formwork shall not be re-used if in the opinion of the Project Manager the making good would impair the surface appearance of the concrete. 6.5.3 System of Formwork Before construction of formwork begins, the Contractor shall notify the Project Manager, in writing, of the system of formwork he proposes to use for all structural members. No metal part of any device for maintaining formwork in the correct location shall remain permanently within the specified concrete cover to reinforcement. 6.5.4 Propping Formwork props shall mean props that are part of the formwork and are necessary to support new construction until it is strong enough to carry its own weight. If formwork props are to be left in place when soffit forms are removed, they shall not be disturbed during the removal process except with the approval of the Project Manager. Formwork props shall be positioned between permanent supports so that all members are supported at no more than 3 metres centres in both directions. Temporary supports may also be necessary to assist the structure or part of the structure in resisting imposed loads during construction. 6.5.5 Tolerances Permissible deviations appropriate to the degree of accuracy required will be applied to linear dimensions, position, verticality level, squareness, and bow. The degree of accuracy may be one of the following: Degree of Accuracy III for use where a high degree of accuracy is unnecessary, e.g. mass foundations. Degree of Accuracy II for what is commonly called "good work". Degree of Accuracy I where the use of special, as opposed to normal, methods of materials (or both) is warranted despite the probability of higher costs than are caused by the use of Degree of Accuracy II. This may apply where, for example, prefabricated units (windows, precast panels) are required to fit in position.

Methods of Measurement of Deviations Certain deviations shall be measured as set out below: (a) Any deviation from flatness of a plane surface shall be measured as the maximum deviation of the surface from any straight line of length 3 metres joining two points on the surface, determined by means of a straight-edge the ends of which are supported on identical blocks of suitable thickness placed over each of points. Any abrupt change in a continuous surface, including a local depression or peak in a floor or wall and any abrupt change caused by a joint in formwork shall be measured as specified in (a) above. Out-of-squareness of a corner or an opening or an element such as a column will be measured by taking the longer of two adjacent sides as the base line, and

(b)

(c)

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Section VII. General Specifications determining any departure from the perpendicular of the side at either end of the base line. Permissible Deviations The Contractor shall construct each of the various parts of the works within the limits of the applicable permissible deviations set out in these Specifications appropriate to the degree of accuracy as specified in these Specifications. If no degree of accuracy is specified, Degree of Accuracy II shall apply. Concrete Surfaces Any departure from flatness and the height or depth of any irregularity of a finished plane concrete surface shall not exceed the applicable maximum value given in the table below. The specified accuracy shall be achieved without any treatment except the rubbing down of hardened surfaces with carborundum blocks. Specified Permissible Deviations (PD's) PERMISSIBLE DEGREE OF ACCURACY III A) 1. 2. 3. B) REINFORCEMENT Spacing between two adjacent bars Longitudinal location of bend and ends of bars Cover to reinforcement FORMWORK +25 +40 +20 -0+20 II +20 +30 +20 -0+20 DEVIATION: I +15 +20 +10 +10

Form work shall be so constructed as to endure that the position of the finished work will be as specified, subject to the relevant permissible deviation given in (c) or (d) below, as applicable. C) 1. FOUNDATIONS : MASS & REINFORCED CONCRETE Position on plan of any edge or surface measured from the nearest grid line or agreed centre line Linear dimension on plan cast against excavation sides Linear dimension on plan cast against formwork Level of underside of concrete ELEMENTS OF COMPONENTS ABOVE FOUNDATION (Including floor slabs) Position on plan of any edge or surface +25 +15 +5
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+50

+35

+20

2. 3. 4. D)

+60 +30 -40+20

+40 +20 -30+15

+20 +10 -20+10

1.

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PERMISSIBLE DEGREE OF ACCURACY III measured from the nearest grid line or agreed centre line 2. 3. 4. Linear (other dimensions than cross-section) +30 -10+20 +20 -5+15 II

DEVIATION: I

+10 +5

Cross-section dimension Level (deviation from designed level with reference to the nearest transferred datum (TD) of the upper or lower surface, as may be specified or any slab or other element or component) Vertically, per metre of height Out-of-squareness of a corner or an opening or an element such as a column for short side or length Up to and including 0.5 m Over and up to and including 2 m Over 2m, up to and including 4 m Exposed concrete surface: Flatness of plane surface Abrupt changes in a continuous surface Exposed concrete surface to be plastered : Flatness of plane surface Abrupt change in a continuous surface Location of holding-down bolts: The centre line of a holding-down bolt from its designated location on plan The top of the bolt from its designated elevation Constituents in concrete mix (including water) PD of quantities from approved or designated or prescribed mix: For cement, sand and water Course aggregate Treatment of Shutter Surfaces

-20+20

-15+5

-10+0

5. 6.

70

50

50

i. ii. iii. 7. i. ii. 8. i. ii. 9. i. ii. 10.

+10 +20 +25 10 10 15 10

+5 +15 +20 5 5 10 5

+3 +10 +15 3 2 * *

* *

+3 -3+5

* *

% +5 +7

% +5 +7

% +5 +7

i. ii. 6.5.6

All surfaces in contact with the wet concrete shall be treated with a releasing agent as approved by the Project Manager which will not stain or damage the concrete finish.

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Section VII. General Specifications 6.5.7 Striking of Formwork

General The Contractor shall be responsible for the safe removal of any part of the formwork or props. Before any formwork is removed, the Contractor shall ensure that the concrete has attained sufficient strength for striking to proceed. The structure shall not be distorted, damaged or overloaded in anyway by the removal of the formwork. Striking Times The minimum periods after casting that the formwork is to be kept in position are specified in these Specifications. The periods may be extended by the Project Manager whenever he considers it advisable. The Contractor may determine the striking time, at his own expense, from the strength of the concrete, provided that earlier striking will not result in unacceptable deflections due to shrinkage, creep, etc. The forms and/or formwork props to a structural member may be removed when the strengths of two concrete cubes made from the batch used in the member and cured under the same conditions as the member both exceed 15 MPa or twice the stress to which the concrete will be subjected, whichever is the greater. Permission to carry out this procedure will be withdrawn if the Project Manager is not satisfied that the strength of the cubes is representative of the concrete. Notwithstanding the above, formwork props shall remain in position for at least three days. 6.5.8 Cambers Unless otherwise instructed, all formwork to suspended beams and slabs shall be constructed with the following upward cambers: 6.5.9 Spanning between supports: 0.2% of span at centre. Cantilevers: 0.8% of span at free end. Release Agents

Release agents shall be one of the following types: Cream Emulsion. Neat oil with surfactant added. Chemical release agent.

Release agents shall be stored and used strictly in accordance with the manufacturer's instructions. 6.5.10 Sealers on Timber Surfaces Where their use has been specified or approved by the Project Manager, sealers shall be applied to surfaces which are dry and free from dirt, grease and other impurities. Whether or not the surface of formwork is in contact with the concrete, all edges to plywood or other timber, including the edges of any holes drilled through it, shall be sealed. The manufacturer's instruction regarding the method of applying the sealer shall be followed exactly and the work shall be done by a skilled painter. Before a surface is sealed is shall be sanded to remove any protrusions, or to smooth any rough areas. Any holes or indentations shall be stopped with a water-proof filler.

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Section VII. General Specifications 6.6 6.6.1 Placing and Fixing Reinforcement, Bolts, Water Bars, etc. Cleanliness

All reinforcement and items to be cast in place are to be free of loose rust and scale and free of oil and shutter releasing agents. All metal parts to be built-in and in contact with concrete shall be cleaned and free of paint, protective coatings or any other extraneous material. 6.6.2 Fixing All reinforcement and cast in items to be held securely in position by spacer blocks, ties, chairs, etc., in such a way that the positions indicated on the approved Contractor's documents are maintained to the above tolerances during the placing of the concrete. Spacer blocks shall match the mix proportions of the surrounding concrete, be comparable in strength, durability and appearance. 6.6.3 Cutting and Bending All reinforcement shall be bent to the details shown in the approved Contractor's Documents, unless otherwise stated, in accordance with BS 4466 except the shape coding. 6.6.4 Rust Staining Concrete surfaces which will be exposed in the finished works shall be protected from staining due to rusting of projecting reinforcement either by coating the reinforcement with cement grout or by another method approved by the Project Manager. 6.6.5 6.6.6 Welding Final Preparation and Inspection No reinforcement shall be welded without the approval of the Project Manager. The Contractor shall give notice as required by the Project Manager before each concrete pour, so that an inspection may be made before the concrete is placed. 6.7 6.7.1 Construction Joints Positions

The spacing of construction joints other than those in watertight construction shall comply with the following requirements: Maximum area: 100 m2 Maximum length: 13 m

The Contractor shall obtain the approval of the Project Manager to their positions before work starts. 6.7.2 Forming Construction Joints The concrete shall be run up to a stop board and not allowed to run to feather edge. Immediately prior to the casting of the next position, the existing concrete must be cleaned of all laitance and roughened to the extent that the largest aggregate is exposed but not disturbed. When work is to be resumed at a construction joint, the contact face shall be clean. The fresh concrete shall be placed directly against it. No grout or mortar shall be used except with the approval of the Project Manager. 6.7.3 Forming Moving Joints Movement joints shall be constructed strictly in accordance with these Specifications and in cases where water bars are used, they shall be continuous. All joints shall be to the Project Manager's approval.

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Section VII. General Specifications Concrete shall not be placed on both sides of a movement joint at the same time unless otherwise approved by the Project Manager. 6.7.4 Watertight Construction

General Methods of fixing formwork which result in holes through the concrete section when the formwork is removed shall not be used. Wall ties shall have water baffles. Wall kickers shall be cast monolithically with the base slab. The Contractor will be required to carry out remedial work at his own cost and to the satisfaction of the Project Manager in the event of leaks or damp patches occurring. Water Bars Water bars shall be used in all construction joints in accordance with the manufacturer's instructions. The Contractor shall obtain the approval of the Project Manager of the methods to be used to maintain them in their correct locations while the concrete is being placed. 6.8 6.8.1 Finishes Smooth or Wrote Shuttering (Fair Face)

The minimum standard of finishes for smooth shuttering shall be as follows. On removal of the formwork, concrete surfaces shall present a uniform, clean and smooth appearance, free from honey-combing and faulty junction with concrete previously pieced and unevenness due to movement and/or warping of timber and/or leaking joints. The surfaces shall conform in every way to the outline and sections shown on the approved Contractor's Documents. All curved, straight, horizontal, vertical or inclined surfaces shall be true to the lines and shapes indicated on the approved Contractor's Documents and shall not show distortion or blemish. All surfaces shall be cleaned and rubbed down to the satisfaction of the Project Manager and freed from all irregularities. The costs of this work shall be deemed covered by the rates and prices of the Contract. All shuttering shall be approved by the Project Manager before concrete is poured. Where badly honey-combed surfaces are evident, the Contractor shall break down and remove the portion of the structure affected, on the instructions of the Project Manager. The Project Manager, at his discretion, may allow remedial measures to be carried out. Remedial measure to make good any defects shall not be commenced until the Project Manager has approved the manner of effecting repairs. Repair work shall be made at the full expense of the Contractor and no payment additional to the rates and prices of the Contract will be allowed. 6.8.2 Rough Shuttering Where appearance of exposed surfaces is not important, rough shuttering will generally be allowed. 6.8.3 Free Surfaces The concrete is to be struck off with a template and tamped with a tamping board to bring the mortar to the surface. Either steel or wood float finishes will be accepted.
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Section VII. General Specifications 6.9 6.9.1 Testing of Structures General

All water retaining structures shall be tested for water-tightness to ensure compliance with the relevant design parameters and acceptance of the structure for its intended use. The method of testing shall be agreed with the Project Manager to suit site conditions, visibility and position of the elements under consideration. No backfilling around (or burying of) concrete elements shall be allowed prior to testing and acceptance of the effected structure by the Project Manager. Prior to undertaking any testing, the structure should be thoroughly cleaned and all foreign matter removed. In the first instance all inspections, testing and interpretations of results shall comply with BS 8807: 1987 Section 9 (and other related clauses contained within that document) which shall be deemed as part of these Specifications. 6.9.2 Testing of Water Retaining Structures

Procedure for Testing The following method shall be adopted for testing purposes: All outlets shall be sealed to prevent loss of water through pipes, overflows and other connections. The structure shall be filled to its normal maximum operating level at a uniform rate. The maximum acceptable rate of rise in water level is 2.0 m in 24 hours or as otherwise directed by the Project Manager. Upon completion of filling the structure, a 7-day stabilization period is to be allowed for complete saturation and absorption of the retained liquid by the concrete. During this 7-day period, the structure shall be topped-up as required. The water is to be allowed to stand for a further seven days during which time the top water level is to be monitored and recorded according to these Specifications. No additional water may be added at this time.

The structure shall be visually inspected to ensure there are no signs of leakage occurring. Following approval by the Project Manager, the test period may commence. During the test period, the water level shall be recorded on the first day of the test and subsequently at the same time each day for a total of seven days. The results are to be reviewed by the Project Manager at the end of the test period to ensure compliance with these Specifications. Should the structure fail the test for water tightness, at the discretion of the Project Manager, the structure shall be tested for a further seven days at which time the new results will be reviewed. No structure shall be subject to more than three weeks of testing without determination of the source of water egress and the institution of appropriate remedial works. The water levels are to be measured by fixing scales to the inner walls at four equally spaced position on open tanks and at all access positions on roofed tanks. In the case of open tanks, allowance shall be made for rain and evaporation. This shall be measured in evaporation pans of the same design as those used by the Meteorological Department of Government of Zimbabwe. Measurements of these tanks shall take place at the same time as those taken for the open concrete structure.

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Section VII. General Specifications Any losses or gains shall be included in the calculations for water loss in the open tank. Acceptance of Structures (Limiting Parameters) The difference in level of the water over the 7-day test period is used to assess the results of the tests. The maximum allowable difference in water level shall be the lesser of 1/500th of the average of the full water tank or 10 mm during the stipulated test period of seven days. At the discretion of the Project Manager, the above acceptance criteria may be altered to suit the nature of the structure and its requirements in accordance with the design and intended use. Notwithstanding the satisfactory completion of the tests, any evidence of seepage of the liquid to the outside faces of the liquid-retaining elements shall be addressed in accordance with these Specifications.

Localised Inspection The appearance of damp patches on the dry faces of any structural element after the element under review has been continuously subjected to water testing for three weeks or more shall be deemed as failure. The affected area shall be repaired and waterproofed, at the Contractor's expense, preferably from the water side, in accordance with the Project Managers instructions. 6.9.3 Testing of Roofs Procedure for Testing The roofs of liquid retaining structures should be water tight and shall be tested in accordance with the following procedure: Where practicable, the roof shall be flooded with water to a minimum depth of 25 mm for 24 hours (or longer if so specified by the Project Manager). Where it is impracticable to contain a 25 mm depth of water, the roof should have water applied by a continuous hose or sprinkler system to provide a sheet flow of water over the entire area of the roof for not less than 12 hours.

Acceptance of Structures (Limiting Parameters) The roof shall be considered satisfactory if no leaks or damp patches show on the soffit. Should the roof structure not satisfy either of the above tests, then after completion of the remedial work it should be retested in accordance with these Specifications. The roof covering (with stone or other materials so specified) shall be completed as soon as possible after satisfactory testing. Summary All water retaining structures shall be tested for water-tightness. The method of testing shall be to fill with water at a uniform rate of not more than 2 m in 24 hours and allowed to stand for seven days for absorption. During the 7-day absorption period, the structure shall be topped-up. The structure shall then be left a further seven days, during which time no signs of leakage must take place. In the case of underground or partially underground tanks, backfilling shall not be carried out until testing has been completed.
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Section VII. General Specifications The maximum drop in water level allowed is to be 10 mm in seven days, with due allowance made for rain and evaporation in the case of open tanks. 6.9.4 Disinfection of Structures Where structures holding potable water have been tested and before they are handed-over and put into service, they shall be disinfected as follows: (1) (2) The Reservoir shall be cleaned and washed down with clean water until all sediment and other foreign matter has been removed. The Reservoir shall then be filled with water containing not less than 150 mg/l of calcium hypochlorite. The concentrate solution shall be added slowly into the reservoir until it fills the whole reservoir and shall be left for a maximum of 24 hours. The Reservoir shall be emptied and washed down so that any further sediment is removed and re-filled with potable water. Tests shall be taken to ensure the water complies with the local authority or Government Requirements before being discharged into the water reticulation system. Measurement

(3)

6.10

6.10.1 Concrete Concrete shall be measured according to volume and shall incorporate any variations authorised by the Project Manager. 6.10.2 Shuttering Shuttering shall be measured according to concrete surface area excluding the free surfaces and underside of concrete cast direct on the ground. All alterations authorised by the Project Manager shall be incorporated. 6.10.3 Reinforcement Reinforcement shall be measured in tonnes as calculated from the bar bending schedules and shall incorporate alterations authorised by the Project Manager. The mass of the bars per metre run to be used for these calculations are to be as follows. MASS OF BAR PER METRE SIZE 6 mm 8 mm 10 mm 12 mm 14 mm 16 mm 20 mm 22 mm 25 mm 30 mm ROUND MILD STEEL 0.249 kg 0.395 kg 0.616 kg 0.887 kg 1.207 kg 1.577 kg 2.464 kg 2.981 kg 3.850 kg 5.544 kg ROUND RIBBED TYPE 2 0.222 kg 0.395 kg 0.616 kg 0.888 kg 1.210 kg 1.579 kg 2.466 kg ---------3.854 kg ----------

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Section VII. General Specifications

SIZE 32 mm 40 mm

ROUND MILD STEEL 7.546 kg ----------

ROUND RIBBED TYPE 2 6.313 kg 9.869 kg

Except where specifically provided for otherwise, no payment will be made for stools, chairs, spacers, tying wire etc. 6.10.4 Joints All construction joints shall be measured in linear metres and shall incorporate any variations authorised by the Project Manager. 6.10.5 Testing The cost of testing and sterilization of water retaining structures shall be deemed covered in the rates and prices of the Contract. Any re-tests due to faulty workmanship shall be to the Contractor's full expense. The cost of water supply shall be deemed covered in the rates and prices of the Contract.

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Section VII. General Specifications

TABLE A PRESCRIBED MIXES FOR ORDINARY STRUCTURAL CONCRETE WHERE AGGREGATES ARE BATCHED BY VOLUME Grade (MPa) Nominal Size of Stone (mm) 37.5 19 37.5 19 37.5 19 9.5 37.5 19 9.5 37.5 19 9.5 Quantities of Aggregates (litres/sack) Stone (mm) Sand 160 155 135 130 115 110 125 100 95 105 85 80 90 Max. allowed amount of water (litres/sack) 9.5 165 140 125 110 100 80 70 65 34.0 34.5 29.5 30.0 26.5 27.0 26.0 23.5 24.0 23.5 21.5 21.5 21.0 4.4 4.8 5.1 5.6 5.7 6.3 7.0 6.5 7.1 8.0 7.0 8.0 8.9 6.5 12.0 15.0 Min cement content (sacks/m3) Min current margin (MPa)

37.5 200 170 155 135 120 -

19

10 15 20

25

15.0

30

15.0

TABLE A: NOTES (1) The sand quantity for volume batching is the bulked volume of damp sand. Provided the sum total of the quantities of sand and stone for a mix is not altered, the proportions of sand and stone may be revised by +/- 10 litres. Maximum slump shall be - 60 mm (2) The proportions by volume may be calculated using the following densities: Coarse Aggregate 1,400 kg/m3 Fine Aggregate 1,550 kg/m3 If the fine aggregate is damp, 15 per cent bulking can be assumed. Where possible, actual figures for bulking and as-batched densities should be used to calculated the equivalent volumetric proportions.

