schedule 43 - brighton & hove city council · • steam turbine, generator and associated steam...

CONFORMED COPY

OF THE PRINCIPAL CONTRACT DATED 31ST MARCH 2003

AND THE AMENDMENTS TO THE PRINCIPAL CONTRACT

PURSUANT TO THE DEED OF AMENDMENT DATED 28TH MAY 2003

SCHEDULE 43

CONSTRUCTION COMPETITION SPECIFICATION

Energy from Waste – Technical Specification

Part 1 Specification – Electricity and Heat Recovery Facility This specification covers the main design requirements for the Energy from Waste Plant principally relating to the systems and facilities.

The main contents are:

• Performance and Operation Requirements • Architectural Concept and Drawings • Combustion Process, Boiler and HP Pipework • Steam Turbine, Generator and Associated Steam Systems • Flue Gas Treatment Equipment, Ash and Metal Separation • Electrical Systems • Instrumentation and Control • Distributed Control System • Other Facilities • Civil Engineering and Building • Detailed Civil Engineering Specification • Construction Requirements

Part 2 Specification – Civil Engineering and Building Specification This part of the specification covers the building works, fabric of the building and services. It details the minimum acceptable standards and includes principally the following:

• Mechanical Services • Electrical Services • Excavations • Structural Steelwork • Fixtures and Fittings • Civil and Building Works

Schedule 43 of 1

Purchaser EFW Contract

SPECIFICATION:

ELECTRICITY and HEAT RECOVERY FACILITY

EAST SUSSEX AND BRIGHTON & HOVE CITY COUNCIL

ESCC/B&HRev1 1 Specification

Purchaser EFW Contract Contents

1 Introduction 1.1 General 1.2 Design Philosophy 1.3 Scope of Work and Services supplied by the Contractor 1.4 Performance Requirements 1.5 Operational Requirements 2. Detailed Technical Requirements 2.1 Architectural Concept and Drawings 2.2 Access, Tipping and Waste Handling Facilities 2.3 Combustion Process, Boiler and HP Pipework 2.4 Steam Turbine, Generator and Associated Steam Systems 2.5 Flue Gas Treatment Equipment, Ash and Metal Separation 2.6 Electrical Systems 2.7 Instrumentation and Control 2.8 Distributed Control System 2.9 Other Facilities 2.10 Civil Engineering and Building 2.11 Detailed Civil Engineering Specification 3. Construction Requirements 3.1 Design and Construction 3.2 The Site 3.3 Regulatory Requirements 3.4 Health and Safety 3.5 Project Documentation 3.6 Spares and Warranties Appendix A Weighbridge SpecificationAppendix B Mass Balance, Energy Balance, Service Life Schedule, and Data Sheets Appendix C Architectural Concept Drawings Glossary of Terms

ESCCBH_EFWSpec_Rev1.doc 2 Specification


1. INTRODUCTION 1.1 GENERAL The Intent and spirit of the Contract is to provide for the Works herein specified within the Contract dates and Contract Price, in every detail for the purpose designed and it is hereby understood that the Contractor, in accepting the Contract, agrees to furnish everything necessary for such purpose notwithstanding any omission in the drawings or specifications. The Contractor shall prepare a detailed Project Quality Plan, which shall be subject to approval by the Purchaser. The Project Quality Plan shall detail, but not be limited to, the following: the design, construction, manufacture, welding, inspection, testing, installation and commissioning of all items within the Works. The Contractor shall comply with all elements of this Specification and deviations or variations from this Specification shall only be permitted with the written approval of the Purchaser. The Contractor shall comply with the conditions of the Site Lease, the Environmental Protection Act 1990, the Waste Incineration Directive and all other Statutory Legislation. Onyx intends to build a new Energy from Waste Plant at the following preferred site subject to granting of planning permission and at the following base capacity: • Newhaven, North Quay 1 x 28 tonnes per hour The Plant will form part of an integrated waste management scheme. The Plant shall be designed to burn municipal solid waste. The plant shall be designed to maximise the quantity of electricity generated, and subject to confirmation by the Purchaser, a quantity of heat exported to a District Heating Network yet to be identified. The plant design shall allow the possibility to install, in the future, a second incineration line in a parallel configuration. The Contractor shall take special care on this point and shall not install heavy equipment on this provisional additional plant location without the approval of the Purchaser. This Specification covers the main design requirements for the Energy from Waste Plant.


Purchaser EFW Contract 1.2 DESIGN PHILOSOPHY The Plant shall be designed for a service life of at least 25 years from Takeover. The Contractor shall organise the following meetings with attendance by representatives from the Purchaser and the Project Manager: • HAZOP Reviews • Main Purchase Order Meetings • Design Reviews The Plant shall comply with the standards in the following order of precedence:

1. Standards referenced in this Specification 2. British Standards and British and UK Codes of Practice 3. Alternative Standards proposed by the Contractor which shall be approved in writing by the Purchaser.

Adherence to the applicable standards shall not be confined to the manufacture of equipment and civil works but also extend to the regulations governing the construction and commissioning of the Plant and include, but not be limited to, the following: • Management of Health and Safety at Work Regulations • Manual Handling Regulations • Management Regulations • Reporting of Injuries Diseases and Dangerous Occurrences Regulations (RIDDOR) 1995 • Construction (Design and Management) Regulations (CDM) • The Workplace Health and Safety Welfare • The Workplace Equipment Regulations • Site Noise Requirements • Building Control Requirements • Fire Codes • COSHH Regulations • The Construction (Health and Safety and Welfare) Regulations 1996 All phases of the Works shall comply with the relevant terms of the Planning Permission. The Contractor shall be appointed as "Principal Contractor" in compliance with the CDM Regulations.


Purchaser EFW Contract 1.3 SCOPE OF WORK AND SERVICES SUPPLIED BY THE CONTRACTOR The Contractor shall be completely responsible for the site preparation, the design, manufacture, supply, works testing, transportation, delivery to site, unloading at site, construction, painting, commissioning and putting into commercial operation, and testing for performance and reliability up to and after Takeover of the new Plant comprising, but not limited to, the following basic elements: • Presentation of a project as defined in this Specification and the Tender requirements. • The complete execution of the works allowing the Acceptance by the Purchaser of a

“turnkey” type installation in full working condition and including the installation at the worksite, the supply and transport to the worksite of all necessary materials and equipment, together with their implementation or assembly, and namely:

The installations for the reception and handling of waste materials: weighbridges, tipping hall and waste handling area, overhead cranes and grabs. Incinerator furnace, waste heat boiler, the condensing turbogenerator, and air-cooled condensers together with all required ancillary equipment. Installations and equipment for the extraction, evacuation and storage of residues. Gas treatment and purification systems including coolers, dust extractors, induced draught fan as well as a chimney for the removal and dispersion of flue gases. Installations and equipment for the extraction, evacuation, storage and packaging of flue gas treatment and purification residues Control System. Boiler Water Treatment Plant and Laboratory. Fire Tank and Pumps and associated Fire Systems to NFPA requirements. Transformer and Switchgear. LV Transformers and Switchgear. Standby Electrical Supply. Plant and Instrument Air. Export/import Connection to 33kV metering circuit breaker and Onsite Compound. UPS. Air conditioning of electrical rooms, control room, management offices and conference room. Mechanical Ventilation Systems for technical rooms. Natural Ventilation system for boiler hall. Fuel Tanks and Delivery Systems (subject to the re-use provisions in 1.1). Site Circulation Roadways and Entrance/Exit Roadways and Ramps. Management Offices, Amenity Facilities, Mess, Washing and Changing Facilities.

• The loading diagrams and plans, foundation plans, equipment and civil works and associated guidelines

• The file of works completed, the starting-up of the installation, and the tests carried out during works and performance tests

• The remuneration for the services in particular includes: contract management of a “turnkey” type principal installations contract, co-ordination of works with sub-contractors, the start-up, maintenance and operating costs of all provisional construction works necessary for completion of the works

• All design costs • All ancillary costs arising from materials acceptance testing and inspections and all checks,

including the review of works plans as per Building Regulations and other regulations and including pressurised appliances, handling equipment, electrical installations, etc

• List of spare parts for two years



• Expenses related to functional tests of equipment (3rd party tests will only be required to the extent required by law, codes and statutes)

• All cost of lighting, signposting and marking for the site, the equipment and materials stores • All patent costs • All costs resulting from the supply and installation of those protective devices required by law

including works legislation • All taxes and duties together with Contractor profits, but excluding value added tax (VAT) • Responsibility for the organisation of traffic, cleanliness of roads, equipment deliveries in

relation to the Contractor’s activities. • Burdens resulting from the provisions required to observe building site regulations • The works which the Contractor may be required to undertake to ensure that the Works are

completed satisfactorily. • The initial provisions of consumables such as oils, greases, printer paper, listing paper, etc • The implementation of road and utilities connections . • The supply and installation of a worksite notice board giving notice of the nature of the

works, the Purchaser, the Project Engineer, and Control and Monitoring Company(ies), the Contractor and all Sub-Contractors

• The supply in sufficient number of all documents necessary for the Works • The application for and receipt of Building Regulations approval • The construction of the Plant in accordance with the Planning Authority, the Environment

Agency and Statutory and Regulatory Authorities • The installation and withdrawal of equipment from the Site and laydown areas, upon

completion of the Works. • Sound attenuation protection to equipment in all technical rooms and to meet the noise limits

identified in Schedule 7 • Contractors personnel during commissioning • Consumables and utilities during commissioning • Connection to the existing water supply The Plant shall be capable of achieving the requirements, levels and standards of performance set out in this document. The Contractor shall provide all the necessary operation materials, lubricants, chemicals, raw materials, consumables and fuel other than municipal waste up to the time of Takeover. The Contractor shall be responsible for providing the Purchaser with all special tools required for maintenance and repair of the Plant, and in particular, but not limited to, a mobile bridge to access the furnace during maintenance periods, and provision for a suspended platform for inspection of inconel cladding. In general, provision shall be made for access where this is required every 6 months or more frequently. The Plant layout shall be chosen to ensure that waste combustion takes place in the best possible conditions of hygiene, safety and efficiency. The general layout, the choice of equipment, centralisation of control and monitoring devices, simple and rational automation shall all be considered in order to maximise operational efficiency, optimise personnel requirements and avoid contact with the waste brought to the plant. The plant shall be designed such that the boiler, FGT residue and bottom ash extraction and loading areas are not recessed below floor level to enable clear access for forklift and other vehicles from site ingress and egress levels. All requirements specified in this document shall be adhered to by the Contractor unless specifically exempted and agreed in writing by the Purchaser. The Contract Price shall exclude revenues derived from electricity sales, and waste gate fees


Purchaser EFW Contract derived prior to Takeover.


Purchaser EFW Contract 1.4 PLANT PERFORMANCE The Contractor shall design the plant for a 30 year operating life. This shall be achieved by use of the appropriate design parameters, codes, standards and specifications and the selection of suitable equipment, materials and methods of construction. The Plant shall be designed to process Acceptable Combustible Waste which will comprise, the following waste types: • Unsorted waste including items up to 900mm by 700mm by 700mm in size and not

exceeding 250kg in weight in the following categories: -Collected Household Waste and Commercial Waste (excluding loads of Commercial

that is inert in nature) -Grey Waste and Waste that is of a confidential nature (in either case where suitable for

combustion) • Combustible Waste shall include Collected Waste after the removal of Collected Dry

Recyclables, Biowaste and/or Green Garden Waste. • Solid household waste: such as rubbish and refuse normally collected and disposed of

by residential households and commercial, institutional or industrial establishments which may comprise: leaves, twigs, glass, metals and other constituents that normally appear in household refuse and, certain wastes which are difficult to process such as leather or automotive waste when mixed with other Acceptable Wastes

• Solid combustible waste arising from segregated HWRC waste • Solid industrial waste, in so far as it is of similar composition of household waste • Any of the above waste, after storage in bales • All the above waste types may be delivered to Plant. The Plant shall be designed to burn all of these waste types. The following waste shall not be considered as Acceptable Waste: • sewage sludge, spoils, screenings, debris from waste water treatment plants • rubble and materials rejected from rubble sorting • waste liquids or bulk liquids from industrial processes or commercial premises • Infectious wastes or human or animal body parts from hospitals or clinics, wastes from

slaughterhouses and special wastes which cannot be treated by the same means as municipal waste without risks to people or environment because of their flammability, toxicity, corrosivity or explosiveness.


Purchaser EFW Contract The Plant shall meet the following design conditions: Site Newhaven – North Quay Design capacity based on 8000 hrs 220.000 tpa Plant Design Capacity (MCR) 28 tphr Design Waste Net Calorific Value (MCR)

9.2 MJ/kg

Waste LCV range **MJ/kg Base Stream Arrangement

single stream 1 x 28 tphr

Export/Import connection and voltage 33kV connection provided by Purchaser. Water Supply

Existing Towns water supply

Cooling Supply Air Condenser at 10°C reference temperature Demolition Existing amenities and clinical incinerator to be

demolished 11kV Standby Supply Not Used Weighbridge Automated to allow control from plant control

room and local cabin 1 x entry 1 x exit

Crane/Grab

2 sets of equipment

The Contractor has been invited to assess the calorific value of the Acceptable Waste and estimate what parameters should be used. The Contractor shall identify the effect and bottlenecks of operating the plant at the design waste throughput but with a waste calorific value of 110% of design. The effects on the each element of the process: furnace, boiler, steam plant, flue gas treatment equipment shall be documented. The steam turbine shall have the provision for a steam takeoff flange that shall be used to provide steam for the district heating. The Contractor shall ensure that adequate provision and space is provided in the Plant layout to enable district heating equipment, exchangers and pipework to be installed. The layout shall be reviewed by the Purchaser. The Contractor shall provide in the form of a graph, the quantity and temperature of the maximum district heating load that can be accommodated and the resultant reduction in exported electricity. Mass Balances, Heat Balances, Service Life Schedule, and Data Sheets are contained in Appendix B. Noise level studies shall be carried out on the following elements to ensure adherence to the guarantee levels detailed in Schedule 7:

-turbogenerator -bottom ash ferrous metal separator and large item separator -turbogenerator oil cooling system -fluestack -fans -transformers



-boiler water feed and condensate pumps -overhead cranes -air compressors -soundproofing to the turbogenerator room -soundproofing to technical rooms defined as the following: workshops, laboratory, stores, water treatment room, pump rooms, compressor rooms, electrical and instrument rooms -soundproofing to the offices and control rooms


Purchaser EFW Contract 1.5 OPERATIONAL REQUIREMENTS The Plant shall operate 24 hours per day, 7 days a week all year round except for planned outages and be designed for the minimum of downtime. The Plants shall be designed to maximise electricity or heat export at 100% MCR. The tipping hall and waste handling equipment shall be designed to function as a transfer station. Therefore the area and equipment shall be designed to enable bunker waste to be backloaded into articulated vehicles in the event of extended maintenance and. The Contractor shall design the Plant and associated facilities to take account of the requirements of the staff levels required for operation and maintenance , weighbridge, clerical/admin and plant management . The Plant shall be automated sufficiently to enable a two person operator shift staff to operate the Plant. The two waste cranes shall be designed to operate simultaneously. The Plant shall be designed to operate for extended periods at 100% MCR in island mode with steam dumped to the condensers with an ambient temperature of up to 30ºC. Suitable noise suppression shall be allowed in the design of the Plant to ensure that the noise level at the site boundary is in accordance with the requirements in Schedule 7. Load rejection testing shall confirm the turbogenerator operation is stable when going from full loading to island mode. The Plant shall also be designed with an emergency generator sufficient to safely shut down the plant. All metering, associated equipment and protection systems shall be designed to meet the requirements of:

• G59/1: Recommendations for connection and protection settings for embedded generating plants <5MW

• G75: Recommendations for the connection of embedded generating plant to public electricity suppliers distribution systems above 20kV or with outputs over 5MW

• Code of Practice 2: Code of Practice for the metering of circuits with a rated capacity not exceeding 100MVA for settlement purposes

Code of Practice 4: Code of Practice for the calibration, testing and commissioning requirements of metering equipment for settlement purposes



2. DETAILED TECHNICAL REQUIREMENTS 2.1 ARCHITECTURAL CONCEPT The Purchaser includes Architectural Concept Drawings prepared by Purchaser’s Consultant which are to be used by the Contractor to develop the detailed design and these are contained in Appendix C. For the avoidance of doubt, the Contractor shall comply with the requirements and concepts in the drawings and shall be solely responsible for the detailed design of the Plant and no deviations or claims or variations will be considered by the Purchaser in this respect. The Contractor is permitted to propose modifications as agreed in writing with the Purchaser. The Contractor shall be responsible for the detailed design of the Plant. 2.2 ACCESS, TIPPING AND WASTE HANDLING FACILITIES 2.2.1 Plant Access The following vehicular access shall be provided to the Plant: • Tipping hall for waste deliveries • Bottom Ash and FGT Residue collection vehicles • Vehicle access for maintenance purposes • Vehicle access for reagent and consumables deliveries • Vehicle access to staff parking areas • Allocated parking spaces for 2 Articulated Trailers Acceptable combustible waste shall be delivered to the site by the Purchaser. The Plant storage areas shall segregate the dirty and dusty bottom ash and ferrous storage bays. Wheel wash facilities shall be provided for all site vehicles to ensure clean and dirty areas and bays are contained. In addition a fuelling area shall be provided for off-road and site vehicles. The Contractor shall ensure that the layout of the plant and equipment enables forklift access to all necessary areas. 2.2.2 Weighbridge and weighing software A computerised weighing facility shall be provided which complies with the requirements of The Environmental Protection (Duty of Care) Regulations 1996 and Customs and Excise Requirements. The equipment shall record and issue waste transfer tickets with the following details: tare weight, gross weight, net weight, waste type, carrier, vehicle registration, vehicle type, etc and as required by the Principal Contract with East Sussex County Council and Brighton & Hove City Council. Two 18 metre weighbridges shall be provided, one on incoming and one on outgoing roadways. The following equipment shall be provided: barrier induction loops, traffic lights, weighing terminal including: weatherproof casing, electrical heater, digital display, tag reader, ticket printer, entrance and exit barriers, two way intercom system. Vehicle identification shall be achieved using radio frequency/proximity tags. These tags shall have been used in similar situations. An automatic weighing system which interfaces with the Sabre 8000 shall be installed comprise the following: one digital weight indicator, one complete Pentium Windows based


Purchaser EFW Contract computer , one printer for summaries/reports, one floppy disc reader/writer for data saving, hardware, twin weighbridge computer input screens, CCTV of weighbridge. A modem link shall be installed to enable weighbridge information to be transferred to other Purchaser facilities. The weighbridges shall be preferably visible from the CCR and CCTV of front and rear of the weighbridge shall be provided in all cases. Audiovisual communication shall be provided between the weighbridge and the CCR. Typical weighbridge details are found in Appendix A. In addition to the weighbridge administration facilities with the CCR, a duplicate automatic weighbridge system shall be installed at the weighbridge administration/security gatehouse which is provided with additional weighbridge inputing facilities and site cameras and display monitors. This weighbridge/security gatehouse shall have the following facilities: an office and a toilet with washbasin, heating and lighting and 240V mains. Weighbridge electrical supplies shall be taken from the emergency distribution board. 2.2.3 Tipping Hall The hall shall be installed with electrically operated incoming and outgoing sliding doors with a height clearance of 8 metres and capable of being controlled remotely from the CCR and locally. The Contractor shall provide details of the doors for review by the Purchaser. Air for combustion shall be drawn through the building to minimise odours. The shutter doors shall be capable of withstanding air pressure loading when closed. The tipping hall shall have unloading bays for acceptable combustible waste. The turning area and unloading bays shall be suitable for the unloading vehicles commonly used for the transportation of waste such as, but not limited to, the following:

-Conventional Refuse Collection Vehicles (RCV) -80m³ articulated vehicles -Walking floor type transfer station vehicles -Rolonofs tipping and drag type -Commercial waste in containers and skips with allowance for hook lift -Compactor trailers

The Contractor shall provide large enough tipping hall for the waste capacity of the Plant and to ensure vehicle turnaround is as fast as possible. Traffic lights shall be provided to control traffic flows and avoid congestion. Particular attention should be paid to avoidance of queuing on the ramp and associated roadways. Unloading bays shall be provided with bollards and raised kerbs to enable vehicles to reverse safely. The raised kerbs shall have a notch to allow waste to be brushed back into the bunker. Red/green lights shall be installed to indicate which bays are operational and designed to be clearly seen by reversing vehicles. Any structural steel columns shall be protected from fire and from damage from refuse vehicles in the tipping hall and from crane/grab movements in the bunker. The Contractor shall provide Armco or equivalent to all other areas where damage is expected. Water floor wash facilities shall be provided around the feedchutes. The tipping area shall have a power floated hardened concrete surface to accommodate front loading shovel activities at unloading bays. The tipping hall shall be well lit to enable efficient delivery operations to take place.


Purchaser EFW Contract Pushwalls shall be provided as indicated on the pushwall drawings in section 2.11 Detailed Civil Engineering Specification. 2.2.4 Waste Bunker The fully enclosed waste bunker shall include a solid concrete wall directly above the raised curb between the tipping hall and the bunker areas (as constructed at SELCHP) and shall be designed to provide 3 day storage as a minimum at normal waste discharge level without stacking. Further capacity shall be accommodated by readily stacking waste above the vehicle unloading level, without it emerging from the bunker. Waste delivery vehicles shall offload waste from one side of the bunker. The bunker width shall be at least twice the maximum diameter of the grab. The bunker shall be designed and constructed as an “aqueous liquid retaining structure” to BS 8007. The bunker and structure directly above shall be designed with no horizontal shelves and ledges to avoid dusts and refuse collecting. The Contractor shall provide smoke vents in the bunker area. Roof vents/louvres shall be designed for a maximum differential temperature of 10°C between inside and outside conditions. 2.2.5 Travelling Crane and Grab Travelling CraneEach crane and grab shall be designed to transfer the Plant’s daily waste capacity into the feed hopper in a 16-hour period. In addition, the crane and grab shall be capable of further continuous operation for the remaining 8 hours of the day for lifting, moving, mixing, casting and stacking waste in the storage bunker. Continuous operation of each crane shall be clearly demonstrated and tested during the Reliability Testing Period prior to Takeover. Two identical travelling cranes shall be supplied, designed for heavy duty class incorporating well proven features developed especially for waste grabbing duty ensuring continuous highly reliable service and availability in a dusty atmosphere. The capacity of the grab shall be based on a maximum of 30 grab loadings per hour during the 16-hour period. The crane controls and relays shall be located in a control panel near the crane laydown area/tipping hall. The Contractor shall ensure that a suitable crane and grab parking and laydown area is provided and that either of the cranes can continue to feed the hopper while the other crane is undergoing maintenance. The travelling crane and grab shall meet BS 466 and BS 2573 latest editions as a minimum with the highest classifications:

Crane as a whole - A8 Class utilisation - U8 Group Class - Q4 Mechanism Classification. Hoist - M8 Bridge - M7 Trolley - M7 State of Loading - L4 Class of utilisation - T8


Purchaser EFW Contract The travelling crane of a double beam type resting on 4 wheels, two of which are driven. Each driven wheel is actuated by one geared motor-brake unit. Anti-collision devices shall be provided for safe operation. A maintenance gantry and access way on both sides shall be provided on each crane together with anti-personnel limit switches. All crane travel limit switches and drives shall have visual indication of being tripped out. The crane shall be capable of manual, semi-automatic and fully automatic operation. The crane operator shall be able to direct and discharge the grab automatically into predetermined feed hopper positions once the grab is loaded (semi-automatic function). The crane shall be complete in all respects including software, instrumentation and mechanical equipment. The crane operator station shall allow clear unimpaired vision of the waste bunker and vision directly below the operator station. The crane operator station shall be incorporated into the Central Control Room. The crane operator station glass panel shall have 2 hour fire protection through water spray and/or fireglass. The glass windows shall be designed to enable the manual cleaning of both sides of the window from within the crane operator station. The feed hoppers shall be monitored by colour CCTV cameras and displayed in the crane cabin. Each crane shall be designed to have access to all areas of the waste bunker. Two of the offices detailed in section 2.10.20 shall be provided adjacent or on the same floor as the CCR.. The crane operators’ chair shall be ergonomically designed and capable of swivelling to all orientations necessary. It shall enable the chair to be replaced easily without the removal of the control harness. Traffic lights and management systems shall be duplicated on each crane operator control console. The hoisting ropes shall be specified to be widely spread between the trolley anchorage and drum mounting position. This is to attain the widest possible rope fleet angle to improve the crane's resistance to grab spinning. The hoist drum grooving shall be specified to be surface hardened to 500 Brinnell Hardness and optimised with rope material hardness to produce a satisfactory life for the drum and so as not to cause excessive rope wear. These features shall ensure long life and lower stress fatigue induced by arduous continuous grabbing activity. Special features including limit switches shall also be incorporated to prevent ropes double winding and fouling on the drum. The grab shall be connected to the crane block with high tensile bolting. The Grab The electrical connection between the crane and the grab shall be hard wired without sockets and be highly durable and well proven. The layout of the cranes shall allow for the effective maintenance of each crane grab. As detailed in figure 1, the maintenance area shall allow for the grab to be lowered to ground level for transportation to the appropriate laydown area or off-site. The crane grab shall be capable of simultaneous operation in two directions in the horizontal plane whilst operation raising and lowering the grab in the vertical plane. Semi-automatic control of the crane shall be provided which includes combined motions of the crane to minimise grab swing. The Contractor shall ensure the safe segregation of the two operational cranes. The grab shall be fitted with visual indication of being tripped out. A load cell based weighing system for the grab shall be provided to enable the operator to record the weight of each grab load before discharge into the feed chute. The weighing system shall have an accuracy better than 2.5% and be displayed in the crane operator station and


Purchaser EFW Contract connected to the DCS. 2.2.6 Feed Hopper The dimensions of the hopper shall be greater than those of the grab when fully open and sufficient clearance shall be provided around the grab during feeding operations. The feed hopper shall be designed to avoid jamming. In the event of a jam, there needs to be easy access to remove the obstruction. Lifting beams and electric winches shall be fitted above each loading hopper to enable the removal of blockages from the furnace feed mechanism. The lifting beam shall be rated at SWL 2 tonne minimum. The feed hopper perimeter shall be surrounded by 1.1m high above floor level solid balustrade at least 150mm thick on three sides to allow access for manual stroking in the event that the hopper becomes obstructed by bulky waste. All other edges to the upper feed hopper floor area shall be fitted with 1.1m high above floor level heavy duty steel railings of 150mm diameter/concrete balustrades at least 150mm thick to act as physical and safety protection for personnel as regular access in this area is required. Sufficient access hatches, fitted with a handling system to enable easy opening and closure and grab laydown areas shall be provided to enable both grabs to be transported to tipping hall level. A general arrangement showing the balustrades and the overall arrangement shall be submitted to the Purchaser for approval. Efficient hoists and lift systems shall be provided for maintenance of the crane and grab between hopper floor level and tipping hall level. A back-loading hopper shall be provided by the Contractor. Access to Maintenance

Hatch and Grab Laydown Area

Feed hopper Bunker So15

lid balustrade 0mm thick

Heavy duty steel or concrete railings at least 150mm thick

Hopper to enable backloading of waste

to bulker vehicle below


Purchaser EFW Contract 2.3 COMBUSTION PROCESS, BOILER AND HP STEAM PIPEWORK The Contractor shall provide a furnace with the ability to combust fuel without leading to excessive slagging or fouling and with an online cleaning system such as rappers and sootblowers (either semi or fully retractable type). If sootblowers are fitted, they shall operate intermittently and be designed not to reduce Plant net electrical output by more than 1.0%. The Contractor shall design the plant in all respects to operate at 6% O2 and to meet the performance improvements at 6% O2. The current guarantees in Schedule 7 paragraph 7.4.2 are based on 7.5% oxygen levels and in the event of favourable experience gained from operation at lower oxygen set points at other Plants operated by the Contractor, the Contractor shall link these improvements in the guarantees of performance, efficiency, plant lifetimes and electricity generated in line with any reduction in the oxygen set point. 2.3.1 Moving Grate The moving grate shall be suitable for the combustion of all wastes identified in Section 1. As with the design of the whole Plant, the grate shall be designed to operate safely and efficiently over a 30-year design life with minimal maintenance. Residence times shall meet the requirements specified in section 1.4. The grate shall consist of reciprocating bars slowly stirring and mixing the waste in order to give good mixing, combustion and flame position control. The stroke of bars shall be adjustable. The grate bars shall be designed to be self-cleaning and avoid the build up of clinker residue. The grate shall give consistently good performance with a wide range of waste types and have a long trouble-free life. The Contractor shall provide data on the grate life and operating temperatures and give details and full costs of spares and equipment required over the design life. The grate shall be designed to accept possible future water cooling, in case of LCV increase. The Contractor shall be responsible for designing effective combustion and airflows through the furnace. Combined primary air and secondary air fans shall be direct shaft driven by the motor and provide combustion air to the furnace. The air fans shall be motor driven and draw air via the air heater (at low steam pressure) from the waste bunker to ensure that odours and dusts are drawn into the incineration stream and prevented from escaping directly from the tipping hall into the environment. At least, the following furnace parameters shall be controlled from the DCS:

• quantity of undergrate air in each zone • speed of grates • speed of feeders • quantity of secondary air • burner operation

Flow measurement of the primary air shall be with equipment designed for a dusty environment and be self-cleaning. The Contractor shall present whole life cycle assessment costs in the choice of refractory material. The tube walls in the flame area are to be covered with high quality refractory retained


Purchaser EFW Contract bysuitable anchors. Inconel overlay and wear tubes shall be considered for all the first pass (roof included) in order to minimise corrosion and improve life.. The Plant design shall take into account this overlay. The grate bars shall be manufactured from high-grade chrome cast iron alloy capable of good longevity, withstanding high temperatures and being easily removed and replaced. The Contractor shall specify life and replacement profiles. The grate bars shall be powered in such a manner as to provide variable control of the reciprocating or rotating movement. The hydraulic mechanism shall be filled with fire resistant oil. Hydraulic equipment shall be to high quality standards to minimise leaks. The Contractor shall ensure that such fittings can be purchased locally. Good quality, fine mesh strainers shall be provided in the hydraulic system. A waste hydraulic oil storage tank shall be provided and suitably piped for draining down the hydraulic system. All lubrication for the grate, feeder and discharger shall be centralised for ease of maintenance. Operation of auxiliary burners shall be protected by the effective and reliable use of flame protection cells to specifically monitor the burner flame as opposed to the waste combustion. The grate ash and boiler ash streams shall be collected together to constitute bottom ash. However the Plant shall possess a flange connection that enables boiler ashes to be collected separately. The Contractor shall ensure that the boiler design allows the future modifying and easy separation of the boiler ash from the bottom ash by directing the boiler ash to the FGT residue using suitably designed conveyors. The Contractor shall submit the conveying arrangement to the Purchaser for review prior to construction. The Plant shall possess thermowells positioned on the front and back walls of the furnace to monitor fire positioning in the combustion chamber. Provision in the furnace shall be made for the installation of infrared cameras and associated equipment in order to monitor the furnace fire. The DCS shall be compatible with the future installation of infrared cameras. In order to meet the NOx emissions limits, the Contractor shall install SNCR. These systems shall be integrated with the DCS. The Contractor shall provide full details of the proposed DeNOx processes. Systems shall be of proven design and operational in Europe. The SNCR system shall at least include: a duty and a standby pump arrangement, filtration, preparation vessel, instrumentation, injection lances for long life operation in the furnace, quick connection fittings for ease of maintenance, all necessary strainers, non-return valves, isolating valves, loading valves, and piping. Automatic changeover to the standby system, should the duty system fail in service, and shall be provided complete with all necessary controls/electrical items and alarm indication. The SNCR reagent shall have at least a 3-day storage capacity. Where the SNCR system is based upon liquid Urea, the SNCR system shall include sufficient equipment to receive dry Urea prills in bulk and process this to provide liquid urea of the correct strength and quality. The water volume and quality requirements of this process shall be included in the plant water treatment systems. 2.3.2 Boiler Heat recovery shall be achieved by means of an integral water tube boiler. The boiler shall be designed for a steam outlet temperature of up to 400ºC. The boiler shall be designed for 100% MCR and a 250,000 hours operating life in accordance with BS 1113 and resist erosion and corrosion.


Purchaser EFW Contract The boiler shall be designed with a 10% temporary overload above MCR for 1 hour in every 24 hours. The Contractor shall declare the boiler design philosophy including time at temperature, pressure and temperature cycling and testing. The Contractor shall provide the complete boiler design file with his O&M manuals. The Contractor shall also provide with the O&M manuals the overall maintenance requirements. The boiler shall be of horizontal type with rapping cleaning system. The boiler shall be designed such that no manual cleaning shall be required before 8000 hours of continuous operation. The boiler shall be of regulated temperature type, with automatic regulation of flue gas outlet temperature according to tubes fouling. The boiler tube thickness shall include a declared corrosion allowance. The boiler and associated equipment shall be of the type and quality suitable for municipal waste incineration plant service and shall be a well proven design. The boiler shall meet the steam requirements of the turbine generator as well as all other steam requirements of the Plant. Boiler tube minimum thicknesses are detailed in Appendix B Data Sheets. All the boiler first pass, including the roof, shall have Inconel overlay. It shall be the Contractor decision to execute these works either on site or directly in the workshop. The boiler fabrication shall be maximised at the supplier’s works to minimise fabrication and installation work at site. The Contractor shall design a boiler, which shall incorporate:

-exit temperatures to avoid excessive fouling in the furnace -combustion chamber sized for low gas velocity and long residence time -adequate spacing of tubes in the tube banks to prevent bridging of tubes by fouling and allow access for repair -cleaning of boiler pressure parts by methods of well-proven design. If provided, sootblowers shall be of the semi-retractable type. -superheaters providing steady steam temperatures matched to turbine operating conditions -system to control and maintain a steady boiler outlet flue gas temperature during all operating periods

All vessels within the steam circuit, including condensate drum and deaerator shall be designed to BS 5500 Category 2 with NDT reviewed by the Purchaser. The boiler drum shall have at least two independent water level gauges and comply with BS1113 section 7.3.1. The Contractor shall state the full and part load steam conditions, which at least shall be met. The boiler shall be insulated to ensure that the surface temperature is not higher than 50°C. External cladding shall be minimum 0.75mm aluminium. The superheater shall be installed with the inlet and outlet headers located outside the flue gas stream. Deadends shall be avoided in the design of the boiler. Access doors and inspection holes shall be provided to enable satisfactory access to the convective passes and to enable the furnace to be observed. These inspection doors shall be


Purchaser EFW Contract suitably large enough to enable on-line cleaning with high-pressure water. Inspection doors shall be positioned face to face on the same horizontal plane and at waist/shoulder level relative to the walkways. Walkways shall be suitable for all maintenance, access and cleaning activities. 2.3.3 Steam and Feedwater Pipework All equipment and pipework shall be insulated to ensure that the surface temperature is not higher than 50°C. External cladding shall be minimum 0.75mm aluminium. The high pressure and low pressure, steam and feed water pipework shall be designed and manufactured in accordance with BS 806. Welding and testing shall comply with the Purchaser Quality Plan. All steam and feedwater pipework shall be adequately supported. Wherever possible, expansion shall be accommodated within the pipework arrangement. The Purchaser shall have the final opportunity to reject expansion joints. A cold water fill system shall be provided for leak testing. All pumps wherever located in the Plant shall be provided with adequate bypasses to avoid overheating in continuous operation against closed valve. Motorised vent valves on the boiler drums shall be provided with remote control from the DCS. Start up vents and safety valves shall be silenced by means of silencers to minimise noise emissions in the event of the following: start-up, shut-down, air cooled condenser trips, etc. Vents and drains shall be located to provide easy operational access and allow discharge to tundishes. Vent drains shall be fed back to the feedwater system via a suitably sized and located flash drum. Feedwater heating shall be provided to optimise the thermal cycle. Valves shall be positioned in vertical steam pipework wherever possible. The steam pipework shall be tested to ensure the integrity of all valves. A “double isolation valve and drain” philosophy shall be applied to the design of the steam system pipework and equipment to enable online maintenance of all main equipment items. All safety valves shall meet BS 1113 requirements and shall be to the approval of the Purchaser’s statutory boiler insurer. These valves shall be designed to adequately pass the required flow of steam and water without blowing back.


Purchaser EFW Contract 2.4 STEAM TURBINE, GENERATOR AND ASSOCIATED STEAM SYSTEMS 2.4.1 Steam Turbine Steam turbine shall be designed to API 612, NEMA SM 24 for piping forces and moments, and BS EN 60045. Deviations from these Codes proposed by the turbine manufacturer shall be subject to approval by the Purchaser. The Contractor shall state the forces and moments on the turbine in cold and hot conditions and state how the forces and moments due to dead-weight will be minimised. The steam turbine shall be designed for 110% MCR steam flow. A high efficiency turbine shall be specifically provided by the Contractor in order to maximise the electricity and, if notified by the Purchaser, heat generated by the EfW plant. The design shall be well proven in small and medium sized power stations worldwide. The turbine manufacturer shall demonstrate reliable operation of reference machines at the condensing conditions. Upon loss of the main 33kV export system whilst the turbogenerator is running, the turbine output shall automatically reduce in a stable manner to island mode without tripping. The preferred turbine shall be single or multiple cylinder, multistage, condensing type with a horizontal split design and axial or vertical flow design. Steam takeoffs shall be provided for plant use and, unless otherwise agreed with the Purchaser, to provide for the district heating take off. The Contractor shall advise the number, pressure and maximum flow of the district heating steam takeoffs. The turbine rotor shall be machined from a solid steel forged block. The turbine shall be designed such that the first and second lateral critical speeds are well outside the turbine running speed. The complete rotor shall be dynamically balanced. The Contractor shall state the vibration levels of each element of the steam turbine-gearbox-generator. All steam turbine inlet and exhaust pipework shall be fitted with an isolation valve and a ring position to enable an isolation spade to be inserted in order to fully isolate the turbine without shutting down the process. The valve shall be motor or pneumatically actuated and operate and seal effectively and the time from fully open to closed sealing position shall be less than 2 hours. The Contractor shall provide the spades and rings for each location. A bleed valve arrangement shall be provided between the valve and the ring position. All turbine casing drains shall have double isolation using master/martyr valving principles. The steam turbine, gearbox if applicable, and generator shall be located in a noise proofed area and be protected with a fire protection system. This shall also be to the satisfaction of the Local Fire Officer. If a liquid spray system is installed, the turbogenerator package shall be suitably designed for liquid deluge conditions such that there are no deleterious effects on the following: motors, lube oil tank vents, lube oil quality and control systems. Upstream steam pressure shall be regulated through the turbine by the governor-controlled steam admission valves. The governor valves shall operate sequentially to provide maximum efficiency corresponding with the design rating of the boiler at 100% MCR. The operation of the turbine and auxiliaries shall be interfaced with, controlled from and displayed on the DCS. The Contractor shall supply and install a full health monitoring system


Purchaser EFW Contract which can be externally interrogated via function analysers; recording devices and also by modem. A turbine maintenance crane shall be provided suitable for the lifting and removal of the elements of the turbine-gearbox-generator onto road vehicles. The crane shall be capable of lifting the heaviest element clear, including turbine rotor withdrawal, without disturbing the existing ducting, cabling and associated equipment from the rest of the turbine-gearbox-generator assembly except as agreed by the Purchaser. All special tools and lifting beams for the maintenance and overhaul of the turbine-gearbox-generator assembly shall be provided by the Contractor. Drains from the steam pipework and casing shall be provided to heat the turbine casing from cold within 2 hours. All pipework sections between boiler drum and turbine shall be subject to a steamblow procedure to be agreed between the parties. A calculation shall be presented no later than 12 months after notification to proceed tabulating the steam flows, pressures and disturbance factors to be achieved at inlet and outlet of each pipework section during the steamblows. In addition the turbine shall be protected with inlet steam strainers during commissioning and start-up. All necessary steam blow-down pipework and silencers shall be provided by the Contractor. The turbine foundation shall be designed using a three dimensional dynamic calculation to DIN 4024/BS 4675 Part 1 Class IV as well as to the approval of the turbine maker. Combined stop and emergency valves shall be provided on the inlet and extraction pipework to prevent turbine overspeed in any circumstances. Inlet Governing Valves shall provide stable modulating control of the steam pressure at all loads. A gland steam exhauster system consisting of a condenser and fan exhauster shall recover heat and condensate to the feedwater system, while non-condensable gases are exhausted to atmosphere outside the building. The turbine oil system shall meet API 614 and shall supply oil for lubricating the turbine and generator main and subsidiary bearings as well as for hydraulic operation and servo-control of the governing and emergency valves. Deviations from API 614 proposed by the turbine manufacturer shall be subject to approval by the Purchaser. The main oil pump shall be ac electric and supply oil to the complete assembly for both lubrication and power control purposes. A standby pump shall be provided to start in the event of failure of the main pump. A dc or ac UPS rundown/cooling pump shall be supplied for safe stoppage in case of failure of the main pump. A high pressure control oil system shall be permitted. Lubrication oil shall be passed through one of two 100% heat exchangers and a duplex filter for removing particles down to at least 5 microns. A lube oil centrifuge shall be provided for lube oil conditioning together with fan extraction vented to the outside. The emergency dc or ac UPS driven pump which operates on low pressure in the event of both the main pumps being unavailable for maintaining bearing lubrication, and shall maintain effective cooling for a sufficient length of time, while the unit coasts to a halt and is mechanically or hand barred. The turbine shall be protected with a mechanical overspeed trip device and an electronic


Purchaser EFW Contract overspeed unit using speed sensors and operating a 2 out of 3 voting system. The subsequent loss of oil pressure causing the stop valves to rapidly close and the governing valves to close. The vacuum condensers shall be designed for full vacuum to protect against turbine trip. The reduction gearbox shall be designed to API 613 with minimum service factor of 1.1. The steam turbine shall be fitted with motor driven barring gear. Hand barring facilities shall also be provided independent of the ac motor driven barring gear. This barring shall be demonstrated to be easy enough for a single employee. Sufficient access shall be provided to achieve effective handbarring. 2.4.2 Generator The generator shall consist of a synchronous 2 pole or 4 pole totally enclosed cooling air-cooling water (CACW) machine excited by rotating diodes with no brushes or rings. The generator shall be designed for 110% MCR and a 0.8 power factor. The generator shall be designed for 120% overspeed with BS 2757 class F insulation. The generator shall comply generally with BS 5000 Part 2. The generator shall be mounted on a discrete baseplate which shall also accommodate a shaft mounted fan and which may be common with the turbine and gearbox baseplate. The exciter shall use a brushless rotating rectifier system and be mounted on the baseplate. Careful provisions shall be made to avoid any possibility of oil contamination of the windings from bearing leakage. The generator shall be supplied with appropriate excitation cabinet containing:

-auto excitation controller for voltage control, power factor -neutral point cabinet with current transformers, earth resistor with a homopolar detection core and connection terminals. -monitoring panel containing the following: line voltage meter, excitation ammeter, wattmeter, phase meter, frequency meter, duplex voltage meter, duplex frequency meter, a synchroscope, emergency stop switch, power factor control, voltage and current excitation control, automatic or manual control, control for turbine speed, generator voltage, generator power factor

Stator laminations shall be punched from low loss electrical sheet, coated with an insulating film, to minimise eddy current losses. The stator coil insulation shall be fully rated Class F. A minimum of six RTD's shall be embedded in the stator winding for sensing temperature. The synchronous rotor shall be of a solid, single piece construction in which the pole bodies, pole tips, spider and shaft are machined from a single steel forging. The machine rotor shall have Class F insulated strip-wound field winding applied to the pole bodies. After assembly the generator shall be run at rated speed, rated voltage and frequency for a final check to ensure vibration is within the required limits. Brushless Excitation System shall consist of a stationary exciter field, the exciter rotating element generating 3 phase AC power, plus the rotor mounted rectifier system. The field coil shall be wound Class F insulated, and vacuum pressure processed in epoxy resin. The armature shall be a laminated core supported by a spider, which has provision for mounting on the generator shaft and for mounting the converter on the armature. The laminated core shall be made up of resin enamelled magnetic steel punchings. The 3 phase armature windings are random wound coils that are coated with epoxy resin under vacuum pressure. The AC-DC converter shall be made up of solid state rectifiers mounted on revolving case aluminium heat sinks. The rectifier system shall consist of silicon diodes, thyristors and static switching devices.


Purchaser EFW Contract Terminal box enclosure shall contain three line leads with surge capacitors, current transformers and lightning arresters. Also three neutral leads with different current transformers. The governor programmable microprocessor control unit shall control the turbine speed and accept an external control signal generated from boiler outlet steam pressure, and provide all the control functions required to maintain safe operation of the turbine. The control unit shall be fully interfaced with the DCS and the boiler control system. 2.4.3 Associated Steam Systems Condensers and associated pipework Exhaust steam from the turbine shall be ducted to an air cooled condenser. The unit shall perform in a vacuum condensing mode under all turbine operating conditions. The design and provision of auxiliary equipment shall permit the condenser to function as a dump condenser when all or any proportion of the steam flow bypasses the turbine. The turbine bypass valve shall be of proven design and be capable of tight shut-off and long term full flow operation without erosion and comply with leakage rates to Class V ANSI/FCI 70-2 1991. Condenser fan motors shall be variable speed type and be protected with vibration monitoring instrumentation. Bursting discs shall not be permitted for pressure relief in any part of the steam system. A combination of bursting disc and relief valve shall be permitted to protect the turbine exhaust and ACC and sized and positioned to avoid the bursting disc breaking under operational events, such as ACC fan failure, island mode, turbine bypass. At the earliest opportunity following erection the Contractor shall vacuum test the condenser using temporary exhausters, if necessary. Vacuum decay test shall not exceed 50mbar/hour from 0.07 bara. The condenser capacity and system absorbed power shall be optimised by producing turbine power generation versus exhaust pressure curve against the local average temperature data. These shall be provided by the Contractor for review by the Purchaser. Condenser power consumption shall be displayed on the DCS and incorporated into the performance monitoring system. Condenser performance shall be demonstrated using an agreed standard such as VDEW Regulation "Acceptance and Operational test of Air Cooled Steam Condensers". The condenser supporting structure shall allow adequate full air entry and discharge taking account of all adjacent restrictions. The Contractor shall ensure a suitable condenser design and orientation, which avoids hot air recirculation through the air condensers. Condensate systems The ducts, pipework and valves included in the main steam duct between turbine and steam condenser, condensate pipework connecting condenser, condensate tank, condensate pumps and flow control valve shall have the following:

-isolation of the turbine exhaust without interrupting the operation of the boiler. -vacuum line from the condenser to the ejectors



-condensate pump isolating valves and non-return valves and all necessary upstream filters, drain and vent valves. -pump isolation valves and non-return swing check valves. -vacuum breakers are not required as system shall be designed for full vacuum. - bursting discs shall not be permitted for pressure relief in any part of the steam system. - the air condensers design shall also meet the 10ºC ambient air temperature condition. -the design systems and configuration chosen shall not limit the ability of the condensers to operate at 100% MCR at less than atmospheric pressure with 30ºC air temperature in the dump mode in the event that one condenser fan is non-operational.

The condensate tank shall be sized for at least 5 minutes storage capacity at design throughput between the upper and lower operating levels. The Contractor shall justify and demonstrate the adequacy of the design. Two 100% duty centrifugal condensate pumps shall be provided. A separate steam hogger ejector shall be provided for start-up. The condensate tank level shall be monitored with high and low level alarms and shall be maintained at minimum levels using a bypass from the condensate return line. The condensate and treated water tank shall be epoxy lined or have other protection against corrosion. These tanks should be sized to enable prompt boiler start-up and shutdown. A spray type deaerating heater and feedwater storage tank shall be provided operating at approximately 130oC. The storage tank below the deaerator shall be designed for 20 minutes storage capacity at design throughput between the upper and lower operating levels. The deaerator shall be fitted with an off-gas condenser and shall meet a residual oxygen content guarantee of less than 0.02 mg/litre. Dearator performance and related reagent consumptions shall be referenced to the Plant Operation Guarantee Schedule in Schedule 7. Boiler feed pumps Electrically or steam driven boiler feed pumps shall be provided with one pump acting as standby. Centrifugal boiler feed pumps shall be designed and tested to API 610 or other manufacturer standard as approved by the Purchaser. The rated capacity shall not exceed the capacity at the best efficiency point of the pump curve. The impeller diameter shall be not exceed 95% of the maximum impeller diameter for the pump casing. The pump shall be witness tested for NPSH at the manufacturer’s works to meet BS 5316 Class B or other standard as approved by the Purchaser. Stainless steel strainers shall be fitted in the suction lines to the boiler feed pumps. The pump discharge pipework shall be fitted with double isolation, which may be achieved through a lockable non-return valve, and an isolation valve downstream of each boiler feed pump. 2.4.4 Water Treatment and Makeup Facilities General The intent of this section is to define a complete Water Treatment and Makeup Facility capable of continuous satisfactory operation with the minimum of maintenance. The Contractor shall propose a water treatment system based on towns water.


Purchaser EFW Contract The Facilities shall be designed for the bulk delivery of materials and chemical products with no manual handling of caustic soda and should be located in a closed room. All materials shall be suitable for a corrosive environment. The area shall be designed for wash down and all junction boxes shall be designed to at least IP65. The Contractor shall provide a suitably sized boiler water connection point for the rapid filling of the boiler by external means. Boiler water treatment plant The equipment shall be located in a bunded area with additional bunds for each tank. Tank bunds shall be suitably coated for acid or alkali resistance and the floor shall be epoxy coated and laid to falls. The plant shall treat towns water and have a total capacity allowing a minimum of 2% of losses peak flow and a minimum storage tank volume of at least 150% of the capacity of the boiler. The treated water quality shall equal or be better than to BS2486 Table 3 for water tube boilers up to 60 bara with conductivity less than 5 micro ohms/cm and silica content less than 0.02 mg/l SiO2 The water treatment plant shall be self contained in terms of control and monitoring equipment with status monitored via DCS control system. Automatic ion exchange regeneration shall be initiated by a water flow meter with conductivity cells, pH meter and silica analyser constantly monitoring the outlet water quality. Resin traps shall be provided downstream of the ion exchange vessels. Boiler feedwater dosing package A boiler feedwater dosing package shall consist of the following major components: -pH adjustment chemical stock tank and dosing pumps. -oxygen scavenger stock tanks and dosing pumps. -additional chemical stock tank and dosing pumps. -amine inhibitor chemical stock tank and dosing pumps. The boiler feedwater dosing package shall be self contained in terms of control and monitoring equipment and shall be fully automatic in normal daily operation. The status of the plant shall be monitored via control system to the DCS. Two chemical dosing pumps shall be supplied with each chemical dosing package, one duty and one standby. The pumps shall be complete with all necessary strainers, non-return valves, isolating valves, loading valves, piping etc. Automatic changeover to the standby pump, should a duty item fail in service, and shall be provided complete with all necessary controls/electrical items and alarm indication. Chemicals typically for, but not limited to, pH adjustment, phosphate and amine inhibitor shall be injected directly into the boiler drum. The oxygen scavenger chemical shall be injected in the deaerator through a stainless steel injection quill. Stainless steel capillary pipework shall be used for the injection of all chemicals. Provision shall also be made for dosing of amine inhibitor into the steam main.


Purchaser EFW Contract 2.5 FLUE GAS TREATMENT EQUIPMENT, ASH AND METAL SEPARATION 2.5.1 FLUE GAS TREATMENT EQUIPMENT 2.5.1.1 General The Contractor shall install a dry flue gas treatment system, which is designed to be easily adapted with further equipment to meet more stringent emission regulations. Particularly, the Plant shall be convertible in a semi-dry system with simple modification of the economiser and with the addition of a reactor. Place shall be let to allow these modifications. The Contractor shall consider various emissions scenarios with the Purchaser to identify space in the FGT layout for future equipment. A semi-dry option shall be presented, showing specifically the possibility to implement this modification. The FGT shall allow place for the addition of, as a minimum, a two fieldselectrostatic precipitator: this device could be added to do pre-separation of dust and recirculation of reaction products only. Flue gas treatment equipment shall be provided consisting of: • a gas scrubber (as an option) • a Fabric filter containing fabric filters • reagent injection system (slaked lime), • activated carbon injection system • system for removal of waste/recycled product from the Fabric filter • quicklime reagent preparation and distribution system (as an option) • activated carbon preparation and distribution system (as an option), • bulk reagent storage facility capable of receiving bulk deliveries of reagent • NOx reduction system • flue gas sampling points • forward feeding HCl monitoring and control system which guarantees spikes not exceeding

the guaranteed emission requirements whilst processing Acceptable Waste. The flue gas treatment system shall be designed to meet the emission requirements detailed in Schedule 7. The Contractor shall as far as possible ensure that the FGT equipment spares such as silo vent filters, instrumentation, bag filters, motors, etc shall be kept to a minimum by standardising the equipment. Convenient openings shall be provided for duct cleaning. The flue gas treatment system shall be capable of continuously treating the full operating range of gas flow 60% to 100% MCR and shall also be capable of treating short term peaks in the flue gas flow within the capacity of the firing diagram, including overload. The Contractor shall provide adjustable temperature heat tracing to vessels and ductwork where required to ensure that blockages do not occur. All vessels and ductwork shall be thermally insulated and clad to prevent heat loss. Screw conveyors with intermediate bearings shall only be permitted after Purchaser’s review.


Purchaser EFW Contract Pipework shall be designed with drawn or long radius bends to minimise blockages. Air connections should be provided to unplug blockages. 2.5.1.2 Reagent and Activated Carbon Storage Reagent shall have at least 5 days storage capacity and make best use of delivery truck capacities to minimise delivery costs. These vessels and pipework shall be designed for long corrosion free operation, the effective filling from articulated vehicles containing reagent and for the blockage-free emptying to the reagent mixing and atomiser/injection equipment. Option: A standby lime slurry pump shall be provided per Plant. The pumps shall be complete with all necessary strainers, non-return valves, isolating valves, loading valves, piping etc. Non automatic changeover to the standby pump, should a duty item fail in service, and shall be provided complete with all necessary controls/electrical items and alarm indication. The Contractor shall ensure that the lime preparation room is provided with a heating system. The Contractor shall provide a lime slaker grid to ensure that inerts are not introduced into the slaking process. The FGT system shall be supplied with a dual feed for towns water and raw water. 2.5.1.3 Scrubber Reactor (as an option) The reactor vessel and associated mechanical handling equipment shall be designed to allow rapid changeout of the reagent atomisers or injection devices making use of quick couplings and connectors. A standby lime turbine shall be provided at the Plant. A spare atomiser/injector position shall be located on top of thereactor. A cover plate shall be provided on the atomiser flange to avoid ingress of materials and air during changeout of the atomiser. The atomisers/lime turbines and shall meet the availability requirements specified in Schedule 7. Chemical storage tanks and pipework shall be designed for blockage-free operation with 110% bunded tanks. The Contractor shall conduct a HAZOP study for this installation and the design of the cleaning system shall be reviewed and approved by the Purchaser. The reagent feed control system shall be PLC based and interfaced with the DCS. Viewports and manholes shall be provided to enable easy and safe inspection of the interior of the reactor. Support points shall be provided to enable easy scaffold erection, and shall not affect the flow of dried reacted reagent to the discharge conveying system. Manholes for the removal of reagent shall be at least 1000mm x 500mm to allow reagent to be dug out and removed effectively. Thermal insulation shall be provided to ensure there are no cold spots and no steel is in direct contact with the atmosphere. Hopper heaters shall be included to keep the walls warm and prevent condensation. Hammer blocks and chain arch breakers shall also be provided to counteract any bridging. The reagent mixing equipment shall be designed to allow the direct feeding of reagent via big bags or similar into the mixing vessel to enable the flue gas treatment equipment to continue operation in the event of a blockage in the hoppers. The Contractor shall install a nozzle on the mixing tank for connection to a future second preparation tank and allow sufficient space in his layout design for the future installation of a


Purchaser EFW Contract second preparation tank. 2.5.1.4 Fabric filter The Fabric filter shall be consist of filter bags made from Ryton or P84 or coated glassfibre or Gore-Tex with access platforms, safety locking access doors and bypass ducts. The Fabric filter shall be a modular design with on-line cleaning and the ability to isolate one compartment such that performance remains within emission limits. Fabric filter design velocities shall be limited to 65m/hr. The Contractor shall provide maintenance procedures, which describe how the maintenance of filter bags can be achieved safely with a filter compartment isolated. The Contractor shall provide filter bags with a service life of greater than 4 years. Stairs shall be provided to access to all platforms. A walking route shall be provided which directly links the flue gas treatment Fabric filter to adjacent plant equipment at a similar level. In order to avoid cold spots, the insulation arrangement shall be such that no steel is in direct contact with the atmosphere. There shall be sufficient headroom above the Fabric filter to ensure that the complete bag section can be readily removed and a new bag installed without difficulty. The cleaning sequence shall be such that it avoids creating preferential paths for the gas through the Fabric filter. The system shall be normally fully automatic. Manual cleaning of any row of bags shall be possible direct from thelocal panel. The filter cleaning cycle shall have adjustable pulse and interval control. The hoppers of each Fabric filter compartment shall be provided with heaters to maintain metal surface temperature at an acceptable level and anti-bridging devices. The Contractor shall ensure that the fluidising system gives smooth flow. A bypass duct and associated dampers for each Fabric filter shall be provided for start-up with auxiliary burners and under emergency conditions. The ducting arrangement shall be such that air can be recirculated through the system and heated on start-up to achieve the required temperature. 2.5.2 Bottom Ash, FGT Residue and Metals Separation Handling General Fork lift access shall be provided to all ash handling areas. Bottom and ferrous storage bays shall each be designed for at least four days storage and be designed to avoid the build up of materials into piles. The bays shall be designed for a loading shovel to load ash or metals directly into bulk vehicles. Each bay layout shall be designed to accommodate 16.5m long articulated vehicles and the layout must allow at least a 7 metre headroom directly under the bottom ash and ferrous metal conveyors. These areas shall be steel floored or have power floated hardened concrete surface suitable for front loading shovel activities. The ash areas and metals bays shall be separated by walls to ensure that smell and gases emanating from these areas do not contaminate the atmosphere of the main Plant. Any liquids drained from the ash and ferrous shall be contained and reused within the process.


Purchaser EFW Contract The Contractor shall have facilities to sample bottom ash and FGT residue from within the process. Bottom Ash and Metal Separation The Contractor shall propose a conveyor arrangement for review by the Purchaser. A ram bottom ash discharger shall push the residue ash onto a vibrating or slipstick type internal conveyor via a “large item” separator and ferrous separator to a bottom ash storage area. A bottom ash bypass system shall be installed to enable bottom ash to be routed to containers for collection by forklift truck. The bottom ash discharger tank shall be fitted with equipment to enable the discharger liquids to be sampled and injected with stabiliser. The bottom ash shall be loaded onto bulk vehicles using a shovel loader. External belt conveyors shall be covered and designed such that no ashes are discharged into the open and that bottom ash does not collect on the floor of the building. The belt conveyors shall possess a tungsten return blade to clean the belts and belt tightening/self-cleaning devices, which can be readily accessed from the plant floor. The bottom ash conveyor shall be designed so that the bottom ash is spread and distributed evenly at the back of the bottom ash storage bay and not discharged into one pile. The bottom ash conveyor shall also be fitted with rotation detectors. The ash discharger shall be supplied with a dual feed for towns water and raw water. For areas where vehicles require access underneath transportation conveyors between furnace/boiler buildings and the ash storage area, the Contractor shall ensure there is a clearance of at least 5m to enable obstruction free vehicle movement. A ferrous metal separator of the drum type shall be provided immediately prior to the discharge of the residue streams into the ash bay. The position of the ferrous metal separator shall be adjustable above the horizontal conveyor and achieve at least the guaranteed ferrous metal recovery rate. A lifting beam shall be provided above the metal separator. Ferrous metals shall be discharged to a storage area to be loaded by front loading shovel into articulated vehicles. This floor area shall be designed for front loading shovel activities. The Contractor shall make provision for the installation and operation of non ferrous separation facilities located downstream of the ferrous separator. FGT Residue FGT residue shall be collected and discharged into fully enclosed silos with at least 4 days storage.. The system shall be provided for FGT residues recirculation but shall be able to operate without it. The Contractor shall take into account all the possible problems associated with this system, particularly residues obstruction (moisture) and pipework erosion. The configuration, bending radii, design and material specification of the pipework or the means of conveying, shall take into account the high wear rate due to erosion, the potential for blockage and any necessary rodding points. All pipework shall be soundly lagged and trace heated. Pneumatic conveyors shall use heated air or dry air with a dewpoint less than -20°C to avoid blockages. The FGT residue silo shall be kept at a sufficient temperature using temperature adjustable external electric or water heating with insulation and cladding on the outside of the silos to prevent condensation. Manways in the cone shall be provided to enable access to remove blockages. The silo temperature, level and diverter valve positions shall be monitored. The Contractor shall make provision for the installation of a big bag position to collect FGT residues


Purchaser EFW Contract upstream of the FGT residue silo in the event of a blockage in the silo itself. FGT residue Silo and Bagging System The Contractor shall install a dual FGT residue discharging system, one direct into powder tankers and the other direct into a single line of 2m3 double skinned sealed bags. The FGT residue silo shall be designed to discharge FGT residue into 20 tonne powder tankers together with associated control and safety equipment. In addition the silo shall also be designed such that FGT residue can be routed onto a bagging machine consisting of a single line of 5 bags. The bagging machine shall allow the empty bag to be inflated with air prior to filling, to prevent any risk of residue spillage during filling and enable full bags to be handled using a 4 tonne forklift truck.. The full big bags shall be rolled on one roller conveyor and capable of storing at least five full bags. The whole system shall be internal to the building and protected from wind and rain. The Contractor shall ensure forklift truck access to all areas where big bags are located and require lifting. The discharge equipment shall be specifically designed to avoid spillage of dust into the environment. 2.5.3 Induced Draught Fan A variable speed ID fan shall be provided by the Contractor. Greasing of fan bearings shall be accessible externally to the ductwork and noise attenuation equipment. 2.5.4 Chimney Where an existing chimney is not re-used, the Chimney shall be self supporting and fully insulated complete with test ports and access platforms. The chimney shall be designed for all atmospheric conditions including wind and snow loadings. Vortex shedding studies shall be conducted by the Contractor to confirm the design and these shall be reviewed by the Purchaser.. Suitable access ladder fixing points shall be provided on the chimney above the building to enable inspection to the top. The chimney insulation shall be completely sealed and shall not allow any water or vapour ingress.. The chimney shall be designed to BS 4076 with a 25 year life. In addition to the British Standard, the chimney shall receive a paint system with a minimum of 25 year life to first maintenance to BS 5493. The Plant shall be designed to enable the changing of chimney lamps from the top of the building CEMS platform. The Contractor shall demonstrate and satisfy to the Purchaser and the Environment Agency that the chimney height is satisfactory. Where emissions monitoring equipment is located in the chimney, the emission monitoring equipment shall be protected from water ingress and all cable entries shall be from below and equipment and terminal boxes shall be at least IP55. The test ports shall be positioned as recommended by the MCERTS emissions monitoring equipment supplier and in accordance with ISO 9096, HMIP Technical Guidance Note M1, Source Testing Association recommendations and shall enable effective measurement of all gas species. The chimney shall be provided with permanent access ladders and step off platforms up to the CEMS level The new plant shall have to re-use the existing stack or at least the existing stack location in order to avoid Planning permission problems. The Contractor shall check, and demonstrate to satisfy the Purchaser and the Environment Agency, that the existing stack is suitable for the operation of the new Plant during all its


Purchaser EFW Contract Service Life. The Contractor shall ensure that the flue gases are above their dewpoints at all times. Test ports shall be provided in the ductwork leading to the Chimney. The test ports shall be positioned as recommended by the MCERTS emissions monitoring equipment supplier and in accordance with ISO 9096, HMIP Technical Guidance Note M1, Source Testing Association recommendations and shall enable effective measurement of all gas species. The equipment shall be provided with permanent access ladders and step off platforms up to the CEMS level. The emission monitoring equipment shall be protected from water ingress and all cable entries shall be from below and equipment and terminal boxes shall be at least IP55.


Purchaser EFW Contract 2.6 ELECTRICAL SYSTEMS 2.6.1 Electrical Design Electrical equipment and systems shall comply with all relevant Electrical Regulations, Standards and Codes of Practices including the Distribution Code, Engineering Recommendations G59, BS 7671 IEE Wiring Regulations 16th edition. The Contractor shall be responsible for the satisfactory progress and for the timely liaison with Electricity Distribution Company (EDC) on matters pertaining to the electrical import/export connection, overall protection and interlocking arrangements for the electrical connection and metering. The technical design and progress meetings shall be organised by the Contractor but initiated and directed by the Purchaser, who shall chair each meeting and monitor the progress of the detailed design of the electrical connection and metering. Minutes of meeting and other records shall be written and issued by the Purchaser. The Contractor shall provide an integrated electrical system for the EfW Plant. It shall provide for the export of power to the local EDC, import power to run the plant when not generating and for the distribution of power to the plant auxiliaries. A standby power supply shall be provided as shown in Figure 2(a). Interlocks shall comply with the requirements of the EDC, and satisfy the Engineering Recommendations G59 and the NETA Contract requirements. The electrical design proposed in Figures 2(a) and 2(b) are intended to indicate how the Generator Supply interfaces with the main switchboard and this philosophy shall be applied by the Contractor to the Plant. This in no way relieves the Contractor of his responsibility to design an effective electrical system which meets both the above operating philosophy and also normal operating conditions. The Contractor shall design and build the electrical system in accordance with EDC requirements and particularly in line with the EDC fault levels and interlock requirements. The Contractor shall provide a generator with a subtransient fault level infeed including equipment tolerances, of less than 62MVA. Compliance with this fault level infeed shall be demonstrated by the Contractor to the satisfaction of the EDC.


Purchaser EFW Contract The existing incoming supply for the ERF site to be confirmed but is assumed to be 11KV and shall be used as a construction supply. A new 33kV standby supply shall be provided by the Purchaser and the Contractor shall be responsible for all equipment, facilities and ducts for this supply within the site boundary and for the termination of this standby supply onto his metering circuit breaker. The Plant shall export and import electricity to and from the local EDC distribution system at 33 kV . The Contractor shall provide a comprehensive interlock system to the satisfaction of the local EDC. The Contractor shall supply an electrical protection system with an accuracy class of protective current transformers in accordance with BS 7626: 1993; designated Class X for earth fault protection and differential protection. The Purchaser shall supply the export/import 33kV cable connection to the site. The Contractor shall be responsible for the following: the busbar, metering circuit breaker, the current and voltage transformers for metering; line protection; the installation and termination of the current and voltage transformers for the main line protection ; the structures complete with civil works for all the CTs and VTs; the installation of an earth mat to BS Code of Practice 1013 and connected to the EDC earth systems; all busbars and cabling; meterhouse complete with batteries; Code of Practice 2 (CP2) tariff metering earth trunk, protection, relay panels, lighting and small power; including the LV supply and electric meter, outside lighting, lightning protection and telephone. The Contractor shall supply the Code of Practice 2 tariff metering equipment to enable signals to be transmitted to the EDC telecommunications equipment in the substation and also the EfW Plant DCS. The design of the metering shall meet the requirements of the Pooling and Settlements Code of Practice 2, 3-Phase 4-Wire for the metering of supplies above 10 MVA and below 100 MVA. The Contractor shall supply the metering equipment installed inside a Metering Cubicle and be designed to function with a minimum of maintenance. The Metering Cubicle shall have installed: • The three meters; Main meter kWh, Check meter kWh and Reactive meter kWhr. Each

meter shall have two relay outputs for each energy measurement (Import and Export MWh and MVArh) and the first set of relays to impulse to an Outstation. The second set, from the main meters only, to impulse to isolation relays with four outputs for each quantity. These isolation relays shall provide impulsing to the EFW Plant Main Control Room DCS and up to three other locations.

• An Outstation. The outstation shall be designed to store half-hourly demands for all meter outputs; these demands are to be collected by the power purchaser using a modem to call up the data and by the Purchaser.

• The metering system shall have alarms installed for local and remote monitoring via the DCS.

• Outstation modem; for connection to external telephone line, fibre optic lines or other transmitting medium.

• Watchdog circuit, used to monitor the outstation. • Alarm Lamps. • Test terminal blocks. • Voltage failure alarm relay; to be a sensitive phase imbalance relay for detecting faults. • Meter impulsing-interposing unit; to provide a barrier between the impulsing outputs of the

energy meters and the data processing equipment. • Voltage sector relay. • Data collection equipment; an interrogation unit, PC based, shall be supplied for ‘local’

analysis of the metering equipment. The Contractor shall also supply a Castell key system for interlocking the disconnect and line earth switches with the EDC circuit breakers and the plant 11 kV metering circuit breaker. The pilot wire shall be terminated by the Contractor at both ends. The Contractor shall specify a latest date for the installation of the EDC electrical import/export connection on the Contract..


Purchaser EFW Contract All electrical rooms shall have installed heating, ventilation and air extraction systems fitted, taking into account the heat dissipation of the equipment installed. System overview The switchgear fitted on the plant shall be equipped with protection and control facilities. Table 1 summarises the standard level of protections to be installed. The highest possible degree of protection to persons against access to hazardous parts and interlocks between different components of switchgear and control gear for rated voltages above 1 kV shall be provided. The status and control of the 11 kV and 415 V LV board breakers shall be interfaced with the plant DCS in order to provide control of the various breaker functions. The DCS shall provide monitoring of the circuit breakers at emergency switchboard (or similar) level. Interlocking Electrical interlocks shall be provided between the main and standby supplies in order to prevent parallel operation. Electrical and mechanical interlocks shall also be provided between EDC's substation and Purchaser’s HV switchgear. Means shall be provided which ensure the correct sequence of operation of the switchgear. When maintenance is to be carried out on the switchgear the method of interlocking shall result in the removal or locking on of a unique device, e.g. key, which ensures that the equipment to be maintained remains safe. All disconnecting and earthing devices within a station shall be interlocked in a manner that ensures that they always operate safely. The system employed shall satisfy two distinct categories as follows.

Operational interlocking Interlocking associated with normal system operation and switching and intended to ensure that a predetermined switching sequence is satisfied. Such interlocking shall be achieved by electrical means in a manner that permits the equipment to perform any safe operation for either local or remote conditions. Maintenance interlocking Interlocking associated with a series of switching operations to render the equipment or sections of the station safe for access and maintenance by personnel. Such interlocking shall be achieved by mechanical interference type interlocks to BS 7354.

