Federal Electricity & Water Authority Water Directorate ... General Specs for...BS 2853 The design and testing of steel overhead runway beams. BS 5395 Code of Practice for Stairs BS

WAM

Client: FEDERAL ELECTRICITY AND WATER AUTHORITY (FEWA) Project: STANDARD SPECIFICATIONS FOR WATER WORKS

Engineer WATER DIRECTORATE / ASSET MANAGEMENT DEPARTMENT

Title: Technical Terms / Chapter-3 / General Specifications

GS04-GENERAL SPECIFICATIONS FOR CIVIL ENGINEERING WORKS

office: DUBAI order: Document: MWA_PRO_07/WAM-03-GS04 rev:

OCT/ 2014 sheet: 1 of: 42

Federal Electricity & Water Authority

Water Directorate

Asset Management Department

STANDARD SPECIFICATIONS

FOR WATER WORKS

TECHNICAL TERMS

Chapter - 3

General Specifications

GS 04

General Specifications for

Civil Engineering Works

WAM





office: DUBAI order: Document:

MWA_PRO_07/WAM-03-GS04 rev:

OCT/2014 sheet:

2 of: 42


TABLE OF CONTENT

1. GENERAL

2. STANDARDS AND GENERAL REQUIREMENTS

3. CAPACITIES RATINGS, SIZES, QUANTITIES AND MATERIALS

4. TANK, PLANT AND OTHER BUILDINGS/STRUCTURES

5. ENGINEERING DESIGN REQUIREMENTS

5.1 Architectural Design

5.2 Structural Design

5.2.1 Calculation Methods

5.2.2 Standards and Codes

5.2.3 Structural Design Principles

5.2.4 Loadings

5.3 Setting out and Construction Tolerances

6. GENERAL PARTICULARS

6.1 Intent

6.2 Civil Engineering Instruments

6.3 Civil Engineering Standards

6.4 Notice of Operations

6.5 Covering up Work

6.6 Temporary Works

6.7 Inclement Weather

6.8 Inspection & Testing

7. SOIL/SUB-SOIL INVESTIGATION

8. EARTHWORKS

8.1 Excavations Generally

8.2 Excavated Materials

8.3 Bottom Level of Excavation

8.4 Dewatering

8.5 Filling & Reinstatement

8.6 Slips & Settlements

8.7 Compacted Fill Areas

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9. TYPE OF STRUCTURE

10. SITE PREPARATION AND PROJECT LEVELS

11. SITE SURVEY

12. GROUND WATER TABLE

13. ANCILLARY FACILITIES/UTILITIES

14. SCHEDULES

15. FOUNDATIONS AND SUBSTRUCTURE UPTO PLINTH LEVEL

16. SUPER STRUCTURE - WALLS

17. CONCRETE WORKS

17.1 Design, Materials & Workmanship

17.2 Testing

17.3 Cement

17.4 Cement Test Certificates

17.5 Cement Samples

17.6 Cement Storage

17.7 Aggregates

17.8 Aggregate Storage

17.9 Aggregate Sampling

17.10 Approval of Materials

17.11 Water

17.12 Admixtures

17.13 Supervision

17.14 Plant

17.15 Concrete Strength Requirements

17.16 Concrete Mixing

17.17 Workability

17.18 Transportation

17.19 Placing

17.20 Compaction of Concrete

17.21 Vibrations

17.22 Construction Joints

17.23 Construction Bays

17.24 Expansion Joints

17.25 Curing

17.26 Trial Mixes

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17.27 Work Test Cube Procedures

17.28 Records of Test Cubes

17.29 Changes in Materials or Mix Proportions

17.30 Failure of Concrete to Meet Test Requirements

17.31 Concrete Cores

17.32 Ready Mixed Concrete

17.33 Form Work

17.34 Cleaning & Treatment of Forms

14.35 Removal of Formwork

17.36 Finishes for Concrete

17.37 Grouting of Bolts & Plant

17.38 Reinforcing Steel

17.39 Type & Quality of Steel Reinforcement

17.40 Reinforcing Fabric

17.41 Wire

17.42 Protection of Material

17.43 Fabrication

17.44 Placing & Fastening

17.45 Splicing

17.46 Testing of Reinforcement

17.47 Information on Drawings

18. ROOFING

19. FLOORING

20. PAINTING, TILING

21. CONCRETE BLOCKS

21.1 Mortar for Block Work

21.2 Jointing

21.3 Block Laying

21.4 Protection Against Damage

22. PLASTER WORK

22.1 Materials

22.2 Mixing of Mortar Ingredients

22.3 Preparation of Surfaces

23. DOORS / WINDOWS / VENTILATOR

23.1 Steel Doors

23.2 Aluminium Doors, Windows, Frames, Ventilator

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23.3 Roller Shutter Doors/Over head doors

23.4 Timber Doors and Frames

23.5 Ironmongery

24. CHEQUERED PLATES FOR TRENCHES & PITS

25. PLUMBING, DRAINAGE AND RAIN WATER SERVICES

26. ROAD WORKS AND PAVEMENTS

26.1 Kerbs

26.2 Materials

26.3 Drains, Sewers & Cable Ducts

26.4 Preparation for Formation

26.5 Granular Base for Pavement, Hard Core & Gravel Spreaded Areas

26.6 Wet-Mix Macadam for Road Bases

26.7 Dry Bound Macadam for Road Bases

26.8 Prime Coat

26.9 Bituminous Surface

26.10 Interlocking Blocks for Road & Pavement

26.11 Concrete Beds & Casings

26.12 Protection & Dust Control

26.13 Stabilization of Sides

26.14 Tests

27. CABLE AND PIPE TRENCHES

28. CABLE DUCTS

29. VALVE AND OTHER PITS AND CHAMBERS

30. STRUCTURAL STEEL WORK

31. ROOFING & CLADDING

31.1 Vertical Cladding

31.2 Composite Roof & Wall Cladding

31.3 Metal Deck Roofs

31.4 Workmanship

31.5 Holes Through Cladding

31.6 Fasteners, Flute, Closers & Flashings

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1. GENERAL

The following are the general specifications of the Civil Engineering works. The design, fabrication, construction, workmanship, etc. shall conform to the relevant British Standards and Code of Practices. All materials, fabrication, workmanship, etc. for the items described in particular application shall conform to the applicable requirement of the particular specifications or approved international codes unless otherwise approved.

The specifications are the engineering requirements which are complimentary to the other specifications for design, investigations, engineering, material procurement, construction and warranty confirmation of the complete civil works which are required for the stuctures, roads and services being provided under the scope of this tender contract.

It is not intended here to describe the design, arrangement or installation, or to specify or to select each and every material required for the completeness of the works. In general all the relevant works in performance of the entire project shall be provided.

2. STANDARDS AND GENERAL REQUIREMENTS

Unless otherwise stated in these specifications, the standards and the general requirements shall be in accordance with the Engineering Specifications for Civil Works as given in of this Volume-2 and shall be applicable to all the structures of the similar type and size. Also, all workmanship and materials shall comply with the relevant British Standards or equivalent.

3. CAPACITIES RATINGS, SIZES, QUANTITIES AND MATERIALS

The capacities, ratings, sizes, quantities and materials of the project are to be considered as the minimum requirements to be provided. It is the responsibility of the contractor/manufacturer to determine the required capacities, rating, sizes and quantities and select the appropriate material based on the guidelines given in the following specifications.

If the evaluated requirements are higher than the minimum requirements specified in Specific requirements of the project, then the required design capacity/rating/size/quantities shall be provided. If the evaluated requirements are less than the minimum requirements then the minimum requirements shall be complied.

In case of discrepancy in capacities, rating, sizes, quantities, and materials, then the

requirements given at the specific Requirements of projects shall prevail.

4. TANK, PLANT AND OTHER BUILDINGS/STRUCTURES

The sizes given for various rooms/areas are to be considered as absolute minimum. The tenderer shall prepare a general layout plan with pipe/cable trenches, cable trays, equipments, etc to justify the sizes proposed by him. While sizing various rooms/areas, care shall be taken so that the building and the system do not become congested. Enough circulation space, access for regular operation/maintenance and space for breakdown repairs shall be provided.

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5. ENGINEERING DESIGN REQUIREMENTS

The Contractor shall be responsible for the design, construction and maintenance for the whole of the civil building works, associated stuctures, roads and services. Designs and details shall fully meet the technical and operational requirements of the mechanical and electrical installations. All designs and details must be prepared to comply with the best engineering practice, the appropriate standards and codes of practice and the requirements of this specification. No departures from the approved standards and specification will be allowed without the approval of the Engineer.

The specification gives the minimum acceptable standards for the design, workmanship and materials with which the Contractor shall comply.

The information provided in the tender indicate the minimum requirements to be provided by the Contractor. Buildings and room sizes shall not be smaller than shown but will be larger if required for plant installations and operations identified in the technical schedules. Dimensions shall be based on the actual requirements necessary for the safe, reliable, continuous and economic operation of the plant. The cost of any enlarged buildings or modified layout required to meet the design parameters and manufacturer’s requirements are deemed to be included in the contract price. Failure of the Engineer to comment on the drawings submitted by the tenderer during the tender stage, which show modified arrangements not complying with the specification, drawings or the design parameters, shall not be accepted as approving such arrangements.

5.1 Architectural Design

The design of the whole work shall be in accordance with the best standards of modern industrial practice. Finishing materials shall be selected so as to match each other and to present ample guarantees of durability. Samples shall be submitted for the Engineer’s approval, as well as selection of colours and textures.

5.2 Structural Design

5.2.1 Calculation Methods Designs shall be carried out in accordance with accepted engineering principles and shall meet the requirements of the applicable Standards and Codes of Practice. Any static and dynamic calculation is to be submitted for the Engineer’s approval. When the Contractor uses computerised calculation methods for special kinds of structure, he shall provide a full explanation of such method, should the Engineer require it, together with adequate documentation and reference.

5.2.2 Standards and Codes Standards and Codes of Practice employed by the Contractor shall satisfy in all respects the provisions of any National or State Statute, Ordinance or other Law or any Regulation or By-law of any local or other duly constituted authority appropriate to the location in which the construction will be undertaken.

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The works shall be designed and the materials, workmanship and tests conform to the following standards and codes of practice that are referred to within those standards.

Title Subject BS 308 Engineering Drawing Practice. BS 5950 The use of structural steel in building BS 1192 Building drawing practice BS 2750 Method of measurement of sound insulation in buildings and of building elements. BS 2853 The design and testing of steel overhead runway beams. BS 5395 Code of Practice for Stairs BS EN 12056-2 Gravity drainage systems inside buildings. Sanitary pipework BS 9999 Code of practice for fire safety in the design, management of buildings BS EN 1996 Design of masonry structures. BS 5720 Code of Practice for mechanical ventilation & air conditioning in buildings

BS 5821 Method for rating sound insulation in buildings and of building elements. BS 5930 Site investigation BS 5964 Methods for setting out and measurement of buildings-permissible measuring deviations BS 6031 Code of Practice for Earthworks. BS 6177 Guide to selection and use of elastomeric bearings for vibration isolation of buildings.

BS 6180 Code of Practice for protective barriers in and about buildings. BS 6262 Code of Practice for glazing of buildings. BS 6297 Code of Practice for the design and installation of small sewage

treatment works and accessories. BS EN 12056-3 Gravity drainage systems inside buildings. Roof drainage, layout and

calculation BS EN 1991-1-4 Eurocode 1. Actions on structures. General actions. Wind actions BS 6465 Sanitary installations.