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Section VII. General Specifications TABLE B PRESCRIBED MIXES FOR ORDINARY STRUCTURAL CONCRETE WHERE AGGREGATES ARE BATCHED BY WEIGHT Grade (MPa) Nominal Size of Stone (mm) Quantities (kilograms per sack) Stone (mm) Sand 200 190 165 155 140 135 150 120 115 125 100 95 110 of Aggregates Max allowed amount of water (litres per sack) Min cement content (sacks per m3) Min current margin (MPa)

10 15 20

25

30

37.5 19 37.5 19 37.5 19 9.5 37.5 19 9.5 37.5 19 9.5

37.5 270 235 210 185 165 -

19 220 190 170 150 135 -

9.5 110 95 85 34.0 34.5 29.5 30.0 26.5 27.0 26.0 23.5 24.0 23.5 21.5 21.5 21.0 4.4 4.8 5.1 5.6 5.7 6.3 7.0 6.5 7.1 8.0 7.0 8.0 8.9 6.5 12.0 15.0

15.0

15.0

TABLE B: NOTES (1) Provided the sum total of the quantities of sand and stone for a mix is not altered, the proportions of sand and stone may be revised by +/- 15 kg. Maximum slump shall be - 60 mm. Concrete for water retaining structures shall be designed mixers in accordance with these Specifications

(2)

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Section VII. General Specifications

(3)

For Statistical analysis by batching by volume or weight: Target strength = specified strength + (K times standard deviation) Degree of control under which the number of results falling below the specified strength K Factor from Normal Distribution Curve 16% 5% 2%

1.0

1.7

2.0

(4)

Standard Deviation Degree of Site Control Good Poor None Absolute Minimal Acceptance Example: Target strength = 30 + (1.7 x 7) = 41.9 say 42 MPa Normal Minimal Acceptance Example: Target strength = 30 + (1.7 x 8) = 43.6 say 44 MPa. Standard Deviation (MPa) 5 7 8

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Section VII. General Specifications TABLE 1 TABLE OF CONCRETE MIXES Grade of Concrete (MPa) 10A 10B 15A 15B 20A 20B 25A 25B 25WR 30A 30B 30WR 40A 40B 50A 50B Maximum Aggregate 20 40 20 40 20 40 20 40 20 10 40 20 10 20 10 20 Slump Limits 25 - 75 50 - 100 25 - 75 50 - 100 25 - 75 50 -100 25 -75 50 - 100 25 - 50 25 -75 50 - 100 25 - 50 10 - 25 25 - 50 10 - 25 25 - 50 Type of Cement Portland or PC 15 Portland or PC 15 Portland or PC 15 Portland or PC 15 Portland or PC 15 Portland or PC 15 Portland or PC 15 Portland or PC 15 Portland or PC 15 Portland or PC 15 Portland or PC 15 Portland or PC 15 Portland or PC 15 Portland or PC 15 Portland or PC 15 Portland or PC 15 Indicated Class of Work Blinding Backfilling Blinding Backfilling Structural Backfilling Structural Mass Sections Water Retaining Structures Structural Large Structural Sections] Water Retaining Structures Special Structural Sections Structural Special Structural Sections Structural

NOTE: Concrete Mixes 25 WR and 30 WR to have a minimum cement content of 360 kg/m3 and a maximum of 400 kg/m3.

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Section VII. General Specifications TABLE 2 COMPRESSIVE STRENGTH AT 28 DAYS EXPRESSED IN MPa Grade of Concrete (MPa) Design Strength Used in Structural Calculations Absolute Minimum Compressive Strength (no more) than 5% may be below design strength 9.0 13.5 18 22.5 Minimum Average Compressive Strength for two consecutive tests 10.0 15.5 20.5 25 Minimum Average Compressive Strength for three consecutive tests 11.5 17.0 24 28.5 Minimum Average Compressive Strength for four consecutive tests 13.5 20.5 27.5 32.5

10A 10B 15A 15B 20A 20B 25A 25B 25WR 30A 30B 30WR 40A 40B 50A

10 15 20 25

30

29.5

32.0

36.

39.0

40 50

36.5 45.0

38.5 47.5

43 52.5

47.5 57.0

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Section VII. General Specifications TABLE 3 NORMAL CURING PERIODS Condition under which concrete is maturing Minimum periods of protection for different type of cement Curing Period Portland cement blast days Damp or indoors Ambient Temperature greater than 18 C (normal) 5 C to 18 C (cool) under 5 C (cold) 8 12 14 6 8 10 2 3 4 4 furnace PC15 Portland cement days 3 High early strength Portland cement days 1

NOTE: During the first three to five days of the curing period, effective measures should be taken to maintain the concrete at a temperature of between 10 C and 25 C.

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Section VII. General Specifications TABLE 4 MINIMUM PERIOD BEFORE STRIKING FORMWORK TYPE OF CEMENT USED Normal Portland Cement and PC 15 High early strength Portland cement & High early strength PC 15 Normal Cool Cold* Portland blast furnace cement

WEATHER TYPE STRUCTURAL MEMBER FORMWORK OF OF

Normal

Cool

Cold*

Normal

Cool

Cold*

Beam sides: walls & unloaded columns Slabs with props left under Beams soffits with props left under and ribs on a ribbed-floor construction Slab props Beam props

36 h 4d 7d

3d 7d 12 d

4d 7d 12 d

24 h 2d 3d

30 h 4d 5d

36 h 4d 5d

3d 7d 10 d

5d 10 d 17 d

6d 12 d 17 d

10 d 14 d

17 d 21 d

17 d 28 d

5d 7d

9d 12 d

9d 12 d

14 d 16 d

17 d 21 d

21 d 28 d

Weather may be regarded as "normal" when atmospheric temperatures adjacent to the concrete, as measured by a maximum and minimum thermometer, do not fall below 18 C ; as "cool" when the temperature measured similarly is between 5 C and 18 C ; as "cold" when under 5 C. * Shorter periods may be used for sections of thickness at least 300 mm.

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Section VII. General Specifications

7 7.1

MANHOLES AND ANCILLARY CHAMBERS Cement, Reinforcement, Aggregate and Water

All cement, aggregate, reinforcement and water used, shall comply with these Specifications. 7.2 Bricklaying and Plastering

All brickwork and plastering shall comply with these Specifications. 7.3 Covers Unless otherwise specified, covers shall be of cast iron and comply with BS 497 or SABS 558, with triangular heavy-duty manhole covers in roadways and circular medium duty covers elsewhere. The initials of the Beneficiary Municipality shall be cast on the upper surface of the cover. 7.4 Manholes and Inspection Chamber Construction In all cases, pipe gradients shall be continuous through the manhole, and the benching on junction manholes shall provide for smooth free flow in all of the channels in the manhole. No concrete, including the base, shall be poured under water, and particular care shall be exercised to ensure that the complete manhole structure, especially at the points where pipes enter the manhole, is waterproof. 7.4.1 Precast Concrete Manholes Precast members used in this construction shall comply with relevant SAZS. Aggregate used in manufacture of the precast sections shall preferably be limestone or dolomite, to the Project Manager's approval. Unless otherwise specified, manhole chamber rings shall be reinforced with not less than 100mm2 of hard drawn steel wire, placed circumferentially per 300 mm of height with suitable longitudinal steel. Shaft rings shall be similarly reinforced with not less than 570mm2 of hard drawn steel wire per 300 mm of height. The Contractor shall submit full details of the precast products to the approval of the Project Manager, including slab thickness, reinforcement details, design concrete strength, and the loading which medium and heavy duty slabs are designed to carry. Precast manholes shall be constructed with an in situ base slab of well compacted 20 MPa concrete and pre-cast chamber, chamber roof, access shaft and shaft cover which shall incorporate step irons as detailed and specified by the Project Manager. The chamber ring shall be in the form of a butt-ended pipe, the ends of which shall be roughened to give adequate bond with the mortar joint at base and roof slab, and intermediate ring joints shall be OG. Particular care shall be exercised to prevent the ingress of ground water at the joint between the chamber ring and the base slab. Backfilling behind precast manholes shall ensure adequate compaction, uniform around the circumference of the manhole, and to eliminate future settlement. Cover frames shall be bedded on a prepared cement mortar (1:3 mix) bed and where necessary shall be tilted to conform with the slope on surfaced roads. The frame shall be set such that the closed cover shall be flush with the road surface, and in open country shall project 150 mm above the ground surface.

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Section VII. General Requirements 7.4.2 In-Situ Concrete Manholes

The concrete mix used shall be 20 MPa, except in water logged or bad ground where the Project Manager may order 30 MPa concrete, mechanically vibrated. Chamber wall and floor slabs shall not be less than 150 mm thick, the actual thickness depending on site conditions and as directed by the Project Manager. Step irons shall be built into the walls and shafts, as concreting proceeds. The rates and prices of the Contract shall be deemed to cover for setting the step iron into position, trimming shutters, etc. Unless otherwise instructed by the Project Manager, manhole walls and the outer faces of manhole shafts shall be cast against rough external shutters. 7.4.3 Ancillary Chambers Unless otherwise specified the covers and frames shall comply with Grade C light duty rectangular covers and frames, solid section having a 600 mm x 450 mm clear opening, all as specified in BS 497. Frames shall be set so that the highest levels of surrounding ground are not less than 100 mm below cover levels. 7.4.4 Channels and Benching Unless otherwise specified by the Project Manager, for 100 mm to 225 mm diameter sewers, the channels in manholes shall be formed in half round channels of the material used on the pipeline, using straight channels, bends and channel junctions as required, all laid true to level and grade and properly bedded and jointed in 1:2 cement mortar. For 300 mm diameter and larger sewers, channels in manhole base slabs shall be formed to slope and grade complete with bends, junctions etc., all with the largest possible radius. For 100-mm diameter house connection pipework, which joins the sewer at manholes, half round channels shall be formed in the concrete base slab with bends of minimum centre-line radius. Benching shall be constructed of 20 MPa mix concrete unless otherwise instructed by the Project Manager and shall be grano-rendered as specified by the Project Manager, placed into position while the concrete is still green and properly keyed to it, laid to falls, and made good to channels, and where necessary carried through the invert, 20 mm thick, all finished true to line and level with a smooth uniform finish. In backdrop manholes, the 90 degree bend at the foot of the backdrop shall be turned to face the channel outlet to eliminate splashing of the benching. 7.4.5 Pipes into Manholes and Ancillary Chambers Manhole and inspection chamber positions shall be accurately located and the base slabs set out before pipe laying commences. When completing the pipe laying, the pipes entering and leaving the manhole shall be laid to grade and cut to length such that the face of the socket or spigot of the pipes entering and leaving the manhole shall be to the Project Manager's approval. During pipe laying, the pipes entering and leaving the manhole shall be firmly supported on a continuous haunching of 10 MPa concrete, the manhole base slab being cast complete immediately the sewer lengths on either side of the manhole have been completed. Care must be taken during the pouring of the base slab to ensure that the concrete is properly consolidated around the pipes but without disturbing them from the true grade line.

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Section VII. General Specifications Particular care shall be taken in pouring the base slab, to prevent the future ingress of ground water from under the base slab. 7.4.6 Testing Manholes Completed manholes shall be watertight and in testing, the inlet and outlet pipe work shall be plugged with expanding stoppers and the manhole filled with water to top of roof level. The manhole shall show no signs of leaking or weeping, and the water level shall not fall for a period of one hour. The rates of the Contract for manhole construction shall be deemed to include for the supply and disposal of all water and all equipment necessary to carry out the testing and disposal of the water. 7.5 Precast Concrete Specials Precast concrete specials, e.g. boxes for meters, stop-cocks, valves, etc.., shall be of approved manufacture using 30 MPa concrete with maximum aggregate size 12 mm (or other mix approved by the Project Manager) and shall be made using vibrating or pressing methods. 7.6 Measurement Measurement of manholes and ancillary chambers shall be taken from the invert level of the sewer to the underside of the frame of the cast iron or precast concrete cover, and shall be broken down in gradations of 0.5 metres. The rates and prices of the Contract shall be deemed to cover extra excavation beyond the normal trench width and depth in soft material and for all materials and labour etc., required to completely construct the manhole or ancillary chamber in terms of these Specifications. They shall include for step irons, any special shaft rings, make up brickwork and plastering beneath the cover, and shall include the supply, delivery and fixing of a medium duty cover and frame, either in cast iron or precast concrete. No extras shall be allowed for bends in the main sewer, or for connections into the Chamber.

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Section VII. General Requirements 8 8.1 MECHANICAL WORKS Introduction

This chapter covers workmanship, materials of construction and other miscellaneous items applicable to all items of mechanical works. All component parts of the works shall, unless otherwise specified, comply with the provisions of this chapter or be subject to the approval of the Project Manager. 8.2 Materials and Workmanship All submerged moving parts of the works, or the pins and spindles, etc., of the submerged moving parts or the faces, etc., in contact with them shall be of corrosion-resistant metals. All parts in direct contact with various chemicals, shall be completely resistant to corrosion, or abrasion by these chemicals, and shall also maintain their properties without ageing due to the passage of time, exposure to light or any other cause. Where "stainless steel" is specified or used, it shall have resistance to atmospheric corrosion not less than that provided by BS EN 10088, Grade 410 S3. Particular attention shall be made to the prevention of seizure by fretting where two corrosion-resistant metals are in contact, by the selection of materials of suitable relative hardness and surface finish and the application of lubricants. Where "bronze" is specified or used, it shall be zinc-free. Particular attention shall be paid to the prevention of corrosion due to the close proximity of dissimilar metals. Where it is necessary to use dissimilar metals in contact, they shall be selected so that the bimetallic corrosion is as low as possible. Workmanship and general finish shall be of first class commercial quality and in accordance with best workshop practice. All similar items of plant and their component parts shall be completely interchangeable. Spare parts shall be manufactured from the same materials as the originals and shall fit all similar items of plant. Machining fits on renewable parts shall be accurate and to specified tolerances so that replacements made to manufacturer's drawings may be readily installed. All plant shall operate without excessive vibration and with the minimum of noise. All revolving parts shall be dynamically balanced so that when running at all operating speeds and any load up to the maximum, there shall be no vibration due to lack of balance. All parts that can be worn or damaged by dust shall be totally enclosed in dustproof housings. 8.3 Design Life Unless otherwise specified, all items of works shall be rated for continuous service at the specified duties under the prevailing atmospheric and operational conditions on site. All materials and plant shall be designed for long life with a minimum of maintenance and the Contractor may be called upon to demonstrate this for any component either by the service record of similar mechanical works elsewhere or by records of extensive type tests. Routine maintenance and repair shall, as far as possible, not require the services of highly skilled personnel. Except for consumable items such as gland packing, carbon brushes, etc., which normally require replacement more frequently, no part subject to wear shall have a life from new to replacement or repair of less than three years of continuous normal operation and where major dismantling is required to replace a part, such service life shall be not less than ten years.

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Section VII. General Specifications 8.4 Welding

Welded parts consisting of steel to BS EN 10113, BS EN 10028 or similar steel shall be welded in accordance with BS EN 1011. Circumferential welds, etc., shall be fabricated and tested in accordance with PD 5500, BS 2633 or equivalent standards where applicable. All joints shall have the plate edges accurately prepared to the appropriate profile for welding. The parts shall then be assembled and accurately checked before welding proceeds. The welding and fabricating procedure shall be such that residual stresses are a minimum and distortion avoided. Special attention shall be given to ensure that distortion does not occur after machining to affect the alignment and operation of the part concerned. Welding procedures shall be in accordance with BS EN 288-3:1992. Each unit shall be fabricated and welding completed before final machining or other fitting work is carried out. All fillet welds shall be continuous. Electrodes used shall be low hydrogen type and shall comply with requirements not less than BS EN 499 or equivalent standard for carbon steels, and BS EN 1600 or equivalent standard for stainless steels. Only stainless steel electrodes shall be used for welding stainless steel. Stainless steel to be welded shall be suitably stabilized. Heated storage and ovens shall be provided for the electrodes. Only skilled, qualified and tested welders shall be employed. The welders shall be tested in accordance with BS EN 287-1:1992, or other equivalent standard. Detailed records of welding shall be kept, showing the name of each welder against each run in a weld and any welder found to be producing an unacceptable amount of defects shall be removed until he has passed the test again. Where valve bodies, sleeves, etc., are of welded construction, all longitudinal butt welds in the shell plates shall be completely radio graphically tested. All circumferential butt welds in pipes shall, where possible, have at least 100 mm in 1000 mm of their lengths radio graphically tested. All welds shall be 100% ultrasonically tested. Ultrasonic testing shall be carried out in accordance with BS EN 1714:1998 and the Contractor shall propose a standard of acceptance. All fillet welds shall be tested by ultrasonic crack detection, or other approved means. For all other items of plant, the Contractor shall allow for adequate radiographic examination of the welds. The positions to be examined will be indicated by the Project Manager. The "International Institute of Welding Collection of Reference Radiographs of Welds" shall be used as a guide for the interpretation of radiographs and as a basis for comparison regarding the nature and extent of weld defects. The minimum grade for acceptance shall be blue. 8.5 Castings All cast iron shall be of standard grey close-grained quality to BS EN 1561:1997. The structure of the castings shall be homogeneous and free from non-metallic inclusions and other injurious defects. All surfaces of castings that are not machined shall be smooth and shall be carefully fettled to remove all foundry irregularities. Minor defects not exceeding 12.5% of total metal thickness and that will not ultimately affect the strength and serviceability of the casting may be repaired by welding techniques approved by the Project Manager. The Project Manager shall be notified of larger defects and no repair welding of such defects shall be carried out without prior approval. If the removal of metal for repair will reduce the stress-resisting cross-section of the casting by more than 25%, or to such an extent that the computed stress in the remaining metal exceeds the allowable stress by more than 25%, then that casting may be rejected. Castings repaired by welding for major defects shall be stress-relieved after such welding. Non-destructive tests will be required for any casting containing defects whose extent cannot otherwise be judged, or to determine that repair welds have been properly made.

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Section VII. General Requirements 8.6 Forgings

All major, stress-bearing forgings shall be made to a standard specification that shall be submitted to the Project Manager for approval before work is commenced. They shall be subject to internal examination and non-destructive tests for the detection of flaws, and shall be heat treated for the relief of residual stresses. The name of the maker and particulars of the heat treatment proposed for each such forging shall be submitted to the Project Manager. 8.7 Fixings Nuts, bolts, studs and washers for incorporation in the works shall conform to the requirements of the appropriate BS standard or other approved standard. Nuts and bolts for pressure parts shall be of the best quality bright steel, machined on the shank and under the head and nut. Bolts shall be of sufficient length such that one thread shall show through the nut when in the fully tightened condition. Fitted bolts shall be a light driving fit in the reamed holes they occupy, shall have the screwed portion of a diameter such that it will not be damaged in driving, and shall be marked in a conspicuous position to ensure correct assembly at site. Washers, locking devices and anti-vibration arrangements shall be provided where necessary and shall be subject to the approval of the Project Manager. Where bolts pass through structural members, taper washers shall be fitted where necessary to ensure that no bending stress is caused in the bolt. Where there is a risk of corrosion, bolts and studs shall be designed so that the maximum stress in the bolt and nut does not exceed half the yield stress of the material under all conditions. All bolts, nuts and screws which are submerged in water shall be made of nickelbearing stainless steel. 8.8 Allowances for Wastage The Contractor shall supply as specified and to the satisfaction of the Project Manager reasonable excess quantities to cover wastage of those materials which will normally be subject to waste during erection, commissioning and setting to work. 8.9 8.9.1 Lubrication General