When designing an interlocking scheme, the following assumptions shall be made based on specific duties for disconnectors :

• disconnectors are capable of switching the capacitive current of associated connections • disconnectors have zero load making and breaking capacity • disconnectors are not capable of making or breaking transformer magnetising current • disconnectors are capable of the duty imposed when operated under parallel switching

conditions • it is not possible to close or open any earth switch unless the point of application is

disconnected from all possible sources of supply, and the power operating devices of associated disconnectors are isolated from their remote control position

• it is not possible to operate any disconnectors if an associated earth switch is already closed

• disconnectors concerned with supplies from a remote point cannot be fully interlocked and shall carry a warning notice to this effect and similar notices shall be applied to earth switches.

The overall protection and interlocking arrangements for the electrical connection shall be jointly agreed between EDC and the Contractor. 11 kV systems protection ESCCBH_EFWSpec_Rev1.doc 35 Specification

Purchaser EFW Contract The protection systems shall be subdivided into specific unit protection schemes and general schemes which also act as back-up to certain unit protection relays. In general, the basic protection shall be incorporated into the Merlin Gerin Sepam 2000 multi-function relays (or similar approved supplier) in the 11kV switchboard, with specific, single function relays being selected from the Alstom range (or similar approved supplier), located in the 11kV switchboard and in the turbo-generator control panel. The “G59” protection shall be incorporated in separate relays, located in the 11kV switchboard. Generator protection The operating philosophy of the generator protection shall be submitted by the generator supplier , via the Contractor for review by the Purchaser. Cable protection The 33 kV interconnecting cables to the EDC substation shall be protected from both the Purchaser’s and EDC’s ends by Alstom MBCI Translay S balanced feeder relays (or similar approved supplier) incorporated in dedicated panels. The scheme shall also include a pilot wire protection scheme, which has its active component at the Purchaser’s end and an injection filter at EDC’s end. Back up protection from the Purchaser’s end shall be provided by a non-directional over-current element in the Sepam relay (or similar approved supplier) in the 33 kV switchboard. From the EDC’s end, back up protection shall be provided by EDC. Neutral earthing resistor Back-up earth fault relays Alstom MCGG22 (or similar approved supplier) shall be provided in the neutral earthing resistor panel, purely to protect the resistor against long term earth path currents. 33 kV switchboard In order to disconnect the 11 kV switchboard from the incoming supply more quickly in case of an internal fault, directional over-current and earth fault elements shall be incorporated into the Sepam 2000 relay (or similar approved supplier). They shall have lower settings than the non-directional elements, as they only have to cope with the plant parasitic load, not the full export capacity of the alternator. 11 kV/415 V transformer protection The 11 kV/415 V transformer unit protection shall be provided by winding temperature alarm and trip facilities connected through auxiliary units in the 415 V switchboard. Restricted earth fault protection shall be provided on the 415 V winding using MCAG14 relays (or similar approved supplier) in the 415 V switchboard. Back-up protection for the 415 V winding shall comprise over-current and unrestricted earth fault elements of the universal control unit STR68UT (or similar approved supplier) built into the incoming air circuit breakers of the 415 V switchboard. For the 11 kV winding, back-up protection shall be provided by unrestricted earth fault elements of the Sepam relay (or similar approved supplier), mounted in the 11 kV switchboard. 415 V switchboard In order to disconnect the 415 V switchboard from the incoming supply more quickly in case of an internal fault, directional over-current and earth fault elements shall be incorporated into the universal protection control unit STR68UT (or similar approved supplier). Protection system panels In addition to the multifunction relays built into the Merlin Gerin Sepam 2000 (or similar approved supplier) and the specific single relays located in the 11 kV and 415 V switchboards and the turbo alternator control panels, dedicated protection panels shall be provided and installed in the plant’s 11 kV switch room and in the metering house at EDC’s substation. The primary function of these panels is to provide balanced feeder protection, emergency and inter-tripping systems between the plant and the EDC’s substation. The insulation level of the


Purchaser EFW Contract panels shall be 5 kV and the panels shall be designed to withstand the instantaneous power reversal in the feeder, i.e. from normal operation in export mode from the plant to EDC’s substation to import mode from EDC’s substation to the plant on turbine trip. Protection panel at EDC substation The Contractor shall provide the protection panel at EDC’s substation, which shall be wall, mounted type and housing the protection, control and inter-tripping relays. The protective relays shall be of the solid state type with the tripping relays being of the attracted armature type. Both types shall be from the Alsthom protection relays system (or similar approved supplier). The MBCI Translay-S relay (high speed biased differential type) shall be used to provide high stability for through faults and simultaneous tripping at both ends of the cable. The pilot wire supervision shall be provided by the MRTP type relay (or similar approved supplier). The MVAA11 and MVA13 relays (or similar approved supplier) shall be used to provide the control and inter-tripping functions. Protection panel at EfW plant The protection panel at the plant shall be similar in design to the one at EDC’s substation with the exception that it shall be of a floor standing type and also provide emergency tripping functions to the 11 kV and 415 V systems. The MBCI Translay-S and MRTP type relays (or similar approved supplier) shall be used in the same way as that at EDC’s substation. The MVAA11 and MVAA13 relays shall be used to provide emergency and inter-tripping for the 11 kV and 415 V systems and also controlling the neutral earthing contactor and resistor panel. Inter-tripping In order to disconnect the ERF plant from the incoming supply from EDC’s substation and vice versa and various voltage levels within the plant, in case of a fault, inter-tripping between the various voltage levels shall be provided. The inter-trip signal shall be distinguished into two types namely, inter-trip fault and inter-trip operational. The system at each end shall be designed to send and receive the inter-trip signals. 11 kV and the steam turbine generator inter-tripping The inter-tripping between these two systems shall be achieved by using protection relays mounted in the steam turbine generator control panels and the auxiliary contacts of the circuit breaker and input and output channels of the Merlin Gerin Sepam 2000 multi function relays (or similar approved supplier) mounted in the 11 kV switchboard panel 2. 11 kV and the standby supply inter-tripping The inter-tripping between these two systems shall be achieved by using the auxiliary contacts of the EDC’s circuit breaker and the auxiliary contacts of the circuit breaker and input and output channels of the Merlin Gerin Sepam 2000 multi-function relays (or similar approved supplier) mounted in the 11 kV switchboard panel 4. This shall be designed to receive inter-trip signals from EDC only. The standby supply shall be designed to close upon loss of both the EDC’s supply and the generator automatically but be tripped manually. Suitable hard wired interlocks as well as Sepam 2000 interlocks (or similar approved supplier) shall be provided to prevent closing of the circuit breaker by default. 11 kV and 415 V inter-tripping The inter-tripping between these two voltage levels shall be achieved by using the auxiliary contacts and input and output channels of the Merlin Gerin Sepam 2000 multi-function relays (or similar approved supplier) mounted in the 11 kV switchboard panel 3 and the auxiliary contacts of the incomer circuit breakers of the 415 V switchboard. In the event of fire in the switchroom or if the electrical equipment is under distress, the Contractor shall supply electrical system trip facilities for disconnecting the 11 kV and 415 V systems. The tripping of the electrical systems shall be accomplished via ‘break glass’ units installed in the main Plant Control Room, for all systems; in the 11 kV switchroom (on the Protection Panel) for the 11 kV systems, and in the 11 kV/415 V Transformer LV Board Switchroom for 415 V systems.


Purchaser EFW Contract TABLE 1 SYSTEM PROTECTION: PROTECTION TYPES FOR ENERGY FROM WASTE PLANT - All circuit breakers shall have short circuit (50) and overload (27) protections

PROTECTION TYPE DEVICE No.

11kV:415V TRANSFORMER

STANDBY SUPPLY

EXPORT/IMPORT LINE

TURBO GENERATOR

NEUTRAL EARTH RESISTOR

Differential protective relay 87 X Apparatus thermal device 26 Instantaneous overcurrent relay 50 X X X Instantaneous overcurrent relay 50N X X X A.C. time overcurrent relay (unrestricted earth fault) 51 X X A.C. time overcurrent relay (unrestricted earth fault) 51N X X X X X Undervoltage relay 27 X X X X Ground protective relay (earth fault E/F) 64 X X Ground protective relay (earth fault E/F) 64(L)& (H) Overvoltage relay 59 X Liquid or gas pressure or vacuum relay (Buchholz system) 63 Transformer thermal relay 49 X Transformer thermal relay 49(O) Transformer thermal relay 49(W) X Carrier or pilot-wire receiver relay (MBCI Translay S) 85 X A.C. directional overcurrent relay 67 A.C. directional overcurrent relay 67N Synchronism-check device 25 X Frequency relay (under and over frequency) 81 X Under impedance relay 21 X Checking or interlocking relay 3 X X Rate of change of frequency (df/dt) relay Df/dt Rotor earth fault ROT X Stator earth fault STA X Directional power relay (reverse power) 32 X Field failure relay (loss of excitation) 40 X Reverse-phase or phase-balance relay (-ve phase sequence) 46 X Voltage controlled overcurrent relay 50V/51V X Tripping or trip-free relay (pilot link) 94X X Tripping or trip-free relay (pilot link) 94/86 X X X Locking-out relay (pilot link) 86 X X X X Rectification failure relay (rotating diode fault detector) 58 X V/Hz protection V/Hz X Automatic voltage regulator AVR X Overspeed 12 Starting-to-running transition contactor (start failure) 19 Emergency stop 5 X X X Mechanically & electrically interlocked changeover contactors X X Mechanically & electrically interlocked circuit breakers X X X X


Purchaser EFW Contract The ID fans shall be controlled by variable speed drives. General Rooms All electrical, instrumentation and control rooms shall be designed for bottom access to panels as far as possible. Plant equipment system and MCCs The complete LV switchboard assembly and MCCs shall be floor mounting and free standing, manufactured from sheet steel, with a minimum of IP 31 (for indoor use) and IP 55 (for outdoor installation) degree of protection and Form 4 Type 3 internal separation as defined in BS EN 60439-1, shall be applied to the Main LV switchboard. Form 3b Type 2 construction to BS EN 60439-1 internal separation shall be acceptable for all other MCC’s and single circuit feeds. The latter shall have supplementary protection, i.e. protective roofing or the like. The motor starters for the majority of plant and auxiliary equipment shall be housed in the MCCs, whilst the motor starters for the auxiliary equipment packages shall be housed in either the individual small MCCs or special starter panels supplied by the equipment package vendor. The motor control centre shall be designed so that modifications to ratings or functions can be effected quickly and easily and work shall be carried out on any individual compartment of the motor control centre in complete safety, without the need to switch off the rest of the board. All panels shall be designed and installed to allow all normal operational functions (cabling operation and maintenance functions) to be carried out from the front of the panel. Panels shall be supplied with a purpose-made separate base plinth 125 mm high of fabricated and corrosion protected sheet steel or rolled steel channel, which shall be fixed true and level on the structural floor before the panel itself is mounted and fixed to its top. The plinth shall be inset from the vertical faces of the panel by 12 mm such that a continuous flat vertical surface faces outwards. Floor screed and finishes may subsequently be laid to abut the plinth. Each sub-section shall have an individual front cover, which is hinged to provide access to all equipment inside the cubicle for maintenance purposes (withdrawable and removable modules type may be acceptable subject to agreement with the Purchaser). These covers shall be of sheet steel and rigid construction, complete with jointing material to ensure a seal in accordance with the degree of protection specified for the control panel and shall be fitted with T-Type handles, only one of which shall be lockable. Each sub-section, except for the ‘maintenance instructions cubicle’, shall be fitted with an isolator, mechanically interlocked with the sub-section front cover such that the cover cannot be opened unless the isolator is in its ‘OFF’ position, and an anti-condensation heater and thermostat operating on 110 V. Sub-sections less than 500 mm in height shall be mounted with their bases not less than 500 mm above finished floor level. Each MCC shall have one sub-section not less than 400 mm x 400 mm x 400 mm to house maintenance instructions and diagrams. The inside face of this sub-section’s front cover shall be fitted with spring clips containing 10% of each size of fuse and not less than 3 of each size and type within the control panel. The LV switchboard shall be designed and certified to withstand a short circuit fault current of 70 kA rms or lower subject to justification by the Contractor for 1 second. The MCC busbar systems shall have an ASTA certified short time withstand current rating of 50 kA rms for 1 second without causing damage. The main circuit switching mechanisms fitted in the MCCs incoming supply cubicles shall be rated to the full fault level and have a circuit breaking rating of 50kA rms. One common solid copper earth shall be installed internally throughout the length of each MCC and shall be extendible at both ends. It shall be adequately rated for all possible short-time continuous fault currents. Each dual feed MCC shall be provided with two 415/110 V transformers complete with a change over logic arranged such that continuity of supply to the control circuits is maintained in the event of failure of one transformer. Each starter circuit within the MCCs i.e. contactors, fuses and overload relays shall be designed to achieve type “2” co-ordination as defined in BS EN 60947-4-1 (IEC 947–4) and have control circuit suitable for operation from the 110 VAC control circuit supply system. Each starter shall incorporate a “normal/test” switch, mounted inside the sub-section. The “test” position of this switch shall energise the control circuits only whilst the compartment door is open. It shall not energise the motor. All electrical connections on this switch shall be fully shrouded. This switch shall be mechanically interlocked with the door such that the door


Purchaser EFW Contract cannot be closed when “test” is selected and “test” cannot be selected unless the compartment door is open (i.e. it shall only be possible to close the cubicle front cover, and the door interlocked cubicle isolator, when this switch is in its “normal” position. Refuse crane and local turbine MCCs and controls shall be located in a dust and wet free technical room. The MCC shall be as follows: Internal separation Form 4 type 3 or Form 3b Type 2 construction Prospective earth fault current (fault current) 50 kA or lower subject to justification Type Multi-cubicle IP rating Minimum of IP 31 if located indoors and IP 55

for outdoor installation Mounting Free standing Compartment access Front or rear Cabling access Bottom or top (IP rating to be maintained) Busbars Required Compartment door MCCBs interlocked All compartments except marshalling. Controls

to include internal MCCB Supply ammeter Yes Electricity supply indication Three (RED/YELLOW/BLUE) lamps,

one/phase Distribution and incomer RCDs 30 mA for 240 V sockets, domestic distribution

and internal 13 A socket. 100 mA for incomers (with adjustable time delay)

Rubber mats Required Preferred manufacturers Brook Compton, Klockner Moeller, Legrand,

Merlin Gerin, MTE, Telecontrol, Telemecanique or similar approved supplier

Sockets Yes Power factor correction Controlled from Generator Phase failure and reversal protection Incomers (adjustable settings to trip incomer) Standby generator inlet Not required Spare fuses Include 100% spares of each fuse size, rack

mounted in respective compartments Spare cubicles Min. of 20% required. Fitted with ∋ 2 of each

size and type of isolator used within the MCC Selector switches to be key lockable None Domestic distribution Distribution board mounted on the front of the

distribution compartment. Cubicle heaters All compartments except for records Starters Star Delta, Soft Start or D.O.L. as required Internal compartment test switches Required, not key switches Standard motor starter modules shall include provision for control operating devices with their associated indicators. Equipment shall include an interlocked circuit breaker (including motor protection) or BS 88 fuses, contactor and overload. Power distribution modules shall be supplied with an interlocked circuit breaker. Switchgear battery and battery charger Switchgear batteries and battery chargers shall be supplied to provide the 110 V DC for the following functions as a minimum.

Tripping and closing of 11 kV switchgear and protection system Tripping and closing of 415 V switchgear and standby power supply to other equipment Protection system at EDC substation.


Purchaser EFW Contract Each battery shall consist of a group of cells connected in series or parallel to provide the output voltage and a one hour discharge period. Batteries shall be nickel cadmium alkaline type. Each battery shall have a storage capacity sufficient to carry out at least 100 consecutive operations singly and in rapid succession, and supply its standing load for the above-specified time without the battery terminal voltage falling below 85% of its normal value. Each battery with the associated battery charger shall be accommodated in fabricated free-standing floor-mounting steel enclosures. The battery chargers shall be of the automatic constant voltage current limit type and suitable for one of the following modes of operation: • Trickle charging • Trickle charging with occasional manually controlled boost • Float charging • Float charging with occasional manually controlled boost • Charge/discharge cycle Each system shall be equipped with a low-voltage disconnect facility in order to protect the battery from over discharge. The facility shall comprise of a contactor controlled by a voltage detection module which automatically disconnects the battery from the load should the battery voltage fall below the preset level. The 110 V DC within the plant shall be distributed to the user points via distribution boards. Malfunctions and failures of the battery chargers located in the remote Meter House, in the 11 kV Switchroom and in the UPS room shall be indicated to the main Plant Control Room via the DCS. Turbine emergency oil pump supply In addition to the three switchgear batteries and battery chargers, a further battery and battery charger system shall be supplied to provide 110 V DC for the turbine emergency oil pump or other supply as advised by the turbine manufacturer. The battery shall consist of a group of cells connected in series/parallel to provide the output voltage and sixty minutes discharge period. The battery shall be of valve regulated gas recombination lead acid type, with the other features identical to the other three systems described earlier. The starter circuit for the DC motor driven run-down pump shall be mounted in the turbine auxiliary MCC, whilst the control logic shall be mounted in the turbine control panel. The function of this pump is to safeguard the bearings in the event of a power failure. Personnel Fire Lift Standby Supply The personnel lift shall be fed from the 415v emergency distribution board. Rubber mats Rubber matting complying with BS 921 shall be provided for all electrical equipment, on all floor areas where maintenance work may be effected. Each mat shall be at least 0.9 m wide and of sufficient length to extend 50 mm beyond either end of each piece of equipment. 2.6.2 Earthing The Generator neutral shall be earthed via an NER. The Plant shall be solidly earthed having an Integrated Earthing System, compatible with the EDC earthing systems. Earthing rods shall have inspection points. All metalwork, cable tray and equipment shall be equipotentially bonded. The whole of the earthing installation shall comply with BS 7671: 1992 the IEE Wiring Regulations 16th Edition and EDC’s requirements. The Contractor shall supply the Purchaser with the site ground conditions report, including all soil resistivity readings taken. The design of the earthing mat system shall be such as to limit the earth grid potential rise under maximum


Purchaser EFW Contract fault conditions to be within CCITT requirements. The Contractor shall demonstrate to EDC and the Purchaser that the Site and Plant earthing have been satisfactorily designed, installed and tested prior to any connection. A TNS earthing system which consists of a system having separate neutral (N) and protective conductor (PE) shall be provided and shall include a dedicated earthing circuit to which all electrical equipment shall be connected. The protective conductor (PE) shall be the metallic covering of the cable supplying the installations or a separate conductor. All exposed-conductive-parts of the installation shall be connected to the protective conductor via the main earthing terminal. This system shall be connected to a main earth system for the Plant. Installation of the main and supplementary equipotential bonding conductors shall be in accordance with the requirements of BS 7671. The main earth shall be connected onto a test bar, which shall be used to carry out periodic tests and also for the connection of miscellaneous earth circuits. A clean earth (electronic earth) shall be provided to earth independently from the main earthing system, the sensitive equipment such as electronic devices and control systems. The clean earth shall be mainly composed of clean earth bars installed in electrical rooms and connected to earth rods buried as far as possible from the normal earth. The requirement for a separate clean earth may be waived by the Purchaser if it can be demonstrated by the Contractor that it is not required. At all main and sub-main distribution points, a copper strip earth busbar of minimum cross sectional area of 80 mm2 shall be provided and all equipment including switch and fuseboard cases, framework and cable armouring shall be bonded to it. The busbar shall be mounted on suitable insulators and located where the main earth connection enters the site. At all main and sub-main distribution points; earth bars shall be provided and consist of high conductivity copper strip mounted on insulated supports on the substation walls and shall have 400 A isolating links fitted in order that the earth bar can be isolated from the earth mat for test purposes. The size of each bar shall be determined from the prospective fault current as follows: • 14 kA 25 mm x 3 mm • 30 kA 37 mm x 6 mm • 33 kA 50 mm x 6 mm Earth rods shall be of stainless steel and connected by thermal welding systems to the earth grid to the satisfaction of the Purchaser. Where copper strip is used either for bonding purposes or as an earth continuity conductor, the following shall apply: • All strips shall be of soft high conductivity copper untinned except where otherwise

specified. • Where fixed to building structure, independent purpose made brass clamps or saddles shall

be used. Fixings requiring the drilling of holes through the strip shall not be used. • Where the strip is run to ground or otherwise liable to corrosion, it shall be wrapped with

PVC tape. Alternatively, PVC sheathed strip shall be used. • Joints shall be exothermic welded. • Fixing of connections to the strip shall be made by high tensile brass or bronze nuts, bolts

and washers and the cross section of bolts connecting equipment to the strip shall be not less than that of the bonding lead.

All the items of plant, metal equipment on the site e.g. ladders, handrailing, pump guide rails, cover frames, tanks, machinery casings etc. and glands for PVC/SWA/PVC cables, incoming gas and water mains or other metallic services where applicable shall be bonded to earth in


Purchaser EFW Contract accordance with the IEE Regulations. The surfaces of all equipment to which earthing bonds are fixed shall be cleaned free from paint and other non-conducting materials and the surfaces coated with petroleum jelly. All connections shall be made using bolted, tinned compression type eye cable lugs, Denso taped on completion to completely seal the lug and any bare copper from the atmosphere. All metal clad electrical equipment and related plant shall be soundly connected electrically and mechanically to earth but shall not be used as an earth conductor for other metal work earth connections. All electrical systems shall be designed in accordance with IEE Regulations, applicable British Standards Code of Practice for Earthing BS 7430 (formerly CP 1013). Neutral earthing resistor and contactor panel A neutral earthing resistor shall be provided to control the flow of earth currents during plant operation. Its prime purpose shall be to ensure that only one neutral-earth connection is present on the 11 kV system at any one time. Normally, the transformer 11 kV neutral shall be connected to earth. If, however, the transformer circuit breaker is open, the generator neutral earthing switch shall close, so maintaining the system voltages in balance. The generator neutral earthing switch shall also close when it is running up. The complete assembly shall be housed in a floor mounting, free standing, sheet steel enclosure with degree of protection to IP 31. The contactor and resistor shall be suitable for limiting the earth fault current to 1000 A for ten seconds at the system voltage of 11 kV and a basic impulse level of 75 kV. Each contactor shall be provided with a three position control switch CLOSE/NEUTRAL/TRIP, and a LOCAL/REMOTE selector switch. A fully rated isolator shall be provided at each contactor to enable maintenance procedures to be carried out without interrupting normal operation. While operating under remote control, the neutral earthing contactors shall be fully automatic, closing and opening as the changing 11 kV system configurations demand. 2.6.3 Lightning Lightning protection shall be provided for the chimney and buildings and consist of conductors bonded to the main earthing points to provide an integrated system of protection. The chimney stack and all buildings shall be provided with lightning protection in accordance with BS 6651: 1985. The Contractor shall supply the Purchaser with all calculations, analysis and design details for defining the Zones of protection and method of connecting the protection to the main plant earth mat. All electronic equipment shall be protected from lightning and transient overvoltage. 2.6.4 Distribution Design The distribution design shall be as that indicated in single line diagrams Figures 2(a) and 2(b) of Clause 2.6.1 above. Distribution boards network shall be provided and installed in various parts of the plant, giving the most practical access for the ancillary building services system and ancillary plant equipment. The final circuits shall be protected by MCBs or MCCBs as necessary. Transformers and distribution boards shall be designed to accommodate 100% start up load. The 11 kV/415 V cast resin auxiliary transformers shall be sized for total plant loading plus 20% continuous overload. The main LV switchboard, MCCs and LV distribution boards shall be


Purchaser EFW Contract designed for and include spare feeds of suitable capacity rating. The Contractor shall design for the automatic changeover and standby feed to the plant as indicated in Fig. 2(a). As indicated in Figure 2(b), the Contractor shall design for a suitably rated emergency switchboard supply for : the personnel fire lift, fire pump, weighbridge, CEMS, emergency lighting, UPS, TG emergency auxiliaries, 110V DC, grate emergency oil pump, Confidential/veterinary/medical Waste handling and small power requirements. Electrical distribution drawings shall be reviewed by the Purchaser. The operation, control and monitoring of all circuit breakers and isolators, down to and including the main LV switchboard shall be via the DCS. The incomers to the main MCCs and all other distribution boards shall be monitored by the DCS. The electrical distribution system and equipment shall be designed to the Codes and Standards of the following Bodies: Institution of Electrical Engineers, Institution of Mechanical Engineers, British Standards, British Standard Codes and Practice, Health and Safety Executive, Electricity at Work Regulations and International Electrotechnical Commission. European Standards may only be considered where they are specifically compatible with British Standard equivalent equipment and systems. The Contractor shall submit to the Purchaser a full set of electrical load and control schedules, fault level and fault level contribution calculations and list of protection settings to be applied, for review. All electrical switchboards, enclosures, distribution boards and control cabinets that are floor mounted and completely free standing shall be manufactured from sheet steel, with a minimum of IP 31 (for indoor use) and IP 55 (for outdoor installation) degree of protection. All wall mounted electrical and control cabinets shall have IP ratings as above and shall not be flush mounted on the wall, at least 25mm shall be provided between cabinets and walls. 2.6.5 Cables Cabling and earthing shall be in accordance with British and IEC Standards BS 7671 IEE Wiring Regulations 16th edition and BS 7430 Earthing. All cables run shall be supported on heavy duty galvanised cable rack BS 729 or return flange tray supported at regular intervals and secured with PVC coated steel ties. Cable trays and ladders rack shall have 30% spare capacity. Single cables shall be supported on heavy duty cable tray, manufactured to BS 1449. All cables run below ground, shall be installed inside cable ducts of 150 mm minimum diameter. All cabling shall be identified using permanent markers securely attached to the cable ends. All cores shall be clearly identified at each end using a consistent identification system. Identification labels of durable material, shall be provided suitable for permanently affixing to the cable sheath by means of a buckle type straps and shall carry the cable reference in PVC channel strip. The reference character sizes shall not be less than 4 mm (5/32”) high (Critchley Unilabel or similar). Cable identification labels shall be fitted to each cable end below its respective cable gland also where the cable passes through ducts or trenches and at each entry and exit to a room or building. The Contractor shall supply electrical cables as follows:

-High voltage cables shall be rated at 6350/33000 Volts with XLPE insulated conductors steel wire armoured (SWA) cables to BS 6622 and IEC 502 -Low voltage cables shall be rated at 600/1000 Volts with XLPE insulated conductors steel wire armoured (SWA) cables to BS 5467 (with PVC LSF oversheath to BS 6224)



- All other cables shall be PVC insulated armoured cables to BS 5467 -All fire protection cables to BS 5467 -All control and instrumentation cables shall be PVC insulated SWA cables to BS 5308 part 2, type 2. The cable cores shall consist of individually screened pairs with overall screen -All conductors for earthing shall be copper, manufactured to BS 1432, for strip and BS 4109, for cable

All cables shall have stranded copper conductors to comply with BS 6724, amply rated in accordance with IEE Wiring Regulations taking into account short-circuit and overload protection, temperature considerations, voltage drop and method of installation. The Purchaser shall review cable calculations. The voltage drop from any cable shall not exceed that specified in the current edition of the regulations of the Institution of Electrical Engineers. Cable schedules shall include such details as: cable number, length in metres, rated current and voltage, cross sectional area, number of cores, type of cable, cable run from/to as a minimum. Cables shall be segregated into the following categories: HV AC power cables, LV AC power cables, DC cables, control cables, instrumentation cables (analogue signals) and instrumentation cables (digital signals). All cable entries shall be from the bottom, to distribution boards and local panels that are located on the plant. However, bottom and/or top entries shall be acceptable inside the switchroom provided the IP ratings of the panels are maintained. All cables shall be identified and properly glanded to BS 6121: Part 1 1989 and shall be coiled once prior to glanding into field instrumentation. All fire protection cables shall comply with BS 6387: 1994 class CWZ. All multicore cables shall have 10% extra cores. Cables laid in ground shall not have the same colours to statutory undertakers pipework (i.e. yellow for gas and blue for water pipework). 2.6.6 Transformers General Transformers shall be designed to BS 171 and BS EN 60076. Any oil filled transformers shall supplied with blind bunds with a capacity of 110% of the capacity of the transformer for pumping out by others. Oil filled HV transformers shall be either protected with deluge system or so positioned such that there is no possibility of any consequential loss or damage to either plant or equipment in the event of a fire. Cast resin insulated, encapsulated transformers nominal rating shall be achieved using natural air circulation, the 120% rating shall be achieved using forced air circulation (AN/AF). Cable boxes shall be provided for the 33kV power cable connections. 2.6.7 Cable Ducting All underground cables shall be installed in dedicated cable ducts with sufficient air space to avoid the cables overheating and shall comply with the Electricity Association Technical Specification 12.24. Cables laid to plant and equipment that are external to buildings, structures etc. shall be conveyed through or under hard standing surfaces by means of ducts. Ducts under roads shall be laid such that the cover from the top of the ducts to the final road surface is not less than 750 mm. Wherever cables, earthing strips and other current carrying apparatus pass through walls, floors etc; the Contractor shall thoroughly and effectively seal all voids formed between the cables and the openings against the ingress of moisture and gas sufficient for the requirements of Fire Protection. The Contractor shall ensure that the materials used are fire resisting and have no deleterious effect on the cables.


Purchaser EFW Contract Before drawing any cables in ducts, the Contractor shall ensure that they are clean and free from obstructions. Adequately spaced temporary supports and cable rollers shall be provided for the drawing in of cables such that abnormal strains and damage to the cable is prevented; approved supplier lubricants shall be used as necessary. Cable stockings shall be used for general drawing work, core pulling eyes being specially fitted for heavy hauls. Stresses shall not exceed: • 10MN/m2 (1,500 lb/sq in) on the load sheath • 70MN/m2 (10,000 lb/sq in) on the core Maximum pulling tension shall be 20 kN (4500 lb) Duct seals and cable transits After the cables are drawn in, the Contractor shall seal the ends of all ducts, pipes or trenches leading into buildings for cabling associated with this Contract, whether occupied or not. The seals shall be reviewed by the Purchaser for water, gas and fire sealing transit units with appropriate fillers and insert blocks fitted to suit all cables, conduits or pipes passing through the walls or floors. All steelwork on such transit assemblies and frames shall be hot dip galvanised. Alternative materials may be used subject to the Purchaser review. Protection of exposed cables Where a cable rises out of a duct or the ground in an exposed situation a galvanised steel pipe or protective cover fabricated from 3.0 mm (10 SWG) galvanised mild steel (or heavier as appropriate) shall be provided and fixed to the associated structure for a minimum height of 1.5 metres above the local finished ground level. 2.6.8 Emergency Generator The Contractor shall install anemergency generator, as indicated in Figure 2(a) of Section 2.6.1. The Contractor’s equipment shall be designed and rated to ensure that the Plant can be safely shut down with no electrical grid supply. The system shall be designed to accommodate EDC fault levels and possess appropriate interlocks and switching and meet the requirements of the EDC and the requirements of the NETA agreement. Upon loss of the main 33kV EDC’s supply whilst the turbine is not running, the emergency generator shall automatically operate and shut down the. 2.6.9 Turbine Generator The turbine generator and all ancillary systems shall be designed for 110% MCR and 0.8 power factor. The Contractor shall supply all electrical protection and metering for the turbine/generator. In addition to the protection a turbogenerator monitoring system shall be provided to monitor bearing vibration, turbine axial position, turbine speed and temperatures. Synchronising facilities shall be provided in the central control room and the turbo generator local control room to enable the generator to be run in parallel with the local EDC distribution system. 2.6.10 11 kV AC Switchboard The Contractor shall supply an 11 kV metal clad type switchboard, utilising drawout circuit breakers, suitable for operation on an 11 kV 50 Hz three wire supply, with low resistance earthed neutral. The switchboard shall be extendible at both ends and comprise four SF6 or vacuum type circuit breakers fully complying with BS 4752 suitably rated for the circuits feeds as indicated in Clause 2.6.1 of this specification, Single Line Diagram Figure 2(a).


Purchaser EFW Contract The switchboard shall be floor mounting, free standing, manufactured from fabricated sheet steel not less than 2 mm thick and have at least IP 31 degree of protection. The switchgear shall fully comply with BS EN 60298 and BS 5311. The circuit breakers and busbars shall be suitable for a short circuit fault level of 40 kA for 3 seconds at a system voltage of 11 kV and a basic impulse level of 95 kV. Electrical interlocking and Castell key interlocking shall be provided in order that the circuit breakers, feed cables and circuit feeds can be isolated and operated safely, and in accordance with the EDC’s requirements where applicable. The protection and metering CTs shall be compatible and matched with the protection CTs installed in the generator, the EDC’s Standby Supply and Auxiliary Transformers. The main operation, control, monitoring and protection of the switchgear shall be incorporated in a SEPAM 2000 unit or similar approved supplier. All Safety labels shall be colour coded in accordance with BS 5378 and Safety Signs Regulations 1980. 2.6.11 415V AC System The 415 V LV system shall be as indicated in Clause 2.6.1 Figure 2(b) and Clause 2.6.4 of this specification. The Contractor shall supply one 11kV/415V auxiliary transformers to provide supplies for all AC auxiliaries on the plant, the rating and type as indicated in Clause 2.6.6 of this Specification. The transformer shall be of cast resin design built to the required BS 171. Suitable ventilation shall be provided in electrical rooms to avoid overheating of equipment. The Contractor shall supply 415V LV switchboard suitably rated and fitted with switchgear and isolators suitable rated to supply all the 415 V feeds as per Figure 2(b) of the specification. In addition, the Contractor shall supply 415 V motor control centres and distribution boards. Distribution boards for lighting, heating, socket outlets and small power shall be located at strategic positions throughout the plant and have an enclosure degree of protection to a minimum of IP 31 (for indoor use) and IP 55 (for outdoor installation). The switchboards and MCCs shall be designed and manufactured to BS EN 60439 Part 1 with an enclosure degree of protection to a minimum of IP 31 (for indoor use) and IP 55 (for outdoor installation) . The busbars and busbar connections shall comply with BS 159 and BS EN 60439-1 assembly Form 4 Type 3 or any equivalent as agreed by the Purchaser. All motor starter/controllers shall include as a minimum: disconnect switch, main fuses, visible fault indication and provision for remote alarm indication, air/vacuum contactor (electrically held type), ambient compensated thermal overload relay, ammeter, start/stop buttons with coloured indication lamps, local/remote selector switch, provision for remote overload/trips/start/stop/emergency stop buttons and provision for motor anti-condensation heaters. 2.6.12 Welding and Small Power The Contractor shall supply switched 415V AC 3 phase welding sockets and 110V AC sockets for small power each rated at 100A. The welding and small power circuits shall be designed such that the two adjacent sockets furthest from the distribution board can each draw the full rated current associated with all the sockets being used concurrently. These sockets shall be located such that the maximum distance to any socket is 20m. Power supplies for control and


Purchaser EFW Contract instrumentation shall be fed from isolating transformers with secondary windings at 110V 1 phase 50 Hz having one pole earthed. Power supplies for all monitoring equipment in direct contact with water, such as electrodes, float switches, pH cells, etc., shall not exceed 50V, earthed at one end. Power supplies for portable tools and 110 V 1 phase 50 Hz socket outlets shall be fed from isolating transformers with secondary winding centre-tapped and connected to earth. Power supplies for hand lamps shall be 25V 1 phase 50 Hz from isolating transformers with secondary winding earthed at one end. 50V and 25V systems shall be ‘functional extra-low voltage systems’ as defined in the IEE Wiring Regulations BS 7671. Power supplies for heating and lighting (other than hand lamps) shall be 240 V 50 Hz single phase and neutral via distribution boards specified elsewhere. Socket outlets, within buildings, rated 13 Amp 240 V 1 phase 50 Hz shall comply with BS 1363 and be of the switched socket outlet (SSO) type, coloured white metal clad. All other socket outlets; plugs; connectors and appliance-inlets rated up to 125 Amp shall comply with BS 4343 (CEE 17) and shall be to watertight classification. They shall be as follows: • 25 V 1 phase 50 Hz - 2 pole coloured violet. • 110 V 1 phase 50 Hz - 3 pole (2P + E) coloured yellow. • 230 V 1 phase 50 Hz - 3 pole (2P + E) coloured blue. • 415 V 1 phase 50 Hz - 5 pole (3P + N + E) coloured red. All BS 4343 socket outlets and appliance-inlets shall be supplied complete with mating plug and connector. All socket outlets and appliance-inlets shall be mounted so that the centre of the pins/sockets is not less than 1 m above finished floor level. In addition, angled socket outlets and appliance-inlets shall be positioned so that there is adequate room and accessibility for inserting the mating plug/connector with its associated cable. The cables shall not be stressed beyond their recommended minimum bending radius. All single phase socket outlets rated above 25 V shall be protected by a residual current device having a rated residual operating current not exceeding 30 mA and a disconnection time within 0.4 second. The fuse or MCB ratings and number of ways shall be reviewed by the Purchaser and neutral bars shall have a separate terminal for each outgoing fuseway. Insulating barriers shall be fitted between phases on 3-phase and neutral boards. All ways designated ‘spare’ shall nevertheless be equipped with fuse carriers and fuses or MCBs. All fuseboards or MCB boards shall have securely fixed to the inside of the lid, a typewritten circuit chart mounted inside a transparent non-flammable pocket. Electrical distribution circuits for power and lighting shall not incorporate ring mains. The height of accessories in millimetres as measured from the finished floor level to the top of the accessory cover plate shall be as follows: • Distribution boards 2000 • Light switches 1400 • Socket outlets 1200 • Connection units for water heaters 1400 • Room thermostats 1600 2.6.13 Lighting The lighting shall be designed to comply with the CIBSE Code for Interior Lighting and relevant Lighting Guides including:- • LG1 - The Industrial Environment • LG3 - Areas for Visual Display Terminals • LG6 - The Outdoor Environment – Lighting in Hostile and Hazardous Environments


Purchaser EFW Contract Internal and external lighting shall be provided and planned throughout the facility to provide lighting levels in accordance with IEC Codes and illuminate all working levels, rooms, walkways, access points, special work stations, etc. in order to provide for the safety of the personnel and of the operation. The lighting appliances shall be positioned so as to be easily accessible and maintenance shall be possible without danger using a simple ladder or a slide-out ladder. Lighting shall be generally by high pressure sodium floodlights and plant wide fluorescent lamps. High bay fittings to IP 54 with polycarbonate bodies and low bay fittings to IP 65 with corrosion resistance fitted in ash discharge area, reagent preparation area and bag filter area. External lighting shall be by high pressure sodium fittings; installed around the boundary of the site and mounted off buildings or from lamp standards in order that the light levels are maintained to IEC Codes. An emergency lighting system shall be provided for all areas including all emergency exits and exit routes for personnel safety and be installed in accordance with the requirements of BS 5266 and the local fire officer. The Luminaires shall be of self-contained non-maintained type, connected to local lighting circuits. Emergency light fittings shall be self contained battery operated units which have the facility to interconnect the lighting circuit with normal mains lighting double circuit switches such that the emergency lights shall only illuminate in the event of a main supply failure if the mains lighting is energised in the ‘ON’ position. This interconnection shall not, however, prevent the normal charging circuit within the emergency light fitting from functioning when the mains lighting is in the ‘OFF’ position. Illuminated exit signs shall be located over fire exit doors. Light sources shall be selected from those, which provide maximum conversion efficiency and optimum longevity. The Contractor shall make due allowance for any deterioration effect in lighting levels of equipment over time, and ensure the minimum light levels at 1m from the ground during operations shall be as follows:

Representative activities/interiors Standard service illuminance (lux)

General offices, kitchens, laboratories, control room, conference/meeting room

500 lux

Workshop and electrical rooms, tipping hall 300 lux Monitoring automatic processes (measurement, command and control areas), turbine hall, local work

250 lux

Loading bays, stores, toilets, washroom, corridors, walkways inside the buildings

150 lux

External manoeuvring areas, building exteriors, weighing station, installation road accessways, external walkways, cable tunnels

50 lux

Table 2. Activities/interiors for each standard illuminance The lighting maintenance factor in areas exposed to dust shall be of the order of 1.6. In areas under positive pressure, it shall be of the order of 1.3 to 1.4. Lighting and power socket installations in administrative areas shall be supplied from a separate network, taken from the secondary of the HV/LV isolating transformer in order to maintain an adequate level of isolation for the whole of the electric power network. The transformer shall be rated to supply future installation lighting requirements in order to allow for future expansion. Zones and areas with a large surface area (greater than 200 m2) shall be supplied from several protection circuits in order to provide a minimum level of lighting in the


Purchaser EFW Contract event of one of the circuits tripping. Technical area lighting shall be controlled locally and centrally using indicator lamps. Administrative, toilet, cloakroom and social areas, the workshops and stores shall be controlled locally. Manual outside lighting controls and indicator lamps shall be grouped together on a console located in the control room and the weighing station. Automatic controls shall employ light level switches. A three-position switch shall be fitted for each function (Off-Manual-Automatic). High performance sealed lights units fitted with a self-cleaning dust filter shall be employed in areas which are prone to dust such as the tipping hall. Low luminance lights shall be installed in the control room, the offices and the conference/meeting room in order to avoid glare or fluorescent tube reflection on monitor screens and crane operating position. These shall be a non-glare type, which reflect external light away from the screen and shall have minimal or no effect on the screen brightness and clarity. The luminance values in the control room shall be less than 200 lux at angles of incidence of 45o. In accordance with legislation, safety lighting shall be provided as luminaires distributed in the various rooms and halls, along corridors, above command-control points and above exits. The luminaires shall be sealed industrial type in technical areas with environmental protection rated in accordance with the nature of the risks involved (minimum IP 667). Protective grills shall be fitted in areas where there is a risk of mechanical damage (as per IEC 529 or equivalent). The requirements for external lighting installation works shall be the same as those applicable to the public (street) lighting network. The installation shall be in accordance to NF C 17.200 or equivalent. Lamp posts shall be used where aesthetics are important, for access to the plant, for internal roadways and the parking areas. Wall-mounted appliances shall be used for approaches to the buildings. Additional lighting shall be provided for external equipment such as the reagent and residue storage areas, the domestic fuel oil tank, the weighbridge etc. High-pressure sodium vapour lamps shall be used and lamp posts shall be made of galvanised steel coated in bitumen paint up to 200 mm above the ground. Exterior lighting switches and those in damp situations shall be metal clad galvanised water-tight with rotary switch action, alternatively MK ‘Seal’. 2.6.14 Fire Alarm and Evacuation System A fire alarm and evacuation system shall be installed in accordance with BS 5839, Part 1 - 1988 and amendments and meet the requirements of the local Fire Officer, the Local Authority Building Control, the Building Regulations, the NFPA and the Purchaser’s Insurers. The Plant shall be segregated into Fire Zones for the whole Plant including the office/administration building. The activation of the system shall be by manual operation from the main plant control room and automatic operation via plant wide 'break glass' stations, smoke detectors, optical sensors, infra red detectors and heat detectors as applicable. The detection and initiation of the fire system in electrical switchroom, fire pump house and around the turbine/generator/lubricating oil skid shall be via a ‘double knock’ system. The number of detectors fitted in the plant shall be sufficient to cover all areas of risk. The plant shall have installed sufficient audible units in order that in the event of an evacuation being required that they can be heard in all access areas, the dB level of the units being set at least 5dB above the ambient levels.


Purchaser EFW Contract The complete fire alarm system shall include a fire system control and annunciator panel, which shall be located in the control room, in accordance with the Fire Officer and reasonable insurers requirements such as: diesel fire pump, electric fire pump, fire lift, fire detection and protection system, etc. as a minimum. 2.6.15 Fire Protection and Detection Systems The Plant shall have installed a comprehensive fire protection and detection system, which meets the requirements as indicated in Clause 2.6.14 above. Fire water cannons shall be provided in the waste bunker area. The firewater cannons shall be capable and demonstrably capable during system testing, of covering the entire area of the waste bunker, hopper and Confidential/veterinary/medical waste storage areas. The fire water cannons shall not be installed in any area where they can affect the operation or maintenance of the refuse cranes. The refuse bunkers shall have installed two independent fire detection systems, one heat detectors and the other infra red. These cannons shall be capable of remote operation from the central control room. The Contractor shall provide full details of the cannon nozzles, pressures, spray patterns etc for review by the Purchaser. The fire equipment shall be provided by approved specialist fire equipment suppliers and contractors. Firewater cannons shall be protected by steel frameworks to avoid damage from the waste grabs. The Plant shall have a reciprocating engine directly driven firepump complying with NFPA 20 1980. In addition, the Plant shall have an electrically operated firepump of the same rating. Firepumps must be fitted with a flow line and indicator for testing by the insurer. The fire system pressure shall be maintained with a jockey pump. This jockey pump shall be generously designed to ensure the firepumps do not operate more frequently than once per week. Operation of the firepumps shall be indicated at the DCS by an audible alarm. In addition the status of each of the firepumps, available/running/tripped, shall be indicated on the DCS and on the Fire System Control and Alarm Annunciator panel installed in the main control room. The Plant shall have a firewater storage tank and fire pumps in accordance with the Purchaser’s insurer’s reasonable requirements, the Fire Officer and Building Regulations but in no case shall the firewater tank be capable of storing less than the design firepump capacity for 1 hour. The tank shall be connected to the local water supply and shall be insulated to avoid freezing. A fire pump performance test line, complete with LPC approved Shunt Orifice Flowmeter, shall be installed in order that the fire pumps performance can be tested and demonstrated on a routine basis. The Plant shall be provided with a dry riser. Fire hydrants and fire fighting connections (dry risers and others) shall meet the requirements of the Fire Officer . 2 hour fire protection shall be provided to all buildings, rooms and panels around the waste bunker. This 2 hour protection shall be applied to the glass partition in the Control Room/Crane Cabin as the fire may be dug out by the crane grab and cooled by the firewater cannons. In the event of a fire being detected in the waste bunker area, the control room/crane cabin glass partition shall be cooled by automatically initiated externally fitted fixed water spray nozzles. The turbine-generator and ancillaries shall be protected by a fire detection and fire protection system. The area shall be segregated into three fire zones namely: turbine, generator and lubricating oil skid. The fire detection and protection system shall be installed such that detectors cover all the areas of risk and the fixed nozzle water sprays installed to BS 5839, System type P1 and the NFPA. The fire detection shall be installed as a ‘double knock’ system using dry glass bulb for 1st knock and dedicated heat detectors as the 2nd knock: break glass units shall be installed at each entrance to the Turbine Hall. These detection and protection systems shall be segregated from the main EfW Plant fire detection and protection system.


Purchaser EFW Contract Locations of pipes and equipment shall be selected to minimise the risk of oil fires spreading. Passive fire protection to the generator and the air condenser shall be included to meet the insurer requirements. Smoke extractors shall be fitted the boiler house, refuse bunker roofs and turbine hall to avoid the build up of smoke. All electrical rooms, MCC rooms, DCS rack room, UPS and battery room, crane control room and instrument rooms shall be fitted with an automatic gas (Inergen or similar approved supplier) protection system with detection loops all to NFA 2001. The fire detection shall be a ‘double knock’ system comprising of heat and smoke detectors. In addition there shall be break glass units installed at each entrance to the rooms. The detection system shall be so designed so that the units can be tested to BS 6266 to demonstrate the effectiveness regularly. The rooms shall be of blockwork construction with suitable air tightness for effective use of the gas system. The fuel oil tank shall be bunded to 110% and located away from the main buildings. The tank area shall be well lit with appropriate fire zoning. The filling position and hoses shall be designed to efficiently refuel on-site forklift trucks, shovel loaders, articulated tractor units and other waste vehicles. Suitable metering of the fuel inlet/outlet connection shall be provided. In Sheffield, the existing tank may be used subject to the conditions set out in 1.1. If propane gas burners are required, these systems shall be designed in accordance with pressurised flammable gas regulations and tanks shall be located away from the main building and fitted with appropriate fire zoning. (Not applicable in Sheffield) The boiler auxiliary burner shall have installed a wire and fusible link system such that in the event of an external fire the local fuel supply isolation valve is automatically shut. Extinguishers of suitable types shall be installed in all parts of the facility to BS 5306 part 3. All fire products and services including building products shall be supplied from the Loss Prevention Certification Board's List of Approved Fire and Security Products and Services. Their design, manufacture and installation shall be carried out by companies having achieved LPCB's Quality systems certification. 2.6.16 UPS System The plant shall be provided with an uninterruptible power supply and battery complete with battery charger for specific essential equipment. The UPS system shall maintain all critical information and safety conditions including CEMS and weighbridge for at least 30 minutes. This shall be demonstrated by the Contractor. The UPS system shall supply 240V, 50 Hz, single phase supplies for instrumentation and other essential controls such as the DCS. The UPS shall be self-contained and fed from the 415 V Emergency switchboard. The unit shall be equipped with a static by-pass switch, which provides a no-break changeover to a by-pass supply. The unit shall be fully rated. 2.6.17 Telephone System and PC Network Infrastructure The Contractor shall install a comprehensive telephone system around the Plant based on an ISDX PABX Micro Telephone System being automatic, fully programmable and installed to BS 6450, BS 6305, BS 6789, BS 6328, BS 7378, BS 6833 BS 6317, BS 6320 and BS 7671 the IEE Wiring Regulations 16th Edition. The telephone system shall be compatible with the Onyx Environmental Group network and shall be reviewed by the Purchaser. The Contractor shall install a minimum of three telephone direct lines; to the plant Main Control Room, Switchboard


Purchaser EFW Contract and a dedicated fax line in the Manager’s office. The switchboard shall be designed for a fibre optic incoming cable. The switchboard shall have a 4 hour UPS backup. The ISDX system shall have up to 64 extensions, programmed as listed below.. The automatic switchboard and main marshalling cubicle shall be installed in the Control Equipment Local to the plant Main Control Room. The telephone/modem sockets for switchboard extensions and direct lines, location, type of handset, programme requirements and particular requirements are as follows: Location Telephone

Type Connection Type

Particular Requirements

Weighbridge Desk Top External Line UK Only Weighbridge Desk Top External Line UK Only Weighbridge Modem External Line UK Only Residue Hall Wall Mounted Direct Dial Soundproof Booth and Flashing

Beacon All Electrical Rooms Wall Mounted Direct Dial Amenity Building Wall Mounted Internal Only Capable of receiving external calls CEMS Room Wall Mounted Direct Dial Confidential/veterinary/medical Waste

Wall Mounted Direct Dial Soundproof Booth and Flashing Beacon

Store Wall Mounted Direct Dial Soundproof Booth and Flashing Beacon

Workshops Wall Mounted Internal Only Capable of receiving external calls Laboratory Wall Mounted Direct Dial Lift Motor Room Wall Mounted Direct Dial Fire Lift Wall Mounted Direct Dial Turbine Hall Wall Mounted Direct Dial Soundproof Booth and Flashing

Beacon Water Treatment Wall Mounted Direct Dial Soundproof Booth and Flashing

Beacon Iron and Ash Store Wall Mounted Direct Dial Soundproof Booth and Flashing

Beacon Fuel and Propane Wall Mounted Direct Dial Soundproof Booth and Flashing

Beacon Chemical Tanks Wall Mounted Direct Dial Soundproof Booth and Flashing

Beacon Recycling Area Wall Mounted Direct Dial Soundproof Booth and Flashing

Beacon EDC Meter House Wall Mounted Direct Dial Via Pilot Cable Offices x 3 Desk Type External Line Incoming/Outgoing World-wide Offices x 3 Modem External Line Incoming/Outgoing World-wide Conference Room Desk Type External Line Incoming/Outgoing World-wide Control Room Desk Type Direct Line Incoming/Outgoing World-wide Control Room Desk Type External Line Incoming/Outgoing World-wide +

Designated In Control Room Modem External Line Incoming/Outgoing World-wide Control Equip Room

Desk Type External Line World-wide

Boiler House Levels Wall Mounted Direct Dial Soundproof Booth and Flashing Beacon

FGT residue Handling

Wall Mounted Direct Dial Soundproof Booth and Flashing Beacon

There shall be a direct telephone access from outside the plant to the various plant locations


Purchaser EFW Contract fitted with external lines. Telephones located in other noisy areas shall be wall mounted, installed in soundproof booths with flashing beacon attached. For safety reasons, telephones shall be located in similar positions on each floor and in particular the Boiler Hall. The handsets installed in the Control Room shall be colour coded to identify their connections e.g. Red for Direct Line and Green for External Line designated for receiving all plant Direct Dials. The Direct Dial plant wide telephones shall be programmed in order that upon lifting the handset the telephone direct-dials to the plant Main Control Room designated telephone; but can receive internal calls. The telephones designated as External Line shall be programmed to receive any incoming call but have the dial out capability designated. The Purchaser shall review the locations and positions of all telephones prior to their installation. The telephone board shall have the following facilities as a minimum: • Reception of all the calls at a reception position • Direct routing on arrival of a line to an extension • Transfer of the lines to a night station or answering machine • Voice mail • Option of switching to general ringing, closure, no answering by the reception position and

transfer to a control room • Assignment of an outgoing line to a station • Reservation of a line for reception position • Standby music (customised music) • Centralised charging with printer and monitor screen • Adaptation card for internal cordless telephone and for 10 mobile portables The mobile telephone installation shall be based on a radio system and shall allow: • Making of calls from these telephones with discrimination options from the exchange board • Execution of transfers • Sending of alarm messages • Cover for all of the site The communication exchange equipment shall have the following facilities as a minimum: • Management of call routing • Processing and routing of the calls from the declared mobile extensions • Quality control of the connection and the automatic execution of inter-cell transfer when the

users are on the move • Accessibility of the antennae for maintenance The origin of the installation shall be the cable brought to the telephone board A telephone exchange shall be installed in the Control Equipment local to the plant Main Control Room. The capacity of the telephone exchange shall be mixed network lines and secondary extension lines as shown in the above table. The extension telephones shall be installed, including all associated work involving sockets, connections, etc. All the distribution shall be executed for the secondary extensions in PVC conduit. Multiple-pair cable shall link the zone distribution frames.


Purchaser EFW Contract PC Network The Contractor shall supply and install a PC network infrastructure based on Microsoft Windows NT and Category 5 Data Network. The network shall consist of plantwide fibre optic cables connected to a Medium Capacity Server with a 4 hour UPS backup, mounted in a lockable cabinet, located in the Control Equipment Room. The network shall connect to the Server fibre transceivers via 4-core fibre optic cable to Category 5 UTP outlets located in the plant Main Control Room, the Weighbridge, Conference Room and all the offices; two UTP outlets per location. The Server shall have installed as a minimum 8 GB of hard disc storage plus tape streamer disc type mass storage and CD ROM drives. The PC Network shall be compatible with the Onyx Environmental Group network and shall be reviewed by the Purchaser 2.6.18 Motors - Synchronous and Variable Speed. Motors shall be single speed, continuous duty, three phase, squirrel-cage, and induction type, to comply with BS 4999 and BS 5000. Motors shall be designed for full voltage (across the line) starting. The rating of each motor shall permit the driven equipment to develop its specified capacity continuously without exceeding the standard motor temperature rise limits measured by resistance over an ambient air temperature of 40oC. Motors shall be provided to operate satisfactorily at rated load under short-term voltage dip to 80% rated voltage for 1 minute during start-up of certain other large electric motors connected to the auxiliary power system. All outdoor motors shall be supplied with electric anti-condensation heaters to maintain dry windings during periods of plant shutdown. Motors shall have the following voltage ratings: less than 0.25 kW, 240 V 50 Hz single phase; 0.25 to 150 kW, 415 V 50 Hz 3 phase. Motors greater than 150kW operating at 415V are acceptable provided suitable soft start or variable speed drives are used. The motor type and electrical design shall be reviewed by the Purchaser. Electric motor variable speed drives shall be of the Pulse-Width-Modulated converter type fitted with Regenerative Braking. All motors should have protective enclosures to BS 4999 Part 20 and IP 54 rated generally with IP55 protection when situated outdoors or exposed to the weather or where hose washdown is anticipated, including the lime preparation area. All motors shall be of a totally enclosed fan cooled design, method of cooling IC 0141. The cooling fans shall be directly driven from the motor shaft. All variable speed motors operated in noise sensitive technical halls and areas shall have acoustic hoods fitted to attenuate sound to the required dB limits. In order that routine greasing of the motor bearings can be carried out, the greasing points shall be extended outside the enclosures. 2.6.19 Switchgear and Isolators All LV Switchgear, Isolators and Control Assemblies shall be lockable and comply fully with BS-EN 60439-1: 1994 with an assembly of Form 4 Type 3; separation or equivalent as agreed by the Purchaser such that gases produced by any fault do not impair the operation of functional units in adjacent cubicle. All circuit breakers shall be of the horizontal withdrawable four pole type, with automatically operated shutters covering the main fixed isolating contacts. They shall be provided with


Purchaser EFW Contract provision for locking the shutters in the CLOSED position when the breaker has been withdrawn. The switching mechanism shall be robust and “trip free”, interlocked to prevent access under energised conditions and shall incorporate a mechanically driven switch indicator labelled ON/OFF driven positively in both directions. The circuit breakers shall be equipped with 240 V 50 Hz motor charged spring wound closing mechanism and 110 V shunt tripping and closing release. Volt free auxiliary contacts shall be provided with connections to outgoing terminals to give remote indication of the state of each circuit breaker. All status signals shall be terminated in a common termination section. • All switchboard outgoing feeders shall include but not limited to the following features: Fuse

Switch/Circuit Breaker (four pole) complete with door interlocked handle and “OFF” position padlocking facility, mechanical ON/OFF indicator and correct rated fuse links/trips

• Up to 800 A - Fuse Switches or MCCBs which conform with the requirements of BS 4752 • 800 A and above – MCCBs or ACBs • 3 current transformers for ammeter on front of each compartment • Flush mounting moving iron meter for indicating voltage • 4 position ammeter selector switch to select each phase and OFF, the switch shall be rotary

pattern with a rating of not less than 15 A LV distribution switchgear isolating switches shall be rated in accordance with BS EN 50947-3: 1992. MCCBs shall conform to the requirements of BS 60947-2: 1992. MCBs shall conform to the requirements of BS EN 60898: 1991 and BS 5486 Part 12: 1979. 2.6.20 Electromagnetic Compatibility The Contractor shall ensure that all electrical equipment supplied complies with the EMC Directive and free from communications interference and protect personnel from environmental or usage hazards which can be prevented. Equipment shall have an adequate level of immunity to electromagnetic disturbance and must not itself generate excessive electromagnetic disturbance. 2.6.21 Export Metering Software The Contractor shall provide a computer and computer software to enable interrogation of the export and import meters from a remote location. The Contractor shall supply a modem and telephone connection as part of the Code of Practice 2 metering for remote monitoring, via the software of the import/export meters.


Purchaser EFW Contract 2.7 INSTRUMENTATION AND CONTROL 2.7.1 General The Plant shall be operated by an Integrated Computer Controlled System located in the control room. Typical control loops are, but not limited to, the following:

Furnace and Grate Control Flue Gas Treatment System including Fabric filter Steam Control System Turbogenerator Control (Remote Control only) Water Treatment Package (Could be controlled by separate PLC) Conveyors District Heating

The Contractor shall offer a consistent control philosophy for the Plant using the same DCS. The System shall be designed with sufficient redundancy to enable any one controller to fail with no effect to the rest of the system. All control systems shall be designed to operate within the manufacturer’s recommended computer loading limits and in any case no greater than 60%. The computer control system shall have the provision for 20% expansion. The DCS system shall readily interface and download information to a Windows based portable computer for manipulation. 2.7.2 Security Systems The Contractor shall provide a CCTV system using fixed cameras stationed to monitor sensitive areas such as tipping hall, feed hopper and ash conveyors. These cameras shall be auto-iris, colour, wide angle and suitable for low ambient lighting levels. All camera housings shall be IP64. There shall be a minimum of 13 cameras. The system shall include for 4 colour 14-inch high-resolution monitors located in the control room. The monitors shall be capable of displaying four pictures simultaneously in quad format or zoom to a single picture according to setting. The Contractor shall provide a night security system using appropriate detectors/sensors, high intensity lights and remotely adjustable cameras arranged around the perimeter of the plant. Surveillance of all areas of the site is required at all times. A general evacuation alarm system shall be provided. 2.7.3 Control System The Contractor shall install a Distributed Control System with the operator interface console located in the CCR and module cabinets located in a dedicated control room. The operator interface shall be a comprehensive unitised console comprising of identical parallel CRT based standard operator interface units plus auxiliary bays housing, closed circuit TV, emergency shutdown. From this console, the plant operator shall have command over all control areas and observe the status of the complete Plant. The basic design philosophy of the DCS shall be to utilise multi-function control modules


Purchaser EFW Contract arranged in duty/standby back up pairs for security. The extent and configuration of the control loops and the instrumentation incorporated shall be based on proven experience with Municipal Waste Incinerators of similar size and design. The Contractor shall design, supply, programme, install, commission a monitoring system to display "on-line" the actual operation of the plant compared to its design performance. The system shall measure turbine terminal conditions as follows:-

-Inlet steam pressure, temperature and flow. -Extraction steam pressure and temperature and flow -Exhaust steam pressure and temperature.

Flow will be pressure and temperature compensated. The accuracy of the energy balance will be checked against extraction and exhaust steam temperature and where an error is detected of more than 1% this will raise an alarm and indicate on the display that figures are suspect. The system shall be able to calculate Plant performance and directly prepare monthly management reports. All VDU screens and targets shall be agreed with the Purchaser prior to installation. 2.7.4 Control Loops A summary of the major control areas is as follows:

-Waste Input Control -Combustion Air Control -Furnace Pressure Control -Furnace Temperature Control -Steam Drum Level Control -Deaerator Controls -Steam Pressure Control -Condenser Control -Flue Gas Scrubbing Control -Fuel Oil -Compressed Air -Turbine Auxiliary Control -Auxiliary Controls -Complete control from control room of District Heating network

All vendor packages with individual integrated control systems, shall interface with the DCS. 2.7.5 Safety Measures and Interlocks All control systems shall be arranged to ensure that adequate safety measures are initiated in the event of electrical power failure and other emergency conditions. All plant wide alarm and trip monitoring equipment shall “flag” the alarms and trips to the DCS on a “first up” basis; with time/date tagged to the alarm/trip. A system of interlocking to be incorporated to ensure correct start-up, trips out, and shut down of the control systems. The safety systems shall give protection in accordance with the British Standards of which the following emergency conditions are examples but not an exhaustive list:



-Electrical Power Failure -Instrument Air Failure -Low Drum Water Level -High Drum Water Level -Low Deaerator Water level -High Flue Gas temperature -Combustion Air Failure -Operation of Emergency Stop Buttons

The Contractor shall be consistent with his approach as to the function of Emergency Stops. Full compliance with BS 7671.53-04-05 is required to ensure that the resetting of the Emergency Stop buttons will not restart plant and equipment and that all DCS and PLC equipment “start” signals are disabled in order that the plant and equipment cannot restart without operator intervention via the DCS, PLC’s or MCC’s. 2.7.6 Emissions Monitoring The monitoring of exit flue gases shall be accomplished by a Continuous Emissions Monitoring System (CEMS) which shall basically comprise of the following: sample handling system, analytical device/devices, logging/reporting equipment. The CEMS shall be provided by an approved supplier as detailed in the Contract Schedules. The components measured shall be those stipulated by current legislation, EA IPC operating licence and shall be, as a minimum, Opacity, HCI, S02, CO and 02. The CEMS shall have an emergency electrical supply connected to emergency board as figure 2 (b) in the event of a power failure. The CEMS enclosure shall contain an anti-condensation heater. 2.7.7 Field Instruments A complete set of field instruments and control items shall be included as necessary for the safe and efficient monitoring of the plant. These shall be IP 55 minimum level of protection. The Contractor shall ensure that full access is possible to all electrical, control and instrumentation items for operational and maintenance activities. The layout and routing of the computer cabling shall be reviewed by the Purchaser. 2.7.8 Pneumatically actuated control valves The control valves listed below shall be bypassable and have local upstream and downstream isolation valves and drain valves in order that they can be isolated without the need to take the plant out of service. • air heater condensate return level control (100% capacity bypass valve) • feedwater regulator valve drum water level (100% capacity bypass valve) • condensate tank level control (100% capacity bypass valve) • dearator level control (100% capacity bypass valve)


Purchaser EFW Contract 2.8 DISTRIBUTED CONTROL SYSTEM 2.8.1 General overview This section details the general requirements for the DCS. The Contractor shall present reasonable assurances to the Purchaser that the chosen system equipment will not be obsolete in the next 10 years. In the belief that portions of the system will eventually be withdrawn from sale, the Contractor shall provide to the Purchaser, a firm commitment by the manufacturer of the DCS that for their standard products, there will be either repair capability or equivalent parts and/or products available for a minimum of 10 years from the withdrawal date. Every item detailed in this specification shall be deemed to be within the scope of supply. The design, construction, testing, workmanship and materials selection shall be in accordance with the latest industry standards. The proprietary DCS shall form the plantwide control and monitoring system for the facility and shall be complete with sufficient hardware and software to automatically control the main process and auxiliaries. The basic framework of control and monitoring is detailed in the table below. Basic Control and Monitoring Schedule Automatically control

& monitor Monitor only

Separate from DCS

Per Stream:

Refuse handling (Crane) Refuse feed Primary air Secondary air Auxiliary burners Grate action Combustion process and DeNOx Flue gas extraction Flue gas scrubbing Boiler feedwater Boiler outlet steam Ash discharge Ash conveyors Surface cleaning Emission monitoring Emergency shutdown


Purchaser EFW Contract Common Services:

Steam distribution Condensate & feedwater Blowdown Vacuum condensers Lime preparation (option) Deaerator Active carbon Fuel oil Air compressor Water treatment Turbine generator Turbine controls Turbine/generator health monitoring Residue discharge Electrical distribution Chemical dosing Fire pump 2.8.2 Detailed Requirements The main purpose of the distributed control system is to maintain and optimise production. The brief requirement is therefore a fail safe control (redundant) dual-channel (redundant buses) based open system for both safety and availability with redundant operator stations. The operator stations shall obtain quick and complete information on the process sequence as well as having command over all major control areas (ability to directly intervene at various process points), including turbine generator (selected between pressure and speed control) and steam valve, synchronisation, water treatment plant, ventilation system, compressors, 11kV and 415V circuit breakers, utilities systems and equipment, analysers, systems providing regulatory reports (CEMS), auxiliary burners, grate and every system needed to start-up or restart the plant, including motor drives, from the central control room. The steam turbine governor controls of the turbine governor, generator (AVR, Synchronisations etc.) and Water Treatment Plant may be a stand-alone system (working as part of the plant DCS with interconnection to the DCS through standardised and reliable data bus connections), handling controls informally, while providing an information exchange with the overall plant DCS. The DCS shall be capable of handling and providing the necessary control function for the steam turbine automation (control and auxiliary devices) i.e. start and stop of auxiliary devices, automatic changeover between redundant objects, turning gear control, vacuum breaker control, emergency stop valve control and test, set point adjustment overspeed test, gland steam control etc. The adopted process control concept shall define three levels of control namely: • Process control by means of a distributed control system (DCS). • Process safeguarding by means of a safety related system (sequential shutdown of plant). • Fire detection and mitigation via an independent fire system.



Key Features Requirements Process control concept: - Process control by DCS - Process safeguarding by DCS and safety related system - Fire & gas detection via independent fire & gas systems

Yes Yes Yes Yes

System architecture Distributed and open DCS type - Operator & engineering stations - Process control stations (process controller) - Programmable controller

The Contractor shall provide a list of selected suppliers to be approved by Purchaser. Typically ABB’s "Advant OCS”; Bailey’s “Freelance 2000”; Fisher Rosemount (Integrator); Foxboro; Honeywell’s “Total Plant Solution”; Rockwell’s “Open Network Architecture”; Siemens’s “SIMATIC PCS 7”; Toshiba’s “TOSDIC-CIE 1200 Integrated Control System”; Yokogawa etc.

Reliability: fail safe control systems (redundancy at all levels) - Operator stations (configured redundantly) - Control networks (configured redundantly) - Process control station: CPUs, memories & power modules (redundant) - Fieldbus network (configured redundantly) - Power supplies, volt. Regulators, backup batteries & chargers (redundant) - I/O boards for regulatory control (configured redundantly)

Yes Yes Yes Hot stand by type, with a fully bumpless take-over Yes Yes Yes

Open systems integration - Operator command over turbine genr control & major ctrl areas - Interface with the turbine generator control cubicle - Interface with other packages: CEMS; water treatment

Integration with other computer systems in the plant Yes Yes Yes

Communications (Transmission Lines) - Highest level (management information system network) - Intermediate level (control LAN) - Lowest level (field bus)

MIS network (Ethernet - TCP/IP) @ 10Mbps Redundant control LAN: Ethernet TCP/IP @ 10Mbps Noise-resistant fieldbuses @ 500kbps to 2Mbps

Upward Integration into MIS and sharing between plant operations and other business related functions (other departments at corporate level)

Vertical integration of process, operations and business management, allowing: data exchange and access to database/network communications by personnel, examination of key aspects of plant at any time – in real time, looking up the operations data, examining the cost/revenue accounts etc.