BS 6700 Design of services supplying water BS EN 1997- Geotechnical design. General rules BS 8301 Code of Practice on building drainage. BS EN 1991-1-1 Eurocode 1. Actions on structures. General actions. Densities, self-weight,

imposed loads for buildings CP 102 Water proofing of buildings. BS 8110 The structural use of concrete. BS EN 1994-1-1 Design of composite steel and concrete structures. CP 118 The structural use of Aluminium CP 143 Sheet roof and wall coverings. BS EN 1992-3 Design of concrete structures. Liquid retaining and containing structures.

The standards shall include all latest revisions and amendments.

5.2.3 Structural Design Principles a) Foundations shall be so designed to minimize settlements, especially differential settlements,

which shall be kept within limits preventing any danger to the construction and the equipment. When necessary, piles of suitable type shall be provided.

b) The requirements related to fire protections shall be taken into consideration.

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5.2.4 Loadings The design loadings shall conform to the requirements of adopted standards and codes of practice, as well as special Site Conditions and Technical Specifications. The minimum design loading shall comply with the requirements of B.S. 6399. Where known loads exceed those of BS 6399 the higher loading shall be adopted. All loads arising from wind having maximum speed of 160 Km/Hour shall be adopted The minimum earthquake factor shall be taken as 0.15g. In the absence of information covering any special case, the design shall be based on loadings indicated by previous experience or by the results of special tests.

5.3 Setting out and Construction Tolerances

The contractor is responsible for the accuracy of all setting out and construction tolerances. These shall not be greater than the following :

a) Setting out 1 in 3000 b) Structural steel work : 1. Position of first erected column + 10mm 2. Linear Dimensions upto 8m + 10mm From 8 to 15 m + 15mm

From 15 to 25 m + 20mm Over 25 m + 25mm 3. Plumb of columns in 30 m height + 15mm 4. Level of base of first erected columns + 5mm 5. Level of beam at junction with column measured from transferred bench mark. + 15mm

6. Level of beam at junction with column measured from transferred bench mark of storey in which beam is located + 10mm 7. Levels of upper or lower surfaces of two or more beams meeting at a column + 6mm 8. Difference in level of ends of a beam : Up to 8 m long + 5mm From 8 to 15 m + 10mm

c) In-situ Concrete :

Mass Concrete Foundations Dimensions on plan + 50mm

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Formation level + 50mm Level of upper surface + 25mm

Reinforced concrete foundations excepting Plant Foundations :

Dimensions in plan 1 in 30 but not exceeding 35mm Formation level + 25mm Level of upper surface + 20mm

Elements and components above Foundations including Plant Foundations : Position on plan measured from nearest

building grid line + 10mm Vertically - Plumb in height of : Upto 0.5 m + 5mm Over 0.5 m and upto 1.5 m + 10mm Over 1.5 m and upto 3.0 m + 15mm Over 3.0 m and upto 30 m + 20mm Cross Section and linear dimensions: Dimensions of beams, slabs, columns & walls. Upto 300 mm + 5mm Over 300 mm and upto 600mm + 10mm Over 600 mm and upto 1.5 m + 15mm Over 1.5 m and upto 3.0 m + 20mm Over 3.0 m and upto 15 m + 30mm Over 15 m and upto 30 m + 40mm d) Level (permissible deviation from designed level with reference to nearest temporary bench mark) : Extensions above Plant Foundations Foundations

Length of Elements: Upto 8 m + 10mm + 5mm Over 8m and upto 15m + 15mm + 10mm Over 15m + 20mm + 15mm Overall dimensions of a concrete Framed building - length and width for Dimensions: Upto 15 m + 15mm Over 15 m and upto 30 m + 25mm For each subsequent 30 m + 15mm Height upto 30 m + 20mm e) Items Cast in Position :

The permissible deviation of the position of a component fixing or hole cast in shall not exceed + 10mm from its design position.

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6. GENERAL PARTICULARS

6.1 Intent The Contractor shall design, construct and maintain all the works covered unless otherwise specified. All the civil works including ancillary facilities shall be designed and constructed. The specification given under this section set minimum standards to which the design and construction/erection proposed by the Contractor shall comply. Based on these specifications the Contractor shall produce detailed design, drawings and specifications. These drawings and specifications shall be submitted with the tender documents. Authority may give comments prior to signing of the Agreement. However this in no way be construed as the approval. After the signing of the Agreement the Contractor shall produce detailed design calculations, drawings and specifications which shall be submitted to the Authority for approval. After this approval only the contractor shall place the order for material and start construction/erection. The approval by the Authority shall in no way release the contractor from responsibility for safety of his design and structure.

The information given in the tender specification and drawings is not intended to be complete and detailed description of works to be done. The information given is guideline for design and execution of the works. For design, construction and materials, reference shall be made to the relevant British Standards and codes of practice.

As a general rule requirements of the national and/or local regulations shall be adhered to but if these are less stringent than the requirements of the codes or this specifications the latter shall prevail. Design, transport, storage, execution and working up of materials shall be done in accordance with the requirements of the supplier/manufacturer. If there are no codes or supplier's or manufacturer's requirements then the design, transport, storage, execution and working up of material shall be done in a good workmanlike manner and to the satisfaction of the Authority.

A drawing of general layout of the site, supporting facilities, roads, pavement, etc. is included in the tender documents. This drawing is for guidance only and is not to be considered as the limiting. However the requirements shown on this drawing are to be considered as minimum. The contractor should ascertain for himself during the tender stage that the plant he proposal will be suitable for the arrangement shown on the drawings.

Cladding, flashing and the like shall be as tightly fitting as practicable so as to exclude sand and pollution under all likely weather conditions. External doors shall be sealed to prevent ingress of dust, using heavy duty seals/thresholds which should be easily replaceable. Due attention shall be paid in the design to all aspects including internal and external appearance, thermal and acoustic insulation, durability of materials, resistance to moisture, structural stability, fire resistance and means of escape, ventilation and public health requirements.

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6.2 Civil Engineering Instruments The Contractor shall provide and maintain at the site all surveying instruments and testing equipment required for setting out and checking the works and for controlling and testing the quality of materials and workmanship.

6.3 Civil Engineering Standards All workmanship and materials shall comply with the relevant British Standard, or equivalent.

6.4 Notice of Operations The Contractor shall give to the Engineer not less than 24 hours notice of his intention to set out lines or levels for any important parts of the work, or to place concrete, in order that arrangements may be made for checking, if considered necessary. The Contractor shall obtain written permission from the Engineer before any concrete is poured or before bolts are grouted.

6.5 Covering up Work Before backfilling concrete work, drainage etc. the contractor shall give the Engineer 24 hours notice in which to arrange inspection and measurement of the buried work. No work may be backfilled without a written permit from the Engineer.

6.6 Temporary Works The Contractor shall submit for approval by the Engineer drawing detailing all proposed temporary roads, access roads, false works etc. No such work shall be commenced until approval is obtained. Notwithstanding the Engineers approval of any submitted design the Contractor shall remain wholly responsible for the security of temporary work and maintenance thereof until removed, and he shall reinstate the same at his own cost.

6.7 Inclement Weather The Contractor shall be responsible for the adequate protection of the works from injury or damage. The Contractor shall be responsible for taking such measures as may be necessary to ensure the uninterrupted progress of the work, but such measures shall be with due approval of the Engineer.

6.8 Inspection & Testing The cost of all routine samples and tests required by a British Standard or similar approved, or elsewhere called for this Specification, shall be borne by the Contractor.

7. SOIL/SUB-SOIL INVESTIGATION

The contractor shall carry out full soil/sub-soil investigation of the project site immediately after signing of the agreement or as agreed if earthworks are involved. The result of this investigation shall form the basis of design as regarding bearing capacity of soil, ground water table, type of foundations, special protective measures if needed etc. The Contractor shall not proceed with the execution of project works without first ascertaining these data and reaching a joint agreement with the Authority on the applicability of said data.

The Contractor is to ascertain for himself the nature of the soil conditions over the site of the works by means of boreholes, trial excavations, etc. Samples shall be taken as necessary and tested to determine the Physical and Chemical characteristics of the various strata and of the ground water, if encountered. Records of boring and trial excavations and results of tests on samples shall be incorporated into a soil investigation report.

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This should include a technical description of the site investigation; strata description and identification sketch plans show borehole locations and levels (relative to established site datum) comments on results of field and laboratory tests and recommendations for design bearing capacity of the soil, foundation type and precautions. The survey plan shall be prepared showing the survey results and the proposed layout of works and submitted for approval.

8. EARTHWORKS 8.1 Excavations Generally Excavations shall be carried out to the widths, lengths and depths described or directed and no unlicensed or indiscriminate digging is permitted. Contractor shall be responsible to excavate the areas near the existing plants by hand shovel without causing any dust pollution.

The Contractor shall allow for risk of meeting and having excavating through any sort of material including rock and buried concrete foundations, if any.

The Contractor may excavate by any method he considers suitable, subject to the approval and shall allow for the use of types of plant most suited for excavations in any location and at any time. The Contractor is to include for all strutting and shoring necessary for the safe execution of the works. Due care should be taken to protect existing under ground services such as cables or pipes and where required shall be diverted.

8.2 Excavated Materials During the construction of the works, the Contractor may use materials from the excavation if approved by the Engineer. Other excavated material shall be backfilled where required or deposited where directed anywhere on site. The Contractor shall remove the surplus materials from the site. The Contractor shall at all times keep the site free from all surplus materials, rubbish and offensive matter.

8.3 Bottom Level of Excavation The bottom of all excavated areas shall be trimmed, leveled and well rammed. The bottom level of excavations or foundations shall be inspected and approved before foundations are constructed.

8.4 Dewatering The excavated surfaces shall be kept dry and clean by pumping or any other method deemed necessary and approved by the Engineer. Water from such dewatering shall be properly drained away from the site or disposed of by tankers. The Contractor in his tender shall cover the cost of pumping or dewatering. No concrete, masonry brickwork or other materials shall be placed or built until the surface is properly drained.

8.5 Filling & Reinstatement Filling for trenches, excavations and leveling of the site shall be deposited in layers not exceeding 225mm in thickness each layer watered well and rammed by mechanical rammers, to consolidate in 95 % of the maximum dry density. Where excavations, whether in rock or other material, are made to a greater depth than required or as instructed by the Engineer, the intervening space shall be brought up to the proper level in plain concrete of Grade M-20

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Any ground encountered during the excavations which is observed not suitable to bear the expected loads which will be imposed on it, shall be excavated and replaced with concrete of Grade M-20. 8.6 Slips & Settlements Should any slips occur in the excavations, banks or filling during the execution of the works or during the period of maintenance from any cause whatsoever, the contractor shall execute the necessary remedial work in such manner and form and with such materials and/or as approved by the Engineer. The Contractor shall make good all settlement of filling that may occur up to the end of the period of maintenance.

8.7 Compacted Fill Areas In areas where excavated or imported material is to be used as compacted fill, the contractor will be required to achieve a density of not less than 95% of the dry density for the excavated or imported material. The Contractor shall maintain all equipment, for determination and checking of the compact density at the site and the tests shall be carried out in the presence of the Engineer.

9. TYPE OF STRUCTURE

Large plant hall shall be steel structure with insulated hollow block in fill walls. The block wall could either be up to full height or upto about 4.0 m height with remaining wall in insulated double skinned profiled coated metal wall panels. Roofing shall be with insulated double skinned profiled powder coated Aluminium roof sheet. Clear height of this hall shall be governed by maximum height of equipments and lifting crane. However minimum clear eaves height shall be 6.00 m.

Pumping structure, office, control buildings, service buildings, etc. shall be of reinforced concrete frame structure and R.C.C. roof slab .The RCC roof slab shall be insulated and water proofed. The clear height shall be not less than 4.0M.

The plant hall and office/service block shall be designed to have pleasing look. Architectural details and colour scheme shall be finalized in consultation with the Authority.