Provision shall be made for suitable lubrication to ensure smooth operation, heat removal and freedom from undue wear. Plant selected shall require minimum lubrication attendance and down time for lubricant change. The Contractor shall furnish a complete schedule of recommended oils and other lubricants. The number of different types of lubricants shall be kept to a minimum. The schedule and the name of the supplier of the lubricants shall be submitted to the Project Manager for approval before incorporation in the O&M Manuals. In the case of grease lubricated roller type bearings for electric motors, lithium base grease shall be required. The Contractor shall supply the first fill of oil and grease from approved lubricant suppliers. All grease nipples, oil cups and dip sticks shall be readily accessible, being piped to a point as near as practicable to the lubrication point. 8.9.2 Grease Lubrication Where lubrication is effected by means of grease, preference shall be given to a pressure system that does not require frequent adjustment or recharging. Frequent, for this purpose
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Section VII. General Specifications means more than once weekly, and grease systems having shorter periods between greasing should be avoided. Where necessary for accessibility, grease nipples shall be placed at the end of the extension piping and, when a number of such points can be grouped conveniently, the nipples shall be brought to a battery plate mounted in a convenient position with spacing in accordance with the recommendations of BS 1486 Part 1. Button head type nipples shall be used for normal grease lubrication. (Anti friction bearings requiring infrequent charging shall be fitted with hydraulic type nipples). Where more than one special grease is required, a grease gun for each special type shall be supplied and permanently labelled. 8.9.3 Oil Lubrication Oil sumps shall be fitted with oil level indicators of the sight glass type, or where this is not practicable, with dipsticks. The indicators shall show the level at all temperatures likely to be experienced in service. The normal, maximum and minimum levels at 30 C shall be clearly visible in the sight glass type as viewed from the normal access floor to the particular item of plant, and they shall be easily dismantled for cleaning. All sight glasses shall be firmly held and enclosed in metal protection in such manner that they cannot be accidentally damaged. All lubrication systems shall be designed so as not to present a fire hazard and particular care shall be taken to prevent leakage of lubricants and to avoid leaking lubricants coming into contact with any electrical works, heated surfaces or any other potential source of fire. Gear boxes and oil baths shall be provided with adequately sized filling and draining plugs and suitable means of oil level indication. Roller chain drives shall have oil bath lubrication. Drain points shall be located or piped to a position such that an adequately sized container can be placed beneath them. Where a large quantity of oil is involved or drainage to a container difficult, a drain valve and plug shall be provided at the point of discharge. Bearings equipped with force-fed oil lubrication shall be automatically charged prior to machinery starting up and pressure monitored during operation with automatic shutdown of machinery and alarm on low oil pressure. Access, without the use of portable ladders, to lubrication systems shall be such as to permit maintenance, drainage and re-filling, without contamination of the charged lubricant. The design of breathers shall take into account the humidity and atmospheric contamination at the vent point. Measures shall be incorporated to prevent contamination of the lubricant. The Contractor shall supply flushing oil for each lubrication system when an item of plant is ready for preliminary running, and a sufficient quantity of the approved lubricants for setting to work, and for the commercial operation of the plant for two years after the Certificate of Completion has been issued. 8.10 Machinery, Lifting, Dismantling, Guards, Noise and Vibration 8.10.1 Alignment Machinery bedplate design, packing and fixing shall be such as to minimize distortion and vibration. Aligned machinery shall be mounted on either bed or sole plates permitting removal and reinstatement without a requirement to re-grout. Bedplates shall incorporate fine adjustment of the vertical and horizontal alignment between driver and driven members.
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Section VII. General Requirements 8.10.2 Lifting All machinery shall be fitted with lifting facilities. Large structures shall be provided with jacking points. 8.10.3 Machinery Dismantling Tapped holes or other provisions must be made in all main castings, for the insertion of jacking screws or the fixing of drawing gear to facilitate dismantling. On items of machinery subject to frequent dismantling, bolts or studs shall be employed rather than set screws. 8.10.4 Guarding Guards shall be provided to prevent access to electrical apparatus and moving parts of machinery. They shall be designed to be secure but removable without disturbing other parts of the plant. The Contractor shall ensure that stationery points, requiring access, are located safely, outside the guards. Large guards shall be equipped with small removable panels for the inspection and checking of enclosed components. 8.10.5 Noise and Vibration The Contractor shall provide a quiet installation. All items of plant supplied and installed under this Contract shall be carefully chosen with a view to quiet operation. All plant must be capable of being operated without excessive vibration and the minimum amount of noise. Should the overall sound level of any item of Plant exceed 85 dB(A) at one meter radius, the Contractor shall include for suitable sound attenuation to achieve this level. This will apply in the audible frequency range 20 Hz - 20 kHz. Above 20 kHz, the Contractor shall state whether any fundamental frequencies are generated in the ultrasonic region. Where plant is operating in the vicinity of residential buildings, then the sound level at one meter radius from outside of the pump or plant house enclosure or building shall not exceed 65 dB(A). The Contractor shall provide and fix all material for the prevention of transmission of noise and vibration through the structure. All fans, motors, A/C package units, compressors, diesel engines and other motive plant shall be mounted on resilient mountings in such a manner that the plant foundations are isolated from the floor or structure. In addition, all rotating plant shall be statically and dynamically balanced. Mechanical vibration shall be isolated by the use of anti-vibration mountings and flexible connections to ensure an isolation efficiency of 95% from the building structure. 8.10.6 Gearboxes Gearboxes shall have a life of 100,000 hours, be selected in accordance with AGMA recommendations for horsepower calculation and service factor application, and employ a standard reduction ratio. Gearboxes that have to be angle mounted shall have a rating, choice of bearings, seals and lubrication system which are suitable for such mounting. Dependence on splash lubrication alone is not acceptable but it may be used in conjunction with a forced feed method to reach all bearings and gears. Calibration of the oil dipstick and its position together with that of the sump drain plug requires special consideration. 8.11 Bearings 8.11.1 Bearings below Water The Contractor shall select the most appropriate type of bearing for the plant being supplied.

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Section VII. General Specifications Plant with vertical shafts shall have thrust and guide bearings. All bearings shall be designed to exclude the ingress of water except where the bearings are water lubricated. Sealed for life units are acceptable subject to a minimum design life of 50,000 hours operation at maximum loading. Plant which may be subject to vibration whilst stationary shall be provided with bearings designed to withstand damage from such a cause. Below water bearings shall be of the journal type, of rubber, gunmetal or equal and journals of stainless steel. 8.11.2 Bearings above Water Single journal plain bearings shall have phosphor bronze or synthetic lubrication impregnated bushes, and carbon or stainless steel journals, respectively. Synthetic bearings shall only be used where bearing condition can readily be inspected. Plain type bearings shall be self-lubricating by grease, forced oil or impregnation. Ball and roller type bearings shall be adequately lubricated by oil or grease and sealed to prevent leakage of lubricant along the shaft. Attention shall be given to ensure that dismantling of bearings is simple and free from risk of damage. Bearings fitted to gear boxes shall have a minimum design life of 100,000 hours at maximum loading. 8.12 Pumps 8.12.1 General Each pump shall be designed and constructed to be suitable for the particular liquid to be pumped. Pumps shall be of the type specified and arranged as indicated in these Specifications. Pumps shall be designed to give the specified output against all losses including those relating to the pump station pipe work and valves. The Contractor shall match his pump characteristics to the pipe system networks to achieve the highest pump efficiency and reliability. The pumps shall have a non-overloading characteristic over the complete range of head and quantity delivered, and the drive shall be capable of operating the pumps against maximum run-out conditions and still have a 10% operating margin. Each set must be capable of running satisfactorily in parallel with other sets in the system without throttling and by itself, without cavitation or overload under all operating conditions within the system characteristics. Centrifugal pumps shall have head/flow characteristics which fall continuously from the maximum pressure at closed valve conditions and which are steep in order that variation in head shall have a minimal effect on the quantity discharged. The whole pumping unit shall be capable of withstanding, without detriment, reverse rotation to a speed that would occur if the pump were to stop when the differential head was at a maximum and the delivery and/or non-return valve failed to close. 8.12.2 Pump Casings The pump design shall ensure that alignment is maintained between the various assemblies by recesses, spigots and dowels and shall be such that all components liable to wear can be replaced. Components shall be permanently marked with the manufacturer's number and where dowels are not used, permanently marked for correct assembly. The pump casing shall have replaceable wear rings. The casings of the pumps shall be of a suitable grade of close-grained cast iron to BS EN 1561:1997 or nickel iron and have flanges to match the specified pipe work. The waterways through the pumps shall be smooth in finish and free from recesses and obstructions.
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Section VII. General Requirements Pumps shall be designed to facilitate maintenance, and man-holes or hand-holes shall be provided to allow the interior of the casings and bearing seals to be examined without dismantling the pump. It shall be possible to remove pump impellers with the minimum disturbance to pipe work and by suitable joints to allow the pump to be removed without dismantling the main pipe work. All joints shall be machined and faced and bolt holes shall be drilled and arbored. Locating pins shall be provided where necessary, also starting screw holes, the latter being provided with set screws. 8.12.3 Impellers The impellers and guide vanes (if any) shall be of suitable material, accurately machined and smoothly finished to minimize hydraulic losses. The rotating elements shall be statically and dynamically balanced before final assembly. The impeller shall be readily withdraw-able from the pump casing without the need to disconnect pipe work. 8.12.4 Pump Shafts The pump shaft shall be of high tensile or stainless steel adequately sized, with good fatigue, shock load and corrosion resistance. The duty speed range shall be well below the first critical speed of the shaft. Where a change in diameter of the shaft occurs the shoulder shall be radiuses or undercut to reduce stress concentration. The shaft shall be complete with easily renewable stainless steel protecting sleeves at glands and bearings. 8.12.5 Bearings All bearings shall be liberally rated to ensure cool running and meet the load factors required for the pump function. For vertically mounted pumps, the bearing shall be a combined thrust and journal type, designed to prevent any thrust loads being imposed upon the drive motor. The pump bottom bearing shall be lubricated by an enclosed water lubricated sleeve bearing suitable for potable water applications. Where grease points are necessary they shall be fitted with removable screwed plugs which shall be accessible without removing guards. All bearings having automatic lubrication shall also have provision for hand lubrication. 8.12.6 Shaft Seals The Contractor shall select a seal, compatible with his plant and best suited for the worst conditions likely to be met when the plant is in operation. All seal materials shall be compatible with and/or resistant to the fluid or gas being handled. For potable water, seal materials shall be those specifically approved for use in the water industry. Stuffing boxes shall be provided with renewable gland packing. Glands subject to abrasive liquors or negative pressures shall embody suitably positioned lantern rings and a clean water continuous flushing system, operative whenever the plant is in motion or a corrosive element is present. Gland adjustment nuts shall be readily accessible for routine maintenance. Gland drain pipe work shall be installed, incorporating rodding facilities and adequate inclines discharging to the nearest sump or drainage channel. Mechanical seals which are on pumps subject to abrasive liquor or gas, or subject to negative pressures or corrosive elements, shall be provided with a clean water continuous gland flushing system, operative when the item of plant is in motion or a corrosive element present. A back-to back sealing arrangement with a flush/cooling system shall be accepted as satisfying the requirements of this clause.

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Section VII. General Specifications Special care in the selection of materials shall be taken in order to avoid binding and electrolytic action between the shaft sleeve and the seal components, particularly where long periods of idleness are inherent in the duty cycle as in the case of stand-by pumps. The gland water connections supplying water seals of the pumps shall be provided with suitable filters to prevent abrasive matter in suspension from entering the gland stuffing box. These filters shall be designed to facilitate easy cleaning. 8.12.7 Pumps Miscellaneous Cooling and lubrication water pipe work shall be fitted with flow indicators where specified. Horizontal pumps shall be mounted on a common fabricated steel bedplate manufactured from substantial rolled steel sections of welded construction with machined pads for mounting both pumps and motors. Folded plate type bedplates shall not be acceptable. Pumps and motors shall be dowelled in position to allow for easy relocation in the event of their being removed. The pump shall be connected to its driving motor by a flexible coupling of a type approved by the Project Manager which shall be adequately guarded. On horizontal pump-sets fitted with hydraulic balance devices, the couplings shall permit free movements of pump shafts under load. On vertical pump-sets where the shaft couplings are of the screwed type, the couplings shall be positively locked. The Contractor shall ensure that adequate net positive suction head is available to ensure that pumps operate without cavitation under the worst operating conditions. Indicating pressure gauges each with an isolating cock and snubber shall be provided on the suction and delivery side of each pump except that a suction gauge is not required on submersible type pumps. All pressure gauges shall be provided with high and low level adjustable contacts which can be used to provide additional pump protection where specified. 8.12.8 Sump Pumps Suitable submersible sump pumps shall be installed in all basements liable to flooding. The pumps shall be float operated and be complete with non-return valve, galvanized steel discharge pipework, cables and electrical control gear. The pumps shall be rated to deliver the specified flows at the worst head conditions. Switchgear shall be suitable for 15 starts per hour. 8.13 Flanges 8.13.1 General Unless otherwise specified, all flanged connections of pumps, pipe work, valves and other relevant plant shall have flanges in accordance with BS EN 1092:1997. 8.13.2 Jointing All flanged joints shall be made with 3 mm thick full-face reinforced rubber insertion gaskets to BS EN 1514-1:1997. During installation all pipes shall be hung on their respective supports and lined up so that their joint faces are parallel before flanges are bolted together. In making joints, no springing of pipes into position shall be allowed. Joints on flanges that exist or have been installed under other contracts shall be made with the same material and suitable for the flange faces.

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Section VII. General Requirements 8.14 Pipe Work

8.14.1 Pipe Work General All pipe systems shall be arranged, installed, supported and provided with all necessary means of venting, draining and expansion, all to the approval of the Project Manager. The pipe work layout shall be designed so that items of plant and sections of pipe work can be removed without major disturbance to the adjacent pipe work. Particular care shall be taken to ensure that pipe work thrusts are not transmitted to machinery or associated apparatus. The Contractor shall indicate on his Shop Drawings the thrust blocks required to anchor his pipe work. The Contractor shall provide flexibility in the pipe work at joints in the main structures and shall submit proposals for the approval of the Project Manager. Flexible joints or collars and cut pipes shall be allowed on all pipe work where necessary to allow for some margin of error in the building work. Wherever possible, flexible joints shall be provided with tie bolts or other means to transfer longitudinal thrust as a whole so that external anchorages may be kept to a minimum. Flexible joints shall also be provided for ease of erection and future dismantling. All necessary supports, saddles, slings, fixings bolts and foundation bolts shall be supplied to support the pipe work and its associated plant in an approved manner. Valves, meters, strainers and other devices mounted in the pipe work shall be supported independently of the pipes to which they connect. Dead legs shall be avoided, but where this is not possible, provision shall be made for flushing the pipe work. Changes in pipe bore sizes shall be by the use of proprietary fittings or fabricated sections to avoid sudden changes. Where relevant, formed bends and offsets shall be used and be cold formed in a standard pipe bending machine. They shall have an inside radius of not less than four times the outside diameter of the pipe. Flushing and drain connections on pipe work below 150 mm shall be made using proprietary welded fittings with internal parallel threads to BS EN ISO 228-1:2003 which shall be immediately sealed with hexagon headed shouldered plugs and seals. Holes thus made in the pipe shall have burrs removed and be finally pulled through to remove loose particles. Template or closure pipes shall be provided where necessary to facilitate erection. The design and construction of the template pipes shall be to the approval of the Project Manager, and the Contractor will be responsible for establishing the dimensions of the template pipes such that there will be no strain placed on the connected items after installation. All nuts, bolts, washers, flanges, gaskets, flanged tied adapters, drain valves, special connection pieces, together with all terminal point connection materials shall be supplied under the Contract. Viking-Johnson or approved equivalent flange adapters shall be fitted where necessary to facilitate the removal of valves, etc. Adequate provision shall be made for anchoring pipes at these joints. Hydraulic pipe work shall be sized to maintain fluid velocities below those specified and provide a safety factor of 4:1 on the design pressure, which shall be taken as 120% of the pump closed valve head. Pipe work for compressed air shall be sized such that air flow velocity does not exceed 8 m/s. To provide adequate condensate drainage, the pipe work system shall be run with a horizontal fall of not less than 1 in 50 in the direction of air flow and incorporate drainage points at distances of not less than 30 m. Drainage points shall be formed by use of equal tees with a down-pointing leg fitted preferably where changes of direction of flow occur.
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Section VII. General Specifications 8.14.2 Steel Pipe Work General purpose steel pipe work with screwed fittings shall be of galvanised mild steel to BS 1387 heavy grade with fittings of galvanised malleable iron to BS 143 and 1256, having tapered internal and external threads to BS 21. Steel pipe and fittings over 80 mm diameter, shall be carbon steel seamless tubes in accordance with BS EN 10216-1:2002 or welded tubes in accordance with BS EN 102171:2002 with pipe sizes to BS EN 10220:2002. Joints shall be flanged. Pipes shall be fabricated in accordance with BS EN 10224:2002 with welding in accordance with BS 2633 or BS 2971 and BS 4515-1:2000. After fabrication and machining of flanges, all pipe work and fittings shall be tested to a test pressure equal to 1 times the flange pressure rating. Where pipes are to be joined with sleeves or couplings, a sufficient length of pipe shall be left bare of coating to accommodate the sleeve or coupling. Plain-ended pipes shall be supplied rounded at both ends. An adequate number of pipes shall be supplied rounded throughout their length so that they may be cut and such pipes shall be clearly marked. Couplings for use with steel pipes shall comply with BS EN 10224 except where other types of couplings are specified in other sections of these Specifications. Components of flexible joints from different manufacturers shall not be used together. Tests on pipes shall be made in accordance with relevant British Standards at the manufacturer's works as required by the Project Manager. Two copies of the results of all such tests shall be submitted to the Project Manager. Flanges on steel pipes shall be welded in accordance with BS 2633 or BS 2971 and shall have raised or flat faces. Gaskets for use in flanged joints shall consist of rubber complying with BS EN 681-1:1996. On flat face flanges, the gaskets shall extend over the full flange area and on raised face flanges, they shall cover the raised face only. No asbestos shall be used on any flange of pipe work or fitting carrying potable water. Steel pipes that are to be welded shall have the ends prepared by the manufacturer to suit the type of welded joint as required by the Project Manager. The pipes shall be free of external and internal coating for a distance of 75 mm from each weld line. After fabrication, all welding scale and beads as well as hardened fluxes shall be removed and joints shall be free of pores and as smooth as possible. Where specified by the Project Manager, all pipes and specials shall then be degreased and grit blasted prior to coating with an approved fusion bonded epoxy coating. The coating shall be tested to ensure the correct thickness and the absence of pores using spark testing equipment. Bends, branches and other fittings for use with steel pipe shall comply with BS 534 or other approved standard. Calculations for the design of all special fittings shall be submitted to the Project Manager before manufacture commences. Pipes shall be stacked on a firm base using two timber packers only under the barrel of pipes. Fittings and specials of any type shall be stored in a single layer only. Pipes and fittings shall at all times be adequately protected from damage during transport, storage and handling. Pipes shall be fitted in the factory with end caps and reinforcement adequate to prevent distortion during transport, storage and handling. Rubber rings and other pipe jointing material shall be stored under cover away from direct sunshine.

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Section VII. General Requirements 8.14.3 Accuracy of Work The fabrication, machining and finish of all pipe lengths shall be such that when assembled either in the shop or on the site, the appropriate tolerances are obtained. Clearance at joints shall be sufficiently small to avoid turbulence, etc., and thus avoid vibration. All moving parts shall operate freely without risk of undue wear or jamming. Finished faces shall be free of any wind or twist. Pipe dimensions shall conform to the following tolerances: Roundness: 0.2% on a gauge length of D/4 Ovality: 0.2% D Step between adjacent strakes: 2.0 mm maximum. Straightness: 20 minutes Line and level: Each section shall be set within 2 mm of the true line and level.

8.14.4 Cutting Pipes The cutting of pipes for making up lengths shall be carried out by a method that leaves a clean square end. Steel pipes used for cutting shall have been rounded throughout their length and shall be clearly marked as such. Cutting shall be done by cutting disc or by oxyacetylene, and the cut end shall subsequently be ground to the correct profile for the method of jointing in use. 8.14.5 Welded Joints Line-up clamps shall be designed to prevent tears, scars, or indentations of the pipe walls and keep misalignment of pipes at a minimum. Interior line-up clamps are required. All welding shall be carried out in accordance with specific procedures prepared by the Contractor and approved by the Project Manager. Adequate precautions shall be taken to protect welding operations from wind, rain, blowing sand, etc. All welders employed on the works shall be fully qualified and shall have successfully passed all tests required by BS EN 287-1:1992 or API 1104 for the type of work each individual welder does. Welder qualification tests shall be carried out in the presence of the Project Manager. The Contractor shall provide all necessary labour, pipe welding materials, and equipment for performing welder qualification tests on site. Arrangements for laboratory tests of coupons, if required, will be made and paid for by the Contractor. The Contractor shall maintain a list of approved welders agreed upon with the Project Manager, and thereafter no other employees shall perform welding operations on the permanent works. Before welding, the pipe ends shall be swabbed with a leather or canvas belt disc to remove dirt, loose mill scale, rust, oil, grease, and other matter which may be injurious to the weld. Cleaning of pipe ends shall be done by power wire brushing and/or grinding. Damaged pipe ends that no longer meet joint specifications shall be re-bevelled by a suitable machine. Pipe ends shall be aligned with line-up clamps such that the longitudinal weld seams of the adjacent pipes are staggered by at least 20. Stringer bead shall be applied by at least two welders welding in opposite quadrants. The number of filler and finish beads shall be in accordance with procedures approved by the Project Manager. Completed welds shall have a substantially uniform cross-section around the entire circumference of the pipe. At no point shall the crown surface be below the outside surface of the pipe nor be raised above the parent metal by more than 1.5 mm. All joints on which welding has started shall be completed before the end of each day's work. At night or when work is not in progress, pipe ends of the pipeline shall be securely capped with a suitable cover to prevent the entrance of dirt, small animals, water, and foreign matter into the pipeline. Tie-ins shall be carefully aligned to limit residual and/or reaction stresses after completion of the weld. Tie-ins shall be made within the temperature range of 10 to 30 C.
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Section VII. General Specifications All production welds shall be subject to visual inspection by the Project Manager. Visual inspections by the Project Manager may be carried out at any stage of the welding of a joint. Each weld shall be clearly marked adjacent to the weld indicating the identification of the welder. Steel die-stamping will not be permitted. Non-destructive testing shall be carried out on all welds, both in the shop and on the site. All longitudinal butt welds shall be radio graphically tested. All circumferential butt welds carried out in the shop shall have 10% of their length radio graphically tested at positions indicated by the Project Manager. Junctions between longitudinal and circumferential welds shall be included in this test. The remainder of the shop and site welds shall be ultrasonically tested throughout 100% of their length. Ultrasonic testing shall be carried out in accordance with BS EN 1714:1998 and the Project Manager shall approve the standard of acceptance. Where ultrasonic tests indicate a flaw or defect in the weld, this shall be examined using radiographic means. In the case of fillet welds, the Project Manager may require dye penetrate tests to be carried out on selected welds. The Project Manager retains the right to have cut out and removed one weld for each welder at no cost to the Employer. Welds rejected by the Project Manager shall be cut out and replaced by the Contractor. If the cut out weld is found on test not to meet these Specifications, the cost of the cutting out and re-joining shall be borne by the Contractor. If the weld is found satisfactory, the cost shall be borne by the Employer. Welds rejected by the Project Manager may, at his discretion, be repaired subject to the following: Repairs to the filler weld that would penetrate the stringer bead will not be permitted. Arc burns shall not be repaired by welding, but shall be removed by grinding provided that no reduction in wall thickness is made in excess of 12.5% of the nominal wall thickness.