2.8.3 System Architecture The hierarchical structure shall be divided into three levels as a minimum namely: operator, process control and direct connection to plant or process and shall be capable of upward integration into a corporate management information system at a remote location. The system configuration shall allow direct connection of certain programmable controllers and personal computers to the control LAN. Operator Level The operator level shall include traditional control system functions such as operation and observation (process supervision and intervention) from the synoptic views, command over all major control areas, archiving and logs, trends and alarms (event and alarm handling), process sectioning and operator authority definition, information search capabilities, curve presentation of historical data and system status monitoring and display, including free format generation of mandatory/regulatory reports. Supervision shall be carried out on supervisory computers located in operator’s console in a central control room. System operators shall be capable of reaching all parts of the plant from the screens in front of them. The operator stations shall be redundant and use standard PC hardware, either conventional high-performance PC or industrial PC, running on Windows NT and other Window based operating systems. The system software shall be capable of being transferred to any PC. One engineering station and two operator stations shall be installed at the operator level. The engineering station shall be used to configure and commission the system. It shall be a standard desktop PC. The operator level PC shall also be capable of being used for configuration tasks. A separate


Purchaser EFW Contract station shall be dedicated to the CEMS. Emissions monitoring data and calculations concerning emissions, mandatory/regulatory reports and performance of the plant shall be automatically generated, logged, stored and transmitted to the DCS and MIS. The reports shall be customised to comply with the following requirements as a minimum: operating licence, the Environmental Agency’s Integrated Pollution Control Guidance Note S2 5.01: Waste Incineration, all statutory requirements, regulations, related guidance notes and codes of practice that are in force as agreed with the Purchaser. Process Level The process level shall consist of process stations, which consist of several rack-mounted modules that can be extended with I/O units. The process station shall be configured redundantly (CPU and power module redundancy). Modular plug-in input/output modules shall be used in accordance with the type and quantity of process signals. Loop and logic control functions shall be processed in their own process stations. The processing capacity and speed of the process station shall be easily adapted to the demands of the automation task in order to achieve the desired level of performance and allowing for 40% spare capacity and 20% for future system expansion. 2.8.4 System communication The operator/engineering and process levels shall communicate with each other via redundant system buses – Ethernet TCP/IP high speed control LAN according to ISO 8802.3 (IEEE 802.3) at 10Mbps and employ a coaxial cable as the transmission media. Connection to a higher plant management information system level shall be through the standard TCP/IP protocol. A noise-resistant, high-performing (500Kbps to 2Mbps) redundant fieldbus network, which complies with control area network (CAN) shall be used for connecting process controllers to I/O units, various drive units and subsystems, such as weighing systems, PLCs for electrical control, controller, remote I/O units, fixed and variable speed motor drives, safety systems as well as emission quality measuring and control etc. Intelligent I/O Modules The Intelligent I/O modules shall link the CPU module and the process. They shall receive data from sensors and contacts, primary detectors, transmitters and other field devices and issue positioning commands and feedback messages to the process. The I/O modules shall have the following facilities as a minimum, to be adapted to the manufacturers proposed technology : • Input and conversion of conventional types of process signals and signal levels • Galvanic or optical isolation between process and system • Status LEDS for inputs/outputs • Externally-powered outputs • Automatic fault detection, fault signalling and temperature monitoring • Sensor and line-break monitoring • Short-circuit and overload protected digital outputs • Digital inputs protected against incorrect polarity • Isolated analogue inputs • Replaceable during operation • No switches, jumpers or potentiometers – all settings shall be configured by the software • Front panel connection of process signals via screw terminals with keyed blocks codeable

against incorrect connection 2.8.5 Mechanical Design


Purchaser EFW Contract The construction of the process station, which consists of several rack-mounted modules – including link modules, CPU modules with its input/output modules, communication modules etc. shall be made of sheet steel material. The front panel connection shall be user friendly and make wall mounting possible. All modules shall be contained within a metal enclosure, with a swingout frame, provide exceptional mechanical ruggedness, electromagnetic immunity and be inserted into racks from the front and secured in position with screws. I/O signals shall be marshalled in the I/O marshalling terminals of the process station and taken to the modules using suitable multicore cable enclosed in, and mechanically protected by trunking, so that external connections go through connection units, (cables terminated on Klippon marshalling terminals) fitted inside the enclosure. These marshalling terminals shall be connected to the I/O plant interface modules as agreed with the Purchaser. I/O marshalling terminals shall include for at least 10% spare signals. The multicore cable connecting the marshalling with the process control unit shall include sufficient cores to carry all the I/O signals, including the signals for future use, and shall include sufficient spare cores to carry 10% of the signals. Each process station shall include a plant schedule securely fixed to the inside of the cubicle door. The schedule shall include full and complete details of the plant signals. The enclosure shall be suitable for bottom cable entry and the degree of protection shall be a minimum of IP31 if located in an air-conditioned room: ventilated, tropical and sealed, with or without heat exchanger and with sheet steel or glazed door. The module housing shall completely enclose any printed circuit board and other internal assemblies. The process stations shall be designed to operate in ambient conditions of 0 to 50 oC. A temperature sensor shall monitor the temperature of the module and trigger an alarm when the maximum value permitted is reached. Manufacturers proposed technology shall be taken into account for application of the above requirements. 2.8.6 Quality and Electromagnetic Compatibility The entire DCS shall comply with the European Union EMC standards. 2.8.7 Plant-Specific Displays Plant specific displays geared to the demands of the plant operator shall be configured to depict process activities. This shall include emissions and plant performance graphic displays. Current process data or process states shall be viewed in digital or analogue form (e.g. bargraphs, dynamic filling and trend windows). Depending on process states, graphic symbols shall be replaced, flash and change colour and position in the graphic display. Selected process points shall be viewed either via faceplates in the graphic displays or via the standard group displays. If display selector fields or buttons have been configured, a specific selection hierarchy shall be set up within free graphics for operation. A standard selection hierarchy shall be offered by the display menu. This menu shall appear on the lower part of the screen, and shall be capable of being cancelled in any situation to show all display types in which the required process point is displayed. The latest alarm shall be displayed at the top of the screen, no matter which display is active. The alarm shall also be announced audibly to make the operator aware of it. From this alarm line, the troubled object shall be capable of being selected for inspection and control directly. The alarm list shall be capable of being chosen to examine the previous alarms. Process events and alarms shall be time-tagged in the process controllers for best possible timing accuracy. Event messages and alarms shall be grouped and gated in a multitude of ways, ensuring that only relevant and primary events are brought to the operator’s attention. 2.8.8 Alarms


Purchaser EFW Contract The alarm shall also have the following features available: • Be issued over a limit set-up on an analogue value and/or a change in digital level • Be filtered; deletion of alarms in cascade and inhibition of alarms on systems not operating

or stopped • Be split into 3 levels:

Level 1: urgent alarm causing a release Level 2: urgent alarm without release but requiring a rapid action from the operator Level 3: information without any urgent aspect

• Each level shall be subject to a specific treatment which shall combine: Alarm appearance on the screen Addition in the alarms list Buzzer warning Activation of the plant warning system Current stream printer printing Archiving in a monthly file

2.8.9 Archiving The DCS shall be capable of calculating hourly average values upon 50 analogue values and store them for a period of 2 months. These data shall be stored on a monthly data storage unit (mass storage on a suitable fixed and removable media). The system shall be able to sample 50 analogue values in less than 1 minute and store them in a 10 days storage file. The stored values shall be capable of being displayed in a graphical format. 2.8.10 Configuration and Commissioning A standard PC shall serve as an engineering station, while a laptop computer shall be used for commissioning and service. The operators shall witness the elaboration of the synoptic views. The functionality of the graphic screen creation shall be tailored to match the requirements of the operators who shall also be involved with the step-by-step of the screen creation. The process controllers shall be capable of being configured, debugged and documented either on-line (while DCS is running) or off-line from the engineering station. For off-line configuration, the DCS shall not be necessary – the application program shall be capable of being transferred to the system at any time. The software tool for configuration, parameter definition and commissioning shall offer the following features: • A single software engineering tool for configuration of the automation functions and the

operator interface with displays and logs • Graphic configuration with high performance editors according to IEC 1131-3 standard in

the following programming languages or similar languages reviewed by the Purchaser: -Function block diagram (FBD) for performing loop and logic control functions, i.e. loop flow

diagram (LFD) and logic sequence diagram (LSD) -Instruction list (IL) -Ladder diagram (LD) -Sequential function chart (SFC) or sequence flow diagram (SFD)

• A function block library with more than 170 proven and tested functions, greatly exceeding the basic ones outlined in IEC 1131-3

• Large ( > 200 symbols), extendible and user-definable macro libraries for graphic symbols • Project tree for flexible program generation and transparent program structuring (managing

and commissioning the entire user program) • General checking and plausibility checking of the automation functions via off- and on-line

test functions, including the option to call up the error source directly from the error list


Purchaser EFW Contract • Variables and tags easily found in any editor with the help of convenient cross-reference

functions • ASCII importing and exporting of programs, displays, variables, tags and parts of the project

tree • Password protection to prevent unwanted modification • Systemwide uniform graphic documentation of the entire user program including automatic

system communication and peer-to-peer communications • An integrated on-line Help facility under Windows • Backup of the project file to an operator station (e.g. for reverse documentation) Manufacturers proposed technology shall be taken into account for application of the above requirements. During commissioning, all or some of the user program shall be loaded into the operator and process stations. It shall then be possible to: • Load modifications • Start and stop process stations • Start and stop reset tasks • Define parameters for function modules, and activate them • Display, set and track process values • Combine any values at any time in a trend window • Perform version and status checks • Perform diagnostics, including network diagnostics • Programme and set up data base of the DCS • Set up automatic report forms • Exchange data with Excel, Word, Access, G2 etc. • Call direct operating views with the same direct access as the operator stations • Optimise control/reconfigure 2.8.11 Sensors and Measuring Equipment The Contractor shall supply a fully instrumented plant such that all parameters measured on an individual system will enable the operator to fully understand how the plant is operating and can diagnose faults from the measurements. The installation shall be fail safe (separate field measuring instruments shall be employed for control and monitoring/indication purposes associated with furnace chamber temperature, flue gas temperature outlet scrubber and boiler drum water level). and fitted with all regulatory control systems to optimise the plant operation and avoid any hazards to the operator staff and the equipment. The installation associated with Boiler drum water level measurement shall comply with BS1113 Section 7 and Pressure Systems and Transportable Gas Regulations 1989 in force. The installation shall also include all pressure, temperature, and sample points needed for the execution of the performance tests and current operational control. Each waste incineration line shall include in addition all measuring points to allow the calculation of the waste LHV, boiler yield (separated losses method) and steam cycle yield as well as to identify and locate the current maximum continuous rating conditions (MCR) point within the firing diagram. The Contractor shall provide a sufficient number of analogue and digital I/O capacity (channels). Analytical instrumentation taking water samples via coolers (locally mounted) and sample lines from the boiler water, steam and condensate shall be installed in the plant laboratory. The analytical instrument shall measure parameters such as conductivity, pH, dissolved oxygen, silica and sodium. All pressure tappings greater than 10 bars and associated with pressure, level and flow measurement shall have double isolation valves fitted.


Purchaser EFW Contract 2.8.12 Performance, Consumables and Energy Production, and Emission Metering In addition to sensors and actuators necessary to run the plant, the Contractor shall provide equipment for the technical supervision of the plant and the preparation of regulatory reports in general and the following in particular: • Reagents consumption measurement • Water consumption measurement • Electricity consumption and production measurement • Steam production measurement as well condensate measurement back to boilers • Emissions and other plant performance measurement The above measurements necessitate at least the following instrumentation interfaced with the DCS.

MEASUREMENT RATIO INSTRUMENTATION REPORTED TO DCS MSW Refuse Processed (t/h) MSW weight input via weighbridge software to DCS, refuse

crane grab load interfaced to DCS, number of grabs to each furnace hopper to be recorded

Bottom Ash/Refuse Processed Bottom ash weight input via weighbridge software to DCS FGT Residues/ Refuse Processed

FGT Residues weight input via weighbridge software to DCS

Metals/ Refuse Processed Metals weight input via weighbridge software to DCS Chemicals/ Refuse Processed Caustic and acid weights input via weighbridge software to

DCS Consumables/ Refuse Processed

Urea and activated carbon weight input via weighbridge software to DCS. The urea and activated carbon injection equipment shall be designed with a framework to allow load cells to be readily fitted by others during the performance test and during operation.

Lime storage Load cells on silo Lime consumption/ Refuse Processed

Load cells on preparation tank

Process water consumption/ Refuse Processed

DCS signal from process water flowmeter

Raw water consumption/ Refuse Processed

DCS signal from raw water flowmeter

Total condensate returned to boilers

DCS signal from condensate flowmeter

DCS signal from steam flowmeters Steam produced per stream and total steam produced, steam / Refuse Processed Fuel oil storage capacity DCS signal from level transmitter Electricity generated DCS signal from turbine generator Turbine/generator running hours and availability

DCS signal from turbine health monitoring

Sewer flow DCS signal from sewer outlet as per IPC requirements CEMS Annual releases and monthly release rates

DCS to compile monthly and annual IPC requirements and reports. (temperature at boiler outlet to be monitored at DCS)

Export Power/Refuse Processed Export meter to DCS Parasitic load/Refuse Processed Metering on HV side of 11kV/415V auxiliary transformer


Purchaser EFW Contract 2.8.13 DCS Requirements

SYSTEM DATA DESCRIPTION

REQUIREMENTS

Operator/Engineering interface station

CPU Min. of Intel Pentium III or similar OS Compatibility with MS-DOS 7, Microsoft

windows NT or other windows based operating system.

Windows graphical user interface (GUI) Free format graphic screen creation Memory capacity Minimum of 256MB high performance (to be

proposed by the manufacturer subject to Purchaser review.

Chipset To be proposed by the manufacturer subject to Purchaser review.

Hard disk drive (HDD) storage capacity Minimum of 6.4GB UDMA hard disk Compact disk ROM drive (CDROM) 32 speed, only on Engineering Stations Multimedia features N/A Data storage unit (mass storage on fixed and Removable media)

Min. of 3 magnetic, optical or tape streamer disk type for long term data storage of: operator station data, CEMS data & plant performance calculation data

Advance graphics features To be proposed by Manufacturer subject to Purchaser review.

Sound N/A Communications 56 kbps data/fax/internet/ modem Exchange of data with other system and Applications (software bundle) i.e. access of Real-time process database to resident software and all surrounding computers

Exchanges possibilities with such systems as : Office application (Microsoft office, Excel etc.), Data base (Excess & oracle), G2 from GENSYM, plant network via Ethernet, data to Purchaser’s Management Information Systems (MIS)

No of tags/station: (points displayed to operator)

Minimum of 2,048 per station

Number of monitoring stations Minimum of 2 Number of emissions monitoring station Minimum of 1 (with associated reports

printer & long term storage device) or provide standalone PC dedicated to CEMS in the CCR.

Number of plant performance calculation station

Minimum of 1 (with associated reports printer & data storage device)

Number of engineering station Minimum of 1 for configuration Laptop computer For commissioning and service Stand alone PC For office applications High resolution video colour projector set with a large screen (1.5 m x 1.5 m)

To be installed in the conference room as a presentation tool and to incorporate remote control with a built-in mouse and facilities for changing and viewing locally, the schematic view of the entire process and electrical parts of the plant from the conference room


Purchaser EFW Contract • Viewable image size 30” to 300” • Display 3 panel polysilicon LCD • Resolution 1,024 x 768 • Lamp type 150W DC - 260W DC metal halide • Lamp life (Hrs) Minimum of 800 • Input sources 3 selectable • Speakers 2 x 1W • Video compatibility PAL, NTSC, SECAM, S-Video CRT (high resolution computer monitors)

For high level graphics use. Monitor with enhanced display to provide a high quality image

• Screen size/viewable 21”/20” SVGA • Resolution and refresh rate 1,280 x 1,024 @ 75Hz or better, non-

interlaced display and flicker-free image • Screen controls Controls shall be easy to use and locate.

Basic, geometry and colour controls are all needed. Digital controls with on-screen displays are preferred

• Safety and ergonomics Tilt and swivel base, non-glare, MPR-II or TCO certified

• Others Aperture grille technology, 0.25 aperture grille pitch or better, plug & play +, colour management software

Printers (No. and type of event/alarm printers)

Minimum of 5 printers 720 dpi resolution, comprising 3 for alarms & data logging, reports printing and a coloured printer for the operator station data plus 1 each for CEMS data and plant performance calculation data

Mouse/trackball Mouse or trackball Touch panel Optional Operator’s keyboard Dedicated to process control giving operator

direct access to normal control functions Uninterruptible power supply for DCS (redundant)

Sized for 30 minutes supply with 30% reserve

Display colours Minimum of 256 Mimic views Optional Number of tag characters Minimum of 16 Real-time trends Minimum 128 points (cycle 1,5,10,30,60

seconds) Historical trends Minimum 512 points (cycle 1,2,10,20,30

minutes) Historical storage points Minimum of 10,000 Graphic screens Minimum of 64 Alarm grades (user configured) 3 types (very serious, serious and minor),

latest alarm displayed at the top of the screen & announced audibly

Labels (associated with the number of tags)

Minimum of 2,048

Guidance message Minimum of 512


Purchaser EFW Contract Software features • Transparent & rapid operation Yes • Large no. of standard displays Overview, group, faceplate, SFC, time

scheduler, trend, message & operator hint list, system etc.

• Easy operation using mouse & keyboard

Yes

• Direct & rapid selection of measuring points

Yes

• Full graphic display Yes • Uniform message concept Clearly arranged display of messages &

operator hints • Configurable sound for each

message Yes

• Messages displayed in different colours

Yes

• No. of user groups/access profiles Minimum of 16 • Specific password for each user Access to operator station function shall be

security protected by keylock and password • Trend archiving Yes, locally at plant. In addition, archived

files requested from stations on the Ethernet • Logging (signal sequence, plant

and disturbance course logs) To document events, states & sequences from the process

• System diagnostics Minimum of 3 detailed levels (system, station and module overviews)

• Easy and secure on-line maintenance

System diagnostic utilities, portable diagnostic computer, system maintenance alarms, screen error codes and diagnostic messages pointing to documentation, LED status indicators

• Self-documenting and periodic reports for plant management – custom display/report generation (free format report generation and documentation of data from plant)

Daily collection/summary of operating data from the individual plant and supervisory computers: operation reports, water and reagents consumption, electricity consumption and production (revenues), steam production counting as well as condensate back to boilers, emissions etc., as a minimum

Functions – Process visualisation (Display): Coloured mapped graphics

Information on automatic functions represented by graphic symbols

• Plant-specific free graphic displays: Single displays of the entire process lines, including PID and function with mini trend display including emission and plant performance, indication lights, analogue displays, electrical single line diagram, circuit breakers and disconnecting switches, synchronisation column, synchro coupler and associated devices, DCS architecture etc.


Purchaser EFW Contract • Standard displays: (User

configured) 1 overview, 96 group, 42 trend, time scheduler, SFC, system, faceplates for process points, 12 signal sequence, disturbance course and plant logs, 2000 message list and lines, and operator hint list display, tabulated information on command etc. as a minimum

• Advanced graphic features Including split vision, windowing and zooming

• Display update Typical of 1 s • Display build up time Typical of 1 to 2 s Control LAN (System bus) Configured redundantly Bus type Full ethernet or similar Application System bus. Connection of operator stations

(for operation and observation), engineering station and process stations

Access method ISO 8802.3 (IEEE802.3) CSMA/CD or a suitable deterministic access method

Transmission speed 10 MBPS Transmission cable Coaxial cable or similar Transmission method or standard Baseband 10 BASE 5 or similar Transmission Distance > 500 m, extendible to 1555 m through the

use of repeaters Number of connection nodes Up to 99 consisting of operator stns, process

controllers, general-use PCs, PLCs etc. Transmission protocol TCP/IP or similar EMS features EMC council directive 89/336/EEC Process controller (Process station) For logic, sequencing, data and text,

arithmetic, reporting, and regulatory control (including self-tuning adaptive control and advanced PID control), digital positioning, direct electronic weighing and direct control of variable speed motor drives, calculation and cumulative functions and communication with other makes of programmable controllers, including peer-to-peer communications

Link modules For connecting the mains supply & for interconnection of the racks

CPU modules (two for CPU redundancy)

For processing the application program including communication: Minimum of 32-bit processor with high speeds bit processing

• RAM capacity Minimum of 16 MB SRAM with battery backup

• EEPROM For storing station/operating data • Task execution Cyclic, cycle times to be proposed by

Manufacturers subject to Purchaser review, configurable, event-driven, free running (PLC-mode)

• Process interface I/O modules for analogue and digital sensors replaceable during operation


Purchaser EFW Contract • Interfaces Ethernet connection for system

communication and for linking to a redundant CPU, field bus, RS 232 for diagnostics, RS 485 for linking subsystems e.g. weighing systems & PLCs

• EMC Radio interference suppression to EN 55022 & EN 55014, interference immunity to IEC 801, EN 60801, VDE 0843, severity level 3 and NAMUR industrial standard class II

• Ambient temperature 0 to 50 oC • Program languages FBD (LFD & LSD); IL; LD; SFC or SFD or

similar reviewed by the Purchaser • Program capacities Minimum of 96 control loops (including 16

high-speed tasks) & 64 sequences/station • General-purpose timers Minimum of 192 • General-purpose counters Minimum of 96 • Polynomial lines Minimum of 48 Process I/O modules & number of I/O points

For process connection. Intelligent and include own processors. Minimum of 1800 points

• Scan-time (signal update) User configurable, minimum of 5ms for digital signals and 20 ms for analogue signals

• Total I/O capacity (I/O channels) Minimum of 1800 • Analogue/pulse input to match application • Analogue/pulse output to match application • Digital input to match application • Digital output to match application Communication modules (redundant) For interfacing other systems or devices Process station functions and function blocks

Continuous process application

• Analogue processing I/p & o/p conversion, linearisation, delay & dead time filter, averaging/extreme value, determination in time, set point adjustment, counter with analogue i/p, time scheduler, regulatory & motor-drive control with manual supervision & intervention, self tuning and adaptive PID control etc.

• Digital value processing Digital output, monostable, switch on/switch off delay, pulse time counter, pushbutton etc.

• Loop control Continuous control, step control, on/off control, three position control, ratio control, basic functions etc.

• Logic control Individual drive functions, instrumentation sequence control, dosing circuits etc.

• Logic functions Logic processing, average/extreme value determination, comparator, binary switch, multiplexer, converter (data type and code), flip-flop, edge detection, string blocks, summertime switching via clock etc.

• Monitoring Analogue, binary, event, connection



monitoring and audible alarm control. • Acquisition Disturbance course acquisition, trend

acquisition • Arithmetic functions Basic arithmetic, numerical, logarithmic,

trigonometric functions and analogue value & time limitation

• Fieldbus functions Master and slave functions (PLC, weighing systems…)

• Send/receive Send and receive blocks for systemwide communication

Power supply (configured redundantly) Typically 230 VAC (-15% to +10%); 115 VAC (-15% to +10%); 24 VDC (-20% to +35%); interruption (< 20 ms without function disturbance), to be proposed by the manufacturer subject to Purchaser review

Field bus (Station bus) Configured redundantly Application Station bus and as connection to additional

I/O units, PLCs, remote I/O, weighing systems etc.

Transmission distance (short to medium)

Minimum of 400 metres

Transmission rate 500 KBPS to 2Mbps Data throughput update time for signals Minimum of 5ms (digital) or 20ms (analogue) Transmission cable Screened, suitable for the operation

environment and signal type to be carried. Twisted pair/s for noise immunity and shielded twisted pair/s to reduce further the effects of extraneous interference signals.

EMC feature EMC council directive 89/336/EEC Programmable controllers (PLCs) Number of I/O points Minimum of 1800 Program memory To be proposed by manufacture subject to

Purchaser review. Run speed to be proposed by manufacturer subject to

Purchaser review Program languages Ladder diagram, SFC or similar Programmable external interrupts 8 I/O modules Power supply to be configured redundantly Standard type modules to be proposed by the manufacturer subject to Purchaser review.

Communication mode With 4 serial interfaces RS232C, RS 485, RS 422 etc. for field buses

Environmental conditions: Operating conditions.

Ambient temperature 0 to 50oC Relative humidity permitted [ 75% annual average, no condensation; [

95% for 30 days per year


Purchaser EFW Contract Equipment implementation and integration

The Contractor shall propose a layout of the central control room, which shall have a window partition with the engineering station. The process controller and interface enclosure shall be located in a safe & clean room environment, which is air conditioned, filtered and pressurised to a positive pressure

Arrangement of operators console The operators console, when fully assembled to form 1 composite suite of desk type panel housing all equipment & facilities required by the operator for the day to day ctrl & monitoring of the plant

An assembly with a horizontal or inclined control panel or a combination of both, which incorporates PC hardware, VDU,

Operators console construction Desk type assembly comprising sections for: 2 operator stations each comprising keyboard, VDU, disk drives & associated electronics, CEMS, weighbridge control station, 2 emergency shutdown buttons, CCTV monitor & camera selector unit, telephone set, fire fighting system, stand alone PC, socket outlets, plus separate alarms events printer and logs reports printer tables at each end and other utilities as a minimum

Cable entry Bottom cable entry Engineering station To be located in a separate room within the

vicinity of the central control room & separated by a transparent window

User support Planned user support, training, documentation, human support, change mechanism, continued user support etc.

Documentation As built, programming and setting data and files of the DCS

Equipment standardisation Shall be selected from one supplier with standardised modules used throughout

Agency approvals Class/division Certified for use in hazardous locations UL, CE Electromagnetic compatibility (EMC) feature

EMC council directive 89/336/EEC

Security systems Type of CCTV camera (coloured) Fixed, Pan and tilt, Infra red as agreed with

the Purchaser Number of cameras Minimum of 13 Process/site surveillance/areas covered Site entrance, weighbridge x 2, tipping hall,

feed hopper, grate, ash conveyor, bottom ash storage, turbine hall, chimney, others as reviewed by the Purchaser

IP rating Minimum of IP 54


Purchaser EFW Contract Type and number of monitors Minimum of 4 high resolution colour

monitors


Purchaser EFW Contract Number of pictures displayed on monitors

Up to 16

Multiplex features Yes, 13 cameras to be fully multiplexed Recording and playback media VCR Night security Yes Evacuation alarm Yes Auxiliary equipment Yes Installation and cabling Installation To BS 7671 and latest industry standard Cabling To BS 7671 and latest industry standard Labelling To BS 5378 Parts 1, 2 & 3 and BS EN

60439-1 Earthing Clean earth in accordance with

Manufacturers standards for the DCS and other sensitive electronic equipment and control systems


Purchaser EFW Contract 2.9 OTHER FACILITIES 2.9.1 Laboratory A fully equipped and furnished laboratory shall be provided in line with the technical requirements of the Plant complete with a manual analyser cubicle, installed conductivity meters, sodium monitors, dissolved oxygen analysers and pH meters to fully analyse boiler waters and condensate together with the initial fill of these reagents. The laboratory shall be located adjacent to the demineralisation plant with sampling facilities capable of being safely routed directly to the laboratory. The laboratory shall be fitted with laboratory grade facilities: laboratory work benches, externally vented fume cupboard, a wash basin, hot and cold water, drying facilities and desk. 2.9.2 Galleries, ladders and access/maintenance areas Stairway access shall be provided to all items requiring regular/routine operation and maintenance. Galleries shall be provided to enable access to all equipment that requires maintenance. The Plant shall be designed to enable the maximum access to equipment for maintenance purposes. Dead ends shall be avoided. Permanent safe access shall be provided in accordance with the relevant British Standard (hoops correctly spaced on the back of vertical ladders, correct handrail heights and kickboards, correct step width on stairs) to allow normal inspection and routine maintenance on major items of plant and machinery. Access for entry into pressure vessels boiler drums and gas passes must be adequate and in line with the most recent Confined Space Regulations. Platforms, hatches and channel covers shall be galvanised. 2.9.3 Maintenance Hoists and Beams and Working Areas Items of equipment weighing more than 25kg that require regular removal/replacement during operation or for routine maintenance at each scheduled maintenance shutdown shall be provided with a maintenance beam. Items of equipment weighing more than 25 kg requiring less frequent removal/replacement for maintenance shall be provided with access for mobile or temporary lifting equipment provided by the purchaser. If the provision of such access is not possible maintenance beams shall be provided. The following shall also be provided with lifting beams: Primary and secondary air fans ID fan Electrical maintenance hoists and lifting beams shall be provided for the following: Waste feed crane Waste feed hoppers Reagent and chemical handling areas as necessary Residue handling areas as necessary Steam Turbine hall Fabric Filter covers Workshop


Purchaser EFW Contract The Contractor shall ensure that when lifting items of equipment, the lifting hoists have clear unobstructed lifts, working areas and the ability to move horizontally. Sufficient anchorage points shall be provided elsewhere to enable effective maintenance of all items of equipment. 2.9.4 Mechanical/Electrical/Instrumentation Workshop A mechanical workshop with a minimum 150m2 floor area shall be provided with access at ground level for fork lift truck vehicles. An electrical/instrumentation clean workshop shall be provided with a minimum 50m2 floor area, which can be located at any level and segregated from the mechanical workshop. The maintenance workshop shall have a entrance door wider than 3 metres. The workshops shall be fully serviced with instrument air, plant air and electrical supplies at all voltages. 2.9.5 Stores A stores area with a minimum of 100m2 floor area shall be provided. Forklift truck access shall be provided. 2.9.6 Insulation Specification BS 5322 and BS 5970 for energy efficiency purposes and in areas of personnel access based on a cold face temperature of 50oC. Removable valve and flange boxes shall be provided and cladding shall be aluminium of minimum thickness 0.75mm. Trace heating shall be installed in such a manner that pipe sections and equipment can be removed without the need to interrupt other sections of trace heating. 2.9.7 Instrument and Plant Air Instrument and Plant air shall be provided with at least 50% standby compressor capacity and 100% standby drier capacity with a dewpoint of -20 oC. Reciprocating air compressors shall not be permitted. Forklift truck access shall be provided to the instrument and plant air compressor room. 2.9.8 Vacuumation System A centralised vacuumation system shall be provided to enable a high standard of housekeeping with in the Plant. Layout of connection points to be reviewed by the Purchaser 2.9.9 Pipework The Contractor shall design the Plant pipework in conformance with British Standards. All pipework shall be painted or banded, named and identified in accordance with BS 1710 with the provision of arrows indicating the direction of flow. All pipework shall be laid to falls to avoid ponding of liquid with the provisions of drains to completely drain any system. All pipework of 50mm diameter and above shall be office


Purchaser EFW Contract designed using isometric drawings and not be site routed. No drain pipework shall discharge directly onto floors, suitable gullies shall be provided. 2.9.10 Security The Contractor shall provide site security facilities in the form of a gatehouse with the provision for weighbridge weighing, monitoring and control activities. These functions shall be duplicated in the CCR. In Sheffield, the existing gatehouse may be re-used subject to the requirements of 1.1. 2.9.11 Colour coding and identification of systems Unique permanent tags shall be fitted to all plant and equipment, valves, electrical and mechanical equipment, cabinets and safety systems detailing identification number and purpose and reviewed by the Purchaser 2.9.12 Isolation and locking mechanisms Electrical panels, isolators, pipeline valves and other items where required for safe maintenance shall be capable of being locked off by means of key, padlock or other approved method. The list of applicable items shall be agreed with the Purchaser. 2.9.13 Spares The Contractor shall supply a complete list of all spares including critical and 6 month O&M spares for review by the Purchaser. The Contractor has priced in Schedule 16 for costs of spares. These documents shall be priced and open for acceptance.


Purchaser EFW Contract 2.10 CIVIL ENGINEERING AND BUILDING 2.10.1 General The whole civil engineering design shall be carried out by the Contractor and shall be under his entire responsibility. The Contractor shall provide all demolition, building and civil engineering works for the clearance, support and housing of the plant and equipment contained in the Plant together with all necessary internal and external infrastructure works to enable safe and efficient operation of the Site and Plant. Details of the civil works are described in the Detailed Civil Engineering Specification attached hereto in Part 2 Volume 2 of this Specification. Principal elements shall include all necessary temporary and permanent works associated with the construction including, but not limited to: standby substation, main export substation, weighbridge, fuel tanks, water treatment tanks, interceptors, main plant buildings, foundations, piling, structures, cladding, electrical and mechanical services, roads, landscaping ….. 2.10.2 Design The Contractor shall be responsible for the detailed design and co-ordination of all elements of the civil engineering and building works. All design shall be carried out with due regard to accepted current engineering practice and in strict accordance with all relevant current Legislation, Regulations, British Standards, Codes of Practice and, current Building Regulations. Structural elements shall be designed to carry specific loads imposed by plant and machinery and complimented by design loads taken from BS 6399, Design Loadings for Buildings. Design wind loads shall be generated using CP3: Chapter V : Part 2, Wind Loads, and snow loads shall be taken from BS 6399, Design Loadings for Buildings. On-site access roads shall be designed in accordance with Highways Agency Design Manual for Roads and Bridges, TRRL Report LR 1132, TRRL Report LR 192 and associated Council Engineer's Department publications, relevant local Standards and Acts. The Contractor shall submit the relevant drawings for Building Regulation approval in co-ordination with and after review by the Purchaser and his Consultant, and the Contractor shall make such detailed submissions as may be necessary to the Planning Authority pursuant to the Consents given under the Town and Country Planning Act. The Contractor shall pay all fees related to these works. The Contractor shall also inform and liaise with Building Control Inspectorate including the local Fire Officer for the required on site inspections. Each part of the works shall be designed for a reliable operating life and not less than the design life stipulated below:-



Years Roads and Fencing: Roads and Car Parks 60 (resurface every 25 years) Fencing 20 Buildings: Brick concrete or stone 60 Steel and timber 60 Temporary 10 Cladding vertical and roofing 20 Drainage: Other than PVC 60 PVC including fittings 40

The Purchaser shall engage Consultants to evaluate and control the Contractor’s Works. The Contractor shall co-operate at all times with the Purchaser’s Consultants. 2.10.3 Demolition and Site Clearance The Contractor shall demolish the structures and foundations existing on the new plant location, reusing certain features or processing recovered materials. The Contractor shall demonstrate that any recovered parts or items shall meet all appropriate standards and legislation including any Environment Agency requirements. The Contractor shall also satisfy the Purchaser that all recovered parts or items satisfy the design life criteria as detailed in 2.10.2 for reliable operation without incurring annual maintenance and repair costs in excess of new parts or items. The Contractor shall be responsible for ensuring all services and supplies and water courses are not damaged and the Contractor shall be responsible for the cost of their reinstatement. The Contractor shall provide a copy of all waste disposal tickets for all material sent offsite. The disposal of crushed concrete shall be reviewed by the Purchaser. 2.10.4 General Earthworks and Grading All earthworks shall be carried out in accordance with Series 600 of 'The Specification for Highway Works' published by HMSO and only construction plant suited to the materials to be handled and traversed shall be employed. All surplus excavated material shall be removed from site to a licensed tip. The Contractor shall ensure all disposal costs are included in the Contract Price. 2.10.5 Roads The Plant shall be furnished with a road system to facilitate safe and efficient traffic circulation onto and around the site. This shall be achieved with the construction of rigid pavement designed and constructed in accordance with Highway Agency Design Manual for Roads and Bridges. The Contractor shall confirm through a traffic study that the site road system is suitable. The infrastructure works shall include but not limited to, all necessary hardstandings, kerbing,


Purchaser EFW Contract footways, street lighting, road markings, signage and barriers, drainage, hard landscaping and protective barriers. 2.10.6 Fencing Works and Gates The site shall be fully enclosed by the Contractor at commencement of the works complete with suitable gated access constructed. Temporary fencing may be erected and then replaced by a permanent fence of 2.5m height and to a specification to be approved by the Purchaser. The security of the site shall be the responsibility of the Contractor from commencement on site until handover to the Purchaser following successful Acceptance Testing. 2.10.7 Landscaping The Plant shall be provided with landscaping designed and constructed to meet the relevant planning conditions. The Purchaser shall undertake all necessary discussions with the Local Authority Planning Department to satisfy Planning Conditions relating to the landscaping of the site. 2.10.8 Drainage Systems Details of the existing connection points for water supplies and discharges shall be under Contractor responsibility. The Contractor shall be responsible for connecting up to these services at the site boundary or. In the event that the Contractor recovers any of the existing drainage systems, then a CCTV survey shall be conducted to prove the integrity of the system and this shall be reviewed by the Purchaser and approved by Local Building Control. Foul and stormwater drainage systems shall be designed in accordance with Sewers for Adoption, the Building Regulations 1992, BS 8301, Private Water Utility, EA and County Council requirements. Contaminated surface water shall be intercepted. The Contractor shall arrange and pay for the necessary connections to be made to the water supplies and sewers and pay all associated charges up until Take Over. Upon Take Over, the Contractor shall provide all necessary information to enable the Purchaser to take over the water supply and to obtain the necessary discharge consents from the EA. The Contractor shall comply with all discharge consents during the construction and commissioning of the Plant. The drainage system shall include all necessary road gullies, manholes, catchpits, interceptors and ironmongery which shall be tested in accordance with British Standards. Surface water or storm water run-off shall be discharged to the surface water system according to the EA Prevention of Pollution Guidelines. Typical sources of process or contaminated waste waters are: boiler blowdown, water treatment plant regeneration liquors, drains and overflows. The Plant shall be designed as a zero discharge plant. Drainage, pipework and tanks receiving liquids from the steam system shall be designed for a liquid temperature of at least 90ºC. The Contractor shall provide a wastewater interceptor pit, suitably lined/painted, capable of holding high pH liquids with a capacity of 60m3 above low level pump cut off position with pH metering, and acid tanks to enable these liquids to be treated for discharge into the local utility system and meet EA limits. A sampling system shall also be supplied. The Contractor shall provide a specific services supply point (connected to the Plant network) which shall be connected to a contractor’s portacabin during future shutdown periods when


Purchaser EFW Contract there is a need for extra office accommodation. This supply point shall consist of the following easily connected services: a switched 415V AC 3 phase welding sockets and 110V AC sockets for small power each rated at 100A, 1” towns water supply, WC/foul drain connection. The location of the supply point shall be reviewed by the Purchaser, a typical position is adjacent to the storage bays or below elevated structures. 2.10.9 Underground Pipework Excavation, earthwork support, trench bottoming, bedding and surrounding backfilling and making good activities shall be provided for the safe and efficient installation of process and mechanical pipework. All chambers, inspection pits and thrust blocks shall also be provided. Stormwater drainage, chambers, manholes, interceptors etc., shall be inspected designed and tested in accordance with the Sewers for Adoption, Building Regulations 1992 and BS 8301, Clause 25 as well as with published EA guidelines. All testing shall be carried out to the satisfaction of the Purchaser and the approval of Local Building Control and shall be carried out at the time of construction and at the end of the commissioning period. 2.10.10 Substructure The Contractor shall design and construct the foundations of the Plant to BS 8004 and make due allowance for all existing structures and topographical features. 2.10.11 Superstructure The main complex shall be either of concrete construction to BS 8110 or steel framed structure designed and erected to BS 5950 with reinforced concrete slab floors, galvanised steel grating platforms, catwalks and profiled steel or concrete roofs. The enclosing envelope shall consist of typical features including: masonry walls to approximately 2.5m together with plastic coated profiled steel sheeting on galvanised steel sheeting rails and attached to the building's structural frame. The exterior metal panels shall be a sandwich, field assembled type and insulated to reduce thermal and noise transmission as specified elsewhere. The cladding shall incorporate glazing panels and louvres as appropriate. Further details of the external finishes are identified in the Detailed Civil Engineering Specification. All lift shafts shall be enclosed and meet the relevant Fire Officer requirements. External doors and fire exits shall be provided and agreed with the Fire Officer. The steel structure shall be in accordance with the National Structural Steelwork Specification for Building Construction which shall include, but not be limited to: the steel structure shall be blast cleaned to Swedish Standard SA 2½, painted with a primer prior to being brought to site and then properly stored. Damage to steelwork during erection and from other works shall be repaired by power tool abrasion and touched up using an appropriate matching paint. This work and procedure shall be reviewed by the Purchaser. The Contractor shall apply paint coating systems to all steelwork to ensure a typical time to first maintenance of 10-20 years as per BS 5493. The paint system must contain a site applied top coat with an easily cleanable aesthetically acceptable finish similar to polyurethane. As an alternative to a painted structure, the Contractor may propose a galvanised steel


Purchaser EFW Contract structure to BS 729. A common approach must be taken for all steelwork protection and this shall be agreed with the Purchaser. All external steelwork such as condenser supports shall be galvanised to BS 729. 2.10.12 Construction The Contractor shall be responsible for the accuracy of all setting out and construction in accordance with BS 5606 Accuracy in Building and the Contract. The classification of surface regularity of all insitu concrete floors shall conform to Class S.R. 2 given in table 1 of BS 8204. 2.10.13 Turbine Hall The turbine hall shall be designed to house the turbine-alternator with sufficient laydown area to allow for the turbine casing, diaphragms and shaft to be easily accommodated. The turbine hall and crane shall be designed to allow easy removal of any component or equipment for loading on the equipment removal vehicle for removal from site without removing other equipment ducting, racking and pipework. Access shall be designed to accommodate 16.5m long low loading type vehicles. All floor laydown areas shall be designed to withstand the imposed loads. The turbine foundation design shall be designed using a three dimensional dynamic calculation to DIN 4024/BS 4675 Part 1 Class IV as well as to the approval of the turbine maker. The Contractor shall carry out a site analysis and vibration signature to verify the assumptions made in the design model. The results of these tests shall be submitted to the Purchaser for review prior to construction. The Contractor shall demonstrate to the Purchaser at the design and construction stages that the steam turbine and the turbine foundations shall not cause vibration interaction. 2.10.14 Waste Transfer Station Facilities The bunker shall be designed to transfer waste by out-loading waste from the bunker into bulk haulage vehicles without interruption to the operation of the ERF. Out-loading capacity shall be at least 700 tonnes per 10 hour working day. 2.10.15 External Storage Bays Not used 2.10.16 Ash Conveyors The Contractor shall design the vibrating ash conveyors such that no vibration shall be transmitted to other areas of the plant, in particular the Offices and Amenity Buildings. The vibrating conveyors shall be erected on independent and insulated single large plinths to avoid vibration transmission and this shall be designed to the satisfaction of the Purchaser. 2.10.17 Cladding


Purchaser EFW Contract All cladding shall be designed in accordance with BS 5427 for a design life requirement of 20 years to first maintenance. All cladding shall be protected during the erection of all works to avoid damage from construction traffic including all installation operatives. The Contractor shall provide in his submission costs and maintenance schedules. Guarantees shall be issued to the Purchaser on completion, in compliance with the manufacturer’s requirements and shall not violate the exclusion list of guarantees of the coating system. All fasteners for the cladding shall be of a high quality such as stainless steel in accordance with the design life of the cladding material and in accordance with the written recommendations of the cladding manufacturer. The Contractor shall ensure that access is provided to all areas of cladding, glazing and other exteriors for the safe cleaning of all elevations to the satisfaction of the Purchaser. 2.10.18 Building Finishes All roller shutter doors shall be electrically operated and painted galvanised steel. All external and fire doors shall be steel fire-resisting, flush, hinged doors and frames with appropriate door furniture. Internal plant doors shall be of steel construction with appropriate door furniture. Where steel doors are likely to be damaged by the environment, the Contractor shall propose alternatives for review by the Purchaser. Windows shall be double glazed. Window frames shall be finished in acrylic and shall include all matching sills, sealants and window boards. The finish of concrete floors shall be power floated and shall be subject to the application of a proprietary liquid floor hardener such as Rockbond Ferroplate or similar. All electrical rooms shall receive an epoxy resin floor coating. The Contractor shall ensure that the floor finishes are faultless at Takeover and this may necessitate the work being carried out again at the end of the project. The Contractor shall supply all external signage for the plant including, but not limited to: door nameplates, fire exits, emergency signs. 2.10.19 Amenity Facilities The Amenity Facilities, located in the incinerator itself, shall comprise of the following:

• Office for the Plant Manager, • Office for the Operation Manager, • Office for the Maintenance Manager, • Office for secretary, • Meeting Room for 10 people, • Library and archive

The Amenity Facilities, located in the ex-CWI building, shall comprise of the following:

• Clean/dirty area male locker rooms, WC/shower rooms • Clean/dirty area female locker rooms, WC/shower rooms • Mess/kitchen room

In the same building, space shall be made available for 30 people for management/ administration with associated meeting and conference room.


Purchaser EFW Contract The location and construction of the amenity facilities shall be such that noise emanating from the plant is reduced to the levels detailed in Schedule 7 Guarantee Tests and Procedures. Locker rooms shall come complete with at least 35 full height lockers (size: 1775 height x 450 width x 550 depth) for each staff member. All changing rooms shall be sized to accommodate at least 20 personnel simultaneously. All the Locker Room equipment shall be made available for temporary accommodation at the Lumley Street Depot. WC/Showers, wash basins, shower units, urinal and cistern and WC pan and cistern shall be Armitage Shanks or similar approved supplier. All taps shall be of the mixer type. The whole area shall designed as a wet area and shall be laid to falls with floor gullies fitted with rodding eyes. Suitable heating and ventilation shall be provided, and particular attention shall be paid to the WC/Showers and mess room where humidity and strong smells are to be expected. The mess/kitchen room shall be equipped with a single bowl and drainer sink, fridge, cooker, storage cupboards below and above with a minimum of four double electrical sockets. Safety flooring shall be provided throughout the Amenity areas. Shower areas shall be furnished with slip resistant ceramic tiles. Amenity Facilities shall be suitable for the anticipated staffing levels. All necessary sanitaryware shall be provided including all water closet units, urinal bowls, drains, taps, paper towel and toilet paper dispensers, hot air dryers, soap dispensers, mirrors, shower units, basins etc. Ceramic wall tiling shall be provided to dado height on all walls in kitchen areas. Full height wall tiling shall be provided to all toilet and shower rooms. All fixtures and fittings shall be submitted to the Purchaser for review. Toilet partitioning shall be of melamine faced chipboard with edges faced in PVC and 'H' section extruded aluminium jointing. All areas of regular occupation shall be painted and decorated to high standard. Internal partition walls shall be of dense concrete block or plasterboard on wrought softwood studding as appropriate for fire resistance and noise considerations. The Amenities Facilities partitioning shall receive a plaster finish. Painted timber skirtings shall be provided throughout the facilities except where noted in the Detailed Civil Engineering Specification. 2.10.20 Office Facilities Internal partition walls shall be of dense concrete block or plasterboard on wrought softwood studding as appropriate for fire resistance and noise considerations. The Office Facilities partitioning shall receive a plaster finish. The Plant shall be designed with offices as dimensioned on the Architectural Concept Drawings in Appendix C and further detailed in section 2.11 Detailed Civil Engineering Specification. All offices shall be provided with a high quality finish, solid wood doors, carpet and high quality lighting.


Purchaser EFW Contract Separate toilet facilities shall be provided within/adjacent to the office facilities as detailed below: Male toilet: 1 x WC, 1 x urinal, 1 x basin, drains, taps, paper towel dispensers, hot air dryers, soap dispensers, mirror Female toilet: 2 x WC, 1 x basin, drains, taps, paper towel dispensers, hot air dryers, soap dispensers, mirror All plumbing and drainage installations shall be in accordance with the Local Water Company requirements and installed in compliance with the appropriate British Standards to the satisfaction of the Local Building Control. The Detailed Civil Engineering Specification details the minimum standards for the room finishes. The Contractor shall provide greater finishes detail during the contract and these details shall be reviewed by the Purchaser. 2.10.21 Continuous Emissions Monitoring Equipment Enclosure A weatherproof, secure enclosure shall be provided to house the emissions monitoring equipment. 2.10.22 Foundations and Plinths All necessary purpose designed plinths, thrust blocks and temporary works of a civil engineering nature shall be provided with a good standard of finish to the satisfaction of the Purchaser. 2.10.23 Building Services Lighting shall be designed in accordance with the latest CIBSE Guide to Current Practice including Parts A, B & C of Guide Code of Interior Lighting and all wiring shall conform with the 16th Edition IEE Wiring Regulations. All necessary sanitaryware complete with hot and cold water supplies, wastes and soil-vent pipework shall be provided. The hot water system shall be provided from local electric heating. Lighting shall be provided to all areas using mainly moisture-proof fluorescent fittings with a small number of high bay type fittings as appropriate. Lighting levels shall be provided in accordance with IES Codes. Emergency lighting and illuminated fire exit signs shall also be provided. The emergency lighting system shall be installed in accordance with the requirements of BS 5226 and the Fire Officer. Small power shall be supplied for cleaning and handtools by 13 amp sockets mounted on columns extending the existing system, suitably protected via ERD's. 2.10.24 Mechanical Services


Purchaser EFW Contract Clean and odourless air shall be drawn from an external fresh air source and filtered for use in heating and ventilation systems. Ventilation systems shall be correctly designed to take account of high humidity and smells, particularly in changing rooms, showers, toilets. Offices, control rooms, electrical and similar rooms shall be protected against dust and fume ingress. Proper ventilation shall be provided to all rooms to ensure proper dissipation of heat generated by equipment at maximum ambient temperature. Rooms shall be designed to a slight over-pressure without causing problems with doors closing and opening. Heating and inlet and extract ventilation shall be provided to all rooms such as: central control room, stores, offices, amenity facilities, motor control rooms, turbine hall, and all electrical battery rooms. Air conditioning shall be provided to the Central Control Room, Conference Room and Offices, as detailed on the Detailed Civil Engineering Specification, which shall be maintained at a slight over-pressure using a supply of filtered air. For firefighting purposes hose reels and extinguishers where appropriate shall be provided within the buildings as recommended by the Fire Officer. Sufficient pressurised hose reels shall be positioned at appropriate locations within the building and these shall be agreed by the Purchaser and the Local Fire Officer. Sufficient pressurised washdown hoses shall be provided by the Contractor. 2.10.25 Lift Installation The Plant shall be provided with an electrically operated heavy duty goods lift with an operating capacity of 2000 kg with a single point load of 1000 kg. The lift shall have all entrances on the same side. The supply, erection, testing and commissioning of the lift shall be in accordance with BS 5655 all parts and to the requirements of the Fire Officer. The Plant shall be provided with an electrically operated personnel and disabled access fire lift with a capacity of 10 persons and 830 kg. The lift shall operate from carpark/ground level to the offices and visitor routes levels and shall have all entrances on the same side. The supply, erection, testing and commissioning of the lift shall be in accordance with BS 5655 all parts and to the requirements of the Fire Officer. The lift will be supplied to a high standard of finish to be reviewed by the Purchaser. The visitor route shall be designed for disabled access and the routing of three groups of ten visitors around in the Plant at the same time. 2.10.26 Services to Ancillary Buildings Electric Lighting, Small Power and Heating Services shall be provided to all ancillary buildings as necessary. 2.10.27 Site Signage, Identification and Plant Marking The Contractor shall supply and install internal and external site signage in line with the Purchaser’s Company Policy. These items are required in public areas, offices and visitor routes and shall consist of the following with graphics, wording and corporate logos:

External Signage: 2 x Entrance panel 2.5m x 1.5m 15 x Activity Area/Direction Totems 2.0m x 1.0m



2 x Orientation Plans 2.5m x 1.5m 10 x Security/Safety Panels 1.0m x 0.6m Internal Signage: 3 x Corporate/Information Panels 0.8m x 0.8m 8 x Security/Safety Panels 0.5m x 0.5m 2 x Process Arrangement Panels 1.5m x 1.0m For each Office plus 5 extra: Door Signage 12mm x 65mm

These exact specification and details of the logos and wording shall be provided by the Purchaser during the construction.


Purchaser EFW Contract 3. CONSTRUCTION REQUIREMENTS 3.1 DESIGN AND CONSTRUCTION The Contractor shall design and construct the Works to comply with all relevant legislation and good engineering practice. 3.2 THE SITE 3.2.1 Inspection of the Sites The Contractor is deemed to have visited the Sites and evaluated the nature, extent, character and difficulties of the Works, local conditions, accessibility of the Works, the supply of and conditions affecting labour, materials and any other matter which may affect his Tender. No claim will be considered for want of knowledge in this respect. 3.2.2 Use of the Site The Contractor shall not use the site for any purpose other than execution of the Contract Works. The Contractor shall not obstruct any public way, path or otherwise or suffer to be done anything which may amount to nuisance or annoyance and shall not interfere with any right of way, access or light to adjoining properties. The Contractor shall provide for all construction laydown and accommodation areas within the agreed boundary of the Site to complete the Works. The Contractor shall not permit cranes or other plant to swing over or otherwise encroach upon or over any adjoining property owned or operated by a third party or the Purchaser without their written consent. 3.2.3 Site Access The Contractor shall not cause any plant or vehicles to obstruct the main entrance or shared accessway at any time so as to cause disruption to the free flow of vehicles onto and off the site. 3.2.4 Demolition Works The following requirements stated in this section 3.2.4 shall only apply ifdemolition works are required. The Contractor shall be responsible for the complete decontamination (to the extent required by the General Conditions of Contract), cleaning and safe, efficient demolition and restoration of the Amenity block to completely meet the requirements of the Environment Agency, the HSE, Local Authority and the Approval of the Planning Authority prior to the commencement of the new EfW Plant construction. The Contractor shall apply for and comply with the Section 81 Notice of Demolition as issued by the Local Building Control, as well as any other notifications


Purchaser EFW Contract required in accordance with Regulations including the Asbestos Regulations and the Health and Safety at Work Act 1974. Specifically for the demolition works, the Purchaser shall engage the services of a Specialist Demolition Consulting Engineer to act on his behalf and to perform the role of Planning Supervisor for the demolition works. In order to comply with the CDM Regulations, the Contractor shall demonstrate that the proposed demolition subcontractor is competent to carry out decontamination and demolition works of this nature.The demolition of the existing structure shall be monitored and controlled by the adoption of method statements to describe each stage of the demolition. All method statements shall be reviewed by the Purchaser prior to any demolition activities commencing on site. All materials, wastes and contaminants (to the extent required by the General Conditions of Contract) produced by the demolition works shall be recorded and a complete set of records maintained for review by the Purchaser at any time during the demolition and construction of the Plant. On completion of the demolition works, the Contractor will make available a complete set of records which details the full traceability of all materials, wastes and contaminants (to the extent required by the General Conditions of Contract) produced by the demolition works as required by legislation and in particular CDM, Duty of Care, Local Authority section 81 and HSE requirements. 3.2.5 Existing structures, site services and building on site The Contractor is responsible for determining all existing structures, buildings, ground conditions, mains and other services on and adjacent the Site and for arranging with the appropriate authorities for their protection, re-use, demolition, re-routing as may be necessary. The existing 11kV supply (to be confirmed) will be available as a construction supply for the EfW Plants. It shall be the Contractors responsibility to relocate this supply whilst developing the Site. The Contractor shall be held responsible for any damage occurring as a result of the Works The Contractor shall be responsible for the design, supply and installation, and maintenance of all temporary and permanent water distribution systems up to Takeover, The Contractor shall satisfy himself that the size and available water pressure for both supplies are acceptable for the new Plant.. The Contractor shall connect to the supplies and pay all associated costs. The Contractor shall be responsible for installing and maintaining all other site temporary/construction supplies and utilities including water, electricity, drainage and telephones including the cost of metering and consumption from commencement on site up to Takover. The Contractor shall be take care not to damage any culverts and foul sewers during construction. The costs of repairing any damage shall be recovered from the Contractor. 3.2.6 Working Hours The working hours shall be 8:00am to 6:00pm Monday to Friday. No working on Bank Holidays shall be permitted. Working outside these hours may be permitted, however in these circumstances any deviation from these hours, shall require written consent from the Purchaser prior to the Contractor to preparing an application to and obtain written consent from the


Purchaser EFW Contract Planning Authority, Landlord and County Council. All site work shall be carried out without causing disruption to the traffic accessing the existing incinerator facilities. This may necessitate the Contractor organising major deliveries outside peak vehicle flows. 3.2.7 Site Security The Contractor shall be responsible for the erection and maintenance of fences around the areas handed over to him for the execution of the Works and shall be responsible for site security in these areas. The Contractor shall take all reasonable precautions to prevent unauthorised access to the site whilst under his possession, and of his employees and subcontractors into adjacent operational ones until Takeover. 3.2.8 Construction Meetings, Progress and Reporting The Contractor shall organise weekly site meetings with the Project Manager’s/Purchaser’s personnel. In addition monthly meetings shall be held between the Contractor and the Project Manager/Purchaser to discuss the overall progress of the project and consequent evaluation of interim payments. The Contractor shall co-ordinate all subcontractors and suppliers to ensure that the Works are progressed in a co-ordinated and efficient manner, information is available to all parties, delays are addressed promptly and the Takeover date is achieved. The Contractor shall hold regular management and co-ordination site meetings and report in writing to the Purchaser each month. Reports shall cover, but not be limited to, the following issues:

• programme review • shortages/delays • progress • completion date • outstanding information

3.2.9 Site Facilities The Contractor shall provide a new 40’ by 12’ secure, quality portacabin for use by the Purchaser as a visitor/conference room, kitchen and office suitably partitioned and complete with all furnishings, power and water for the duration of the Contract. 3.2.10 Contaminated Materials The Contractor shall be responsible for the loading, hauling and disposal of contaminated wastes (to the extent required by the General Conditions of Contract) and materials from the Site during the construction of the Plant. Landfill sites operated by the Purchaser and its affiliated companies shall be used in preference to alternative disposal sites. 3.2.11 Contaminated Soil All soils that have contaminant levels below the Threshold Trigger Levels as defined by the


Purchaser EFW Contract Interdepartmental Committee for the Redevelopment of Contaminated Land (ICRCL) 59/83 List shall be considered as uncontaminated. In the absence of any ICRCL limit, then either The New Dutch list or The Kelly Indices shall be utilised. These materials shall be utilised by the Contractor on Site, as appropriate. All soils that have contaminant levels ranging between the Threshold Trigger Levels and the Action Trigger Level as defined by the ICRCL 59/83 List shall be re-used on the Site by the Contractor as an element of the site levelling exercise. In the absence of any ICRCL limit then either The New Dutch list or The Kelly Indices shall be utilised. If no clear guideline for the Action Trigger Level then exists, the established principle of using ten times the ICRCL Threshold Trigger Level shall be used. All soils that have contaminant levels above the Action Trigger Level as defined by the ICRCL 59/83 List shall be considered as contaminated and shall be removed from Site by the Contractor (to the extent required by the General Conditions of Contract) to an appropriately licensed site. In the absence of any ICRCL limit, then either The New Dutch list or The Kelly Indices shall be utilised. If no clear guideline for the Action Trigger Level exists, then the established principle of using ten times the ICRCL Threshold Trigger Level shall be used. The Contractor shall be responsible (to the extent required by the General Conditions of Contract) for the loading, hauling and disposal of contaminated soils from the Site during the construction of the Plant. Landfill sites operated by the Purchaser and its affiliated Companies shall be used in preference to alternative disposal sites. 3.3 REGULATORY REQUIREMENTS 3.3.1 Legislation and Regulations The Works shall comply with all appropriate by-laws, statutory regulations, Factory Acts, Health and Safety, Construction and Design Management and Fire Regulations and other provisions required by Law. The Contractor. shall prepare, make all submissions and pay all costs in obtaining approvals from the appropriate Authorities. The Contractor shall be responsible for the timing of all submissions and no extensions of time will be entertained by the Purchaser regarding obtaining such approvals or for any related costs. 3.3.2 Construction Noise and Pollution The Contractor shall have taken into account all costs and be responsible for preparing and applying for an Application for Consent under Section 61 of the UK Control of Pollution Act 1974, and subsequent compliance with any special provisions required under the Consent as granted during all construction works. The Contractor shall provide the Application for Consent for review by the Purchaser. The Purchaser shall then forward the Application for Consent to the Local Authority for their response. The Contractor shall be responsible for the timing of all submissions and no extensions of time will be entertained by the Purchaser regarding obtaining such approvals or for any related costs. The Contractor shall also comply with the recommendations of British Standards BS 4227 "Code of Practice for Noise Control on Construction and Demolition Sites" All equipment shall be operated, wired and maintained so that disturbance to people living or working in the immediate area is minimised. In particular, all items of machinery powered by internal combustion engines must be fitted with effective and well-maintained exhaust silencers and acoustic insulation to minimise noise. Demolition and piling operations must be carried out using the quietest practicable method


Purchaser EFW Contract available. 3.3.3 Fees, Rates, Licences and Permits The Contractor shall pay any Local Authority fees and rates in respect of all temporary buildings/structures/hoardings etc provided by the Contractor for the purposes of the Works. The Contractor shall also be responsible for obtaining all licences and permits in connection with such temporary facilities. 3.3.4 Import Permits, Licenses and Duties The Contractor shall obtain all import permits or licences required for any part of the Plant or Works within adequate time having regard to the time for delivery of the Plant and date for Take Over. The Contractor shall pay all customs and import duties arising from the importation of plant/materials into the country in which the Plant is to be erected. The Purchaser possesses various drawings of the Site and the existing structures and services that are available for review by the Contactor. This information is available on a “for information only” basis. The Contractor is to satisfy himself of its accuracy and relevance and the Purchaser absolves himself of any responsibility for this information. The section Additional Documentation contains civils drawings, which were reviewed by the Contractor from the original project plant drawings.. It is the Contractor’s responsibility to satisfy himself that all available information has been used in the design and construction of the Plant, as no variation shall be considered on the grounds of lack of information.


Purchaser EFW Contract 3.4 HEALTH AND SAFETY 3.4.1 Safety, Health and Welfare The Contractor shall be responsible for the safety, health and welfare of all persons visiting or employed at the site in connection with the Works. The Contractor shall strictly observe all relevant legislation, regulation and safe working practices. The Contractor shall ensure that the Works are carried out safely and in accordance with all applicable Health and Safety Regulations, and the requirements of the local Health and Safety and Fire Officers. Smoking is not permitted on the site or within the confines of the building. The Contractor shall observe and ensure compliance with the Purchasers existing site rules and regulations. As soon as practicable after notification to proceed, the Contractor shall agree with the Purchaser evacuation procedures from the site in the event of fire or such other emergency. The Contractor shall keep daily records of site personnel working on the site and provide copies to the Purchaser on a weekly basis. The Contractor shall notify the Purchaser of the name of the Safety Adviser to be allocated to the project as soon as notice to proceed is received. The Contractor shall maintain a proper accident/incident/near miss reporting system for both their personnel and that of their subcontractors throughout their presence on site and shall comply with the Reporting of Injuries Diseases and Dangerous Occurrences Regulations 1995 (RIDDOR) copied monthly to the Purchaser. The Purchaser shall employ an independent Planning Supervisor appointed in conformance with the CDM Regulations. The Contractor shall ensure that his employees and subcontractors do not park on or obstruct in any way any public roadways. Arrangements for off-road vehicle parking or the bussing or transporting of employees to and from the site shall be the responsibility of and cost to the Contractor. 3.4.2 Safety Rules and Permit to Work Procedures The Contractor shall supply to the Purchaser details of all their Safety Rules and Procedures to be implemented on the site. These Safety Rules and Procedures shall be similar and “transparent” with the Purchaser’s Safety Rules in order that the new plant and equipment can be handed over with the least amount of disruption. These Rules and Procedures shall be agreed with the Purchaser prior to implementation. The Contractor shall ensure the competency of his staff and subcontractors staff prior to allowing them to commence work on site. In particular, the Contractor shall provide to the Purchaser a list of names of all their Senior Authorised Persons, Authorised Persons, Control Persons, Persons allowed to Receive Sanctions for Tests and Competent Persons; the dates when they attended the training courses for their authorisations as well as the venues and against the names shall be notes as to their limits of authority. The Contractor shall have in place prior to testing and commissioning a “key safe” system for


Purchaser EFW Contract controlling the isolation and access of plant and equipment and a procedure for the control and issuing of Permits to Work. The Contractor shall adopt the Purchaser’s Permit to Work procedures. 3.5 PROJECT DOCUMENTATION All project documentation shall be supplied in the English language. 3.5.1 Project Programme The Contractor shall submit with his tender a preliminary programme bar chart of the whole of the Works showing Takeover and Performance Testing. 3.5.2 Technical Bid Summaries The Purchaser shall be entitled to attend technical review meetings with any tenderers prior to order placement for the following: Civil Engineering Grate Boiler Turbo Generator Cranes Air Compressor Driers & filters Flue Gas Treatment Equipment DCS Fans CEMS Air Cooled Condensers Water Treatment Plant Generator Transformer HV, MV and LV electrical equipment The Purchaser shall be allowed access to any drawing to which the Contractor has access other than detailed manufacturing drawings, specification, tests, contracts, calculations, electrical drawings etc and copies will be provided by the Contractor on request. 3.6 SPARES AND WARRANTIES 3.6.1 Spares The Contractor shall request that all equipment suppliers submit with their bid, a required list of spare parts with unit prices for 6 months operation. This list shall differentiate between long term delivery/ strategic spares and 6 months operating spares. All spares required to ensure the guaranteed availability shall be included in the list. Before placing any order for plant or equipment, the Contractor shall use their best endeavours to obtain confirmation of spare parts list from the supplier and a 12 month guarantee on unit prices. The definitive list shall be passed on to the Purchaser together with the Contractor’s final recommendation at least two weeks before the order is placed by the Contractor.


Purchaser EFW Contract The cost of optional spares shall be provided as per Schedule 16 (Price Breakdown) of the Construction Contract.


Purchaser EFW Contract APPENDICES Appendix A General Weighbridge Specification Appendix B Mass Balance, Energy Balance, Service Life Schedule and Data Sheets Appendix C Architectural Concept Drawings


Purchaser EFW Contract APPENDIX A: WEIGHBRIDGE SPECIFICATION An Approved Supplier Refer to Schedule 14 (Sub-Contracting)

Type of Weighbridge Full Pit Mounted 18m length

Standard Features British Steel, Fully Blast Cleaned to SA 2.5

Epoxy Zinc Phosphate weldable primer Bitumous Anti-corrosive micaceous iron oxide topcoat Lightning Protection Restraint-Post-System for loadcell protection

Number of Computer Screens and number of input screens

Two PC’s for input and two screens are required, operating through a Control Hub

CCTV Cameras Colour Camera, lens, case, 12” monitor, fixing bracket and heater. Internal Junction Box and wall mounted. Cameras shall be fitted to ensure full visibility of all fours corners of local or remote weighbridges. Alternatively a camera tower

Traffic Light Red / green lights polycarbonate construction with 200mm diameter. Manually operated by weighbridge operator in the weighbridge office with a timer and a mimic panel.

Intercom Two-way intercom required for driver to weighbridge office

Software/Communications Typically, Shering Sabre 8000 with internal modem link.


Purchaser EFW Contract APPENDIX B MASS BALANCE, ENERGY BALANCE, SERVICE LIFE SCHEDULE, AND DATA SHEETS


Purchaser EFW Contract APPENDIX C ARCHITECTURAL CONCEPT DRAWINGSThe Architectural Concept Drawings are as follows:Internal Architectural scheme for office buildings


Purchaser EFW Contract GLOSSARY OF TERMS A Current (Amps) AC ac Alternating Current ACB Air Circuit Breaker AGP Advanced Graphics Port BATNEEC Best Available Techniques Not Entailing Excessive Cost BHN Brinnell Hardness Number BPEO Best Practicable Environmental Option BS British Standard CCR Central Control Room CCTV Closed Circuit Television CDM Regulations Construction, Design and Management Regulations CEMS Continuous Emission Monitoring System CIBSE Chartered Institute of Building Services Engineers CP Code of Practice COSHH Care of Substances Hazardous to Health CT Current Transformers CTV Colour Television DC dc Direct Current DCS Distributed Control System DVDROM Digital Versatile Disk Read Only Memory EA Environment Agency EC European Community EDC Electricity Distribution Company or National Grid Company whichever

shall apply. EFW Plant Energy from Waste Plant EMC Electro Magnetic Compatibility ERD’s Earth Resistance Detectors EU European Union (including European Community) FBD Functional Block Diagram FGT Flue Gas Treatment HAZOP Review Hazard and Operation Review HDD Hard Disk Drive HSE Health and Safety Executive HWRC Household Waste Recycling Centres Purchaser Purchaser Limited ICRCL Interdepartmental Committee for the Redevelopment of Contaminated

Land IEC International Electrotechnical Commission IEE Institution of Electrical Engineers IL Instruction List IP Internal Protection IR Infrared LCV Lower Calorific Value LD Ladder Diagram LFD Loop Flow Diagram LHV Lower Heating Value LPC Loss Prevention Council LPCB Loss Prevention Certification Board LSD Loop Sequence Diagram MCB Miniature Circuit Breaker MCC Motor Control Centre MCCB Moulded Case Circuit Breaker MIS Management Information System ms Millisecond


Purchaser EFW Contract msec Millisecond NCV Net Calorific Value NER Neutral Earthing Resistor NETA New Eletricity Trading Arrangements - Power Purchase Agreement with

REC NFPA National Firepump Association, USA NTSC National Television Systems Committee (CTV System Adopted in USA) O&M Operation and Maintenance OEM Original Equipment Manufacturer OS Operating System PAL Phase Alternation Line (CTV System Used Generally in Europe) PCI Peripheral Control Interface pf Power Factor PWU Private Water Utility QA/QC Quality Assurance/ Quality Control REC (or PES) UK Regional Electricity Company (or Public Electricity Supplier) RCV Refuse Collection Vehicles RPI Retail Price Index SDRAM Super Dynamic Random Access Memory SECAM Séquentiel Couleur à Mémoire (CTV System Adopted in France) SNCR Selective Non Catalytic Reduction SVGA Super Video Graphics Adaptor SWA Steel Wire Armoured SWG Standard Wire Gauge TRRL Transport and Road Research Laboratory UA Unitary Authority UDMA Ultra Dynamic Memory Adaptor UPS Uninterruptible Power Supply UTP Un-Twisted Pairs UV Ultraviolet V Potential Difference (Volts) VA Volt-Amps VDU Visual Display Unit VME Virtual Memory Extension VT

Voltage Transformer


ABC Ltd HV-LV SINGLE LINE DIAGRAM EFW Contract

33kV IMPORT/EXPORT SUPPLY

EDC Interface/Boundary RECMetering Contractor Contractor

MeteringNo. 1 33kV/11kV

Exp. Tran.Generator

Metering NERNo. 2

11kV BOARD

No. 3 No. 4 No. 5Emergency

11kV/415V 11kV/415V Diesel Generator 11kV/415V Existing EquipmenAux. Tran. Aux. Tran. 415V Aux. Tran.