Ancillary works like plinth protection all around building, parking apron, pavements, roads, sanitary and storm/surface water drainage etc. shall also be integral part of the works. The sheds shall be steel structure with insulated profiled roofing sheets and vertical cladding. The buildings shall be weatherproof and rainwater shall be discharged by gutter and down pipes directly to surface water drainage system. Special drip flashing is to be provided at the junction of vertical cladding and dado wall. All buildings shall have reinforced concrete foundations and ground slabs. The design shall allow for thermal and other movements, expansion and movement joints being provided where necessary.

10. SITE PREPARATION AND PROJECT LEVELS

As per topographical data, low areas shall be raised with an engineering fill and high areas shall be excavated, such that the existing natural gradient is reestablished and water drains off the project area. Paving/aprons, external concrete ground slabs etc. shall be raised by about 150mm. from surrounding ground levels. Minimum plinth level for any building/structures shall not be less than 300 mm from surrounding ground level. Plinth level shall be agreed with reference to the plant road levels with FEWA.

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The contractor will be responsible for all necessary earthworks and clearance of site required for the development of the project. The contractor shall submit for Authority's approval his proposed finished site levels, plinth levels, apron/paving/external concrete ground slab levels showing gradient, fall, surface drains/ditches etc. Only after establishing these levels in consultation with the Authority, the construction works shall start.

11. SITE SURVEY

A 1:100 topographical plan showing all salient features with a contoured 5 m grid of levels shall be submitted to the Authority prior to the beginning of works or as agreed as per the specific requirements of each site.

12. GROUND WATER TABLE

The contractor shall, prior to commencing the foundation design/works have established for himself an accurate ground water level. The contractor shall check the buoyancy effect on the structure during and after construction. He shall not commence foundation works prior to final joint agreement with the Authority on the buoyancy effect on the structures.

13. ANCILLARY FACILITIES/UTILITIES

The requirements shall be carefully assessed by the contractor to suit the type and size of buildings and process selected. It is the contractor's responsibility to assess and include all the ancillary facility/utilities to make the buildings and plant functional, safe and sound. If any particular facility/ utility or safety measure is not mentioned, but is considered essential, the contractor shall be obliged to provide it. Few of the facilities/utilities and protection systems are listed below:

a) Complete plumbing system for the plant/buildings including water storage

tanks, hot & cold water supply system. b) Sanitary sewerage and drainage system including septic tank, soak pit etc. c) Rain water/surface/storm water drainage & disposal. d) Roads and pavements. e) Cable and pipe trenches, cable ducts, cable trays. f) Valve and other pits and chambers. g) Transformers / H.V./ L.V. switchgear rooms

14. SCHEDULES

A room finishing schedule, door/window schedule and furniture list for the rooms shall be incorporated while detailed designing is carried out.

15. FOUNDATIONS AND SUBSTRUCTURE UPTO PLINTH LEVEL

The Contractor shall design and execute the complete foundation works on the basis of results of soil/sub-soil investigation report and it's recommendations. The type and size of foundation structures shall be decided by the contractor in consultation with the Authority. The effect of

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buoyancy in case of high ground water level shall be properly taken care of. Protective coating/system shall depend on aggressiveness of the soil. The type of foundation could be isolated footings, combined footings, piled or raft depending on load coming on the structure and soil bearing capacity.

All equipments shall be provided with the suitable foundation depending on the weight of the equipment, vibrations, lateral thrusts transferred etc. Heavy equipments shall have raft foundations. All rooms shall have reinforced concrete ground slabs. The foundation shall not be laid at less than 1.20 M below the general ground level.

After excavation the surface shall be leveled and compacted. A layer of PCC, mix grade 20, minimum thickness 150 mm shall be laid below all footings, raft, foundations etc. above a layer of polythene sheet and thickness 100mm for trenches, chambers etc. All foundation works like footings, columns/ pedestals, ground slab, tie beams at plinth levels shall be done in reinforced cement concrete, mix not leaner than grade 35. Block work up to plinth levels shall be not less than 200mm thick and will be solid concrete block masonry. Tie beams shall be provided at plinth level. Water proofing membrane shall be laid under all foundations.

Only sulphate resistant cement shall be used for all the works upto plinth level and all the works shall be protected by the application of a waterproofing membrane. An additive such as Calcium Nitrite shall be added to the concrete in order to provide resistance to chloride attack and additional protection to the reinforcement. If the soil is found to be aggressive than other protective measures may become necessary and the contractor will provide the same at no extra cost. This may be required specially for foundation, underground sump etc. Filling shall be done with selected soil and it shall be well compacted. A waterproof membrane of suitable type shall be provided in whole area of the building, Damp proof course shall be provided in walls. The waterproof membrane shall be properly tucked in at the walls, beams, footings etc. Joints filled with compressible filler shall be provided all around the walls, around any projecting foundations for equipments and in large bays. The slab in plant hall area, and other such areas (having vehicular access) shall be minimum 200 mm thick heavy duty industrial flooring type. The room finishing schedule for final floor finish type shall be prepared. The filling and the level of slab shall be adjusted to take care of difference in level of plant and other areas and different type of floor finishes. Matching skirting shall be provided in all rooms. Suitable slope shall be provided in floors for areas where water/chemical spillage or leakage is probable. The layout for pipeline and cable trenches, equipment foundations, pipelines entry/exit, cable entry/exit, drain pipes exit, trenches, ducts etc. shall be carefully prepared before slab laying to avoid cuttings at later date. Apron and plinth protection outside buildings shall be of cast in situ reinforced cement concrete, mix not leaner than grade 30. Expansion/construction joints filled with compressible material and properly sealed shall be provided for large areas. Suitable kerb shall be provided around the periphery of aprons. Apron and plinth protection shall be laid on compacted sub- grade.

Vehicular areas shall also have heavy duty ground reinforced concrete slab. The areas marked to have interlock tiles/block pavement, shall be laid on gravels on compacted sand and shall have retaining curb all around. The whole of the external area including roads, pavings, gravel beds etc. shall be designed such as to drain storm water off project area and existing natural gradient shall be maintained.

The transformer room shall have heavy duty ground reinforced concrete slab pedestal to house transformer and large trenches to suit the proposed transformers. The rails shall be provided in

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reinforced concrete slab for easy removal of transformers. The concrete slab and rails shall be extended outside the transformer room. Gravels beds and oil containments sump shall also be provided in transformer room.

16. SUPER STRUCTURE – WALLS

The super structure shall be with insulated hollow concrete block infill. The walls shall be 200 or 250 mm thick (thermally insulated sandwich block work with built in insulation for all external walls) and shall be plastered with cement mortar, 1:4 inside 15 mm thick and outside 20 mm thick.

The walls shall be plastered with cement mortar on both sides. The finishing materials shall be either paint or tiles as per room finishes schedule. Matching skirting shall be provided in all rooms. The details of joint between steel structure and block walls shall be got approved by the Authority prior to start of construction.

The super structure specially of large industrial plant shall be provided with necessary bracings, gantry girders, brackets/trays for pipes, cables etc. Lighting/power outlets and plumbing, pipes, entry/exits etc. shall be finalised prior to start of the work. Door window, air conditioners, extract fans and ventilators openings shall be neatly finished.

In plastering, wire mesh, corner protection Laths etc. shall be provided to avoid cracking and corner/edge chipping. Where tiles are the final finish, the plaster shall be scratched to make good bond for tiles. The structure shall be designed considering all the loads/stresses and suitable safety margin shall be added.

All the external entrances to the buildings and windows of the building shall be provided with cantilever shades canopy.

17. CONCRETE WORKS

17.1 Design, Materials & Workmanship Standards of design, materials and workmanship shall be as per BS EN 1992-1-1 code of practice or the International Recommendations of CEB-FIP.

17.2 Testing All required tests should be carried out at an approved independent testing laboratory. The contractor shall prepare, store and transport the test specimen to the place of testing.

17.3 Cement Sulphate resisting cement shall be used wherever required as per soil test report and particularly in all RCC foundations. The ordinary Portland and sulphate resisting cement shall comply with all the requirements of BS 4027 and BS EN 197-1 for Cement composition, specifications and conformity criteria for common cements.

17.4 Cement Test Certificates All cement shall be certified by the manufacturer as complying with the requirements of the appropriate specification. The Contractor shall, obtain the manufacturer's certificate for any consignment as soon as possible after delivery.

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17.5 Cement Samples Where required the Contractor shall draw samples of cement from locations as specified by the Engineer and submit the same for inspection and testing. 17.6 Cement Storage Cement shall be kept dry and used in rotation of deliveries. If delivered in bags, these shall be stored in a ventilated and waterproof building used exclusively for this purpose. If delivered in bulk, an approved type of cement silo shall be used. Cements of different types shall be kept separately. 17.7 Aggregates The fine and coarse aggregate shall be durable hard material, free from excessive chlorides and sulphates. The coarse aggregate shall be of crushed stone or Natural River aggregate and shall be graded to fulfil the conditions of standard table of percentage by weight passing through B.S. sizes. The sand shall contain no salts. It deemed necessary by the Engineer, it shall be washed before use. The sand shall be graded to confirm with the Fuller curve or any other internationally recognized standard curve guaranteeing optimum concrete quality. The aggregates shall be brought from approved sources.

17.8 Aggregate Storage The aggregates shall be stored at mixer positions on drained concrete paved areas in such manner that intermingling of different sizes and types of aggregates is prevented. The stockpiles are to be protected from rubbish or wind blown dust.

17.9 Aggregate Sampling Where required the Contractor shall draw samples of cement from locations as specified by the Engineer and submit the same for inspection and testing. Testing shall be carried out at an independent approved laboratory.

17.10 Approval of Materials The Contractor shall obtain the Engineers’ approval for all the materials to be used in the construction. If requested by the Engineer the samples such materials shall be tested. If materials are observed to be not suitable and rejected by the Engineer, the Contractor shall remove them from the site.

17.11 Water The water used for making concrete, curing of concrete mortar, grout, or similar purposes shall be clean, fresh and free from injurious amounts of oil, acid vegetable or organic matter or any other deleterious substances in suspension or solution.

17.12 Admixtures Admixtures shall not be used without the approval of the Engineer.

17.13 Supervision The Contractor shall employ a competent supervisor at the works. The primary duty of such supervisor will be to supervise all stages in the preparation, placing and curing of concrete. All test cubes shall be made and site tests carried out under his direct supervision.

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17.14 Plant The concreting plant shall be suitable in type, capacity and design for its purpose. The performance of the plant and its disposition shall be as approved. 17.15 Concrete Strength Requirements The strength requirements for each grade of concrete proposed in the design shall be proven by means of preliminary trial tests as specified. The minimum cement content shall be 380kg/cu.m (C-35Grade, 30N/mm.sq. compressive strength at 28 days). The maximum free water cement ratio shall be 0.45. These figures shall be revised if the sulphate content of the soil is greater than 0.5% (test SO3).

17.16 Concrete Mixing All concrete except where specifically permitted by the Engineer in writing shall be mixed in weigh batch mixing machines. The machines shall have a large water storage tank with a gauge so that predetermined quantity of water can be injected direct into the mixer drum. The dry concrete ingredients shall be mixed until a uniform colour is obtained. After the addition of the water the concrete shall be mixed for a further two minutes or until a uniform colour is achieved. In computing the quantity of water to be added, due account must be taken of the water contained in the aggregates. The amount of water shall be sufficient to ensure through hydration, good workability and high strength.

The contractor shall take all precautions to protect the concrete from the injurious effects of the elements. A cover or other suitable means shall be provided to shield the aggregates stockpiles from the direct rays of the sun or suitable means provided to cool the aggregates by spraying with water and to insulate the mixing water tank and pipe lines to ensure that the temperature of concrete, when deposited shall not exceed 32º C.