The Contractor shall maintain records of all repairs of whatever nature to pipe and pipeline describing and locating such repairs. Welding pipes together which have been cut shall be done with one weld if it is practical to pull the line into position, otherwise, two welds shall be made by setting in a piece of pipe at least 2 metres in length. The testing of welds shall be in accordance with the requirements of the International Institute of Welding, Collection of Reference Radiographs. These shall be used as a guide to the interpretation of radiographs and as a basis for comparing the nature and extent of weld defects. The minimum grade for acceptance shall be blue. 8.14.6 Flexible Joints Any flexible joints in steel pipework shall be of the type specified in these Specifications. Flexible joints between pipes having integral sockets shall be formed by a shaped rubber gasket fitted within the socket or by a rubber ring of circular cross section (O-ring) placed on the pipe spigot. The type of flexible joint to be used shall be subject to the approval of the Project Manager. Before any joint is made all parts of the joint shall be clean and free from mud, oil, grease or other deleterious matter. Fixed gaskets shall be lubricated strictly in accordance with the manufacturer's recommendations. O-ring gaskets shall not be lubricated. Components of flexible joints from different manufacturers shall not be used together.
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Section VII. General Requirements After jointing, the position of O-rings shall be tested with a feeler to ensure that they are correctly positioned. If any ring shows a significant departure from a line following a pipe circumference, the joint shall be broken and remade using a new ring. After completing the joint, any damage to the protective coating shall be made good. 8.14.7 Flanged Joints Flanged joints shall be made with rubber gaskets and shall be fitted without twist or distortion. Pipes and fittings shall be fully supported so that the flange faces are parallel and concentric. The flanges shall be drawn together uniformly by tightening opposite pairs of bolts in succession and no bolts shall be omitted. The size and number of bolts in flanged joints shall be in accordance with BS EN 1092: 1997 for the pressure rating of the pipeline. Bolt threads shall be coated with an approved paste such as Loctite before use unless otherwise instructed by the Project Manager. 8.14.8 Bonding All flexible, flanged and similar discontinuous joints shall be bonded across the joint to provide electrical continuity throughout each pipeline. 8.14.9 Deviations at joints The maximum deflection at each joint shall not exceed the following: For any type of flexible joint, three quarters of the maximum permissible deflection stated by the manufacturer. No deviations shall be made at flanged or solvent welded joints. Gaps for Plant

8.14.10

Where gaps have to be left in pipe work for the later installation of items such as valves, the ends of the pipes shall be accurately aligned one with the other across the gap paying strict attention to bolt positions if relevant. The length of the gap shall be accurately determined with the aid of dimensional sketches that shall be submitted to the Project Manager for his approval before the work is carried out. 8.14.11 uPVC pipework Unplasticised PVC (uPVC) pipes shall comply with BS EN 1452. Joints on exposed pipes shall be solvent welded. Pipes shall not be laid across floors but shall be adequately and securely clipped or clamped to walls. Joints made with rubber sealing rings shall be laid in trenches or as specified. Ferrules, straps and other metal fittings shall be gunmetal. 8.14.12 Small Bore Pipework Small bore pipe work up to OD 15 mm shall be manufactured from stainless steel tubing with suitable compression type fittings. All small bore pipe work and capillary tubes shall be adequately and securely clipped or clamped. Compression fitting bends shall be kept to a minimum, as pulled bends of generous radii are preferred. Compression couplings shall be heavy series according to BS 4368. Any gauges, transducers or switches, etc., fed via small bore pipe work shall have an individual isolating cock adjacent to each component with adequate space being allowed for component removal for servicing.

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Section VII. General Specifications 8.14.13 Puddle Flanges

Puddle flanges shall be fitted to pipes where the structure through which they pass is required to take thrust resulting from the pipe. Puddle flanges shall also be fitted where a water barrier is required. Puddle flanges shall only be fitted with the Project Manager's prior approval. After the pipe work is installed, the Contractor shall seal the ends of all ducts, pipes, or trenches leading into buildings. The seals shall be approved water, gas and fire sealing transit units with appropriate fillers. Insert blocks shall be fitted to duct and trench entries. All steel work on such transit assemblies and frames shall be hot dip galvanized. 8.14.14 Reference Marking Before dispatch from the manufacturer's works, each pipe section shall be marked with an appropriate reference number for future identification. 8.14.15 Protection of Pipe Work Immediately after the completion of fabrication at the works or on site and during transport and storage, pipe ends shall be protected from external damage and sealed against ingress of dirt by suitable caps, plugs or other similar means. After cleaning and inspection, machined surfaces of all steel and ironwork shall be covered with preserving fluids of types or otherwise protected, as approved by the Project Manager. All flanges shall be fitted with blank discs bolted to each face. 8.14.16 Branch Pipes and Bosses Whenever any small bore pipe work makes a connection into the pipeline system, a boss or branch pipe shall be provided which shall be at least twice the diameter in width and one diameter in thickness of the tapped hole which it contains. Bosses shall be located at the main pipe horizontal centre line and those provided for water sample cocks shall be tapped 38 mm (1.5") BSP and have reasonable access for sampling. Bosses provided for instrumentation shall be tapped 25 mm (1") BSP with a reducer fitted to suit the small bore pipe work and isolating cock. Unused bosses shall be fitted with blank plugs having a central squared projection for tightening or removal. Bosses shall be provided for pump performance monitoring. These shall be installed on all pump suction and delivery pipes at least two pipe diameters from the pump flange unless otherwise specified in these Specifications. Each tapping shall be provided with a 15 mm isolating cock. 8.14.17 Testing Pipe Work Before testing commences, the Contractor shall ensure that all anchor and thrust blocks are complete or that temporary supports have been installed. Thrust from temporary pipe ends or branch pipes shall be adequately strutted, and the section under test closed off with stop ends, blank flanges or other closure fittings. All pipes shall be cleaned before testing by flushing or as agreed by the Project Manager. All tests shall be carried out in the presence of the Project Manager, and for this purpose the Contractor shall give the Project Manager 24 hours notice in writing of any pressure tests which he intends to carry out. Within 24 hours of the completion of any test, the Contractor shall submit two copies of a full record of the test to the Project Manager. The record shall be in a form acceptable to the Project Manager. The pipe work to be tested shall be filled with clean water and all air shall be expelled.
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Section VII. General Requirements Mortar lined pipe shall then be kept under nominal working pressure for 24 hours. The pressure shall then be raised to the specified test pressure using a hand operated force pump that is fed from a calibrated tank. The test pressure will depend upon the particular circumstances and will be specified by the Project Manager, but for general guidance only will be about 1.5 times the maximum sustained operating pressure. The test pressure shall be held for the period instructed by the Project Manager, pumping in water as required from the calibrated tank, and the amount of water used per hour shall be noted. The pressure shall be held for 24 hours and there shall be no loss of water. 8.14.18 Commissioning Pipe Work Commissioning shall not be commenced until the Project Manager has approved the whole of the installation in writing. 8.15 Valves and Penstocks 8.15.1 Valves and Penstocks General Valves shall be specifically designed for use in raw and treated water, and in chemical solutions used in water treatment. All valves and penstocks shall be of the sizes specified in these Specifications and shall be obtained from manufacturers approved by the Project Manager. Where specified, valves shall be fitted with easing screws and a clean-out box in the base. All valve bodies shall give the following information: Manufacturer's name Hydraulic test pressure Size of valve Direction of flow arrow

8.15.2 Valve Access All valves, hand-wheels, spindles and headstocks shall be positioned to give good access for operational personnel. Extension spindles shall be supplied wherever necessary to achieve the specified operating requirements. Valves buried or installed in underground chambers where access to a handwheel would be impractical shall be key-operated. It shall be possible either to remove and replace or to recondition seats and gates. Gland packing shall be accessible without removal of the valve from the pipe work. 8.15.3 Operation The operating gear of all valves and penstocks shall be such that they can be opened and closed by one man against an unbalanced head 15% in excess of the maximum service value. Any gearing shall be such as to permit manual operation in a reasonable time and not exceed a required operating torque of 150 Nm. All hand-wheels shall be arranged to turn in a clockwise direction to close the valve or penstock. The direction of rotation for opening and closing the valve shall be indicated on the hand-wheel. Unless otherwise stated, the hand-wheel shall be coated with black plastic and incorporate facilities for padlocking in either the open or closed position.

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Section VII. General Specifications Headstocks and valves of 50 mm, or greater, nominal bore shall be fitted with mechanical position indicators to show the amount which the valve is open or closed in relation to its full travel, i.e. 0.25, 0.50, 0.75, and 1. 8.15.4 Materials Valve bodies, discs and wedges shall be of cast iron, with facing rings, seating rings, wedge nuts and other trim of corrosion resistant bronze, all as specified. The valve stem, thrust washers, screws, nuts and other components exposed to the water shall be of a corrosion resistant grade of bronze or stainless steel. Valve bodies and other components of plastic or other non-metallic materials shall be compatible with the medium and of robust industrial design. 8.15.5 Wedge Gate Valves All wedge gate valves, unless otherwise specified, shall be of the non-rising spindle type and be in accordance with the relevant clauses of BS 5163. Valves shall have good quality cast grey iron bodies, high tensile brass spindles, gun-metal nuts, wedge gates with gun-metal faces and seats, bronze gland bushes and bonnets fitted with soft packing glands. Valves of diameter greater than 400 mm shall have detachable bolted covers for inspection, cleaning and flushing purposes. Valves shall be provided with renewable seats. It shall be possible to remove the gates without removing the valve body from the pipe work. The gate face rings shall be screwed into the gate or alternatively securely pegged over the full circumference. Unless otherwise specified in these Specifications, gate valves in chambers, and other similar locations shall be provided with hand-wheels. Valves which are to be buried in the ground shall be provided with extension spindles, protection tubes, spindle caps, spindle supports and surface boxes. Valves larger than 400 mm diameter and accessible for maintenance shall be fitted with a studded cast iron cover at the bottom of the valve body for inspection, cleaning and flushing purposes. Where necessary to meet the requirements of these Specifications, gate valves shall be provided with appropriate thrust bearing guides, and/or gearing and/or bypass valves. When reduction gearing is employed, the gear ratio shall not exceed 4:1. Valves of 450 mm diameter and above shall always be provided with reduction gearing for manual operation. Valves of 600 mm diameter and above shall always be provided with a bypass valve. Each valve shall be tested in accordance with the requirements of BS 5163 open-ended in each direction. Where specified, resilient seat type valves shall be provided. The wedge shall have a resilient Nitrile Rubber bonded to the cast iron wedge. Gates of all resilient seal valves of the same size and class shall be completely interchangeable, and be shaped so that the shoulders of the gate seal against the valve bonnet when the gate is fully open. Stem sealing shall be by O-rings, which shall be replaceable under pressure with the gate fully raised. 8.15.6 Butterfly Valves Rubber seated butterfly valves shall be airtight when shut-off. Valves shall be suitable for the application/pressures and for mounting in any position and shall comply with BS EN 593:1998, for double flanged valves, except where otherwise specified. All bolts, nuts and other fixings that will be in contact with the contents of the pipelines or, in the case of buried valves within the ground, shall be stainless steel.
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Section VII. General Requirements Butterfly valves shall be suitable for frequent operation as well as for operation after long periods of idleness in either the open or closed position. Unless otherwise specified, valves shall be hand operated with hand-wheels driving through 90 gearboxes. The valve body shall be cast grey iron, the flanges and hubs for the shaft bearing housing being integrally cast with the valve body. The disc shall be ductile iron having edges machined with rounded corners and polished to a smooth finish. The valve disc shall rotate through an angle of 90 from the valve opened to the fully closed position where the seating shall be at an angle normal to the axis of the pipe. Adjustable mechanical stops shall be provided to prevent over-travel of the valve disc in both the open and closed positions. Particular attention shall be given to the pipe work both upstream and downstream of all butterfly valves to ensure that the disc cannot foul the adjacent pipe. The shaft shall be fabricated of stainless steel. The shaft, disc and mechanical stops shall be capable of absorbing the full operating torque with a minimum design safety factor of five. Shaft seals, when used, shall be rubber O-ring type. Packing shall be either rubber O-ring or self-adjusting chevron type. Shaft seals, when used, shall be rubber O-ring type. The valve seat shall be replaceable and formed of Nitrile Rubber 70/75 IRHD securely clamped into a machined groove in the valve body or to the edge of the disc by seat retention members, or equivalent so as to prevent leakage and to hold the seat securely during operation. The seat retention members shall be of stainless steel and securely clamped with stainless steel fasteners. All fastenings shall be set flush and shall offer the least resistance possible to the flow through the valve. Valve seats which extend over the face of the flanges to secure the seat in place, or which require surface grinding and/or hand fitting of the disc, or which require the adjoining pipe flange to retain the seat in place and resist line pressure, are not acceptable. Each valve shall be tested in accordance with the requirements of BS EN 593:1998 for body, seat and disc strength tests. Seat and disc strength tests shall be carried out in each direction and the valve shall be drop-tight. Metal-faced butterfly valves shall generally be as above except: The valves shall have metal to metal seating. The valves shall be designed for operation in the partly closed, throttled position for long periods. The valves shall not be of tight shut-off type and the leakage rate shall not be greater than the following: 300 mm - 0.075 l/s; 500 mm - 0.150 l/s; 1200 mm - 0.225 l/s.

8.15.7 Non-Return Valves Non-return valves shall be suitable for the operating condition and where applicable conform to BS EN 12334:2001. Long-pattern valves shall generally be used. Check valves shall possess high speed closing characteristics by use of heavy flaps with external weights where specified, but designed for minimum slam condition when closing. Flaps shall be fitted with renewable bronze or gun-metal sealing faces, which shall mate accurately with renewable bronze on gun-metal seating rings in the valve body. All seating/seals shall be positively located.

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Section VII. General Specifications Covers shall be provided to allow ample access for inspection, cleaning and servicing, and shall be supplied complete with tapped boss fitted with an air release cock. Valves of diameter greater than 500 mm shall be provided with lifting eyes, feet and jacking screws. Hinge pins/shafts and internal fixing devices shall be stainless steel. Hinge pins/shaft shall preferably be square in section to ensure positive location of flaps and to provide for secure fixings. For valves with external levers and adjustable balance weight, the hinge pins/shafts shall extend through a renewable sealing gland on the side of the body. Valve body design shall be such that there is adequate clearance around and at the back of the flap to minimize jamming by rags, solid matter, etc. Check valves for potable water shall be free-acting type, single-flap or multi-flap with external by-pass and hand-operated control valve as necessary. Flaps shall be of design and weight to suit the prevailing hydraulic conditions. Shafts shall turn in close-fitted lowfriction bearings. Each valve shall be tested in accordance with BS EN 12334:2001 or if outside this standard, to the form as set out in BS EN 12334:2001 and to the nominal pressure designation/test pressure relationship set out therein or 700 kPa for 30 minutes whichever is the greater. 8.15.8 Air Release Valves Air valves shall normally be installed at high points in the pipework. The valves shall be capable of exhausting air from pipe work automatically when being filled, the air being released at a sufficient high rate to prevent restriction of the inflow rate. The valves shall also automatically release air accumulating in pipe work during normal working conditions. Air valves shall be designed to prevent premature closure before all air having been discharged from the line. Similarly, the valves shall be capable of ventilating pipe work automatically when being emptied, the air inflow rate being sufficiently high to prevent the development of a vacuum in the pipelines. The material of the body and cover shall be cast grey iron. Air valves shall be of the double orifice type with a large orifice for ventilation or exhaustion of the pipeline, and a smaller orifice for automatic release of air under normal working pressure. The valves shall be suitable for the maximum working pressures in the systems and tested for pressure tightness in steps of 200 kPa up to the maximum working pressures and then for mechanical strength at 1.5 times maximum working pressures. All air valves shall be provided with isolating valves and flanged end connections. The orifice shall be positively sealed in the closed position, but the float (ball) shall only be raised by the water and not by a mixture of air and water spray. The seating shall be designed to prevent the float sticking after long periods in the closed position. 8.15.9 Pressure Relief Valves Pressure relief valves shall be designed to prevent the pressure in the pipeline immediately upstream of the valve rising above a pre-set value. The valve shall remain closed at lower pressures. Adjustment of the pressure at which the valve opens to relieve pressure shall be made by a screw on the relay valve or by changing weights as appropriate. A pressure gauge indicating upstream pressure shall be incorporated.
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Section VII. General Requirements 8.15.10 Diaphragm Valves

Diaphragm valves shall be of the straight-through design with minimal flow resistance and glandless construction conforming to the requirements of BS EN 13397:2002. Diaphragm valves shall be completely leak-tight and suitable for pressures up to 10 bar. Diaphragm valves shall be supplied with extended spindles or extensions for pedestals. The valves shall be made up of two durable body parts and the diaphragm, all interchangeable with replacement parts for easy maintenance. The diaphragm shall be moulded in a reinforced, flexible material of a grade to suit the specified duty and liquid content of the system. In the open state, the diaphragm shall lift clear and not obstruct the flow of liquid. The internal surfaces of the valve body shall also be lined with material compatible with diaphragm duty. The valves shall be operated by hand-wheel unless otherwise specified in these Specifications. Hand-wheels shall have adequate leverage to give the closure effort required and a facility to lock in any position. 8.15.11 Ball Float Valves Ball float valves shall be designed for installation on the inlet pipe to a storage tank and shall automatically shut off when the water reaches a predetermined level. They shall be of the single-beat type with balancing piston and direct float and lever operation. Valves shall be designed for a working pressure of 1,000 kPa. Valves shall be drop-tight when they are held shut by the floating ball. Valves shall be tested for leakage at 1000 kPa when they shall be drop-tight, and shall be tested for body and valve element strength with the valve closed and a test pressure of 1,500 kPa applied to the inlet end. Valves shall be constructed of meehanite cast iron to BS EN 1561:1997 with gun-metal trim to BS EN 1982:1999. The valves shall incorporate rubber faces. The ball float shall be made in tinned copper and the float lever shall be mild steel. 8.15.12 Isolating Cocks For isolation of small bore pipe work tapping for instrumentation, etc., and for individual component isolation, the cocks shall be stainless steel, 0.25 turn ball or plug valves with the operating handle arranged to indicate the open and closed positions. Where instructed by the Project Manager, means shall be provided for securing the valve body to a front panel or rear surface. Where corporation cocks are specified, these shall be similar to the above isolating cocks but shall have a detachable key handle for fitting onto a squared operating shaft, the shaft end being marked to indicate the open and closed valve positions. 8.15.13 Penstocks All penstocks shall be of the rising type unless otherwise specified by the Project Manager, and the spindles shall be of adequate size to avoid buckling under load. All spindle nuts shall be self- aligning and their length shall be not less than twice the spindle diameter. The top part of the penstock frames shall be sufficiently robust and substantial to prevent the frames bowing and if necessary, additional holding down bolts shall be fitted. On rectangular penstocks the inverts shall be flush with renewable synthetic rubber seals on the bottom of the doors. The rubber shall be suitable for the application and of a type approved by the Project Manager.
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Section VII. General Specifications Penstocks shall be designed to ensure water tight closure at maximum head encountered in service as specified by the Project Manager. Materials of construction shall be as follows: Stems and spindles - stainless steel. Stem nuts - gun metal to BS EN 1982:1999. Sealing face - appropriate to the conditions to be met in service. Fixing bolts, nuts & washers - stainless steel.