415V LV BOARD No.1 415V LV BOARD No.2 415V LV BOARD DHS415V Auto Changeover

See Fig. 2 (b). LV Single Line Diagram415V LV EMERGENCY BOARD

To Fig. 2(b)Emergency Switchboard 415V Auto c/o switch

Notes

11kV/415V Auxiliary Transformer nominally rated for stream load plus 20%Interface/boundary between Contractor and REC defined at metering circuit breaker for import/export connection

Fig 2(a)

ESCCB&H-HV-LV-2aRev2.xls 34 Specification

ABC Ltd HV-LV SINGLE LINE DIAGRAM EFW Contract

nt

ESCCB&H-HV-LV-2aRev2.xls 35 Specification

ABC Ltd LV SINGLE LINE DIAGRAM EFW Contract

See Fig.2(a)HV-LV Single Line Diagram Emergency11kV/415V 11kV/415V Diesel Generator To Fig. 2(a)Aux. Trans. Aux. Tran. 415V

Sp Sp Sp415V LV BOARD 1 2 3

415V LV BOARD No.21 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 Sp 415V Auto Changeover

1 2 SP

415V LV EMERGENCY BOARD

Fans Pumps 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 SP SP SP

Note: Switchboard feeds Note: Emergency Switchboard FeedsAll LV Board Switches monitored and controlled via DCS UPS Hydraulic Pump BP (2)Auto C/O of 415V Standby Supply upon loss LV board supply switch No. 4 Hydraulic Pump HP (2)Furnace / boiler (others) Air RegisterPrimary fan PB AuxiliariesSecondary fan Fire LiftRefuse crane Bottom AshPB auxiliaries 110V/ 24V UPS Hopper HeatingReagent injection Distribution Boards Screw Conv. HeatingBag filter Lime Inj. Rotary valveI.D. fan 1 2 3 4 5 6 7 CompressorEnd product Lighting / heatingRecirculation Feedwater pumpsLighting and small power Note: UPS feeds HP oil pumpsSpare switches suitably rated CEM (Gas analysis) Generator heater

Turbine aux. Oil pump WeighbridgeEmergency oil pump Spare switches suitably ratedTurbine control systemPLC system

Fig 2(b)

UPS

ESCCB&H-HV-LV-2bRev1.xls 35 Specification

OnyxUK Ltd

SERVICE LIFE SCHEDULEEFW Contract

EQUIPMENT SERVICE LIFE

SERVICE LIFE per STATION ELEMENT

ContractorStation description Service life ObservationsWaste reception and handling equipment

Sheet 1 Weighbridge - Weighing station YearFURNACE -FLUE GAS Overhead cranes and grabs YearCOOLING - Other handling equipment YearANCILLARY

EQUIPMENT FurnaceFurnace (grate) YearCombustion ancillaries (ducting, fans, burners, etc.) Year

Heat recovery installationsBoilers YearAncillaries (pipework, cleaners, etc.) YearSteel frame, walkways, stairs, platform and duckboarding YearHeat export heat exchangers YearExternal DHS connection pipework YearBoiler Feed pumps Year

Ash DisposalConveyors and Loading Equipment YearFerrous sorting YearOther Year

Miscellaneous equipmentWater treatment, demineralisation process YearWater treatment, deaerator YearCompressed air YearSpecial machinery - lifting gear YearEffluent treatment Year

Measurement - Control - Regulation Year

HV electrical installations Year

Supply station and transformer Year

Standby Supply Year

CCTV monitoring Year

The Contractor shall list the mandatory options in the same detail as per this Service Life table.

ESCCB&HServiceLife1.xls 1/2 Service Life Schedule

OnyxUK Ltd

SERVICE LIFE SCHEDULEEFW Contract



ContractorStation description Service life Observations

Sheet 2

TURBO- Turbine ) Year

GENERATOR Generator )

Ancillaries and condenser (incl. bypass) Year

Packaging, transport Year

Unloading Year

Turning gear Year

Oil centrifugal pump Year

Coolant Year

Special tools for alternator rotor Year

Equipment assembly/disassembly Year

MV connections Year

LV connections Year

First oil fill Year

Refrigeration loop Year

Local control cabinet Year

Ancillaries cabinet Year

Electrical installation Year




ContractorStation description Service life Observations

Sheet 3Dust extraction (Fabric filter) Year

FLUE GASReactor / filter inlet ductwork Year

TREATMENTReagent preparation / fresh reagent transport Year

Residue removal/transport Equipment Year

Reagent recirculation equipment Year

Dewatering Equipment Year

Framework, walkways Year

Flue gas ducting and fluestack Year

Electrical instrumentation Year

Measurement Year


ESCCB&HServiceLife1.xls 2/2 Service Life Schedule

Onyx UK Limited Contractor - Energy Balance Diagram - Sheffield EFW Contract

2 Loss of pipework

4

Soot blower 3 5 6

Superheater HP steam header 22 21

20 7 Turbo-generator

Air 1 preheater 8

1 10

19 MP steam header

13 Air condenserProcess off- take

loss 11

18 16

Flashtank

Make-up water

17 15 23 14 12 EjectorHot tracing

9

14

minimum* = minimum LCV without supplementary fuel oil

Operation 8000 h/yr. N° 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 Boiler yield (%) at MCR1500 hr(1) 8000 hr.

Fluid HP Steam HP Steam HP Steam HP steam HP Steam HP Steam MP Steam MP Steam MP Steam LP Steam MP Steam MP Steam MP Steam Condens. Water LP Steam Water Water Water Water Electricity HP Steam LP Steam Air temperature reference (°C)

Type Saturat. S. heated Soot b. loss Ejector Turb. Intake Pass out 1 Pass out 2 Pass out 3 Turb.

Exhaust Deaerator Air heater Process To deaerator make-up Deaerator

loss feed pump Eco. Inlet Boiler Blow d.

Desuper heater Alternator Saturat. Air

heater Hot tracing French code (without heat from combustion air) case 2-1

Pressure Bar abs. Yield ASME code (with heat from air combustion) Mini

case 2-1 Temperature °C

Mini Enthalpy kJ/kg Turbo-generator yield (PF=0,8) 25% load 50% 75% 100% case 2-1

Mini

Stream LHV MJ/kg kg/h kg/h kg/h kg/h kg/h kg/h kg/h kg/h kg/h kg/h kg/h kg/h kg/h kg/h kg/h kg/h kg/h kg/h kg/h kg/h kW (2) kg/h kg/h Thermal (Avg) %

Alternator %

2 case 2-1 Mini 7.0 mechanic kW

(1) The flue gas temperature at boiler exit is controlled to ensure temperature

remains as per fouled conditions. Hence, boiler efficiency is the same in both situations

.../.... (2) For an ambient air temperature of 10 °C








heater Hot tracing French code (without heat from combustion air) case 2-2

Pressure Bar abs. Yield ASME code (with heat from air combustion) MCR

case 2-2 Temperature °C

MCR Enthalpy kJ/kg Turbo-generator yield (PF=0,8) 25% load 50% 75% 100% case 2-2

MCR


Alternator %

2 case 2-2 MCR 9.2 mechanic kW


remains as per fouled conditions. Hence, boiler efficiency is the same in both situations.../.... (2) For an ambient air temperature of 10 °C








heater Hot tracing French code (without heat from combustion air) case2-3

Pressure Bar abs. Yield ASME code (with heat from air combustion) maxi.

case2-3 Temperature °C

maxi. Enthalpy kJ/kg Turbo-generator yield (PF=0,8) 25% load 50% 75% 100% case2-3

maxi.


Alternator %

2 case2-3 maxi. 12.0 mechanic kW


remains as per fouled conditions. Hence, boiler efficiency is the same in both situations

.../.... (2) For an ambient air temperature of 10 °C

Boiler

Economiser

Deaerator

Condensate tank

Boiler

Economiser

Deaerator

Condensate tank

Boiler

Deaerator

Condensate tank

Boiler

Deaerator

Condensate tank

r 1 preheat

ESCCBHMassEnergy.xls Energy Balance Diagram

Onyx South Downs EFW Contract

TECHNICAL SPECIFICATION WORKGROUP: 210: STEELWORK AND METALWORK SECTION NO: 220 TITLE: FIXTURES AND FITTINGS TABLE OF CONTENTS GENERAL MISCELLANEOUS METALWORK

Fabrication Drawings Materials and Workmanship Handrails and Ladders Open Grid Steel Flooring

PARAPETS UN-TENSIONED SAFETY FENCE ANCILLARY STEELWORK BOLTED CONNECTIONS FOUNDATION BOLTS

CWSpec-220-Rev4.doc 1/5 Detailed Civil Engineering Specification


220.010 GENERAL

The contractor shall submit to the Purchaser for his agreement the names of all suppliers and manufacturers of proprietary or fabricated items prior to entering into any agreement for the supply of such items. The Purchaser may order the removal from site of any materials not so agreed.

220.020 MISCELLANEOUS METALWORK 220.021 Fabrication Drawings

The Contractor shall prepare fabrication drawings and associated documentation for all items of Miscellaneous Metalwork, and copies of these shall be submitted to the Purchaser for his agreement in accordance with Section 211 of this Specification.

220.022 Materials and Workmanship

Materials and workmanship for Miscellaneous Metalwork shall comply generally with the requirements of Section 211 of this Specification.

Surface preparation galvanising and painting of Miscellaneous Metalwork shall be in accordance with the requirements of this Specification.

Steel used in fabrication of Miscellaneous Metalwork shall be new material of Grade S275 to BS EN 10025 : 1993 or equivalent unless instructed otherwise by the Purchaser.

220.023 Handrails and Ladders

Handrails shall be provided to stair cases and elevated platforms.

Handrails shall be designed and detailed by the contractor in accordance with BS 6399 : Part 1, and BS 5395 : Part 3 as appropriate. Handrails shall be designed to withstand a horizontal force on the top rail of 0.7kN/metre. All handrails shall be steel, fabricated generally in accordance with Section 211 of this Specification, and shall be finished with a galvanised metal coating and decorative paint system in accordance with this Specification.

Steel handrails shall be fabricated from steel tubes complying with BS 6326. The minimum section thickness shall be 4mm for rails and 3mm for posts.

Handrail standards shall be at maximum 1.5 metre centres. Minimum 100mm



high kick plates shall be provided.

Handrails and standards may be solid bar or hollow tube with minimum 3.25mm wall thickness.

Full details of the proposed handrail layout shall be submitted to the Purchaser for agreement prior to commencement of fabrication.

Access, maintenance and safety ladders shall generally comply with BS 4211 and the recommendations of BS 5395 Part 3.

220.024 Open Grid Steel Flooring

Open grid steel flooring shall be designed to support a uniformly distributed load of 5kN/m2 with a maximum deflection not exceeding 1/200 of the span, and to withstand three times the design load without collapse. The walking surface of such flooring shall have a serrated or equivalent non slip finish.

Open grid steel flooring shall comply with BS 4592 except where amended below.

The minimum thickness of load bearing bars shall be 5mm and the load bearing bars shall have a minimum depth of 1/40 x span but not less than 20mm. They shall span in the shortest direction and, where practical, the pattern shall be continuous at the meeting point of separate pieces of decking.

Floor panels shall be clipped down to the supporting steelwork so that each individual panel is held by a minimum of four clips. Studs shall be welded to the supporting steelwork as required. All panels shall be removable and fixing shall be such that where a panel is removed, the remaining panels will remain firm and replaced panels are safe against displacement and dropping through before the clips have been fastened.

Each panel shall have an edge bar on the bearing edges, which shall have a thickness not less than the load bearing bars.

Open grid steel flooring shall be finished with a hot dip galvanised coating.

Materials used in construction shall comply with BS 4360: 1990. Rolled steel sections shall comply with BS 4: Part 1 and BS 4848: Part 2.

220.030 PARAPETS



Parapets shall comply with the requirements of The Department of Transport Technical Memorandum BD 53/93 and BS 6779. They shall be BD 52/93 Group 1 and shall be supplied by an approved manufacturer.

Parapets shall be erected to the lines and levels shown on the agreed drawings, but with the agreement of the Purchaser, may be adjusted where necessary to give a smooth flowing alignment to the finished parapet.

Parapets shall be securely supported in their final position until the anchorages and bedding have attained adequate strength.

The threads of the steel anchorage sockets shall be treated with red lead compound Type 3 complying with BS 217 immediately prior to fixing parapet holding down bolts into their final positions.

220.040 UN-TENSIONED SAFETY FENCE

Safety fences shall be of the single-sided untensioned corrugated beam type with a maximum post spacing of 3.2m. Materials and fabrication of components and fittings, assembly and tensioning shall all be in accordance with the Department of Transport “Specification for Highway Works”.

220.050 ANCILLARY STEELWORK

All rolled steel plate and sections shall, as regard quality test, method of manufacture and general procedure to be followed during fabrication, conform to BS 5950, Part 2 and the standards referred to therein where these are relevant to the works. Angles and hollow sections shall conform to BS 4848. The material to be used for this Contract shall be new selected for the purpose for which it is intended to be used, and shall in accordance with BS 4360: 1990.

The Purchaser or his appointed representative shall at all reasonable times have free access to the works where the steelwork is being fabricated and to the places where materials for the works are being manufactured or from which it is being supplied, and shall be at liberty to inspect the steel and reject it if it is not in accordance with the Specification.

220.060 BOLTED CONNECTIONS

All connections shall be bolted with bolts and nuts to BS 4190 which shall be fitted with one flat circular washer conforming to BS 4320 under each nut.



Where bolt heads or nuts bear on bevelled surfaces they shall be provided with square taper washers conforming with BS 4320 to afford a seating square with the axis of the bolt

The size and location of all bolts shall be clearly shown on the Contractor’s Shop Drawings.

Rivetting will not be permitted.

220.070 FOUNDATION BOLTS

Holding down bolt assemblies shall be of approved manufacture and shall be fitted with washer plates of angles and nuts, etc. as required by their design.

Purpose made templates shall be provided to facilitate accurate positioning of holding down bolts during the placement of concrete.



TECHNICAL SPECIFICATION WORKGROUP: 210: STEELWORK AND METALWORK SECTION NO: 225 TITLE: PROTECTIVE COATING TO STEELWORK TABLE OF CONTENTS GENERAL MATERIALS

Paint Storage of Paint

SUBMISSIONS

Particulars of Paint Details of Vent Holes for Galvanising

PAINTING TRIALS

Paint Trials Results of Paint Trials

PREPARATION OF SURFACES

Cleaning of Steelwork and Coated Surfaces Preparation of Steelwork Surfaces Blast Cleaning of Steelwork Acid-pickling of Steelwork Mechanical Cleaning of Steelwork Cleaning of Bolts Nuts and Washers Agreement of Surface Preparation



TABLE OF CONTENTS METAL COATINGS TO STEELWORK

Galvanised Coatings PAINTING OF STEELWORK

Painting Systems Application of Paint Working Conditions for Painting Priming and Over coating Time Limits Stripe Coats to Steelwork Paint Coats to Steelwork Etch Primers and Blast Primers Repairs to Damaged Areas of Paint

PROTECTION OF JOINTS IN STEELWORK

Protection of HSFG Bolted Joints Protection of Other Shop-bolted Joints Protection of Other Site-bolted Joints Protection of Welded Joints Joints Made After Coating the Parent Material Sealing of Joints in Steelwork

PROTECTION OF SPECIAL SURFACES OF STEELWORK

Protection of Hollow Steel Sections Protection of Uncoated Steelwork Surfaces



225.010 GENERAL

All surface preparation and coating of steelwork shall be carried out in accordance with BS 5493 and with BS 7079. All steelwork shall be blast cleaned in accordance with this Specification unless specifically noted otherwise.

All exposed surfaces of steelwork shall be finished with a surface coating as indicated in Table 7.1.

Item

Paint System - Table 7.2 Structural steel including maintenance walkways and associated works

System C or D1 as agreed with the Purchaser

Open grid flooring

System D1

Handrailing and miscellaneous metalwork

System D2

Lighting columns.

System D3

Table 7.1 Protective Coating Systems

The finish coat to painted members shall be a high gloss finish colour as directed by the Purchaser. The finish coats to galvanised and painted surfaces (systems D2, D3) shall generally be the same paint as used for the finish coats to painted steelworks (system C), subject to compatibility with the galvanised coating.

225.020 MATERIALS 225.021 Paint

Paint and materials shall comply with the requirements of BS 5493 and shall be applied strictly in accordance with the manufacturers' instructions. The complete surface coating system shall be detailed from one manufacturer only, and the Contractor shall liaise with the supplier to guarantee continuity of supply and consistency of colour between batches.



Paint shall be supplied in sealed containers of not more than 5 litres capacity. Each container shall be marked on the side to show the following:

(a) the name of the manufacturer,

(b) the paint manufacturer’s reference number,

(c) intended purposes, type of pigment and binder,

(d) batch number, date of manufacture, expiry date and pot life,

(e) colour, gloss, drying times and flash point.

The containers shall be stored in ventilated temperature controlled premises in accordance with the manufacturer's instructions.

225.022 Storage of Paint

Paint and associated materials shall be stored in sealed containers marked as stated in this specification and protected from exposure to conditions which may affect the material. The materials shall be stored in accordance with the manufacturer's recommendations and shall not be used after the recommended expiry date has been exceeded. The materials shall be stored in a locked store.

225.030 SUBMISSIONS 225.031 Particulars of Paint

The following details of the proposed paints and associated products shall be submitted to the Purchaser not less than 14 days before application of any system commences:

- name of manufacturer

- duplicate copies of the manufacturer's data sheets including

temperature, humidity and other conditions at the workshop or on the Site under which the paint is to be applied,

- - manufacturer's product specifications, product range and technical

information.



225.032 Details of Vent Holes for Galvanising

Details of the method of plugging vent holes required for hot dip galvanising of hollow sections shall be submitted to the Purchaser for Agreement.

225.040 PAINTING TRIALS 225.041 Paint Trials

A painting trial shall be carried out for each painting system to demonstrate that the proposed materials and methods of application will produce a painted surface which complies with the specified requirements.

Paint trials shall be carried out at the place where painting to the permanent work will be carried out and using the employees and equipment which will be used to carry out painting to the permanent work.

Painting trials shall be carried out on blast cleaned steel.

225.042 Results of Paint Trials

If the painted surface produced in a painting trial does not comply with the specified requirements for the paintwork, the cause of failure shall be established by the Contractor and particulars of proposed changes shall be submitted to the Purchaser. Proposed changes to the paint formulation, other than an adjustment in the amount of thinner, shall be carried out at the paint manufacturer's works before the final painting trial and before the first batch of paint is delivered.

Commencement of Painting

Painting shall not commence until the painted surface produced in painting trials complies with the specified requirements for paintwork. Changes in Materials and Methods of Application for Painting

Unless permitted by the Purchaser, the materials and methods of application used in a painting trial which complies with the specified requirements shall not be changed.



225.050 PREPARATION OF SURFACES 225.051 Cleaning of Steelwork and Coated Surfaces

Soil, concrete and other adherent matter shall be removed immediately from steelwork or coated surfaces and the surfaces shall be made good by methods agreed by the Purchaser.

Dust, soot, grit, detritus, metallic or other loose particles shall be removed by vacuuming after steelwork surfaces have been blast cleaned or before coated surfaces are washed or steam cleaned.

Oil and grease shall be removed by emulsion cleaners, by steam cleaning or by high pressure water jets before removing rust and mill scale or overcoating. Oil and grease shall not be removed by turpentine or other solvents. If steam cleaning is used, steam cleaning shall be carried out after the greasy deposits have been removed by scraping and a detergent shall be added to the feed water of the steam generator.

Salts, chemicals, corrosion or paint degradation products, including rust-spotting on blast cleaned surfaces and zinc salts on zinc coatings or zinc-rich paints, shall be removed by washing with detergent solution before coating steelwork surfaces or over coating.

Unless otherwise permitted by the Purchaser finished coated surfaces shall be cleaned as stated above not more than 14 days before handover of the steelwork.

Cleaning agents to be used shall be as agreed by the Purchaser. Surfaces which have been cleaned using cleaning agents shall be rinsed with fresh water to remove all traces of cleaning agent.

Cleaning tools shall be a type which will not result in damage to the surfaces being cleaned. Wire brushes and brooms shall not be used for cleaning coated surfaces.



225.052 Preparation of Steelwork Surfaces

Bare metal surfaces of steelwork which are to be painted or metal coated shall be treated before rust and mill scale are removed in accordance with the following requirements:

(a) Burrs, arises and serrations shall be smoothed by grinding or filling.

(b) Weld spatter, weld slag and raised metal laminations shall be

removed by grinding or chipping and the surface shall be made good.

Rust and mill scale shall be removed from steelwork which is to be painted or galvanised by blast cleaning.

Steelwork to be galvanised will then be treated by a pickling process which is compatible with the metal coating process.

225.053 Blast Cleaning of Steelwork

Blast cleaning of steelwork shall be carried out to second quality of surface finish in accordance with Sa2½ in Swedish Standard SIS 05 59 00 using chilled iron abrasive.

Chilled iron grit shall be graded in accordance with BS 2451. The maximum size of grit shall be G17 for use in automatic impeller type equipment and shall be G12 for manual or compressed air equipment. The difference in level between a peak and the adjacent trough of the blasted surface profile shall not exceed 0.1mm.

Non-metallic abrasives with a maximum particle size not exceeding 1mm shall not be used other than with portable equipment.

Abrasives shall not contain materials which may contaminate the steel surfaces. Sand containing salt or excessive amounts of silt shall not be used. Contaminants shall be removed from recovered abrasives before re-use.

Blast cleaning shall be carried out in a fully enclosed space separated from the place of painting. The enclosed space shall be fitted with dust extractors and filters to prevent the dispersal of dust outside the enclosed space.



225.054 Acid-pickling of Steelwork

Acid-pickling of steelwork shall be carried out by the Footner process in accordance with BS 5493, Clause 14.3.2. The first priming coat of paint shall be applied as soon as the steel has dried and is still warm.

225.055 Mechanical Cleaning of Steelwork

Mechanical cleaning of steelwork where agreed by the Purchaser shall be carried out using carborundum grinding discs or other power-driven tools followed by steel wire brushing and dusting to remove all loosened material which is not firmly bonded to the metal surface. Excessive burnishing of the metal through prolonged application of rotary wire brushes shall not be carried out. Visible peaks and ridges shall be removed. Pneumatic chipping hammers shall not be used.

225.056 Cleaning of Bolts Nuts and Washers

Bolts, nuts and washers for steelwork shall be kept free from dirt and deleterious material. Oil and grease on bolts, nuts and washers, other than agreed lubricants for nuts of HSFG bolts, shall be removed before assembling and coating the exposed parts of assembled bolts, nuts and washers.

225.057 Agreement of Surface Preparation

Surfaces shall not be coated until the cleaning and preparation of the surfaces has been agreed by the Purchaser.

225.060 METAL COATINGS TO STEELWORK 225.061 Galvanised Coatings

Galvanised coatings shall be applied by hot-dip galvanising in accordance with BS 729. The coating thickness shall comply with BS 729, Table 1.

Metal coatings which will be overcoated with paint shall be passivated Allowance for the thickness of the metal coating shall be made in the sizes of the threads of metal coated threaded components. Nuts shall not be tapped oversize by more than 0.4mm. Metal coated HSFG bolts and nuts shall not be tapped oversize unless agreed by the Purchaser.

Damaged areas of metal coatings shall be rubbed down to remove



excessive roughness, cleaned and made good by the use of an aerosol zinc rich paint containing an aluminium pigment, of a type agreed by the Purchaser, to give a repair coating thickness of 100 microns.

Metal coatings required on part of a component shall be completed before the rest of the component is painted.

225.070 PAINTING OF STEELWORK 225.071 Painting Systems

Painting systems for steelwork shall be as detailed in Table 7.2. Members shall be finished with the paint system identified in this Specification or as otherwise instructed by the Purchaser.

System Reference C:

Surface coating to new structural steelwork.

preparation:

Blast clean to SIS SA2½.

coating :

BS 5493 system reference SE7. Nominal total dry film thickness 475 mm.

System Reference D:

Surface Coating to Miscellaneous Metalwork.

preparation:

In accordance with BS 729.

coating :

D1 - Galvanise. BS 5493 System Ref. SB2. D2 - Galvanise. BS 5493 System Ref. SB2, plus compatible paint system. D3 - Galvanise. BS 5493 System Ref. SB9.

Table 7.2 Paint Systems

Different paints in a given system shall be compatible with each other and shall be manufactured by the same manufacturer. Successive coats in a paint system including stripe coats, shall be in contrasting colours to aid identification.



225.072 Application of Paint

Surfaces which are to be painted shall be dry and clean immediately before paint is applied.

Paint shall be taken from the paint store ready for application. Thinning, if necessary, shall be carried out in the paint store in the presence of the Purchaser and using the type of thinner in the ratio stated in the manufacturer's data sheets.

Paint shall be applied by airless spray. Sealer and primers shall be applied by continuous spraying.

Each coat in the paint system shall be sufficiently dry or cured before the next coat is applied. The time between the application of successive coats shall be within the limits recommended by the manufacturer and stated in this Specification.

Paints having a pot life specified by the manufacturer shall be discarded on expiry of the pot life or at the end of each working day, whichever comes first. Other paints in opened containers shall be kept in sealed containers with not more than 10% ullage in store after each day's work and shall not be thinned or mixed with fresh paint when re-issued for another day's work.

225.073 Working Conditions for Painting

Paint shall not be applied to steelwork under the following conditions:

(a) when the ambient temperature falls below 4°C or the relative humidity rises above 90%,

(b) for outdoor work, during periods of inclement weather including fog,

frost, mist, rain and snow or when condensation has occurred or is likely to occur on the metal,

(c) (c) when the surface temperature of the metal to be painted is less than

3°C above the dew point of the ambient air,

(d) when the amount of dust in the air or on the surface to be painted is excessive in the opinion of the Purchaser.



225.074 Priming and Over coating Time Limits

Blast cleaned steel shall be primed or metal coated within 4 hours after blast cleaning. After fabrication, welds shall be cleaned using portable blast cleaning equipment and primer applied to give a nominal DFT of 75mm .

Primed steel surfaces shall be overcoated within 8 weeks after priming.

Second undercoats shall be applied within 72 hours after application of the first undercoat.

No more than one coat shall be applied in a 24 hour period.

Etch primer to galvanised steelwork shall be applied within 14 days after delivery of the steelwork to the Site. The etch primed surfaces shall be overcoated within 48 hours after priming.

225.075 Stripe Coats to Steelwork

Immediately after the first undercoat of the painting system to steelwork has dried, a stripe coat of undercoat paint shall be applied by brush to edges, corners, crevices, exposed parts of bolts, nuts, rivets and welds. Another stripe coat of finishing paint shall be applied in the same manner after the last undercoat has dried.

225.076 Paint Coats to Steelwork

The dry film thickness of paint coats to steelwork shall be measured using a magnetic dry film thickness gauge or other apparatus agreed by the Purchaser. The total dry film thickness shall be measured at spacings of approximately 1.0m. If the measured dry film thickness is less than 85% of the specified nominal dry film thickness or if more than 10% of the measured dry film thickness are less than 95% of the specified nominal dry film thickness, repair work shall be carried out as stated in this Specification.

Wet film thickness gauges shall not be used as a means of determining whether the dry film thickness of the painting system complies with the specification.



Where a finish coat is to be applied on site, the procedure for application shall be:-

- The exposed surfaces of any nuts, bolts, washers and other

untreated areas shall be prepared to SA 2½ if not previously blast cleaned, or ST3 if previously blast cleaned to SA 2½ and the works paint system applied.

- All steelwork shall be thoroughly washed down to remove any site

contaminants.

- The finish coating shall be applied overall to a nominal dry film thickness of 75 microns. The colour of this coat shall be in accordance with the Purchaser's instructions. The Contractor shall verify with the paint manufacturer that for each colour, the method of application will provide an acceptable cosmetic finish with a single coat. Where this is not achievable the Contractor shall apply additional coats to achieve the desired quality of finish.

Each coat of paint shall be free from embedded foreign matter, mechanical damage and surface defects, including bittiness, blistering, brush marks, bubbling, cissing, cracking, cratering, dry spray, floating, pinholing, rivelling, runs, sagging, spotting and spray mottle as stated in BS 2015. The finished paintwork system shall have an even and uniform appearance.

Each coat of paint shall adhere firmly to the substrate without blistering, chipping, flaking or peeling.

225.077 Etch Primers and Blast Primers

Etch primers and blast primers shall not be applied on phosphated steel and shall not be overcoated with zinc-rich primers.

225.078 Repairs to Damaged Areas of Paint

Areas of paint to steelwork which have been damaged shall be cleaned to bare metal or to the metal coating; the edges of the undamaged paint shall be bevelled. Care shall be taken not to damage any galvanised or sprayed metal coating.

The full specified painting system shall be restored in such a manner that each new paint coat overlaps the existing paint by at least 50mm all round



the affected part. 225.080 PROTECTION OF JOINTS IN STEELWORK 225.081 Protection of HSFG Bolted Joints

The faying surfaces of HSFG bolted joints in steelwork which is metal sprayed overall and sealed or metal sprayed and painted overall shall be coated with the sprayed metal. The sealer on the parent material shall extend for a distance of between 10mm and 20mm inside the perimeter of the faying surfaces. Free surfaces and edges of the joint material shall be coated with the same sealer.

The joint material and the faying surfaces on the parent material of steelwork which is metal sprayed only at joints and painted overall shall be metal sprayed. The sprayed metal on the parent material shall extend for a distance of between 10mm and 20mm outside the perimeter of the faying surfaces. The primer on the parent material shall extend for a distance of between 10mm and 20mm inside the perimeter of the faying surfaces. Sprayed metal on the free surfaces and edges of the joint material shall be coated with a sealer which is compatible with the painting system.

The primer on the parent material of steelwork which is painted overall and uncoated at faying surfaces of HSFG bolted joints shall extend for a distance of between 10mm and 20mm inside the perimeter of the faying surfaces.

225.082 Protection of Other Shop-bolted Joints

Blast primer for painted steelwork or sprayed metal plus sealer for metal sprayed steelwork shall be applied to the joint and parent material of shop-bolted joints other than HSFG bolted joints; joints for painted steelwork shall be assembled after the first undercoat of the painting system has been applied to the contact surfaces and while the undercoat is still wet.

225.083 Protection of Other Site-bolted Joints

Surfaces of the parent and joint material of site-bolted joints other than HSFG bolted joints shall be coated with the same protective system as the parent material.

225.084 Protection of Welded Joints

Welds and steelwork surfaces which have been affected by welding shall be coated with the same protective system as the parent material.



225.085 Joints Made After Coating the Parent Material

Hot-dip galvanising to steelwork shall not be carried out until all welds for the steelwork which is to be galvanised or electroplated have been completed.

Except as stated below, successive coats of paint on the parent material shall be stepped back to 30mm intervals commencing at 100mm from welded joints and at 10mm from the perimeter of HSFG bolted joints.

If the parent metal in the agreed welding procedure is coated with the pre-fabrication primer or sprayed metal such coatings are permitted to cover the area to be welded. After welding the pre-fabrication primer or sprayed metal adjacent to the weld shall be made good.

The parent material, jointed material, exposed parts of bolts, nuts and washers, welds and weld affected areas shall be cleaned, prepared and brought up to the same protective system as the adjoining surfaces not more than 14 days after the joints have been made.

225.086 Sealing of Joints in Steelwork

The different parts of joints in steelwork shall be dry immediately before the joints are assembled.

Gaps around the perimeter of bolted joints and load indicator gaps of HSFG bolts in steelwork painted overall shall be sealed by brush application of the same painting system as the parent material; gaps shall be plugged if necessary with soft solder wire without flux core as a backing before sealing with paint.

225.090 PROTECTION OF SPECIAL SURFACES OF STEELWORK 225.091 Protection of Hollow Steel Sections

The ends of hollow steel sections shall be sealed by welding mild steel plates over the open ends; the plates shall be at least 5mm thick. Immediately before hollow steel sections are sealed, bags of anhydrous silica gel shall be inserted in each void at the rate of 0.25kg/m3 of void.

225.092 Protection of Uncoated Steelwork Surfaces

The coated surfaces of steelwork coated over part of the surface shall be protected from rust which may form on the uncoated surfaces. Temporary coatings which may affect the bond between concrete and uncoated



surfaces against which the concrete is to be placed shall be removed and the uncoated surfaces shall be cleaned before the concrete is placed. The full coating system shall extend 25mm, or 75mm for steel piles, into areas against which concrete is to be placed.



TECHNICAL SPECIFICATION TITLE: GENERAL REQUIREMENTS TABLE OF CONTENTS SECTION 1 - GENERAL REQUIREMENTS GENERAL STANDARDS AND CODES DESIGN LIFE MAINTENANCE DATUM LEVELS GROUND CONDITIONS QUALITY ASSURANCE CONTRACTOR'S SUBMISSIONS

Purchaser’s Requirements Submittal Procedure Mechanical and Electrical Work

RECORD DOCUMENTS

CWSpec-BGENREQRev4.doc 1/9 Detailed Civil Engineering Specification


TECHNICAL SPECIFICATION SECTION 1 - GENERAL REQUIREMENTS 1.1 GENERAL

The design of the Works for which the Contractor has design responsibilities shall be strictly in accordance with current good practice, the principles set out in the relevant British Standards, Codes of Practice, the Building Regulations and other relevant regulations and fully comply with the Contract.

Allowance shall be made in the structural design of the buildings, structures and all other elements for all combinations of dead and live loads which can be reasonably assumed to act together to give the most onerous condition.

All design work shall be undertaken within a Quality Management system with minimum standards equivalent to BS 5750.

In the Specification reference is made to items being shown, specified, indicated or detailed on the Drawings. Where the Contractor is responsible for the design associated with the items concerned then he shall, unless otherwise agreed with the Purchaser, comply with the intent of the Specification by including the information required on the relevant Drawings.

1.2 STANDARDS AND CODES

Notwithstanding the following provisions within this Clause, European Standards as defined in Annex III to EEC Directive 89/440/EEC shall be used where they exist.

The designs shall conform with the requirements of all relevant parts of the latest editions of British Standards, British Standard Codes of Practice, other relevant standards, regulations and statutory documents and amendments thereto current at the date of the Tender being issued, except where qualified by this Specification, and applicable to the type of buildings and forms of construction adopted.

The Contractor's designs shall comply in all respects with the Building Regulations and all amendments thereto current at the date of the Tender being issued.

The Contractor shall liaise with the Building and Fire Authorities to ensure full compliance with any fire safety precautions and building control requirements for all the buildings. Copies of all correspondence and the submissions to the Local



Authority, Service Authorities and Fire Authorities shall be provided to the Purchaser.

The Works shall also comply in all respects with the relevant requirements of the following regulations:

Health and Safety at Work Act Factories Act 16th Edition of the IEE Regulations The Work Equipment Regulations 1992 The Safety Signs Regulations

1.3 DESIGN LIFE

The design life for all the buildings and structures described in this Specification shall be in accordance with, Section 2.10 - Design, of the Civil Engineering and Building Specification.

Mechanical and electrical systems shall be designed to be of sufficient duty robustness and reliability to ensure that, unless the Contractor had identified otherwise with his Tender, major components shall not require replacement during the design life of the Works.

1.4 MAINTENANCE

The designs shall take full account of requirements for future maintenance of the buildings structures and equipment. All equipment and fittings shall be mounted to facilitate ease of maintenance and repair. Means of access shall be provided as necessary for maintenance or inspection purposes.

Any items requiring frequent maintenance or replacement (eg consumables) shall be readily available in the UK.

In general the Works shall be designed to minimise any requirement for maintenance. All parts of the structures and other items shall be suitable for the environmental conditions.

1.5 DATUM LEVELS

Datum levels are to be agreed with the Purchaser.



1.6 GROUND CONDITIONS

The Contractor's attention is drawn to his obligations to carry out such investigations as may be necessary to establish parameters for his designs.

1.7 QUALITY ASSURANCE

The Contractor is required to operate procedures to control and verify all designs for which he is responsible in order to ensure that all specified requirements are met.

At the commencement of the design work the Contractor shall submit his procedures for the consent of the Purchaser indicating how this will be achieved. All companies employed by the Contractor to carry out design work shall comply with the Contractors QA System and shall operate their own QA system for the checking of design work.

As a minimum, all calculations, drawings and other design related documents shall be independently checked. The independent check shall be carried out by suitably qualified and experienced staff from the Contractor’s own design organisation, or his subcontractor’s organisation, or by an independent firm.

The design check shall include but not necessarily be limited to the following:-

i) Checking of all calculations in accordance with Contractors and Designers

QA Systems.

ii) Check that all items detailed on drawings are supported by appropriate design calculations.

iii) Review of all drawings to check dimensions particularly with regard to items

affected by site constraints.

iv) Confirm that the overall design will meet specified requirements.

v) Confirm that the design concept is proven and appropriate to use.

vi) Confirm that the design inputs, design methods and assumptions made are satisfactory.

vii) Confirm that all statutory requirements, including safety issues, are met.

viii) Confirm that the design is practical and safe to construct, use and

maintain.



The Contractor shall provide a certificate for all calculations, drawings and other design documents which confirm that independent checks as specified above have been carried out. The certificate(s) shall clearly indicate which sections of calculations, with page numbers and which drawing numbers and other documents have been checked. The name of the checker shall be clearly stated and the checker shall sign the certificate to confirm that the check has been made and any required corrections also carried out and checked.

The Contractor shall only use properly qualified and experienced engineers and technicians to undertake design and drawing preparation and checking.

All Drawings shall be prepared to microfiche standards in accordance with BS 4210.

1.8 CONTRACTOR'S SUBMISSIONS 1.8.1 Purchaser's Requirements

The Purchaser will require the following Construction Information to be provided by the Contractor:

i) Preliminary Scheme Proposals - Within 28 days from the date of

acceptance of the Contractor's Tender he shall provide a full and detailed description of his proposed buildings, walkways, sewage treatment plant and mechanical and electrical services and systems. The description shall confirm and expand upon information previously supplied and shall include comprehensive details of the Works to be provided together with detailed performance characteristics and features and preliminary general arrangement drawings, services schematics and design basis statements. The information shall be adequate to demonstrate compliance with the overall minimum requirements set out within this Specification.

ii) Design basis statements: Design Basis Statements shall be prepared by

the Contractor for the whole of the Works and shall include the following:-

- Identify structures, section of work or elements covered by the statement.

- State functional and performance requirements.

- Specify the applicable statutory regulations, design standards,

criteria and parameters.



- Define the basic design concepts.

- Define the construction materials to be used including grades, class

as appropriate.

- Specify the method of design and any computer program to be used.

- Specify the superimposed loads.

- Identify principal design assumptions.

The Purchaser will review the design basis statements and provide his consent or non-acceptance with explanatory comments.

iii) General arrangement drawings - These will clearly show the arrangement

of the buildings, structures or other item to be provided. All principal dimensions are to be included. The drawings shall include plans of all floors, all elevations and appropriate sections. Architectural drawings shall indicate the type and make of all cladding materials with column and surface texture as appropriate.

The drawings shall clearly indicate how the buildings or structures relate to existing works and where appropriate indicate space allocations and clearances for vehicles and plant.

iv) Plant, Equipment and Services Details: Schematic drawings are to be

provided for all building and other services which clearly indicate the Contractor's proposals. The information shall generally be as follows:

a) Plumbing:

Isometric drawings showing pipe arrangements and sizes, break tanks, pumps, boilers, etc.

b) Electrical (including alarm systems etc):

Single line diagrams showing arrangement and number of circuits, fuse and distribution boards, transformers, switches sockets, alarms, etc.



c) Ventilation:

Single line flow diagrams showing duct runs and sizes, grill locations and sizes, location and size of fans, location of fire dampers etc.

d) Full technical specifications of plant and equipment.

v) Calculations: A set of calculations for all the works together with certificate of independent checking as specified in Clause B1.7 herein.

The Purchaser will generally not review or check these calculations which are to be provided for reference and proof of independent checking.

vi) Detailed working drawings: A set of detailed working drawings in a style

and format appropriate for the work involved shall be supplied together with a certificate of independent checking as specified in Clause B1.7.

1.8.2 Submittal Procedure

Submissions may be made as a complete design package or in stages. In the latter case the submissions shall be made in a logical and progressive order following the necessary sequence of design. For staged submissions the Purchaser will provide interim consent to each stage, with final consent being given once all stages have been reviewed as appropriate. The granting of interim consent by the Purchaser does not prejudice his right to refuse consent at later stages of design.

The Purchaser will generally require 14 days after receipt of a submission or resubmission for review.

Prior to commencement of designs for each section of work the Contractor shall submit for the agreement of the Purchaser a programme or schedule which sets out dates for submission of each section or stage of design.

The Contractor shall allow in his programme sufficient float such that any unacceptable submissions can be modified without having a detrimental effect to the programme.

On receipt of final consent from the Purchaser the Contractor shall provide 5 copies of the Construction Information.

Copies of accepted drawings for which consent has been received from the Purchaser shall be provided within 14 days of acceptance and shall be endorsed "WORKING DRAWING".



1.8.3 Mechanical and Electrical Work

Additional requirements for submissions for mechanical and electrical work are detailed in Part C of the Specification.

1.9 RECORD DOCUMENTS

Record documents shall comprise the following as appropriate for the class of work concerned:-

a) Final Design Calculations.

b) Record Drawings and Schedules for all architectural, structural, mechanical

and electrical services layouts and details.

c) Electrical Wiring and Schematic Drawings.

d) Maintenance and Operating Manuals and Relevant technical literature.

e) List of proprietary items which details and name and address of manufacturer.

f) Commissioning certificates, guarantees, warranties and maintenance

agreements.

g) Maintenance and cleaning instructions for all finishes. (This information to be supplied at handover).

The Contractor shall provide the Purchaser with all record documents within 28 days of the final completion of the Works.

All record documents shall be provided in triplicate except that six copies of maintenance and operating manuals shall be supplied. In the case of drawings and diagrams the material shall be stout plastic, one of the three sets shall be opaque and the other two sets shall be transparencies suitable for photocopying. All record drawings shall also be provided on 3½ inch computer diskette in AutoCad v.14.0 drawing file. All record drawings shall also be provided on microfilm individually mounted on card and complete with index cards, all in accordance with BS 4210.



The Record Drawings provided by the Contractor shall be endorsed clearly "RECORD DRAWINGS" near to the title block. The record document shall be adequate for the following purposes:

a) To record clearly the arrangements of the various sections of the Works as

actually constructed and to identify the locations of all component parts thereof.

b) To make it possible to comprehend the extent and purpose of the works

and the method of operation of any equipment.

c) To demonstrate the methods of operation for any equipment.

d) To identify the items requiring regular maintenance or components of equipment requiring inspection, servicing or replacement, the periods between maintenance and the methods and equipment to be employed.

Each drawing prepared by the Contractor shall contain the following information:-

a) Name of Contract. b) Description of drawing. c) Drawing number. d) Scale. e) Name and address of the Contractor. f) Name and address of the Employer. g) Names of the Architect or Consulting Engineers, if any, employed by the

Contractor to undertake the design on his behalf. The Contractor shall demonstrate from time to time as required by the Purchaser during the progress of the Works that adequate and accurate records are being kept as will ensure the ultimate completeness and accuracy of the record drawings and that the record drawings are themselves being compiled progressively as the work proceeds on site. If the Contractor fails to comply with these requirements the Purchaser shall have the right to arrange for the record drawings to be prepared elsewhere and the whole of the costs involved including all costs of surveying and printing shall be borne by the Contractor.



CWSpec-PTBSEC2Rev4.doc 1/10 Detailed Civil Engineering Specification

TECHNICAL SPECIFICATION TITLE: PARTICULAR REQUIREMENTS FOR CIVIL AND BUILDING WORKS TABLE OF CONTENTS DESCRIPTION OF THE WORKS BUILDINGS GENERAL PERMANENT BUILDINGS

General Foundations and Structural Frame External Walls Roofs Internal Walls Service Supplies Building Services and Equipment within Buildings Fire Engineering Systems Drainage Fixtures, Finishes and Decoration Signage

FUNCTIONAL DESCRIPTION - PERMANENT BUILDINGS MECHANICAL AND ELECTRICAL SERVICES VEHICULAR GATES WEIGHBRIDGE ELECTRIC ARM BARRIERS DESIGN LOADS AND FLOOR FINISHES DOOR PROTECTION FRAMES



TECHNICAL SPECIFICATION SECTION 2 - PARTICULAR REQUIREMENTS FOR CIVIL AND BUILDING WORKS 2.1 DESCRIPTION OF THE WORKS

This Section describes the particular requirements for design of the building, civil, structural, mechanical and electrical services comprising the Contractor designed Works.

2.2 BUILDINGS GENERAL

The Purchaser's requirements for the Buildings are shown on the Drawings and further specified on the Room Data Sheets. The Contractor shall develop these designs architecturally and undertake detailed engineering designs whilst maintaining the general form, dimensions and layout of the buildings.

The Contractor shall be entirely responsible for the design of all elements of the Works, as defined in the Scope of Works.

The materials, fabric and mechanical and electrical services within the building shall be designed to be energy efficient so that operational costs are minimised. Mechanical and electrical systems shall all be designed for ease and economy of maintenance.

2.3 PERMANENT BUILDINGS 2.3.1 General

The permanent buildings have been conceived as a 'family' of buildings with common architectural and structural features.

2.3.2 Foundations and Structural Frame

The foundations shall be either piled, pads or rafts as appropriate for the structural configuration, loadings and ground conditions. The foundations shall be designed and located not to interfere with existing structures and foundations that are to be maintained. Foundation design shall comply with BS 8004.



The structural frames shall comprise steel columns and beams with columns located within external and internal walls as far as is practical. Where columns are not located within walls they should be sited to minimize any effect on the use of rooms or on the efficient circulation through the public areas.

Design Loadings shall be in accordance with BS 6399, Part 1 unless otherwise specified.

The roof beams shall be formed from either curved universal beams or fabricated curved beams. All beams following curved roof lines must be curved where they are exposed to view (ie where there is no ceiling).

The steelwork shall be fire protected as required by the Building Regulations and the local Fire Safety Authority. Any steelwork requiring such protection shall be clad with a proprietary system.

The Contractor shall be responsible for consulting and liaising with, and satisfying all requirements of the Fire Safety Authority and shall demonstrate to the Purchaser that this has been done.

2.3.3 External Walls

Design of cladding shall be in accordance with Part C of the Specification.

External walls shall comprise:

i) Cladding as detailed on the Architectural drawings and as per the external elevation data sheets, with all necessary vapour barriers and insulation fixed to secondary steelwork. The blockwork shall be flush jointed and suitably restrained with stainless steel ties firmly fixed to the structural steelwork. Materials to form a suitable and appropriate damp proof course shall be included.

ii) Glazing in anodised aluminium frames suitably fixed to the structural steel

frame. Glazing units shall be double glazed with solar control glass (Suncool Float standard silver finish by Pilkington Glass Ltd or similar agreed). The glazing system shall be provided with thermal breaks.

External wall constructions shall provide insulation U values in accordance with current Building Regulations.

2.3.4 Roofs



The roofs shall comprise galvanised steel sheeting, complete with all insulation and waterproof membranes as appropriate. Details given on the external elevation data sheets shall dictate. Where appropriate and indicated on the layout drawings and Room Data Sheets the soffit shall be exposed internally and colour coated. The system adopted shall incorporate an inner layer of sheeting spanning between the roof beams/purlins. If the system adopted incorporates purlins they should be sandwiched between the outer and inner sheeting layers such that they are not visible.

The roof construction shall provide insulation U values in accordance with the Building Regulations.

Surface water drainage shall be via gutters and downpipes connected to the surface water drainage system designed by the Contractor.

2.3.5 Internal Walls

Internal walls shall be blockwork of a strength and thickness appropriate to room uses and wall dimensions.

2.3.6 Service Supplies

Incoming service supplies to each of the buildings shall be designed by the Contractor.

All services will be connected to the existing in the location of the site boundary.

2.3.7 Building Services and Equipment within Buildings

Building Services including heating and ventilation, water and electrical building services shall be in accordance with Part C of the Specification.

Small power, lighting, alarm and security circuits shall be provided to rooms as detailed in the Room Data Sheets in the Scope of Works and Part C of the Specification.

Requirements for design, performance, materials and workmanship for these items are included in Part C of the Specification.



2.3.8 Fire Engineering Systems

The Contractor shall provide fire extinguishers, emergency lighting and all other equipment required by the local fire safety authorities.

Water cannon/drenchers in bunker area are detailed in the main specification.

2.3.9 Drainage

Foul water drainage within the buildings shall be designed to suit the accommodation layouts shown on the Drawings.

2.3.10 Fixtures, Finishes and Decoration

Fixtures, finishes and decorations shall be as detailed on the Drawings and described in the Room Data Sheets.

2.3.11 Signage

A scheme for signage fixed to the buildings internally and externally shall be in compliance with the Purchaser’s requirements. The Contractor shall liaise with the Purchaser to arrive at a scheme which reflects the Terminal Operator's corporate identity whilst at the same time providing clear messages.

2.4 FUNCTIONAL DESCRIPTION - PERMANENT BUILDINGS 2.4.1 These requirements shall be read in conjunction with the Scope of Works and

Room Data Sheets and are provided as general background to the intended usage for the Buildings which shall be taken into account by the Contractor in undertaking his designs.

2.5 MECHANICAL AND ELECTRICAL SERVICES

Design requirements for building and external site mechanical and electrical services are included in Part C of this Specification.



In addition to the design of permanent mechanical and electrical installations the Contractor shall design and construct all temporary electrical, water, drainage service diversions or other measures which may be necessary to maintain existing services as specified and to enable the Works to be constructed, together with permanent diversions of these services where they pass under or unacceptably close to permanent buildings.

2.6 VEHICULAR GATES

(i) Main Gate - electrically operated from control room. (ii) Secondary vehicle gate - electrically operated from control room and key

pad or sensor tab. 2.6.1 Vehicular gates shall be hinged or sliding gates with clear opening. 2.6.2 The gates shall be fabricated in accordance with Section 071 of Part C of the

Specification. 2.6.3 Gate posts shall have suitable fittings for attaching the adjacent fence and the

posts and their foundations shall be capable of acting as a straining post for the fence.

2.6.4 Each hinged gate shall be secured in closed position by a 30mm drop bolt with

guides welded to frame and handle at top, which shall be between the closing stiles and inoperable when the gates are locked, and which rests on a flush fitting cast iron ground support block which will be set into the roadway. Hinged gates shall be secured in the open position by adjustable foot-operated holding back catches, which shall attach to hooks welded to bottom rail of gate.

2.6.5 Stiles of hinged gates shall be extend vertically and fitted with brackets to take

three rows of twin strand barbed wire at 100mm centres to match the wire on adjacent fences.

2.6.6 Gate hinges shall enable 180 degree opening with phosphor bronze bushes and

greasing points, and with facility to allow vertical, horizontal and lateral adjustment. When installed the gap beneath the bottom of the gate shall be no greater than 130mm when closed and no less than 20mm when open. The Contractor shall be responsible for any modifications to the pavings necessary to achieve these limits.



2.7 WEIGHBRIDGE 2.7.1 The Contractor shall design, construct, install and commission a complete

weighbridge in the position shown on the drawings. This shall be of a size and capacity to cater for all current HGV's currently using public highways and planned for the next 5 years. The weighbridge shall be mounted in a pit with its running surface level with finished surfacing level.

The weighbridge shall be of robust and durable construction designed for operation in the prevailing environment and shall be supplied and installed by an established specialist manufacturer agreed by the Purchaser. All materials and equipment shall conform with the appropriate British Standard Specifications and Codes of Practice and with Part C of this Specification.

The following minimum dimensions and capacity shall apply:

Platform length 18m Capacity 50 tonnes Accuracy ±0.1%

2.7.2 The weighbridge control system shall be in accordance with main specification documents.

The weighbridge control system shall be linked to a traffic light control at the weighbridge such that the light turns green after the ticket is dispensed and turns red to prevent passage of the next vehicle until after the weighed vehicle has departed. Traffic light control shall also be provided to prohibit more than one vehicle on the weighbridge.

2.7.3 The load cell shall be microprocessor controlled and capable of recognising and

automatically correcting errors and compensating for off-centre loading and temperature changes.

The load cell shall be contained in a stainless steel or equal non-corrodible sealed container, waterproof and totally resistant to lightning and other electrical discharges.

2.7.4 The bed shall be manufactured from high quality steel blast cleaned to Swedish

Standard SIS 055900, grade SA 2½ and then a suitable protection coating applied to the Purchaser’s agreement and to Table 3 Part 9 of BS 5493, to provide a 10-20 year life. The surface of the flat bed shall be skid-resistant.

Suitable multiple manholes shall be provided for access to the load cells and for



cleaning.

2.7.5 The electrical installation shall comply with the requirements of Part C of this Specification. All enclosures, junction boxes etc shall have a minimum enclosure classification of IP65.

2.7.6 Lightning protection shall be provided to BS 6651 and all electronic equipment

shall be designed so that outside interference cannot affect the accuracy of the operation. All signal cable cores shall be screened and the cable screened overall. Power supplies shall be surge protected.

2.7.7 Adequate drainage shall be provided in the pit. Effluent shall pass through an

interceptor before discharge. This interceptor and the associated outfall are part of the Contractor's design.

2.8 ELECTRIC ARM BARRIERS 2.8.1 Electric Arm Barriers shall be installed with appropriate clearances for vehicles. 2.8.2 The power requirements shall be 240V, 50Hz Single Phase Supply. The barrier

arm shall incorporate a shearing feature to suit left and right hand knock-off facility. The base shall be fixed to a concrete foundation and the electrical supply will be ducted in the concrete and rise into the barrier from below.

2.8.3 The control circuitry shall provide for the following:

- Pass card operation. - "Loop to open" and "loop to close" operation. - Remote operation from Control Room. - Remote operation from sender unit in vehicle.

2.8.4 An inductive loop vehicle detector is required at each barrier. It shall be sensitive

enough to detect vehicles from loops that are wound into slots, approximately 5-7mm wide and 25-50mm deep, cut into the road surface.

2.8.5 The Contractor shall indicate his specification for laying loops where concrete

reinforcement or mesh exists with dimensions and conditions required. Specifications of loop cables shall also be given with maximum length of feeder cable from loops to detector box.

2.8.6 The detector must be capable of "Screening" out other metal objects such as

prams, bicycles and supermarket trolleys which may inadvertently induce



incorrect signals into the system. The loops should be capable of detecting "back off" and vehicles manoeuvring in error and details of the loop configurations or patterns of loops to accommodate this shall be submitted for agreement by the Purchaser. Loop detectors shall have automatic tuning and fault detection with facility to transmit fault messages to the central controller.

2.8.7 Electric arm barriers shall be of robust and durable construction and shall be

supplied and installed by a specialist manufacturer agreed by the Purchaser. 2.9 DESIGN LOADS AND FLOOR FINISHES

Design loads shall be calculated on accordance with relevant codes, standards and regulations provided that design superimposed loads shall not be less than the following:

Area

Load

Finish

Unloading areas, silo area, flue gas treatment area

15 kN/m2

Quartz mineral hardener

Effluent storage areas and water treatment plant area

10 kN/m2

Acid-resisting coating

Transformer areas, tank areas

10 kN/m2

Dust proofed concrete

Workshops, stores

15 kN/m2

Quartz mineral hardener

Lift and load lift machinery rooms, electrical rooms and archives

10 kN/m2

Floor paint

Oil storage

15 kN/m2

Unfinished

Tipping Hall and Storage Bays

30 kN/m2

Quartz hardener

ferrous scrap and bottom ash storage

30 kN/m2

Quartz hardener

Turbine and Generator Room

15 kN/m2

Dust proofed concrete

Truck circulation areas

15 kN/m2

-

Refuse grab parking areas

80 kN

-

Light rooms and corridor zones 6 kN Dust proofed concrete



2.10 DOOR PROTECTION FRAMES

All steel columns at main door openings shall be protected against damage by an in-situ concrete encasement not less than 1.5m high and providing a minimum concrete cover to the steel section of 100mm. The encasement shall be reinforced in accordance with BS8110.


CWSpec-PTCAPPA-Rev4.doc 1/7 Detailed Civil Engineering Specification

TECHNICAL SPECIFICATION WORK GROUP: 060: EXTERNAL WORKS SECTION NO: 062 TITLE: PERMANENT TRAFFIC SIGNS AND ROAD MARKINGS TABLE OF CONTENTS GENERAL LOCATION OF TRAFFIC SIGNS

General Position of Traffic Signs

FACES OF TRAFFIC SIGNS

Legend Installation

POSTS FOR PERMANENT TRAFFIC SIGNS

General Tubular Steel Posts

PREPARATION AND FINISH OF STEEL POSTS AND POST HOUSINGS FOUNDATIONS FOR PERMANENT TRAFFIC SIGNS SIGN LOCATIONS IDENTIFYING MARK MANUFACTURER'S TRADE MARK



TABLE OF CONTENTS COMPARTMENTS FOR ELECTRICAL EQUIPMENT

Base Housing

Locks and Keys BOLLARDS EXTERNALLY ILLUMINATED SIGNS DAMAGE TO SIGNS, POSTS AND FITTINGS CLEANING OF SIGNS PERMANENT ROAD MARKINGS



062.010 GENERAL

Traffic signs shall comply with the Specification for Highway Works - Series 1200, Traffic Signs issued by the Department of Transport December 1991. This particular specification contains the information which the Highway Works Specification indicates as being in Appendix 12/1.

LOCATION OF TRAFFIC SIGNS

062.020 General

The location of each traffic sign shall be shown on Traffic Signs and Road Marking Drawings.

062.030 Position of Traffic Signs

All traffic signs shall be positioned and erected in accordance with the requirements of Chapter 1 of the Traffic Signs Manual published by Department of Transport (HMSO).

FACES OF TRAFFIC SIGNS

062.040 Legend

Details of the legend layout of directional information signs and non-prescribed traffic signs shall be shown on the Drawings.

Other traffic signs which have standard symbols and markings (with permitted variants) are detailed in the Traffic Signs Schedule. These traffic signs are shown in the Traffic Signs Regulations and General Directions, 1981 (as amended).

062.050 Installation

Traffic signs fascias shall not be erected until 3 days after concreting the posts. All sign fixings shall be stainless steel or aluminium.



POSTS FOR PERMANENT TRAFFIC SIGNS 062.060 General

All posts shall be steel. The number type and size of post required for each traffic sign shall be detailed on the Drawings.

062.070 Tubular Steel Posts

Tubular steel posts shall have the following Sections.

(i) 76mm (3") outside diameter x 10 swg (ii) 89mm (3½") outside diameter x 8 swg

Each post shall have a base plate having a minimum area of 0.052 square metres (81 sq. inches) and also where no lighting unit is fixed to the top of the post a waterproof cap. Both base plate and post cap shall be in accordance with BS 873.

062.080 PREPARATION AND FINISH OF STEEL POSTS AND POST HOUSINGS

Post and switch boxes shall be cleansed from grease, scale and rust, shot blasted and then galvanised.

Galvanising shall be by an agreed hot-dip process at the rate of 610g per m2 (2 ounces per sq. foot) and in accordance with BS 729. When finished the galvanising shall be smooth, reasonably bright, continuous and free from imperfections. Where flux, ash and dross inclusions, bare patches or spots due to inefficient pickling or persistent types of scale etc. are apparent, the work shall be completely stripped and regalvanised. Where it is necessary to drill a hole in a hollow member to allow air to escape, the hole shall be 12mm in diameter and shall be plugged with Neoprene or other agreed material after dipping.

062.090 FOUNDATIONS FOR PERMANENT TRAFFIC SIGNS

The type and size of foundations required for each sign shall be shown on the Drawings.

Where signs are illuminated provision shall be made for cable entry by means of a 75mm diameter UPVC duct. The base section of bollards shall be concreted to within 50mm of the top of the base



section, so that the whole of the holding down bolts are embedded in concrete. Bollard bases shall be set in a block of concrete extending to 300mm in width outside the edge of the base unit with provision for a cable entry.

062.100 SIGN LOCATIONS IDENTIFYING MARK

The reference number of the sign shall be indicated by self-adhesive 25mm sign numbers on the reverse side of the sign in the bottom left hand corner so that it is readily visible and legible after erection.

062.110 MANUFACTURER'S TRADE MARK

The manufacturer's name or trade mark will not be permitted on the face of the sign. It may be affixed to the back provided prior agreement to the size and colour of the mark is obtained from the Purchaser in writing.

062.120 COMPARTMENTS FOR ELECTRICAL EQUIPMENT

Base Housing

Where illuminated signs are erected on tubular posts the electrical equipment shall be enclosed in a large integral base housing of inside diameter not less than 130mm. Entrance to the interior of such compartments shall be by means of a weatherproof door having tamper-resistant key fastenings. The door opening shall be not less than 100mm x 400mm and shall be positioned so that, when the post is installed as intended, it is not less than 300mm above ground level.

An internal baseboard of dimensions not less than 80mm x 300mm x 12mm manufactured from substantially non-hydroscopic and rot-resistant material shall be fixed in the box and an earthing screw or bolt shall be provided. The distance from the face of the baseboard to the inside front to the housing shall be at least 100mm. A suitable cable entry shall be provided just below ground level.

062.130 Locks and Keys

All compartments for electrical equipment shall be provided with vandal and weather resistant locks. The number of different types and patterns of lock shall be kept to a minimum. The Purchaser shall be provided with size keys for each type of lock.

062.140 BOLLARDS

Bollards shall be all plastic knock-down type.



Bollards shall be complete with all wiring, fluorescent lighting units, lamps, starters, capacitors, ballasts, fuses, photo-electric switches and with sockets or clips as necessary.

The power supply to each bollard shall be 240 volts, 50 Hz, single phase.

Light sources shall be hot cathode tubular fluorescent lamps with a colour defined as 'standard colour 2' in BS 1853 : Part 1.

062.150 EXTERNALLY ILLUMINATED SIGNS

The traffic signs schedule indicates those signs which are required to be externally illuminated.

Sign luminaries shall comply with requirements of BS 873, BS5433:Part 2, Section 2.7 and Chapters 11 and 13 of the Traffic Signs Manual.

Luminaries shall be completed with all wiring, fluorescent lighting units, lamps, starters, capacitors, ballasts, fuses, phot-electric switches and with sockets or clips as necessary.

The power supply to each luminaire shall be 240 volts, 50 Hz, single phase.

Light sources shall be high pressure mercury fluorescent lamps, type MBF complying with BS 2677.

Details of the types of illuminations shall be shown on the Drawings.

062.160 DAMAGE TO SIGNS, POSTS AND FITTINGS

Signs, posts or fittings having damaged faces, backs, paintwork or plastic coating may be rejected by the Purchaser and shall then be replaced at the Contractor's expense. Slight damage may be rectified by touching in, at the Contractor's expense, but only with the agreement, and in accordance with the instructions, of the Purchaser.

The Contractor shall be responsible for the protection of sign posts, sign fascias and fixings until such a time as this responsibility is discharged by the Purchaser.

062.170 CLEANING OF SIGNS

Upon completion and servicing of the signs, they shall be thoroughly cleaned



immediately prior to being handed over.

The type of detergent used shall be to the agreement of the Purchaser. 062.180 PERMANENT ROAD MARKINGS

The types and locations of permanent road markings shall be shown on the Drawings. The exact locations shall be agreed with the Purchaser prior to installation.

All permanent road markings shall be thermoplastic material complying with BS 3262 Class A except that markings applied to proprietary non-slip surfacing shall be compatible with the surfacing system. All road markings shall be white and shall be reflectorised. The Contractor shall submit evidence of a current BSI Certificate and Kitemark licence for all thermoplastic materials used. Materials that have been modified subsequent to the issue of certification shall not be used.

Road markings shall be applied in accordance with the Department of Transport Manual of Contract Documents for Highway Works, Volume 1, Specification for Highway Works, Clause 12.12. They shall only be applied to surfaces which are clean and dry. Markings shall have smooth edges and shall be uniform thicknesses and free from streaks.

Thermoplastic material shall be laid to the following thicknesses:

a) Screed markings 4mm + 1mm b) Sprayed markings 2mm + 0.5mm

The method of thickness measurements shall be in accordance with BS 3262, Part 3. Tack coats are not required except on concrete surfaces.


CWSpec-SECT001-Rev4.doc 1/4 Detailed Civil Engineering Specification

TECHNICAL SPECIFICATION WORK GROUP: 000 : INTRODUCTION SECTION: 001 TITLE: GUIDANCE NOTES TABLE OF CONTENTS SCOPE STRUCTURE OF THE TECHNICAL SPECIFICATION CONTENTS OF CIVIL AND BUILDING WORKS SPECIFICATION



SCOPE

001. 010 These Guidance Notes define the purpose and use of the Specification for

Civil and Building Works as part of the Contract Documents.

STRUCTURE 001. 050 The Specification is divided into Work Groups, Sections and Clauses.

. Work Groups are generally major divisions of engineering activity.

. Sections are sub-divisions of these activities which enable the appropriate specifications to be selected for a particular contract.

. Clauses are single subject statements within Sections grouped

under three main headings, Materials, Workmanship and Quality Control.

001. 060 The clause numbering system adopted for the Sections provides a unique

reference for each Clause. It identifies the Work Group, Section, clause number within the Section e.g. 212.070 is a typical clause reference.

212 The first two numbers indicate the Work Group,

212 The last number indicates the Section,

.070 This represents the clause number within the Section,

001. 070 New Clauses are inserted at the appropriate point in a Section by the

allocation of the next clause number after the immediately preceding Clause. Clause numbers are not necessarily sequential.



CONTENTS OF THE CIVIL AND BUILDING WORKS SPECIFICATION SECTION TITLE 001 Guidance Notes 012 Setting out and Monitoring 041 Excavation and Filling 051 Buried Foul and Surface Water Drainage 052 Building Drainage 061 Roads, Hardstandings, Car Parks, Paths, Kerbs, etc. 062 Permanent Traffic Signs and Road Markings 071 Fences and Gates 121 Buried Pressure Pipelines 131 Ducts and Trenches 201 Concrete Production 202 Reinforcement 211 Structural Steelwork 215 Crane Gantry Girders, Rails and Rail Fixings 231 Brickwork and Blockwork 241 Metal Cladding 251 PVC Sheet Roof Coverings 261 Carpentry and Joinery 271 Sanitary and Plumbing Installations 281 Plastering, Rendering and Dry Lining 282 Suspended Ceilings 283 Wall Tiling 284 Screeds and Floor Finishes



311 Windows, Doors and Shutters 312 Shutter Doors 331 Painting of Buildings 401 Waterproofing and Waterstops 402 Caulking and Sealants 403 Proprietary Anchor Systems 411 Copings and Flashings 412 Louvres 413 Piling



GENERAL SETTING OUT AND MONITORING 012 TECHNICAL SPECIFICATION WORK GROUP: 010 : GENERAL SECTION: 012 TITLE: SETTING OUT AND MONITORING TABLE OF CONTENTS SCOPE MATERIALS

Permanent Setting Out Stations Bench Marks Temporary Reference Points Instruments

WORKMANSHIP

Site Datum Permanent Setting Out Stations Temporary Setting Out Points Temporary Bench Marks Monitoring of Ground and Structures Movements

QUALITY CONTROL

Accuracy of Setting Out Adjustments in Setting Out Instruments Records



APPENDIX 1 BSI STANDARDS AND OTHER REFERENCES APPENDIX 2 ENGINEERING DOCUMENTS



SCOPE 012. 010 This Section defines the standards to be applied to the setting out register for the

Works and surveys for the monitoring of ground and building movements.

MATERIALS

Permanent Setting Out Stations 012. 030 These shall be constructed in locations agreed by the Purchaser.

Bench Marks 012. 040 These shall be dome headed brass bolts fixed into the concrete of the Setting

Out Stations or at other locations agreed with the Purchaser.

Monitoring Reference Points 012. 050 Monitoring Reference Points shall be non-corrodible pins or plates set in

concrete of suitable proportions and location to avoid movement of the point.

Instruments 012. 060 Instruments to be used for checking setting out and monitoring shall be provided

by the Contractor and maintained in good working order.

WORKMANSHIP

General 012. 070 All survey, setting out and levelling shall be carried out in accordance with BS

5964. 012. 080 The setting out of the works shall be defined to an arbitrary site grid. On entry to

the site the Contractor shall check that co-ordinates of any existing survey stations are consistent with each other and with critical existing features. He shall then establish an adequate number of Permanent Setting Out Stations as specified from which to set out the works, and establish and record their co-ordinates on the site grid.



Site Datum 012. 090 Site Datum levels and co-ordinates shall be established as necessary and

agreed with the Purchaser prior to commencement of any setting out of the Works.

Permanent Setting Out Stations

012. 100 Permanent Setting Out Stations shall be accurately positioned and shall be

adequately protected from damage during the construction of the Works. Each Permanent Setting-Out Station shall be visible from at least two other Permanent Setting Out Stations and be referenced in such a way that it can be accurately re-established if disturbed.

Temporary Setting Out Points

012. 120 All temporary setting out points which the Contractor deems necessary in order

to set out the Works shall be established to the accuracy given in BS 5964 Section 7.

012. 130 Temporary setting out points shall be adequately protected during the

construction of the Works and replaced if damaged or displaced. They shall be removed at the completion of the Works or when directed by the Purchaser.

012. 140 Survey records for temporary setting out points shall be maintained by the

Contractor and made available to the Purchaser.

Temporary Bench Marks 012. 150 The Contractor shall establish such temporary bench marks as are necessary for

the execution of the Works. The levels shall be established and recorded and shall be accurate to within the permissible deviations set out in BS 5964 Section 11.

012. 160 The Contractor shall record which bench mark has been used for each section of

the Works when setting levels. 012. 170 Bench marks shall be checked against permanent stations at frequent intervals

and at least weekly when in use. 012. 180 Survey records for verification of bench marks shall be maintained by the

Contractor and made available to the Purchaser upon request.



Monitoring for Movements of Ground and Structures

012. 190 Monitoring for movements of ground or structures shall be carried out by the

Contractor at locations and frequencies as specified or when instructed. 012. 200 The locations of monitoring reference points shall be established by the

Contractor and adequately protected against any damage or displacement and shall be accessible at all times.

012. 210 Precise methods of survey shall be used and the Contractor shall submit details

to the Purchaser of his method and the equipment to be used. 012. 220 All surveys shall be related to the Site Datum. Survey records shall be submitted

to the Purchaser. 012. 225 On entry to the Site the Contractor shall check the invert levels of all existing

drains and sewers to which the new drainage will connect and report any discrepancies to the Purchaser.

QUALITY CONTROL

Accuracy of Setting Out

012. 230 The Contractor shall set out all the works as accurately as possible from the

appropriate setting out lines, established as described above. The maximum tolerance permitted for any part of the works shall be as given in BS 5964 Section 8 unless specified otherwise in the Specification.

Adjustments in Setting Out

012. 240 Changes proposed because of discrepancies of line or level shall be submitted

to the Purchaser for agreement. Any consequent minor adjustments to the setting out shall be made prior to the re-commencement of the construction work.



Instruments

012. 250 All equipment shall be regularly checked and calibrated to BS 5781 in

accordance with the manufacturers instructions or the Contractor’s own QA Procedures.

012. 260 Tests on calibration shall be carried out at least every 6 months and at any time

when the accuracy of the equipment is suspect. Calibration certificates shall be retained by the Contractor.