17.17 Workability The concrete shall be of such consistency that it can be readily worked into the corners and angles of the formwork and around reinforcement without segregation of the materials or bleeding of free water at the surface by adding super plastisizer. On striking the formwork it shall present a face, which shall be superior to the standards laid down in later clauses of this section.

17.18 Transportation The concrete shall be discharged from the mixer and transported to the works site. The Contactor shall place suitable measures to prevent adulteration, segregation or loss of ingredients and ensure that the concrete is of the required workability at the point and time of placing.

17.19 Placing The concrete shall be placed in the positions and sequence indicated on the drawings, in the specification or as directed by the Engineer within two minutes of mixing. Except where otherwise directed, concrete shall not be placed unless the Engineer or his representative is present and has previously examined and approved the positioning, fixing and condition of the reinforcement and of any other items to be embedded, the cleanliness, alignment and suitability of the containing surfaces, and the adequacy and position of plant. The concrete shall be deposited as nearly as possible in its final position and in such a manner as to avoid segregation, displacement of the reinforcement, formwork or other embedded items.

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Placing shall be continuous between specified or approved construction joints. Works shall be brought up to full thickness in 500mm maximum compacted layers as the work proceeds.

Where chutes are used to convey the concrete, their slopes shall not be such as to cause segregation and suitable spouts or baffles shall be provided to avoid segregation during discharge. Concrete shall not be allowed to fall freely from more than 1.5 meters except with the approval of the Engineer. Where pneumatic placers are used suitable baffles or hoppers shall regulate the velocity of discharge where necessary to prevent segregation or damage and distortion of the reinforcement, other embedded items and formwork caused by impact. Concrete shall not be placed in standing or running water unless so specified or approved.

17.20 Compaction of Concrete The concrete shall be fully compacted throughout the full extent of the layer. It shall be thoroughly worked against the formwork and around reinforcement and other embedded items, without displacing them. Successive layers of the same lift shall be thoroughly worked together.

17.21 Vibrations Unless otherwise directed by the Engineer, approved power driven vibrators of the immersion type shall be used. They shall be inserted at such distances apart or applied in such a manner as will ensure that the concrete is satisfactorily and uniformly compacted. The Contractor shall ensure that a sufficient number of vibrators are on hand at all times including allowance for breakdown of vibrators. Vibrators shall penetrate the full depth of the layer and where the underlying layer is of fresh concrete, shall enter and re-vibrate that layer to ensure that successive layers are well knitted together. Over-vibration, causing segregation, surface laitance or leakage through formwork, shall be avoided; immersion vibrators shall be withdrawn slowly to prevent the formation of voids. Vibrators shall not be used to work the concrete along the forms, or in such a way as to damage formwork or other parts of the structure, or displace the reinforcement or other embedded items.

17.22 Construction Joints Concreting shall be carried out continuously up to construction joints, the position and arrangement of which shall be indicated on the drawings and approved by the Engineer.

When the work is resumed adjacent to a surface, which has set the whole surface, shall be thoroughly roughened. It shall be cleaned of all loose and foreign matter and laitance and washed with water immediately before placing the fresh concrete, which shall be well compacted against the joint.

17.23 Construction Bays The contractor shall obtain approval of Engineer, prior to the commencement of concreting, upon the sequence of placing concrete and the positions of vertical and horizontal joints whether shown or not in the drawings. In general, slabs in excess of 6 meters in length or width and walls exceeding 6 meters in length shall not be poured in one operation and subsequent adjacent bays shall not be concreted within 7 days.

As an alternative to alternate bay construction, shrinkage gaps of up to 1 meter in width may be left at 6 meters intervals; the shrinkage gaps shall not be concreted until concrete on all sides is at least seven days only.

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17.24 Expansion Joints The Contractor shall provide expansion joints as and allowance for the elastic behaviour of the concrete. The Contractor shall submit for approval his proposals for expansion joints & filling materials. All expansion joints shall be sealed against the ingress of water as approved. 17.25 Curing Concrete shall be protected during the first stage of hardening from the harmful effects of sunshine drying winds, cold, rain or running water. The protection shall be applied as soon as practicable after completion of placing by one or more of the following methods, as approved. The concrete shall be covered by a layer of sacks or canvas or Hessian or straw mats, or similar absorbent material, or a layer of sand and are constantly kept wet.

Alternatively after thoroughly wetting, the concrete shall be covered with a layer of approved waterproof paper of plastic membrane kept in contact with the concrete.

Except in case of surface to which concrete has subsequently to be bonded, the concrete may be the application of an approved liquid curing membrane. Application shall be made by low-pressure spray in accordance with the manufacturer's instructions. On vertical surfaces, the curing membrane shall be applied immediately after removing the formwork. The curing of the concrete shall be maintained for at least one week.

17.26 Trial Mixes At least four weeks before commencing any concreting in the works, the contractor shall make trial mixes using samples of aggregates and cements typical of those to be used. If possible, the concreting plant and the means of transport to be employed in the works shall be used to make the trial mixes and the first batch shall be discarded.

Preliminary test cubes shall be taken from the proposed mixes as follows:

For each grade a set of 6 cubes shall be made from each of 3 consecutive batches.

Three from each set of 6 shall be tested at an age of 7 days and

Three at an age of 28 days.

The cubes shall be made, cured, stored, transported and tested in compression in accordance with approved standards and tested in an approved independent laboratory. At each age of test no cube strength shall fall below the appropriate minimum specified in the Contractor's designs. Before commencing the works the Contractor shall submit full details of the mixes he proposes to use, with their anticipated average strength, which must be based on the satisfactory results of these preliminary tests. The Engineer shall, if required, be present at all preliminary tests.

17.27 Work Test Cube Procedures Samples of concrete for tests shall be taken and cubes made to the agreed frequency. Normally for each grade of concrete, 6 cubes shall be made for each 20 cubic meters of concrete or part thereof, in each day's work. The Engineer may reduce this number of cubes to be tested, if consistently satisfactory results are obtained, or increased up to a maximum of 12 when consistency is not satisfactory and additional tests are required. The procedure for making and testing the cubes shall be the same as that approved for the preliminary test cubes. The laboratory shall submit the reports of all tests made to the Engineer directly within 24 hours of the cubes being tested.

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17.28 Records of Test Cubes Up to date records shall be kept by the Contractor at the works of position in the Works of all batches of concrete, of their grade and of all test cubes, cores or other specimens taken from them. Copies of these records shall be supplied to the Engineer. 17.29 Changes in Materials or Mix Proportions Neither the mix proportions nor the source of supply of materials shall be altered without the prior approval of the Engineer, except that the Contractor shall adjust the proportions of the mix as required, to take account of permitted variations in the materials. Such approval shall be subject to the execution of trial mix procedures set out herein.

17.30 Failure of Concrete to Meet Test Requirements If the strength of the specimen is less than the appropriate specified minimum crushing strength or if the concrete fails to meet the specified requirements in other respects, the concrete in that part of the works from which it is a sample will be considered not to comply with the specified requirements. If the specified requirements have not been met, the Contractor shall take such remedial action as the Engineer instructions. Before proceeding with concreting the Contractor shall submit for the Engineer's approval details of the action proposed to ensure that the concrete to be placed in the works will comply with the specification.

17.31 Concrete Cores Where requested by the Engineer, cylindrical core specimens shall be cut from the hardened concrete in the works for the purposes of examination and testing. The cutting equipment and the method of doing the work shall be approved. Prior to preparation for testing, the Contractor shall provide specimens for examination by the Engineer.

Testing of the core shall be in accordance with approved standards. The results of such tests shall not nullify the fact of non-compliance with the specification.

17.32 Ready Mixed Concrete Ready-mixed concrete as defined in BS 5328, batched off the Site, may be used only with due written approval of the Engineer and shall comply fully with all requirements of the Contract.

The concrete shall be carried in purpose made agitators, operating continuously or truck mixers. The concrete shall be compacted and in its final position within 2 hours of the introduction of cement to the aggregates, unless otherwise approved by the Engineer. The time of such introduction shall be recorded on the delivery note together with the weight of the constituents of each mix.

When truck-mixed concrete is used, water shall be added under supervision, either at the site or at the central batching plant, with due approval of the Engineer, but in no circumstances shall water be added during the transport.

Unless otherwise approved by the Engineer, truck mixer units and their mixing and discharge performance shall comply with the requirements of BS.4251. Mixing shall continue for the number and rate of revolutions recommended in accordance with item 9 in Appendix B of BS.4251 or, in the absence of the manufacturer's instructions, mixing shall continue for not less than 100 revolutions at a rate of 7 revolutions per minute.

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17.33 Form Work Forms shall be designed and so constructed that the concrete can be properly placed and thoroughly compacted and that the hardened concrete shall conform accurately to the required shape, position and level, subject to the tolerance and to the standards of finish specified.

When concrete is to be vibrated, special care shall be taken to maintain the stability of the formwork and the tightness of the joints during vibrating operations.

The Engineer shall approve the material and position of any ties passing through the concrete. The whole or part of the tie shall be capable of being removed so that no part remaining embedded in the concrete shall be nearer than the surface of the concrete than the specified thickness of cover to reinforcement. Any holes left after the removal of ties shall be filled with concrete or mortar of approved composition.

17.34 Cleaning & Treatment of Forms All rubbish, particularly chippings, shavings and sawdust, shall be removed from the interior of the forms before the concrete is placed and the formwork in contact with the concrete shall be cleaned and thoroughly wetted or treated with an approved composition. Care shall be taken that such approved composition is kept out of contact with reinforcement.

17.35 Removal of Formwork All forms shall be removed without damage to the concrete. The use of mould oil or other material to facilitate this shall be subject to the approval of the Engineer. All formwork for pits, ducts, and holding down bolt holes must be constructed that it can be easily collapsed to facilitate withdrawal after the initial set of the concrete.

The Contractor's proposed method for the construction and fixing of the formwork for bolt hole pockets shall be submitted to the Engineer for approval before Construction. The top of the shuttering shall be suitably covered to prevent entry of excess grout, materials used for curing etc. Solid timber must not be used for forming holding down boltholes. Bolt hole formers may be made of plywood, expanded metal, polystyrene or other method approved by the Engineer, who may require the Contractor to carry out a test pour, using the proposed bolt hole former. In no circumstances shall forms be struck until the concrete reaches strength of at least twice the stress to which the concrete may be subjected at the time of striking.

In normal circumstances (generally where temperatures are above 20 degree C), and where ordinary cement is used, forms to be struck after expiry of following periods:

Walls, columns, and vertical : 24 to 48 hr. sides of beams with the approval of the Engineer

Slabs (Props left under) : 7 days

Beam soffits (props left under) : 7 days

Removal of props to slabs 1. Spanning up to 4.5 mm : 7 days 2. Spanning over 4.5 m : 14 days

Removal of props to beams & arches: 1. Spanning up to 6 m : 14 days 2. Spanning over 6 m : 21 days

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17.36 Finishes for Concrete The Tenderer shall use suitable type of formwork, which will be stated in his drawings/plans. Any defective concrete finish will be rejected. The Contractor if instructed shall cut out the defective part and made good. Power float finish shall be adopted for floors of tanks and similar large areas.

Plastering of defective concrete, as a means of making good will not be permitted. In case of minor porosity on the surface with the Engineers approval, the Contractor may apply a surface treatment and shall be made immediately after removing the formwork.