Simple templates shall be supplied as soon as possible after approval of Shop Drawings to position the holes for holding down bolts for all penstocks over 1.0 m square. 8.15.14 Extension Spindles and Pedestals Extension spindles shall be adequately sized to prevent buckling and shall be attached to the valve/penstock stem by a suitable adapter incorporating two muff couplings, scarf lap jointed and pinned with at least two coupling joints included. Universal joints and waterproof sleeves shall be provided where specified. Extension spindles shall be manufactured from 080M40 (EN 8) steel. Intermediate bearing support or guide brackets of cast iron, with slotted holes for site adjustment, shall be fitted to long shafts where necessary. Bearings shall be of PTFE or similar approved type. Penstock and valve pedestals shall be of cast iron or heavy duty, welded, mild steel construction, with a substantial base and fixing provision. The base and top of the pedestals shall be machined normal to the axis of the drive shaft. Where necessary, support guide bushes shall be fitted at the base of the pedestal. The pedestal height shall be such that the hand wheel is approximately one meter above the operator's floor level. Covers of an approved type shall be provided for all rising spindles to totally enclose them when in the fully raised position. 8.16 Instruments and Ancillaries 8.16.1 General All instruments, gauges and control gear that perform similar duties shall be of uniform type and manufacture throughout the works in order to facilitate maintenance and the stocking of spare parts. Panel mounted instruments shall have damp-protecting and dust-protecting cases. Instruments mounted outside instrument panels shall have weather-proof and dust-proof cases. Instrument cases shall be of corrosion-resistant material or finish. Instrument screws (unless forming part of a magnetic circuit) shall be of brass or bronze. Access to terminal compartments of instruments mounted outside panels or other enclosures shall not expose any working part. Moving parts and contacts shall be adequately protected from the ingress of dust. Unless otherwise specified, instruments shall be finished in the manufacturer's standard colour. Instrument dials shall be of such material that no peeling or discoloration takes place. Plant-mounted indicators and gauges shall be sized to give full legibility when viewed from a position with convenient and easy access or from the point at which any operation requiring observation of the gauge is performed. The minimum diameter for any gauge shall be 100 mm except where forming part of standard instruments and accessories such as air-sets.
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Section VII. General Requirements Dials and bezels shall be of bronze and internal components shall be of stainless steel, bronze or other corrosion-resistant material. Plant mounted in enclosures shall be suitable for continuous operation at the maximum internal temperature possible in service, due account being taken of internally-generated heat and heat dissipated by other plant. All components shall be rated adequately, and circuits shall be designed so that changes of component characteristics within the manufacturers' tolerances shall not affect the performance of plant. All plant shall be designed to operate without artificial cooling. Instruments shall be easily withdrawable from cases without interrupting their circuits. Plant provided with anti-condensation heaters shall be capable of operating without damage if the heaters are left on continuously. Measuring instruments shall have zero and span adjustment. Instruments not mounted in panels shall be supplied complete with all brackets, stands, supporting steelwork and weatherproof enclosures (separate from the instrument cases) necessary for securing them in their working positions and affording complete protection at all times including periods of servicing, adjustment, calibration and maintenance. Instruments mounted in open areas that could be vandalized shall be mounted in lockable vandal proof boxes. 8.16.2 Mechanical Water Meters Mechanical water meters shall be of the in-line helical vane type conforming to the Class B requirements of BS 5728. Meters shall have flanged spheroidal graphite iron casings to BS EN 1563:1997 coated with two-pack epoxy enamel. The rotors shall be manufactured from polypropylene with stainless steel shafts. The counter housing shall be sealed and be provided with a seven figure straight reading digital counter and have a centre sweep hand calibrated to give 10% of the smallest unit on the counter per revolution. The units shall be cubic metres or litres, dependent on the application. The counter covers shall be provided with a hinged polyacetal or brass cover to protect the counter face from dirt and damage. The meter shall be flanged to BS EN 1092: 1997 and be supplied complete with a low loss strainer to prevent any large particles in the water from clogging or damaging the meter. 8.16.3 Pressure Gauges Pressure gauges shall comply with BS EN 837-1:1998. Pressure gauges, transmitters and switches shall have over-range protection. No plastic material shall be used in their construction. Internal parts shall be of stainless steel, bronze or approved corrosion-resistant material. Pressure gauges shall have concentric scales. Where compensation of more than 2% of the instrument span is needed for the difference in level between the instrument and the tapping point, the reading shall be suitably adjusted and the amount of compensation shall be marked on the dial.

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Section VII. General Specifications 8.16.4 Load Cells Load cells, using the strain-gauge principle, shall be used, when specified, for accurate measurement of large masses to close tolerances. Installation is very application specific. The mechanical/structural design shall be designed so as to keep horizontal forces to a minimum. Load cells shall be connected in parallel and correctly shimmed to ensure equal load distribution. Three cell configurations shall be used where reasonable. Protection against electrical noise and lightening is essential. Particular care shall be exercised regarding the earthing requirements. Load cells shall be hermetically sealed and the terminal boxes shall offer protection to IP65. Temperature compensation shall be incorporated. Ranges shall be 0 1 kg, up to 1500 kg. The parameters shown below shall be selected to suit the application: Maximum usable load : 150% of range Ultimate load : 500% of range Accuracy : 0.1% Repeatability : 0.02%

8.16.5 Chart Recorders Chart recorders shall have auto-balancing potentiometric or programmable movements, and shall conform to BS EN 61143-1:1994 where applicable and shall be able to pass each test specified in BS EN 60873:1993. Recording instruments shall have an accuracy of 0.5% FSD or better and indicating scales and pointers. The pen and a reasonable length of chart shall be visible without opening the case. Recorder inks and inking systems shall be suitable for use both in highly humid conditions and in air-conditioned environments. Inks of differing colours shall be used for recording two or more quantities on the same chart. Each recorder chassis shall be easily withdrawn from its housing for chart changing without interrupting its circuits. Single-pen recorders used for more than one measurement shall have rotary switch selectors with plates engraved to show the identity of the selected measurement. 8.16.6 Analogue Indicators and Integrators Indicators for use with analogue signal transmission systems shall comply with BS 89 and have an accuracy class index of 1.0. Indicator movements shall be critically damped (deadbeat). Indicators for use on more than one circuit shall have rotary switches to select the circuit, with engraved plates to show the circuit selected. Indicators shall have circular scales or shall be of the vertical edgewise type and shall be designed to avoid parallax error. Scales shall be clearly marked in the specified units and shall comply with BS 3693. All instruments that are mounted on one panel or board, or are in adjacent groupings, shall have similar styles of figures and letters. Dials shall be white with black scales and lettering not subject to fading. The material for scales shall be such that no peeling or discoloration will take place with age under all environmental conditions. Major scale marks and numerals shall be of the same size and thickness and shall be separated by not more than twenty five minor marks. Pointers shall taper to the width of the scale marks.

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Section VII. General Requirements Integrators shall be of the multi-digit cyclometer type. Each integrator shall have an integral or separate current-to-pulse converter with sufficient adjustment of the pulse rate to avoid the use of any multiplying factor except in integer power of ten. Each integrator shall incorporate an adjustable limiter whereby any input below a pre-set value is inoperative. Unless otherwise specified by the Project Manager, integrators shall have minimum of eight digits with a decimal point where applicable. 8.17 Chemical Dosing Plant 8.17.1 Materials As far as possible, materials resistant against the chemicals to be handled shall be used. Where this is impractical, suitable corrosion-resistant coatings shall be applied. Moving parts, chains, electric motors and electrical switchgear shall be suitably enclosed or sealed against the ingress of chemical dust or liquids as appropriate to the working environment. Moving parts in contact with the chemicals must also be wear resistant. Assembly of the unit must be such as to facilitate repairs and the replacement of all parts. 8.17.2 Plant (a) Solution Mixers

Mixers shall be mounted in such a way as to minimize possible contact of the solution being mixed with the motor, gearbox (if any) and electric controls. The unit should be such as to be easily removed or repositioned during cleaning operations. Chemical mixers shall be designed to give a turnover rate of at least four times per hour. Control shall be manual. All components of the mixer shall be of rigid design. Particular care shall be provided in the design to provide hydraulically balanced operation. Stresses in all members shall be limited to ensure 100,000 working hours without danger of fatigue failure due to the cyclic nature of the loads. The mixer blades shall be self-cleaning as far as possible. (b) Solution Tanks

Corrosion resistant materials shall be used. Pipe work connections to the tank shall be such as to avoid excessive stress in the wall of the tank or fatigue failure. Where it is intended that a mixer be mounted on the tank, the mounting points must be designed for the purpose. All tanks shall be fitted with a drain to facilitate cleaning of the tanks. Solution tanks shall be securely fixed to the working platform. (c) Dosing Pumps

Pumps to meter and deliver chemical solutions to points of application shall be either diaphragm or piston pumps. The pump shall be capable of stroke adjustment from 10% to 100% while the pump is in operation. Variability of the delivery flow for a particular setting shall be not greater than 2.5% and the stroke adjustment mechanism shall be graduated clearly to facilitate setting. The instantaneous flow delivered to the dosing point shall not vary by more than 10% of the average flow due to pulsation action of the pump, over the full working range of flow settings. The position and assembly of the pump-head should be such as to facilitate routine maintenance and cleaning.

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Section VII. General Specifications The facility to gang several pump-heads in one unit is essential. The pump system shall include flushing and drain connections. (d) Pipe Work, Valves and Fittings

All pipe work, valves and fittings shall be of corrosion resistant materials. Wherever possible, readily available domestic pipe and fittings shall be used. Facilities for routine cleaning of all pipe runs shall be provided. Where flexible hosing is required, such as lime delivery lines, natural rubber shall be used. Valves shall be ball or globe valves which can be readily maintained. Mounting of valves shall be secure so as to ensure that undue forces are not imposed on pipe work or plant by regular operation, or occasional "stiff" valves. (e) Polyprep Units

Unit for the preparation of polyelectrolyte or polyamide solutions from powder or granular stock shall be of such a design as to avoid lumping, clogging and caking. The ployprep units should be easily disassembled for cleaning. Water for use with the units is available from the service later system. (f) Gaseous Chlorinator

Gaseous chlorinators shall be of the modular, vacuum operated type. The chlorinators shall be operated in conjunction with chlorine motive water pumps and each chlorinator shall be complete with its injector unit, manifold gas inlet, and drain lines. Chlorine rate control valves shall be suitable for manual control to give flow rates within +/- 4% of the set point. The mechanism for manual control shall act directly on the gas rate control valve. The chlorinator shall be complete with a flow meter having a 20:1 range, differential pressure regulator and vacuum/pressure relief devices. Gauges shall be provided to indicate gas pressure and injector vacuum. The vacuum gauge shall be fitted with alarm contacts to initiate an alarm on high or low vacuum. The entire chlorination plant shall be provided for manual operation and control. All critical states shall be monitored and indicated by messages, which are shown on the local control panel and as a summarized message at the central control panel. The control panel within the chlorine dosing room shall be fed from the main switchgear. A gas alarm device shall be installed in the chlorine storage room, which shall sound an audible alarm and flashing light. A spring-loaded emergency shut-off valve shall be provided upstream of the pressure-reducing valve to close the system when the gas alarm is activated. Supply and installation of chlorine cylinders shall conform to the following specifications: Chlorine cylinders filled with nominal 70 kg liquid Cl2, suitable for drinking water, welded type with connecting and fixing devices, test pressure p = 35 bar with official certificate of the test; Isolating valves for each cylinder; Gas manifold from the cylinders to the chlorinators; Automatic change-over switch for the un-interrupted supply of gas; Liquid traps to retain the liquid Cl2; Electrical pipe heater; Emergency shut-off valve;
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Section VII. General Requirements Pressure reducing valve with pressure gauges and strainer; Vacuum regulating valve and vacuum safety valve; Control panel of the protecting Class IP 54, for the power supply and the controlling of the components installed within the chlorine feeding room; Power cable and control cable within the chlorine feeding room; Electric weighing machine; and Gas detector probe.

The gaseous chlorinator shall have a vacuum created at the throat of a water operated injector. The whole of the chlorine dosing system shall operate under this vacuum up to the gas pressure-regulating valve that connects to the storage cylinder. Should the vacuum fail, the chlorinator shall shut off immediately. Feed water to the injector shall be supplied from the service water system. The chlorination plant shall be supplied complete from connector to the storage cylinder to sparge pipe at point of application including all connectors, pipe work, regulating valves, metering apparatus and dose rate indicator (in kg/h). The chlorinator gas inlet shall be fitted with thermostatically controlled element heaters. Gauges to indicate chlorine gas pressure and injector water pressures shall be supplied and suitably mounted. An automatic change-over panel shall be provided to change-over the chlorine supply from the empty cylinder to a full one. The residual pressure in the chlorine vessel shall activate the change-over when the residual pressure in the duty cylinder drops to a pre-set figure. The change-over shall be affected in such a manner as to prevent a backflow of chlorine from the full cylinder to the empty one. Scales for indicating the mass of each of two cylinders shall be provided. A cradle to locate the cylinder on the scale shall be provided. Horizontal centrifugal pumps are to be provided according to the chlorinator specifications. These motive water pumps will be designed for all sites uniformly. The total head of the pump is to be adjusted to the functional requirements of the injector. The pump shall be assembled with coupling and on a common base-frame or direct coupled. 8.17.3 Overhead Cranes Cranes shall comply with the requirements of BS 466:1984 Class 2 medium duty operation. The term crane shall be deemed to include gantry rails, platform with hand rails for maintenance purposes, down shop conductors, end stops, holding down bolts and all other items required for complete installation. The Contractor shall be responsible for the provision of detailed information for the successful and complete installation of his plant, and for carrying out the installation, testing and commissioning. Two name plates, showing the safe working load of the crane, will be mounted on the bridge structure as well as identification "Crane Serial Number". 8.18 Horizontal, Single Suction-End, Centrifugal Pump Horizontal, single end-suction, centrifugal pumps shall be of the single-stage type and shall be directly coupled to their driving motors and mounted together with their motors on a
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Section VII. General Specifications robust combined base plate. Pumps shall be of the back dismantling type which enables the impeller to be removed without breaking the main pipe connections. Pump casings shall be of high quality cast. They shall be fitted with a removable back plate incorporating jacking screws to enable it to be eased out of the casing. The plate shall be precisely doweled in position so that it can be accurately reassembled after dismantling. Casings shall incorporate integral feet for bolting to the base plate means for attachment of lifting gear, and shall be fitted with brass drainage cocks and automatic air-release valves, piped to drainage. Couplings shall be of the flexible-spacer, multi-pin and bush-type generously rated to cover the full range of duties. An adequate guard shall be provided over the coupling. The guards shall be readily removable without the need to first remove or replace any major item of plant. The spacer coupling shall be of sufficient length to enable the pump motor and impeller to be removed without disturbing the pipe joints or motor. Couplings shall not transmit axial thrust. The pump shafts shall be fully machined stainless steel. Impellers shall be of bronze, shrouded type and shall incorporate balancing back vanes. They shall be machined where possible with the water passages filed and scraped to perfectly smooth surfaces. Hard bronze sleeves shall be fitted to the shaft where it passes through the gland. The sleeves shall extend right up to the impeller boss. The sleeves shall be keyed to the shaft to prevent lateral movement and fitted with seals to prevent leakage passing along the shaft. Renewable bronze wearing rings shall be fitted to the casing where it is in contact with rotating parts. The impellers shall be keyed to the shafts by stainless steel keys. After assembly of the impeller and shaft in their correct position the manufacturer shall test for static and dynamic balance at his works. Adjustments shall be made as necessary to ensure the assembly is perfectly balanced both statically and dynamically and shall be free from vibration over the working speed range. For quietness and good suction performance the impeller eye velocities shall be kept to a minimum, but in any event they shall not exceed four m/s at the pumps rated output. The rotating element shall be carried on ball and/or roller bearings generously rated to ensure satisfactory and stable running without vibration under all conditions of operation. Bearings shall be suitable for an ISO B10 life of 50,000 hours at the pump speed. Seals shall be provided to protect the bearings from ingress of moisture, dust, sand and the particular climatic conditions prevalent at the facilities. Mechanical seals shall be used. Sealing/cooling water for the gland shall be used. A deep bowl shall be provided below each gland to collect any leakage. Each bowl shall be connected into a common gland drainage system using chromium plated copper tubing. 8.19 Submersible Centrifugal Pumps Submersible sewage pumps shall be designed to pump satisfactorily solids of up to 100 mm diameter and shall be non-clogging. The pumps shall be designed to have stable head/discharge characteristic so as to avoid large changes of discharge with small changes of head. They shall be capable of operating with the sump surcharged to its maximum level. Pump motors shall be rated to meet this condition.