Records

012. 270 All surveys shall be fully recorded by the Contractor and the details and results

provided to the Purchaser as soon as possible on completion of each section of the Works.



APPENDIX 1 BSI STANDARDS AND OTHER REFERENCES ° The British Standards referred to in Section 012 are listed below, together with any other

references specified therein. ° The latest editions shall be used, including all current amendments and additions. ° Any differences between their requirements and this Specification shall be submitted to

the Purchaser for his ruling.

BS 5781 Measurement and calibration systems. BS 5964 Methods for setting out and measurement of buildings: permissible

measuring deviations.



APPENDIX 2 - ENGINEERING DOCUMENTS TO BE SUBMITTED BY CONTRACTOR

CLAUSE REFERENCE

DOCUMENT DESCRIPTION

COMMENT

012. 080 012.100 012.180 012.210 012.220 012.240

Site datum establishment. Survey of setting out stations. Verification of bench marks. Details of method and equipment. Movement survey records. Discrepancies of line or level.


CWSpec-SECT041Rev4.doc 1/21 Detailed Civil Engineering Specification

TECHNICAL SPECIFICATION WORK GROUP: 040 : EARTHWORKS SECTION: 041 TITLE: EXCAVATION AND FILLING TABLE OF CONTENTS SCOPE MATERIALS

Unsuitable and Suitable Materials Topsoil Turf Grass Seed Fertilizer Classification of Special Filling Material Hardcore Materials Used in Reclaimed Areas

WORKMANSHIP

General Materials Arising from On Site Excavations Dealing with Water Excavation Explosives and Blasting Filling Method of Compaction of Suitable Filling Materials Compaction of Hardcore Planning & Compaction of Material in Reclaimed Areas



TABLE OF CONTENTS QUALITY CONTROL

Sampling of Fill Materials Samples of Imported Filling Material and Hardcore Soil Testing Laboratory Laboratory Tests on Fill Materials Field Tests and Fill Materials Tolerance Limits Settlement and Heave Allowance

CONTAMINATED SOILS TOP SOILING, TURFING AND GRASS SEEDING APPENDIX 1 BSI STANDARDS AND OTHER REFERENCES APPENDIX 2 INFORMATION TO BE PROVIDED BY CONTRACTOR



SCOPE

041. 010 This Section describes the general requirements for earthworks with

respect to excavation works and filling works.

MATERIALS

Unsuitable and Suitable Materials 041. 030 Unsuitable fill material shall comprise:

(a) Material from swamps, marshes and bogs and organic material.

(b) Peat, logs, stumps and perishable materials.

(c) Material susceptible to spontaneous

combustion.

(d) Material in a frozen condition.

(e) Clay of liquid limit exceeding 90 and/or plasticity index exceeding 65.

(f) Material having a moisture content outside the limits

permitted by this specification. All material with a moisture content more than 2% above the optimum shall be classified as unsuitable.

(g) Any natural material or industrial or domestic product which

will not compact to form a stable fill or will adversely affect other materials in the Works.

(h) Any other material which the Purchaser considers to be

unsuitable.

Materials of type (d) if otherwise suitable may be classified as suitable when thawed.

041. 040 Suitable fill material shall be categorised as follows:



Class I: General cohesive fill shall include

- Clays with not more than 20% of gravel or any larger sized

particles and having a moisture content within -4% to +2% of the plastic limit unless otherwise stated.

Class II: Well graded granular fill which shall include:-

- Sands and gravels with a uniformity coefficient greater than 10.

- Chalk with a saturation moisture content within the range 15-

20%.

- Inert shales and clinker ash.

- Maximum particle size 125mm.

Class III: Dry cohesive fills which shall include:-

- Clays containing more than 20% of gravel or any larger sized particles, and with a moisture content less than 4% below the plastic limit.

Class IV: Uniformly graded fill which shall include

- Sands and gravels with a uniformity coefficient of 10 or less.

- Pulverised fuel ashes.

- Silts containing 80% or more of material in the particle size

range 0.06mm to 0.002mm.

Topsoil 041. 050 Topsoil shall be from the top humus-bearing horizons of the soil, free from

chemical or other pollutants, pests, unwanted weeds, roots and rubbish. Imported topsoil shall be “medium rated” to BS 3882.

Turf

041. 051 Imported turf shall comply with BS 3969.

Grass Seed



041. 052 Imported seed, including where agreed by the Purchaser, that incorporated

in a hydraulic mulch, shall be a tested mixture suitable for a severe coastal environment and certificates of germination and purity shall be provided before sowing, together with the names of the varieties used in the mixture. Unless otherwise agreed by the Purchaser, this shall contain the seeds listed in Table 1 to the proportions therein.

Table 1: Grass Seed Mixture per 50kg

kg

%

Strong creeping red fescue

17.5

35

Smooth-stalked meadow grass

12.5

25

Highland browntop bent

5.0

10

Saltmarsh grass

12.5

25

White clover

2.5

5

Note: Seed varieties to be from the UK National List.

Fertilizer 041. 053 Fertiliser, including where agreed by the Purchaser that incorporated in

hydraulic mulch, shall consist of a compound containing not less than 10% nitrogen, 15% phosphoric acid and 10% potash and samples shall be submitted to the Purchaser for agreement prior to its use in the permanent Works.

Classification of Special Filling Material

041. 060 Special material for filling shall be classified as follows:-

CLASS 'A' filling material shall consist of:

Crushed rock ) Hoggin ) Graded as follows: Well burnt colliery shale ) Sand and gravel )

BS Sieve Percentage by



Weight Passing

75mm 100 63mm 85-95 37.5mm 50-70 19mm 20-40 9.5mm 0-15

CLASS 'B' filling material shall consist of Hardcore as specified in Clause [041.070], graded as follows:

BS Sieve or Ring Percentage by

Weight Passing

125mm 100 75mm 70-90 37.5mm 30-50 19mm 10-25 9.5mm 0-10

CLASS 'C' filling material shall consist of:

Quarry stone ) Graded as follows: Concrete or stone rubble )

BS Sieve or Ring Percentage by

Weight Passing

375mm 100 150mm Not exceeding 50 75mm Not exceeding 15



CLASS 'E' filling material shall consist of well graded crushed rock graded as follows:

BS Sieve Percentage by

Weight Passing

37.5mm 100 9.5mm 40-70 4.75mm 25-45 600 micron 8-22 75 micron 0-10

CLASS 'F' capping material shall consist of selected granular material other than unburnt colliery point, argillaceous rock or in the case of class F1, chalk. Capping may be either fine graded F1 or coarse graded F2 as follows:

Percentage by Weight Passing

BS Sieve F1

F2

125mm

100

90mm

80-100

75mm

100

65-100

37.5mm

75-100

45-100

10mm

40-95

15-60

5mm

30-85

10-45

600 micron

10-50

0-25

63 micron

<15

0-12

Hardcore

041. 070 Hardcore shall consist of any combination of broken or crushed concrete,

clean hard brick, coarse gravel or hard stone capable of passing in every direction a ring of diameter not greater than two thirds the thickness of the placed layer subject to a maximum diameter of 150mm. It shall be free from dust, rubbish and any other deleterious matter.



Materials Used in Reclaimed Areas

041. 075 Material placed below MHWN in reclaimed areas shall meet the

requirements of Class 6A of the Department of Transport's Specification for Highway Works.

WORKMANSHIP

General

041. 080 All earthworks shall be adequately supported or formed to ensure stability

of the sides and to prevent any damage to the surrounding ground or structures.

041. 090 The Contractor shall submit for agreement when required method

statements for his temporary support arrangements.

Materials Arising from On Site Excavations 041. 100 Excavated materials suitable for re-use in the works shall be stored in

stockpiles at locations and to profiles specified or otherwise agreed with the Purchaser.

041. 110 Excavated top soil for re-use as topsoil shall be stockpiled separately in

storage heaps not more than 1.5m high to retain fertility for re-use as topsoil. Compaction of the material shall be avoided and the only plant permitted to travel over the heaps shall be that used for the transport of the soil.

041. 120 Surplus excavated materials and excavated material not agreed by the

Purchaser for reuse shall unless stated otherwise be removed from site to a tip provided by the Contractor and controlled or recognised by a Local Authority.

041. 130 Where excavation reveals a combination of suitable and unsuitable

materials, the Contractor shall, when agreed by the Purchaser, carry out the excavation such that the suitable materials are excavated separately for use in the Works without contamination by the unsuitable materials.

041. 140 No excavated material shall be dumped or run to stockpile without the

agreement of the Purchaser. Material which is unsuitable only by reason of being frozen may be retained on Site for future use.



041. 150 Material used for haul roads shall not be re-used without the agreement of the Purchaser.

Dealing with Water

041. 160 The Contractor shall not permit water to accumulate in any excavation unless otherwise instructed.

Any water whether arising from the excavation or draining into it shall be drained or pumped to an agreed location via adequate settlement arrangements or other means to prevent the deposition of solids or other pollution into the receiving water.

041. 170 The Contractor shall take adequate steps to prevent adjacent ground from

being adversely affected by loss of fines through natural drainage or any dewatering process and shall submit his proposals for dealing with water.

Excavation

041. 180 Topsoil shall be removed from the area of the Works and the working area

and set aside when required for reuse. 041. 190 For excavations in cohesive materials the final 150mm of material above

formation level shall only be removed immediately prior to placing the blinding concrete or sub-base when the work can be programmed to be carried out during the same day.

041. 200 Unsuitable hard or soft material encountered at formation levels shall be

removed and made good as agreed by the Purchaser. 041. 210 The Contractor shall make good at his own expense and in a manner

agreed with the Purchaser any parts of the formation and sides of excavations made unsuitable by his working methods.

041. 220 Notice shall be given to the Purchaser prior to covering any formation.

Explosives and Blasting 041. 230 The use of explosives for blasting of excavations is not permitted without

the Purchaser’s written agreement.



Filling

041. 240 No filling shall be carried out without the agreement of the Purchaser.

Haulage of material to areas of filling shall proceed only when sufficient spreading and compacting plant is operating at the place of deposition. Areas to be filled shall be clear of topsoil, rubbish, scrap material and standing water when fill is placed.

041. 250 Filling material used in forming embankments, raising site levels, backfilling

around structures, in trenches and other similar works shall be deposited in layers. Compaction shall be carried out in accordance with British Standard BS 6031.

Each layer of fill shall be adequately consolidated throughout its full depth prior to placement of an additional layer.

The filling material shall be compacted to a dry density not less than 95 percent of its maximum dry density as determined by BS 1377 where the fill is to support any structure, including roads, and services, and to not less than 90 percent elsewhere.

041. 260 Areas of general fill and embankments shall be built up evenly over the full

width and with side slopes not greater at any time than agreed by the Purchaser. Areas of fill shall be kept free of water. During construction of areas of fill the Contractor shall control and direct construction traffic uniformly over their full width. Damage to compacted layers by construction traffic shall be made good by the Contractor. In carrying out embankments up to or over culverts, piped drains or other services, and where required in the Contract up to or over bridges, the Contractor shall bring the embankment up equally on both sides. Sloping surfaces of fill shall be compacted.

041. 270 Backfilling to foundations shall be carried out at a time and to a programme

agreed by the Purchaser. Pipe trenches shall be backfilled as soon as possible consistent with the specified testing requirements; power rammers shall not be used within 300mm of any part of the pipe.

041. 280 Unless otherwise directed backfilling shall consist of agreed suitable

material as specified which shall be deposited in layers not exceeding 250mm loose depth.



041. 290 Due regard shall be paid to the method of backfilling and of compaction to ensure that no damage is done to any structure, including pipes and services. Care shall be taken to ensure that the filling to all trenches and excavations proceeds at the same rate as the timbering or other supports are removed.

041. 300 Filling around flexible pipes shall be brought up uniformly on each side of

the pipe and the method and degree of compaction shall be carried out as a controlled process using suitable compacting equipment in a manner not to cause irregular or excessive distortion of the pipe.

041. 310 Trenches under structures and roadways including up to 1m outside the

roadway edge shall be filled with imported fill material class 'A' (Clause 041.060) in layers fully compacted to the underside of the road-base or structure.

041. 320 Filling around structures shall be carried out in such a manner as to avoid

uneven loading of the structure and only at such time as any Works have achieved adequate strength to accept the loading.

041. 330 The upper surface of intermediate layers of fill material shall be laid to falls

to allow drainage of surface water and prevent ponding.

Method of Compaction of Suitable Filling Materials 041. 340 All materials placed as filling or embankments shall be compacted as soon

as possible after deposition. 041. 350 The permitted depth of each layer of fill is dependent upon the type of fill to

be consolidated and the compaction plant which will be used for its compaction.

041. 360 The Contractor's proposals for compaction shall be submitted to the

Purchaser for agreement. The submission shall include full details of the type of plant and method of operation to be used. Regardless of the method of compaction he proposes to use, the Contractor shall compact the filling to the specified density or as agreed by the Purchaser. Tests shall be carried out in accordance with this Specification to measure the actual density achieved.

Wherever low test results are obtained the Contractor shall improve the degree of compaction to the specified level and carry out additional tests.

041. 370 Where materials of widely divergent characteristics are used they shall be



deposited in separate clearly defined areas as agreed by the Purchaser so that compaction as appropriate may be carried out in each area.

041. 380 The depth of a compacted layer is the height by which an area is raised by

each successive compacted deposition 041. 390 The number of passes is the number of times that each point on the surface

of the layer being compacted has been traversed by the item of compaction plant.

041. 400 Where different types of compaction plant are used in combination, the

depth of layer shall be that applicable to the plant requiring the greatest number of passes.

041. 410 Where the Contractor uses a lighter plant to provide some preliminary

compaction, this shall be disregarded in arriving at the compaction requirements.

041. 420 The effective width of pneumatic tyre rollers shall be taken as the sum of

the widths of the individual wheel tracks plus the sum of the spaces between the wheel tracks providing each space does not exceed 225mm. Where the spaces exceed 225mm the effective width shall be the sum of the widths of the individual wheel tracks.

041. 430 The load per metre width shall be the total weight on the roll divided by the

total roll width. Where a smooth-wheel roller has more than one axle, the machine will be assessed on the basis of the axle giving the highest value of load per unit width. For pneumatic-tyre rollers the wheel load shall be the total weight of the roller divided by the number of wheels.

041. 440 Vibratory rollers shall have means of applying mechanical vibration to one

or more roller. Their requirements are based on the use of the lowest gear on a self-propelled machine or a towing speed 1.6 to 2.4 km/h for a towed plant. Where higher gears or speeds are used an agreed increased number of passes shall be made in proportion to the increase in speed. They shall be operated with their vibration mechanism operating only at the frequency recommended by the manufacturers, and all rollers shall be equipped with a device automatically indicating this frequency and the speed of travel. Vibratory rollers which are operated without their vibration mechanisms working shall be classified as smooth-wheeled rollers.

041. 450 Vibrating-plate compactors shall have a baseplate to which is attached a source of vibration consisting of one or two eccentrically weighted shafts, and shall be operated at the frequency of vibration recommended by the



manufacturer. Where they are operated at travelling speeds greater than 15m per minute the number of passes required shall be increased in proportion to the increase in speed of travel.

041. 460 Vibro-tampers shall have an engine-driven reciprocating mechanism acting

on a spring system to set up oscillations in a baseplate. 041. 470 Power rammers shall be actuated by explosions in an internal combustion

cylinder, each explosion being controlled manually by the operator. One strike of the compacting shoe shall count as one pass on the area concerned.

Compaction of Hardcore

041. 480 Each layer of hardcore shall be compacted and the degree of compaction

obtained on layers not exceeding 300mm thick shall be not less than that which would be obtained by six passes with a vibration-plate compactor with a static pressure under the baseplate of not less than 17 kN/m2.

Planning and Compaction of Material in Reclaimed Areas

041. 481 Clauses 041. 482 to 041. 490 relate to material placed below MHWN in

reclaimed areas. Fill material above MHWN shall be placed and compacted in accordance with Clause 041. 240 to 041. 480 hereof.

041. 482 All filling in reclamation areas shall be carried out in accordance with

principles contained in BS 6349 Part 5 1991, except as amended herein 041. 483 The Contractor's method of transporting, placing and forming the fill shall

ensure that environmental impacts are minimised. In particular he shall ensure that fill is stable at all times under the action of currents, wind and waves and that the loss of material into suspension is minimised either by ensuring that exposed material is of sufficient size and grading to remain in position or that the material is protected from wave and current action by such measures as containment bunds or temporary armouring.



041. 484 The Contractor shall also ensure that the drainage of water from

reclamation placed above sea water level shall be such as to minimize suspended sediment in the vicinity and shall continually monitor concentration levels of suspended materials to demonstrate that no increase in concentration levels results from his operations and he shall submit his proposals to the Purchaser for agreement.

041. 485 Prior to the commencement of filling operations the Contractor shall provide

details of the post construction settlement characteristics of the completed reclamation based on his proposed construction methods and sequencing, fill gradings and seabed conditions. The details shall include full justification of the suitability of the completed fill for the construction of the road above.

041. 486 The Contractor's methods and sequence for placing fill within the

reclamation area and for treating the fill during and following placement shall be subject to the Purchaser’s agreement.

041. 487 The formation of silt-ponds in the reclamation areas will not be permitted

and any significant soft areas which, in the opinion of the Purchaser, would cause differential settlement of the fill, shall be removed at the Contractor's expense and disposed off site.

041. 488 The layout and details of containment bunds for the purpose of retaining

material shall be agreed with the Purchaser. 041. 489 Any material placed outside agreed site limits shall be removed by the

Contactor prior to completion or sectional completion as appropriate. 041. 490 All finished surfaces shall be trimmed and graded to the levels agreed with

the Purchaser and rolled by an agreed weight and type of roller. All settlement below the agreed levels shall be made good and re-rolled and repeated as necessary.



QUALITY CONTROL

Sampling of Fill Materials

041. 495 The Contractor shall provide all necessary plant and labour for obtaining,

handling and testing samples.

Samples of Imported Filling Material and Hardcore 041. 500 Sample loads of imported filling material and hardcore shall be supplied for

agreement by the Purchaser. Filling material or hardcore shall not be delivered to the Site for use in the Works before the Purchaser has agreed the sample and the source from which it was obtained. The quality of all materials in the Works shall conform with that of the agreed samples which shall be retained on Site.

Soil Testing Laboratory

041. 510 For permanent earthworks the Contractor shall nominate, subject to the

Purchaser’s agreement, a suitable laboratory where soil tests may be carried out independently to confirm that the workmanship is in accordance with the Specification. Tests shall include Tests 1, 2, 3, 4, 7, 8, 9, 11, 12, 13 and 15 as specified in BS 1377. The Contractor shall make all arrangements with the laboratory at his own expense.

Laboratory Tests on Fill Materials

041. 520 Before using fill materials in permanent earthworks the Contractor shall, if

required by the Purchaser, carry out compaction tests using BS 1377, Test 13 to determine the dry density/moisture content relationship for each classification of fill material he proposes to use and submit the results of these tests to the Purchaser for information.

Field Tests on Fill Materials

041. 530 At the commencement of the permanent earthworks the Contractor shall, if

required by the Purchaser, construct a trial area of filling or embankment for each classification of fill material proposed. Field density tests shall be carried out in accordance with BS 1377 Test 15 to determine the density of placed fill and the acceptability of compaction methods. Results of these tests shall be submitted to the Purchaser for agreement.

041. 540 During the progress of the Works the Contractor shall carry out field density



tests in accordance with BS 1377 Test 15, and the results of these tests will be used as a check on the Contractor's operations. The frequency of these tests shall be:

For all areas of fill there shall be a 1 test per 1000 m2 with a minimum of three tests per layer. If a material of uniform consistency is used and a reliability of testing achieved then subject to the approval of the purchaser NDM testing may be used.

041. 550 If a test shows the compaction achieved to be inadequate compared with the trial area, a further test shall be carried out in the fill. Should this test show the compaction achieved to be inadequate compared with the trial area then the Contractor shall carry out such further measures as are necessary to obtain the required compaction.

041. 560 Results of all tests shall be submitted to the Purchaser within 24 hours of

each test. A monthly summary report of all tests shall also be submitted to the Purchaser.

Tolerance Limits

041. 570 The tolerance limits for the permanent finished earthworks shall be as

follows:

° Horizontal dimensions shall be within + 150mm.

° For slopes to embankments or cuttings the horizontal deviation between the top and the bottom of the slope shall be within + 5 percent of the horizontal component of the slope.

° Formation levels shall be within zero and -25mm.

° Other earthworks levels shall be within zero and -100mm.

Settlement and Heave Allowance

041. 580 In the setting out and construction of excavations and filled areas the

Contractor shall allow for settlement and heave whether caused by consolidation of fill, settlement of foundations, heave in excavations or change in volume of materials after excavation.

CONTAMINATED SOILS



041. 590 The Contractor shall satisfy the Purchaser as to the likelihood of excavation, backfilling or transport operations causing hazards to health or pollution either immediately or over an extended period of time. Operations involving contaminated soil shall be subject to prior agreement from the Purchaser.

TOPSOILING, TURFING AND GRASS SEEDING

041. 700 In areas where existing roads or other hard surfaces are to be broken out

and topsoiled, all material down to formation level (except as noted below) shall be excavated and removed.

Excavation for topsoiled areas shall not take place where this would reduce support to the kerb. This requirement will be satisfied if none of the concrete race or haunch is removed and no excavation takes place within a line at 45° to the horizontal extending down and outwards from the point on which the kerb meets the surfacing.

041. 710 No work shall be carried out when rain is falling, when there has been rain within the previous 24 hours or when, in the opinion of the Purchaser, the sub-soil is likely to be damaged.

041. 720 Topsoil shall not be stored in temporary stockpiles unless agreed by the

Purchaser.

If temporary stockpiles are agreed by the Purchaser, topsoil shall not be excavated from stockpiles:

i) which have been exposed to a cumulative rainfall exceeding

100mm over the preceding 28 days measured at a point agreed by the Purchaser; or

ii) when heavy rain is falling; or iii) with a tracked vehicle.

041. 730 The areas to be grassed shall be topsoiled, fertilised and seeded or

topsoiled, fertilised and turfed. Fertiliser and seed may be applied by hydraulic mulch.

041. 740 Topsoil mounds to be grassed shall be constructed at no steeper than 25°

to the horizontal.

Topsoil shall:



i) be deposited and spread to a minimum thickness of 100mm for seeding and 75mm for turfing. It shall not be spread using a tracked vehicle;

ii) have stones and other debris removed and disposed off Site which

have:

a) dimensions greater than 100mm equivalent diameter, unless otherwise agreed by the Purchaser; and

b) dimensions greater than 50mm equivalent diameter which lie within 50mm of the surface;

iii) not have stones or other debris protruding above the surface by more than 30mm; and

iv) immediately prior to sowing of seed, including that applied by hydraulic mulch, and before laying of turf, have:

a) its upper 50mm thickness reduced to a fine tilth by use of a

chain harrow or other plant producing a similar fine tilth; and b) fertiliser shall be evenly distributed and raked in, at a rate not

less than 75g/m2. If hydraulic mulch seeding is used such fertiliser may be incorporated in the mulch and no raking in is necessary.

041. 750 Seeding shall:

(i) include that incorporated in a hydraulic mulch shall be a tested mixture and certificates of germination and purity shall be provided before sowing, together with the names of the varieties used in the mixture. This shall contain the seeds listed Table 6/5 of Volume 1 of "Specification for Highway Works".

(ii) be carried out by evenly distributing such seed at a rate of not less

than 35 g/m2 unless agreed by the Purchaser; and

iii) be immediately followed by lightly raking, by use of a chain harrow or other plant agreed by the Purchaser, the surface of the topsoil to cover the seeds, except that no raking is required following hydraulic mulch seeding.

iv) Hydraulic mulch seeding shall be applied by a process and consist

of a mulch agreed by the Purchaser. 041. 760 Turf shall:



i) be laid well bonded and lightly tamped and, when on slopes, be laid diagonally;

ii) be regularly watered as necessary during prolonged dry weather. 041. 770 Areas that have been grassed by seeding or turfing shall be mown twice to

leave a nominal 75mm height. The first mowing shall be carried out once the grass has reached a height of between 100mm and 150mm, the second when it has re-grown to between 150mm and 200mm. All areas shall, unless agreed otherwise by the Purchaser, be left clear of grass cuttings following each mowing, by raking or other method agreed by the Purchaser and arisings disposed off Site.

041. 780 At the times (which may include times within the period of maintenance)

and within the areas agreed by the Purchaser, a selective herbicide, agreed by the Purchaser, especially formulated for the eradication of docks, thistles, ragwort and other pernicious agricultural weeds, shall be applied by spot treatment spray to such plants individually; the use of a spray boom will not be permitted.



APPENDIX 1 BSI STANDARDS AND OTHER REFERENCES ° The British Standards and other documents referred to in Section 041 are listed

below and shall be the current edition, including all amendments. ° The Contractor shall bring to the attention of the Purchaser any inconsistencies

between the requirements of these Standards and this Specification Section.

BS 1377 Methods of test for soils for civil engineering purposes.

BS 6031 Code of practice for earthworks.

Department of Transport: `Specification for Highway Works': Part 2 (HMSO) (including all BSI Standards referenced therein).



APPENDIX 2 - INFORMATION TO BE PROVIDED BY CONTRACTOR

CLAUSE REFERENCE


COMMENT

041.100 041.170 041.220 041.230 041.250 041.360 041.484 041.486 041.488 041.500 041.510 041.520 041.530 041.560 041.560 041.590

Method statements for temporary supports. Proposals for dewatering. Covering formation. Method statement for blasting. Start of compaction. Contractor's proposal for compaction. Proposals for monitoring suspended solids. Methods and sequence for placing fill in reclamation areas. Details of containment bunds. Sample details of fill materials. Soil Testing Laboratory Results of compaction tests. Results of field density tests. Results of field tests. Monthly summary of all density tests. Details of operations involving health or pollution hazards.



TECHNICAL SPECIFICATION WORK GROUP: 050 : DRAINAGE SECTION NO: 051 TITLE: BURIED FOUL AND SURFACE WATER DRAINAGE TABLE OF CONTENTS SCOPE MATERIALS

Pipes and Gullies Pipe Joints and Fittings Pipes Protection Pipe Bedding and Fill Material Chambers and Manholes Open Channel Drains

WORKMANSHIP

General Excavation Pipe Laying Cutting Deflection Pipe Jointing Backfilling Reinstatement of Surfaces Pipe Sundries Chambers and Manholes Laying Open Channel Drains



TABLE OF CONTENTS

Cleaning and Survey of Existing Drains QUALITY CONTROL

Testing - General Water test Air test Infiltration Test Testing - Manholes Testing - Line and Level Tolerances

APPENDIX 1 BSI STANDARDS AND OTHER REFERENCES APPENDIX 2 INFORMATION TO BE PROVIDED BY CONTRACTOR



SCOPE

051. 010 This Section defines the materials and workmanship required for the

installation of buried gravity foul and surface water drainage.

MATERIALS

Pipes and Gullies 051. 020 UPVC drainage pipes and fittings shall conform with the requirements of BS

4660 and BS 5481 as appropriate to the size of pipe. 051. 030 Clay pipes and fittings shall be vitrified and shall be to BS 65. They shall be

flexibly jointed using an external sleeve or spigot and socket joints. 051. 040 Precast Concrete pipes, fittings and road gullies shall be to BS 5911. They

may be reinforced or unreinforced and shall have flexible joints. Gulley gratings shall be to BS 497.

051. 050 Ductile Iron pipes, fittings and joints shall be to BS 4772 and shall have

flexible spigot and socket joints. 051.055 In the Tipping Hall and Boiler Plant Area, floor gullies shall be fitted with

removable covers and stainless steel lift-out baskets.

Pipe joints and fittings 051. 060 All jointing materials shall be unaffected by the material being carried.

Elastomeric joint rings shall be to BS 2494 and shall be obtained from the pipe manufacturer.

051. 070 Gaskets for flanged joints shall be to BS 2494 and be of the inside-bolt-

circle type to BS 4865. 051. 080 Black hexagon bolts and nuts shall be to BS 4190. 051. 090 Metal washers shall be to BS 4320. 051. 100 Pipe Couplings and flange adapters of the Viking Johnson type may be

agreed by the Purchaser for use in special circumstances. 051. 110 Compressible board for movement joints in concrete bedding and surround

shall be expanded polystyrene to BS 3837 or bitumen impregnated fibre



board to BS 1142.

Pipe Protection 051. 120 Polythene tubular sleeving shall be used to protect ductile iron pipelines

and joints and shall be to BS 6076. 051. 130 All exposed ferrous metal including pipes, valves and brackets in chambers

shall be given two coats of an agreed bitumen solution to BS 3416. 051. 140 All buried Viking Johnson couplings and adapters shall be protected with an

agreed self-adhesive bandage prior to being covered with polythene sleeving.

Pipe Bedding and Fill Material

051. 150 Concrete for use as pipe bedding, surround, cradle or arch shall be Class

C20. 051. 160 Granular bedding Type 'A' for pipes, and backfilling material for temporary

drains (trench sub-drains), shall consist of aggregates from natural sources or sintered pulverized-fuel ash complying with the relevant provisions of BS 882 and BS 3797, respectively, sized in accordance with the following table:

Alternative Aggregate sizes (mm)

Nominal bore

of pipe (mm)

Single-sized

Graded

100 150

225-300 375-525

exceeding

10

10 or 14 10, 14, or 20

14 to 20 14, 20 or 40

-

14 to 5 14 to 5 or 20 to 5 14 to 5 or 20 to 5 15 to 5, 20 to 5

or 40 to 5



051.170 Selected fill Type 'B', whether selected from locally excavated material or

imported, shall consist of uniform, readily compactible material, free from vegetable matter, building rubbish and frozen material, or materials susceptible to spontaneous combustion, and excluding clay of liquid limit greater than 80 and/or plastic limit greater than 55 and materials of excessively high moisture content. Clay lumps and stones shall be retained on 75mm and 37.5mm sieves respectively.

051.180 Pipe bedding and fill materials to concrete pipes shall not contain more than

0.3 per cent sulphate, expressed as sulphur trioxide.

Chambers and Manholes 051. 190 Brick chamber construction shall be in Class B Engineering brick to BS

3921 in English bond 215mm thick with 1:3 cement mortar on a base of concrete Class C20.

051. 200 Precast concrete units for manhole and other chamber construction shall be

to BS 5911. 051. 210 Cast iron manhole covers and frames shall be to BS 497 and be bedded

and haunched with class M1 mortar. 051. 220 Step irons shall be to BS 1247.

Open Channel Drains 051. 240 Open channel drains shall be ACO Drains S300 or S200 Super Heavy-Duty

channel as supplied by ACO Polymer Products Ltd, or similar agreed.

The system shall be of 300mm/200mm nominal width and manufactured to a constant depth. The channel and grating combinations shall be designed to withstand imposed loadings up to Grade A to BS 497.

051. 250 The channels shall be constructed from Syntolit P polyester concrete with a

cast-in-ductile-iron frame and shall be installed with the manufacturer's standard cast ductile-iron grating, the grating shall be locked securely in position by bolting to the channel edge railing using eight high-tensile steel bolts to each metre length of channel.

051. 260 The system shall be designed to provide uninterrupted access to the



channel for cleaning when the gratings are removed. WORKMANSHIP

General

051. 270 All pipes and fittings are to be handled, stored, installed and jointed in

accordance with the relevant manufacturer's requirements. 051. 280 Work shall be carried out in a safe manner in accordance with all applicable

Safety Regulations.

Excavation 051. 290 All excavation shall be carried out in accordance with Section 041,

'Excavation and Filling' of this Specification except where varied by the following requirements.

051. 300 The stability of trenches and other excavations must be adequately ensured

by the Contractor to provide a safe working environment as well as protecting any adjacent services or structures. The Contractor shall submit details of his proposed method of working to the Purchaser for agreement prior to commencement.

051. 310 Trench excavation for pipelines shall be cut with vertical sides not less than

300 mm wider than the outside diameter of the barrel of the pipe and not greater than the maximum trench width necessary to install the pipe. The sides of the trench excavation shall not be battered without the agreement of the Purchaser.

051. 320 Excavations shall be kept free of water from any source and such water

shall be drained or pumped to an agreed discharge position taking steps to prevent any loss of fines which might adversely affect the surrounding ground and any pollution of water courses.

051. 330 Trench and chamber formations shall be inspected and agreed prior to work

proceeding. Any unsuitable hard and soft material removed shall be replaced with compacted selected granular material.

Pipe Laying 051. 340 Natural bedding - The bottoms of trenches shall be accurately formed to



levels and gradients with pockets cut for pipe joints so that full bearing support is provided over the whole length of the pipe barrel.

051. 350 Granular bedding - The trench formation shall be trimmed to permit a

minimum thickness of 100mm of granular material to be laid and compacted to support the barrel of the pipe over the full width of the trench.

051. 360 Pipes laid on natural or granular bedding shall be laid on firm material over

the length of the pipe barrel. Temporary supports shall not be used. 051. 370 When the pipe has been bedded to the correct line and level granular or

selected material shall be placed either side of the pipe and compacted by hand in layers 100 to 150mm thick up to the specified level. Thereafter the material should be placed and compacted in 150 to 200mm layers to a minimum height of 300mm above the crown.

051. 380 Concrete bedding - The trench bottom shall be trimmed to permit the

minimum thickness of concrete required under the barrel of the pipe. The pipe shall be laid and supported to the correct line and level on precast concrete support blocks covered with two layers compressible packing.

051. 390 Concrete shall be placed on to the trench formation and brought up evenly

either side of the pipe to the required level in one operation ensuring that no voids are left and that the pipes are not disturbed by this operation.

051. 400 Where flexibly jointed pipes are bedded or surrounded in concrete the

concrete shall be discontinuous at every pipe joint and shall be jointed using compressible packing 15mm thick shaped to fit around the pipe and to match the concrete cross-section.



Cutting

051. 410 Pipes which are cut on site shall be cut clean and square with minimum

damage to any coating, using equipment recommended by the manufacturer. Where ductile iron pipes larger than 450mm diameter are to be cut to form non-standard lengths the manufacturer's instructions regarding ovality correction shall be carried out.

Deflection

051. 420 Where joints are to be deflected such deflection shall not exceed the

manufacturer's recommendations and a method statement shall be submitted to the Purchaser for agreement prior to work being carried out. Joints to be deflected shall be made square before being displaced. With bolted joints the required deflection shall be set prior to final tightening.

Pipe Jointing 051. 430 All pipes fittings and valves shall be carefully cleaned immediately prior to

jointing, and pipes shall normally be laid uphill with the socket leading. 051. 440 The closure of spigot and socket joints shall be made in accordance with

the manufacturer's recommendations using special equipment as necessary.

051. 450 Flange joints shall not be pulled into alignment or drawn together by the

flanges. The setting of flanges must be parallel and as close together as possible before the bolts are tightened up to the specific order and torque recommended by the manufacturer. Flange gaskets shall not be held in position using lubricant.

051. 460 Bolts and nuts shall be run by hand before assembly and shall be greased

with graphite paste or equivalent before use. 051. 470 After jointing, the open end of each pipe shall be closed to prevent the

ingress of water or foreign material. Care shall be taken to prevent flotation of sealed pipes.

Backfilling



051. 480 Where the particular bedding type specified does not extend to a level

300mm above the top of the pipe, backfilling to that level shall be made using carefully selected material free from large stones etc. and compacted by hand in 100mm layers, carefully working under and around pipes .

Backfilling shall proceed thereafter using suitable material as specified in layers not exceeding 250mm placed thickness, each layer being thoroughly compacted whilst progressively withdrawing trench supports.

051. 490 Mechanical compaction shall not be carried out until there is 600mm of

compacted material above the pipe crown. The use of mechanical compactors shall not be permitted without the agreement of the Purchaser.

051. 500 Where the pipe has been protected with concrete bed or surround,

backfilling shall not be commenced for 24 hrs; neither shall traffic loads be imposed within 72 hours of placing the concrete. Reinstatement of Surfaces

051. 505 Where a trench for a pipeline is cut through an existing paved surface that

will not be reconstructed as part of the works, the surface shall be reinstated in accordance with the HAUC "Specification for Excavations and the Reinstatement of Openings in Highways (1991)".

In permanent reinstatement of bituminous surfacing each layer of the original construction shall be reinstated with material to match the original. Joints in bituminous materials shall be saw cut in straight lines and painted with hot bitumen. Joints in any course shall be steeped back 100mm from the joint in the course below.

In situ concrete shall have sawn edges to the trench in the top 30mm only. Below this level the trench sides shall be rough. Before re-casting the sides shall have all laitance and loose material removed. They shall be painted with cement grout before casting of the new slab. Concrete mix shall be of Grade C40 concrete complying with Section 301 of this Specification with the added requirement that it shall be air-entrained (4½ ± 1½%). Surface finish to match existing.

051. 508 When excavating blocks, setts, cobbles or brick paving ("blocks etc") care

shall be taken to ensure that all blocks etc. excavated are set aside for re-use. Reinstatement shall be the same as the existing construction where



this is possible, except that where no sub-base or roadbase exists at present a suitable sub-base shall be provided. All blocks etc. that are disturbed or have moved in any way shall be re-set even though this may involve re-laying the blocks etc. for a considerable distance outside the pipetrench. The requirements of Section 061 of this Specification shall apply where appropriate.

Pipe Sundries

051. 510 Where connections to existing services are to be made the written

agreement of the Purchaser shall be obtained for any works involving live chambers or pipes.

051. 520 The position and invert levels of existing chambers and pipes to which

connections are to be made shall be verified by the Contractor before pipe laying commences and any discrepancies notified to the Purchaser immediately.

051. 530 Where loose polyethylene sleeving is applied to ductile iron pipes it shall be

held in position using PVC tape applied in accordance with the manufacturer's recommendations and with appropriate overlap at the joints made after any other joint protection has been applied.

051. 540 At each point where a pipeline is temporarily terminated a fixed marker shall

be attached to the pipeline and held above ground level. 051. 550 During cold weather adequate protection shall be given to prevent freezing

of any charged pipeline prior to backfilling.

Chambers and Manholes 051. 560 All brick and precast concrete chambers shall be constructed to be

substantially watertight with no identifiable flow of water visible within the Permanent Works.

051. 570 All manhole covers shall be set on 1:3 cement mortar and where the

manholes are of precast concrete on at least two but not more than four courses of Class B engineering brickwork.

051. 580 Precast concrete manhole units shall be bedded on mortar and flush

pointed internally. 051. 590 Concrete surrounds for the chambers shall be formed using a suitable



shutter with any horizontal construction joints formed at least 150mm from the ring joint.

051. 600 For main pipe diameters up to and including 300mm, the open channel of

the manhole or inspection chamber shall be formed in complete channel sections tapers or junctions of the same material as the pipe.

051. 610 Side branches shall be brought into the main channel by the use of

standard channel bends within the manhole which shall have the largest practicable radii. Connections to the main channel shall be such that the discharge from the branches is in the direction of flow in the main channel.

051. 620 Channels, branches and bends shall be fully bedded in mortar. 051. 630 Where channel fittings are not available in the appropriate sizes, they shall

be properly formed in in-situ concrete and finished with granolithic or mortar rendering to a minimum thickness of 20mm in two coats.

051. 640 The soffits of the main pipes entering and leaving a manhole or chamber

shall be set to equal levels. 051. 650 The inverts of branch drains entering a manhole shall be set above the

horizontal diameter of the main channel. 051. 655 Rectangular manhole covers shall be set with two sides parallel to the

kerbline or nearby road markings. 051. 660 Connections to main pipes not made at manholes or inspection chambers

shall generally be made using pre-formed junctions ("branches"). Pre-formed saddles may be used to joint into existing pipes or in special circumstances with the Purchaser's agreement. Saddle connections shall be made in accordance with the manufacturer's instructions using an epoxy mortar adhesive and carefully making good the inside of the pipe prior to any connection being made. In either case the junction shall be surrounded with concrete up to the next pipe joint.

051. 670 Where a connection either direct or as a back-drop enters an existing

manhole, the benching shall be cut away, built up and made good to form a channel equal in depth to the diameter of the incoming connection, and shaped to direct the discharge in the direction of flow.

Laying Open Channel Drains



051. 760 The channels shall be installed in continuous trenches bedded on a C20

concrete foundation 150mm deep with C40 concrete haunching brought up both sides.

The system shall be installed in accordance with the manufacturers instructions.

Cleaning and Survey of Existing Drains

051. 761 On entry to the Site the Contractor shall clean all existing drains and sewers

within and in the immediate vicinity of the Site.

Pipelines shall be cleaned by high pressure jet or rodding and flushing or by other means agreed by the Purchaser. Cleaning shall be continued until flushing water is clean, there is no resistance to drainage rods other than that which could be expected from pipe joints and (in situations where there are straight runs between manholes) no debris is visible in the invert when a light is shone from one manhole to the next. All gullies and manholes shall be cleaned by suction until visibly clean.

051. 762 After cleaning the drains the Contractor shall carry out a complete survey of

the location, level, size and condition of the existing drainage runs and report the results to the Purchaser. The survey shall define the position of all visible features by co-ordinates related to the local grid and define the size, direction and invert level of all pipes entering or leaving. Where there is any doubt as to which pipe connects to which the Contractor shall prove the network by die testing. The Contractor shall plot the results at a scale of 1:500 on a film copy of the survey drawings, which he will provide for the purpose. The survey drawing shall be accompanied by a written report on the condition of the drains suitably cross-referenced to the drawing. A record of manhole sizes is also required.

051. 763 If the cleaning and survey or the shape of the external pavings imply the

likelihood of the existence of manholes or gulleys that are not visible from the surface, the Contractor shall locate them by trial excavation (combined if appropriate with the use of metal detectors) and clean and survey them as specified above.

051. 764 If the Purchaser considers that existing drains may be in an unacceptable

condition the Contractor will carry out a CCTV survey of specific lengths of



pipeline. In this event the survey shall take place in the presence of the Purchaser’s Appointed Representative. A complete log shall be made of the condition and shape of the pipe and any signs of leakage, infiltration or displacement and it shall all be fully referenced by chainage to manholes. The survey shall be in colour and copies of a VHS video tape shall be made with the reference and chainage visible when the tape is played.

One copy of the videotape shall be delivered to the Purchaser and one to his Appointed Representative within one week of the survey.

QUALITY CONTROL

Testing - General

051. 765 Clauses 051.770 to 051.880 apply to surface water sewers. In the event of

salt water infiltration, in the case of foul sewers the permitted quantities of air or water lost in the testing process shall be half those quoted.

The test methods shall remain the same.

051. 770 All pipelines shall be initially tested, utilizing either an air or a water test, after laying and jointing, but before any concreting or backfilling takes place other than that which may be necessary for the structural stability whilst under test. A final water test shall be applied after completion of backfilling.

051. 780 The Contractor shall submit a statement of his proposed methods for

testing including details of the pipe lengths to be tested. 051. 790 Each test shall be witnessed by the Purchaser and results documented. 051. 800 Wherever possible, testing of drains shall be carried out from manhole to

manhole. Short branches up to 3m to the main pipelines shall be tested as one system with the pipeline. Long branches shall be tested separately.

Water Test

051. 810 Clean water shall be used for the water test, and shall be removed after the

completion of the test. 051. 820 The test shall be carried out temporarily plugging the ends of the gravity



pipe under test including any connections, erecting a stand pipe at the head of the pipe and filling the system with water at least one hour before test commencement to allow for absorption.

051. 830 Drains and sewers shall be subject to an internal pressure test of 1.2m

head of water above the crown of the pipe at the high end but not more than 6m at the low end. Steeply graded sewers shall be tested in stages whenever the above maximum head would be exceeded if the whole length was under test.

051. 840 The test shall measure the loss of water over a period of 30 minutes. Water

shall be added from a measuring vessel at intervals of 5 minutes, noting the quantity required to maintain the original level. The quantity of water added for pipes up to 750mm diameter shall not exceed 1 litre per hour per linear metre, per metre of nominal internal diameter. For larger diameter pipes the Contractor shall submit a statement agreed by the pipe manufacturer stating the method of testing, the test head and the permissible loss of water for the agreement of the Purchaser.

051. 850 Notwithstanding satisfactory testing any discernable leakage from a pipe or joint shall be made good and the test repeated. Air Test

051. 860 The length of pipe under test shall be effectively plugged and air pumped in

until a pressure of 100mm of water is indicated in a glass U-tube connected to the system. The pressure shall not fall to less than 75mm during a period of five minutes without further pumping after allowing a suitable time for stabilisation of temperature. Failure to pass an air test shall not preclude acceptance subsequently by a water test.

Infiltration Test 051. 870 When agreed by the Purchaser and where the crown of the high part of the

length under test is more than 1.2m below the water table, an infiltration test shall be employed. All inlets shall be effectively closed. Visual inspection of manholes or inspection chambers will then reveal any excessive flow. The acceptable rate of infiltration shall not exceed 0.5 litre per linear metre per metre of nominal bore in 30 minutes.

Testing - Manholes



051. 880 After sealing all pipe openings all manholes shall be filled with water up to

underside of the cover or to a maximum of 9m total head in the system, whichever is the lesser, and left for a minimum period of 24 hours. At the end of this period the manhole shall maintain the test water level for a minimum period of 1/2 hour without the water level falling more than 10mm per metre depth. Before sealing the outgoing pipe the Contractor shall ensure that the seal may be easily removed upon completion of the test.

Testing - Line and Level

051. 890 Test for line, level and freedom from obstruction shall be applied to all

pipelines prior to the placing of the backfill and again when backfilling and the reinstatement of the surfaces has been completed. The tests shall be carried out by means of a mirror at one end of the line and a lamp at the other demonstrating a 90 percent "full moon". When this test cannot be applied a mandrel of the size and type agreed by the Purchaser with a maximum diameter 10mm smaller than the pipe diameter shall be drawn through the pipeline to prove the pipework. Tolerances

051. 900 The position of the internal face of any pipeline shaft or tunnel shall not

deviate from that detailed in the contract by more than:-

Pipeline Line and level ± 10mm. Provided that no pipe shall have a reverse gradient.



APPENDIX 1 BSI STANDARDS AND OTHER REFERENCES

° The British Standards and other documents referred to in Section 051 are listed



BS 65 Specification for vitrified clay pipes, fittings joints and ducts. BS 497 Specification for manhole covers, road gully gratings and

frames for drainage purposes. Part 1: Cast iron and cast steel.

(Withdrawn) Replaced by BS EN 124: 1994. BS 882 Specification for aggregates from natural sources for

concrete. BS 1142 Specification for fibre building boards. BS 1247 Specification for manhole step irons. BS 2494 Specification for elastomeric joint rings for pipework and pipelines. BS 3416 Specifications for bitumen based coating for cold application suitable for

use in contact with potable water. BS 3797 Specifications for lightweight aggregates for concrete. BS 3837 Expanded polystyrene boards. BS 3921 Specification for clay bricks. BS 4190 Specification for ISO metric black hexagon bolts, screws and nuts. BS 4320 Specification for metal washers for general engineering purposes. BS 4346 Joints and fittings for use with unplasticized PVC pressure pipes. BS 4660 Specification for unplasticized PVC underground drain pipes and

fittings. BS 4772 Specification for ductile iron pipes and fittings. BS 5480 Specification for glass fibre reinforced plastics (GRP) pipes and fittings

for use for water supply or sewerage. BS 5481 Specification for unplasticized PVC pipe and fittings for gravity sewers. BS 5834 Surface boxes grounds and underground chambers for gas and

waterwork purposes. BS 5911 Precast concrete pipes and fittings for drainage and sewerage. BS 6076 Specification for tubular polyethylene film for use as protective sleeving

for buried iron pipes and fittings. BS 6209 Specification for solvent cement for non pressure thermoplastics pipe

systems.

Highway Authorities and Utilities Committee - Specification for the Reinstatement of Openings in Highways (HMSO)




CLAUSE REFERENCE


COMMENT

051.300 051.320 051.330 051.420 051.490 051.510 051.780 051.790 051.890

Temporary excavation details. Proposals for discharge of water. Notification for formation inspection. Method statement - deflection of joints. Agreement of mechanical compactors. Agreement for connections to live services. Proposed method of testing. Notification of tests. Agreement of mandrel.


TECHNICAL SPECIFICATION WORK GROUP: 060 : EXTERNAL WORKS SECTION NO: 061 TITLE: ROADS, HARDSTANDINGS, CAR PARKS, PATHS, KERBS ETC. TABLE OF CONTENTS SCOPE MATERIALS

General Car Parking, Footways, Kerbs etc. Traffic Signs Road Markings Safety Fences

WORKMANSHIP

General Earthworks and Filling Drainage and Buried Services Roads Tolerances for Roads Hardstandings Car Parking Areas Block Paving Tolerances for Block Paving Footways Kerbs, Channels, Edgings and Quadrants Traffic Signs Road Markings Temporary Road Markings



Safety Fences Repair of Damaged Pavings Regrading of Surfaces Reinstatement of Surfaces

QUALITY CONTROL

General Inspection and Testing

APPENDIX 1 BSI STANDARDS AND OTHER REFERENCES APPENDIX 2 INFORMATION TO BE PROVIDED BY CONTRACTOR APPENDIX D PUBLICATIONS REFERRED TO IN THE

SPECIFICATION FOR HIGHWAY WORKS



SCOPE 061. 010 This Section defines the materials, workmanship and quality control

required for the construction of roads, hardstandings, car parks and paths, road signs, road markings and associated works.

MATERIALS

General

061. 030 The primary construction materials for use in the construction of road

pavements (i.e. unbound materials, bituminous bound materials, concrete and cement bound materials), hardstandings, car parks, footways, and associated kerbs etc shall comply with the DTp 'Specification for Highway Works' 6th edition as amplified by Appendices D, 7/1 and 7/4 herein and except where otherwise specified herein.

061. 031 All roads and pavings for vehicular traffic shall be constructed in rigid

pavement construction. Footways shall also be constructed in rigid pavement construction, unless agreed otherwise with the Purchaser.

061. 035 Traffic signs shall comply with the DTp Specification for Highway Works

except where modified by this Specification, which contains the information the DTp Specification indicates as being in Appendix 12/1.

061. 040 Materials selected for use within 450mm of the designed final road surface

shall not be frost susceptible. 061. 050 Natural sands and gravels are not acceptable materials for Type 1 Sub-

base.

Car Parking, Footways, Kerbs etc. 061. 055 Rigid pavement construction to be adopted for car parking and footways,

unless agreed otherwise with the Purchaser. 061. 060 Concrete paver blocks shall be 200mm x 100mm x 80mm to BS 6717: Part

1, coloured or Brindled blocks from Marshalls "Keyblock" range or similar agreed. Colours and patterns will be agreed by the Purchaser.

061. 070 Clay and calcium silicate paver blocks shall be to BS 6677: Part 1.



061. 080 Bedding sand for block paving and sand for filling joints shall be washed clean sharp sand graded in accordance with Table 2 of BS 6717 Part 3.

061. 090 Precast concrete flags shall be to BS 7263 : Part 1. 061. 100 Precast kerbs, edgings and channels shall be to BS 7263 : Part 1.

Traffic Signs 061. 125 The Contractor shall provide details of the legend layout of directional

information signs and non-prescribed traffic signs.

Traffic signs shall be as shown in the Traffic Signs Regulations and General Directions, 1981 (as amended), or such variants as may be agreed by the Purchaser.

Sign fabrication drawings shall be submitted for agreement by the Purchaser.

All traffic signs, other than internally illuminated bollards, shall be reflectorised, using materials having a photometric performance complying with the requirements set out in Table 1 of Annex C of DTp Technical Advice Note TA/19/9.

061. 121 The type and size of posts required for each traffic sign shall be determined

by the Contractor and submitted to the Purchaser for agreement.

Alternatives to steel posts may be used. These shall be designed by the Contractor and the design submitted to the Purchaser for his agreement.

Tubular steel posts shall have the following Sections.

(i) 76mm (3") outside diameter x 10 swg (ii) 86mm (3½") outside diameter x 8 swg (iii) 114mm (4½") outside diameter x 8 swg (iv) 140mm (5½") outside diameter x 5 swg

Each post shall have a base plate having a minimum area of 0.052 square metres (81 sq. inches) and also where no lighting unit is fixed to the top of the post, a waterproof cap shall be provided. Both base plate and post cap shall be in accordance with BS 873.



061. 122 The manufacturer's name or trade mark will not be permitted on the face of

traffic signs. It may be affixed to the back provided prior agreement to the size and colour of the mark is obtained from the Purchaser in writing.

061. 123 Where illuminated signs are erected on tubular posts the electrical

equipment shall be enclosed in a large integral base housing of inside diameter not less than 130mm. Entrance to the interior of such compartments shall be by means of a weatherproof door having tamper-resistant key fastenings. The door opening shall be not less than 100mm x 400mm and shall be positioned so that, when the post is installed as intended, it is not less than 300mm above ground level.

061. 124 Where switch boxes are used as root boxes, they shall be bolted to the

posts so that their base is just within the ground. Otherwise the boxes shall be fixed to the posts in such a position that they are not unsightly when viewed from the front of the sign.

Switch boxes shall be of steel not less than 5mm thick. An internal baseboard of dimensions not less than 80mm x 380mm x 12mm manufactured from a substantially non-hydroscopic and rot-resistant material shall be fixed in the box and an earthling screw or bolt shall be provided. The opening to the box shall afford easy access to the equipment. A weatherproof door shall be provided for the opening and this shall be fitted with a tamperproof lock. The distance from the face of the switchboard to the inside front shall be at least 100mm and a suitable cable entry shall be provided just below ground level.

All compartments for electrical equipment shall be provided with vandal and weather resistant locks. The number of different types and patterns of lock shall be kept to a minimum. The Purchaser shall be provided with six keys for each type of lock.

061. 125 Bollards shall be Baselite Bollard MK2 manufactured by Haldo

Developments Limited or equivalent agreed.

Bollards shall be complete with all wiring, fluorescent lighting units, lamps, starters, capacitors, ballasts, fuses, photo-electric switches and with sockets or clips as necessary.

The power supply to each bollard shall be 240 volts, 50 Hz, single phase.



Light sources shall be hot cathode tubular fluorescent lamps with a colour defined as 'standard colour 2' in BS 1853 Part 061. 126 Lantern(s) is (are) to be overhead mounted for those signs which are required to be externally illuminated.

Sign lanterns shall comply with requirements of BS 873 and Chapters 11 and 13 of the Traffic Signs Manual.

Lanterns shall be completed with all wiring, fluorescent lighting units, lamps, starters, capacitors, ballasts, fuses, photo-electric switches and with sockets or clips as necessary.

The power supply to each lantern shall be 240 volts, 50 Hz, single phase.

Light sources shall be high pressure mercury fluorescent lamps, type MBF.

Road Markings

061.135 Thermoplastic markings shall comply with BS 3262 Class A. The

Contractor shall submit evidence of a current BSI certificate and kitemark licence for all thermoplastic materials used. Materials that have been modified subsequent to the issue of certification shall not be used.

061. 139 Road marking paint shall be suitable for applying by brush or mechanical

means to concrete or bituminous pavement to give a chemically stable film of uniform thickness and shall be either chlorinated rubber, one pack epoxy or alkyd based.

061. 140 The Contractor shall submit details of paint materials and methods of

application to the Purchaser for agreement. 061.150 The paint shall be supplied fresh and ready for use in sealed containers and

stored in accordance with the manufacturer's instructions. 061. 190 White paint shall contain not less than 6% by mass of titanium dioxide as a

pigment, conforming to Type 'A' (Anatase) or Type 'R' (Rutile) specified in BS 1851.

061. 200 Yellow paint shall be standard colour BS 3816 No 355, except where an

alternative shade is specified and contain not less than 6% by mass of a suitable yellow pigment.

61.205 All road markings shall be reflectorised white unless otherwise detailed.



061. 210 Road studs shall be to BS 873. The Contractor shall submit details of the

studs to the Purchaser for agreement.

Safety Fences 061. 215 Tensioned Safety Fences shall be single sided tensioned corrugated beams

with posts at 3.2m centres, complying in all respects with the Department of Transport's "Specification for Highway Works" (Ref TSI in Table 4/1).

061. 216 Demountable Safety Fences. The post and baseplate assembly shall be of

all welded construction with full strength fillet welds on each joint. Fabrication and galvanising of the post and baseplate assembly shall comply with Section 211 of this Specification. Minimum thickness of galvanizing is 85 microns.

WORKMANSHIP

General

061. 220 Road pavement construction shall be to the Department of Transport's:

'Specification for Highways Works' 7th Edition and Appendices herein with due cognisance taken of any related Sections of this Specification. Any more onerous requirements in this Specification shall take precedence.

061. 230 Any conflicts between the above specification documents shall be referred

to the Purchaser.

Earthworks and Filling 061. 240 All earthworks and filling shall be in accordance with the Section 041 of this

Specification the requirements of which shall take precedence over any related clauses in the DTp 'Specification for Highway works'.

061. 250 Fill under roads and backfilling of trenches shall be completed before any

pavement construction is started. 061. 260 Particular care shall be taken to ensure that appropriate compaction

methods are used to prevent uncompacted spots in the fill, backfill, sub-base or base materials when backfilling immediately against structures.

061. 270 The preparation of the formation shall be carried out only after completion

of the sub-grade drainage and immediately prior to the application of the first layer of the pavement construction.



The surface shall be cleaned and trimmed to shape and compacted.

Drainage and Buried Services

061. 280 All drainage and "services" work beneath the proposed pavement

construction shall be completed before any pavement construction is started. Drainage shall be in accordance with Section 051 - 'Buried Foul and Surface Water Drainage'.

061. 290 All drainage and pressure pipelines under the road pavement shall be

completed and tested before any pavement construction is started. 061. 300 All chambers and road gullies located in permanent roads shall have the

access covers or gratings flush with the finished road surface. 061. 310 Temporary roads which eventually will become part of the permanent road

system shall have covers and gratings set flush with the top of any course used as a temporary running course and re-set flush with the finished wearing cause when this is laid.

Roads

061. 330 All necessary traffic signals and road warning lamps shall be installed and

maintained throughout the duration of the construction. 061. 340 Temporary roads required due to the Contractor's method of working shall

be removed on completion. 061. 350 Contractor's proposals for additional temporary roads shall be submitted to

the Purchaser giving details of the layout, materials and traffic signs. 061. 360 Unless stated to the contrary, any thickness of construction material layers

shall mean the compacted thickness after construction. 061. 370 Works construction traffic other than that involved with the road construction

shall not be permitted on pavements under construction unless permitted by the Purchaser.

061. 380 All road construction plant proposed shall be agreed by the Purchaser

before the start of the works. All plant shall be maintained in good order.

Tolerances for Roads



061. 390 Surface levels and surface regularity of pavement courses for permanent roads shall be to DTp 'Specification for Highway Work' - 702.

061. 400 Horizontal alignments shall be determined by the Contractor to suit the

general layout.

All other parallel alignments shall be correct within a tolerance of ± 13mm except for kerbs, channel blocks and edge lines which shall be laid with a smooth alignment within a tolerance of ± 10mm.

061. 410 Tolerances for temporary roads shall be twice the tolerance for permanent

roads. 061. 420 The Contractor shall carry out surveys at each stage of construction i.e.

sub-formation, formation and pavement courses. Records to be submitted to the Purchaser.

Hardstandings

061. 440 Concrete block paving hardstandings shall be constructed as for Block

Paving. 061. 450 Rigid hardstandings shall be constructed as for concrete pavement

construction as specified in this Generic Section. 061. 460 The surface of hardstandings shall be laid with falls to the drainage system.

No material shall enter the drainage system. 061. 470 Precautions shall be taken at the junction of hardstandings and road

pavements to ensure that any subsurface drainage for the hardstanding does not detrimentally affect the road foundation.

061. 480 Concrete hardstandings shall be treated after the curing period with an

agreed proprietary surface hardener and dustproofer.



Car Parking Areas

061. 490 Car parking areas shall be of rigid pavement construction, unless agreed

otherwise with the Purchaser.

Block Paving 061. 500 Concrete block paving shall be laid in accordance with BS 6717 : Part 3. 061. 510 Clay block and calcium silicate paving shall be laid to BS 6677: Part 3. 061. 520 Sample areas of interlocking blockpaving of approximately 1000mm x

1000mm shall be constructed for the Purchaser's agreement prior to the commencement of any permanent work construction.

061. 530 The sand bedding course to blockpaving shall have uniform moisture

content at or around its optimum value and shall be spread loose in a uniform layer, the precise depth being determined on site prior to spreading such as to produce a compacted layer of a minimum thickness 50mm after the blocks are laid.

061. 540 Sand shall not be laid more than 3000mm in advance of the block laying

unless otherwise agreed by the Purchaser and shall not be trafficked or disturbed before blocks are laid. It shall be protected against inclement weather during laying.

061. 550 The bedding sand under unrestrained edges of blocks disturbed by

inclement weather shall be raked out across the full width of the paving and for a depth of at least three rows of laid blocks.

061. 555 Blocks shall be laid with chamfered face upwards. 061. 560 The blocks shall be laid working away from kerb or substantial edge

restraints which shall be bedded in concrete and haunched. Rectangular blocks shall be laid in a regular diagonal herringbone pattern. Mitre blocks shall be used at boundaries to minimise cutting. No cut block shall be less than half size.



061. 580 The blocks shall then be compacted using a vibrating plate compactor to

BS 6677: Part 3 Clause 7.5.2 or as recommended by the block manufacturer. At least two passes of the compactor shall be made to prevent further movement of the blocks and to provide an even riding surface. The actual number of passes shall be determined by trial. Gap filling sand shall be brushed into the joints after two passes and a further pass shall then be made, this process being repeated as necessary.

061. 590 The vibrating plate shall be kept at least one metre away from any

unrestrained edges. 061. 600 The blocks shall be protected as necessary from vibrating plate damage by

methods recommended by the block manufacturer. 061. 610 On completion of the compaction brush away surplus sand.

Tolerances for Block Paving 061. 620 The finished levels shall be within the following tolerances:

(a) any point on surface ± 6mm

(b) maximum deviation under 3000mm straight edge to be not more than 5mm with allowance for any vertical curves

(c) levels between adjacent blocks not to exceed 2mm

(d) levels between block and adjoining gullies or drain entries

not to exceed + 6mm and - 0mm

Footways 061. 630 Footways shall be of rigid pavement construction, unless agreed otherwise

with the Purchaser. 061. 640 In-situ concrete, bitumen macadam, concrete or clay block paving shall be

laid as specified herein. 061. 650 Precast concrete flags shall be laid to the required cross falls with a bond

pattern and with joints at right angles to the kerb.

Kerbs, Channels, Edgings and Quadrants



061. 670 Precast concrete kerbs, channels, edgings and quadrants shall be laid onto a concrete base. The concrete shall have a 'roughened' surface to form a key.

061. 680 The kerbs, channels etc. shall be bedded on 1:3 cement: sand mortar and

haunched in concrete to within 75mm of the top of the kerb. 061. 690 Expansion joints, requirements for curved runs, and tolerances for precast

concrete kerbs etc shall be to DTp 'Specification for Highway Works' - Clause 1101. Joints shall not exceed 3mm in width.

061. 700 In-situ concrete kerbs and edge details shall be to DTp 'Specification for

Highway Work' - Clause 1103.

Traffic Signs 061. 701 All traffic signs shall be positioned and erected in accordance with the

requirements of Chapter 1 of the Traffic Signs Manual published by Department of Transport (HMSO).

061. 702 Post and switch boxes shall be cleansed from grease, scale and rust, shot

blasted and then galvanised.

Galvanising shall be by an agreed hot-dip process at the rate of 610g per m2 (2 ounces per sq. foot) and in accordance with BS 729. When finished the galvanising shall be smooth, reasonably bright, continuous and free from imperfections. Where flux, ash and dross inclusions, bare patches or spots due to inefficient pickling or persistent types of scale etc. are apparent, the work shall be completely stripped and regalvanised. Where it is necessary to drill a hole in a hollow member to allow air to escape, the hole shall be 12mm in diameter and shall be plugged with Neoprene or other agreed material after dipping.

061. 703 The type and size of foundations required for each sign shall be determined

by the Contractor and submitted to the Purchaser for agreement prior to construction.

Where signs are illuminated provision shall be made for cable entry by means of a 75mm diameter UPVC duct.



The base section of bollards shall be concreted to within 50mm of the top of the base section, so that the whole of the holding down bolts are embedded in concrete. Bollard bases shall be set in a block of concrete extending to 300mm in width outside the edge of the base unit with provision for a cable entry.

061. 704 The reference number of every traffic sign shall be indicated by self-

adhesive 25mm sign numbers on the reverse side of the sign in the bottom left hand corner so that it is readily visible and legible after erection.

061. 705 Signs, posts or fittings having damaged faces, backs, paintwork or plastic

coating may be rejected by the Purchaser and shall then be replaced at the Contractor's expense. Slight damage may be rectified by touching in, at the contractor's expense, but only with the agreement, and in accordance with the instructions, of the Purchaser.

The contractor shall be responsible for the protection of sign posts, sign fascias and fixings until such a time as this responsibility is discharged by the Purchaser.

Upon completion and servicing of the signs, they shall be thoroughly cleaned immediately prior to being handed over.

The type of detergent used shall be to the agreement of the Purchaser.

Road Markings

061. 710 Road marking materials shall only be applied to surfaces which are clean

and dry. Markings shall have smooth edges and shall be of uniform thickness and free from streaks. Carriageway lane and edge lines shall be laid by mechanical means to the correct alignment.

061. 720 Road markings shall be in accordance with the "Specification for Highway

Work" 7th Edition. 061. 730 Thermoplastic material shall be laid to the following thicknesses:

(a) Screed markings 4 ± 1mm (b) Sprayed markings other 2 ± 0.5mm

than yellow lines (c) Sprayed yellow edge lines 1 ± 0.2mm

061. 740 These thicknesses are exclusive of surface applied glass beads. The

method of thickness measurement shall be in accordance with BS 3262,



Part 3. 061. 750 Thermoplastic markings shall be screed or spray applied incorporating

glass beads and also having a surface application of glass beads applied evenly at the rate of 400-500 grams/sq.m.

061. 760 Where road markings are to be reflectorised with glass beads it shall be

sprayed uniformly onto the wet paint film at the rate of 400-500 grams/sq.m. Glass beads shall comply with the requirements of BS 3262, Clause 15.

061. 770 The pavement shall be prepared in the following manner to receive

markings.

(a) On concrete surfaces the transverse texturing, where the marking is to be applied, shall be freed from all traces of curing compound by wire brushing or other agreed means. A tack coat compatible with the marking materials shall be applied in accordance with the manufacturer's instructions prior to the application of thermoplastic material. Tack coats are not required except on concrete surfaces.

(b) On surface dressed pavements, all loose chippings where

the marking is to be applied shall be removed from the surface before applying markings.

061. 780 Reflecting and Depressible road studs shall be fixed in accordance with the

manufacturer's recommendations.

Temporary Road Markings 061. 785 All temporary road markings and studs which conflict with the final

permanent road markings shall be removed or permanently obliterated to the Purchaser's satisfaction where they are not subsequently required.

Permanent lines which conflict with temporary road markings and are subsequently required shall be masked by a black paint meeting the requirements of BS 6044 : 1987, or a temporary removable tape agreed by the DTp. The use of black overband sealing compounds to temporarily cover redundant markings will not be permitted.



Safety Fences

061. 786 Tensioned Safety Fences shall be installed and tensioned in accordance

with the DTp "Specification for Highway Works". 061. 787 Demountable Safety Fences shall be installed to a smooth flowing

alignment with the laps on the beam facing away from on-coming traffic.

Repair of Damaged Pavings 061. 788 Where new pavings are not specified, the Contractor shall remove all

rubbish and thoroughly clean the existing pavings. He shall then carry out a joint inspection with the Purchaser to establish whether any repairs are required. If, as is anticipated, repairs are only required in small areas, they shall be carried out as below.

061. 789 Cracks in bituminous paving shall be sealed with hot bitumen unless they

are considered by the Purchaser to be an indication of a serious local weakness, in which case they shall be treated as below.

061. 790 Inadequate reinstatement of service trenches by others shall be cut out and

reinstated in accordance with Clauses 051.485 or 489 061. 791 Where there is localised failure of existing pavings or formation

(characterised by "pot-holes" or local "crazing", depression, or significant movement of the pavement under traffic) the full thickness shall be cut out and the formation excavated out until sound material is found.

Any local remedial works to the formation will be agreed by the Purchaser (backfilling with Class 'E' material to Clause 041.060 or Type I sub-base to Clause 061.030 are envisaged) and the surface reinstated in accordance with Clause 051.485 or 489.

061. 792 The extent and details of all works to Clauses 061.788 to 061.791 shall be

agreed with the Purchaser in advance.



Regrading of Surfaces

061. 793 For large areas of regrading no layer shall be laid thicker or thinner than

recommended for the material concerned and that the wearing course shall always be of constant thickness.

The Contractor shall establish the extent of each layer and shall mark on the surface of each layer for the Purchaser’s agreement the extent of the next layer above.

061. 794 The Purchaser may instruct local re-grading of surfaces to avoid sudden

changes of level or gradient or avoid unacceptable local ponding. If such instructions are issued, the Contractor shall:

a) in the case of block, brick paving, cobbles or setts, re-lay them

locally to achieve the required profile or level. Bedding shall be as indicated in Clause 051.489.

b) in the case of in situ concrete or bituminous paving, regrade with

close-textured bitumen Macadam to BS 4987. In this case the existing surface shall be cut out such that at no place less than 30mm thickness of new bitumen macadam is laid, the edges of the cut out area being straight, vertical, and painted with hot bitumen.

061. 795 Local Regrading shall be kept to a minimum and only short ramps are

envisaged.

Reinstatement of Surfaces 061. 796 Reinstatement of surfaces after excavation for bases for lighting and CCTV

masts or any other foundations shall be in accordance with Clauses 051.485 or 051.489.

QUALITY CONTROL

General

061. 797 A statement of the Contractor's proposed method of working shall be

submitted to the Purchaser prior to commencement of the Permanent Works.



Inspection and Testing

061. 800 The extent and location of any demonstration trials shall be agreed with the

Purchaser. The trials shall be programmed to ensure that all the tests required by the Specification are carried out and test results available for examination before the planned start of construction of the Permanent Works.

061. 810 Where practical and with the Purchaser's agreement, the demonstration

areas shall form part of the Permanent Works if the trial tests successfully comply with the Specification.

061. 820 Any changes in the source of supply of materials shall require new trial mix

designs and tests to be carried out before the Permanent Works can proceed.