17.37 Grouting of Bolts & Plant Materials for Grouting The cement and water shall be as described elsewhere in this specification. The all-in aggregate for grout shall consist of hard siliceous sand, and granite chips, gravel or crushed stone, or other approved inert sharp materials with similar characteristics, having clean, hard, uncoated grains, free from lumps, soft or flakily particles, shale, crusher dust, silt, alkali, loam, organic matter or other deleterious substances. The aggregate should be of uniform grading and it should be of such a size that 100% will pass through a 10mm mesh and not more than 10% will pass through a No. 100 Sieve.

Admixture An admixture, which are non-shrinking agent type shall only be added to the grout with the approval of the Engineer. All proprietary admixtures shall be added and mixed strictly in accordance with the manufacturer's instructions.

Surface Treatment The surface area of the concrete, which is to be covered by grout, is to be thoroughly cleaned and all laitance removed from the surface by means of a hammer and chisel. (A power hammer may not be used).

Supervision All work in connection with grouting under steel work shall be carried out under the supervision of an experienced person employed by the Contractor.

Mixing The Contractor shall submit to the Engineer for his approval details of the mix and the methods he intends to use prior to the commencement of the grouting.

Placing At least two hours before the commencement of cement grouting, the concrete surface to be grouted shall be thoroughly saturated with water; the surplus being removed just before grouting commences. 7 days after the grouting of the boltholes the Contractor shall tighten the bolts and carry out a final alignment check. On receiving confirmation from the Engineer that the final alignment has been approved, the Contractor shall complete the grouting under the base plates, ensuring that the grout completely fills the space and that it is thoroughly compacted and free from air pockets.

Defective Work

Any grouting that which is defective shall be cut out and replaced by the Contractor.

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17.38 Reinforcing Steel All reinforcement shall be placed strictly in accordance with the approved drawings and as instructed by the Engineer. Nothing shall be allowed to interfere with the required disposition of the reinforcement, and Contractor shall make a particular point of seeing that all parts of the reinforcement are placed correctly in every respects, and are temporarily fixed where necessary to prevent displacement before or during the process of tamping and ramming the concrete in place.

The ties, links or stirrups connecting the bars shall be taut so that the bars are properly braced; the inside of their curved parts shall be in actual contact with the bars, around which they are to be fit.

17.39 Type & Quality of Steel Reinforcement

Reinforcing steel shall be high yield steel of specified characteristic strength fy 460 N/mm2 following BS 4449 or BS 4461 or ASTM A615 M for all diameters unless otherwise noted. Reinforcement shall be obtained from an approved source. It shall comply with the following standards or approved equivalent BS 4449 or ASTM A615 M, latest edition. In case the steel reinforcement is subject to welding, the steel shall strictly comply with BS 4449 or 4461 or approved equivalent relevant to wieldable reinforcement steel. Moreover, the Contractor shall submit the procedure for welding, type of electrodes, welder qualifications, etc. for the Engineer’s approval.

17.40 Reinforcing Fabric Steel fabric reinforcement shall be of an approved type complying with B.S. 4483. Steel fabric reinforcement shall be supplied in the form of flat sheets or in rolls. The Contractor shall supply the Engineer with a certificate for each consignment from the steel manufacturers showing that the steel meets the requirements of the Specification. One tension test and one bond test shall be made for each of 50 tones or less supplied for the permanent works.

17.41 Wire Wire binding reinforcement bars shall be of galvanized steel wire. Where epoxy coated steel reinforcement (below plinth Level) is used the wire shall be coated wires. The diameter of the wire shall not be less than 16 SWG (1.6mm) and the binding shall be twisted tight with proper pliers. The free ends of the binding wire shall be bent inwards.

17.42 Protection of Material Steel reinforcement shall be protected at all times from injury. When placed in the work, it shall be free from direct, detrimental scale, paint, oil, loose rust, grease or other foreign substances.

17.43 Fabrication Bar reinforcement shall be bent to the shapes shown on the approved drawings and steel bending (diagrams) and in accordance with B.S. 4466 B: 1969, Bending dimensions and scheduling of bars for the enforcement of concrete. All bars shall be bent cold, unless otherwise permitted by the Engineer.

No bars partially embedded in concrete shall be field bent except as shown on the plans or specifically permitted by the Engineer.

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17.44 Placing & Fastening All steel reinforcement shall be accurately placed in the position shown on the drawings and firmly held during the placing and setting of concrete. Bars shall be tied at all intersections except where spacing is less than 3cms in each direction, in which case alternate intersections shall be tied. Distances from the forms shall be maintained by means of stays, blocks, ties, hangers or other approved supporters. Blocks of approved shape and dimensions or approved metal chairs. Metal chairs, which are in contact with the exterior surface of the concrete, shall be galvanized. Layers of bars shall be separated by precast mortar blocks or by other equally suitable devices. 17.45 Splicing All reinforcement shall be furnished in the full lengths indicated on the drawings. Splicing of bars, except where shown on the drawings, will not be permitted without the written approval of the Engineer. Splices shall be staggered as far as possible.

Additional splices, where required and the steel supports for holding reinforcement bars shall be provided by the Contractor. Concrete cover to reinforcement shall be:

i) Underside of foundations - 70mm (all steel) ii) Sides and tops of foundations - 70mm (all steel) iii) Super structures External faces - 40mm (all steel) Internal columns - 40mm (all steel) Internal beams - 30mm (all steel) Internal slabs - 30mm (all steel) Other internal - 30mm

For internal work, the cover should be neither less than the above nor less than the diameter of the bar.

17.46 Testing of Reinforcement Upon request by the Engineer the selected samples of reinforcement steel shall be tested in accordance with the relevant approved standard.

17.47 Information on Drawings

Following information on drawings shall be provided for approval: i) Type of cement ii) Minimum cover to reinforcement. iii) Maximum size of aggregate. iv) Characteristic cube or cylinder strength at 28 days. v) Type of reinforcing steel and cross section of bars. vi) Reference to bar bending Schedules. vii) Workability of concrete. viii) Concrete finishes. ix) Minimum cement content. x) Minimum water/cement ratio. xi) Proposed location & details of construction joints. xii) Proposed location and details of expansion joints. xiii) Full details of any grout required.

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18.ROOFING

The roof for the large industrial plant shall be with roof cladding of insulated double skinned profiled powder coated Aluminium sheets. The cladding shall be protected metal sheeting suitable for long life and be maintenance free and adequate to withstand the site climatic conditions. Eaves, ridge, gutter, flashings etc. shall be of matching and compatible type.

The roof slab and other superstructure work shall be of reinforced concrete mix not leaner than grade 35. On top of slab suitable insulation and water proofing membranes shall be laid. Water proofing membrane shall be carefully tucked in at walls and in/around rainwater outlets, openings etc. The roof shall be finished with cement tiles laid to slope in cement concrete bedding. Skirting preferably laid on 45 deg. fillet shall be provided all around the roof periphery.

Domestic potable water supply tank, A.C. compressors, etc. shall be placed on concrete slab. The roof of plant hall and service/office block shall have openings for exhaust fans. Access to roof of all the structures shall be by ladder or by stair as per requirement.

All buildings shall be weatherproof and sufficient number of rain water outlets shall be provided. Rainwater shall be discharged by gutter and down pipes directly to surface/storm water drainage system. Drip flashings are to be provided wherever required. Soffit of concrete slabs shall be fairfaced and painted. The final finishing shall be as per the Room finishes Schedule.

19. FLOORING

All floor slabs shall be reinforced concrete slabs. Concrete shall be as specified in the concrete clause of this Specification. Minimum thickness of floor slab shall be 200mm at all locations of vehicular access and 150 mm at other locations. Reinforcement shall be min. 8mm diameter mesh in two layers at 150mm centre to centre, both ways.

Reinforced concrete floors, which are required to be surfaced with screed, shall have a roughened surface, produced by backing and wire brushing. The roughened concrete floor shall be cleaned, wetted preferably overnight, the surplus water removed 1:1 cement/sand grout brushed into the surface, keeping just ahead of the screed bed.

The screed bed shall be minimum 40 mm thick and shall be well compacted and levelled with a screeding board and steel towelled smooth. If the screed is the finished surface it should be treated with an approved silicate of soda solution hardener to prevent dusting.

The screed shall be mixed in the proportions of 1:1-1/2:3 (cement, sand, 10mm pea shingle) by volume with the minimum quantity of water necessary to give a good hard smooth, steel towelled finish. The section hereof concerning concrete applies.

Flooring in different rooms shall be multi-layer epoxy screed, epoxy resin mortar screed, ceramic tiles, etc. as described in room finishes schedule. The type of flooring selected shall be suitable for the utility of the room/area. Matching skirting shall be provided wherever required. Flooring shall be level surface except in rooms where spillage/leakage of water, chemicals etc. can be expected. In such room/areas drain pit, drain trench/channel shall be provided and floor drainage shall be discharged safely.

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Expansion joints shall be provided in flooring in line with good engineering practice. Joints shall also be provided all around walls and around projecting machine pedestals etc. Joints shall be filled with compressible filler and sealed with suitable compound compatible with floor finish.

20. PAINTING, TILING

The walls shall be finished with paint, tiles etc. as per the room finishes schedule. Plastered portion, which is to be painted shall first be applied two coats of lime putty (majoon). Each coat shall be polished to avoid any undulation in the surface. On top of this minimum one coat of alkali resistant or other suitable primer shall be applied. Finally minimum two coats of acrylic paint of approved colour and quality shall be applied. Ceiling soffit shall have the same finish as walls. Externally the walls shall be finished with best quality textured paint and polyurethane top coat. The number of coats, primer and method of application shall be as per the paint manufacturer's recommendations. Coatings shall meet the requirements specified.

The tiles shall be ceramic, chemical resistant or fire clay tiles as per room finishes schedule and shall be of approved colour and quality. Tiles shall either be bedded with cement mortar or glued with adhesive.

21. CONCRETE BLOCKS

Precast concrete blocks shall have a compressive strength of 7N/sq.mm average for 10 blocks calculated on the gross area of block. Minimum strength of individual block 6N/sq.mm (at 28 days). Concrete Blocks (Solid or Hollow) shall be of the following dimensions:

Height = 20 cm. + 1% tolerance.

Length = 40 cm. + 1% tolerance.

Width = as required + 1% tolerance.

21.1 Mortar for Block Work Mortar shall be prepared in the following proportions with the addition of the minimum quantity of clean water for workability.

Cement and sand or crushed marble mortar (1:3) mix, shall be composed of one part cement to three parts of sand or crushed marble by volume. Hydrated lime up to 1/4 (one quarter) by volume of the dry cement may be added for bedding blocks, upon the approval of the Engineer, to improve workability without appreciably reducing the strength. The ingredients for cement and sand or crushed marble shall be measured in proper clean gauge boxes and the mixing shall be carried out by means of an approved mechanical batch mixer. In the case of cement-lime mortar, the sand and lime shall be mixed first and the cement added. It shall be assumed that the lime has not increased the bulk of the sand.

Cement mortars shall be used within thirty (30) minutes of their mixing. Hardened mortars shall not be used in the work and shall upon the request of the Engineer, be immediately removed from the site.

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21.2 Jointing External wall faces shall be joined with an approved joint, faces of walls, which are to be plastered or rendered, shall have their joints raked out to form key. All other wall faces and partitions shall be flush jointed. All jointing shall be completed with painting as the work proceeds.

21.3 Block Laying All blocks shall be kept damp during building and shall be laid on a full bed of mortar. All joints shall be completely filled with mortar. The thickness of the horizontal mortar joints shall not exceed 40 mm to every four joints.

Block work shall be built in a uniform manner in truly level courses and truly vertical or battered. Corners and other advanced work shall be racked back and not raised above the general level more than one meter. Tooting shall be used only where provision has to be made for a future extension.