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Section VII. General Requirements The fluid velocity at the entrance to the pump impellers shall not exceed 2.5 m/s for pumps with suction pipe work larger than 200 mm diameter. The fluid discharge velocity shall not exceed 3.6 m/s for all sizes of pumps. Pumps bodies, covers, brackets, bearing housings, wearing plates, eye rings, support brackets and similar items shall be manufactured from close-grained cast iron or nickel iron. Pump casing shall be of substantial construction to give long life under abrasive conditions and to enable them to withstand shock loads caused by solids in suspension. Impellers shall be of best quality close-grained cast iron or nickel iron. Shafting shall be of high tensile steel of adequate size to avoid the possibility of fatigue failure. The duty speed range shall be well below the first critical speed. At any change in diameter of the shaft the shoulder shall be generously radiused to reduce stress concentrations. The rotating elements of pumps larger than 300 mm diameter inlet shall be dynamically balanced before final assembly. Smaller pumps shall be statically balanced. Glands shall be fitted with mechanical seals (Material: SiC/SiC) with automatic seal supervision in the oil chamber. The shafts of pumps shall be made wear resistant with protection sleeve where they pass through the mechanical seal. The pump motor shall be of squirrel cage induction type, with protection class IP 68, ex-rated and be continuously rated for use in sewage at ambient temperature. The size of the motor shall be appropriately selected and de-rated as specified to ensure the pump operation over the full range of the Q/H curve. The motor shall be housed in a completely watertight air-filled chamber. The motor shall allow 15 starts per hour and be protected from overheating by the use of PTC thermistors. The motor shall be protected with a moisture resistant Class F insulation capable of resisting temperature of up to 155C. For monitoring moisture intrusion into the motor cavity, the pump shall be supplied with an additional and independent moisture sensor in the motor cavity. The pump/motor shaft shall rotate on a minimum of two grease lubricated and adequately sized bearings with an ISO B10 bearing life of at least 50,000 hours. Pumps shall have temperature measuring of the thrust bearing by PT 100 sensors. The pumps power and control cable entry design shall ensure that no entry of moisture into the pumps terminal board and/or motor is possible even if the cable is damaged. 8.20 Mixer Units Submerged mixer units shall comprise a coaxial multi-reduction type gearbox, incorporating an integrally mounted squirrel cage motor having a totally enclosed fan cooled dust and weatherproof enclosure. The output mounting arrangement shall be baseplate mounting. The mixer shaft and hydro-blade impeller shall be installed to suit the application and designed to operate in an immersed condition. The mixer shall be electrically driven for direct on-line starting with a starting frequency of ten starts per hour. The drive shall incorporate mechanical seals with seal supervision in the oil chamber. The integral unit shall be flange mounted onto a sturdy cast iron mounting housing, which incorporates a substantial deep groove double shielded roller bearing, which isolates the gearbox from harmful axial loads and high bending moments from the mixing operation. The
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Section VII. General Specifications housing output shaft shall be coupled to the mixer shaft through a precision coupling which is designed to take axial, radial and torsional loads encountered during operation. 8.21 Surface Aerator Units The surface aerator units shall have suitable aerating and mixing characteristics for biological treatment of sewage. The aerator unit shall incorporate an integrally mounted squirrel cage motor having a totally enclosed fan cooled dust and weatherproof enclosure. The aerator unit shall be multi-directional, where the rotation of the impellor can be reversed at predetermined intervals using timers and an electrical change-over switch. The aerator impellor shall be uncloggable and free from ports or passages. The supporting plate and aerator blades shall be designed to allow a rapid flow of liquor throughout the unit with a minimum of resistance and negative pressure. The impellor shall be constructed of mild steel and consist of a number of blades welded to the underside of the horizontal plate. The specially shaped blades shall radiate from a central hub and project beyond the top plate. The lower edge of each blade shall project forward the unit. The unit shall have truly concentric rotation and balance. The impellor shall be accurately coupled with a bolted flange to a tubular drive shaft which shall be designed to withstand the combined torsion and bending moments encountered during operation. The heavy wall seamless tube shall be securely welded to a rigid half coupling which shall be bolted to the gearbox half coupling. A spigot register shall be incorporated between the half couplings to ensure true alignment. The gearbox half coupling shall be securely fixed to the gearbox output shaft by a plate washer and axial retaining bolt. 8.22 Settlement Tank Bridge Scrapers The bridge shall be driven by a double-wheeled drive unit. The centre bearing assembly shall permit both horizontal and vertical rotation of the bridge structure. The slewing and trunnion arrangement shall withstand the total loading of the bridge and other forces associated with the bridge and scraper in operation. Lubrication for the pivot pins, trunnions, etc. shall be provided from a readily accessible grease nipple battery plate. Gearboxes shall be helical spur reduction gear trains with a gear case of robust cast iron construction provided with a large inspection cover, oil breather and oil level indicator for routine maintenance and inspection. Gearboxes shall be oil bath lubricated, the system being designed to ensure that all the gear receive adequate lubrication. Gearboxes shall be capable of transmitting maximum motor torque in the partially stalled condition. Jacking screws shall be provided to enable gearboxes to be accurately positioned in all three principal axes. Suitable stainless steel support plates shall be welded to the supporting steelwork to carry the gearboxes. The surface of the plates shall be machined after welding in position to ensure an even bearing from the gearbox baseplates. Allowance shall be made for inserting shims (up to 1.5 mm in thickness) between the support plates and the gearbox base plates to ensure even support of the gearbox. The coupling between the gearbox and the bridge drive shall accommodate the full load power of the drive motor. The coupling shall also include a slipping clutch arrangement which shall operate and de-clutch the gearbox drive in the event of scraper stoppage. A switch shall also be provided to trip the drive motor in the event of the clutch operation. 8.23 Ancillary Mechanical Works 8.23.1 Foundation Bolts and Fixing Arrangements All foundation bolts and fixing bolts required to secure the items to be supplied and erected under this Contract shall be provided by the Contractor at no additional cost to the Employer.
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Section VII. General Requirements The Contractor shall provide dimensioned Working Drawings showing the type of foundation or fixing required for each item of plant. The Contractor shall state the mechanical strength of large fixing bolts, which shall be of an approved size and diameter, galvanized where not embedded in concrete, with galvanised nuts and washers. 8.23.2 Brackets, Fixings, Anchor Points and Pipe and Valve Supports All brackets, hangers and fixings, anchor points and supports for the satisfactory installation of all pipe work, valves and other plant shall be supplied and erected. The supports shall prevent excessive movement of the pipe work and eliminate extraneous stress on pump casings and other items of plant. Where pipe and valve supports or anchors at attached to structures, the loadings imposed at the point of attachment shall be stated by the Contractor on submission of the relevant Working Drawings and approved by the Project Manager. All necessary nuts, bolts and washers for such fixings shall be included. 8.23.3 Guarding and Protection of Moving Parts Moving parts of machinery including all shafts, couplings, collars, projecting key heads, gear wheels, belt drives, chain drives and all other moving machinery shall be guarded where necessary to give complete protection to operating personnel. All set screws on revolving shafts shall be countersunk or suitably protected. Guards shall be of an approved design, fitted where necessary with inspection doors. All guards shall be arranged so that they can be removed without disturbing the parts of the plant they protect. Guards for shaft couplings shall at least be equal to PD 5304:2000. 8.23.4 Floor Trench Covers, Chequer Plating and Egg Crate Flooring Unless otherwise specified by the Project Manager, pipes and cables shall be laid in ducts below the finished floor level. The ducts shall be covered with steel plates with diamond chequering or other approved non-slip pattern, or with egg crate flooring. The plates or flooring sections shall be galvanised, be of sufficient thickness not to bend or spring in ordinary usage and shall fit evenly and truly into galvanized steel angle frames or kerbing with suitable attachments for building into the concrete floor. The Contractor shall supply complete Shop Drawings showing the arrangement of trenches, chequer plates and egg crate flooring sections, fully dimensioned so that the trenches can be formed and the kerbs built into the floor. The plates and flooring sections shall be divided into suitable sizes and lengths for lifting, with two holes in each section. One set of lifting keys shall also be supplied at each location. 8.24 Painting and Protective Coatings 8.24.1 Galvanizing and Metal Coatings Surface preparation for the application of metal coatings shall be in accordance with the following British Standards: BS EN ISO 14713:1999 Protection against corrosion of iron and steel in structures. Zinc and aluminium coatings. Guidelines. BS EN ISO 1461:1999 Hot dip galvanized coatings on fabricated iron and steel articles. Specifications and test methods. BS 4921:1988 Specification for sherardized coatings on iron or steel. BS EN 22063:1994 Metallic and other inorganic coatings. Thermal spraying.
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Section VII. General Specifications All materials and fabricated parts to be galvanized shall be of the full dimensions specified with all welding, punching, cutting, screw tapping, removal of burrs, etc., completed before the galvanizing process commences. All galvanizing shall be done by the hot-dip process with spelter of which not less than 98% shall be pure zinc. The zinc coating shall be uniform, clean, smooth and as free from spangle as possible. The zinc coating shall weigh not less than 400 g/m2 of area covered and be not less than 0.6 mm in thickness. No parts likely to come in contact with oil shall be galvanized. Bolts shall be completely galvanized but the threads of all nuts shall be left uncoated. All galvanized parts shall be protected from damage to the zinc coating due to poorly ventilated damp conditions and abrasion during the periods of transit, storage and erection. Damaged areas of the coating shall be cleaned back to bright metal leaving feathered edges of the surrounding galvanized coating and touched up with a zinc-dust paint or other flake metallic compound. All galvanized parts must be finally protected on site by an approved paint system. Sampling and testing shall be carried out in accordance with BS 729; or BS 2569; Part 1, whichever is appropriate. All metal sprayed steelwork shall be protected within four hours of spraying with one coat of approved etching primer. Where a metal coating is required only on part of an assembled section, it shall be applied before the rest of the section receives its first. 8.24.2 Paint All paints shall be obtained only from suppliers approved by the Project Manager. Unless otherwise approved by the Project Manager, all paints forming part of any one painting system shall be obtained from the same source. Paints shall be supplied in sealed containers of not more than five liters capacity, and shall be used in strict rotation. Preparation, application and conditions of work shall be in accordance with: BS EN ISO 12944-1:1998 Paints and varnishes: Corrosion protection of steel structures by protective paint systems. 8.24.3 Storage of Paint Paint shall be stored in sealed containers in a lock-up store where it is not exposed to extreme temperatures. The temperature of the store shall be kept between 4C and 27C; any special storage conditions required by the manufacturer shall also be observed. Paint that has not been used within the shelf-life period specified on the containers or within twelve months of the date of manufacture, whichever is the lesser shall be replaced. Paint from painters kettles shall be returned to the store at the end of each working period where it shall be kept in a sealed container. This is not permissible for any two-pack paints such as epoxy type. Before it is re-issued for use, it shall be thoroughly mixed and no fresh paint or thinners shall be added. 8.24.4 Protection during Transportation All plant shall receive adequate protection in the workshop or factory to ensure that metal is not affected by corrosion during transportation, loading and off-loading, storage and site erection. The Contractor shall supply full details of the extent to which blasting, metal spraying and painting will be carried out in his supplier's workshops, or on the site of the work prior to erection or after erection. If it is decided to carry out the bulk of the painting on the site of the work, a properly equipped painting shop shall be set out using a specialist organization, experienced and
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Section VII. General Requirements skilled in the preparation of surfaces and the application of protective coatings under the prevailing conditions. 8.24.5 Parts built into Concrete Cast iron or mild steel parts to be built into concrete over a depth of 75 mm shall remain unpainted. Immediately before it is cast in-situ, it shall be made perfectly free from dirt, scale, loose rust, paint, oil, lime-wash or any other coating. 8.24.6 Inspection and Tests The plant shall be inspected and reviewed at the various stages of the coating application both at the manufacturer's works and at the site of the work. The completed paint systems shall be tested by instruments to ensure that the protection is of adequate thickness and is free from pinholes and the adhesion shall be checked by the removal of a small section of the coating. The Contractor shall be responsibility for the availability of all instruments and apparatus required for carrying out such tests at no additional cost to the Employer. 8.24.7 Corrosion-Resistant Materials No blast cleaning or painting shall be applied to corrosion resistant materials such as stainless steels, Ni-resistant cast iron, bronze and other metals used for seals, bearings, lighting fittings, etc. 8.24.8 Box and Tubular Sections Box and tubular sections shall be permanently sealed. All such sections shall be thoroughly dried out using hot dry air before final sealing and painting is carried out. After sealing, all sections shall be tested for air tightness. 8.24.9 Machined Surfaces Machined surfaces such as gear-teeth shall be coated with a thick layer of grease. Other machined surfaces such as shaft ends, deep plates and other bright parts shall be coated with two coats of an anti-rust solution that can be removed easily when required. Permanently bolted machined interfaces such as flanges shall be coated with a thin coat of anti-rust compound before assembly. 8.24.10 Manufacturer's Standard Finishes Where it is the usual practice of the manufacturer of items such as pumps, electric motors, switchgear, control panels and similar plant, to apply a high standard of protective paintwork in the shop before dispatch, this will normally be acceptable provided that such standard finishes are at least equal to the surface finish specified. Full details of such manufacturer's standard finishes shall be given to the Project Manager for his approval prior to manufacture. Special care shall be taken to ensure that standard finishes are suitable for the particular conditions applicable to the individual items of plant.

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Section VII. General Specifications

9 9.1

ELECTRICAL WORKS Introduction

This section covers workmanship, materials of construction and other miscellaneous items applicable to all items of electrical works. All component parts of the works shall, unless otherwise specified, comply with the provisions of this section or be subject to the approval of the Project Manager. 9.2 Electricity Supply General electricity supply will be 380 volt, 3-phase, 4-wire and 220 volt single phase, 50 Hz for other uses. All motors supplied are to be compatible with this supply. 9.3 9.3.1 Low Voltage Distribution Equipment Switch Panels

All switchgear, fuse gear, circuit breakers and distribution equipment shall be of 500 volts rating. As well as the latest IEC Standard Specifications, to comply with: IEC 439 - 1 IEC 439 - 3 IEC 947 - 2 IEC 947 - 3 IEC 947 - 1

The rating of the equipment shall be shown on the electrical schematic diagrams. Clearance and spacing between phase and phase, phase and neutral, phase and earth neutral and earth shall be adequate and in accordance with IEC 439-1. A disconnectable neutral link shall be put on the right hand side of the main breaker or isolator of each switch panel. The neutral link shall be accessible with the switch in the closed position. All spare ways shall be blanked off using PVC blanking plates to the approval of the Project Manager. All switchgear, fuse gear, circuit breaker panels and distribution equipment shall be complete with all the necessary cable terminations to suit electrical services schematic diagrams. The main incoming switch on the main and sub-main panels shall be equipped with three maximum demand meters rated to the full load capacity of the main switch to measure the full load taken by the board. A voltmeter complete with a 7-position selector switch shall also be included to measure all phase to phase voltages and phase to neutral voltages and on-off position. Other metering required shall be as specified elsewhere. Selector switches for volt meters shall be of the break before make type and selector switches for ammeters shall be of the make before break type. The Contractor shall ensure that adequate cable entry positions are provided to suit the particular circumstances. The phase rotation, when viewed from the front, shall be Red, Yellow, Blue from left to right, or top to bottom. The colour finish required shall be according the Project Manager's specifications. Shop Drawings of the proposed arrangements, including circuit diagrams, overall dimensions, holding down bolt positions and wiring channels for out-going distribution boards shall be submitted by the Contractor to the Project Manager for approval before manufacture.

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Section VII. General Requirements 9.3.2 General Mechanical Construction

Switchboards shall be manufactured with a rigid and compact structure and shall be supplied complete for installation with minimum site assembly being necessary. Cubicle pattern switchboards shall be in sections for easy assembly separately aligned throughout. There shall be front access to the equipment for cabling. With rear access cubicle pattern boards, full height access doors shall be provided. The doors shall be fitted with lockable chromium-plated handles and substantial chromium plated hinges. Where switchboards are to be floor mounted, adequate facilities for holding down bolts shall be provided and a plinth 40 mm high shall be incorporated as an integral part of the base. Wall mounted cubicles shall be provided with suitable internally positioned bolt holes to withstand the operating function and the weight of the panel. Medium voltage switchboards shall be totally enclosed, metal clad, flush front and back pattern, suitable for front access and shall comprise such circuit breakers, busbars, distribution boards, contactors, control relays and meters etc., as specified. Switches shall be front operated with removable or retractable handles, and a full complement of handles shall be provided. All protection relays, ammeters etc., shall be mounted at or near eye level. Unless otherwise stated, all distribution boards shall be mounted at a height of 1.5 m measured from the floor to the bottom of the distribution board. Each distribution boards with a door up to 500 mm wide shall have one door only. Distribution boards wider than 500 mm shall have double doors with left and right hand vertical hinges. All distribution boards supplied under this Contract shall be equipped with miniature circuit breakers of the same manufacture. All isolator and main switches of distribution boards shall be of the rating as detailed in these Specifications. A copper earthing bar shall be provided throughout the length of the switchboard, suitably positioned to accept the earth termination of each cable. All instrument and panel wiring shall be run in square and symmetrical lines and shall be fixed by means of purpose made insulated cleats, and shall be harnessed together by means of hole and stub polyvinyl chloride strip or other equal and approved. All instrumentation wiring shall have identification ferrules fitted to both ends, marked with circuit numbers. Trip circuits shall have an additional ferrule coloured red and marked Trip. Each circuit shall be suffixed with the panel identification letter. Trip circuit cables shall be coloured black and current transformer cables shall be coloured with their respective phase colour. Final cable terminations shall be by means of crimped ferrules or lugs secured to the conductor(s) by the use of an approved crimping tool. Where an assembly of loose equipment is specified, this will be detailed in the relevant section of these Specifications. Ammeters and current transformers shall comply with the relevant clauses of these Specifications. The cubicle shall be arranged for adequate heat dispersion such that every component does not exceed its rated temperature limit and is at its optimum condition for maximum life and reliability. All switchboards shall be capable of future extensions and shall be factory tested before delivery to site. The Contractor shall be responsible for ensuring that the switchboards are delivered to site in sections suitable for installation at the appropriate location, and no claim will be entertained for extra payment due to his negligence to arrange accordingly.

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Section VII. General Specifications All the metalwork used in the construction of the panel shall be cleaned of all scale and rust before painting, and the panel shall be bonderised and receive two finishing coats of colour to BS 381C. All doors and removable panels shall contain suitable gaskets to make the compartments dustproof and vermin proof. Before hand-over, the interiors of all electric panels, starter panels and switchboards shall be cleaned. This includes the removal of any surplus wiring, filings, swarf, insulation ends, etc. All equipment within or on the panels or switchboards shall be carefully dusted, and any accumulation removed by a suitable vacuum cleaner. A check is then made to ensure that all equipment is fully operational and all connections tightened. 9.3.3 General Electrical Construction All insulating construction materials and components shall be non-hydroscopic non-tracking. They shall not be readily combustible and shall be completely suitable for temperatures which may occur within the switchboard. All internal wiring of the panel shall comply with the relevant IEC Specification with regard to colour coding. The minimum size of the conductor employed for auxiliary wiring shall not be less than 1.5mm and no terminal studs smaller than 2BA shall be used. No terminal shall have more than two wires connected thereto. Tee joining of auxiliary wiring shall not be permitted. There shall be complete earth continuity throughout the switchboard and each section shall be adequately bonded internally. An earth terminal shall be provided at each end of the switchboard for external earth connections and adjacent to each cable termination box. 9.3.4 Busbars Busbars shall be of the rating specified and arranged to give an effective cooling surface. Busbars shall be rectangular hard drawn, high conductive/copper adequately rated and supported on non-hygroscopic insulators non-tracking. The busbars shall be adequately supported against short circuit forces, be provided with phase identification and be individually enclosed in solid insulation. The complete assembly shall be capable of withstanding the maximum possible mechanical stresses to which it may be subjected under fault conditions. 9.3.5 Busbar Chambers Busbars shall be enclosed in sheet metal enclosures of not less than 14 gauge (SWG) sheet metal. The enclosure shall be stove enamelled. The front cover shall be secured by means of hexagonal bolts. Entry into the busbar chambers shall only be by the use of tools to remove a cover or panel. Busbars and busbar connections shall be constructed in accordance with IEC 439 - 2. Connections to busbars shall be by means of a compatible split type cast clamp. Busbars shall be fitted with phase colour identification discs at not more than 1500 mm centres. Busbar chambers shall not be used as wiring ways. Only busbar and cables connected thereto shall be permitted within busbar chambers. Busbar chambers included in any switchgear shall be of the same manufacture and extend the length of the switchgear arrangement.
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Section VII. General Requirements 9.3.6 Inspection and Testing at Works

The manufacturers shall carry out tests at the works after the completion of the switchboards and shall provide certificates of all tests carried out, which shall include the following: (a) (b) (c) Over-voltage Insulation Operation of all individual switches

The Contractor shall advise the Project Manager when the Board has been completed and is available for inspection as an assembled unit. The Project Manager reserves the right of access to the manufacturers works at any reasonable time to ascertain progress and to inspect workmanship. 9.3.7 Instruments Instruments and meters shall be provided on incoming and outgoing circuit breakers as required and specified in these Specifications. Instruments shall conform to BS 89 (1st grade) and shall have pointers of not less than 50mm length. The scales of ammeters and voltmeters shall be arranged so that the normal working maximum shall be approximately at the mid-way position on the scale. Meters shall be of flush mounting pattern and of 100 mm diameter, with 900 scale, having back connections. The movements shall not be damaged by the passage of full currents within the capacity of the switchboard. The instruments shall be provided with an external zero adjustment. Current transformers shall be installed on the side of the switchgear remote from the busbars. Transformers shall conform to the requirements of IEC 185-1 and be suitable for the instruments specified. Voltage transformers shall conform to the requirements of IEC 186-1. The manufacturer shall provide for maintenance purposes, approved as fitted wiring diagrams fully numbered in accordance with the numbering scheme. The ammeters shall be connected into the red phase of each switch or starter cover, or immediately above the switch or starter with which it is associated. Where they are used in motor circuits, the normal full load running current of the motor which the starter controls shall be indicated on the ammeter by means of a red line. All ammeters of greater than 30 amperes scaling shall be current transformer operated, and shall be suitable for 5A current transformer secondaries. 9.3.8 Identification Labels All labels shall be of a three layer Traffolyte fixed by means of permanent mechanical fixings. For general purposes the Traffolyte shall be White/Black/White with 8 mm high characters. Ancillary fuses or auxiliary relays shall be clearly and permanently labelled with the function and operating details including fuse type and rating where required. All auxiliary wiring shall be labelled fully numbered in a logical sequence by permanent slip on numbered ferrules and all terminal blocks and terminations shall be similarly identified.

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Section VII. General Specifications 9.3.9 Identification of Equipment

Busbars shall be coloured to identify the phasing. All switchgear, fuse gear, circuit breakers and distribution equipment shall have a label identifying the function of that item. All controls, indictors and push buttons shall be clearly labelled to show the associated function. All equipment arrangements shall be further identified with a DANGER Notice. The Contractor shall provide a diagrammatic layout of the distribution system and cables, clearly marked with all sizes and types of equipment, cabling, circuit references and the areas of equipment served, together with the information necessary for the identification of devices performing the functions of protection, isolation and switching and their locations and a description of the method used for compliance with regulations 413-3 of the IEE Regulations. The main electrical switch panels shall be provided with a black rubber mat 5 mm thick extending 1 metre in front and the length of the panels. 9.3.10 Operating Instructions and Special Tools Any special tools and four bound copies of all operating and maintenance instructions shall be provided by the Contractor to be suitable for use by the Beneficiary Municipality. 9.3.11 Low Voltage Circuit Breakers Low voltage air circuit breakers shall be the air break, horizontal draw out pattern. The rupturing capacity shall be as specified in these Specifications. Circuit breakers shall comply with IEC 934/IEC 947-2 and shall be complete with overload, shunt-trip or no-volt coils and provision for remote tripping, all as detailed hereinafter. Circuit breaker closing mechanisms shall be of the trip free type and shall incorporate a mechanical ON/OFF indicator and mechanical interlock in order to prevent withdrawal, plugging or access to the breaker in the closed position. Contacts shall be robust in design, of adequate cross-sectional area and shall be provided with an arc quenching device, and shall be capable of carrying full load for an indefinite period. Contacts shall be readily renewable tips. The live fixed contacts shall be carefully shrouded. Where a circuit breaker forms part of a switchboard, it shall be so arranged that it can be completely isolated from the switchboard. When isolated, automatic shutter(s) shall close over the fixed contacts in order to prevent inadvertent access and lockable shutters shall be lockable. Circuit breakers shall be of the current rating specified and shall incorporate the following: (a) (b) Closing mechanism, trip coils and all ancillary apparatus. A wheeled carriage so arranged to move horizontally for isolation of the circuit breaker, with hinged rails so that further withdrawal is possible for maintenance outside the cubicle. The closed circuit breaker shall be suitable for standing on the floor without the use of a trolley when it is completely removed from the cubicle. Hand operated closing mechanism. The trip mechanism shall be electrically operated by means of the protection equipment specified.
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Section VII. General Requirements (e) (f) (g) There shall be an ON/OFF/ISOLATED indicator. Six 15 ampere secondary isolating contacts shall be provided, three being normally closed. These contacts shall be wired out to a terminal box. The circuit breaker shall be equipped with interlocks to prevent access to live parts.