061. 830 Throughout the construction of the Permanent Works a continuous

programme of site control field testing and field surveys shall be carried out. Records shall be submitted to the Purchaser on completion of the appropriate test or survey.






Department of Transport: 'Specification for Highway Works': (including all British Standards referenced therein).

Department of Transport Technical Advice Note TA/19/9.

The Traffic Signs Regulations and General Directions (Amended) - (HMSO)

Traffic Signs Manual (Amended) - (HMSO)

BS 729 Specification for hot dipped galvanised coatings on iron or

steel works. BS 873 Road traffic signs and internally illuminated bollards. BS 882 Specification for aggregates from natural sources for

concrete. BS 1851 Specification for titanium dioxide pigments for paints. BS 1853 Part 1 (Withdrawn) Replaced by BS EN 60081: 1994. BS 3262 Hot applied thermoplastic road marking materials. BS 3816 Specification for colours for identification, coding and special

purposes. BS 6044 Specification for pavement marking paints. BS 6677 Clay and calcium silicate pavers for flexible pavements. BS 6717 Precast concrete paving blocks. BS 7263 Part 1 : Specification for precast concrete kerbs, channels,

edgings, quadrants and paving flags.




CLAUSE REFERENCE


COMMENT

061.120 061.121 061.122 061.140 061.210 061.360 061.390 061.430 061.520 061.703 061.705 061.790 061.800 061.830

Traffic sign fabrication drawings Type and size of posts for traffic signs Size and colour of traffic sign trade mark Road marking paint details. Road stud details. Temporary road proposals. Road construction plant. Construction level surveys. Notification of sample block paving. Type and size of traffic sign foundations Sign cleansing detergent Method statement. Demonstration trials and test results. Field test results and survey records.



APPENDIX D Publications Referred to in the Specification for Highway Works 1. British Standards

(i) BS 63: Single Sized Road Stone and Chippings

Part 2 : 1971 : Metric Units

Delete dated 1971 and replace with 1987.

(ii) BS 812 Testing Aggregates

Right-hand column, beneath "Table 6/1" insert "705.2"; beneath "1001.9" insert "1001.10"

Insert the following beneath Part 119:

Part 124: 1989. Method for determination of frost-heave.

(iii) BS 4550: Methods of Testing Cement.

Right-hand column, above "1032.4 insert "705.2"

Insert the following beneath Part 2:

"Part 5 : 1978. Standard sand for concrete cubes".

(iv) BS 4987 : 1973: Coated Macadam for Roads and Other Paved Areas.

Delete the whole section and insert the following:

"BS 4987: Coated Macadam for Roads and Other Paved Areas

Part 1 : 1988 Specification for constituent materials and mixtures

Part 2 : 1988 Specification for transport, laying and compaction."

(v) BS 5212 : 1975: Cold Poured Joint Sealants for Concrete Pavements



BS 5212 : Cold Applied Joint Sealant 1016.2 systems for concrete pavements 1016.7

Part 1 : 1990 Specification for Joint Sealants 1016.11 Part 2 : 1990 Code of Practice for the Application

and Use of Joint Sealants. 1017.4



1. Production Documents

(Published by the British Standards Institution)

(i) Add the following BSI Production Documents:- 2. Publication Specification

Clause/Table/ Appendix

PD 6518 1987: Prefabricated temporary road Appendix 12/3

marking materials for use at road works.

3. Department of Transport Publications

(Published by HMSO)

Delete item (iv) and replace with the following:

(iv) Traffic Signs Manual Chapter 1. Introduction 1977 Clause 1208.5 Chapter 8. Traffic Safety Measures Clause 117.2 and Signs for Road Works and Temporary Situations. 1991 Chapter 13. Sign Construction and Clause 1216.2 Mounting. 1963.

4. Department of Transport Publications

(Published by the Department)

Delete item (ii) and insert the following:

(ii) Highway Construction Details 4th Edition Clause 1218 5. Transport and Road Research Laboratory Reports



(i) Add the following Transport and Road Research Laboratory Reports in addition to those listed in Appendix D dated August 1986 and as amended by Appendix L dated March 1988:-

Publication Specification

Clause/Table/ Appendix

TRRL Research Report RR 90 Clause 632 TRRL Contactor Report 1 Clause 927 TRRL Accelerated Wear Machine Clause 1033



TECHNICAL SPECIFICATION WORK GROUP: 070 : BOUNDARIES/FENCES SECTION NO: 071 TITLE: FENCES AND GATES TABLE OF CONTENTS SCOPE MATERIALS AND WORKMANSHIP

General Site Preparation

CHAIN LINK FENCING

Materials Workmanship Workmanship - Demountable Security Fencing

PALISADE FENCING

General Materials Workmanship

WOVEN WIRE FENCING

Materials Workmanship

STRAINED WIRE FENCES

Materials & Workmanship WOODEN POST AND RAIL FENCES

Materials and Workmanship TABLE OF CONTENTS



CLEFT CHESTNUT PALE FENCES


SOLID STEEL FENCING


HANDRAILS


PARAPET FENCING


PERMANENT VEHICULAR GATES

Swing Gates - Materials - Workmanship

Sliding Gates - Materials PROTECTIVE BOLLARDS LIFTING ARM ROAD BARRIERS

General Workmanship

MOVABLE BARRIERS PEDESTRIAN GUARD RAILING



QUALITY CONTROL




SCOPE 071. 010 This Section defines the materials and workmanship required for the

installation of fences, gates and protective bollards. Final heights of fences and gates to be agreed with the Purchaser prior to procurement.

071.015 Safety Fences are specified in Section 061.

MATERIALS AND WORKMANSHIP

General 071. 030 The Contractor shall agree the proposed fence lines with the Purchaser

before commencing any field work. 071. 040 Demountable fencing shall be provided with panels, posts and struts which

shall be capable of removal and re-installation. 071. 050 It is not permitted to drill into materials which have been galvanised.

Fixings to be made after galvanising shall be made with clamped fixings. The Contractor shall submit his proposals of clamped fittings to the Purchaser for his agreement.

071. 060 Minimum thickness of galvanising shall be 85 microns. 071. 070 Foundations to posts, struts, bases, anti-burrowing kerbs and pedestrian

gates shall be in plain concrete grade C40 where exposed and C30 where buried in accordance with Section 201 of this Specification. Foundations to vehicular gates shall be in plain or reinforced concrete complying with Section 201.

071. 080 Steel embedments into concrete shall be galvanized. 071. 085 All fence types shall be installed plumb. Fence installation shall not deviate

from alignment by more than 10mm. Site Preparation

071. 090 The Contractor shall clear a strip one metre wide, on either side along the

line of the fence except that the width of the strip shall be increased to 1.5m for palisade fencing. He shall grade off this strip to remove local irregularities before erection of the fence commences.

071. 100 The base of excavations for posts shall be consolidated.



071. 110 Unless otherwise specified excavation and backfilling shall be in

accordance with the 'Earthworks' Section of this Specification.

CHAIN LINK FENCING

Materials 071. 120 1.8 metre high chain link fence shall comply with BS 1722 : Part 1. It shall

have galvanised rectangular hollow section steel posts and extra heavy mesh Type GLS 180A.

071. 130 2.9 metre high chain link security fencing shall comply with BS 1722 : Part

10 except that the extension carrying three stands of barbed wire shall be vertical rather than cranked. Posts shall be galvanised rectangular hollow section.

071.131 Chain link mesh shall be 5mmf, 50mm x 50mm. 2.4m high and zinc coated

and plastic coated Ring ties shall be used in preference to wire ties. Posts shall have welded baseplates and be bolted into concrete.

Workmanship

071. 140 1.8 metre high chain link fencing shall be erected in accordance with

BS 1722: Part 1. 071. 150 2.9 metre high chain link fencing shall be erected in accordance with BS

1722 : Part 10. 071. 155 The mesh shall be secured to the ground using hairpin staples threaded

over the bottom row of mesh wire at 750mm centres and drilled and grouted into the concrete haunch or other paving.

071.157 Extra posts and strainers shall be provided as necessary at steps in level

and changes of gradient. 071. 160 Pedestrian Gates in 1.8 metre high chain link fencing shall comply with

Section 2.3.3 and 3.4 of BS 1722: Part 1 to match the adjacent fence. Gates shall have 1.5 metres clear opening and shall be fitted with lever locks containing 5-lever profile cylinder with 3 keys.

071. 170 Pedestrian Gates in 2.9 metre high chain link fencing shall comply with

Sections 6 & 7 of BS 1722 : Part 10 to match the adjacent fence. Gates



shall have 1.5 metres clear opening and shall be fitted with lever locks containing 5-lever profile cylinder with 3 keys.

Workmanship - Demountable Security Fencing

071. 200 Side posts, intermediate post, top and bottom rails and embedments in

foundations shall be in steel to BS 4360 and BS 4848: Part 2 and galvanized to BS 729. The frame shall be of welded construction. Welding shall be to BS 5135 using electrodes to BS 639.

071. 210 The chain link shall be fixed to the frame all along the posts and rails, and

three rows of barbed wire shall be fixed between the side posts, all to form a complete removable panel.

071. 220 The foundations and anti-burrowing kerbs shall be cast with the embedment

for fixing the fencing level with the bases. 071. 230 The panels shall be offered into the embedments and shall form a sliding fit.

Adjacent panels shall be through bolted to each other with galvanized bolts, washers and spacers at not more than 500mm centres along the full height of the side posts.

071. 240 The joint between the posts and the embedments at the bottom shall be

sealed against ingress of water with a mastic agreed by the Purchaser. The vertical tolerance of each panel in place shall not be more than 4mm in 1m.

PALISADE FENCING

General

071. 250 Palisade fencing shall comply BS 1722: Part 12 unless noted otherwise in

this specification. It shall have corrugated pales not less than 3.5mm thick with triple pointed and splayed tops. Pales shall be welded to rails. The lower structural rail shall be provided with two intermediate supports at equal centres and shall be a 30mm x 10mm flat. Post shall have welded base plates and be bolted into concrete.

071. 260 Fencing shall be 2.4m high above finished ground level. 071. 270 Maximum permissible space between adjacent pales or uprights shall be

80mm. 071. 280 All bolted connections shall have the exposed threads burred over upon

completion. Wherever practicable the nuts on bolted connections shall be



on the inside of the palisade. 071. 290 The Contractor shall arrange the setting out of the bases so as to minimise

the number of non-standard panels.

Materials 071. 300 All materials shall comply with the requirements of Table 1.

Table 1

─────────────────────────────────── Item Material ──────────────────────────────────

Post BS 4 Part 1 or BS 4848 Rails BS 4 Part 1 or BS 4848 Pales BS 1449 Part 1 Grade HR154 Bolts and Nuts BS 4190 Plain Washer BS 4320 Table 4 H.R.S. Sections BS 4848: Part 2 and BS 4360 Grade

43 Intermediate Supports BS 4360 Galvanizing BS 729 Concrete Grade C 30 to Section 201 Stainless Steel: - Rivets BS 970 Part 4, Grade 304S15 (Austenitic) - Grooved Fasteners AISI 305 (Avdelok or similar)

──────────────────────────────────

071. 310 All ferrous components of the palisade and gates shall be hot-dip

galvanized before assembly. Damaged galvanizing on rivet heads and bolt threads shall be wire brushed and made good with zinc rich paint to the Purchaser’s agreement.



Workmanship

071. 320 Palisade fencing shall be erected in accordance with BS 1722: Part 10.

The lower structural rail intermediate supports shall be embedded in concrete to a depth of 100mm. The concrete base for each intermediate support shall be 150mm x 150mm x 150mm with the top of ground level. Each intermediate support shall be fixed to the lower rail by an 8mm diameter bolt.

071. 330 Post bases shall be cast in situ concrete Grade C 30 with the top 100mm

below ground level. 071. 340 UB posts shall be erected on the bases with the palisade panels attached.

During erection the panel shall be propped up with the bottom rail with suitable temporary packing to give a slight upward camber to the rail. After lining up and plumbing all bolted connections shall be tightened and the intermediate supports shall be embedded in concrete. The temporary props under the bottom rail must not be removed until the concrete has thoroughly set.

WOVEN WIRE FENCING

Materials

071. 350 Woven wire fencing shall be to BS 1722: Part 2, Woven Wire Fences. The

Contractor shall submit samples to the Purchaser for agreement. 071. 360 The fence shall be constructed from Type C6/90/30W Table 1 BS 1722:

Part 2, woven wire fences. 071. 370 Wood for straining posts, intermediate posts and struts shall be to Appendix

'E' and Tables 4 or 5 of BS 1722: Part 2. The Contractor shall propose the type of timber for use and submit to the Purchaser for agreement with details of the preservative treatment to be applied.

071. 380 Field Gates shall be hardwood to BS 3470 and shall be constructed to the

widths and details.

Workmanship 071. 390 Erection shall be to BS 1722: Part 2, section 2, Clause 3. 071. 400 Intermediate posts shall be placed at not more than 3.50m centres.



071. 410 Straining posts on a straight line shall be spaced at not more than 150m apart.

071. 420 Straining posts shall be provided at all ends and corners, at changes in

direction horizontally and vertically greater than 1:3. 071. 430 A single line of galvanized mild steel barbed wire to BS 4102 shall be

strained and stapled 30mm below the top of each post. 071. 440 Mass concrete for surrounding the bases of posts and struts shall be not

lower by mass than one part of cement to ten parts of graded aggregate of 40mm nominal maximum size thoroughly mixed with the minimum requisite quantity of clean water. The concrete shall be placed and compacted as soon as possible after mixing.

STRAINED WIRE FENCES

Materials and Workmanship

071. 450 Concrete post and seven line wire fencing shall comply generally with the

requirements of BS 1722 Part 3 : 1986, Type SC 135A. 071. 460 Fencing shall be set with the top wire 1350 above the level of the adjacent

footpath and have concrete posts with 7 No. line wires. Fence posts shall be 2.02m long 125 x 125mm at base tapering to 75 x 75mm at top. Posts shall be set into the ground at maximum 3.50m centres in concrete foundations, the dimensions of which shall suit ground conditions with a minimum of 75mm of concrete below the bottom of the posts. Line wires to be 3.15mm zinc coated high tensile steel passing through holes in concrete posts.

End straining posts shall be precast reinforced concrete each with 45 degree reinforced concrete raking strut set into the ground in concrete foundations, the dimensions of which shall suit ground conditions but with a min. of 100mm of concrete below bottom of posts. Correct tensioning of line wires shall be carried out by using 250mm fully threaded galvanised eye bolts.

071. 470 Corner or intermediate straining posts shall be as previously described but

with 2 raking struts and 2 sets of eye bolts. Intermediate straining posts to be set at a max. of 300m in straight runs of fencing and at all changes of direction.



WOODEN POST AND RAIL FENCES

Materials and Workmanship

071. 490 Wooden post and rail fences shall be to BS 1722: Part 7.

CLEFT CHESTNUT PALE FENCES

Materials 071. 500 Posts and struts shall be to BS 1722: Part 4. 071. 510 Stirrup wire shall be galvanized mild steel to BS 4102, 2.5 mm diameter. 071. 520 Barbed wire shall be galvanized mild steel to BS 4102. 071. 530 Pales shall be to BS 1722: Part 4. 071. 540 Fixings and fittings shall be to BS 1722: Part 4 galvanized to BS 729.

Workmanship 071. 550 Cleft chestnut pale fences shall be erected in accordance with BS 1722:

Part 4, Section 3.

SOLID STEEL FENCING

Materials 071. 551 Solid steel fencing shall consist of galvanised solid steel panels mounted

securely on steel posts at centres no greater than 3.0 metres and to the height shown on the Drawings. The fixings shall be designed in such a way that it is impossible to remove a panel or any other part of the fence from outside the Site. Fence posts shall be extended upwards to carry 3 strands of barbed wire.

071. 552 The fencing shall be a proprietary system of proven design by a responsible

manufacturer.



Workmanship

071. 553 The fence shall be installed in accordance with the manufacturer’s

instructions and Clauses 071.030 to 071.110 of this Specification. 071. 554 Fence posts shall be cast into concrete adequate to resist the design

loading.

HANDRAILS

Materials 071. 555 Handrails shall consist of natural, mill finish aluminium or galvanised steel

2-rail panels 1.1m high with vertical infill bars at 125mm centres. The height between the top and bottom rail shall be 1.0m and post centres shall be no greater than 2.5m. The system shall be sufficient to resist a design load of 750N/m.

Posts shall be embedded in concrete footings adequate to resist the design loading.

Workmanship

071. 556 The handrails shall be installed in accordance with Clauses 071. 030 to

071. 110 of this Specification.

PARAPET FENCING

Materials 071. 557 Parapets shall comply with the requirements of The Department of

Transport Technical Memorandum BD 52/93 and BS 6779. Parapets shall be Group 1 class as designated by BD 52/93 and shall be supplied by an agreed manufacturer.

Workmanship

071. 558 Parapets shall be erected to the agreed lines and levels, but with the

agreement of the Purchaser, may be adjusted where necessary to give a smooth flowing alignment to the finished parapet.

071. 559 Parapets shall be securely supported in their final position until the

anchorages and bedding have attained adequate strength.



071. 560 The threads of the steel anchorage sockets shall be treated with red lead compound Type 3 complying with BS 217 immediately prior to fixing parapet holding down bolts into their final position.

PERMANENT VEHICULAR GATES

Swing Gates in Chain Link Fencing

Materials

071. 561 Swing gates shall be either of a single leaf or two leaves type. 071. 570 The perimeter and bracing rails shall be in steel to BS 4360 and shall be

fabricated from hollow structural sections to BS 4848. All free ends shall be capped.

071. 580 Gates shall be of all welded construction and galvanized. Welding shall be

to BS 5135 using electrodes to BS 639. 071. 590 The gate infill shall be chain link of the same type as the adjacent fencing.

The Contractor shall submit drawings and details of the gate to the Purchaser for agreement.

071. 600 The gates shall open and shall be provided with the following furniture:

(a) Hasp and bolt for padlocking

(b) Handles on both sides

(c) Drop bolts for securing the gate in the shut position

(d) Catch for retaining the gate in the open position

071. 610 The gates shall swing freely and stops shall be provided for the open and shut positions. Wide gates shall have diagonal bracing and shall be provided with suitable tracks and ground wheels unless the Contractor can demonstrate that the gate will continue to swing freely throughout its design life without this assistance. Ground wheels, if provided, shall be complete with a suitable spring or other mechanism to support the gate in a level position above a non-level track.

071. 615 Gates shall have a minimum ground clearance of 20mm at all times and a

maximum ground clearance of 130mm when closed. If the paving levels beneath the gate are not such that this can be achieved, the Contractor



shall be responsible for any necessary modification of the pavings. Any such modifications shall comply with Section 061 of this Specification.

071. 616 The tops of all gates shall be level in both the open and closed positions.

The top level of both leaves of a two leaf gate shall be the same.

If necessary to achieve the ground clearance limits specified in Clause 071.615, it is acceptable to slope the bottoms of gates provided that where two leaves meet in the centre they shall be at the same level, and the two leaves do not slope in opposite directions.

071. 620 The gate post shall be of hollow steel section and shall be anchored into the

foundation base concrete. 071. 630 The posts shall be provided with straining bars for connection of the

adjoining chain link fencing, straining wires and barbed wires. 071. 640 The gate shall be supported off the hinge post with three heavy duty rust

proof adjustable hinges of a design which will prevent the gate being easily lifted off.

Workmanship

071. 650 The top of the gate shall line up with the top of the adjacent fencing. Gates

in security fencing shall be extended upwards to a total height of 2.9m to carry three strands of barbed wire to match the adjacent fence.

071. 660 The height of the gate post shall suit the height of the adjacent fence and

top wire.

Sliding Gates

Materials 071.680 Sliding gates shall be single leaf. They shall be manually operated. 071.690 Gates shall be framed with RHS steel sections to BS 4848 of a size not less

than 90mm x 90mm x 3mm. Intermediate vertical members of a similar section shall be provided at not less than 1000mm centres. Infill shall match the adjacent fencing.

071.700 The support beam shall be fabricated from RHS section of a size not less

than 100mm x 100mm x 4mm welded to a heavy gauge track. 071.710 The gates shall run between 2 No. vertical guide posts of section size not



less than 120mm x 120mm x 4mm RHS and close to full height 100mm x 100mm x 4mm RHS steel posts with catch plate and 5 lever lock.

071.720 Closing posts and outside guide posts shall be complete with fittings for

attaching adjacent chainlink fencing. 071.730 Gate frames shall be provided with 2 hard rubber buffers at the closing end

of the gate frame. 071.740 Gates shall be of welded construction and shall be galvanised. Welding

shall be to BS 5135 using electrodes to BS 639."

PROTECTIVE BOLLARDS 071.745 Protective bollards shall be Grade 43 steel CHS or RHS and galvanised. 071.746 The whole of the bollards shall be painted with black heavy duty enamel

after treating the galvanised surface with an appropriate etching primer. Bands of reflective yellow tape in horizontal stripes 200mm wide shall be applied. Colours to be used are:-

Black: BS 4800 No. DOE 53 Yellow: BS 3816 No. 355 (lemon).

Tape shall comply with BS 873 Part C Table 1 (Class 1).

LIFTING ARM ROAD BARRIERS

General

071. 750 The scope of the work includes design, supply, fabrication, delivery,

storage, erection and setting to work complete and provision of operation and maintenance manuals.

071. 760 The Contractor shall submit to the Purchaser the power supply loads,

cabling requirements including the proposed terminal point with regard to the extent of supply.

071. 770 The Contractor shall erect the barriers at the agreed locations and effect all

the electrical and control connections. 071. 780 The Contractor shall submit general arrangements, details, along with the

electrical and control circuit diagrams to the Purchaser for agreement.



All materials and workmanship shall comply with British Standards. Operation and Maintenance manuals shall be submitted to the Purchaser for information.

071. 790 Manufacturer's details of road barriers shall be submitted to the Purchaser

for agreement. 071. 800 A pair of red lights and a pair of red reflectors shall be provided on both

sides of the boom. The boom shall be aluminium and shall be painted with alternate red and white bands to BS 5378.

071. 810 There shall be provision for manual operation during power failure. When

the system is 'energised' the barrier shall not be capable of manual operation.

071. 820 The control cubicle and the operational panel shall be provided with anti-

condensation heating. 071. 830 The operation of the barriers shall be by remote push button control and shall comprise 'open', 'stop' and 'close' modes. It shall also be able to be manually operated.

Workmanship

071. 840 The Contractor shall maintain the road barriers for the duration of the

Contract. On the completion of the Contract the equipment shall be refurbished before handover to the Employer.

071. 850 The control cubicle and the operation panel shall generally be located in the

Gate House.

MOVEABLE BARRIERS 071. 860 Moveable barriers shall be 1650mm long x 450mm wide x 600mm high.

The system shall be linked together as per the Tuffchain System or similar agreed. The barriers shall be constructed in tough impact resistant L.M.D.P.E. Colours shall be alternate red and white as directed by the Purchaser.

071. 870 The Tuffchain System is manufactured by Raydek Safety Products Limited,

Raydek House, Saltley Trading Estate, Birmingham B8 1BL. 071. 880 The Contractor shall maintain the moveable barriers throughout the

duration of the contract. The Contractor shall be responsible for ballasting with sand or other such suitable fill to the agreement of the Purchaser.



071. 890 The Contractor shall be deemed to have included for ballasting in his Tender.

PEDESTRIAN GUARD RAILING

071.891 Pedestrian guard railing shall be Alcan Bacorail or a similar agreed system

of aluminium alloy construction with 2 rails and vertical infill tubes. 071.892 The guard rails shall be designed and constructed in accordance with BS

3049 for Class A loading. 71.893 The top of the top rail shall not be less than 1.0m above finished ground

level and the minimum distance between posts shall be 2.0m. 71.894 071.894 Infilling shall be aluminium alloy tubes and gaps between adjacent tubes

and between tubes and posts not exceeding 100mm. 071.895 Guard rail posts shall be fitted with cast bases for surface mounting."

QUALITY CONTROL General

071. 900 The Contractor shall submit to the Purchaser full details of products and

materials for agreement including samples where appropriate. 071. 910 Where fencework is required along the limits of ownership boundaries, the

Contractor shall submit for agreement, providing a minimum of 14 days notice, his proposals for demolition of existing fences/gates or construction of new fence/gates.


071. 920 The Purchaser shall be advised of the setting out points before erection of

any fencing is carried out. 071. 930 All fencework shall be checked for line and level on completion. 071. 940 All demountable sections, gates and road barriers shall be inspected on

completion for ease of operation and to confirm compliance with the Specification.


below and shall be the current edition, including all amendments.



° The Contractor shall bring to the attention of the Purchaser any inconsistencies between the requirements of these Standards and this Specification Section.

BS 4 Structural Steel Sections. Part 1: Specification for Hot-rolled Sections.

BS 639 Specification for covered carbon and carbon manganese

steel electrodes for the manual metal arc welding. BS 729 Specification for hot dip galvanised coatings on iron and

steel articles. BS 970 Wrought steels in the form of blooms, billets, bars and

forgings. Part 4: Stainless, heat resisting or valve steels.

BS 1449 Part 1: Carbon and carbon manganese plate, sheet and strip.

BS 1722 Fences. Part 1: Specification for chain link fences. Part 2: Woven wire fences Part 3: Specification for strained wire fences Part 4: Specification for cleft chestnut pale fences Part 7: Specification for wooden post and rail fences Part 10: Anti-intruder chain link fences. Part 12: Steel Palisade Fencing.

BS 3049 Pedestrian Guard Rails (Metal)

(Withdrawn) Replaced by BS 7818: 1995. BS 3470 Specification for field gates and posts. BS 3816 Specification of Colours for Identification, Coding and special

Purposes. BS 4102 Specification for steel wire for fences and wire products for fences. BS 4190 ISO Metric Black Hexagon bolts, screws and nuts. BS 4320 Metal Washers for General Engineering Purposes.



BS 4360 Specification for weldable structural steels. (Withdrawn) Replaced by BS 7613: 1994, BS 7668: 1994, BS EN 10029: 1991, Parts 1 to 3 of BS EN 10113: 1993, BS EN 10155: 1993 and BS EN 10210-1: 1994.

BS 4800 Schedule of Paint Colours for Building Purposes. BS 4848 Specification for hot-rolled structural steel sections. BS 5135 Specification for arc welding of carbon and carbon manganese

steels. BS 5378 Safety signs and colours.




CLAUSE REFERENCE


COMMENT

071.030 071.130 071.590 071.760 071.780 071.790 071.860 071.910 071.920

Agreement of fence lines. Chain link samples. Detail Drawings of permanent gates. Road barrier power supply details etc. Road barrier electrical/control details and operation/maintenance manuals. Road barrier type. Submission of product and material details and samples. Agreement of ownership boundaries. Setting out points.




TECHNICAL SPECIFICATION WORK GROUP: 120 : PRESSURE PIPELINES SECTION NO: 121 TITLE: BURIED PRESSURE PIPELINES TABLE OF CONTENTS SCOPE MATERIALS

Pipes Joints Fittings Pipe (and Fittings) Protection Pipe Bedding Pipe Anchors Chambers Markers

WORKMANSHIP

General Earthworks Pipe Laying Pipe Jointing Backfilling Reinstatement Pipe Sundries

QUALITY CONTROL

Hydrostatic Testing and Inspection Cleaning and Sterilising Chambers Tolerances




installation of buried pressure pipelines for i) Potable water mains ii) Fire water mains iii) Foul pumping mains

121. 020 Gas pipelines are not specified in this section.

MATERIALS

Pipes

121. 030 Polyethylene pipe up to 63mm nominal size shall comply with the requirements of BS 6572 with polyethylene fittings to Water Authorities Association Information and Guidance Note No 4-32-04 or pipe manufacturers agreed non-dezincifiable copper alloy or push fit polypropylene fittings.

121. 040 Polyethylene pipe above 63mm nominal size shall comply with the

requirements of WAA Information and Guidance Note No 4-32-03 with polyethylene fittings to WAA Information and Guidance note No 4-32-04. Joints may be butt fusion welded or socket fusion welded couplings to the pipe manufacturer's requirements.

121.050 Polyethylene pipe shall be blue coloured and capable of safely sustaining

10 Bar working pressure. 121.060 Ductile iron pipes shall comply with the requirements of BS 4772 Class K9

with flexible joints. 121.065 Ductile iron pipes for water mains or for fire mains with potable water

connections shall have a cement mortar lining. The cement used shall be ordinary Portland cement in accordance with BS12, or Portland blast furnace cement to BS 146 : Part 2 except that sulphate-resisting cement to BS 4027 may be used. The sand shall consist of inert, granular material having hard, durable uncoated grains and sand shall meet the requirements of BS 882. The water shall be obtained from the public water supply and shall contain no constituent that adversely affects the quality of the cement.



Joints 121. 090 All jointing materials shall be unaffected by and have no deleterious effect

on the material being carried. In particular for potable water mains all jointing materials, gaskets, lubricants, joint rings, solvent cements etc shall be agreed for use in contact with potable water and the contractor shall provide a certificate confirming that the materials comply with the recommendations in Information and Guidance sheet 4-40-01 published by the Standing Technical Committee on Sewers and Water Mains.

121. 100 Elastomeric joint rings shall comply with the requirements of BS 2494 and

shall be obtained from the pipe manufacturer. 121. 110 Gaskets for flanged joints shall comply with the requirements of BS 2494

and be of the inside-bolt-circle type the dimensions of which shall comply with BS 4865.

121. 140 Black Hexagon Bolts and Nuts shall comply with BS 4190. 121. 150 Metal Washers shall comply with BS 4320.

Fittings 121. 160 Pipe Couplings and flange adaptors of the Viking Johnson type may be

agreed by the Purchaser for use in special circumstances. 121. 161 Flanges shall comply with BS 4504 PN16. 121. 170 Valves shall comply with the following unless stated otherwise

i) Butterfly Valves - BS 5155 ii) Cast Iron Check Valves - BS 5153 iii) Cast Iron Wedge Gate Valves - BS 5150 iv) Diaphragm Valves - BS 5156 v) Stop Valves - BS 1010 Part 2 vi) Air release valves shall be of the double type combining

both large and small orifices and agreed by the Purchaser. 121. 180 Fire hydrants boxes and covers shall comply with the requirements of BS

750 and shall be the screw down type.



121. 190 Penstocks shall be of the cast iron gun-metal type or coated steel and plastic and agreed by the Purchaser for use.

121.195 Fittings on ductile iron piles shall be Class K12 (BS 4772).

Pipe (and Fittings) Protection 121. 200 Polythene tubular sleeving shall be used to protect ductile iron pipelines

and joints and shall comply with the requirements of BS 6076. 121. 210 All exposed ferrous metal including pipes, valves and brackets in chambers

shall be given two coats of an agreed bitumen solution to BS 3416. 121. 220 All buried Viking Johnson couplings and adaptors shall be protected with an

agreed self-adhesive bandage prior to being covered with polythene sleeving.

121. 230 All bolted gland joints shall be given two coats of an agreed bitumen

solution to BS 3416 over a distance of 150mm either side of the face of the socket prior to being covered with polythene sleeving.

Pipe Bedding

121. 240 Concrete for use as pipe bedding, surround, cradle or arch shall be Class

C20. 121. 250 Granular bedding material shall comprise gravel or broken stone graded

from 14mm to 5mm size, or coarse sand, or sand and gravel or single sized gravel 10mm or 14mm, conforming with Water Authorities Association Information and Guidance Note No. 4-08-01 and the relevant provisions of BS 882.

Pipe Anchors

121. 260 Concrete Class C20 shall be provided for pipe anchors/thrust blocks at all

bends junction tees and stop-ends or where otherwise shown unless self anchoring joints are used, and shall be cast in contact with undisturbed ground immediately after the removal of loose or weathered material.

121. 270 A membrane of polythene film wrapped to give a minimum 3 mm thickness

shall be used between a uPVC pipe and the concrete of a thrust block.



Bitumen products must not be used in contact with uPVC pipes and are unacceptable as an alternative membrane material.

Chambers

121. 280 Brick Chamber construction shall be in Class B Engineering brick to BS

3921 in English bond two bricks thick in 1:3 cement mortar on a base of Class C20 concrete.

121. 290 Precast concrete units for washout and other chamber construction shall

comply with BS 5911 and the requirements of the Generic Drainage Specification, Section 051.

121. 300 Cast iron manhole covers and frames shall comply with BS 497 and be

bedded on 1:3 cement mortar. 121. 310 Small surface boxes for access to Valve Spindles shall be cast iron heavy

duty and shall comply with BS 5834. The hinged lid shall have cast in a clockwise arrow and the word 'CLOSE'.

121. 320 Step irons shall comply with BS 1247

Markers 121. 330 Concrete marker posts shall be provided to indicate each valve, air valve,

and hydrant position and shall bear a vitreous enamel plate (size 230mm x 265mm to Class B of BS 3251). The concrete post shall project 600 mm above ground level.

WORKMANSHIP

General

121. 350 All pipes valves and fittings are to be handled, stored, installed and jointed

in accordance with the relevant manufacturer's requirements.

Earthworks 121. 360 All earthworks shall be carried out in accordance with Section 041,

'Excavation and Filling' of this Specification except where varied by the



following requirements. 121. 370 The stability of trenches and other excavations must be adequately ensured

by the Contractor to provide a safe working environment as well as protecting any adjacent services or structures. The Contractor shall submit details of his proposed method of working to the Purchaser for agreement prior to commencement.

121. 380 Trench excavation for pipelines shall be cut with vertical sides not less than

300 mm wider than the outside diameter of the barrel of the pipe and not greater than the maximum trench width shown. The sides of the trench excavation shall not be battered without the agreement of the Purchaser.

121. 390 Excavations shall be kept free of standing water which may arise from any

source and such water shall be drained or pumped to an agreed discharge position taking steps to prevent the loss of fines which might adversely affect the surrounding ground.

121. 400 Excavated formations shall be inspected and agreed prior to work

proceeding. Any unsuitable hard and soft material removed shall be replaced with compacted selected granular material.

Pipe Laying

121. 410 Natural bedding - The bottoms of trenches shall be accurately formed to

levels and gradients with pockets cut for pipe joints so that full bearing support is provided over the whole length of the pipe barrel.

121. 420 Granular bedding - Any soft material shall be removed from the trench

formation which shall be trimmed to permit a minimum thickness of 100 mm of granular material to be laid and compacted to support the barrel of the pipe over the full width of the trench.

121. 430 Pipes laid on natural or granular bedding shall be laid on firm material over

the length of the pipe barrel. Temporary supports shall not be used. 121. 440 When the pipe has been set to the correct line and level granular or

selected material shall be placed and compacted by hand in layers 75 mm thick up to the pipe crown equally on either side of the pipe. Thereafter the material is placed and compacted in 75 mm layers to a minimum height of 150 mm above the crown.



121. 450 Concrete bedding - The trench bottom shall be trimmed to permit the minimum thickness of concrete required under the barrel of the pipe. The pipe shall be supported to the correct line and level on precast concrete support blocks covered with an agreed compressible material.

121. 460 Concrete shall be placed on to the trench formation to within 25 mm of the

underside of the pipe, either to the full width of the trench or within vertical shutters to at least the minimum width required. It shall then be placed equally either side of the pipe and carefully worked under and around the pipe ensuring that no voids are left below the pipe, and brought up to the required finished level, taking care to ensure that the pipes are not disturbed by this operation.

121. 470 Where pipes have flexible joints the concrete support shall be broken with a

shaped compressible material coincident with every pipe joint and over the whole of the concrete cross-section.

121. 480 Pipes which are cut on site shall be cut clean and square with minimum

damage to any coating using equipment recommended by the manufacturer. Ductile iron pipes larger than 450 mm shall not be cut unless specially ordered for the purpose from the manufacturer. All cut ends are to be prepared for jointing as recommended by the manufacturer.

121. 490 Where joints are to be deflected such deflection shall not exceed the


A method statement shall be submitted to the Purchaser for agreement prior to work being carried out. Joints to be deflected shall first be made square. With bolted joints the required deflection shall be set just prior to final tightening.

Pipe Jointing 121. 500 All pipes fittings and valves shall be carefully cleaned immediately prior to

jointing, and the joints made fully in accordance with the manufactures instructions.

121. 510 The closure of spigot and socket joints shall be made in accordance with

the manufacturer's recommendations using special equipment as



necessary. 121. 520 Flange joints shall not be pulled into alignment or drawn together by the

flanges. The setting of flanges must be parallel and as close together as possible before the bolts are tightened up to the specific torque and order recommended by the manufacturer. Flange gaskets shall not be positioned using lubricant.

121. 530 Bolts and nuts shall be run by hand before assembly and shall be greased

with graphite paste or equivalent before use. 121. 540 After jointing, the open end of each pipe shall be closed to prevent the

ingress of water or foreign material. Care shall be taken to prevent flotation of sealed pipes.

121.545 Where ductile iron pipes are required at less than the standard length they

shall be cut with an agreed pipe cutter and the ends machined to suit the particular joint in accordance with the manufacturers' instructions.

Backfilling

121. 550 Where the particular bedding type specified does not extend to a level 300

mm above the top of the pipe, backfilling to that level shall be made using carefully selected material free from large flints/stones etc. and compacted by hand in 100 mm layers, carefully working under and around pipes and into joint holes. Backfilling shall proceed thereafter using selected excavated material in layers not exceeding 250 mm placed thickness, each layer being thoroughly consolidated while progressively withdrawing trench supports.

121. 560 Mechanical compaction shall not be carried out until there is 600mm of

compacted material above the pipe crown. The use of mechanical compactors shall not be permitted without the agreement of the Purchaser.

121. 570 Where the pipe has been protected with concrete bed or surround,

backfilling shall not be commenced for 24 hrs; neither shall traffic loads be imposed within 72 hours of placing the concrete.

Reinstatement

121.575 Reinstatement shall comply with Clauses 051.485 or 051.489 of this



Specification.

Pipe Sundries 121. 580 Where connections to existing services are to be made, the written

agreement of the Purchaser shall be obtained for any works involving live chambers or pipes.

121. 590 The position and invert levels of existing chambers and pipes to which

connections are to be made shall be verified by the Contractor before pipe laying commences and any discrepancies notified to the Purchaser immediately.

121. 600 Service connections to potable water mains shall only be made using

means appropriate to the material of the main and with the agreement of the Purchaser.

121. 610 Where loose polyethylene sleeving is applied to ductile iron pipes it shall be

held in position using PVC tape applied in accordance with the manufacturer's recommendations and with appropriate overlap at the joints made after any other joint protection has been applied.

121. 620 At each point where a pipeline is temporarily terminated a fixed marker shall

be attached to the pipeline and held above ground level. 121. 630 During cold weather adequate protection shall be given to prevent freezing

of any charged pipeline prior to backfilling. 121.635 Where concrete thrust blocks are provided the pipes shall be laid on

concrete blocks 380mm x 150mm x 140mm not fewer than one to each pipe and adjusted to level with hardwood wedges under the blocks. The remainder of the thrust block shall then be placed using Class C20 concrete. All operations of concreting shall be carried out so as to leave the pipes correct and undisturbed as to line and level and undamaged in any way.

QUALITY CONTROL

Hydrostatic Testing and Inspection

121. 640 All pipelines shall be tested before being brought into use. The test shall be

a hydraulic pressure test using clean water. A pipeline may be tested either in one length or in sections, the lengths of section dependent on:



a) The availability of suitable water and discharge points.

b) The number of joints to be observed under test.

c) The difference in elevation between one part of the pipeline

and another.

The Contractor shall submit details of his testing arrangements. 121. 650 Wherever possible joints shall be left uncovered until after testing but

sufficient material shall be backfilled over each pipe to prevent any movement under test pressure.

121. 660 The test pressure for each section or complete pipeline shall be not less

than 1.5 times the working pressure (10 bar on ductile iron Class K9 pipelines) measured on a newly calibrated pressure gauge with a calibration certificate and used only for testing purposes. A copy of the calibration certificate is to be submitted to the Purchaser.

121. 670 When any sections which have been separately tested are joined, a further

hydraulic pressure test shall be carried out on the completed pipeline which shall be not less than the working pressure.

121. 680 Each length under test shall be properly sealed off with special stop ends

secured by adequate temporary anchors. Testing shall not take place against closed valves. All permanent thrust blocks shall be in position and any concrete shall have achieved the required strength.

121. 690 The section or length under test shall be filled with water ensuring that all

air is displaced. Where concrete or concrete lined pipes have been used they shall be filled with water and held at two thirds the working pressure for two days prior to the test commencement to allow for absorption.

121. 700 After filling and any necessary allowance above, the pressure in the

pipeline shall be raised to the working pressure and left for a period in order to achieve conditions as stable as possible for testing. Additional water shall be pumped in until the test pressure is reached in the lowest part of the section. The pump shall then be disconnected and no additional water shall be allowed into the pipeline for 1 hour. If a drop in pressure occurs the quantity of water added to re-establish the test pressure shall be carefully measured.



This shall not exceed the equivalent of 0.1 litres per millimetre of pipe diameter per kilometre of pipeline per 24 hours for each 30m head of pressure applied for the test to be accepted.

121. 710 Work shall not be considered complete until a test has been successfully

applied and the results documented.

Cleaning and Sterilising 121. 720 Before a pipeline shall be considered ready for service, it shall be

thoroughly cleaned internally to ensure that no foreign matter remains inside the pipeline. Pigs or foam swabs of suitable design shall where directed by the Purchaser be passed through completed sections of the pipeline or through the completed pipeline.

121. 730 Potable water pipes shall be dosed with a chlorine concentration of 50 mg/l

and the chlorinated water allowed to remain in the pipe for a minimum of two hours. A sample shall then be taken to check for chlorine residual using a Comparator. If less than 0.2 mg/l is obtained the dosing shall be repeated until a residual is obtained.

121. 740 All chlorinated water shall be thoroughly flushed out prior to bringing the

main into service and discharged in such a manner agreed by the Purchaser to avoid pollution.

121. 750 The Contractor shall provide all suitable equipment for chlorination including

any necessary pumps, tanks, piping cocks and tappings etc.

Chambers 121. 760 All brick and precast concrete chambers shall be substantially watertight

with no identifiable flow of water visible within the permanent works. 121. 770 All chamber covers shall be set on class M1 mortar and where the

manholes are of precast concrete on at least three but not more than four courses of Engineering brickwork. Precast concrete manhole units shall be bedded on mortar and flush pointed internally. The concrete surround for the chamber shall be formed using a suitable shutter with any horizontal construction joints formed at least 150mm away from the ring joint.



Tolerances

121. 780 The position of the internal face of any pipeline shall not deviate from that

detailed in the contract by more than + 20mm.






BS 12 Specification for Portland Cement BS 146 Specification for Portland Blast Furnace Cement BS 497 Specification for manhole covers, road gully gratings and

frames for drainage purposes. (Withdrawn) Replaced by BS EN 124: 1994.

Part 1: Cast iron and cast steel.

BS 750 Specification for underground fire hydrants and surface box frames and covers.

BS 882 Specification for aggregate from natural sources for concrete.

BS 1010 Specification for draw-off taps and stopvalves for water services (screw-down pattern).

BS 1247 Specification for manhole step irons. BS 2494 Specification for elastomeric joint rings for pipework and pipelines. BS 3251 Specification for indicator plates for fire hydrants and water

supplies. BS 3416 Specification for bitumen based coating so for cold application,

suitable for use in contact with potable water. BS 3921 Specification for clay bricks. BS 4190 Specification for ISO metric black hexagon bolts, screws and nuts. BS 4320 Specification for metal washers for general engineering purposes.

Metric series.

BS 4504 Specification for flanges and bolting for pipes, valves and fittings.

BS 4772 Specification for ductile iron pipes and fittings (Withdrawn) Replaced by BS EN 545: 1995, BS EN 598: 1995 and BS EN 969:1996.

BS 4865 Specification for dimensions of gaskets for pipe flanges to BS 4504. (Withdrawn) Replaced by Parts 1-4 of BS EN 1514.

BS 5150 Specification for Cast Iron Gate Values. BS 5153 Specification for Cast Iron Chick Values for general purposes.



BS 5155 Specification for Butterfly Values. BS 5156 Specification for Diaphragm Values.

BS 5834 Surface boxes, guards and underground chambers for gas and

waterworks purposes.

BS 5911 Precast concrete pipe fittings and drainage ancillary products. BS 6076 Specification for tubular polyethylene film for use as protective

sleeves for buried iron pipes and fittings. BS 6572 Specification for blue polyethylene pipes up to nominal size 63 for

below ground use for potable water.

Water Authorities Association Information and Guidance Notes:

No. 4-08-01 No. 4-32-03 No. 4-32-04 No. 4-40-01




CLAUSE REFERENCE


COMMENT

121.370 121.490 121.640 121.660

Details of method of working. Details of joint deflections. Details of testing arrangements. Certificate of calibration of pressure gauge.


TECHNICAL SPECIFICATION WORK GROUP: 130 : BELOW GROUND SERVICES SECTION NO: 131 TITLE: DUCTS AND TRENCHES TABLE OF CONTENTS SCOPE MATERIALS

Buried Pipework Cable Ducts and Service Sleeves Miscellaneous Materials

WORKMANSHIP

Buried Pipework Cable Ducts and Service Sleeves General Excavation and Laying Reinstatement of Surfaces Cleaning and Identification of Ducts Inspection Pits Accessible Ducts and Trenches Pipework Duct Entry into Buildings

QUALITY CONTROL





SCOPE

131. 010 This Section defines the materials, inspection and workmanship to be

applied to the installation of buried pipework cable ducts, open trenches with covers and accessible below ground ducts for routing services external to the buildings. It does not cover the installation of direct buried cables.

MATERIALS

Buried Pipework Cable Ducts and Service Sleeves

131. 030 Unplasticized PVC pipes for cable ducting and service sleeves shall be to

BS 3506. 131. 040 Concrete pipes for service sleeves shall be to BS 5911. Pipes shall be

flexibly jointed. 131. 050 Vitrified clay pipes for cable conduits to BS 65 shall be suitable for high

voltage oil filled cables, and be free from any internal undulations, roughness or projections and shall have smooth radiused internal edges at the joints. The joints shall be of an agreed plastic type, flexible and self-aligning. Grooved cable conduits shall be provided for splitting where split conduits are required for protection of existing services.

131. 060 Galvanised steel conduit shall be to BS 1387 medium grade in standard

lengths with screwed socket and tapered threads to BS 21.

Miscellaneous Materials 131. 090 Bricks shall be to BS 3921 class B (Engineering). 131. 100 Concrete work shall comply with Sections 201 and 202. 131. 110 Access covers and frames to inspection pits, cable draw pits, below ground

ducts etc. shall be to BS 497. 131. 120 Covers to continuous trenches shall be steel, cast iron, concrete infill type

or pre-cast concrete with provisions made for lifting purposes. 131. 130 Four pairs of lifting keys shall be supplied for each separate type of trench

cover. 131. 140 Granular bedding and fill material shall consist of naturally occurring



aggregates to BS 882 or sintered pulverised fuel ash to BS 3797.

WORKMANSHIP

Buried Pipework Cable Ducts and Service Sleeves

General 131. 150 Workmanship shall comply generally with Section 051 'Buried Foul and

Surface Water Drainage' and as specified herein.

Excavation and Laying 131. 160 The permitted maximum deviation in profile of pipework ducts shall be ±

25mm in line and level. At terminal chambers the deviation shall not exceed ± 25mm from the centrelines.

131. 170 Pipework ducts shall generally be laid in straight lines, to even falls, and laid

working uphill from the lowest point in each pipe run. Nominally level duct runs shall be laid with nominal falls to create high points midway in each run to allow moisture to run back to the access chambers.

131. 180 Joints in pipework ducts shall be sealed with a proprietary joint sealing

compound and carried out as recommended by the duct manufacturer. 131. 190 Changes in direction of more than 30o shall only be achieved by the use of

standard bends and fittings or inspection pits. 131. 200 The Contractor shall obtain the Purchaser's agreement of any changes to

the designed route necessitated by the discovery of buried obstructions. Survey records shall be made and submitted to the Purchaser.



131. 210 A change in direction of less than 30o, e.g. to negotiate a local obstruction, may be achieved by laying ducts along a slow radiused bend with the agreement of the Purchaser. Survey records are to be submitted. The radiused bend shall be made up of straight lengths of duct, laid within the tolerance limits for bend deflections recommended by the duct manufacturer.

131. 220 The open ends of pipework ducts shall be free from sharp edges. The

pipes shall terminate 25mm from the inner face of terminal chambers, drawpits etc and bell-mouth terminations shall be formed in the concrete or mortar.

131. 230 Where pipework ducts are built into a chamber or structure the first 3 joints

in the duct run shall be flexible joints. The first joint shall be within 300mm of the face of the structure and the second and third within 600mm of the first and second joints respectively.

131. 240 During the laying of the pipework ducts between inspection pits, a

continuous length of nylon or pigmented polypropylene draw cord of 5 kN breaking load shall be left in each duct to be used later with the cleaning mandrel.

131. 250 Pipework ducts laid under road or hardstandings shall be encased in

concrete for the length under the road/hardstanding plus an additional 1.5m on either side of the road. Details of the concrete encasement, the spacing between pipes in cluster groups, levels etc shall be shown on the Drawings.

Prior to concrete placement, all ducts and sleeves shall be inspected to ensure that they are laid correctly.

131. 260 In the proximity of foundations, pipework ducts shall be encased in

concrete. 131. 270 In open ground, each pipework duct, or cluster of ducts, shall be given a

surround of sand not less than 300mm thickness. 131. 280 The trench shall then be backfilled with suitable excavated material in

layers not exceeding 200mm and compacted. All in accordance with Section 051 of this Specification.

131. 290 Concrete identification tiles or PVC warning tapes shall be laid along with

the backfill.



Reinstatement of Surfaces

131. 295 Reinstatement of surfaces shall be as specified in Section 051 of this

Specification.

Cleaning and Identification of Ducts 131. 300 Following the backfilling of the trench the pipework ducts shall be cleaned

and proved in lengths between inspection pits and termination points. 131. 310 A mandrel shall be drawn through each duct. The diameter of the mandrel

shall be no smaller than 5 mm less than the internal diameter of the duct. The Contractor shall submit details of the mandrel to the Purchaser for agreement. A continuous PVC coated 15 gauge steel draw wire to BS 1052 shall be threaded through each duct properly secured and left for future use.

131. 320 The ends of each duct shall be plugged immediately after cleaning. Ingress

of water and/or concrete shall be prevented. 131. 330 Reinforced concrete marker posts shall be provided along the line of the

ducts at positions shown on Drawings.

Inspection Pits 131. 340 Inspection pits of brickwork, in situ or precast concrete or part plastic

construction shall be constructed to avoid the ingress of groundwater. An access cover and frame of appropriate size and type shall be built into the top slab.

131. 350 The floor of all inspection pits shall slope to a sump of size 300mm square

and 150mm deep. 131. 360 The invert of the lowest duct at the point of entry into an inspection pit shall

be not less than 150mm above the floor.

Accessible Ducts and Trenches 131. 370 Back-filling to the sides of ducts and trenches and over the cover slab of

below ground ducts shall not be carried out until the concrete has attained 75% of its characteristic strength. The back-fill and compaction thereof shall be in accordance with Section 041 of this Specification.

Pipework Duct Entry into Buildings



131. 380 Single or multiple pipework duct entries into buildings shall be constructed

to a plan tolerance of ± 25mm.

The ducts shall terminate with a socket projecting out of the top of the foundation to facilitate future extension. The duct shall have a draw wire and shall be plugged to prevent ingress of debris and water. The exposed socket shall be suitably protected against accidental damage in a manner agreed with the Purchaser.

QUALITY CONTROL

General

131. 390 The Contractor shall obtain manufacturer's product literature and material

test certificates as appropriate and submit to the Purchaser.

Inspection and Testing 131. 400 The levels and alignment of all buried service ducts shall be inspected prior

to surveying and backfilling. Particular attention shall be made when buried obstructions have to be negotiated and slow bends introduced. Record drawings showing as-built duct locations shall be made by the Contractor.

131. 410 The proving of all ducts to confirm that they are clean and have a smooth

bore shall be witnessed and that draw wires have been provided as specified prior to inserting plugs in the ends of each duct run.

131. 420 Inspections shall ensure that duct terminations into buildings or structures

are appropriate; also that flexible joints have been correctly provided as specified eg the first three joints from each inspection chamber or structure.

131. 430 All lengths of ducts which are to be protected by encasing in concrete shall

be checked to ensure the adequacy of the flexible joints.







BS 21 Specification for pipe threads for tubes and fittings where pressure-tight joints are made on the threads (metric dimensions).

BS 65 Specification for vitrified clay pipes, fittings and joints. BS 882 Specification for aggregates from natural sources for

concrete. BS 1052 Specification for mild steel wire for general engineering purposes. BS 1387 Specification for screwed and socketed steel tubes and tubulars and

for drain end steel tubes suitable for welding or for screwing to BS 21 pipe threads.

BS 3506 Specification for unplasticized PVC pipe for industrial uses. BS 3797 Specification for lightweight aggregates for concrete. BS 3921 Specification for clay bricks BS 5911 Precast concrete pipes and fittings and ancillary products. CP 312 Code of practice for plastics pipework (thermoplastic materials).




CLAUSE REFERENCE


COMMENT

131.200/210 and 400 131.390

Survey records. Material certificates.



TECHNICAL SPECIFICATION WORK GROUP: 200 : CONCRETE WORK SECTION NO: 201 TITLE: CONCRETE PRODUCTION TABLE OF CONTENTS SCOPE CONTRACTOR'S INFORMATION MATERIALS

Cementitious Materials Aggregates - Fine Aggregate - Coarse Aggregate Admixtures Water Ancillaries - Waterproof membrane - Grout and Concrete Packing - Mix Design for Grout and Packing

QUALITY CONTROL - MATERIALS

General Testing Facilities and Equipment Sampling and Testing - General - Cement - Pulverised Fuel Ash - Ground Granulated Blast Furnace Slag - Blended Cements - Aggregates



TABLE OF CONTENTS

- Admixtures - Water Frequency of Tests Quartz Mineral Hardener

WORKMANSHIP

Concrete Mix Design - General - Initial Mix Design - Trial Mixes - Production Mix Design - Alkali, Chloride and Sulphate Content Concrete Production - Batching and Mixing - Ready-Mixed Concrete Concreting - General - Transporting - Placing - Blinding Layer - Curing - Joints

QUALITY CONTROL - WORKMANSHIP

General Routine Tests - General - Concrete Strength - Test Cores - Workability - Aggregate-Alkali Reaction Testing



TABLE OF CONTENTS FORMWORK

General Formed Finishes Worked Finishes Permissible Irregularities Sample Finishes

TOLERANCES GENERAL

Construction Loads Proprietary Solutions Grouting and Filling Watertight and Water Retaining Structures Cutting Concrete Faulty Works Deviations

PRECAST CONCRETE WATER RETAINING CONCRETE GROUND BEARING CONCRETE SLABS RETAINING WALLS APPENDIX 1 BSI REFERENCES AND OTHER STANDARDS APPENDIX 2 INFORMATION TO BE PROVIDED BY CONTRACTOR



SCOPE 201. 010 This Section defines all materials and operations relating to the production

of finished concrete. Reinforcement is specified in other Sections within this Work Group.

CONTRACTOR'S INFORMATION

201. 020 The Contractor shall submit to the Purchaser, in accordance with the

requirements of the Contract, the information listed in, but not limited to, Appendix 2 of this Specification and as identified within the Clauses of this Specification.

MATERIALS

Cementitious Materials

207. 030 The term "cementitious material" refers to Portland cement or a combination

of Portland cement and Pulverised Fuel Ash (PFA) or Ground Granulated Blast Furnace Slag (GGBFS).

207. 040 Portland cements shall be ordinary to BS 12 (OPC), sulphate resisting to

BS 4027 (SRPC), rapid hardening to BS 12 (RHPC). Other cementitious materials shall be Pulverised Fuel Ash (PFA), Pozzolanic PFA (PPFA), Portland Blast Furnace Cement, High Slag Blast Furnace Cement or Ground Granulated Blast Furnace Cement to the appropriate standards as listed in Appendix 1.

201. 050 PFA combined with Portland cements on Site shall be to BS 3892 Part 1

but material complying with the Grade A requirements of BS 3892 Part 2 may be used subject to the Purchaser’s agreement.

PFA to Grade B of BS 3892 Part 2 shall only be used for unreinforced, minor items and then only subject to the Purchaser’s agreement.

Aggregates

201.110 Aggregates shall be to BS 882, hard, durable and clean and shall not be

chemically reactive. They shall not contain any deleterious material in sufficient quantity to affect adversely the strength at any age or the durability of the concrete or to cause corrosion of reinforcement.

201.120 The grading and shape of aggregates shall be such that a concrete can be



produced with the specified proportions and consistency and which will readily work into position without segregation and without the use of excessive water and which can readily be compacted into a dense impervious mass.

201.130 Separate fine and coarse aggregates shall be used and these shall conform

to BS 882. All-in aggregates shall not be used in the Works unless specifically authorised by the Purchaser.

201.140 The following tests as described in BS 812 shall be carried out as

appropriate on both fine and course aggregates:

Determination of Particle Size and Shape - Sieve Analysis Determination of Flakiness Index and Elongation Index Determination of Ten Percent Fines Values.

The flakiness index and elongation index when determined in accordance with BS 812 of each of the predominant size fractions in each single sized coarse aggregate, shall not exceed 20% and 25% by weight respectively. Fine aggregate shall not contain appreciable amounts of flaky and/or elongated material.

201.150 When tested in accordance with BS 812: Part 4 the total acid-soluble

chloride salt content for the aggregates shall not exceed the following figures:

Fine Aggregate - 0.05% by weight Coarse Aggregate - 0.03% by weight

The acid soluble sulphate salt content for the aggregates, when tested in accordance with BS 812, shall not exceed 0.25% by weight for both fine and coarse aggregates.

Notwithstanding the above figures every effort shall be made to obtain aggregates with as low a chloride and sulphate content as possible.

201. 160 The shell content (as calcium carbonate) as a percentage by weight of dry

single size aggregates shall not exceed 20% for 5 mm to 10 mm and 8% over 10 mm.

201. 170 All aggregates shall have negligible reactivity. Inspections and tests of

reactivity shall be carried out as required by the Purchaser.



201. 180 The water absorption of aggregate shall not exceed 2.5%.

Fine Aggregate 201. 190 The fine aggregate shall be from an agreed source and shall be sharp and

free from clay, organic matter and other impurities. The gradation of fine aggregate shall be in accordance with gradings C or M of BS 882 Table 4 and the percentage by weight passing the 300 micron sieve shall not exceed 50%.

The clay, silt and fine dust content shall not exceed the appropriate percentage stated in BS 882 :Table 6 by volume when using the field settling test given in BS 812 or such other equivalent test as agreed with the Purchaser.

The amount of hollow shells which are likely to form voids present in material retained on a BS No. 7 sieve determined by direct visual separation shall not exceed 3% weight of the entire sample.

Coarse Aggregate

201.210 The coarse aggregate shall be from an agreed source shall be clean, free

from shell, sand, clay, mica shale, quarry refuse, dust, organic matter and other impurities. The stone shall not be thin or flaky.

201.220 The amount of material passing a BS No. 200 (75 micron) sieve in each

size of the single-sized coarse aggregate, determined in accordance with BS 812 (Decantation Method) shall not exceed 1% by weight.

201.230 The Aggregate Impact Value, determined in accordance with BS 812 and

using standard 14mm to 10mm test sizes, shall not exceed 30 except where specified minimum compressive strength or characteristic strength of the concrete is 50 N/mm2 or higher in which case the AIV shall not exceed 25. Admixtures

201. 260 Admixtures shall be to BS 1014, BS 4887 and BS 5075. 201. 270 The Contractor shall submit to the Purchaser details of admixtures he

proposes to use in advance of their use. 201. 280 Admixtures containing calcium chloride or chloride salt shall not be used.



201. 290 Admixtures shall not contain chloride ions in excess of 2% by weight of the admixture or 0.03% by weight of the cementitious material content of the concrete mix.

201. 300 Admixtures may only be agreed if the Contractor demonstrates to the

satisfaction of the Purchaser that they do not impair the properties of finished concrete in terms of strength, shrinkage, bleeding or any other factor.

201. 310 Admixtures shall be suitable for use in concrete containing PFA or GGBFS

as appropriate. If the use of admixtures is permitted they shall be used strictly in accordance with the manufacturer's instructions and any method statement agreed with the Purchaser after site trials have been carried out.

201. 311 For air-entrained concrete the air-entraining agent shall be added at the

mixer, by an apparatus capable of dispensing the correct dose within the tolerance for admixtures given in BS 5328 : Part 3 and to ensure uniform distribution of the agent throughout the batch during mixing.

Water

201. 320 Water which is to be used for mixing concrete, curing concrete and any

other operation affecting steel or formwork which could subsequently come into contact with fresh concrete shall at all times comply with the requirements of BS 3148. It shall be fresh, clean, potable and free from any substances that may be deleterious to concrete or steel.

201. 330 The ph of water used in concrete work shall be not less than 5.0 and not

more than 8.0. 201. 340 Under no circumstances shall seawater be used for mixing or curing concrete.

Ancillaries

Waterproof Membranes

201. 360 Waterproofing underlay membranes shall consist of waterproof paper to BS

1521 Class B or impermeable plastic sheeting.

Grout and Concrete Packing 201.370 Ordinary Portland cement, aggregate, water and admixtures shall be to the

requirements of Section 201. 201.380 Coarse aggregate shall be 10mm single-size and fine aggregate shall be

within the limits for medium grading.



Mix Design for Grout and Packing

201.390 The characteristic strength of the grout or concrete shall be not less than

that of the concrete in the associated foundation or structure of 20N/mm2 whichever is the greater.

201.400 Uncongested areas shall be filled with concrete having the mix proportions

4:5:7 cement: fine aggregate: coarse aggregate by weight. 201.410 Where the smallest clear dimension of the void to be filled is less than

50mm grout having the mix proportions 1:2 cement: fine aggregate by weight shall be used.

201.420 The water cement ratio shall be kept to the minimum compatible with

adequate workability.

QUALITY CONTROL - MATERIALS

General 201.430 To ensure that requirements in respect of materials quality are met, the

manufacturers and suppliers of materials in the Works shall implement a full programme of Quality Control in respect of all aspects of concrete materials production.

201.440 The Contractor shall submit the following information to the Purchaser for

his agreement at least two weeks prior to the Contractors proposed use of materials in the concrete works, for each type and source of cementitious material, aggregates, admixtures and water, and any other material proposed for inclusion in the Concrete works:-

Material Description and Details of Proposed Use Name of supplier and source Is Supplier a BSI registered firm BS No and Classification Test Certificates.

201.450 The test certificates provided prior to agreement shall indicate the

applicable material test results for at least the preceding 12 month period and shall include the following where readily available from the supplier:

Cementitious Material

Chemical Constituents



Alkali Content Sulphate Content (expressed as S03) Chloride Content Loss on Ignition Insoluble Residue Fineness Soundness Initial Setting Time 3 day and 28 day Compressive Strength Aggregates

Petrographic description Sieve Analysis Clay/Silt/Dust Content Specific Gravity Water Absorption Flakiness Elongation Drying Shrinkage Mg SO4 Soundness Chloride Content Sulphate Content AIV 10% fines LA Abrasion Alkali Reactivity Shell content

Water

As required by BS 3148

Admixtures

Certification to demonstrate that admixture complies with the relevant British Standard.

Testing Facilities and Equipment 201. 460 The Contractor shall provide a suitably equipped testing laboratory for

conducting tests on concrete and its constituent materials. This may be an independent organisation or, alternatively, the Contractor may set up his own laboratory facilities on site. The laboratory and equipment provided



shall be to the requirements of the Purchaser. Full details shall be submitted to the Purchaser.

201. 470 All equipment shall be calibrated by an authority agreed by the Purchaser to

the appropriate British Standard at the commencement of the Contract and subsequently at intervals of 6 months, or lesser period if so directed by the Purchaser. All certificates shall be retained by the Contractor as record documents.

201. 480 Sufficient laboratory staff and equipment shall always be available to

undertake the materials and concrete testing requirements of this Specification.

Sampling and Testing

General

201. 490 The Contractor shall sample and test materials as they are used in the

Works. Samples shall whenever possible be obtained from materials on the Site.

201. 500 The results of all tests or certificates shall be submitted to the Purchaser

with a minimum of delay on completion of a test. 201. 510 The Purchaser shall inform the Contractor of any tests which he intends to

observe. The Contractor shall give the Purchaser 24 hours notice of the commencement of such tests.

Cement

201. 520 Sampling and testing shall be to both BS 4550 and EN196. 201. 530 The Contractor shall obtain manufacturer's certificates for each delivery of

cement, and shall retain these as record documents. These certificates shall include the results of tests verifying all the requirements of BS 12, together with a recent analysis of the main chemical constituents.

201. 540 The Contractor shall give immediate notice of any significant change which

may increase the monthly mean alkali content by more than 0.2% above the previous monthly mean, or give a monthly mean greater than 0.6%. A revised mix design for any concrete which may be affected by the increased alkali content shall be submitted to the Purchaser for agreement with notification of the change.



PFA

201. 550 Sampling and testing shall be to BS 3892. 201. 560 The Contractor shall obtain the supplier's certificates for every delivery of

PFA and shall retain these as record documents. The certificates shall state the results of tests verifying all the requirements specified in BS 3892.

GGBFS

201. 570 Sampling and testing shall be to BS 6699. 201. 580 The Contractor shall obtain the supplier's Certificates for every delivery of

GGBFS and retain these as record documents. The certificates shall state the results of tests verifying all the requirements specified in BS 6699.

Blended Cements

201. 590 Where cement is supplied already blended with PFA or GGBFS, sampling

and testing shall be to both the appropriate British and European Standards and Codes for the individual constituents and also cover the tests required by any British Standard Specifications relating to the final, blended product.

201. 600 The Contractor shall obtain the supplier's certificates for every delivery of

blended cement and retain these as record documents. The certificates shall state the results of tests verifying all the requirements of the appropriate British and European Standards for the individual constituents and also any British Standards relating to the blended product.

Aggregates

201. 610 Sampling and testing shall be to BS 812 unless otherwise stated in this

specification.

Admixtures 201. 620 The Contractor shall obtain, for every delivery of admixture, the

manufacturer's test certificates of conformance with the relevant British Standard and ASTM C494 which he shall retain as record documents.

Water



201. 630 Water shall be tested to BS 3148 if instructed by the Purchaser and the results submitted to the Purchaser.

Frequency of Tests

201. 640 The minimum frequency of testing by the Contractor of site batched

materials shall be as follows:

Weekly:- Cement, PFA and GGBFS: fineness alkali content loss on ignition

Aggregates: sieve analysis

clay, silt and dust content organic impurities shell content

Monthly:- PFA and GGBFS: chloride and sulphate content

Aggregates: chloride and sulphate content

oven dry density moisture content flakiness elongation

Three Monthly:- Coarse Aggregate: water absorption

aggregate crushing value MgSO4 soundness

As Instructed by the Purchaser:- Water

These tests are additional to those by the supplier.

The first test of each kind shall be performed and results reported to the Purchaser at least one week before any materials of that source and type are incorporated into the works.

201.645 Quartz Mineral Hardener

Quartz mineral hardener shall be a proprietary coating, of a type as agreed by the Purchaser, (Polyquartz by Pieri or similar), resistant to impacts and



abrasion, such as quartz mineral hardener applied at a rate of 4kg/square metre, levelled and travelled as recommended by the manufacturer. Surface hardener shall be applied to all heavily trafficked areas, such as the unloading dock, clinker storage area.

WORKMANSHIP

Concrete Mix Design

General

201. 650 The Contractor shall design the proportion of each concrete mix in

accordance with the recommendations of BS 5328 to obtain concrete of a homogeneous structure which can be worked into the corners and angles of the formwork and around reinforcement without segregation of the material or excessive bleeding of free water at the surface and shall also, on striking of formwork present a uniform face free from honeycombing and crazing. When hardened the concrete shall have the required strength the maximum density and low porosity.

The final proportions of cement aggregates and water shall be such that the weight of cement used is the least amount which will produce concrete complying with the Specification.



Evidence should be submitted to the Purchaser for each class of concrete showing the intended workability, the proposed mix proportions and manufacturing method with proportions and manufacturing method will produce concrete of the required quality.

201. 660 The mix design shall be appropriate to the exposure condition as defined in

table 5 of BS 5328. The minimum grade of concrete shall be as defined as listed below:-

Condition of Exposure

Type of Concrete

Minimum Grade

Mild

Unreinforced non-structural Unreinforced structural Reinforced Prestressed

C10 C20 C30 C35

Moderate

Unreinforced non-structural Unreinforced structural Reinforced and prestressed

C10 C30 C35

Severe

Unreinforced Reinforced and prestressed

C35 C40

Very severe

All

C40

Most severe

Unreinforced Reinforced and prestressed

C45 C50

Abrasive

All

C45

201. 670 The following mix design limits shall be used in the Works:

Concrete

Grade

Max. W/CM

Ratio

Min.

Cementitious Material Content

kg/m3

Max. PFA Content %

Min. PFA Content (if PFA is used) %

C10

0.5

160

50

30

C15

0.45

200

50

30

C20

0.45

220

40

30

C30

0.45

275

40

30

C35

0.45

300

40

30

C40

0.45

325

40

30

C45

0.45

350

40

30

C50

0.45

400

40

30



The cementitious material content of any mix shall not exceed 550 kg/m3.

GGBFS contents shall be agreed with the Purchaser.

Adjustments to minimum cement content should be made for aggregates of nominal maximum size other than 20 mm in accordance with table 8 of BS5328.

For concrete made with normal-weight aggregate and used in foundations to low rise structures in non-aggressive soil conditions a minimum grade of C20 may be used provided the cement content is not less than 220kg/m3

Where concrete is subject to freezing whilst wet, air entrainment should be used. In the case of air entrained concrete the grade may be reduced by 5 and the % of air entrainment shall be 4½% ± 1½%.

201. 680 The ̀ Design Margin' shall be the difference between the design strength of

the concrete and the characteristic strength. 201. 690 The "Current Margin" shall be the difference between the statistical mean

of cube test results and the characteristic strength.

Initial Mix Design 201. 700 Details of initial mix designs including the nature and source of all materials,

proposed quantities of each ingredient per cubic metre of compacted concrete and trial mix proposals for each mix shall be submitted to the Purchaser.