Where so described or directed, reveals and piers, together with airbricks, fixing bricks for jointers other work and other relevant items shall be built in as the work progress.

Walls shall be constructed with an approved mesh reinforcement with wall ties every third course. Where shown on the drawings and at the jambs of all openings to hollow concrete blocks shall be filled with weak concrete, well stamped down and carried from base slab to top of such openings. Where the blocks abut reinforced concrete columns and as indicated elsewhere, the blocks shall be tied to the columns every second course by means of approved galvanized wire ties cast into the columns.

During the operation of bedding blocks to cavity walls the void between the two skins shall be protected from dropping mortar into it by means of empty cement bags or other approved means.

Unless otherwise specified window sills shall be precast concrete as detailed, flush jointed in 1:1:6 cement mortar in the manner described. Holes and chases shall be cut out or left in the walls as required and provision shall be made for making good. On completion, all block work shall be cleaned down and mortar dropping and other marks removed. Defective blocks or workmanship shall be made good.

The top courses of hollow concrete block work walls shall be laid in solid blocks unless otherwise indicated.

21.4 Protection Against Damage Architectural features, finished surface and quoins shall be protected against damage during the progress of the works. Sills, jambs and heads shall be protected by basing as soon as built. Door and window frames and other items built-in shall be fully protected by boards, sheets, or other measures. Freshly completed work shall be covered with waterproof sheets in locations where rain damage is like.

22. PLASTER WORK

22.1 Materials

a) Cement for plaster shall be ordinary Portland cement/sulphate resistant cement as required for internal and external plaster as specified under "Concrete work".

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b) Sand (Fine Aggregate) for use in plaster, mortar and screed shall be as specified under "Concrete Work" and shall contain not more than 0.06% chloride.

c) Water shall be de mineralized and shall be as specified under "Concrete Work". d) Metal lath for use in plaster shall be plain expanded metal type complying with B.S.

1369 weighing not less than 1 kg/m.sq.

Metal lath shall be secured between concrete face and block work face by means of steel nails. Complete plastering accessories shall be used wherever required. Stainless steel accessories shall be used for external walls.

22.2 Mixing of Mortar Ingredients Except where hand mixing of small batches is approved, mechanical mixers of approved type shall be used for the mixing of mortar. Frozen caked or lumped materials shall not be used.

22.3 Preparation of Surfaces All surfaces to be plastered shall be clean and free from dust, grease, loose or projecting mortar and all traces of salts are to be thoroughly sprayed with water, but all free water shall be allowed to dry and disappear from the surface before the plaster is applied. Plastering shall not be commenced until the background has been suitably prepared. Block work joints shall be deeply racked out, brushed off and all dust and foreign matter removed. On all external and internal surfaces spatter dash of cement and sand, which shall contain 500kgs of cement per meter cube of sand, shall be applied and allowed to dry before rendering is commenced. The Contractor shall form vertical guide screed 5cms wide. The thickness of plaster shall be from 15mm to 20mm minimum. Internal and external plaster shall be composed of 400kgs of cement per cubic meter of sand (salt free sand). Where dissimilar materials (concrete and block work) are joined, the joints shall be covered by metal lath strips not less than 200mm wide securely fixed to the surfaces. The plaster surface shall be true to shape and angle even in all directions, plumb vertically, horizontally and diagonally, smooth and free from rough areas, trowel marks, checks or other blemishes and cracks. Wherever in external rendering smooth finish is not specified, the plaster shall be given a sand float finish of a uniform texture.

23.DOORS / WINDOWS / VENTILATOR

The dimensions of the doors shall be so adopted to meet the requirements of the electrical equipments passing through these and to the approval of the Engineer.

23.1 Steel Doors Steel doors wherever specified shall be 1.6 mm mild steel sheet suitably reinforced with light section hollow square sections and in filled with mineral wool or polyurethane of approved size, tack welded to mild steel sheet on both side. Main doors shall be double shutter and small doors shall be of single shutter to the approval of the Engineer.

Coating shall be applied on galvanized steel. Preferred coating is polyvinyl Chloride - PVC - Plastisol coating about 175 Micron thickness, applied to galvanized substrate with about 25 micron primer. This coating shall be applied to exterior side of both steel sheets (skins). The

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tenderer may propose alternate coating like powder coating which is equivalent to or better than the specified coating. Finishes shall be as specified in Painting, Tiling & Glazing works.

All doors shall be fitted with high quality ironmongery and finished doors shall be factory assembled form the manufacturers. All locks shall be complete with master key arrangement. Steel doors and frames shall be standard factory manufactured doors from reputed door manufacturing company to the approval of Authority. Coating for doors and frames shall be applied at the factory and shall be suitable for prevailing climatic conditions and plant environment. Coating is of prime importance and only high class coating shall be proposed.

Coating shall be applied on galvanized steel. Preferred coating is polyvinyl Chloride - PVC - Plastisol coating about 175 Micron thickness, applied to galvanized substrate with about 25 micron primer. This coating shall be applied to exterior side of both steel sheets (skins). The tenderer may propose alternate coating, which is equivalent to or better than the specified coating.

Door leaves shall be approximately 45mm.thick with steel sheets (skins) on both sides. The steel sheets shall be 1.2 to 1.5 mm thick. Door leaves shall be manufactured to form an interlocking box construction with internal bracings, stiffeners etc. The inside of steel sheets shall be coated with suitable corrosion resistant coating suitable for climatic condition. The infill shall either be mineral wool or other suitable insulating material.

Door frames shall be profiled or z - section manufactured from 1.6 to 2.0 mm. thick steel sheets. Doors shall be complete with handle, heavy-duty lock/latch, heavy-duty welded hinges (minimum 3 Nos) with bronze/stainless steel pins, door stops, rubber sealing strips, escutcheon plate etc.

Doorframe shall be complete with necessary fasteners, cradlings, sealing compound/strip etc. to obtain weatherproof, tight fitting construction. External doors and doors between air conditioned/non-air conditioned areas shall be insulated with low U factor and and construction shall be lipped edge with heavy-duty seals to reduce ingress of sand. All doors shall have a two hour fire rating.

Control room door and doors between plant hall and office/service block shall be acoustic type to reduce noise transmission. In these doors half height vision panels shall also be provided. Double leaf door shall have door selectors. Wherever required doors shall have automatic door closers. Access doors and escape doors shall be provided and fitted with panic bolts where necessary, so that operating and maintenance staff will not be trapped and can always exit safely from the buildings in fire emergencies of any nature or location.

23.2 Aluminium Doors, Windows, Frames, Ventilator Aluminium doors, windows, ventilators etc. shall be powder coated extruded aluminium sections. Doors and large windows shall be fabricated from heavy sections. Sections shall have built in aluminium architrave, neoprene strips for prevention of draughts/leaks and shall be suitable for puttyless glazing.

Doors, windows, ventilators shall have timber sub-framing. If necessary sealant shall be used to achieve tight and weatherproof construction. Sliding doors/windows and openable areas of other windows shall be provided with fly-wire mesh screen panel on outside.

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Wired, toughened or plate glass shall be used for glazing. Glass thickness for doors and windows shall be 6mm.

Doors, windows and ventilators shall be complete with locks, handles, hinges, kick plates (if required) automatic door closures etc.

Unless other wise specified doors/ventilators/windows shall be powder coated aluminium with all necessary accessories and fittings in accordance with B.S. specification. Window size 1.80m x 1.20, ventilator are 600mm in height and full wall length wherever required. Aluminium windows shall be horizontal sliding type with clear glass panels and with metal mesh fly screen of approved quality. All ventilation shall have 6mm thick double clear / tinted glass as required. The windows and doors shall be fixed on wooden frames with architraves on both sides of approved dimensions and quality.

Prints of shop drawings for aluminium windows, ventilators, doors, frames etc. showing the dimensions, sizes, thickness, materials, finishes, jointing, attachments, fasteners and the relation of this section to adjoining work shall be submitted to the Engineer for approval before ordering such items. All work shall be fabricated and erected in accordance with the approved drawings.

23.3 Roller Shutter Doors/Over head doors Industrial roller shutter doors shall be constructed of heavy gauge interlocking metal slats and shall be complete with slats channel guides, roller box/hood, spindle, counter balance springs, locking device, end locks to prevent lateral movement, wind end locks to prevent excessive deflection of curtain in high winds, T-Section bottom rail, electrical operation mechanism for opening/closing the door(motor unit shall be so designed that the motor can be completely removed without interfering with the operation of the door by the auxiliary chain-gear operator) and all necessary fittings. Shutters shall be standard factory manufactured from reputed shutter manufacturing company to the approval of the Authority. Galvanized steel for curtain slats shall have 0.40 kg of zinc per square meter and shall be chemically cleaned and Bonderized for paint-bond, and shall be given one dip coat of rust-inhibiting synthetic enamel which shall be baked on at 175 degrees C. prior to roll forming. All other surfaces of door parts shall be given one shop coat of rust-inhibiting paint. Overhead doors shall be standard factory manufactured from reputed manufacturing company to the approval of the Authority.

23.4 Timber Doors and Frames Timber flush doors shall be of approved manufacture, with red wood frame for 230mm wide jamb fixed to wall jambs in plumb secured with 4 numbers 150mm long splitter iron hold fasts to each verticals and embedded in concrete. Flush shutters shall be of white wood solid cores covered with 6mm thick teak ply of approved quality, nailed and glued and well pressed.

The red wood frames 3/4 inch thick well wrought and polished shall be provided all round the shutter. The flap shall be hung by best quality of 4 Nos. 4 inches long brass hinges and when closed 1/8-inch allowance should be seen around between frame recess and flap.

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Doors shall be provided with double level chromium plated "Yale" or any other equivalent quality make locks with handles, red wood architraves 6 cm x 3 cm levelled shall be provided all round frame from both sides. All locks shall be complete with master key arrangement. Finishes shall be as specified in Painting, Tiling & Glazing works.

Doors shall be best quality Solid flush doors painted with approved quality matt finish paint. Locks shall be good quality with handle. Minimum thickness of door shutter shall be 44 mm. Door frame shall be of good quality timber and shall be fixed in wall with minimum of 3 galvanized steel cramps shall be used to fix each side of the frame. Width of frame shall be such that after plastering it becomes flush with plaster. Door frame back coming in contact with wall shall be applied with two coats of bitumen. Architraves of approved design shall be provided. Finishes shall be as specified in Painting, Tiling & Glazing works. 23.5 Ironmongery All necessary builder's ironmongery shall be of types approved by the Engineer and shall be provided and fixed into position in the best manner by the Contractor.

The doors, windows, shutters, ventilators etc. shall be complete with all necessary hardware/ furniture. In general the hardware shall be of powder coated aluminium on aluminium doors and windows and on other doors, locks, striking plates kick plates etc. shall be of stainless steel. Sliding windows shall have nylon guides and rails and mohair draught slots. The contractor will supply samples of proposed hardware to the Authority for approval. The Contractor will ensure that the hardware/ furniture is firmly attached, functions perfectly, is clean and lubricated (where necessary). The locks, door handles etc. shall be removed after initial fitting and replaced when the paintwork is completed.

24. CHEQUERED PLATES FOR TRENCHES & PITS

Steel

Structural steel for frameworks, angle sections, etc., shall comply with the requirements of BS 4360 and BS 153, Part 1 and II materials, or other approved standards such as ASTM, DIN, etc.

Chequered Plates

The chequered plates shall be of galvanized steel of minimum thickness of 6mm. The plates shall be cut with care and the edges trimmed with a grindstone. The plate shall be provided with lifting holes. The plates on more than 60cms width of trenches shall be stiffened by 25mm x 25mm galvanized M.S. angles to avoid the deflection of plates. The plates (on both faces), stiffened M.S. angle and seats shall be primed with rust preventing primer and finished with two coats of epoxy paint as recommended by the manufacturers .Suitable resilient liner/rubber pad shall be provided under seating area of chequered plates to avoid noise while walking over it.