9.3.12 Distribution Boards All distribution boards shall conform to IEC 439-1 and shall consist of substantial sheet metal cases with hinged doors. This metal work shall be primed, bonderised and finished in good quality stove enamel. Colour finish to be BS 381C with exact colour match to the main and sub distribution switchboard shall be according to these Specifications. Gaskets shall be fitted to the doors to prevent the ingress of moisture, dust and vermin. The distribution boards shall be supplied with removable end plates. All neutral bars shall have sufficient ways to enable the maximum number of single phase circuit to be connected without bunching. Connections to neutral bars shall be made in such a manner that they correspond to phase connections and conductors, and shall be marked with marker tape to indicate the circuit number and phase of the connection. Every sub-circuit shall be ferruled at the distribution board with the circuit reference. Insulating barriers shall be provided to prevent accidental contact with live parts. Phase barriers shall be fitted where applicable. Where distribution boards are installed in locations remote from their controlling switches, they shall have on-load isolating switches of the rating scheduled, integral with the distribution board. Miniature circuit breaker distribution boards shall be complete with miniature circuit breakers of the type specified. For each distribution board, a type written chart shall be supplied in a translucent holder and securely fixed on the inside of the distribution board door. The chart shall state clearly details of equipment controlled, together with fuse or MCB rating and type, size and type of outgoing cables. A sample circuit list shall be submitted for approval by the Project Manager before installation. On the cover of each distribution board, switch fuse and isolating switch a 45 mm x 20 mm Traffolyte label (White/Balck/White) shall be fixed and engraved in 5 mm characters giving details of service and phase etc. In addition, a Traffolyte (White/Red/White) label engraved in 8 mm characters 415/240 volt shall be fixed to all TP & N distribution boards and isolators. In addition, a Traffolyte label shall be fitted on the inside face of the door to indicate the following: (a) (b) (c) (d) (e) (f) (g) Size, type and origin of sub-main cable Rating of cable protective device Nominal voltage Uo Prospective short circuit current (Ip) present at distribution board. Earth fault loop impedance (Ze) external to the distribution board Estimated max demand (KVA) Type of earthing

All labels shall be permanently fixed by means of screws or nuts and bolts. Gluing will not be accepted.
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Section VII. General Specifications 9.3.13 Miniature Circuit Breakers All miniature circuit breakers shall be of the type rating and duty specified in these Specifications. Where miniature circuit breakers are installed for the protection of three phase circuits, the three phase units shall be interlocked such that operation of any one phase unit will cause the other two phase units to trip. The design performance and test specification requirements for miniature, moulded-case and earth leakage circuit breakers shall comply with the following specifications: IEC 898 Specification for Miniature and Moulded-case Circuit Breakers. Amendment 3- 1987 Miniature Air-break Circuit Breakers for AC Circuits. IEC 947 - 2 Circuit Breakers. IEC 755 Specification for Current Operated Earth-leakage Circuit Breakers. IEC 1009 - 1 Specification for AC Voltage Operated Earth-leakage Circuit.

Miniature circuit breakers shall be of a category to suit the short circuit rating specified. 9.3.14 Moulded-Case Circuit Breakers Moulded case circuit breakers shall comply with IEC 898. The current ratings and AC rated short circuit capacity shall be as indicated in these Specifications. 9.3.15 Miscellaneous Equipment The equipment normally installed in or associated with switchgear, switchboards, starter panels and distribution boards shall comply with these Specifications. These shall also apply when items are installed in other locations. 9.3.16 Contactors Contactors shall be totally in metal cases in high impact polycarbonate with hinged and/or bolted covers and be provided with external earth terminals where required for separate wall mounting. Where mounted with a common enclosure, all components of each individual contactor shall be mounted on a common back-plate. Separate mounting of a contactor and overloads shall not be allowed, except in a larger size unit. Contactors shall have class of duty as defined in IEC 947 - 4 and as required in these Specifications. The operating coil voltage shall not exceed live/neutral voltage on a three phase device, and where groups of contactors are enclosed in a switchboard, a separate control transformer as detailed in these Specifications may be required. Auxiliary contacts shall be fitted as required by the design of the control circuit and other specified requirements. For cubicle type boards and distribution boards, the contactors (together with any associated relays) shall be housed in a separate compartment with its own hinged lid housed in a separate compartment with its own hinged lid and shall be barriered from any other equipment. This arrangement is mainly intended for fuse distribution panels, but as far as possible, the practice should be adhered to throughout for small contactors and relays. 9.3.17 Time Switches Time switches shall be electrically operated and shall be complete with the number and type of contacts specified. All time switches shall have a spring or battery reserve movement of at least 24 hours and be electrically wound. Time switches shall be enclosed in a suitable type enclosure for the location, and designed to prevent damage to the clock movement.

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Section VII. General Requirements 9.3.18 Current Transformers Current transformers for use in conjunction with instruments and protective relays shall be manufactured to IEC 185-1. The minimum accuracy shall be Class C for instruments and S, T or U for protective metering and indicator relays as required. Instrument transformers shall be of the ring type unless otherwise approved and shall be so mounted that convenient access is afforded for maintenance. The transformers shall be air insulated. Transformers shall not be mounted within the busbar chamber. Both primary and secondary ends shall be clearly and permanently marked with polarity. A rating plate indicating the (a) accuracy, (c) serial number and (d) ration, shall be fixed to the cases. The secondary winding of each transformer shall be earthed at one point. Under no circumstances shall the secondaries of instrument transformers be left open circuited. The current density in the primary winding at the rated over-current shall not exceed the figures in IEC. All current transformers shall have 5 ampere secondaries, unless otherwise specified in these Specifications. 9.3.19 Voltage Transformers Voltage transformers for use in connection with instruments and protective relays shall be manufactured to IEC 186 - 1. 9.3.20 Low Voltage Switches Isolators, switch fuses, fuse switches and changeover switches shall be continuously rated to IEC 947 and shall be high impact polycarbonate totally enclosed to IP54. All switch-fuses and isolating switches shall be 500 volt rating and suitable for the fault rating specified in these Specifications. The switching action shall be quick make, quick break. The fixed contacts shall be fully shrouded and with the switch in the open position. An ON/OFF position indicator shall be mechanically operated by the moving contacts to give an accurate and positive indication and means shall be provided for locking each switch in the open position only, unless otherwise stated. All Unit type switches (as opposed to Cubicle type) shall have undrilled detachable end plates or Knock-Outs. The appropriate holes shall be drilled or Knock-Outs removed on site. The covers of all units shall be hinged on solid hinges which shall be capable of being removed only by the use of tools; split pins will not be accepted. The free side of the lid shall be secured by means of captive security devices. Where units form part of a switchboard, fixed contacts shall be shrouded, and when the switch is opened they shall be shuttered. Fuses shall be of the HRC cartridge type having a rupturing capacity appropriate to the current carrying capacity specified. All fused switches, switch fuses and isolating switches shall be fitted with blank end plates for conduit or mineral insulated cable entry, or cable boxes, brass cone wiping glands and armour clamps for PVC SWA cable terminations as required. Reverse entry adaptors and angle end boxes shall be fitted where necessary.

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Section VII. General Specifications All motors shall be provided with a local means of isolation and switching as required under Section 573 of the IEE Regulations lock-off isolating units provided as a means of isolation of motors in compliance with IEE Regulations Clause 537 - (8-11) shall comprise a switch push button operated unit with automatic locking in the off position, and requiring positive action (e.g. key operation) to restore the mechanism to the on position. Where these units are mounted externally they shall be enclosed in a polycarbonate enclosure to IP65, UV inhibited. Where isolates are provided in the live supply conductors to motors, these shall be capable of breaking the supply to the motor in a stalled condition. The Contractor shall be responsible for setting all overload and protective devices to the recommended value. The Contractor shall be responsible for checking that the rotation of all motors is correct for the purpose. Connections shall be carried out by flexible metallic conduit. 9.3.21 Earthing and Bonding There must be complete EARTH continuity throughout the entire system in accordance with the IEE Regulations, with all necessary bonding provided and installed by the Contractor. All conduit connections to distribution boards, luminaires, trunking etc., shall be properly screwed together so as to ensure mechanical and electrical continuity throughout. Care is to be taken in bonding and earthing the installation. Tests are to be carried out as the work progresses to check the electrical continuity of all metal work, conduits etc., and protective and bonding conductors. The Contractor shall be responsible for the bonding and earthing to all exposed metalwork, structural and otherwise. All metal sinks and hot and cold water pipes shall be earth bonded. Where these are within two metres of an electrical outlet, then they shall be bonded to same. This bonding to be effected with PVC Yellow/Green sheathed earth wire installed flush to plaster. Connections to be carried out before painting of pipework, etc. The whole installation must contain a separate EARTH wire to give a second complete earth continuity path. Testing of earth path will include both this earth path and that provided by the conduit/trunking with any associated EARTH cable. No earth continuity conductors shall be less than 1.5 mm tinned copper cable, PVC insulated and coloured Yellow/Green. All protective and bonding conductors shall comply with Chapter 54 of the IEE Regulations. The steel wire armouring of the sub-main cables shall be efficiently bonded together and to the respective switchboard, distribution boards, sealing chamber and conduits at which they terminate and to all metalwork adjacent. The incoming water services shall be bonded to the electrical earth, as near as practicable to the point of entry to the building. The incoming electrical supply cable and the telephone cable shall be bonded directly to the lighting protection system at the point outside the structure of the Public Utilities side of the service in accordance with the BS standard. Earthing and bonding connections shall be provided with warning notices in accordance with IEE Regulations. 9.3.22 Tests Conduits and cables shall be tested during the progress of the work before their concealment as follows:
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Section VII. General Requirements (a) (b) (c) Continuity of protective conductors and equip-potential bonds of conduit, metal sheaths. Continuity of current carrying conductors. Insulation resistance of MICC cables.

Immediately prior to completion and in the presence of the Project Manager, the Contractor shall carry out the initial inspection and testing detailed in the 16th Edition of the Wiring Regulations. Test results are to be documented on test charts containing the following information for each circuit. (a) (b) (c) (d) (e) (f) (g) (h) Design current (IB) Earth loop impedance (Zc) at furthest point Line neutral impedance at furthest point Loop resistance (R1 + R2) Continuity of ring final circuit conductors Insulation resistance readings Polarity test RDC test where applicable

In addition to the aforementioned information, each chart shall contain details of external characteristics pertaining to the distribution board. Following successful inspection and testing, three copies of the Inspection/Test Certificates shall be forwarded to the Project Manager within 14 days of the tests being completed, or at Completion, whichever is the sooner. Note that the Project Manager will not accept the installations as practically complete until a Test/Completion Certificate is presented. The electrical installation shall be designed to give load balance across the 3-phases as far as possible but it is the Contractors responsibility to maintain or improve the balance when making connections to busbars, etc., with the approval of the Project Manager. The Contractor shall check loads and altering connections in order to achieve as even a balance over the phases as possible and modify accordingly. 9.3.23 Standards Throughout this section reference has been made to IEC Standards and IEE Regulations. Where an IEC standard or IEE regulation does not exist, the applicable SAZS-CAS-BS or SABS standard or regulation shall apply. 9.3.24 Cables Cables shall comply with IEC Standards and in particular IEC 55-2 for insulated cables up to 18/30 kV and IEC 189-2 for PVC/PVC cables for indoor use. 9.4 9.4.1 Conduits and Accessories Metal Conduits

Metal conduit installation specified herein shall be carried out in heavy gauge hot dipped galvanised screwed or black enamel conduit, and shall comply with BS 4568. No conduit of less than 20 mm diameter shall be used in the permanent works. As applied to steel conduits and fittings the word protection against corrosion to Class 2 (or to Class 4) shall have the following meaning: Class 2: Medium protection both inside and outside (stone enamel air drying paint). Class 4: Heavy protection both inside and outside (hot-dip zinc coating: sheradizing).

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Section VII. General Specifications Steel conduit shall be galvanised or black enamel according to location. Black steel conduits shall generally be concealed in the building structure or in ceiling voids. Galvanised conduit shall be used in plant rooms and other service areas. Where elsewhere as described in these Specifications, protective coating on surface mounted steel conduit and associated fittings shall be galvanised affording protected against corrosion according to Class 4. In all other situations conduit shall be black enamel affording protection against corrosion according to Class 2. All conduits shall be free from rust patches or mechanical damage and shall be adequately protected from all types of damage when stored on site. Wherever the conduit finish is damaged during installation, the conduit shall be cleaned and painted with black enamel paint. In exposed locations, i.e. where directly exposed to the elements, e.g. on the roof, loading bays etc., the complete conduit installation, including accessories, shall be weatherproof. All draw boxes and junction boxes shall be of ample size to permit the cables being drawn in and out. They shall be of malleable iron or heavy gauge sheet steel hot dip galvanised. All circular boxes shall be provided with long spouts, internally threaded, incorporating a shoulder for the proper butting of the conduit. Standard circular conduit boxes shall be installed at all lighting points, except where conduits terminate at fixed lighting fittings giving provision for direct conduit entry (e.g. bulkhead fittings). At lighting switch points the conduit shall terminate at a suitable box provided with internal adjustable lugs to permit back-plates or switch-grids being attached to them by metal threaded screws. All lids for draw boxes etc. shall be of heavy gauge welded sheet steel pattern. Over-lapping lids shall be provided for flush boxes. The ends of all conduits shall be cut square and reamed to remove burrs and shall butt solidly into the conduit fittings. Where they terminate in switchgear, fuse-boards, trunking, adaptable boxes or other non-spouted enclosures etc., they shall be connected thereto by means of smooth bore male bras bushes, serrated washers and sockets. The length of thread cut on a conduit shall be kept to a minimum consistent with the above requirements. Except at running couplings, any exposed threads shall be cleaned, primed and painted after installation. An approved type of conduit coupler shall be used where necessary. In all cases, castellated locknuts shall be used and the use of ring bushes and locknuts shall not be permitted. Where flush conduits terminate in surface mounted distribution board, this shall be by means of a flush mounted adaptable box with direct bushed rear access to the distribution board. The position of the draw-in boxes shall be arranged so that they will always be readily accessible and an adequate number of draw-in boxes shall be provided in a conduit run to ensure that cables can be installed or removed without damage. The number provided shall not be less than one every nine metres in a straight run of conduit. Where runs include numerous bends, sets or other restrictions, the number of cables is to be appropriately reduced. Efficient means shall be provided to seal boxes and fittings against the ingress of dirt during the building construction. All conduit fittings installed exterior to buildings shall be fitted with efficient permanent gaskets in order to render these watertight. All conduits shall be satisfactorily painted. Conduit boxes shall also be compound filled if the installed conditions require this.

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Section VII. General Requirements All bends and sets are to be made on site to suit conditions and not more than two right angle bends will be permitted without the inter-position of a draw box. No tees, elbows, sleeves or manufactured bends, either of inspection or solid type will be permitted. Draw wires are to be installed in those conduit installations where the cabling is to be installed later by others. Conduits for switches etc., shall be either sunk, cast in or run on the surface of the walls as the case may require. At positions, where more than one switch is to be mounted, multiple boxes shall be used and not a series of single boxes unless this is otherwise specified to provide phase barriers. Where conduits are to be sunk, they shall be cast in, or chased into the walls before plastering, and fixed with heavy gauge BS crampits in the chases, so that the boxes will be flush with the finished surface. The chasing of walls horizontally to install conduits shall not be permitted. Where conduits cross expansion joints in the building structure, an expansion joint on the conduits shall be installed. Conduits shall be secured by spacer bar saddles at intervals not exceeding 1500 mm. Fixing saddles shall also be provided not more than 100 mm on either side of a fitting, accessory or bend. Multiple spacer bar saddles shall be used where two or more conduits are run parallel to each other. All surface conduits shall be run in square and symmetrical lines, but efficient means shall be adopted to provide for the drainage of condensation. All buried conduits shall be thoroughly painted with red oxide paint before plastering or concreting to minimize the risk of rust patches appearing on the finished wall and ceiling surface. Where conduits are installed in walls, these shall be at a depth to give a minimum of 15 mm of plaster. Where conduits are installed in walls or screeds, these shall be securely fixed to prevent movement before the screeds are laid or the plaster applied. All boxes shall finish flush with the finished level of the ceiling/wall/floor, and extension collars shall be used as necessary. Where conduits are run in false ceiling they shall be fixed to the underside of the structural slab by means of spacer bar saddles. Fixing to the hangers or framework of the false ceilings will not be permitted. The spacing fixings shall be as specified by the Project Manager for surface runs. Where conduits are installed in an area that will be subsequently wall tiled, the Contractor is to arrange for switch and outlet boxes to be set to coincide with the tiling pattern as required by the Project Manager. This shall be checked prior to conduit installation in such areas. Under no circumstances shall conduit be erected in such a manner as to form a U shape without outlet, or in any other way that would provide a trap for condensed moisture. Provision shall be made for draining all conduits of fixtures by an approved method. Where conduits cross expansion joints, the Contractor shall install expansion couplers at the position of the expansion joint and at right angles to it. An earth wire shall be installed between boxes on each side of the coupling and bonded to brass earth terminals fitted in each box.

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Section VII. General Specifications Conduit fixed to structural steelwork shall be secured by means of purpose made brackets/clips, but the steelwork shall not be drilled or welded without the approval of the Project Manager. Bracket and/or clips to hold conduits shall not be fixed to pipe work or to duct work. All conduit fittings shall be fixed by 35 mm No. 8 cadmium plated steel screws in expansion plastic plugs or approved equal methods as a minimum standard. The entire conduit system shall be electrically continuous throughout the installation and must form a complete bonded system with the whole being efficiently earthed. In addition, a separate continuous PVC insulated earth wire shall be installed within the entire conduit system. This earth wire shall be sized in accordance with Section 543 of the IEE Regulations. 9.4.2 Cables in Ducts Where cables are to be installed in horizontal ducts, these are to be adequately supported by approved brackets. The brackets are to be installed so as not to damage the cabling and must allow air movement around the cables. The complete bracket assemblies shall be correctly treated against corrosion, primed and painted before installation. The finish and fixing shall be appropriate to the conditions in which the bracket assemblies are installed. Cables rising on vertical surface from floor ducts shall be adequately protected to a height of 1200 mm externally and 2800 mm internally by galvanised steel pipes or purpose made galvanised steel channel. Pipes shall be bushed and sealed with compound. In rising ducts open to access, all non-armoured cables shall be protected against mechanical damage by the installation of the 300 mm high mild steel kick-shield suitably fixed at each floor level. The kick-shield shall be of 14 SWG thickness and treated with one coat of suitable primer. 9.4.3 Cables in Conduit and/or Trunking Where cables are installed into conduits and/or trunking, then the cables shall not be drawnin until the section is complete and the building water-tight. Flexible cables for final connection to heaters shall be of heat resisting cable (e.g. butyl rubber) of appropriate cross-sectional area. In the case of luminaires, the conversion from PVC insulated cable to heat resistant cable shall be effected at the approved porcelain terminal block housed within the conduit box to which the luminaire is attached. Under no circumstances shall cables pass through light fittings. No light fitting or equipment shall form part of the conduit work. Where cables are installed as through wiring of fluorescent luminaires, then these shall be of high temperature butyl rubber type. 9.4.4 (a) (b) (c) (d) (e) Segregation of Wiring Systems Low voltage lighting and power (Category 1) (380/240V) Extra low voltage systems (Category 2) 50V Radio, Public Address, Internal Telephones (Category 2) data transmission Intruder Alarms (Category 2) Fire alarms and emergency lighting (Category 3). Wiring systems shall be independent for the following system:

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Section VII. General Requirements 9.4.5 PVC Conduits

PVC conduits shall be heavy gauge, high impact PVC not less than 20 mm diameter external and manufactured to BS 4607. All conduit and accessories used shall be obtained from one manufacturer only. All draw boxes and junction boxes shall be of ample size to permit the cables being drawn in and out. All circular boxes shall be provided with spouts incorporating a shoulder for the proper butting of the conduits. At all lighting and switch points, the conduit shall terminate in a suitable box provided with internal lugs to permit back plates or switch grids being attached to them by non-corrosive screws. All lids for draw boxes etc. shall be of PVC. Overlapping lids shall be provided for flush points. Proprietary steel or brass inset clips shall be fitted where luminaires are suspended from circular boxes to ensure that the weight of the luminaires is carried by the structure rather than the conduit box. The ends of all conduits shall be cut square and shall butt solidly in the conduit fittings. Where they terminate in switch panels, trunking, adaptable boxes or other non-spouted enclosure etc., they shall be connected thereto by means of smooth bore male PVC bushes and sockets. Where more than one switch is to be mounted, multiple boxes shall be used and not a series of single ones unless boxes are otherwise specified to provide phase barriers. All conduits shall be free of mechanical damage and shall be adequately protected from all types of damage, both when on site and when being installed in the building structure. It shall be the Contactors responsibility to inspect the conduit and accessories for damage before the final building finishes are applied or erected. All conduits joints shall be made using push-in types of couplers and accessories assembled with the adhesive supplied by the manufactured, and the Contractor shall ensure that the conduit butts in fully. The ends of the conduit and the conduit fittings shall be cleaned before applying the adhesive according to manufacturers instructions. All bends and sets shall be made on site to suit conduits and not more than two right angle bends will be permitted without interposition of a draw box. Conduits up to and including 25mm diameter may be bent or manipulated cold by hand or forming machine. Larger sizes shall be bent by application of heat. In any case, the installed conduit is to be free of kinks, distortion or damage. All conduits shall be swabbed through before wiring is commenced, and cables shall not be drawn into any section not fixed in position. Where conduits are to be chased into brickwork having a plastered finish, or run in the floor screed, the conduit shall be fixed with one hole PVC clips. Where direct conduit entry is not possible or desirable, as is the case of motors etc., the conduit shall terminate at an agreed point adjacent to the motor etc., and the wiring shall be continued in a flexible PVC corrugated conduit cemented to an inspection box at the termination of the fixed conduit installation. Conduits shall be run in a symmetrical manner and for surface runs shall be secured by PVC spacer bar saddles using non-corrosive screws at intervals not exceeding 1.3 metres. All conduits and fittings shall be fixed to concrete or brick structure by 35 mm No. 8 cadmium plated steel screws in plastic expansion plugs. Fixing into steel work shall be effected with seraduzed or cadmium plated set screws, brackets and clips. Should conduit be dislodged
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Section VII. General Specifications from boxes during the pouring of concrete it shall be the Contractors responsibility to repair the joint to ensure continuity throughout and repair any damage to the wall, floor or ceiling caused by rectifying the joint. Straight surface runs without bends shall have a flexible adhesive bonded expansion joint every 6 metres. A separate continuous PVC-insulated earth wire shall be installed within the entire conduit system. This wire shall be sized in accordance with Section 543 of the IEE Regulations. Holes shall not be drilled in any structural steelwork or pre-stressed concrete without first obtaining the permission of the Project Manager in writing. 9.4.6 Flexible Conduits Flexible connections shall be made to equipment subject to movement or vibration. In all cases where these form an extension of the conduit system, a special flexible PVC covered conduit such as Kopex (or equal and approved), shall be used connected to an inspection box at the end of the termination of the fixed conduit installation. All flexible conduits shall be watertight, PVC sheathed, spiralled metal type of manufacture approved by the Project Manager. The conduit shall be terminated at boxes and equipment by means of compression glands approved by the Project Manager. A suitably sized, PVC insulated, stranded tinned copper earthing conductor shall be drawn into the flexible conduit and connected to the earth terminal at both ends of the flexible run. 9.5 9.5.1 Metal Cable Trunking General

Trunking shall be used where specified. It may be used in place of conduit if prior approval is obtained from the Project Manager. As applied to cable trunking, the words "protection against corrosion to Class 2 (or Class 3)" shall have the meaning: Class 2: Medium protection both inside and outside (stove enamel, air drying paint, Zintec coating). Class 3: Heavy protection both inside and outside (galvanised steel complying with BS 2989, Class 2A or 2B).