Trial Mixes

201. 710 Trial mixes shall be produced under full scale production conditions using

representative samples of cement and aggregates. Three separate batches shall be produced each on a separate day. The workability of each batch shall be determined and at least 6 cubes shall be made from each batch, three for test at 7 days and three for test at 28 days.

201. 720 The trial mix proportions will be accepted if the average strength of the nine

cubes tested at 28 days is not less than 3.5N/mm2 below the target mean strength. The trial mix may be agreed on the basis of 7 day results provided the Purchaser is satisfied at the likely rate of gain of strength from 7 to 28 days. If the range of the strength of the three cube results in any one batch should exceed 15% of the average of that batch the trial mixes shall be repeated.



201. 730 The Contractor shall take precautions to ensure that the agreed mix proportions are maintained in the concrete that is actually deposited in the Works. The Purchaser may require additional trial mixes to be made if any significant changes are made in the materials or in the proportions of materials used.

The quantity of water used in mixing the concrete shall be controlled by an agreed water measuring device and shall be sufficient, but not more than sufficient, to produce a dense concrete of adequate workability for the different parts of the Works. The water content of the mix shall be maintained within the limits of ±5 litre/m3 of the quantity determined by the trail water content of aggregate. The Contractor is to maintain on Site a suitable apparatus for checking the water content of the aggregate as and when directed by the Purchaser.

Concrete will only be accepted for placement if its workability is within the following limits at the time of placement. Slump test ± _ of the trial mix mean or 25mm whichever is the lesser value.

Compacting Factor ±0.03 of the trial mix mean.

The slump of the concrete will be determined from samples taken from the mixed concrete just before the concrete is placed in the work. The slump tests and/or compacting factor tests shall be carried out in accordance with BS 1881

Production Mix Design

201. 740 The Contractor shall carry out a statistical analysis of cube test results at 28

days for each mix to determine the current margin. The analyses shall be updated weekly and submitted to the Purchaser.

201. 750 Analyses shall commence when the results of cube tests on 40 batches of a

mix are available.

The current margin shall be calculated as follows:

Current margin = 1.64 [# (x - x)2]0.5

[ n - l ]0.5

where n = number of samples x = strength of individual test cubes x = mean strength # = sum of calculated values



For compliance of results the current margin shall not be less than as follows:

a) where the results of tests on 40 batches are considered, 1/3 of the

characteristic strength for mixes of less than 20 N/mm2 in strength or 7.5 N/mm2 for mixes of 20 N/mm2 and above in strength.

b) where the results of tests on 100 or more batches are considered,

1/6 of the characteristic strength for mixes of less than 20 N/mm2 in strength or 3.75 N/mm2 for mixes of 20 N/mm2 and above in strength.

Alkali, Chloride and Sulphate Content

201. 760 The total mass of equivalent alkali in a mix shall not exceed 3.0 kg/m3 of

concrete. This mass shall be the sum of the equivalent alkali contribution from the constituent parts of the mix including all cement, chloride in aggregate, PFA, GGBFS, water and admixtures.

201. 770 The equivalent alkali content contributed to a mix by the Portland cement,

PFA, GGBFS and aggregates shall be calculated by a method to the agreement of the Purchaser.

201. 780 The chloride ion content shall not exceed 0.30% for 95% of test results with

no result greater than 0.4%. 201. 790 The total sulphate content expressed as sulphuric anhydrate (SO3) of the

mix shall not exceed 4% by weight of the cement.

Concrete Production

Batching and Mixing 201. 800 Where the Contractor intends to produce concrete on the Site the location

for the plant shall be agreed with the Purchaser. 201. 810 The batching equipment shall be fitted with an accurate mechanism for

weighing separately the cement, PFA, GGBFS fine aggregate and coarse aggregate. Alternatively cementitious material may be measured by using a whole number of bags in each mix (split, damaged or partly full bags must not be used).



The water may be measured by volume or by weight. All measuring devices shall be constructed so that the correct quantities will be delivered automatically. The equipment shall have an automatic system that records the amount of each constituent material in each batch.

201. 820 The accuracy of the measuring equipment shall be within + 2% of the

quantity of cement, PFA, GGBFS, water, total aggregates or admixtures being measured.

201. 830 The scales of all weigh batching plant and all liquid dispensers shall be

zeroed daily and calibrated at intervals not exceeding one week. The Contractor shall provide all weights, materials and labour for calibration and tests and shall retain all certificates as record documents.

201. 840 Frozen or frost covered materials shall not be used. 201. 850 The mixing equipment shall be of a type and design agreed by the

Purchaser and shall combine the constituents of the mix within the mixing time into a uniform mass.

201. 860 The mixing time shall be not less than that used by the manufacturer in

assessing the performance of the mixer. 201. 870 Control interlocks shall be provided on the mixing equipment to ensure that

a batch cannot be discharged until the mixing time has elapsed. The entire batch shall be discharged without segregation before the mixer is recharged.

201. 880 Separate containers and measuring devices shall be used for admixtures. 201. 890 Gauge boxes may only be used for batching aggregates with the

Purchaser's prior permission. 201. 900 The method of releasing the water into the mixer shall be such that the full

measured quantity is discharged in one operation and the flow is stopped automatically by a valve or syphon arrangement only when the full quantity of water has been released. Arrangements which allow the discharge of partial quantities of mixing at the discretion of the mixer driver will not be permitted.

201. 910 The amount of concrete mixed in any one batch shall not exceed the rated

capacity of the mixer. 201. 920 The whole of the mixed batch shall be removed from the mixer before

materials for a fresh batch enter the drum.



201. 930 The Contractor shall ensure that the mixing efficiency of the equipment is not impaired by the build-up of cement and mortar on the mixing drum blades. On cessation or work, including all stoppages exceeding 15 minutes the mixer and all handling plant should be washed out with clean water.

201. 940 The first batch of a production run shall contain 15% less coarse aggregate

in order to compensate for the coating of the interior of the mixer.

Ready-Mixed Concrete 201. 950 The supply and delivery of ready mixed concrete shall comply with the

recommendations of BS 5328.

Prior to obtaining concrete from a ready-mixed supplier the Contractor shall submit the following information:-

Ready Mixed Concrete Supplier

Location of Plant

Details required under Clause [201.440] and [201.450]

Standard Deviation (strength) currently achieved by Plant (N/mm2)

Design Standard Deviation (strength) (N/mm2)

Target Mean Strength (N/mm2)

Total chloride and sulphate ion content of concrete (%)

Total equivalent alkali content of concrete (Kg/m3)

201. 960 The Contractor shall arrange for the supplier to provide the facilities stated

in Clause 13.1 of BS 5328. 201. 970 A ticket shall accompany each delivery and shall contain the following

information:

Name or number of ready-mixed concrete depot

Serial number of ticket

Date



Registration number of delivery vehicle

Name of purchaser

Name and location of project

Concrete mix designation

Cement content

PFA content

GGBFS content

Free water/cementitious material ratio

Workability

Type of cement

Proportions or quantities of PFA or GGBFS

Nominal maximum size of aggregate

Type name and quantity of admixtures, if included

Quantity of concrete in cubic metres

Time of loading Tickets shall be retained as record documents by the Contractor.

201. 980 No water shall be added to the mix after it has left the ready mixed concrete

plant. Each delivery shall be tested at the site for workability.

CONCRETING

General 201. 990 Materials used in the handling and placing of concrete shall not be

manufactured from or contain materials likely to affect the concrete. 201.1000 The Contractor shall submit to the Purchaser, the following information:

(a) Drawings showing the arrangement of shuttering, supports and



construction joints.

(b) A programme showing the sequence of concrete pours.

(c) A statement describing his procedures for placing, consolidating, curing, protecting and finishing concrete in all types of weather.

201.1010 The Contractor's proposals for concreting during cold, hot or wet weather or

underwater shall take into account the following requirements:

Cold

(a) No materials below the temperature of 2oC shall be used for concreting and unless special heating arrangements are made to the agreement of the Purchaser, concreting shall not be carried out until the shade temperature has reached 1oC on a rising thermometer nor shall it be continued on a falling thermometer below a temperature of 3oC. Fresh concrete shall not be allowed to come into contact with frozen reinforcement and formwork.

(b) The Contractor shall protect all newly placed concrete from frost

and he will be required to cut out and replace, at no cost to the Employer, any concrete damaged by frost.

(c) Methods of heating employed shall not impair the quality of the

concrete. No salts or chemicals shall be used to prevent freezing.

(d) If concreting is permitted by the Purchaser to be carried out when either the air or ground temperature is below 2oC the concrete shall be preheated at no extra cost to the Employer in order that the temperature of the concrete when placed shall not be below 21oC

e) In no case shall the temperature of the mixed concrete be less than

7 or greater than 38oC. The cement shall not be heated. Mixing water shall not be heated above 60oC.

f) All equipment used for concreting such as mixers and barrows and

all formwork shall be warmed by steam or hot water before use.

g) All preheated concrete shall be protected after placing with suitable

coverings to prevent damage by frost. Particular care shall be exercised when steel formwork is used.

Hot



(a) The temperature of concrete at time of placing shall not exceed

30oC.

(b) The Contractor shall maintain records of the temperature at the time of placing.

Wet

(a) Concrete shall not be placed during heavy rain, sleet or snow

without adequate protection.

(b) Newly finished concrete surfaces shall be protected.

(c) The workability of concrete shall be maintained within the agreed limits.

Underwater

a) Concrete to be placed underwater shall be Class C40 placed by

tremie unless otherwise agreed and shall not under any circumstances be discharged freely into the water.

b) The concrete shall be placed in such a manner that segregation

does not occur.

c) During and after concreting care shall be taken to avoid damage to the concrete from pumping and dewatering operations.

d) The hopper and pipe of the tremie shall be clean and watertight

throughout. The pipe shall extend to the base of the boring and a sliding plug or barrier shall be placed in the pipe to prevent direct contact between the first charge of the concrete in the pipe of the tremie and the water. The pipe shall at all times penetrate the concrete, which has previously been placed, and shall not be withdrawn from the concrete until completion of the concreting. At all times a sufficient quantity of concrete shall be maintained within the pipe to ensure that the pressure from it exceeds that from the water. The internal diameter of the pipe of the tremie shall be not less than 150mm for concrete made with 20mm aggregate and not less than 200mm for concrete made with 40mm aggregate.

It shall be so designed that the internal face of the pipe of the tremie shall be free from projections.



e) Concrete shall only be placed underwater with the Purchaser's

agreement and where in his opinion it is not possible to place concrete in the dry.

201.1020 All surfaces on which concrete is to be placed shall be clean with no debris

or free water. 201.1030 The Contractor shall give such period of notice as is required by the

Purchaser of his intention to commence any concreting and shall submit at the same time a record of his inspection of completed preparatory works. Transporting

201.1040 The concrete shall be discharged from the mixer and transported to the

Works by means that shall be agreed by the Purchaser and which shall prevent contamination, segregation or loss of ingredients, and ensure that the concrete is of the required workability at the point and time of placing.

201.1050 Concrete that has been mixed remote from the Works shall be transported

in truck mixers or agitators. The concrete shall be continually agitated during transportation and until discharge. Mixing and transporting shall be in accordance with BS 5328.

201.1060 The drum of the truck agitator or truck mixer shall be completely clean and

empty before it is filled with concrete. Trucks shall not be loaded in excess of the manufacturer's rated capacity, which shall be displayed on the vehicle in terms of volume of mixed concrete. Trucks shall be discharged within one hour after the introduction of the water to the cement unless a longer time is authorised by the Purchaser.

201.1070 The concrete shall be placed in the form as soon as possible after mixing

and before the initial set of the concrete has started. The Purchaser will from time to time specify the maximum time between the mixing of the concrete and its placement in the form and no concrete shall be placed in the Works after this period has elapsed.

201.1080 The Contractor's attention is drawn to the need to ensure that every

precaution is taken to minimize the loss of workability of the concrete during transit. Concrete should be transported from the mixer to the forms as quickly as conditions will allow and the work streamlined and co-ordinated so that delays are eliminated.

201.1090 Each consignment of concrete shall be accompanied by a docket giving the

class of concrete and the time when the mixing water was added.



Placing

201.1100 Every delivery of concrete to the Site must be sampled and checked for workability by the slump or compaction factor method prior to discharge into the work. The Purchaser will generally require to witness these tests. Concrete outside the workability limits will be rejected. Also, the concrete shall be rejected and not placed in the works if the initial set has taken place in any part of the batch or if the Purchaser considers it to be otherwise in an unsuitable condition.

201.1110 The Contractor shall submit and obtain the Purchaser’s agreement for all

details of his proposed method of placing and curing the concrete before commencing work. If required, the Contractor should be prepared to demonstrate, or otherwise prove, to the Purchaser the adequacy and effectiveness of his proposed method.

201.1120 Concrete shall not be placed in the Works unless the Purchaser is present

and the fixing of all formwork and reinforcement has been completed and agreed by the Purchaser. All surfaces shall be free of standing water.

201.1130 The concrete shall be deposited as nearly as possible in it final position,

and shall be placed in such a manner as to avoid segregation of the concrete and displacement of the reinforcement, waterbars or formwork.

201.1140 The concrete shall be consolidated by high frequency mechanical vibrators

agreed by the Purchaser, in such a manner as to obtain complete compaction without segregation or excessive laitence or the formation of "cold" joints. Particular attention should be made to ensure that concrete is thoroughly worked into the corners of the formwork and around all reinforcement, waterbars and embedments.

201.1150 Contact between the vibrators and reinforcement or formwork shall be

avoided and on no account shall vibration be used for the purpose of distributing concrete horizontally.

201.1160 Vibrators shall operate at a frequency of not less than 5,000 cycles per

minute.

Blinding Layer 201.1170 All horizontal or sloping surfaces of reinforced concrete that bear on the

ground shall be protected by a layer of blinding concrete 75mm thick. 201.1180 The Contractor shall place the blinding layer of concrete in such a way, and



at such a time, as to ensure that the exposed surface of the ground on which the blinding layer of concrete is to be placed does not deteriorate after excavation through exposure to weather, traffic or other reasons and the method of securing this shall be to the satisfaction of the Purchaser. Curing

201.1190 All concrete shall be adequately cured and protected from the harmful

effects of sunshine, drying winds, rain or running water. 201.1200 The Contractor shall be aware of the importance of adequately curing the

concrete particularly during the early stages of hardening. 201.1210 All exposed surfaces shall be protected immediately on completion of

placing and compaction of the concrete. All exposed surfaces of the concrete shall be kept moist by means of wet hessian or similar absorbent material, and ponding. The surface of the concrete shall be protected by application of an agreed curing membrane until the concrete has set sufficiently to take the weight of coverings.

201.1220 All shutterings shall be loosened as soon as possible and provision made

for curing water to run down inside them. 201.1230 Timber formwork covering the concrete shall be covered and moistened

with water at frequent intervals to keep it from drying out during the curing period.

201.1240 The wet curing shall continue for minimum of 7 days. 201.1250 All concrete shall be protected from anything which may interfere with the

process of setting or cause damage before the concrete has set.



201.1260 Samples of concrete being placed in the Works shall be taken and 150mm

test cubes made, in metal moulds, as and when directed by the Purchaser's Appointed Representative. In general the Purchaser will require 3 No. cubes to be made for each 40m3 of concrete in a pour and a minimum of 3 cubes from each pour. The slump test and/or compacting factor test will be required for each set of test cubes.

201.1270 The Contractor shall ensure that the method and period of curing of the

concrete achieves the following conditions:

a) sufficient water retention in the concrete to ensure full hydration of the cement;

b) adequate resistance to weathering and abrasion;

c) control of plastic cracking by regulating evaporation from surfaces;

d) control of thermal cracking by regulating temperature differentials

within the concrete to a maximum of 20oC

The Purchaser may require the Contractor to demonstrate that thermal gradients are acceptable.

201.1280 Curing measures shall commence within 30 minutes of completion of a

concrete pour. 201.1290 All surfaces shall be cured and protected for the minimum period shown in

CIRIA Report 67 for the appropriate combination of cement, curing conditions and temperature of concrete. During this period the surface temperature of the concrete shall not fall below 5°C.

201.1300 Water spraying or wet coverings shall not be used until the concrete

achieves a strength of 5N/mm2 or in freezing conditions.

Joints 201.1310 The Contractor shall submit to the Purchaser’s Appointed Representative

details of the type and location of all construction joints he wishes to make. In the case of the principal items of concrete work, these proposals will be regarded as major Temporary Works and sufficient Drawings, covering the whole structure must be submitted in advance of the start of the work to enable the complete concreting plan to be accepted.

201.1311 All construction joints are to be located and designed prior to the element of work being constructed on site. No day joints will be permitted unless



previously designed and agreed. 201.1320 In addition to the foregoing, the Purchaser’s Appointed Representative shall

be empowered to require the inclusion of construction joints not previously intended by the Contractor; such instructions will be issued in time for inclusion with the associated formwork.

201.1330 All construction joints will normally be required to be keyed or toothed and

four clear days allowed between adjacent pours. 201.1340 Except for paper joints, the whole surface of concrete which has set shall

have been thoroughly roughened and cleaned of all loose and foreign matter and laitance before further concrete is placed. Wherever practicable, as at horizontal joints, laitance shall be removed whilst the concrete is still green so as to expose the tops of the larger aggregate particles without undue erosion of the mortar. Where concrete already deposited has set but not set hard, laitance shall be removed and the surface roughened by wire brushing and washing, care being taken not to disturb the underlying mass. Where the concrete first poured has set hard, any skin or laitance shall be removed and the surface roughened by hammering with an agreed pattern, power operated, "bush" hammer followed by wire brushing to remove all loose particles.

When carrying out this method of preparation, care shall be taken to avoid breaking off the arises of the joint face or shattering or loosening particles of coarse aggregate exposed.

201.1350 Immediately before depositing fresh concrete, the face of the joint shall be

thoroughly washed after which the excess water shall be removed. The fresh concrete shall be forced hard on to set faces of concrete by means of compacting and vibrating tools.

201.1360 Free joints to allow for expansion, contraction or shrinkage shall be formed

at positions appropriate to the design of the structure. 201.1370 Joint fillers and sealing compounds shall be of agreed manufacture, and

used in accordance with the maker's instructions as appropriate to the type of joint, vertical, inclined or horizontal.



QUALITY CONTROL WORKMANSHIP

General 201.1380 Tests on concrete shall be to BS 1881. 201.1390 The Contractor shall safely retain all test reports, certificates and records for

tests required by this specification or at the Purchaser's request. He shall provide copies to the Purchaser when so requested. Routine Tests

General

201.1400 The Contractor shall maintain a record showing where the concrete related

to each set of test results is placed in the Works. 201.1410 Test reports relating to a concrete mix, the design of which has been varied

with the Purchaser's agreement, shall carry a suffix letter added to the mix designation.

201.1420 Samples of concrete shall generally be taken at the point of discharge from

the mixer. In the case of ready mixed concrete, the samples shall be taken at the point of discharge from the delivery vehicle.

Concrete Strength

201.1430 Samples of concrete being placed in the Works shall be taken and 150mm

test cubes made, in metal moulds, as and when directed by the Purchaser's Appointed Representative. In general the Purchaser will require a sample for each 40m3 of concrete in a pour and a minimum one sample from each pour. The slump test and/or compacting factor test will be required for each set of test cubes.

201.1435 Three 150mm cubes shall be cast from each sample and tested to

determine the density and compressive strength as follows:

(a) one cube shall be tested at 7 days. (b) two cubes shall be tested at 28 days.



201.1440 Concrete shall be assumed to have achieved its characteristic strength

when, at 28 days:

(a) the average strength determined from any group of four consecutive test results exceeds the characteristic strength by: 3N/mm2 for concrete having a characteristic strength of 20N/mm2 and above. 2N/mm2 for concrete having a characteristic strength of less than 20N/mm2.

(b) the strength determined from any test result is not less than the

characteristic strength minus 3N/mm2 for concrete having a characteristic strength of 20N/mm2 and above and 2N/mm2 for concrete having a characteristic strength less than 20N/mm2

201.1450 The quantity of concrete represented by any group of four consecutive test

results shall include the batches from which the first and last samples were taken together with all intervening batches. A test result failing to comply with Clause [201.1440 (b)] shall represent only the batch from which the sample was taken.

201.1460 The Contractor shall prepare and test at his own expense additional

concrete cubes where he requires to demonstrate to the Purchaser that a concrete element has achieved a particular compressive strength after a period other than those specified for routine tests. Such cubes shall be cured under the same conditions as the related element.

Test Cores

201.1470 When so required by the Purchaser the Contractor shall drill cylindrical

cores from concrete in the Works and shall supply to the Purchaser fully detailed reports thereon with photographs all in accordance with the procedure specified in BS 1881. Testing of cores shall be carried out by an agreed laboratory.

201.1480 The Contractor shall be responsible for the cost of cutting and testing cores

where these are required to satisfy the Purchaser that concrete complies with the Specification.



Workability

201.1490 The results of tests for workability shall be within the following limits

appropriate to the method of assessment and value agreed by the Purchaser.

Slump: Trial mix mean slump ±33% or 25mm

whichever is the lesser.

Compacting Factor: Trial mix mean CF ±0.03% Alkali - Aggregate Reaction Testing

201.1500 Samples from each class of concrete in production shall be tested for

potential alkali-aggregate reaction by casting into prisms of dimensions not less than 200 x 75 x 75mm. For each concrete mix to be tested, one prism shall be made using mix constituents and proportions identical to those used in the works and a second prism made from concrete with its alkali content artificially raised to 6kg/m3 equivalent sodium oxide by the addition of potassium hydroxide. The prisms shall be fitted with measuring points such that change in length can be measured at intervals during storage in conditions of 100% R.H. and 38 ± 1°C.

Sample storage and measurement shall be as described in clause 11 of draft BS 812 Part 123.

In the event that the expansion of the prisms exceeds 0.05%, the Purchaser shall immediately be informed.

As an alternative to the prism test specified above, the Contractor may perform mortar-bar tests to ASTM C227-81.

FORMWORK

General

201.1510 Formwork shall be to BS 5975, BS 8110 and Technical Report 13 of the

Concrete Society and the Institution of Structural Engineers.



201.1520 The formwork shall be in every way adapted to the structure and to the

required finish of the concrete. It shall, unless otherwise stated, be made either of sound and seasoned timber wrought and thicknessed where required and of sufficient thickness, or of treated plywood or other agreed material suitably supported.

201.1530 The formwork shall be fixed in perfect alignment and securely braced so as

to be able to withstand deflection, displacement or movement of any kind, the weight and pressure of the moist concrete and the weight and movements of men materials and plant.

201.1540 The supporting struts to formwork shall be adjusted and fixed in position by

suitable means and where necessary placed on timber bearers to prevent them from sinking into the ground or from causing damage to finished work.

201.1550 Where it is necessary to use spacers or ties through a wall for supporting

the shutter above, such spacers or ties shall be of agreed pattern. The holes left in the concrete shall be neatly pointed with an agreed expanding grout as soon as the formwork is stripped.

201.1560 Concrete shall not be placed against vertical or inclined blinded earth faces

in lieu of formwork without the agreement of the Purchaser. 201.1570 Before any concrete is placed all formwork shall be carefully examined and

cleaned out, and the inside face shall be treated with an agreed mould oil, which must not come into contact with the reinforcement or be allowed to collect in the bottom of the formwork. Upon every occasion on which the formwork is stripped it shall be thoroughly cleaned and oiled, if necessary before re-use.

201.1580 The responsibility for the removal of any formwork after concreting rests

with the Contractor. Formwork shall be removed without causing damage or excessive deflection to the concrete.

The minimum time which shall elapse between pouring concrete and removal of formwork, shall not be less than that required for the concrete to achieve a minimum compressive strength of 10N/mm2 or twice the stress to which the member will be subject at the time of striking, whichever is the greater.

The work of removing such formwork or support shall be carried out under



the personal supervision of a competent Foreman in the Contractor's employment. The Contractor shall be responsible for any injury to the work and any damage caused by or arising from the moving or striking of formwork or supports.

201.1590 The Contractor shall submit to the Purchaser, if required, his formwork

design calculations. 201.1600 Formwork and supports shall resist all loads to which they will be subjected

without detriment to the finished concrete. 201.1610 Where the finished surface of concrete is at a slope greater than 35° a top

shutter shall be used. 201.1620 A 20 mm x 20 mm chamfer shall be formed on all arises exposed in the

finished work except where this would result in a loss of support to masonry work.

201.1630 Joints, including those in form linings and between forms and completed

work, shall be constructed to prevent loss of grout. 201.1640 Formwork shall be in sound condition, clean and free of concrete remnants.

Portion of shutters at the level of each lift shall be removable to ensure a thorough clearing out of any rubbish.

201.1650 Release agents shall be applied to formwork surfaces in contact with

concrete using the minimum necessary to obtain a clean release. Any liquid applied to the formwork surfaces in contact with concrete shall be compatible with any finish to be applied to the concrete and shall not contaminate the reinforcement, embedded items or hardened concrete.

201.1660 No metal part of any fixing device for securing forms shall remain within the

concrete cover.

Formed Finishes 201.1670 A smooth surface is required to all exposed surfaces of the concrete work.

Surfaces shall be true and free from imperfections. Every endeavour must be made to obviate the necessity for surface treatment of the concrete after the removal of moulds. For this purpose the formwork used for such surfaces shall be wrought and thicknessed boards of a properly seasoned timber accurately and closely fixed together or lined, laminated plywood formwork or other agreed material.

201.1680 Before the formwork is removed it shall be tapped on its exterior surface with a light hammer or power operated vibrator in order as far as possible to



obviate the necessity for surface treatment after removal of the formwork. Directly after the formwork has been removed all broken corners and such parts of the surface where the face has been removed, shall be made good with suitable cement mortar to bring same to the general level of the surrounding surface. All exposed surfaces shall be thoroughly rubbed down, if necessary with power operated carborundum grinders, to obtain alignment of the surface, All areas shall be formed with a 50mm chamfer unless otherwise shown.

201.1690 Type F1. As obtained with closely-jointed sawn boards. Voids, superficial

honeycombing and tie holes shall be made good with mortar to Clause [201.1680].

201.1700 Type F2. As obtained with forms designed to produce a dense smooth

finish. Surfaces shall be free from voids greater than 10mm in diameter, and from discolouration. Tie holes shall be in a regular pattern. Abrupt irregularities shall not exceed 5mm and gradual irregularities shall not exceed 10mm expressed as a deviation from a 3000mm straight edge. Minor surface defects shall be made good with mortar to Clause [201.1680].

201.1710 Type F3. As obtained with forms designed to produce a dense smooth

finish with only minor colour variations. Surfaces shall be free from voids greater than 5mm in diameter and discolouration. Tie holes and formwork panel markings shall be in a regular pattern.

Abrupt irregularities shall not exceed 3mm and gradual irregularities shall not exceed 6mm expressed as a deviation from a 3000mm straight edge. Minor surface defects shall be made good with mortar to Clause [201.1680].

201.1720 Mortar for making good surface defects in concrete and filling tie holes shall

consist of ordinary Portland cement and sand in the ratio 1:2. Sand shall pass a No 14 sieve and the water/cement ratio shall not exceed 0.5. The colour of the mortar shall match that of the concrete as closely as possible.

Worked Finishes

201.1730 Type W1. A wood float shall be used to produce an even texture.

Type W2. A steel float shall be used to produce a smooth even finish free from float marks.

Type W3. A power float shall be used when the concrete has stiffened sufficiently to be properly worked to produce a smooth even finish.

Type W4. A power grinder shall be used within the period 24-36 hours after



placing to produce a dense even finish.

Type W5. A stiff brush shall be used to produce a slightly roughened even surface.

Type W6. The surface of the concrete shall be tamped with the edge of a board or beam to produce an even texture of parallel ribs.

Permissible Irregularities

201.1740 There shall be no abrupt irregularities in worked finishes, and gradual

irregularities shall not exceed 3mm expressed as a deviation from a 3000mm straight edge.

Sample Finishes

201.1750 The Contractor shall prepare trial panels of all concrete finishes.

TOLERANCES 201.1760 Positive tolerances given below are the measurements by which the

concrete is permitted to exceed the stated dimensions. Negative tolerances are the measurements by which the concrete can be short of the stated dimensions. Departure from alignment is the permissible deviation from the centre line horizontal or vertical face or edge of the concrete.

STRUCTURE

TOLERANCE (mm)

PERMISSIBLE TOLERANCES IN CONCRETE DIMENSIONS Concrete in structures against which backfill is placed Concrete in structures not backfilled Upper surfaces of concrete Cross-sectional dimensions of concrete members Departure from alignment Dimensions of precast units Position of architectural features and openings

+25 - 5 +10 - 5 + 5 - 5 + 5 - 5 +10 -10 or 1 in 500 whichever is more onerous +10 -10 +10 -10 + 5 - 5



Position of embedded items PERMISSIBLE TOLERANCES IN VERTICALITY Reinforced concrete columns, walls, piers and all plinths Mass concrete columns and walls

± 1 in 1000 ± 1 in 400

PERMISSIBLE TOLERANCES IN LEVEL Concrete floor beams and floors - soffits and surfaces and all plinths Exposed lintels, cills and listed seatings for rails and plant

± 1 in 500 ± 1 in 1000

ARCHITECTURAL FEATURES INCLUDING GROOVES Vertical features Horizontal or inclined features

± 1 in 100 but ± 10mm in any 5m ± 1 in 1000 but ± 10mm in any 7.5m

201.1770 No reduction shall be permitted in the cover to reinforcement because of a

specified negative tolerance in a concrete section. 201.1780 Abrupt changes of surface alignment of concrete such as may occur at

badly made construction joints will not be allowed even though the concrete surfaces are within the permissible tolerances.

201.1781 Variation in relative level of face between the concrete surface and the

surface of sleeve, fixing or embedment shall not exceed -0 + 1mm at all points on the perimeter.

201.1782 Variation in level of face from true level or true face of pipes or flanges of

pipes shall not exceed ±6mm.



GENERAL

Construction Loads

201.1790 The Contractor shall take adequate precautions to ensure that concrete

members are not overloaded during the execution of the Works.

Proprietary Solutions 201.1800 Details of all proprietary solutions which the Contractor proposes to apply to

the surface of concrete shall be submitted to the Purchaser. These solutions shall be compatible with any applied finish.

Grouting and Filling

201.1810 The method for grouting of holding down bolt/base plates shall be agreed

with the Purchaser prior to commencement. 201.1820 Surfaces of voids shall be thoroughly wetted before filling and packing. 201.1830 Dry packing mortar or concrete shall only be used if agreed with the

purchaser. 201.1840 Grout and concrete shall be well worked from one side and in one direction

only to ensure complete filling of the void. Vibrators shall not be used. 201.1850 Bolt sleeves shall be filled to within 50mm of the concrete foundation level

prior to the grouting of the baseplate. 201.1860 Formwork shall be used to contain the grout as necessary to meet the

requirements of this Specification. 201.1870 Excess grout or concrete shall be cut back while still green.

Watertight and Water Retaining Structures 201.1880 Structures required to be watertight or water retaining shall be tested to BS

8007 and as required by this specification.

All water retaining structures are to be filled to capacity prior to backfilling or the application of tanking materials. The water level is to be maintained for a period of 48 hours during which time there is to be no visible or otherwise identifiable leakage.



Cutting Concrete 201.1890 No concrete or steel in the reinforced concrete work shall be cut in any way

without the permission of the Purchaser in writing.

Faulty Works 201.1900 The Contractor shall at his own expense remove and reconstruct any

portions of the work which, in the opinion of the Purchaser, give evidence before or after the removal of the formwork that the concrete was of insufficient quality at the time of placing, or was not properly placed and sufficiently compacted in the formwork or that any bars of the reinforcement have been omitted, incorrectly placed or displaced, or that the formwork has been incorrectly positioned or displaced, or which given any evidence of fault, defect of injury from any cause whatsoever which may, in the opinion of the Purchaser, prejudicially affect the strength, durability, watertightness or alignment of the work.

Deviations

201.1930 Documentation, in the form of as-built drawings, photographs, etc., shall

be prepared for all completed structures which are not in compliance with these tolerances and submitted, to the Purchaser for agreement

201.1931 PRECAST CONCRETE 201.2000 When pre-cast concrete is used in the Works, the design shall comply with

BS 8110. The Contractor shall submit drawings and calculations to the Purchaser in accordance with the Specification.

201.2010 Manufacture of pre-cast concrete components shall comply with BS 8110.

The Contractor shall arrange for the Purchaser or his Appointed Representative to have full access to the manufacturer's works for inspection purposes as if they were part of the site.

201.2020 When standard manufactured precast concrete components are used, the

Contractor shall submit to the Purchaser certificates from the manufacturer of the components certifying the component has the required strength and durability.

WATER RETAINING CONCRETE 201.2050 Notwithstanding anything to the contrary in this Section of the Specification,



concrete mix design for concrete designed to retain water or other liquids shall comply with BS 8007.

201.2051 Effluent storage, water treatment plant rooms, flue gas treatment areas and

ash storage areas shall be constructed in water retaining reinforced concrete.

201.2060 GROUND BEARING SLABS

Ground bearing slabs shall be reinforced concrete slabs placed on a polyethylene isolating membrane on a levelled, blinded and compacted formation suitable for the purpose. The slabs shall be designed and constructed in accordance with Concrete Society Technical Report No 34. Floor slabs which are not to received an applied finish shall be floated and travelled to a flatness so that the gap under a 3m straight edge will not exceed 3mm.

201.2070 RETAINING WALLS

Before backfilling retaining walls, the face in contact with the ground shall be painted with two coats of a proprietary bituminous compound suitable for the purpose as agreed by the Purchaser.



APPENDIX 1 BSI STANDARDS AND OTHER REFERENCES ° The British Standards and other documents referred to in Section 201 and listed



British Standards

BS 12 Specification for Portland Cement BS 146 Specification For Portland Blast Furnace Cement. BS 812 Testing aggregates. BS 882 Specification for aggregates from natural sources for

concrete. BS 1014 Specification for pigments for Portland cement and Portland cement

products. BS 1521 Specification for waterproof building papers. BS 1881 Testing concrete. BS 3148 Methods of test for water for making concrete (including notes on

the suitability of the water). BS 3892 Pulverized fuel ash. BS 4027 Specification for Sulfate Resisting Portland Cement. BS 4246 Specification for High Slag Blast Furnace Cement. BS 4550 Methods of testing cement. BS 4887 Mortar admixtures. BS 5075 Concrete admixtures. BS 5328 Concrete. BS 5975 Code of practice for falsework. BS 6699 Specification for Ground Granulated Blastfurnace Slag for Use With

Portland Cement. BS 8110 Structural use of concrete. BS 8007 Code of practice for design of concrete structures for retaining

aqueous liquids.

European Standards

EN 196 Methods of testing cement. American Standards

ASTM C494 Specification for Chemical Admixtures for Concrete ASTM C227 Test for Potential Alkali Reactivity of Cement - Aggregate

Combinations (mortar-bar method).



Other References

Concrete Society Technical Report No.30 "Alkali Silica Reaction, Minimising the Risk to Concrete"

Concrete Society and Institution of Structural Engineers Technical Report 13 "Formwork".

CIRIA Report 67 "Formwork"




CLAUSE REFERENCE


COMMENT

201. 270

Details of admixtures

201. 310

Method Statement on use of Admixtures

201. 440

Material supply information

201. 450

Material supply test results

201. 460

Testing facilities and equipment

201. 500

Results of sampling and testing

201. 540

Change in alkali content

201. 650

Mix Design evidence

201. 700

Mix Proposals

201. 740

Statistical analysis of results

201. 770

Alkali content calculation method

201. 800

Site batch location

201. 960

Concrete details (ready mixed)

201.1000

Details on concreting

201.1030

Record of inspection prior to concreting

201.1100

Details for placing and curing

201.1140

Details of external vibrators

201.1270

Thermal gradients

As required by Purchaser

201.1310

Construction joints

201.1390

Copies of test reports, certificates and records

201.1470

Test core reports


201.1580

Formwork calculations


201.1780

Details of proprietary solutions

201.1790

Grouting of bolts/assemblies

201.1910 201.2020

Documentation of non-compliance with specified tolerances Certificates of strength and durability for precast concrete components



TECHNICAL SPECIFICATION WORK GROUP: 200: CONCRETE WORK SECTION NO: 202 TITLE: REINFORCEMENT TABLE OF CONTENTS SCOPE MATERIALS

Reinforcement Tying Wire Spacers

WORKMANSHIP

Cutting and Bending Fixing Site Bending

QUALITY CONTROL

General Inspection




SCOPE

202. 010 This Section defines the materials and operations relating to the supply and

placing of reinforcement.

MATERIALS

Reinforcement 202. 030 Only high yield steel shall be used in the Works. High yield reinforcement

shall be either hot rolled deformed bars to BS 4449 or cold worked deformed bars to BS 4461 and shall have Type 2 bond classification.

202. 050 Steel fabric or wrapping fabric shall be to BS 4483. 202. 060 Storage arrangements shall prevent contamination of or damage to the

reinforcement.

Tying Wire 202. 070 Tying wire shall be 1.6mm diameter black annealed mild steel or soft

annealed iron wire for uncoated mild steel bars or high yield steel bars. 202. 080 Galvanised or stainless steel tying wire is to be used for fixing reinforcing

bars of the corresponding material.

Spacers 202. 090 Dense sand/cement mortar spacer blocks shall be of low permeability

having similar strength, durability and appearance to the surrounding concrete.

202. 100 Details of patent or proprietary spacers shall be submitted to the Purchaser.

WORKMANSHIP

Cutting and Bending 202. 110 Reinforcement shall be cut and bent to BS 4466. 202. 120 Reinforcement shall be identified using clearly marked, securely fixed,

durable tags.



Fixing 202. 130 Reinforcement shall be fixed, supported and maintained in position by the

adequate use of chairs, spacers and tying wire. Ends of tying wires shall be turned in so us to not project into the cover concrete.

202. 140 Reinforcement shall be free of all loose rust and scale or contamination of

any kind. 202. 150 Different types of reinforcements shall not be intermixed unless instructed

by the Purchaser.

Site Bending 202. 160 Procedures for heating, welding and bending of bars on Site shall be

submitted to the Purchaser. Site bending of bars shall not be permitted when the bar temperature is below 6oC.

202. 170 Bending and subsequent straightening of reinforcing bars projecting from

existing concrete shall be carried out as follows:

a) The minimum distance from an existing concrete surface to the beginning of a bend, and the minimum inside diameter of the bend shall be:

Bar Size Min. Dist. from Min. Inside

surface to diameter beginning of bend

10mm to 25mm 3 Bar Diameters 6 Bar Diameters 32mm 4 8 Over 32mm 5 10

b) Bars of 10mm to 16mm diameter inclusive may be bent once

without heating; heating is required for subsequent straightening or bending.



Bars 20mm to 32mm inclusive may be bent once and subsequently straightened; heating is required in all cases.

Bars having a diameter greater than 32mm may be bent only with the agreement of the Purchaser; heating is required in all cases.

c) Heat shall be applied as uniformly as possible over a length of bar

equal to 10 bar diameters. The centre of the heated length shall be at the middle of the arc of the completed bend. The bar temperature shall not exceed 350�C. The temperature shall be maintained constant during bending or straightening operations. Temperature measuring crayons or a contact pyrometer shall be used to determine the temperature. Care shall be taken to prevent quenching of heated bars either by application of water or by a high volume of air.

d) Straightened bars shall be visually inspected before and after

straightening to determine whether they are cracked or otherwise damaged. A request for inspection is to be submitted to the Purchaser.

202. 180 Bars not exceeding 32mm in diameter not projecting from concrete may be

bent without heating in accordance with this Section providing no local section is rebent or straightened, and the area of the bend is inspected for cracks. A request for inspection is to be submitted to the Purchaser.

QUALITY CONTROL

General

202. 190 All reinforcement shall be obtained from agreed suppliers or manufacturer's

possessing a current certificate of agreement issued by the UK Certification Authority for Reinforcing Steels (CARES).

202. 200 All documentation relating to the supply of reinforcement shall bear the

CARES mark and certificate number and shall ensure that it is traceable to its parent cast.

202. 210 The Contractor shall obtain the manufacturer's certificates for each

delivery of reinforcement which he shall retain as record documents. These certificates shall state that the reinforcement complies with and has been tested at the frequency specified in the appropriate British Standard Specification. The chemical analysis reported in the manufacturer's certificate shall include the nitrogen content



Inspection 202. 220 The Contractor's record of inspection of completed preparatory works

prior to commencing concreting required under Section 201 shall include the work in this Section.



APPENDIX 1 BSI STANDARDS AND OTHER REFERENCES � The British Standards and other documents referred to in Section 202 are listed

below and shall be the current edition, including all amendments. � The Contractor shall bring to the attention of the Purchaser any inconsistencies


BS 4449 Specification for carbon steel bars for the reinforcement of concrete.

BS 4466 Specification for scheduling, dimensioning, bending and cutting of steel reinforcement for concrete.

BS 4482 Specification for cold reduced steel wire for the reinforcement of

concrete.

BS 4483 Specification for steel fabric for the reinforcement of concrete.

BS 5400 Steel, concrete and composite bridges

BD 37/88 Loads for highway bridges (Department of Transport)




CLAUSE REFERENCE


COMMENT

202.100 202.160 202.170 202.180 202.220

Details of patent spacers. Procedures for Site bending of reinforcement. Notification of inspection for cracks. Notification of inspection for cracks. Notification for inspection prior to concreting.



TECHNICAL SPECIFICATION WORK GROUP: 210 : STEELWORK AND METALWORK SECTION NO: 211 TITLE: STRUCTURAL STEELWORK TABLE OF CONTENTS SCOPE STEELWORK SPECIFICATION CONTRACTOR DESIGN AND DETAILING

Connections and Joints Bolted Connections Welded Connections Drainage Holes Drawings and documents

MATERIALS

Hot rolled steel Bolts Minimum thickness Testing

WORKMANSHIP - GENERAL

Cutting, shaping, machining Fitted stiffeners Marking steelwork Storage Foundation bolts



TABLE OF CONTENTS WORKMANSHIP - WELDING

General Preparation of joint faces Butt welded joints Intermittent welds Structural hollow sections Inaccessible areas and contact surfaces Removal of weld spatter

WORKMANSHIP - BOLTING

General Bolted movement connections Correcting hole alignments High strength friction grip assemblies

WORKMANSHIP - ACCURACY OF FABRICATION

Fabrication tolerances Trial assembly

WORKMANSHIP - PRACTICE AND ACCURACY OF ERECTED STEELWORK

Erection method statement Handling works coated steelwork Tolerances Plumbing of stanchions Damage Packing and wedges Grouting of structures Site bolting Site welding Temporary works



TABLE OF CONTENTS PAINT TREATMENT FOR CORROSION PROTECTION

General Materials Surface preparation prior to paint application Surface defects Paint application Exposed external steelwork Internal steelwork generally Internal exposed steelwork Care and attention Pre-fabrication primer Top coat shade

QUALITY CONTROL

Testing of welding operators Inspection and testing




SCOPE 211. 010 This Section defines the general requirements for Contractor design,

materials, workmanship and erection for structural steelwork construction.

STEELWORK SPECIFICATION 211. 030 Except where modified by this Specification, all structural steelwork shall be

in accordance with the 'National Structural Steelwork Specification for Building Construction hereinafter referred to as 'NSSS'. In the event of conflict between the requirements of this Specification and the 'NSSS', this Specification shall apply.

211. 040 The structural steelwork materials and workmanship for bridges and similar

work is specified elsewhere in the Specification.

CONTRACTOR DESIGN AND DETAILING 211. 050 The Contractor shall carry out the design, detailing fabrication and erection

of all steelwork, connections, supports and details, in accordance with 'NSSS' and this specification.

211. 060 The design code of practice to be used for detail design is BS5950. The

Contractor shall ensure that his designs are based on good engineering practice and are economical.

Connections and Joints

211. 070 The Contractor shall design the connections and carry out the detailing. 211. 080 Shop connections may be bolted or equivalent welded connections unless

specific types of connection are required by the purchaser.

Bolted Connections 211. 090 Bolted connections shall have a minimum of two bolts.

Welded Connections

211. 100 The minimum size of fillet welds shall be 6mm. 211. 110 The effective length of fillet welds shall be the length excluding the first and

last 25mm of the weld. 211. 120 The connection design shall provide adequate accessibility for welding and



inspection during fabrication. The profile of the joint shall enable satisfactory non-destructive testing to be carried out.

211. 130 In addition to meeting the requirements of BS 5950, the guidance given by

BS 5135 shall be applied.

Drainage Holes 211. 140 Drainage holes shall be provided in members where water can collect

during and after erection. Reduced areas and sectional properties shall be computed and the members strengthened as necessary.

Drawings and Documents

211. 150 The Contractor shall prepare the following documents:-

- schematic general arrangement framing layout and detail drawings

- marking plans and details for holding-down bolts and other embedded items

- fabrication drawings - connection details including calculations - welder certificates - welding procedure details - fabrication method statement - erection marking plans - erection method statement including calculations - details of the Q.A. plan for structural steelwork together with full

details of the stage control and inspection documents.

Calculations and drawings shall be independently checked and signed. All drawings shall be prepared to microphotographic standards.

MATERIALS

Hot Rolled Steel

211. 160 Except where modified by the Specification all materials shall comply with

the NSSS. 211. 170 All steel shall be new, selected for the purpose for which it is intended to be

used, shall comply with BS 4360 and shall be of a grade suitable for the environmental conditions it will be subjected to.



211.175 Hot rolled and fabricated sections shall be Grades 43 or 50. Cold formed

sections shall be Grade 50.

Bolts 211. 180 Ordinary bolt assemblies shall use bolts of Grade 8.8 to BS 3692. Higher

grade bolts shall not be used without the prior agreement of the Purchaser. Bolts shall have short thread lengths and be of the correct length for the thickness of material to be connected.

HSFG bolt assemblies shall use general grade bolts and shall be in accordance with BS 4395.

211. 190 The minimum bolt size used shall be M16, unless prior agreement of the

Purchaser is obtained. 211. 200 Bolts are to be self-finished, unless noted on the drawings. Galvanised or

sheradized bolts nuts and washers shall be used for connecting galvanised steelwork.

Minimum Thickness

211. 210 All gusset plates, stiffeners, flanges and elements of built-up sections shall

not be less than 6mm thick.

Testing 211. 220 The Contractor shall obtain all manufacturer's test report certificates for all

material used in the Permanent Works, eg. steel plates, sections, bolts, etc. Details of such tests shall be submitted to the Purchaser for record purposes.

211. 230 When tests are to be made away from the steelworks, the Contractor shall

provide sample pieces 500mm x 75mm for plates, or as near to that as practicable, and 500mm long of full section for angles, joists, channels, flat, rods etc. The sample pieces shall be selected and stamped by the Contractor and as soon as selected shall be despatched to the Testing Works where test pieces shall be made and tested. Test Certificates shall be obtained and made available on request.

WORKMANSHIP - GENERAL

211. 250 Except where modified by the Specification, all workmanship shall comply

with the 'NSSS'.



Cutting, Shaping and Machining

211. 260 The ends of all beams shall be square where required and flanges neatly

cut away or notched where necessary. All notches shall be kept as small as possible and shall be radiused in the inner corner.

211. 270 The butt ends of compression members shall, except where bolts carry the

loads, have their abutting faces machined after fabrication so that they shall be square to the member axes and in tight bearing contact when erected.

211. 280 The ends of columns at intermediate splices and where they bear on bases

or caps shall be cut true and square so that they shall be in tight bearing contact i.e. to within 0.5 degree.

211. 290 All machining operations shall be performed after welding. All machined

surfaces, unless otherwise noted, shall have a finish of 6.5 micrometres CLA. Fitted Stiffeners

211. 300 Where stiffeners are required to be fitted, they shall be ground or machined

to fit and the surfaces on which the stiffeners bear shall be cleaned of all loose mill scale or any deleterious matter to allow tight contact.

Marking Steelwork

211. 310 All members of mass exceeding 5 tonnes shall have their mass marked by

cold stamping and painting. Markings shall be inspected and where necessary, repaired or replaced, upon delivery to site and at regular intervals before erection. In addition each member shall be clearly marked with a unique reference number which can be cross referenced to the shop drawings indicating where that member is located in the structure.

Storage

211. 320 Each grade of steel shall be stored separately and marked to BS 4360. 211. 330 Each type of bolt and each type and grade of welding consumable shall be

clearly identified and stored separately.

Foundation Bolts 211. 340 Foundation bolts and any associated steelwork assemblies shall be

delivered to site in good time for being built into the foundations. Bolts shall



be designed to allow columns to free stand without guying during erection of steelwork, provided no lateral forces are applied to column heads during erection.

WORKMANSHIP - WELDING

General

211. 350 No welding shall be carried out unless a procedure has been submitted and agreed by the Purchaser. This requirement shall include all repair welds, welded attachments, supports and fabrication aids even where these may subsequently be removed.

211. 360 Agreement of the welding schedules and procedures shall not relieve the

Contractor of his responsibility for the correct welding and for the minimising of distortion in the finished structure.

Preparation of Joint Faces

211. 370 Preparation of joint faces shall be to BS 5135.

Butt Welded Joints 211. 380 All butt welds shall have complete penetration. On rolled section this shall

be achieved by the use of extension pieces, cross runs, or other means as agreed by the Purchaser.

Intermittent Welds

211. 390 Intermittent welds shall only be permitted with the agreement of the

Purchaser. Submittals are to be made to the Purchaser for agreement and record purposes.

Structural Hollow Sections

211. 400 The end of one hollow section shall be accurately shaped to fit the other.

This shall be done by using properly prepared templates or equivalent agreed methods. The correct fusion bevel shall then be cut.

Inaccessible Areas and Contact Surfaces

211. 410 Areas which become inaccessible after fabrication or assembly, such as the

inside of structural hollow sections and other box sections, shall be sealed off from the outside atmosphere by continuous welds unless specified otherwise. The interior shall be kept clean, dry and free from loose scale



etc. 211. 420 Galvanised hollow sections shall have suitable vent holes to prevent

explosions due to the expansion of the trapped air during galvanizing. Removal of Weld Spatter

211. 430 All weld spatter shall be removed and where steelwork is to be

blast-cleaned, all traces of spatter, together with any flux and other surface contamination shall be removed before commencement of blasting.

WORKMANSHIP - BOLTING

General

211. 440 Bolting up and final tightening of bolts shall be carried out progressively as

the erection, alignment and grouting proceeds in order to release the steelwork and the area under it for subsequent operations.

Bolted Movement Connections

211.450 Slotted holes for movement connections shall be greased and provided

with shouldered bolts, spring washers and flat washers.

Correcting Hole Alignments 211. 460 When holes can only be aligned by reaming, the agreement of the

Purchaser will be required.

High Strength Friction Grip Assemblies 211. 470 Only one type of HSFG fastening system shall be used on each section of

the Works unless otherwise agreed with the Purchaser. 211. 480 Metallic protective finishes when specified shall only be applied by the bolt

manufacturer. 211. 490 Only HSFG fastenings in good condition shall be used. Threads of bolts

and nuts, in particular, shall be free from damage, grit, corrosion or any condition necessitating excessive torque to attain the required tension. WORKMANSHIP - ACCURACY OF FABRICATION

Fabrication Tolerances



211. 500 All measurements shall be made with respect to a base temperature of 15oC.

Fabrication tolerances shall be in accordance with BS 5950 Part 2, and BS 5606, except where modified by this specification.

(i) Length

Length after cutting as defined in NSSS Section 7.2.5. Length less than 9.0m: _ + 0

- 2mm

Length greater than 9.0m: _ + 0 - 4mm

Trial Assembly

211. 510 Sufficient trial assemblies shall be carried out in the Steelwork Contractor's

works to prove the accuracy of the workmanship.

Where parts which have to fit together cannot be matched before despatch to Site, the Contractor shall make adequate provision to ensure a correct fit.

WORKMANSHIP - ERECTION AND ACCURACY OF ERECTED STEELWORK

Erection Method Statement

211. 520 Prior to the erection of any permanent steelwork on Site, the Contractor

shall submit to the Purchaser a Method Statement detailing a safe system of working. The agreement of the Contractor's Detailed Method Statement shall not relieve the Contractor of any of his responsibilities under the contract.



Handling Works Coated Steelwork

211. 530 The precautions to be taken when handling, storing, transporting and

erecting works coated steelwork shall include the following:

a) All wire ropes and chain slings used for hoisting and securing loads shall be covered to protect coatings and prevent scoring, chafing and other damage.

b) Softwood timber bearers with a sufficient contact area to prevent

crushing shall be provided at all stages including transport to site. Bearers shall be level and sufficient in number to prevent distortion of members. Beams used to support coated steelwork stored externally shall be sufficiently high to ensure that the lowest parts of the stored members are above and clear of the rainwater splash zone and that from passing vehicles.

c) Special consideration shall be given to the arrangements of

bearers if articulated vehicles which allow differential movement of bearers are used to transport steelwork. Vertical timber packing shall be used to separate members when required and to prevent chafing to coatings. The methods used for securing loads to transport vehicles shall ensure that coatings are not damaged.

d) Members shall be stacked in such a manner as to permit free

drainage of rainwater from the surfaces and to avoid ponding.

e) Precautions shall be taken at all stages to prevent coatings being contaminated by oil, cement, soil, chemicals or other deleterious agents. Should any contamination occur, the contaminating agent shall be removed immediately by swabbing or brushing and the surfaces washed thoroughly with clean water.

f) Works coated steelwork shall be loaded and unloaded by hoisting

equipment. It shall not be moved by sliding or skidding. g) Small components without packing shall be handled singly and

shall not be thrown on or off vehicles or at any other time. They shall be stored on pallets and precautions taken to prevent chafing of coatings.

h) All bolts, nuts and washers shall be protected and stored in dry conditions. Adequate precautions shall also be taken to ensure



that threads are not damaged or contaminated with dirt etc.

Tolerances 211. 540 Erection tolerances shall be in accordance with BS 5950 Part 2, the NSSS

and BS 5606 whichever is the most onerous. The Contractor shall be responsible for the correct positioning and levels of the structure in relation to the datums given.

The erection of the steelwork shall be to BS 5950: Part 2 and BS 5531.

Plumbing of Stanchions

211. 550 Plumbing of stanchions shall be undertaken as follows:-

a) The final tightening, or welding if permitted, of connections shall not be carried out until a sufficient portion of the structure has been erected and temporarily connected up to ensure that there shall be no straining of members during erection and lining-up of the remainder of the structure.

b) If the Contractor proposes to use shims he shall submit details to

the Purchaser for agreement and record purposes.

c) At the time of checking plumbness, the steel structure shall be free standing and free of temporary erection ties/bracing, such as tirfors, and the like.

Damage

211. 560 Damage to any part of the structure either before or during erection shall be

immediately brought to the notice of the Purchaser. No damaged part shall be assembled in the structure without the consent of the Purchaser.

Packing and Wedges

211. 570 Packing and wedges shall be suitable for their purpose and shall not

protrude from the stanchion base. Generally they shall be grouted in. Where they are grouted in they shall be totally enclosed by the grout.

Grouting up of Structures 211. 580 The Purchaser shall be notified when stanchions or other members have

been lined, levelled and plumbed and prior to grouting.



Following review and agreement by the Purchaser of the alignment and plumbing, the Contractor shall immediately grout the baseplates and holding down bolts and concrete in stanchions or other members as appropriate.

Site Bolting

211. 590 All site bolting shall meet the relevant requirements of this Specification.

Site Welding 211. 600 Where Site welding is required and permitted by the Purchaser, the

requirements of this Specification shall be met and the welding shall be subject to all the inspection requirements. Special attention shall be paid to the safety of welders working on site.

Temporary Works

211. 610 Temporary bracings shall be provided by the Contractor to ensure the

stability of his work during erection.

PAINT TREATMENT FOR CORROSION PROTECTION

General 211. 620 All workmanship and materials shall comply with the recommendations of

BS 5493: Protective Coating of Iron and Steel Structures Against Corrosion.



211. 630 No paint other than pre-fabrication primer shall be applied within 50mm of any proposed welds.

Materials

211. 640 The paint system described in this specification is based on paints

produced by International Paint Ltd. Agreement of products from alternative suppliers may be granted provided that the Contractor is able to demonstrate that the alternative is of, at least, equivalent quality.

211. 650 All paints within any painting system shall be entirely compatible and

supplied by the same manufacturer.

Surface Preparation Prior to Paint Application 211. 660 All steelwork shall be blasted free from all millscale, rust and other

contamination to a minimum standard of Sa2.5 as defined in Swedish Standard SIS 05 5900.

Surface Defects

211. 670 All surface defects likely to be detrimental to the protective painting system

shall be removed. The requirement of BS4360 shall be observed to ensure that the steel is sound and free from cracks, laminations or surface flaws such as might preclude it for the purpose for which it is intended.

211. 680 After shotblasting all spent shot or grit shall be removed by vacuum cleaner

or by oil and moisture free airline and brush. In the event of any shot or grit being found embedded in the paint film the affected area shall be re-blasted and re-painted to the original specified standard.

211. 690 The blasted surface shall be tested with a copper sulphate solution after

blasting. A 4% solution of copper sulphate in 1% sulphuric acid shall be used. The surface treated shall show less than 10% residual millscale. The requirements of BS5493: 1977 Appendix G shall be observed where the presence of rust producing soluble salts is possible.

Paint Application

211. 700 All steel surfaces shall be dry before painting commences and the

prevailing shop conditions shall be monitored and recorded by the paint applicator at the time of paint application. Painting shall not be carried out at temperatures below that recommended by the paint supplier.

211. 710 The application of protective coatings is to be inspected by the Paint



Supplier. Copies of inspection reports shall be issued directly to the Contractor by the Paint Supplier.

211. 720 Technical support services provided by the Paint Supplier does not relieve

the Contractor of his contractual responsibility to ensure that the coatings are applied in accordance with the specification.



Exposed External Steelwork

211. 730 Application at works.

Apply overall: 1 coat Zinc Phosphate Epoxy Primer - Intergard Wintercure 200 Series to 75 microns nominal dft 1 coat High Build Epoxy MI0 - Intergard Wintercure 420 Series to 100 microns nominal dft 1 finish coat 629 to 50 microns nominal dft

211. 740 Application at site:

Any areas damaged in transit to be hand or power tool cleaned to St2 Swedish Standard SIS 05 5900 and bare areas touched up with two coats Interplus 256 to 100 microns nominal dft per coat, followed by Interfine 629 to 50 microns nominal dft. Internal Steelwork Generally, Except Components Such as Galvanised Pressed Metal Sections

211. 750 Application at works.

Apply overall: 1 coat Zinc Phosphate Epoxy Primer - Wintercure 200 Series to 75 microns nominal dft.

211. 760 Application at site.

Any areas damaged in transit to be hand or power tool cleaned to St2 Swedish Standard SIS 05 5900 and bare areas touched up with Interplus 256 to 100 microns nominal dft.

Internal Exposed Steelwork

211. 770 Application at work.

Apply overall: 1 coat two pack Zinc Phosphate Epoxy Primer to 75 microns minimum dft. 1 coat HB Epoxy M10 to 125 microns minimum dft Finish coats to suit architectural requirements.

211. 780 Application at site.

Any areas damaged in transit to be hand or power tool cleaned to St2



Swedish Standard SIS 05 5900 and bare areas touched up with compatible system.

Care and Attention

211. 790 Painted steelwork shall at all times be stored above ground with suitable

timber bearers to separate individual members. Stacked members shall at all times be accessible for inspection.

211. 800 When erection has been completed all steel shall be further inspected and

areas marked to indicate where remedial work is required. Areas concerned will be hand or power tool cleaned to St2 Swedish Standard SIS 05 5900 and treated with the appropriate touch up system.

Areas of damaged paintwork shall be made good and the repair shall overlap sound paintwork by at least 50mm.

Pre-fabrication Primer

211. 810 Where the use of a pre-fabrication primer is proposed by the Steelwork

Contractor this shall be a Zinc Phosphate Epoxy Prefabrication Primer - Interplate 170 to 25 microns nominal dft. The dft of remaining coats shall remain as specified.

Top Coat Shade

211. 820 Shade of any Interfine 629 top coat to be agreed with by the Purchaser.

QUALITY CONTROL

Testing of Welding Operators 211. 830 The Contractor shall pay all labour, plant and material costs with respect of

testing of welding operatives including independent testing authority costs.


The Contractor shall propose an offsite testing regime during fabrication which is subject to the agreement of the Purchaser. The Contractor shall pay all costs related to the testing together with the cost of rectifying and replacing any defective work.

211. 840 The Contractor shall notify the Purchaser of inspection or checking stages

required by the workmanship section of this Specification and the NSSS.This shall include, but is not limited to:



. Commencement of fabrication

. After completion of surface preparation and prior to application of

protective treatments. . Inspection of prepared foundations and holding down bolts prior

to commencement of erection.

. The first use of each agreed welding procedure.

. At the commencement of major weld repairs.

. Survey of erected structures prior to bolting up and grouting.

. Grouting of base plates and holding down bolts.

. Inspection of bolts before final tightening is carried out.



APPENDIX 1 BSI STANDARDS AND OTHER REFERENCES • The British Standards and other documents referred to in Section 211 are listed


The Contractor shall bring to the attention of the Purchaser any inconsistences between the requirements of these standards and this Specification Section.

Health and Safety at Work Act 1974.

National Structural Steelwork Specification

BS 3692 Specification for ISO metric precision hexagon bolts, screws and

nuts BS 4360 Specification for Weldable Structural Steels

(Withdrawn) Replaced by BS 7613: 1994, BS 7668: 1994, BS EN 10029: 1991, Parts 1 to 3 of BS EN 10113: 1993, BS EN 10155: 1993 and BS EN 10210-1: 1994.

BS 4395 Specification for High Strength Friction Grip bolts BS 5135 Specification for arc welding of carbon and carbon manganese

steels BS 5493 Code of Practice for Protective Coating of iron and steel

structures against corrosion. BS 5606 Guide to Accuracy in Building BS 5950 Structural Use of Steelwork in Building

Swedish Standard SIS 05 5900



APPENDIX 2 - INFORMATION TO BE SUBMITTED BY CONTRACTOR

CLAUSE REFERENCE


COMMENT

211.130

211.220

211.350

211.390

211.460

211.520

211.560

211.580

211.820

Drawings and documents Manufacturer's test report certificates Welding procedures Intermittent welds Agreement of reaming Erection method statement Damage Readiness for grouting Colour of top coats




TECHNICAL SPECIFICATION WORK GROUP: 210: STEELWORK AND METALWORK SECTION NO: 215 TITLE: CRANE GANTRY GIRDERS, RAILS AND RAIL FIXINGS TABLE OF CONTENTS SCOPE RELATED STANDARDS CONTRACTOR DESIGN MATERIALS WORKMANSHIP

Fabrication Site Erection

QUALITY CONTROL APPENDIX 1 BSI STANDARDS AND OTHER REFERENCES APPENDIX 2 ENGINEERING DOCUMENTS



215.010.1 SCOPE

This section defines the materials and workmanship required for the fabrication and erection of steel crane gantry girders, crane rails and the fixing of the rails to the girders. The following clauses are in addition to the requirements of section 211: Structural Steelwork.

RELATED STANDARDS

215.020.0 This section should be read in conjunction with Section 211: Structural

Steelwork.

CONTRACTOR DESIGN 215.030.1 Crane Girders and fixings shall be designed in accordance with BS 6399

and BS 466. 215.040.1 Joints in tracks shall be designed to achieve a structural strength of at least

1.25 times the minimum strength of the section required at that point. The design of any joint shall be subject to the consent of the Purchaser.

MATERIALS

General

215.050.1 Crane rails shall be new and in accordance with BS 105 - Light and Heavy

Bridge Type Railway Rails and shall also comply with the requirements of BS 11 - Flat Bottom Railway Rails. The type and steel grade of the rails shall be shown on the drawings. They shall be supplied by a manufacturer, cold straightened to + 2mm in 1m and shall be free of twist. They shall also be free from pitting, laminations and other defects.

215.060.1 The rail clips shall be of the type shown on the drawings and shall be

adjustable to overcome the differences in rolling tolerances and the tolerances required by the crane manufacturer. The rail clips shall be capable of resisting all applied side loads. The clips shall be used in accordance with the manufacturers recommendations.

215.70.1.1 A continuous resilient pad shall be used between the rail and the gantry

girder to reduce noise, vibration and load concentrations.

This pad shall be specified on the drawings and installed in accordance with the manufacturers recommendations.

WORKMANSHIP



Fabrication

215.080.1 Each crane girder shall be clearly marked with an individual identification

number. 215.090.1 The top flanges of the girders shall be as flat as possible. Any cross

camber over the central width of 150mm shall have the convex surface upwards only and shall not exceed 0.6mm. A concave surface is not acceptable.

215.100.1 All girders shall be straight, the deviation shall be within L/3000 or 3mm

whichever is the lesser. Both flanges shall be straight and the outstand from the web shall not deviate by more than 3mm within the length of the girder.

215.110.1 No connections shall be permitted to the tension flanges. 215.120.1 Intermediate web stiffeners shall be fitted tightly to the top flange. Load

bearing stiffeners shall be fitted tightly to both top and bottom flanges. 215.130.1 Joints in rails shall be scarfed, cut square to the axis of the rail and

smoothly finished. The expansion tolerance allowed shall not compromise the smooth running of the crane. Profile flame cutting shall not be used.

Site Erection

215.140.1 The maximum tolerance for line and level of the crane gantry girders shall

be + 2mm, with the difference in level between the top flanges of two adjacent girders not exceeding 1mm.

215.150.1 Crane rails shall be laid to the tolerances stated in BS 466 Appendix F or

better. Where measurements of crane rails are taken using automatic or laser methods, the calibration of any instrument employed and the precise method of measurement shall be subject to review and consent by the Purchaser.

215.160.1 The location of the rail on the girder shall be such that the centreline of the

rail is aligned on a vertical plane with the centreline of the web, within a tolerance of half the thickness of the girder web.



QUALITY CONTROL

215.170.1 NDT tests on weld shall be carried out in accordance with section 211.

APPENDIX 1 BSI STANDARDS AND OTHER REFERENCES · The British Standards and other documents referred to in Section 215 are listed

below and shall be the current edition, including all amendments. · The Contractor shall bring to the attention of the Purchaser any inconsistencies

between the requirements of these Standards and this Generic Specification Section.

BS 4 Structural steel sections. Part 1: Specification for hot-rolled sections.

BS 11 Specification for railway rails. BS 105 Light and heavy bridge type railway rails. BS 466 Power driven overhead travelling cranes, semi goliath and goliath

cranes for general use. BS 499 Welding terms and symbols. Part 2: Specification for symbols for welding.

BS 639 Specification for covered carbon and carbon manganese steel

electrodes for manual metal-arc welding. BS 709 Destructive testing fusion welded joints and weld metal in steel. BS 729 Specification for hot dip galvanised coatings on iron and steel

articles. BS 1192 Construction drawing practice. Part 1: Recommendation for general principles. Part 2: Recommendation for architectural and engineering drawings. BS 1449 Steel plate, sheet and strip. BS 2451 specification for chilled iron shot and grit. BS 2569 Specification for sprayed metal coatings. Part 1: Protection of iron and steel by aluminium and zinc against

atmospheric corrosion. BS 2583 Specification for podger spanners. BS 2853 Specification for the design and testing of steel overhead runway

beams. BS 2901 Specification for filler rods and wires for gas-shielded arc welding. BS 2989 Specification for continuously hot-dip zinc coated and iron-zinc alloy

coated steel: wide strip, sheet/plate and slit wide strip. BS 2994 Specification for cold rolled steel sections.



BS 3692 Specification for ISO metric precision hexagon bolts, crews and

nuts. Metric units.

BS 3923 Methods for ultrasonic examination of welds. Part 1: Methods for manual examination of fusion welds in ferritic steels. BS 4165 Specification for electrode wires and fluxes for the submerged arc

welding of carbon steel and medium-tensile steel. BS 4190 Specification for ISO metric black hexagon bolts, crews and nuts.

BS 4320 Specification for metal washers for general engineering purposes.

Metric series. BS 4360 Specification for weldable structural steels. BS 4395 Specification for High strength friction grip bolts and associated nuts

and washers for structural engineering. Part 1: General grade. Part 2: Higher grade bolts and nuts and general grade washers.

BS 4570 Specification for fusion welding of steel castings. BS 4604 Specification for the use of high strength friction grip bolts in

structural steelwork. Metric series. BS 4848 Specification for hot-rolled structural steel sections. Part 2: Hollow sections. Part 4: Equal and unequal angles.

BS 4870 Specification for approval testing of welding procedures. Part 1: Fusion welding of steel.

BS 4871 Specification for approval testing of welders working to approved

welding procedures. Part 1: Fusion welding of steel.

BS 4872 Specification for approval testing of welders when welding

procedure approval is not required. Part 1: Fusion welding of steel.

BS 4921 Specification for sherardised coatings on iron or steel. BS 4929 Specification for steel hexagon prevailing-torque type nuts. Part 1: Metric sizes.

BS 4933 Specification for ISO metric black cup and countersunk head bolts

and screws with hexagon nuts. BS 5135 Specification for arc welding of carbon and carbon manganese

steels.



BS 5289 Code of practice. Visual inspection of fusion welded joints. BS 5493 Code of practice for protective coating for iron and steel structures

against corrosion. BS 5536 Recommendations for preparation of technical drawings for

microfilming. BS 5950 Structural use of steelwork in building. BS 6072 Precast concrete masonry units. BS 6363 Specification for welded cold formed steel structural hollow sections. BS 6399 Loading for buildings. BS 6443 Method of penetrant flaw detection. BS 6512 Specification for limits and repair of surface discontinuities of hot-

rolled steel plates and wide flats. Swedish Standard 05 59 00. Health & Safety Executive Guidance Note GS 28. ASME IX AWS D1.1 National Structural Steelwork specification for building construction, BCSA Ltd London.




CLAUSE REFERENCE


COMMENT

215.060 215.070 215.170

Manufacturer’s instructions. Manufacturer’s instructions. Manufacturer’s instructions.