Cable Entry ducts For incoming and outgoing cables inside the rooms, the PVC pipe ducts of minimum 150mm diameter shall be provided wherever required. The PVC pipes of approved length shall be embedded in concrete grade 20. Minimum thickness of concrete shall be 150mm. The entry and exist of the cable ducts shall be suitably sealed and protected against outside bodies and water entering the room through such ducts.

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25. PLUMBING, DRAINAGE AND RAIN WATER SERVICES

The contractor shall prepare detailed design and install plumbing, drainage, sewerage and rainwater services. The drainage system for these areas shall be separated from domestic/foul water drainage system.

Foul water drainage shall include soil drainage, sink waste, floor drains and sewerage and shall be taken through septic tank, soak pit etc. The pipes shall be UPVC and minimum diameter shall be 150 mm. Pipes shall be suitably protected and under the roads they shall be encased in concrete. The system shall be complete with traps, gullies, manholes etc. Septic tank and soak pit location shall be decided in consultation with the Authority.

The surface water drainage shall include all necessary trenches, gutters, down pipes, gullies, traps, catch pits, manholes etc. Chemical drainage shall be suitably neutralized before entering the system. Due attention must be paid to heavy precipitation at in frequent intervals of rainfall. The rain water system shall be designed such that the water is drained away from buildings, aprons, roads and does not accumulate around these areas.

Full allowance must be made for complete installation of lift pumps where necessary in order to provide trouble free drainage systems. All gradients shall be sufficient to ensure self cleaning velocities in the pipes.

Toilet facilities in building washrooms, laboratory shall connect into suitably dimensioned septic tanks with baffle walls. The septic tank shall be constructed in an agreed position at least 10 meters from any building. The design shall be to recognized standards such as BS 6297 and approved by the Authority. The settling compartment shall have a slopping floor and a sump for easy removal of sludge when necessary. The tank shall have separate fresh air inlet and outlet pipes and be provided with access openings. All tank vents shall be 3 meters high. The effluent from the tank shall discharge to either an up flow filter or soak pit.

The effluent from the works shall be to the British Royal Commission Standard of suspended solids less than 30 mg/liters and BOD less than 20 mg/liters and shall be odour free.

All sewage work shall be carried out in accordance with the appropriate British Standards and Code of Practice No. CP 2005 - "Sewerage".

The domestic plumbing and drainage system shall consist of domestic water supply tanks mounted on roof of office block and service block, water distribution pipeline, water inlet connection to these tanks with ball valve, supply from these tanks to respective areas, hot/cold war pipelines, water heater, drainage from these rooms, floor drains, drain pipelines with traps, manholes, septic tank and soak-away pit.

The main supply shall be taken from discharge of product transfer pumps or other suitable location in consultation with the Authority. Chlorine dosing/storage, acid tank area shall also have piped water supply facilities. Hot and cold water system shall be done in copper and PVC piping.

The sanitary fittings shall include washbasin, w.c, ablution tap, shower tray, towel rails, soap trays etc. Fittings shall be installed with valved connections for hot/cold water supply and drainage system. All sanitary fittings, fixtures shall be from reputed manufacturers.

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The tenderer shall submit relevant drawings and specification for approval together with leaflets, catalogues, samples etc. of proposed material.

26. ROAD WORKS AND PAVEMENTS

The Contractor's proposed plant layout shall allow for vehicular access to the various items of plant for installation and subsequent maintenance. The contractor shall ensure that the vehicular access roads are levelled and graded with subkha material and properly compacted with appropriate rollers to ensure that the finished road is suitable for the maximum foreseeable imposed loads, which can be expected from vehicles transporting the various items of plant. In detailing the layout of the roads and parking areas special attention must be given to the manoeuvrings of vehicles delivering plant, stores, spares and other materials and equipment. The minimum requirement of roads, pavement, gravel beds etc. is shown on the layout drawing. All pavement shall be interlocking blocks. The roads shall be connected with existing internal roads marked on the drawing and all external doors of buildings shall have interlocking block paved/asphalt approach from the existing/proposed road system wherever applicable. Road system shall be complete with kerbs, road signs, road markings, hardstand on roadsides. The project area has natural gradient and while designing roads and pavements due care shall be taken to maintain natural gradient. Surface drains shall be provided such that the storm water drains off the buildings, roads, pavements, and there is no stagnant water on or adjacent to buildings/roads/pavements. 26.1 Kerbs Pre-cast concrete kerbs shall be provided at both the edges of the roads, pavement, hard-core surfacing and gravel spreaded areas. The Contractor shall submit to the Engineer for approval his proposals for kerbs sizes as per site condition .

26.2 Materials Hardcore granular material shall consist of natural stone to pass a 75 to 100mm ring. It shall be free from rubbish, wood, vegetable or other injurious matter. Broken stone and chippings shall consist of hard crushed natural stone or gravel, of approved sizes.

26.3 Drains, Sewers & Cable Ducts All drains, sewers, cable ducts pipe ducts and other necessary work below formation level shall be completed, inspected and approved by the Engineer before the construction of any pavement is started. All the road crossings shall be through a PVC duct or culvert. 26.4 Preparation for Formation Preparation and surface treatment of the formation shall be carried out only after completion of any sub-grade drainage and, unless otherwise approved by the Engineer, prior to laying the sub-base. The sequence of operation shall be as follows:

All soft layers as described elsewhere in this Specification shall be removed completely

and reinstated with a compacted approved fill. All low areas shall also be reinstated with a compacted approved fill or areas where cutting is required shall be excavated with hand tools.

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The surface shall be laid and compacted in layers of not more than 200mm thickness, by four passes of a smooth wheeled roller having a mass per meter width of roll of 4400 kg - 6000 kg.

The formation shall be regulated and trimmed to a tolerance of + 20 mm and 30 mm. The trimmed formation shall be rolled by one pass of a smooth wheeled roller having a

mass per meter width of roll not less than 2100 kg.

Where the completed formation is not immediately covered with a base or granular course material it may be protected by a membrane of 500 gauge thick impermeable plastic sheeting with 300mm laps set to prohibited ingress of moisture. Should the moisture content of the compacted material reach an unacceptable level then the Contractor may be required to re compact the trimmed level or wait for the material to revert to an acceptable moisture content. The Engineer may request for CBR tests to be carried out on the prepared formation before further construction proceeds. 26.5 Granular Base for Pavement, Hard Core & Gravel Spreaded Areas After the formation has been properly made, rolled and approved by the Engineer, the granular base shall be laid. The material to be used in the base shall be granular material, i.e. natural sand, gravel, crushed rock, crushed slag, crushed concrete, crushed rock or well burnt non-plastic shale.

The base shall be laid in the compacted formation in two equal layers to yield a compacted total thickness mentioned. The base shall be laid to the required cross falls and gradients and the moisture content of each layer shall be tested and if required the water content shall be increased by spraying with approved mechanical equipment to develop the density required. The compaction of each layer of base shall be equal to 95 % of the maximum density of the material as determined by ASTM method D 1557 (modified AASHO) The material shall be well graded and have a grading envelope similar to the table below:

Table of Graded Granular Sub-base

BS Sieve size Percentage by Mass Passing 75 mm 100 37.5 mm 85 - 100 10 mm 40 - 70 5 mm 25 - 45 0.600 mm 8 - 22 0.075 mm 0 - 10

26.6 Wet-Mix Macadam for Road Bases We-mix macadam shall be made and constructed in the following manner. Aggregates shall consist of crushed rock or crushed slag and shall have the grading shown in the table below; this slag shall comply with BS 882 and bulk density shall not be less than 1100 kg/cu.m.

Table of Graded Aggregate for Wet-Mix Macadam BS Sieve Size Percentage by Mass Passing 50 mm 100 37.5 mm 95 - 100 20 mm 60 - 80 10 mm 40 - 60 5 mm 25 - 40 2.36 mm 15 - 30

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600 um 8 - 22 750 um 0 - 8

The particle size shall be determined in accordance with the requirements of BS 1377 Test7A.

Moisture content The moisture content of the wet-mix macadam shall be the optimum +0.5 percent as per determined in accordance with the vibrating Hammer Method Test 13 of BS 1377.

26.7 Dry Bound Macadam for Road Bases Dry-bound macadam shall be made and constructed in the following manner using coarse and fire aggregate consisting of crushed rock and crushed slag in accordance with BS 882 or BS 1047 so long as the bulk density is not less than 1100kg. cu.m. Coarse aggregate shall comply with either the 50mm or the 40mm nominal sizes of BS 63 as described elsewhere and the fine aggregate shall all pass the 5mm BS sieve size. The fine aggregate shall be dry on arrival at the site and if stockpiled it shall be kept dry by being sheeted until required for use.

The coarse aggregate shall be laid by mechanical plant to a thickness within the range 75-100mm and given two passes by a smooth wheeled roller having a mass per meter width of at least 2500kg on at least one roll. The fine aggregate shall then be spread on it to a thickness of approximately 25mm by a suitable spreading machine and vibrated into the voids of the coarse aggregate by a vibrating plate compactor having a mass per unit area of the base plate or at least 1400kg sq.m. or vibrating roller having a mass per meter width of vibrating roll of at least 1800kg.

The operations of spreading and vibrating the fine aggregate shall be repeated as necessary until no more will penetrate into the layers of coarse aggregate and no hungry patches are visible on the surface, when it shall be brushed to remove the excess fines and leave the coarse aggregate standing 3-6 mm proud. The layer shall then be rolled with a smooth wheeled roller having a mass per meter width of at least 5000kg on at least one roll. The whole operation shall be repeated as necessary to achieve the approved thickness of road bases.

26.8 Prime Coat A prime coat of 1 to 1-1/2 kg/sq.m. liquid bitumen shall be sprayed on in accordance with the Engineers’ approval.

26.9 Bituminous Surface Two layers of Bituminous surfacing of overall thickness of 130 mm or as approved, shall be laid in accordance with BS 3690, BS 434.

26.10 Interlocking Blocks for Road & Pavement Interlocking blocks for road and pavement work shall have minimum thickness of 80mm and of the best quality and size available from the local market and laid on granular base with crushed sand. Blocks shall be clean, sound, hard true to shape, or uniform size, colour and texture. The blocks shall be of concrete containing at least 600 kg of ordinary Portland cement per cubic meter of loose aggregates. Average compressive strength of 10 blocks to be at least 425 kg/cm2. The blocks shall be laid in work wise manner and pattern as approved by the Engineer on prepared granular base. Filling of the joint shall be done with approved sand. Compaction shall be done with smooth wheel roller 8-10 tones in longitudinal direction commencing at one edge of the area and working up the cross fall. The rolling shall be executed in successive passes with

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each rear wheel over lapping the preceding wheel track by one half. The finished surface of blocks shall not show any depression in excess of 5mm. 26.11 Concrete Beds & Casings All drains, sewers, cables, service pipes, etc. below the formations shall be passed through with two halves of UPVC pipe to form a duct and shall be finally concreted in lean concrete with minimum cover 150mm. all round. The exact locations of above services shall be determined at site.

26.12 Protection & Dust Control Use of all means necessary to protect materials before, during and after installation and to protect the finished course of layers. In the event of damage, immediately make it repaired and replacements necessary. Use of all means necessary to protect the spread of dust during performance of work, handing and storage of materials. Materials shall be stored/placed at the storage area given to the contractor or as approved by the Engineer.

26.13 Stabilization of Sides Appropriate gradient shall be provided to stabilize the side’s fill and shall be finished with hard core surfacing materials.