Unless otherwise specified, trunking shall be galvanised, affording protection against corrosion in accordance with Class 3. In all other locations, trunking shall be protected against corrosion in accordance with Class 2. Trunking sizes and sheet steel thicknesses shall be as follows: Trunking Sizes 50 mm x 50 mm 75 mm x 75 mm and above Sheet Thicknesses 1.2 mm 1.6 mm

All steel trunking shall manufactured to BS 4678, Part 1, of a thickness not less than 1.2 mm corrosion resistant steel and shall be rigidly fixed. Where necessary, the trunking shall be internally reinforced in such a manner that distortion will not occur during or after the installation of cables. It shall have a removable lid throughout its length. Trunking of all sizes shall be secured at intervals of not more than 1200 mm and joints shall not overhang a fixing by more than 600 mm. The metal trunking shall be positioned and fixed
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Section VII. General Requirements in accordance with the Project Manager's instructions. Opening for conduit connections etc. shall be provided as required by the Project Manager. Manufacturers standard accessories, e.g. bends, tees etc., shall be of the gusset or radius type. Cable leaving or entering the trunking shall be suitably supported to prevent damage or undue pressure on the insulation. Where partitioned trunking is used, the partitioning shall be maintained at intersections and angle pieces. Where trunking passes through walls and ceilings, the cover shall be solidly fixed at 75 mm either side of the walls and 150 mm either side of the floors and ceilings. Internal fire resisting barriers shall also be fitted. No metal trunking shall be installed with the cover on the inaccessible side. Where switchboards and fuse-gear are connected to metal trunking, such connections shall be made by necks and not by multiple conduit coupling. Where metal trunking is slotted to receive connecting necks, gaskets made from a synthetic resin fabric (to BS 2572) 10 mm smaller than the metal trunking aperture shall be fixed in position to prevent abrasion of cables on sharp edges. Alternatively, a PVC moulding shall be securely fixed around all such apertures. Vertical sections of metal trunking over 900 mm in length shall have staggered insulated tie off studs to support the weight of the cables. All trunkings shall be fixed to concrete or brick structure by 35 mm No. 8 cadmium plated steel screws in plastic expansion plugs. Cable retaining straps shall be provided at no more than 600 mm spacing. Trunking shall not be installed with cover on the underside, unless specified in writing by the Project Manager. Where covers are specified on the underside, suitable cable retainers shall be used to prevent cables from sagging both during and after installation. All trunking systems shall be painted with a complete finish to that of the original where any abrasions to the original have occurred. Electrical continuity shall be ensured by the provision of approved copper continuity straps at all bolted joints in the trunking. All bends and tees shall be prepared and welded at the manufacturers works and shall not be constructed on site. In addition, a continuous earth wire shall be installed throughout the systems rated in accordance with Section 543 of IEE Regulations. Joints in metal trunking shall be kept to a minimum and shall be sealed with a cover strip shaped to the contour of the trunking as approved by the Project Manager. All metal trunking fittings shall leave the main trough completely clear of obstruction and continuously open, except into switchgear equipment and floors at which point suitable fire resistant barriers shall be provided as may be necessary to prevent the spread of fire. Where an installation incorporates galvanised conduit tubing, the trunking shall be galvanised unless specified otherwise by the Project Manager. Screws and bolts securing covers to metal trunking or sections of metal trunking together shall be arranged to have countersunk bushes/nuts so that damage of the cables cannot occur when fixing covers or when cables are installed. Self-tapping screws will not be allowed. All cable covers, dividing plates and intersection units shall be installed prior to the cable installation, and this loss of space shall be taken into consideration when sizing the trunking.
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Section VII. General Specifications Trunking shall be sized in accordance with IEE Regulations with an additional allowance of 10% spare capacity for future installations. All measurements shall be taken on site. The positions and arrangements of bends and tees shall also be agreed on site with the Project Manager, with particular attention given to routing the trunking to be clear of other services. Where trunking is specified to support luminaires, then this trunking shall be installed as approved by the Project Manager. The general principle of the installation shall be as above, and particular attention shall be paid to earthing the trunking to the building conduit system. Adequate fixings shall be provided at no more than the centre distances instructed by the manufacturers. Allowance shall be made also for the operating loads imposed by pull cord switches etc. Manufacturers accessories shall be used to fix luminaires and wiring accessories to the trunking. All trunking shall be complete with manufacturers supply of covering. 9.5.2 Metal Under Floor Cast into the Floor Screed Trunking All trunking shall be manufactured to BS 4678 from continuously hot dipped galvanised sheet steel to BS 2987, 1975. Only the approved manufacturers trunking accessories and service outlets shall be incorporated unless prior approval of the Project Manager is obtained. All components shall be constructed of materials adequate in strength and performance, and shall be protected against corrosion. The interior of the components shall be free from sharp projections and be formed with intersections, bends junctions and elbows that permit cables to be laid or drawn in without damage. Fitted covers and other forms of protection shall be available for use during the installation stage to prevent the ingress of site material into compartments. Service layout boxes shall be adjustable in height independently of the trunking system to take account of differences in floor finish thickness. Allowance for alignment between components shall be incorporated into all details. Service outlet boxes and junction boxes shall be installed in the positions approved by the Project Manager and at all other positions necessary for the ease of installation of cables. Conduits shall only enter trunking at intersection box positions. Draw wires shall be installed for cables which shall be installed later by others, e.g. telecommunications cables. Where possible all drilling and cutting shall be carried out prior to installation, and care shall be taken to ensure that metal particles are not left in trunking after such operations. All metal trunking shall be installed in accordance with the manufacturers instructions. All trunking components shall be mechanically fixed to one adequately, secured to the structure and all covers replaced, before any screeding or floor finishing work takes place. Suitable wire mesh reinforcement shall be laid over all under floor trunking before screeding. A minimum of 25 mm screed shall be maintained over the top of all under floor trunking runs. Care shall be taken to prevent water or concrete from entering the trunking or boxes during screeding. At bolted joints and bends etc., the trunking shall be wrapped in a PVC tape or equal and approved immediately after installation of that section. Where under floor conduits bend up a wall at 900 or terminate at skirting trunking, the bend shall have a 450 angle for easy access of cables. Adequate protection shall be provided to the installation against damage during screeding and until all site works have been completed.
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Section VII. General Requirements Trunking intended for the accommodation of cables for various services shall be divided into compartments in order that complete segregation of different service cables occurs. Where it is stated that future demountable partitions are to be accommodated in the building construction, then it shall be ensured that service outlets and junction boxes are clear of these partitions. All components shall be effectively earth bonded to one another by mechanical means, utilising the manufacturers approved earth bonding straps. In addition, a continuous earth wire shall be installed throughout the system rated in accordance with the current edition of the IEE Regulations. An earth wire from each final sub-circuit shall be connected with the main earthing conductor via an appropriate sized brass earth stud to the trunking floor box and lid. Adequate cable segregation shall be provided between service runs throughout the system and be maintained at intersections and junctions. Cables emerging from service outlet boxes shall be protected against damage as required by safety standards and telecommunications retirement. Plastic Under Floor Trunking The Contractor shall ensure adequate mechanical protection to the installation to prevent damage during screeding, e.g. providing boards for operatives to walk or wheel equipment over. Adequate time shall be allowed prior to the screeding over of plastic trunking for the adhesive to dry, and all joints shall be checked at this time. 9.6 Cable Trays The Contractor shall supply and erect all cable trays, racks, brackets, clips, cleat hangers and other steel work required for supporting the cabling. Cable trays generally shall be formed from plain sheet steel complying with BS 1449, Part 1B, Classification CRA/GP. The cable tray shall be performed and afforded protection after manufacture. All cable trays shall be of perforated steel with a suitable up-stand at each side. Trays up to 300 mm in width shall be 14 SWG metal. All trays, including tees and bends, shall either be hot dipped galvanised or PVC coated, and where trays are cut, the cut ends shall be adequately rust-proofed or a PVC spray respectively to prevent deterioration. Cable trays shall be adequately supported at intervals such that the tray does not bend under the weight of the cables. Where supports exceed 1,500 mm, the cable tray shall be reinforced with mild steel angle of adequate section running the length of the tray. Each support shall consist of an angle or channel steel brace underneath the full width of the tray with 10 mm diameter mild steel rod support, or suitable gallows brackets where the tray is supported from the wall. In the latter case, the tray must be spaced at least 50 mm away from the wall. All trays shall be free from burrs and sharp edges. Joints in trays shall be made at supports and shall not overhang the supports. All cable trays shall be made electrically continuous by means of 25 mm x 3 mm thick copper link across each break of joint in the system. Connections shall be made by means of brass bolts, flat washers, spring washers and nuts (6 mm diameter minimum). At the link position, the finish shall be removed within 6 mm of the jointing strap and the exposed metal primed. The entire system shall be bonded to earth.

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Section VII. General Specifications Screws and bolts securing trays to brackets and joining trays shall be arranged so that no damage to cables can occur. Under no circumstances shall cable trays be turned upside down. Cables shall be fixed to the tray using proprietary straps, saddles, cleats etc., at intervals specified in the IEE Wiring Regulations for the type and size of cable. Where the installation of cable trays involves the use of bends and tees, these shall be made by fittings manufactured for this purpose and not by cutting or modifying straight tray sections. All securing nuts and screws shall be machined brass with a minimum size of 2BA. Where slotting of cable trays is carried out for cable entry or exit, a PVC or equivalent edging shall be provided on the edge of the slots. Cable trays shall be installed where more than two SWA, MICC, earth cables etc., share a common route. 9.7 Luminaires and Lamps Luminaires shall be of a type, size and manufacture specified in these Specifications. The Project Manager reserves the right to request a sample of each type of luminaire for approval prior to the placing of the order. Unless specified otherwise, the lamp-holders shall be formed of insulated high temperatures mouldings rigidly mounted on the luminaire body and be of the type to suit the lamp specified. The cable terminations shall be fixed in the lamp-holder in such a way that the plunger contacts maintain free movement and no strain is placed on the cables. Discharge lamp ballasts shall be formed of high conductivity enamelled copper wire windings around a laminated iron core enclosed in a resin filled sheet metal canister. Ballasts for tubular fluorescent lamps shall comply with BS 2818. Capacitors shall be coiled metallised film construction and enclosed with insulant filled sheet metal canisters. They shall be rupture and leak-proof and shall comply with BS 4017. External starter switches shall be of the electronic type enclosed in a canister, with two contact pins and shall comply with BS 3772. All control gear shall be designed for continuous operation at the voltage and frequency specified in these Specifications. The maximum permissible harmonic content shall not exceed 17% per phase (25% for semi-resonant circuits). All control gear shall be rigidly mounted and shall be provided with shrouded terminals. The wiring within the luminaire shall comprise of high temperature PVC insulated stranded copper cables of such diameter that there are negligible volt drops. A terminal block shall be provided for the incoming supply cables and the metallic content of the luminaire shall be electrically connected to an earthing terminal. All lamps shall be manufactured by a manufacturer approved by the Project Manager. All luminaires shall be installed complete with the correct lamps in accordance with the manufacturers instructions with power factor correction for fluorescent and discharge types. Where lamps are required to be installed in the horizontal plane, then these shall be of the rough service type. All fluorescent lamps shall be of the white correlated colour type, temperature 3400k unless specified otherwise in these Specifications. The Contractor shall confirm the colour type required with the Project Manager. Unless specified otherwise:
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Section VII. General Requirements GLS tungsten lamps up to and including 150 watts rating shall have BC. Sealed beam reflector lamps shall have ES generally. Fluorescent tube lamps shall have bi-pin caps. High pressure discharge lamps shall have ES caps for ratings below 250 watts and GES caps for 250 watts and above. Lamps for the same type voltage, wattage etc. shall be supplied with identical caps.

The number of luminaire suspension conduit rods must be adequate for the type of luminaire and in accordance with the recommendations of the manufacturer for the situation used. If other method is required, then this shall accord with these Specifications. Luminaires and ceiling roses fixed on standard round conduit boxes shall have a matching plaster break ring between. Ceiling roses shall be complete with cord grips. Lamps shall be installed in luminaire immediately prior to practical completion, and shall not be used as a means of temporary lighting. The lamps can only be used for tests of the lighting installation and during handover inspections. All luminaire shall be cleaned by the Contractor before the final inspections. Where batten type lamp-holders are required, then these shall comply with the requirements stated for lamp-holders with pendant drops. ELV transformers supplying luminaires shall be double wound with a fuse fitted in the primary and secondary and a screen between the windings. The transformer shall be contained in a high impact plastic enclosure and controlled from a local spur unit. 9.8 9.8.1 Wiring Accessories Lighting Switches

Lighting switches shall be of the grid switch modular pattern manufactured in accordance with BS 3676. All lighting switches shall be fully rated at 5A or 15A and suitable for fluorescent loads. All lighting switches shall be suitable for conduit installation. Where more than one phase, or dissimilar voltages are present, then these shall be permanently separated by earthed metal barriers within the switch box. The switch plates of phase barrier boxes shall be set square to the vertical and horizontal access. Where wall mounted switches are installed on special wall finishes, for example tiles, marble, timber cladding, fair faced brickwork, then special care must be taken to ensure that the final positions of all switch plates are set symmetrically within the pattern of the wall finish and in the correct position as required by the Project Manager. Switches used in external locations shall be of the weatherproof pattern. Where more than one switch is indicated in a position, then these shall be ganged in the same box and a multi-gang switch plate shall be used. The arrangement of switches in a ganged box shall as far as possible be similar to the plan of lighting points which they control. Switches not so arranged shall have engraved labels to indicate switches controlled.
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Section VII. General Specifications Pull cord ceiling switches shall be mounted in a standard circular conduit box with a matching plaster break ring between. An earth terminal shall be provided at every lighting switch or adjustable grid by means of a Fly Lead of PVC insulated cable of Yellow/Green. 9.8.2 General Socket Outlets and Plug Tops All socket outlets and plugs shall be supplied and installed in accordance with the manufacturer, type, size and finish as specified in these Specifications. Unless otherwise specified, all general socket outlets shall be switched, rated at 13 amperes and be of the three rectangular pin type to BS 1363. The pin apparatus shall have insulated inserts and shall be shuttered on the live and neutral outlets. The shuttering shall be arranged such that the entry of the earth pin of the plug top into the earth outlet shall open the shutter. Plug tops shall be of the finger shield type as BS 1363. They shall be equipped with fuses rated according to the equipment connected. Where no equipment is connected, 3 ampere fuses shall be fitted. Earth leakage circuit protection shall be applied to socket outlet circuits where necessary (i.e. plant-room, external to building). Spur units shall be of 13 A rating complying with BS 5733 and shall be fitted with correctly rated fuses according to the equipment connected. Where the flex outlet type is specified, these shall have a manufactured outlet and be complete with internal grip cord. Where wall socket outlets are installed on special wall finishes, for example tiles, marble, timber cladding, fair faced brick work, then special care must be taken to ensure that the final positions of all plates are set symmetrically within the pattern of the wall finish and in the correct position as required by the Project Manager. All socket outlets and spur units shall be set square to the vertical and horizontal axes. Where metal plates are specified, fixing screws shall be of the identical finish. Boxes shall be fixed by means of 2 No. 35 mm No. 8 cadmium plated steel screws and plastic expansion plugs as a minimum requirement. Boxes shall be cleaned out and free from debris prior to wiring. The knockouts shall not be used as a method of grouting boxes into walls, etc. All plate fixing holes in boxes shall be cleaned and tapped prior to the fixing of screws. All accessory boxes shall be fitted with earth terminals and adjustable fixing lugs. 9.8.3 Radio Interference All apparatus supplied which is likely to cause radio interference shall be provided with an effective suppression device so that the apparatus is interference-free with respect to both radio and television. 9.9 Mounting Heights Unless otherwise specified, all units shall be mounted at the following heights from finished floor level taken to the centre of the units: (a) (b) (c) (d) Lighting switches Socket outlets - general areas Above work units etc. Fused spur boxes 1400 mm 300 mm 1200 mm 300 mm (or 1400 mm)
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Section VII. General Requirements (e) (f) (g) (h) (i) (j) (k) (l) Clocks Telephone outlets Wall mounted telephone outlets Fire alarm contacts Fire alarm bells Fire alarm indicators Individual items of switchgear Motor control units 2250 mm 300 mm 1400 mm 400 mm 2250 mm 1800 mm 1400 mm 1400 mm

Generally, switchboards and distribution boards shall be installed so that any item to which easy access is required, such as a fuse, circuit breaker, instrument etc. is not more than 2150 mm above finished floor level. In all cases, care must be taken to ensure that adequate space is left below and above the equipment for manipulating incoming and outgoing cables and conduits. Actual positions shall be determined on site in conjunction with the Project Manager before the work is commenced. The Contractor shall check with the Project Manager to determine door swings before commencing the installation of lighting switch drops. The Project Manager reserves the right to make minor alterations (up to 900 mm in route length) to positions prior to the work being carried out without incurring extra charges. Lighting luminaires and accessories shall, where practicable, be sited such that they and water systems cannot be touched simultaneously. In areas where the walls have glazed wall tiles, the Contactor shall note that where the lighting switches or points are mounted in the tiled areas, the switch or socket outlets must be mounted at the intersection of four wall tiles, a large hole shall be left 350 mm x 350 mm approximately with a length of conduit protruding complete with end and coupling. The final connection shall be made with a short length of conduit when the tile centres are known. 9.10 Cable Routing and Trenching Before any cable trenches are excavated, the Contractor shall mark the route and obtain approval from the Project Manager. Trenching and backfilling shall be carried out by the Contractor. Cables shall be laid on a 100 mm bed of sand, backfilling shall be carried out using sifted soil in layers. The first layer 150 mm deep shall contain no stones, the remainder shall contain no stones over 25 mm. A warning/marker tape shall be laid on top of the first 150 mm layer of backfill. The minimum cover to all cables shall not be less than 1.0 metres. Where cables cross a road, each cable shall be enclosed in a 100 dia. PVC sleeve, and a spare sleeve shall be provided. After laying of the sleeves, the trench shall be backfilled and compacted to the satisfaction of the Project Manager. Cable markers shall be provided in accordance with the requirements of the Project Manager. These shall be made of concrete and shall stand 500 mm above ground level. The cable markers shall have a plate fitted to the top which shall show the route of the cable and the depth it is buried. These markers shall be provided at each change of direction and at 200 metre intervals on straight runs.

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