26.14 Tests The contractor on samples of materials and on the layers shall perform full-scale field tests. The intent of full-scale field test is to confirm the requirements of relevant clause of standard code of practice. Surface tolerance of hard core surfacing shall not exceeds 4mm in 4M (straight edge)

All courses of fills and granular materials shall be tested as per CBR method and maximum dry density in accordance with B.S. 1377 including moisture content test. Also modified Proctor tests. Sieve analysis, etc. shall be performed. The plates shall be cut with care and edges trimmed with a grindstone.

27. CABLE AND PIPE TRENCHES

These shall be constructed in reinforced concrete walls and floor slabs. The trench shall not be cast in lengths exceeding 10M. The trench bottoms shall be laid to falls and provision made for drainage either to ground or to surface water system.

Trench covers shall preferably be of GRP material and shall be designed and constructed to withstand the loads expected to pass over them whether they may be internal or external. The minimum design load for each application shall be as follows in accordance with BS 497 where applicable. Chequred plates and G.I.gratings shall also be used alternately in non corrosive areas.

28. CABLE DUCTS

All cables which pass under roads or hard standing areas or where they would otherwise be at risk shall be ducted and concrete encased. Under roads or hard-standing areas a 100% additional capacity shall be installed and the whole surrounded in a minimum of 150mm grade 20 concrete. Where cable ducts enter buildings these shall be sealed against the ingress of water by suitable elastomeric or bitumen sealers.

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29. VALVE AND OTHER PITS AND CHAMBERS

Valve and other pits and chambers, which are buried, shall be of reinforced concrete construction, completely tanked with self adhesive bitumen membrane. All chambers shall have a 300mm sump below any pipe invert. The overall size of chambers shall be sufficient to allow easy access for installation and maintenance of the pipe work. The cover to the pits shall be of pre cast concrete planks complete with lifting eyes, sealed by seating them on a bituminous strip, and access opening not less than 600x600 mm shall be formed such that access may be made to valve spindles or if of sufficient size, to gain entry to the chamber. The opening shall be complete with heavy duty cast iron frame and double triangle/circular cover. SCADA chambers shall be min. 800X800mm internal with a min. working space of 600mm under the pipes. 30. STRUCTURAL STEEL WORK

Structural steelwork shall be provided and fixed complete with all plates, cleats, bolts etc., cut to lengths and sizes and drilled as per approved drawings.

Unless other wise specified hot rolled and hollow steel sections will be mild steel Grade 43A or high yield steel Grade 50A to the requirements of BS 4360-

Unless otherwise approved by the Engineer all forms of steel used shall be of standard section and shall be of the exact dimensions. Should the contractor be unable to obtain steel to the required dimensions he shall submit alternative proposals for approval by the Engineer. Two copies of all detailed working drawings, calculations, etc., by the Contractor shall be submitted to the Engineer for his approval.

Black bolts shall be to BS 1769 UNC threads or BS 916 Whit worth threads, High strength friction grip bolts will be BS 3139 grade and will be the load indicating type. Bolts shall be of sufficient length to show at least one full thread beyond the nut after tightening.

Washers, where used, shall be to BS 3410 with a tolerance of 1.5 mm on the diameter of the hole. When bolting to diminishing sections tapered washers shall be used. Welding electrodes will comply with the requirements of BS 639. The qualification of welders and quality of work shall be as specified else where in the specifications.

The design and detailing of connections and workmanship shall be in accordance with the approved drawings and BS 449 to transmit the loads specified. The work shall be erected, fitted and temporarily bolted together with the approval of the Engineer before any riveting or welding is carried out. During erection and prior to the construction of any necessary stiffening members, temporary bracing will be provided as necessary to ensure the stability of the framing against wind or accidental forces.

Shop and site joints will be formed either by riveting, welding or high strength friction bolts to suit the plant, equipment and erection procedure of the steel work, due regard being paid to efficiency, appearance and ease of maintenance. Site connections generally will be made with black bolts, with a minimum of two bolts to any connection, except where fitted bolts, high strength friction grip bolts, or site welding, are specifically referred to in the specification or on the drawings.

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High strength friction grip bolts shall be tightened by a part-torque part turn method. After bedding down of the joints, each nut and the protruding threads of the bolt shall be permanently marked to record their relative positions. The nuts shall then be tightened to the approval of the Engineer by the part-turn of the nut method. High strength friction grip bolts will generally be preferred. The surface of members joined by friction grip bolts shall be free from oil and paint etc. Portal frame site connection at apex and knee where they employ HSFG bolts in tension; such bolts shall be torque up to their proof load.

Plates and sections shall be true to form. Stiffeners, plates and the like shall be ground to fit the profile of the member. Sections to be cut to 'exact' lengths shall be accurately cold swan or machined. Preparation of edges by flame cutting shall, wherever practicable, be done by machine. Cold swan, machine-cut and flame-cut edges shall be cleaned free of burrs and slag and left as smooth and regular as those produced by edge planning. All holes shall be drilled.

Unless otherwise requested the contractor shall submit detailed shop drawings to the Engineer within 2 weeks of the date of signing the contract. Fabrication shall not commence until the contractor has received the Engineer's approval of his proposals. Such approval does not in any way relieve the contractor of his responsibilities to produce an adequate and safe scheme. Holding down bolts will be supplied as required for building into the supporting concrete members. Welding shall be carried out in accordance with BS 5135 using electrodes as specified in BS 639. Welders shall be suitably qualified and experienced and efficient methods will be employed to remove all welding slag, spatter and flux residues thoroughly. When requested by the Engineer and before fabrication is commenced, welding and flame cutting procedure trials shall be carried out using representative’s samples of materials selected by the Engineer to be used in the work, which shall include:

Welding procedure in accordance with BS 1856.

The heat control techniques required to ensure that the flame cut surfaces of steel are free from any defects, which would be detrimental to the finished work.

The trials shall include specimen weld details representative of the actual construction, which shall be welded in a manner simulating the most unfavourable conditions liable to occur in the particular fabrication.

The preparation and treatment of steel work will be in accordance with the requirements of BS CP 2008. All steel work will be shot or grit-blasted free from all mill scale, rust, dirt, and other deleterious matter, and within two hours coated with primer.

One coat of zinc silicate primer DFT 65 microns to be applied in fabrication shop;

One coat, polyamide epoxy high build with micaceous iron oxide (M.I.O.) DFT 125 microns;

One coat, polyurethane top coat DFT 60 microns. All work to be properly executed in accordance with the printed instructions of the manufacturer

All damaged coating and areas around site connections including the bolts will be de-rusted as necessary and touched up with paint. Permissible deviations on structural steel work are as per standard practice.

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31. ROOFING & CLADDING

31.1 Vertical Cladding Cladding where required shall be powder coated profiled sandwich panel insulated aluminium sheet construction suitable for long maintenance-free life, and adequate to withstand the climatic and site pollution conditions. Samples of the proposed cladding shall be submitted to the Engineer for approval. No orders shall be placed with Manufacturers until approval has been given.

Vertical cladding shall be made from profiled aluminium sheet of minimum thickness 0.7 mm (outer) and 0.5 mm (inner) sheets. The outside surface shall be protected by a system of abrasion resistant colour-fast coatings.

The inner face of the internal skin shall have a factory applied finish of approved colour. Any cut edges and holes resulting during manufacture or erection shall be treated so that they are fully corrosion resistant. Care shall be taken to prevent bi-metallic corrosion occurring by the use of heavy PVC adhesive tape between the sheeting and supporting rails, and by the use of stainless steel fasteners and fixings.

The PVC tape shall overlap the edges of the sheeting rails by at least 15 mm along their full length. Fasteners and trim shall be stainless steel. Spacing and location of fasteners and supporting rails shall be as recommended by the manufacturer.

Care shall be taken to remove swarf from holes drilled in sheeting and steelwork as the work proceeds, to prevent rust stains and damage to the PVC tape. Cladding sheets or flashing, which are found to be soiled or damaged, shall be replaced. Insulation shall be phenloic foam having a BS 476 class 1 Surface spread of Flame rating.

Exposed flashings used in conjunction with wall cladding shall be purpose made to the same specification as the external cladding. Flashings shall be fixed with stainless steel self-tapping screws with plastic coated heads or 'pop' rivets, at not more than 450 mm centres.

31.2 Composite Roof & Wall Cladding The roof and wall cladding shall consist of factory finished insulated composite panels comprising powder coated profiled sandwich panel of aluminium sheet construction, face and liner sheets chemically bonded to a foamed in place polyisocyanurate core or polyurethane.

All roof panels shall be made from profiled aluminium sheet of minimum thickness 0.9mm for external sheets and 0.7 mm for internal sheets. The panel units shall be about 50 mm thick measured at the narrowest point with a 50 mm deep profiled and embossed outer sheet and a flat embossed internal liner.

Insulation shall be a rigid thermosetting polyisocyanurate foam or polyurethane, bonded to the inner and outer skins of the material. The space between the inner and outer skins shall be fully filled by the insulation, including the flute patterns leaving no voids. Inner lining shall be powder coated aluminium sheet having an off-white embossed decorative finish.

31.3 Metal Deck Roofs Metal deck roofs where required shall have face sheet of 1.65 mm thick embossed galvanized steel to BS 2989: 1982 G 275 with a multi-layered protective coating system consisting of a 5

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micron nominal epoxy primer followed by a 75 microns epoxy barrier coat and a nominal 50 micron thick polyurethane finish coat. The decking shall be of approved proprietary manufacture suitable for long maintenance-free life and adequate to withstand the climate and Site pollution conditions. Decking shall be coated both sides of sheets.

Samples of the proposed decking shall be submitted to the Engineer for approval. No orders shall be placed with manufacturers until approval has been given. Flashings shall be formed of the same material as the metal deck units. Externally exposed flashings shall be finished with an approved colour.

Care shall be taken to prevent bi-metallic corrosion occurring by the use of heavy PVC adhesive tape between the sheeting and the supporting rails, and by the use of fasteners and fixings of suitable materials. The PVC tape shall overlap the edges of the purlins by at least 15 mm along their full length.

All fixings shall be stainless steel and designed to withstand the maximum predicted loading with a factor of safety of 2.0. Calculations shall be submitted to the Engineer for approval. Where metal decking provides the exposed surface the slope of the roof shall not be flatter than 1 in 10.

The edges of all sheets, including cut ends, holes, etc., shall be taped, painted or otherwise protected from corrosion to the satisfaction of the Engineer. All side and end laps of sheets as laid, trimming pieces and flashings shall be sealed with mastic strips or as otherwise recommended by the manufacturer.

31.4 Workmanship Installation of the work of this section of the specification shall be carried out while a Construction representative employed by the manufacturer is on site in an advisory capacity. All installation shall be in accordance with the manufacturers erection drawings.

The completed wall and roof coverings shall be completely watertight and nearly finished with no unsightly variations in line or plane and without scratches, dents or other defects.

31.5 Holes Through Cladding Holes through walls for passage of pipes and cables must be sealed and weatherproofed in professional manner. Cover plates and collars must be purpose made of materials, which are compatible with the cladding and allow for differential movement.

31.6 Fasteners, Flute, Closers & Flashings Fasteners shall be of a type and material to ensure full structural capability of the installation during fixing and while in service. Only approved fasteners shall be used.

Closures shall be fabricated from black polyurethane to suit unit configuration. Closures shall be applied as required for a weather tight installation.

Flashings shall be fabricated from materials of the same material colour and finish as the adjacent components. Flashings shall be supplied as per approved drawings.

Documents

Federal Electricity & Water Authority Water Directorate ... General Specs for...BS 2853 The design and testing of steel overhead runway beams. BS 5395 Code of Practice for Stairs BS