TECHNICAL SPECIFICATION WORK GROUP : 230 : MASONRY SECTION NO: 231 TITLE: BRICKWORK AND BLOCKWORK TABLE OF CONTENTS SCOPE MATERIALS

General Bricks and Blocks Facing Bricks Pre-cast Concrete Bricks Pre-cast Concrete Blocks Special Shapes and Standard Specials Cement Lime Sand Water Admixtures Pigments Damp Proof Courses Wall Ties Reinforcement in Joint Sills and Copings Lintels Flashings and Weathering Joint Filling Sealants Cavity Insulation



TABLE OF CONTENTS WORKMANSHIP

General Storage and Protection of Materials Storage of Brickwork and Blockwork Storage of Cement Storage of Sand Storage of Lime and Ready Mixed Lime Sand Mixes Storage of Metals (Wall Ties, Reinforcement, etc.) Storage of Bituminous Felt Storage of Thermal Insulation Materials Protection During Laying Protection After Laying Precautions During Cold Weather Precautions During Wet or Warm Weather Portland Cement Mortars Laying Brickwork and Blockwork Construction Tolerances Cutting Brickwork and Blockwork Openings in Brickwork/Blockwork Bond Structural Stability Cavity Walls Joint Finishing Damp Proof Courses (DPC) Movement Joints

QUALITY CONTROL

General Testing Inspection




SCOPE 231. 010 This Section defines the materials and workmanship requirements for

masonry (brickwork and blockwork) and related accessories (damp proof courses and fixings etc.).

MATERIALS

General 231. 030 Brickwork and blockwork shall be to BS 5628 Part 3. 231. 040 Samples of all bricks, blocks, air bricks, insulation, and of associated

building works such as damp proof courses and other materials, shall be obtained from manufacturers or suppliers and shall be submitted to the Purchaser for agreement. The Contractor shall not subsequently change the manufacturer or supplier of any materials without the agreement of the Purchaser.

Bricks and Blocks

231. 060 Pre-cast concrete blocks and bricks shall be to BS 6073: Part 1. 231. 070 Aerated concrete blocks shall be to BS 6073: Part 1. 231. 080 Lightweight aggregate concrete blocks shall be to BS 6073: Part 1. 231. 100 Concrete air bricks shall be to BS 493. 231. 110 Clay blocks shall be to BS 3921. 231. 120 Clay bricks shall be to BS 3921. 231. 140 Clay air bricks shall be to BS 493. 231. 150 Calcium silicate bricks shall be to BS 187. 231. 170 Clay brick slips shall not be less than 25mm thick cut from facing bricks. 231. 180 Shapes and dimensions of special bricks shall be to BS 4729. 231. 190 The Contractor shall make sure that he understands clearly the Purchaser's

requirements for bricks and blocks before placing a procurement order. If clarification is required the Purchaser's ruling shall be sought in writing and confirmation received, also in writing.



Facing Bricks 231. 200 Facing bricks manufactured from brickearth, clay or shale shall be sound,

well burnt bricks of uniform shape and colour.

Facing bricks with chipped exposed edges shall not be used.

Pre-cast Concrete Bricks

231. 210 Concrete bricks used in conjunction with concrete blockwork for infilling round jambs, openings or heads of walls shall be of similar composition, strength and appearance to the blocks and shall be of a size compatible with the selected block.

Pre-cast Concrete Blocks

231. 220 Pre-cast concrete blocks of the specified class, shall be suitable for fair

faced work. The dimensions and compressive strength of the blocks shall be indicated on the Drawings.

231. 230 Hollow concrete blocks shall be used at the discretion of the purchaser. 231. 240 Standard sized blocks shall be used, allowing a nominal joint thickness of

10mm to achieve the designated setting out module.

Special Shapes and Standard Specials 231. 250 Special shapes and 'standard specials' to BS 4729 shall be from the

manufacturer's standard range and shall be used for areas of fair faced work.

Cement

231. 260 Cement for use in mortar shall be Ordinary Portland cement to BS 12

Portland blastfurnace cement to BS 146 unless otherwise specified. 231. 270 Rapid hardening Portland cement when specified shall be to BS 12. 231. 280 Sulphate resisting Portland cement when specified shall be to BS4027. 231. 290 Masonry cement when specified shall be to BS 5224. 231. 300 High alumina cement shall not be used.

Lime



231. 310 Lime shall be made from limestone or chalk and shall be either:

- high calcium lime - semi hydraulic lime - magnesium lime

all in accordance with BS 890.

231. 320 The lime shall be classified as either

- hydrated lime (powder) - quick lime

and shall be to BS 890 Part 2 and Part 3 respectively.

231. 330 Lime putty shall be to BS 890 Part 4. 231. 340 Ready mixed lime/sand building mortars shall be to BS 4721.

Sand 231. 350 Sand for general purpose mortars shall be to BS 1200, Table 1. 231. 360 Sand for reinforced brickwork mortars shall be to BS 1200, Table 2. 231. 370 Sand which has been in contact with sea water, loam or organic matter

shall not be used unless the Purchaser's permission is given in writing. It shall conform to BS 1200 and shall not contain any harmful materials that will adversely affect the hardening, strength, durability or appearance of the finished work.

Water

231. 380 Water for use in mortar shall be of potable quality and tested in accordance

with BS 3148 if required.

Admixtures 231. 390 Details of admixtures proposed for use shall be submitted to the Purchaser

for agreement. 231. 400 Admixtures shall conform to BS 4887 and shall be used in strict accordance

with the manufacturer's instructions. They shall be delivered in sealed containers bearing the name of the manufacturer.



231. 410 Calcium chloride shall not be used.

Pigments 231. 420 Pigments for colouring mortar shall be to BS 1014. They shall only be used

at the discretion of the purchaser. 231. 430 Pigments shall not exceed 10% by weight of cement. Carbon black, if used,

shall be limited to 2% by weight of the cement.

Damp Proof Courses 231. 440 Damp proof course type, class, description and thickness shall be shown

on the Drawings. 231. 450 Lead damp proof courses shall be to BS 743. 231. 460 Bituminous felt damp proof courses shall be to BS 6398. 231. 470 Mastic asphalt shall be to BS 6925 (limestone aggregate) or BS 6577

(natural rock asphalt aggregate). 231. 480 Impervious bricks shall be to BS 743 and shall not absorb more than 3 per

cent of their weight when tested to BS 743. 231. 490 Chemical damp proof courses shall be to BS 6576.

Wall Ties 231. 500 Metal wall ties for use in cavity brickwork or blockwork shall be stainless

steel to BS 1243. 231. 510 Wall ties for use in cavity walls part filled with insulation shall be of a design

which incorporates polypropylene cavity insulation retaining discs. The Contractor shall submit details to the Purchaser for agreement.

231. 520 The minimum length of wall ties shall be equal to 100mm plus the width of

the cavity. 231. 530 Frame ties for securing masonry walls to structural supports shall be

stainless steel. They shall be securely fixed into stainless steel anchor channels fixed to the structural support. Direct contact between stainless steel and structural steel must be prevented.



When the channel is fixed to structural steelwork, plastic coated stainless steel countersunk through bolts shall be used, together with an insulating coating to the back of the channel, in accordance with the manufacturer's instructions.

Reinforcement in Joints

231. 540 Reinforcement type and size shall be shown on the Drawings. 231. 550 Expanded metal (steel) shall be to BS 405. 231. 560 Steel fabric shall be to BS 4483. 231. 570 Galvanising of expanded metal or steel fabric shall be to BS 729. 231. 580 Steel bar reinforcement shall be Austenitic stainless steel, minimum 18/8

composition and to BS 970: Part 1 or BS 1554 excluding free machining grades.

Sills and Copings

231. 590 Sills and copings shall be to BS 5642. The materials, type, dimensions,

profile and texture shall be shown on the Drawings. Lintels

231. 600 Prefabricated pre-cast, prestressed reinforced concrete or galvanised steel

lintels shall be to BS 5977 Part 2. Dimensions, span(s), profile(s) and loading(s) shall be shown on the Drawings.

231. 610 Steel lintels shall be hot-dip galvanised to BS 729.

Flashings and Weathering 231. 620 The material shall be compatible in colour, type code (for lead), grade,

thickness etc. to the cladding. 231. 630 Lead sheet or strip shall be to BS 1178. 231. 640 Hot rolled sheet or strip copper shall be to BS 2870. 231. 650 Zinc alloy sheet or strip shall be to BS 6561. 231. 660 Aluminium sheet or strip shall be to BS 1470.



231. 670 Bituminous felt flashings shall be to BS 747.

Joint Filling Sealants 231. 680 Refer to Generic Section 402. 231. 690 Movement joint filling sealants type and colour shall be stated on the

Drawings and shall be from a manufacturer agreed by the Purchaser.

Cavity Insulation 231. 700 The material type, thickness and method of installation of the insulation

shall be stated on the Drawings and meet the required 'U' values. 231. 710 Insulation shall be accompanied by an Agreement Certificate. 231. 720 Mineral fibre insulation shall be to BS 6676.

WORKMANSHIP

General

231. 730 Workmanship shall be to BS 5628: Part 3. 231. 740 On completion, all putlog and other holes shall be made good using bricks

and mortar of types which ensure that the face matches the surrounding brickwork. Putlog and other similar holes shall where possible be of full brick size.

231. 750 Chasing of completed walls or the formation of holes shall be carried out

only when agreed by the Purchaser after the mortar has set hard.



Storage and Protection of Materials

231. 760 All materials, i.e. bricks, blocks, cement, mortar, sand, lime, ready mixed

sand and lime, damp proof courses, bituminous felts, thermal insulation materials, etc., shall be stored/protected to the agreement of the Purchaser and in accordance with the manufacturer's recommendations and to ensure that they are protected from rain, frost, snow and splashing from passing vehicles and accidental damage.

Storage of Brickwork and Blockwork

231. 770 A suitable hard standing shall be prepared for storing bricks and blocks.

They shall not be off loaded by tipping from vehicles, but shall either be off loaded by hand or in pallets by means of a fork lift truck, crane or similar lifting device.

They shall not be stacked directly on sulphate bearing ground, clinker or ashes. They shall not be stacked on newly cast slabs of concrete.

231. 780 All bricks and blocks shall be arranged in orderly stacks and used

approximately in the order in which they are delivered, except in the case of facing bricks or blocks which shall be intermingled so that any agreed variation in colour or texture of different consignments does not form defined areas in the completed work.

231. 790 Stacks of bricks and blocks shall be arranged so that if they become

accidently wetted, they can be dried out prior to use by forced circulation of air round the stack, and so that in frosty and/or extremely cold weather, heat can be applied to the materials to ensure that the temperature of the completed work shall not be lower than 5°C.

231. 800 Stacks of each type and strength of bricks and blocks shall be kept separate and labelled accordingly. Broken and rejected bricks and blocks shall be stacked separately and removed from site as soon as possible.

Storage of Cement

231. 810 Cement purchased in bulk shall be stored in purpose built containers that

are maintained in good condition all to the agreement of the Purchaser. 231. 820 Bag cement shall be stored off the ground in a well ventilated, weather tight

and damp proof building. 231. 830 The cement shall be stored in such a manner as to permit easy access for

proper inspection and identification of each consignment or type and shall



be used in the order of receipt.

Any cements stored on Site for more than one month shall be tested to BS 4550.

Storage of Sand

231. 840 Sand shall be stored on clean surfaces in such a manner as to allow

adequate drainage. It shall be stockpiled in a suitable manner to prevent contamination by other materials.

Storage of Lime and Ready Mixed Lime Sand Mixes

231. 850 Quick lime shall be delivered to the site as soon after manufacture as

possible and slaking commenced immediately. After slaking is completed, it should be protected from drying out and remain undisturbed for a period of at least two weeks prior to use to permit it to fatten up to a lime putty.

231. 860 Hydrated lime shall be stored off the ground in a well ventilated, weather

tight and damp proof building. 231. 870 Ready mixed lime sand mortar shall be stored on a banker board and

protected from rain and frost.



Storage of Metals (Wall Ties, Reinforcement, etc.)

231. 880 Metals shall be protected by being stored off the ground and under cover.

Ferrous and nonferrous materials shall be kept separate and care shall be taken to prevent direct contact between copper-bearing materials and aluminium or zinc.

Storage of Bituminous Felt

231. 890 Bituminous Felt shall be stored on a level surface, covered from direct sun

and away from heat, in such a manner as to prevent damage by squashing.

Storage of Thermal Insulation Materials 231. 900 These materials shall be stored under cover and off the ground to prevent

contamination. They shall be protected from wetting at all times.

Protection During Laying 231. 910 All masonry shall be adequately protected against physical damage and

splashing with contaminating substances by the use of boards, covers and other agreed means. Special care shall be taken to ensure that angles and sills are adequately protected.

231. 920 Precautions shall be taken against abrasions from scaffolding. Scaffold

boards shall be turned away during periods of heavy rain, and at night, to avoid splashing.

Protection After Laying

231. 930 Where insitu concrete is cast above or adjacent to completed work the

latter shall be protected from splatter and cement paste. 231. 940 Freshly completed masonry shall be covered with waterproof sheets in

locations where damage may be caused by rain or frost, or quick drying. 231. 950 Door and window frames and also other items built in shall be fully

protected by boards, sheets or other measures.

Precautions During Cold Weather



231. 960 Precautions to be implemented during cold weather shall be submitted to the Purchaser for agreement and shall ensure reasonable rates of hardening of the mortar and that the masonry is not subjected to freezing action until the mortar has matured sufficiently. Masonry shall be protected from frost by the use of suitable insulating coverings or by heaters. Coverings shall be adequately supported.

231. 970 Suitable means shall be provided to warm mortar ingredients, including

water and also bricks, to ensure that the temperature of the mortar in the brickwork does not fall below 5°C.

Mixing water shall not be heated above 60°C. In no case shall the temperature of the combined materials exceed 32°C before the cement is added. Mortars of a higher classification than that specified shall not be used for the brickwork for the purpose of preventing freezing or accelerating hardening. The use of additives to the mortar which prevent freezing or accelerate hardening will not be permitted.

231. 980 Bricks and blocks in a frozen condition shall not be used. Mortar shall not

be laid on frozen surfaces. Frost damaged mortar shall be raked out and replaced. Damaged brickwork/blockwork shall be taken down and rebuilt as required by the Purchaser.

231. 990 Rolls of damp proof coursing shall be warmed prior to unrolling to avoid

cracking. 231. 1000 Pointing shall not proceed in frosty weather.

Precautions During Wet or Warm Weather 231. 1010 Masonry shall be protected from the effects of hot sunlight and drying winds

until the mortar has matured. 231. 1020 In dry or warm weather clay bricks and blocks, except engineering bricks,

shall be wetted with water from an agreed source to prevent mortar drying out prematurely.

231. 1030 During construction, and at the end of each working day, masonry shall be

protected from heavy rain. Wet bricks or blocks shall not be used. Portland Cement Mortars

231. 1040 Mortar designation shall be by Class number with a minimum of Class (iii)

as defined in BS 5628 pt 1. Any type of mortar of the same Class may be



selected subject to the agreement of the Purchaser. 231. 1050 Mortar shall have the mix proportions, by volume, stated in the table below:

MORTAR TYPE (PROPORTIONS BY VOLUME) Class No.

BS Mortar Designation

Cement: sand

Cement: Ready mixed lime/sand (proportions of lime and sand as given in brackets)

Cement: sand with plasticizer

Masonry cement: sand

M1 M2 M3

(i) (ii) (iii)

1:3 - -

1:3 (1:12) 1:4 (1:9) 1:6 (1:6)

- 1:3-4 1:5-6

- - 1:4-5

231. 1060 Sulphate resisting mortars shall be specified on the Drawings. Sulphate

resisting cement shall be substituted for ordinary cement in the proportions given in the above table.

231. 1070 Proportions of mixes given in the above table are for dry sand. Allowance

for bulking shall be made when gauging by volume. 231. 1080 Equipment proposed for gauging mix proportions shall be submitted to the

Purchaser for agreement. 231. 1090 Mixing shall be carried out by machine in accordance with BS 5628 Part 3

unless a small quantity only is required. Mixing shall continue until the mortar is of uniform consistency and colour.

231. 1100 Where an admixture is agreed for use it shall be added in accordance with

the manufacturer's recommendations. 231. 1110 The Contractor shall submit details of the proposed mixing sequences for

each mortar type to the Purchaser for agreement, i.e. cement/sand or cement/premixed lime and sand.

231. 1120 Mortar shall not be used more than 2 hours after it has been mixed, unless

retardants have been added. Unused mortar shall be discarded.

Laying Brickwork and Blockwork



231. 1130 Kiln fresh bricks shall not be used. 231. 1140 If facing bricks are delivered in loads with a noticeable variation in colour

they shall not be used in rotation as delivered. Bricks from different loads shall be intermingled to ensure that any differences in colour do not form defined areas in the completed brickwork.

231. 1150 Brickwork and blockwork shall be built in a uniform manner and corners and

other advanced courses, shall not be raised above the general level by more than 1.2m. Corners shall be raised first and these shall be laid to a gauge rod and be racked back to the main wall.

231. 1160 Horizontal and vertical joints shall have a uniform thickness, nominally

10mm. 231. 1170 Bricks and blocks shall be laid on a full bed of mortar and single-frogged

bricks shall be laid with the frogs uppermost. If bricks with double frogs are used then they shall be laid with the deeper frog uppermost and the bed joints shall have sufficient mortar to ensure that the frogs on the underside of the bricks are completely filled with mortar. Voids in hollow blocks shall not be filled with mortar.

231. 1180 All bricks and blocks shall be well buttered with mortar to form the vertical

joints before being laid and all joints shall be thoroughly flushed up after each course has been laid. Particular care shall be taken when laying blocks to ensure that deep vertical joints are completely filled with mortar. After laying, the faces shall be cleaned of excess mortar.

231. 1190 Brickwork built with Standard Format bricks shall rise four courses in

300mm. 231. 1200 Blockwork shall rise four courses in 900mm. 231. 1210 The maximum height of brickwork/blockwork that shall be built in a day is

1.5m. 231. 1220 Work below ground or below DPC level shall be built of Class E engineering

bricks laid in sulphate resisting mortar, unless otherwise specified. 231. 1230 External faced brickwork shall commence two courses below the finished

ground level. 231. 1240 Edge cover to joint reinforcement shall be as the table below:



EXPOSURE CONDITION OF THE MASONRY BRICKWORK OR BLOCKWORK

TYPE OF STEEL REINFORCEMENT

REINFORCEMENT IN MORTAR JOINTS BETWEEN BRICKS OR BLOCKS - COVER TO OUTER FACE OF BRICKWORK OR BLOCKWORK

Unprotected

Galvanised to BS729 Austenitic stainless

Not to be used 25mm

Sheltered from severe rain and against freezing whilst saturated with water. Buried masonry and masonry continuously submerged in fresh water

Galvanised to BS729 and Austenitic stainless

25mm

Completely protected against weather or aggressive conditions

Galvanised to BS729 and Austenitic stainless

25mm

Construction Tolerances

231. 1250 The following tolerances and deviations shall not be exceeded:

a. plan position: ± 10mm b. length (except where defined up to 5m ± 15mm

by adjacent construction):

5m-10m ± 20mm 10m-20m ± 25mm over 20m ± 30mm

c. height: up to 3m ± 15mm

3m-6m ± 20mm over 6m ± 25mm



d. level of bed joints:

up to 5m ± 10mm 5m-10m ± 15mm

e. verticality:

in any 3m ± 10mm overall in walls higher than 6m ± 20mm

f. thickness of walls or width of piers: ± 15mm provided not

more than 10mm at any two points 3m apart.

g. openings up to 3m wide: ± 6mm on structural dimensions. h. openings over 3m wide: ± 10mm on structural dimensions.

Cutting Brickwork and Blockwork

231. 1260 Fair faced blockwork shall be cut to size wet with a mechanical masonry

saw, hosed and dried before use unless otherwise agreed with the Purchaser. Bolstering shall not generally be permitted.

Where lintel bearings over penetrations do not coincide vertically and/or horizontally with incidental blockwork courses the residual volume may be filled with horizontally laid concrete brick matching the colour and texture of the block.

231. 1270 High strength bricks shall be cut with a masonry disc or saw. 231. 1280 Where the underside height of a slab or beam does not coincide with the

top of a blockwork course (i.e. a multiple of 225mm) the residual space may be filled with concrete brickwork to a nominal depth of 75mm, 112mm or 187mm. Where impractical the blockwork shall be cut to size wet, with a mechanical masonry saw.

231. 1290 Rises and quoins shall be racked back, and toothing shall only be used

when appropriate.

Openings in Brickwork/Blockwork



231. 1300 Joint reinforcement of expanded metal 50mm narrower than the width of the wall must be provided at all positions above and below wall openings in blockwork, extending for a minimum of 600mm either side of the opening to the first and second courses above and below the opening. Corresponding reinforcement must be provided in the brickwork of cavity walls.

231. 1310 Door and window frames which are built in as the work proceeds shall be

supported and braced to prevent misalignment and distortion of the frames. 231. 1320 All lintels shall be set level bearing on a full brick/block at each end. The

lengths of bearing of the lintels shall be as specified in BS 5628 Part 3. 231. 1330 Pre-cast reinforced concrete lintels shall be built in with their correct side

uppermost relative to the reinforcement. 231. 1340 Prestressed reinforced concrete lintels spanning 2m or over shall be

propped at centres not exceeding 1m until the superimposed masonry construction has aged at least seven days.

231. 1350 Steel lintels with drip nosings shall be positioned to ensure that they are

clear of main head frames.

Bond 231. 1360 Brickwork one or more bricks thick shall be built in English bond unless

specified otherwise. Half brick walls, including half brick leaves of cavity walls, shall be in stretcher bond.

231. 1370 Where a fair face is required on both sides of a wall one brick thick, each

face shall be in stretcher bond with full width expanded metal placed in alternate courses to tie the leaves together.

231. 1380 Bricks shall be laid throughout the work with cross joints in any course not

less than a quarter of a brick from those in the course below. Half bricks and bats shall not be used except where necessary to maintain the specified bond.

231. 1390 Where dimensions do not permit normal bonding the Purchaser shall be

consulted before laying is commenced. 231. 1400 New brickwork/blockwork shall be bonded to existing work in blocks not

more than 300mm high. 231. 1410 Angles and intersections in walls shall be fully bonded or tied as instructed

by the Purchaser.



Structural Stability

231. 1415 The Contractor shall ensure that brickwork and blockwork is stable and safe

at all stages of construction.

Cavity Walls 231. 1420 During construction, one leaf of the cavity wall shall not rise more than

450mm in advance of the other. 231. 1430 Cavity wall ties shall be laid sloping downwards towards the exterior and

staggered alternate courses to the following spacings:

(a) Both leaves 90mm thick or more

Cavity width Horizontally Vertically

50-75 mm 900 mm 450 mm 75-100 mm 750 mm 450 mm 100-150 mm 450 mm 450 mm (b) Either leaf is 75mm thick or less

Cavity width Horizontally Vertically

50-75 mm 450 mm 450 mm

(c) When the cavity is to receive board or slab insulation the

bottom row of cavity ties above the DPC shall have a maximum spacing of 600mm

231. 1440 Where a vertical damp proof course prevents bonding of the two leaves at

the reveals to openings or similar locations, a vertical line of additional wall ties shall be used at a maximum spacing of 300mm and within 225mm horizontally of the openings.

231. 1450 Cavities shall be kept clear of mortar droppings and other rubbish by means

of lifting screeds. Mortar droppings shall be cleaned from the ties and the inside mortar joints flushed up as the work proceeds.

231. 1460 Openings shall be left at the base of walls and other locations where mortar

and rubbish can collect in the cavity. Rubbish and mortar droppings shall be cleaned from the cavities daily and removed through the openings in the wall. After a wall has been completed the opening shall be closed with



bricks and mortar to match the surrounding wall. 231. 1470 Cavities below ground level shall be in-filled by a method agreed by the

Purchaser, to a level of 150mm below the damp proof course. 231. 1480 Weepholes shall be formed in the outer leaf of a cavity by leaving open

vertical joints at 900mm centres at the base of cavities and where the cavity is bridged horizontally. The cavity in-fill shall slope towards the weepholes and towards the outer leaf.

231. 1490 Where a structural steel or concrete member with a width of at least 450mm

interrupts the inner skin of a cavity wall the outer skin shall have one layer of expanded metal or agreed equal reinforcement to every fourth course carried beyond the steel or concrete member for a distance of 900mm in each direction.

231. 1500 Cavity insulation boards and slabs are to be installed in accordance with

the manufacturers recommendations, clipped against the internal leaf with close butt joints. The cavity face of the inner leaf is to be clean of all mortar droppings before insulation is installed. The retained cavity space is to be kept free of mortar droppings and other debris. All slabs and cut slabs shall be retained by at least two clips.

Joint Finishing

231. 1510 The faces of fair faced brickwork shall be pointed with neat weatherstruck

joints as the work proceeds, unless otherwise specified. The mortar joints to external fair faced brickwork shall, if the brickwork is to be pointed in the bedding mortar, be worked to the required profile whilst the mortar is still green.

231. 1520 Special pointing shall be carried out using purpose made pointing tools. 231. 1530 The joints of brickwork and blockwork finished to receive plaster or

rendering shall be raked out not less than 12mm and not exceeding 18mm deep as the work proceeds.

231. 1540 Gaps in brickwork movement joints shall be left free from debris and shall

be filled with an agreed flexible jointing material to within 20mm of face, and externally the remaining gap will be primed and sealed using a two part polysulphide sealant in accordance with the manufacturers recommendations. Colour to match brickwork.



Hemp, fibreboard, cork and similar materials shall not be used as the filler material.

231. 1550 Control joints shall have a minimum width of 10mm filled with mortar to

within 20mm of the block face and pointed with an agreed two part polysulphide sealant.

Damp Proof Courses (DPC)

231. 1570 Damp proof courses shall be laid in accordance with the workmanship

recommendations given in BS 5628 Part 3. 231. 1580 The DPC shall form a watertight joint with any adjacent waterproof

membranes. 231. 1590 Brickwork and blockwork shall be built up flush with mortar to an even bed.

The DPC shall be laid on the mortar in continuous strips, flush with the outer surface of the bricks or projecting from the wall, with 150mm laps in length and full laps at angles. The joint shall then be completed to normal thickness with mortar.

231. 1600 Proprietary shaped DPC's shall be used at junctions and corners in

accordance with the manufacturer's recommendations. Stepped DPC's shall be used where the external ground is sloping.

231. 1610 In cavity walls, separate DPC's shall be provided for each leaf and the

edges shall not project into the cavity. 231. 1620 The DPC's used with cavity wall bridges, such as door and window opening

lintels, ducts, etc., shall be unjointed wherever possible, but where joints cannot be avoided, lapped at least 150mm and sealed with an agreed jointing compound. They shall be fixed tightly across the cavity, stepped up towards the inner leaf and supported to prevent sagging. They shall extend at least 150mm beyond the end of the bridge.

231. 1630 Vertical jambs in cavity walls shall have the DPC in close contact with the

frame. The DPC shall be fully lapped under the DPC at head and over the DPC at sill and shall extend at least 25mm into cavity.

231. 1640 In parapets a full width DPC shall be placed immediately below the coping.

An additional DPC shall be placed above the roof level and stepped down across the cavity towards the inner leaf.



Movement Joints 231.1650 Movement joints, both horizontal and vertical, shall be provided in

accordance with BS5628 part 3 and the block/brick manufacturer's recommendations.

QUALITY CONTROL

General

231. 1660 Two copies of Certificates verifying that the materials comply with the

Specification, and containing the test results of the tests specified in the relevant British Standards, shall be submitted by the Contractor to the Purchaser at the intervals specified below.

231. 1670 Cement - each consignment within four days of delivery.

Water - (from any source other than a statutory undertaking) - at commencement of work and then monthly.

Sand - each 10m3 or weekly, whichever is the more

frequent, or whenever the supply pit or area of the pit is changed.

Lime - each consignment within four days of delivery.

Bricks and Blocks -each consignment within four days of delivery.

Other - as specified by the Purchaser. Materials

231. 1680 Where manufacturer's documentation is not available, the Contractor shall

carry out tests at a frequency not less than that stated in the appropriate BS to ensure that materials comply with this Specification.

Testing 231. 1690 Building sealants shall be tested in accordance with 402. 231. 1700 Mortar mixes shall be tested at least six weeks prior to use on Site in

accordance with BS 4551. 231. 1710 The laboratory control test shall comprise:



° preparation of specimen mixes with a consistency which allows a dropping ball to penetrate 10mm.

° Cast a set of six sample specimens. The size shall be 100mm

cubes or as agreed with the Purchaser. Store the cubes in accordance with BS 4551.

° Core test three cubes at 7 days and three cubes at 28 days for

compressive strength.

° Submit results to the Purchaser. 231. 1720 Site control tests shall be carried out after commencing the masonry work

at intervals agreed with the Purchaser. The specimens shall be of the same size and stored as for the laboratory control test.

231. 1730 A set of six mortar specimens shall be prepared for each class of mortar, for

every 150m2 of wall or for every storey of a building. 231. 1740 Three specimens shall be core tested after 7 days to BS 4551. If the 7 day

strength falls below that specified the Contractor may elect to continue to work at his own risk.

If the 28 day strengths of the remaining three specimens also fail to achieve the specified strengths then the Contractor shall take down and rebuild the work affected.

231. 1750 The Contractor shall submit all results to the Purchaser.



Inspection

231. 1760 Details of equipment proposed for weigh batching cement, lime and sand

shall be submitted to the Purchaser for agreement. The accuracy of the equipment shall be checked at intervals in accordance with the manufacturer's recommendations, and it shall not be used if it has an error of +2.5 per cent or more. Each material shall be weighed individually.

231. 1770 The Contractor shall build sample panels of faced brickwork and blockwork,

2m long by 1m high. These panels shall be built using bricks or blocks and mortar to the bond and pointed in the manner as specified for the wall for which the panel is representative and submitted to the Purchaser for agreement. They shall form the standard for all subsequent work and shall be protected against damage. They shall be removed on completion of the Works.

231. 1780 The Contractor shall perform inspection of brick and blockwork to ensure

that the work conforms with the requirements of this Specification. A certificate of conformance shall be provided for work in each room or area.

231. 1790 The Contractor shall submit to the Purchaser for agreement an inspection

procedure for blockwork. The procedure shall address the requirements for 'special category' construction as described in BS 5628, Part 1.

231. 1800 All structural blockwork in buildings shall be inspected in accordance with

the agreed procedure. Inspection shall be performed continuously during blockwork construction. Inspections shall be documented and submitted to the Purchaser.

231. 1810 The Purchaser shall be notified when construction of block or brickwork is

started.





between the requirements of these Standards and this Generic Specification Section.

BS 12 Specification for ordinary and rapid hardening Portland cement. BS 146 Specification for Portland-blastfurnace cement. BS 187 Specification for calcium silicate (sandline and flintline) bricks. BS 405 Specification for uncoated expanded metal carbon steel sheets for

general purposes. BS 493 Specification for air bricks and gratings for wall ventilation. BS 680 Specification for roofing slates. BS 729 Specification for hot-dip galvanized coatings on iron and steel

articles. BS 743 Specification for materials for damp proof courses. BS 747 Specification for roofing felts. BS 890 Specification for building limes. BS 970 Specification for wrought steels for mechanical and allied

engineering purposes. BS 1014 Specification for pigments for Portland cement and Portland cement

products. BS 1178 Specification for milled lead sheet for building purposes. BS 1181 Specification for clay flue linings and flue terminals. BS 1200 Building sands from natural sources, for mortar for plain and

reinforced brickwork, brickwalling and masonry. BS 1243 Wall ties for cavity wall construction. BS 1289 Flue blocks and masonry terminals for gas appliances. BS 1470 Specification for wrought aluminium alloys for general engineering

purposes: plate, sheet and strip. (Withdrawn) Replaced by BS EN 485 Parts 1-4, BS EN 515: 1993 and BS EN 573 Parts 1-4.

BS 1554 Specification for stainless and heat resisting steel round wire. BS 2870 Specification for rolled copper and copper alloys: sheet, strip and

foil. BS 3148 Methods of test for water for making concrete. BS 3921 Clay bricks and blocks. BS 4027 Specification for sulphate-resisting Portland cement. BS 4483 Specification for steel fabric for reinforcement of concrete. BS 4550 Methods of testing cement. BS 4721 Specification for ready-mixed building mortars. BS 4729 Shapes and dimensions of special bricks.



BS 4887 Mortar admixtures. BS 5224 Specification for masonry cement. BS 5628 Part 1: Unreinforced masonry. BS 5628 Part 3: Materials for components, design and workmanship BS 5642 Sills and copings. BS 5977 Lintels. BS 6073 Part 1 and Part 2: Pre-cast concrete masonry BS 6398 Specification for bitumen damp proof courses for masonry. BS 6561 Specification for zinc alloy sheet and strip for building. BS 6577 Specification for mastic asphalt for building (natural rock asphalt

aggregate). BS 6676 Code of practice for installation of batts (slates) filling the cavity. BS 6925 Specification for mastic asphalt for building and civil engineering

(limestone aggregate).




CLAUSE REFERENCE


COMMENT

231.040 231.190 231.390 231.510 231.960 231.1080 231.1110 231.1660 231.1710 231.1750 231.1790 231.1800

Submission of samples. Clarification for procurement. Proposals for admixtures. Details of cavity insulation discs. Precautions against inclement weather. Gauging mix equipment. Proposed mortar mixing sequence. Material certificates. Laboratory control test results. Site control test. Inspection procedure for blockwork. Inspection documents.



TECHNICAL SPECIFICATION WORK GROUP: 240 : CLADDING & FACADES SECTION NO: 241 TITLE: CLADDING & FACADES TABLE OF CONTENTS SCOPE MATERIALS General Cladding sheets Sheet Metal Accessories Lining Sheets for Insulated Cladding Filler Blocks Sealants Insulating Tape Insulaton Fixings CONTRACTOR DESIGN Design General Design Life Detailed Design and Drawings Wind Loading Deflection Tolerances Weatherproofing Colour Surface Finish Climatic Variations Thermal Transmission Vapour Transmission Penetrations



TABLE OF CONTENTS WORKMANSHIP Packaging, Handling, Storage and Protection Installation Works QUALITY CONTROL Cladding Tests Fastener Tests Leak Tests APPENDIX 1 BSI STANDARDS AND OTHER REFERENCES APPENDIX 2 INFORMATION TO BE PROVIDED BY CONTRACTOR



SCOPE 241. 010 This Section defines the requirements for the insulated and non-insulated

cladding & facades including all necessary matching accessories, fixings, internal linings, fire stops, gutters and other items required to provide a complete durable and weathertight installation.

MATERIALS

General 241. 030 All materials specified shall comply with the relevant British Standards listed

in Appendix 1. Recommendations of approved manufacturers of proprietary cladding and facade systems, relating to design, materials and workmanship, shall be adhered to in conjunction with the contents of this section 241. Where differences occur, the higher standard will be adopted.

241. 040 All materials shall be resistant to fungal attack, infestation, vermin and other

forms of biological attack. All materials shall be free of asbestos and other substances carrying a health risk.

241.045 Samples of a range of typical flashings and junctions shall be submitted

with the contractors design submissions for agreement by the Purchaser. 241.048 A completed section of cladding & facades including typical flashings,

eaves, cills, closures etc shall be presented for inspection on each building one month before substantial completion.

Cladding Sheets 241. 050 The type of material, the profile and the finish of cladding sheets shall be

shown on the Drawings.

The minimum material thickness of metal cladding shall be 1.2mm unless otherwise agreed by the Purchaser.

Sheet Metal Accessories 241. 060 Sheet metal accessories shall be formed from the same material as the

cladding sheets and shall be colour matched, The material thickness shall be appropriate to the particular application, but shall not be less than 0.9mm for aluminium sheets.

CWSpec-SECT241-Rev4.doc 3/13 Detailed Civil Engineering Specification Lining Sheets for Insulated Cladding


241. 070 The type of material, the profile and the finish of internal lining sheets shall

be shown on the Drawings. The minimum material thickness shall be 0.7mm for aluminium sheets and 0.55mm for steel sheets.

Filler Blocks

241. 080 Filler Blocks shall be manufactured from EPDM and shall be of closed cell

construction to ensure a weathertight seal.

Sealants 241. 090 Lap sealants shall be EPDM or elastomeric compound tape type sealants.

The sealants shall be soft enough not to interfere with the fit of the sheets and resilient enough to accommodate any variations in fit and thermal movements that may occur. Sealants shall not harden with age and shall be compatible with filler block materials.

Insulating Tape

241. 100 Tape for insulating dissimilar metals shall be self adhesive PVC. The

thickness shall not be less than 0.25mm.

Insulation 241. 110 Insulation material shall be mineral wool of 60kg/m3 density unless

otherwise specified.

Fixings

241. 120 Primary fixings shall be grade 316 stainless steel self tapping screws with stainless steel/EPDM sealing washers. The particular type of fastener for a given application shall be selected in accordance with the fastener manufacturers recommendations, noting that hot rolled and cold formed steel substrates require different fastener designs.

241. 130 Secondary fixings shall be blind rivets with integral load spreading washers

and EPDM sealing washers. 241. 140 All fixings shall have integral or snap-on caps colour matched to the

cladding sheets being fixed. 241.145 All fixings shall be agreed by the manufacturer of the cladding.



Design General 241. 150 Designs shall comply with the relevant British Standards listed in Appendix

1. Particular reference shall be made to BS 5427. 241.155 The Contractor's design submissions shall comply in every respect with the

Design Requirements section of this Specification.

Design Life 241. 160 The cladding system shall satisfy the following requirements:-

i) A performance life of 30 years minimum.

ii) A decorative life of 15 years minimum.

iii) A minimum period to first maintenance of 20 years.

iv) A 5 yearly cycle of inspections with maintenance generally limited to repair of accidental damage.

In satisfying the above requirements, the design shall take full account of the environmental conditions at the site.

241. 170 The term "performance life" is defined as the period over which the cladding

system will perform effectively as cladding or roofing with a minimum of maintenance. There shall be no loss of integrity of the metal substrate or coatings over the 30 year period.

241. 180 The term "decorative life" is defined as the period over which the cladding

system will maintain its aesthetic appearance, with maintenance limited to no more than a wash down at the end of the 15 year period.

241. 190 The term "first maintenance" is defined as the time at which repairs are

required to small areas of the coating, (not exceeding 5 per cent of the total area), to maintain protection to the metal substrate.

241. 200 The Contractor shall be responsible for the design of the cladding system,

which shall meet the requirements for design life listed above. 241. 210 The Contractor shall verify that the cladding materials, profiles and finishes

will satisfy the performance requirements of the Specification. Should the Contractor wish to propose alternative materials then these shall be notified at the time of tender.



241. 220 The Drawings may show indicative details for cladding junctions (ridge,

eaves, corners etc.). In such cases the Contractor shall be responsible for developing the working details, but shall not vary the intended architectural treatment without the agreement of the Purchaser.

241.225 The Contractor shall provide extensive and comprehensive details of all

cladding junctions, flashings and closures with the details to be submitted in accordance with Clause 241.155 of this specification.

Detailed Design and Drawings

241. 240 The Contractor shall prepare all necessary detailed design, general

arrangement and detailed drawings to enable fabrication and erection of the cladding to be carried out.

241. 250 The drawings shall show details and sizes for all accessories and shall

specify the type and location of all fasteners. The length and width of cladding sheets shall be shown together with full details of laps, ridges, eaves, gutters, closures etc.

241. 260 The arrangement of cladding sheets shall minimise the need for laps.

Where required, laps and their fixings shall be continuous and shall coincide with the edges of large openings for doors, windows and other major features. Flashings shall be secretly fixed wherever possible.

241. 270 Minimum laps for cladding sheets shall be as follows.

Side Cladding 100 mm

Roof Cladding 225 mm

Larger laps may be required for exposed sites and for low pitched roofs. 241. 280 The Contractor shall submit calculations and shop drawings to the

Purchaser for agreement. The calculations shall include stress and deflection checks for the cladding sheets and designs for all fasteners.

Wind Loading 241. 290 The cladding system shall be designed to withstand the wind loadings

derived from the appropriate British Standards and Codes of Practice.



Deflection

241. 300 The cladding system shall be capable of resisting sporadic pressure from

wind gusts without fracture or permanent deformation. The deflection shall not exceed the following:-

Due to wind load Span/150

Due to imposed load Span/250

The cladding system shall be designed to resist the effects of drifting snow in accordance with BS 6399 Part 3.

Tolerances

241. 310 The out of tolerance of the cladding sheets and accessories shall not

exceed 1/250 of the distance between fixings or width of flat surface. Weatherproofing

241. 320 The cladding system shall be designed to be completely waterproof and

shall be air-tight to the extent that gaps between components shall be closed with filler blocks or seals. Side laps shall be arranged to face away from the direction of prevailing winds.

Colour

241. 330 The following requirements shall apply for the decorative life of the cladding

system:-

i) Differences in colour of adjacent panels or accessories visible to the naked eye shall not occur.

ii) The colour change and loss of gloss of the individual panels

and accessories shall be minimal and the panels shall not be subject to severe chalking.

Surface Finish 241. 335 The cladding coating is to have a smooth, flat finish to minimise retention of

dust, dirt etc on the surface.



Climatic Variations 241. 340 The cladding system shall be designed and detailed to take account of

variations in dimensions and shape due to changes in temperature and humidity without deterioration in performance. Coatings shall not suffer mechanical or chemical breakdown under extremes of temperature and humidity.

Thermal Transmission

241. 350 Unless otherwise specified insulated cladding shall have a sufficiently low

thermal transmittance to ensure that an overall maximum U value of 0.45W/m2 deg C is achieved. Cold bridges, pattern staining, inside surface condensation and interstitial condensation shall be prevented in the design. Vapour Transmission

241. 360 Insulated cladding shall have liner panel side and end laps sealed to

prevent the transmission of moisture and water vapour. 241. 370 Penetrations

Penetrations through cladding shall be sealed with purpose-designed flashings, soakers and seals.

WORKMANSHIP

Packaging, Handling, Storage and Protection

241. 380 The Contractor shall comply with the manufacturer’s recommendations for

packaging, handling, storage and protection of materials. Cladding sheets, linings and accessories shall be supplied in marked, fully enclosed cases with paper interleaves between sheets.

Prior to erection, all materials shall be stored in their packages, off the ground and under cover.

241. 390 All materials shall be protected against mechanical or other damage and

contamination by dirt, oil or other contaminating matter. During erection and until handover measures shall be taken to avoid damage or soiling of materials. In particular, scaffolding shall be independent of the cladding with plastic buffers at the ends of the poles adjacent to complete cladding. During handling operations nylon slings or ropes shall be used. The use of



clamps shall not be permitted. 241. 400 Damaged components shall not be used or repaired. Touching up with paint

will not be permitted.

Installation Works 241. 410 Prior to commencing installation, the Contractor shall inspect the framing to

which the cladding is to be fixed to ensure that it has been erected correctly and within the tolerances specified. Any defects shall be corrected prior to the commencement of installation of cladding in the affected area.

241. 430 The installation work shall be carried out in accordance with the shop

drawings and in accordance with a method statement to be provided by the Contractor for review by the Purchaser prior to commencement of the work.

241. 440 Where possible, sheeting of complete elevations shall be carried out as a

single operation, all sheets being fixed continuously from one end, to ensure tight fitting at end and site laps. Cladding sheets shall be fixed and lined accurately. In particular, fixings shall be arranged in accurate lines to give a neat visual impact.

241. 450 Holes for fasteners shall be drilled to the size recommended by the fastener

manufacturer. The use of punches for forming holes will not be permitted. 241. 460 PVC tapes used in conjunction with aluminium cladding sheets shall have

75mm minimum end laps, 25mm minimum side laps and shall project beyond the edges of the face to be covered by at least 13mm.

241. 470 All extraneous material, such as drilling swarf, metal off-cuts, insulation,

paper, sealants etc, shall be removed as the work progresses. All dirt and grease shall be removed from the surfaces of the cladding prior to hand-over.



QUALITY CONTROL

Cladding Tests

241. 480 Where tests are to be carried out to prove the design of the cladding

system, the Contractor shall provide evidence of the tests for review by the Purchaser.

241. 490 The Contractor shall prepare a sample panel of the complete cladding

system, including the sheeting rails and purlins, in order to prove the design and to provide a comparator which the finished permanent works shall match.

Fastener Tests

241. 500 The Contractor shall provide evidence of the strength of the proposed

fasteners. Particular attention shall be paid to the "fixing pull-through" mode of failure on thinner gauge materials. A minimum of six test results shall be provided for each application. Leak Tests

241. 510 Prior to handover the Contractor shall carry out a leak test to verify the

watertightness of the building. The test shall use a high pressure hose simulating the conditions of a rain storm intensity of once in 20 years. Details of the proposed testing shall be submitted to the Purchaser for agreement.






BS 729 Specification for hot dip galvanized coatings on iron and steel articles

BS 1091 Specification for pressed steel gutters, rainwater pipes, fittings and accessories.

BS 1449 Steel plate, sheet and strip BS 1470 Specification for wrought aluminium and aluminium alloys for

general engineering purposes: plate sheet and strip. (Withdrawn) Replaced by BS EN 485 Parts 1-4, BS EN 515: 1993 and BS EN 573 Parts 1-4.

BS 1494 Specification for fixing accessories for building purposes. Part 1: Fixings for sheet, roof and wall coverings.

BS 2989 Specification for continuously hot-dip zinc coated and iron-zinc alloy

coated steel: wide strip sheet/plate and slit wide strip. (Withdrawn) Replaced by BS EN 10143: 1993.

BS 4174 Specification for self tapping screws and metallic drive screws. BS 4255 Rubber used in preformed gaskets for weather exclusion from

buildings Part 1: Specification for non-cellular gaskets.

BS 4800 Specification for paint colours for building purposes BS 4868 Specification for profiled aluminium sheet for building. BS 4904 Specification for external cladding colours for building purposes. BS 5427 Code of practice for performance and loading criteria for profiled

sheeting in buildings. BS 6213 Guide to selection of constructional sealants. BS 6367 Code of practice for drainage of roofs and paved areas BS 6399 Loading for buildings. Part 1: Code of Practice for dead and imposed loads Part 3: Code of Practice for imposed roof loads.



CP 3 Code of basic data for the design of buildings. Chapter V Loading Part 2: Wind Loads

CP 118 The structural use of aluminium CP 143 Code of practice for sheet roof and wall coverings CP 153 Windows and Rooflights BS EN ISO 11963 Polycarbonate sheets. Types, dimensions and characteristics BS 5516 Code of practice for design and installation of sloping and

vertical patent glazing




CLAUSE REFERENCE


COMMENT

241.225 241.230 241.280 241.410 241.430 241.480 241.500 241.510

Details of cladding junctions, flashings and closures. Additional framing and trimming steelwork. Calculations and shop Drawings. Notification of inspection prior to installation. Method statement. Cladding test results. Fastener test results. Leak test details and notification.



TECHNICAL SPECIFICATION WORK GROUP: 250 : ROOFS SECTION NO: 251 TITLE: PVC SHEET ROOF COVERINGS TABLE OF CONTENTS SCOPE MATERIALS

Timber Warm Deck Insulation Ancillary Products and Accessories

WORKMANSHIP

General Inclement Weather Fixing of Timber Vapour Control Layer on Continuous Base Attachments of Warm Deck Insulation Suitability of Base Movements Joints Laying PVC Sheet Partial Bonding Skirtings and Upstands Edge Trims to Canopies Completion



SCOPE 251. 010 This Section defines the requirements for built-up PVC sheet roof coverings.

MATERIALS

Timber 251. 030 Timber for trims etc used in roofing shall be planed and shall be free from

wane, pitch products decay and insect attack. Maximum moisture content at time of covering shall not exceed 22%. It shall be preserved in accordance with British Wood Preparing Association Commodity Specification C8.

Warm Deck Insulation

251. 040 Warm deck insulation shall be polystyrene board to BS 3837 : Part 1 with foil

face.

Ancillary Products and Accessories 251. 050 Ancillary products and accessories that are not specified shall be types

recommended for the purpose by the PVC sheet manufacturer agreed by the Purchaser.

WORKMANSHIP

General

251. 070 The full roof covering shall be laid in a single operation to provide a secure,

free draining and completely weathertight roof.

The Contractor shall form details with adequate overlapping, staggering of laps and full bonding of successive layers so that they are waterproof. Strips of PVC sheet required for "linear" details shall be cut from the length of the roll rather than the width.



Inclement Weather

251. 080 Rolls of PVC sheet shall be stored indoors in reasonably warm conditions

until immediately before use.

Temporary covers and drainage shall be provided as required to keep unfinished areas of the roof dry.

Daywork joints in warm deck roofs shall be protected as required to keep unfinished areas of the roof dry.

Work shall be suspended in severe or continuously wet weather unless an effective temporary roof is provided over the working area.

If unavoidable wetting of the construction does occur the Contractor shall take prompt action to minimise and make good any damage.

Fixing of Timber

251. 090 Timber for trims etc. shall be fixed with sheradized steel screws at not more

than 600mm centres.

Vapour Control Layers in Continuous Boards 251. 100 Sheets shall be laid with fully bonded 50mm side and 75mm end laps.

Joints in second layer (if any) shall be staggered by half a sheet. Adequate free edge shall be left for sealing perimeter of insulation.

Penetrations shall be fully sealed using bonding or taping methods recommended by the manufacturer.

Attachment of Warm Deck Insulation

251. 110 Boards shall be laid with long edges running at 45 degrees to structure,

tightly butted together with staggered end joints and in a full bed of bonding compound. On completion of laying the Contractor shall ensure that boards are in good condition, well fitting and with no springing, flexing or rocking and that the waterproof covering is sealed to the free edge of the vapour control layer to form a complete envelope around the insulation.

Suitability of Base



251.120 Before laying PVC sheet the Contractor shall ensure that:

- The base is to even falls with no areas which will pond. - Surfaces to be covered are firmly fixed, clean, dry, smooth, free from

frost, contaminants, voids and protrusions. - All preliminary work including formation of upstands, kerbs, box

gutters, sumps, grooves, chases, expansion joints, etc. and fixing of battens, fillets, anchoring plugs/strips, flashings, copings, roof outlets, pipesleeves, ventilators, etc. is complete and satisfactory.

Movement Joints

251.130 Movement joints shall consist of steel plate fixed to insulation board on one

side only and covered with polyester fleece.

The PVC sheet shall be carried straight over the sheet.

Laying PVC Sheet 251.140 The Contractor shall start at the lowest point of roof and unroll PVC sheet up

the slope with not less than 50mm side and 75mm end laps, ensuring that water will drain over and not into laps.

- Between layers, side laps shall be staggered by one half sheet width

in two layer coverings and one third sheet width in three layer coverings. Successive layers shall be applied with minimum delay, ensuring that moisture is not trapped. Liquid PVC shall be applied to all exposed edges of membrane.

- Partial Building

251.150 The Contractor shall loose lay the specified first layer to roof surfaces, but

do not carry up angle fillets and vertical surfaces or through details.

Skirtings and Upstands 251.170 The Contractor shall:



- Form upstands at ends of rolls by carrying felt up without using separate strip. Elsewhere use matching strips of felt, maintaining the specified laps.

- Carry layer of PVC Sheet to full height of upstand, fully bonding each layer. Where practicable carry top layer of felt over top of upstand.

- Secure PVC Sheet to upstand by solvent welding.

Edge Trims to Canopies 251.180 Polyester Fleece Underlayer(s) shall be laid under upstand and free edge

shall be left projecting 25mm from wall or fascia.

The rim shall be secured by solvent welding.

The Contractor shall fit jointing sleeves fixed one side only and leave 3mm gaps between ends of trip.

Purpose made corner pieces shall be used.

Completion

251.190 The Contractor shall ensure that:

- Roof areas are left clean with all outlets clear. - All work by others necessary to provide a weathertight finish is

satisfactorily completed. - Finished roof areas are adequately protected from damage by

subsequent building operations. - Defects are repaired without delay to minimise damage and

nuisance.





between the requirements of the Standards and this Specification.

BS 3837 : Part 1 Specification for boards manufactured from expandable beads.

British Wood Preparing Association Commodity Specification C8.



TECHNICAL SPECIFICATION WORK GROUP: 260 : WOODWORK SECTION NO: 261 TITLE: CARPENTRY AND JOINERY TABLE OF CONTENTS SCOPE DESIGN MATERIALS

General Structural Softwood Softwood for Joinery Hardwood for Joinery Sheet Materials Mechanical Fastenings and Adhesives Structural Fastening and Adhesives Joinery Fastenings Preservatives

WORKMANSHIP

General Joinery Timber Skirtings Removable Duct Panels Protection

QUALITY CONTROL




SCOPE 261. 010 This Section defines all carpentry and joinery and associated fixings to be

carried out on or off the Site for the Permanent Works in wrot or unwrot softwood, in hardwood or using manufactured sheet materials made principally with timber. Additional requirements for timber doors and windows are given in Section 311.

DESIGN

261. 030 The fabrication design of structural timbers shall be to BS 5268.

MATERIALS

General 261. 040 All timber shall be clean, sound, properly seasoned timber free from any

disease, defects or combination of defects, natural or otherwise, making it unsuitable for its function. It shall be selected at time of fabrication as suitable for the particular purpose.

Structural Softwood

261. 050 Softwood for carpentry shall be General Structural (GS) Grade, to BS 4978,

with a minimum average density of 510kg/m3 at 15% moisture content. 261. 060 Softwood for structural use shall be Western Hemlock, European

Whitewood, European Redwood or Douglas Fir, unless otherwise specified. 261. 070 All timber shall be finished sawn, unless otherwise stated, and the sizes

shall, wherever possible, be those listed in BS 4471. Sizes not in accordance with BS 4471 shall be sawn from appropriate larger sizes.

Softwood for Joinery

261. 080 Softwood for trim, skewing and similar items shall be clear grade, straight

grained and air or kiln-dried to a moisture content of 12%, to BS 1186: Part 1, with a minimum average density of 430 kg/m3 at 15% moisture content.



261. 090 Softwood for internal joinery shall be European Redwood, Douglas Fir, Western White Pine or European Whitewood, unless otherwise specified.

261. 100 Softwood for external joinery shall be European Redwood or Douglas Fir,

unless otherwise specified. 261. 110 All timber shall be wrot on all faces, unless otherwise stated, and the sizes

shall be, wherever possible, as those listed in BS 4471. Sizes not in accordance with BS 4471 shall be sawn from appropriate larger sizes.

261. 120 Timber having defects arising from machining, knots etc. shall not be used

unless defects are repaired in accordance with BS 1186: Part 1. Pitch pockets and pin wormholes shall be repaired in accordance with BS 1186: Part 1.

261. 130 Timber containing splay knots, checks or shakes as defined in BS 1186:

Part 1, shall not be used where these defects will appear on the exposed edges or faces of joinery work.

Hardwood for Joinery

261. 140 Hardwood for joinery shall be to BS 1186 Part 1, except that the use of

timber having defects arising from manufacture, knots and other defects requiring plugging shall not be permitted. Sizes shall be as defined in BS 5450. The type of hardwood shall be specified on the Drawings.

Sheet Materials

261. 150 Softwood plywood for general purposes shall be manufactured from

European Pine, European Birch, Douglas Fir, Columbian Pine or other equal agreed timber, Grade CBR to BS 6566.

261. 160 Hardwood ply shall be Weather and Boil Proof (WBP) bonded as Grade

WBP in BS 6566. 261. 170 Wood chipboard shall be of Type II/III as defined in Section 1 of BS 5669. 261. 180 Blockboard and laminboard shall be to BS 3444.



Mechanical Fastenings and Adhesives 261. 190 All ferrous metalwork, nails, screws, bolts and other mechanical fastenings

shall be protected by galvanising or suitable plating for all external work, work in areas of high humidity or corrosive conditions.

261. 200 The types of adhesives used shall be in accordance with the

recommendations in Tables 1 and 2 of BS 5442, Part 3.

Structural Fastenings and Adhesives 261. 210 Nails shall be round wire, annular ringed shank or helical threaded shank to

BS 1202: Part 1. 261. 220 Wood screws shall be of steel, brass or stainless steel to BS 1210 with

slotted countersunk heads as described in Table 1. 261. 230 Hexagon black bolts and nuts for timber/timber or for timber/metal

connections shall be to BS 4190, each supplied with 2 No. large washers to BS 4320. Heads of bolts over 6mm diameter shall be embossed or indented with the letters ISOM or M and the manufacturer's name.

261. 240 Timber connectors shall be of the galvanised split-ring/shear plate/ toothed

plate type to BS 1579. 261. 250 Straps shall be of galvanised pre-drilled factory made steel, but not less

than 2.5 mm x 30 mm in section. 261. 260 Joist hangers shall be standard proprietary galvanised steel of 2.5 mm

minimum thickness to suit timber sizes and predrilled for nailing.

Joinery Fastenings 261. 280 Nails shall be to BS 1202: Part 1. For decorated work they shall be lost-

head nails suitable for stopping. 261. 290 Wood screws shall be of steel, brass or stainless steel to BS 1210. Brass

or stainless steel shall be used for hardwood or clear-finished work. 261. 300 Cups for screws shall be brass or stainless steel heavy pressed socket

pattern.



261. 310 Adhesives shall be cold setting synthetic resin to BS 1203 or 1204 as appropriate, of the correct class for the duty and type of joint. Unless otherwise stated, use Type INT for internal work, Type MR for internal work in areas of humidity, and Type WBP for external work. The Contractor shall submit details to the Purchaser for agreement.

Preservatives

261. 320 Methods of treatment for constructional timbers as protection against

degradation by wood destroying organisms and environment shall be to BS 5268 Part 5, and shall be a double vacuum process appropriate to the timber being treated and as described in British Wood Preserving Association's Specifications BWPA 112-116 (obtainable from BWPA, 150 Southampton Road, London WC1B 5AL).

WORKMANSHIP

General

261. 330 The moisture content of the timber used at the fabrication and erection

stages shall lie within the range 16-20%.

Tests shall be carried out at regular intervals to be agreed with the Purchaser.

Testing to BS 5268 Part 2 using an electrical moisture meter is permitted. 5-10% of the timbers shall be tested and 90% of the test values shall lie within the specified range of moisture contents.

261. 370 Defects which reduce the strength of the connection shall not be permitted

at joints, bearings or assembly locations. 261. 380 Workmanship, testing and maintenance shall generally be to BS 5268. 261. 390 Joints in the length of a structural member shall only be permitted if they

can be shown by calculation to develop the full strength of the member. Joints over bearings shall be made in a manner agreed by the Purchaser.

261. 400 Structural timbers shall not be cut, notched or modified other than as

specified.



261. 410 All joints shall be nailed, screwed, bolted or jointed as necessary.

Glued site joints shall not be permitted without the permission of the Purchaser.

261. 420 Nails shall be of adequate length to provide a secure fixing and, where

appropriate, shall be driven on the slant so that the connection does not loosen under load. Splitting of timber by nailing shall be avoided by sensible spacing and, where necessary, pre-drilling not in excess of three-quarter nail diameter.

261. 430 Masonry nails shall not be used. 261. 440 Screw sizes shall match pre-drilled holes in carpenter's metalwork and shall

be of adequate length to provide a secure fixing. Screws shall be driven tight at right angles to the face in pre-bored holes. Pre-boring shall be for the length of, and to the diameter of, the plain shank and to the diameter of the thread core. Countersink for countersunk holes. Hammering of screws shall not be permitted.

261. 450 Only durable proprietary fibre composition or plastic plugs let into drilled

holes shall be used for screw fixings to concrete, masonry and blockwork. 261. 460 Bolts shall be of a length that will project one complete thread length

beyond the head of the nut without undue tightening. They shall pass through holes slightly larger than their diameter, be fitted with thick washers under the head and nut, and tightened so that the washers just compress the timber.

261. 470 Glued joints shall be made in controlled workshop conditions. The moisture

content shall not exceed 20% and joint faces shall be freshly prepared, clean and clamped together in full contact under pressure.

261. 480 Masonry bolts shall adequately penetrate into masonry to provide a secured

fixing. Resin anchors shall be used instead of expanding bolts near edges of masonry. Large washers shall be used to protect the timbers.

261. 490 Bolt holes for timber connectors shall be accurately located at the

intersection of the centre lines of the timbers to be joined. Toothed-plate connectors shall be embedded before bolting by compressing joint faces with a temporary threaded high tensile steel rod with a large thick washer and nut on both sides, or by cramping or other means of pressure. Split-ring or shear plate connections shall have grooves pre-cut with special tools. Bolts and connectors, size and type,



shall be shown on the Drawings. 261. 500 Straps and anchors shall be fixed at each timber contact point with two

galvanised screws when the number is not specified. Straps shall span at least two members when strapping joists and rafters. Any gaps between timber members and masonry shall be blocked when strapping to masonry. Any strap taken into a cavity wall shall be turned down tight against the inner skin for an adequate distance. The fixing of straps to resist lateral loads to tops of masonry shall ensure that the fixing is not limited to a single brick or cut block. All faces intended to be in contact shall be in close contact without any unspecified bending or improvisation.

261. 510 Joist hangers shall be screw-to-wall hangers, unless otherwise indicated,

and shall be of the correct size to fit the timber and to suit the loadings. They shall be fixed in close contact with all supporting and fixing surfaces and with the timber being supported. The joists shall be nailed through all pre-drilled holes and shall be properly levelled to avoid notching.

261. 520 Framing anchors shall only be used instead of timber joints subject to the

agreement of the proposed type and locations by the Purchaser. 261. 530 Wall plates shall be in one piece between changes of direction wherever

possible, otherwise a 100 mm lap joint shall be used. They shall be laid truly level in a bed of mortar and fixed with straps as necessary.

261. 540 Timbers shall bear in full contact on designed supports. The ends of

timbers that are built into masonry shall be liberally coated with preservative. All timbers shall be protected from contact with potentially damp surfaces and structures. Any necessary packings shall use material that will not rot or compress.

261. 550 Openings shall be properly trimmed. The trimmers shall correctly align with

upper and lower surfaces and shall be fitted tightly using joist hangers. Wherever possible, loads shall be transmitted to other solid structures.

261. 560 Joists shall use regularised timber to ensure level supports for floors and

linings, etc. 261. 570 Studding shall be constructed with tight butt joints securely nailed. The top

of the partitions shall be securely fixed, but shall not transmit any unintended loading from structures above. Regularised timbers shall be used when truly flat backgrounds are required.



261. 580 Noggings shall be provided wherever necessary. They shall be plugged and screwed if end fixing is prevented by joist hangers.

261. 590 Gaps between masonry walls and joists, rafters, trusses, etc. shall be

packed with timber blocking to match fixing centres. 261. 600 Bowing and twisting of joists shall be prevented by solid blocking at all

bearings and solid or herringbone strutting at intermediate span as appropriate. Herringbone strutting shall be in full contact and properly nailed and shall not project.

261. 610 All necessary temporary bracing shall be provided. Diagonal bracing shall

be provided for all rafters and trusses to resist wind forces. 261. 620 Chipboard shall be stored for 2 days prior to fixing in conditions similar to

those which will occur in the completed building. 261. 630 All flooring and decking shall be fixed in a manner that has been agreed by

the Purchaser. 261. 640 Roof trusses shall be erected in accordance with the fabricator's erection

method statement. 261. 650 Timbers shall be prevented from contact with potentially damp surfaces and

structures or shall be provided with suitable protection as agreed by the Purchaser.

261. 660 Designed ventilation routes of the roof structure shall not be obstructed. 261. 670 Holes and notches etc. for services, where required, shall be as small as

practicable and not closer than 100 mm apart unless otherwise agreed with the Purchaser. U-shaped notches, made by sawing down to a drilled hole, shall be located only in the upper edge of the outside quarters of beams and joists and shall have a maximum size one-eighth depth of member. Holes shall only be drilled along centre line through centre two-thirds of span of beams and joists and shall have a maximum size one-sixth depth of member. Notches and holes in other members shall be made in locations of least stress and never adjacent to point loads.

261. 680 2mm minimum flat steel plates, let in flush with top of joists, shall be fixed

over services in notches under flooring to prevent nail damage.



261. 700 Framework to receive laminated panels shall be designed to allow fixings 70mm from the edge of each panel and to allow a gap of 5mm between panels or between an end panel and wall finish. Framing for panelled duct covers in toilets or change areas shall be made entirely of suitably preserved softwood, three faces 'left from the saw'. The framework shall be constructed to present a true and accurate surface for receiving the panels.

261. 710 Supporting timbers for plasterboard shall permit nailing of the board not less

than 13mm from cut or unbound edges and 10mm from bound edges and allow nails to be driven straight, not skewed. The dimensions of the supports shall allow for a gap of 3 mm between the cut edges of boards. Where the above fixing requirements cannot be met by simple framing additional timbers shall be fixed to the side of the support to increase the bearing surface.

Joinery

261. 720 Jointing shall be accurately formed using the recognised form for each

position and shall generally be as described in Part 2 of BS 1186, Section 2, except that the adhesives employed shall be to BS 1203 or BS 1204 as appropriate.

261. 740 Loose joints shall be used in positions where provision shall be made for

shrinkage or movement. Glued joints shall only be employed in positions where provision for movement is not required and where necessary shall be cross tongued or otherwise reinforced.

261. 750 Where 'nominal' dimensions are stated for 'wrot' timber an allowance of

3mm shall be permitted for each planed surface. Large scale detail drawings shall be held to show actual dimensions.

261. 760 The standard of surface finish shall be as described in Part 2 of BS 1186,

Section 5. All exposed faces of timber shall be 'wrot' and shall be machined or worked to the correct shapes and sizes.

261. 770 Where a 'natural' finish for staining, polishing or clear varnishing is required,

timber in adjacent faces shall be matched to be uniform or symmetrical in colour and grain.

261. 780 Reasonable precautions shall be taken to prevent capillary penetration in

external joinery or in places where joinery is exposed to wet conditions. The joiner must ensure that all throatings and grooves are properly executed on all external joinery.



261. 790 Nails shall only be used in areas to be painted. All heads of nails, sprigs

etc. are to be punched home and the surface of the timber be made good with an agreed filler material.

261. 800 Screws in hardwood other than for fixing ironmongery, shall be either

countersunk and pelleted or, if they need to be removable, shall be cupped. 261. 810 Screws for fixing removable panels shall be of the 'mirror' type with screw-

on dome heads. 261. 820 For glued joints in external joinery, Type WBP adhesives shall be used. For

timber in change areas, toilets, and ducts containing plumbing, Type MR adhesives shall be used. In all other cases Type INT adhesives shall be used.

Timber Skirtings

261. 830 These shall be of profiled rectangular softwood, or hardwood, and skew

nailed to grounds or fixing pads. 261. 840 Skirtings shall be installed after the floor has been laid.

Removable Duct Panels 261. 850 These shall be either of blockboard, plywood or of a proprietary laminated

board. The thickness, type and duty (grade/fire rating etc) of the panels shall be shown on the Drawings. The edges shall be lipped with hardwood when specified.

261. 860 Blockboard shall be veneered on both sides and along all edges with all

arisses softened to a 45° angle when hardwood lipping is not required. 261. 870 Holes shall be drilled for screw fixings 70mm from the sheet edges and

equally spaced at a maximum of 900mm centres.

Protection 261. 880 Any floors subject to construction traffic shall be protected by temporary

hardboard or other suitable cover. All joinery exposed to damage shall be cased up. Architectural ironmongery shall be fixed as a final operation or else wrapped.



261. 890 All shavings and offcuts, etc. shall be collected and removed from site. No

surplus material shall be left in concealed spaces where they could attract vermin or contribute to a fire.

QUALITY CONTROL


261. 900 Inspections to roof structures shall ensure that adequate lateral restraint is

provided to the tops of walls and that all bolts have been tightened correctly.

261. 910 All bolts shall be checked, and tightened if necessary, at the end of the

maintenance period. 261. 920 The Contractor shall submit for agreement a programme for the testing of

the moisture content of timbers for use in fabrication and during erection.






BS 1186 Timber for and workmanship in joinery. Part 1: Specification for timber. Part 2: Specification for workmanship.

BS 1202 Specification for nails. Part 1: Steel Nails.

BS1203 Synthetic resin adhesives (phenolic and aminoplastic) for plywood.

BS 1210 Specification for wood screws. BS 1579 Specification for connectors for timber. BS 3444 Specification for blockboard and laminboard. BS 4190 Specification for ISO metric black hexagon bolts, screws and nuts. BS 4320 Specification for metal washers for general engineering purposes.

Metric series. BS 4471 Specification for sizes of sawn and processed softwood.

(Withdrawn) Replaced by BS EN 1313-1:1997. BS 4978 Specification for softwood grades for structural use. BS 5268 Structural use of timber. Part 2: Code of practice for permissible stress design, materials and

workmanship. Part 5: Preservative treatments for constructional timber.

BS 5442 Classification of Adhesives for Construction. Part 3: Adhesives for use with wood.

BS 5450 Specification for sizes of hardwoods and methods of measurement. BS 5669 Specification for wood chipboard and methods of test for particle

board. BS 6566 Plywood.



APPENDIX 2 - INFORMATION TO BE AGREED BY CONTRACTOR

CLAUSE REFERENCE


COMMENT

261.270 261.310 261.330 261.640 261.920

Adhesive details. Adhesive details. Moisture content test results. Roof truss erection statement. Programme for testing moisture content.



TECHNICAL SPECIFICATION WORK GROUP: 270 : SANITARY AND PLUMBING SECTION NO: 271 TITLE: SANITARY AND PLUMBING INSTALLATIONS TABLE OF CONTENTS SCOPE CONTRACTOR DESIGN MATERIALS

Sanitary Fittings, Glazed Ceramic (including associated fittings) Pipes and Fittings Pipe Supports Insulation Storage and Protection

WORKMANSHIP

General Fixing of Appliances Jointing and Pipework Supports Overflows Vent Pipe Terminals Sealing Pipework Open Ends System Access

QUALITY CONTROL

Submittals Testing Sterilisation of Water System




SCOPE

271. 010 This Section defines all sanitary appliances and fittings to be used for

domestic purposes together with associated pipework for hot and cold water services, waste water drainage and overflows.

It does not include equipment for producing hot water or hot water heating systems.

CONTRACTOR DESIGN

271. 030 The installation shall be to BS 6700, BS 5573 and BS 6367. 271. 035 All service runs shall be concealed unless prior authorization is granted by

the Purchaser. 271. 038 The Contractor shall submit detail drawings of all service runs in

accordance with the Design Requirements section of this Specification.

MATERIALS

Sanitary Fittings, Glazed Ceramic (including associated fittings). 271. 040 Sanitary fittings shall be white glazed unless otherwise stated and be to:-

BS 3402 for vitreous china BS 1206 for glazed fireclay

All fitting styles/designs shall be agreed by the Purchaser.

271. 050 WC pans shall be to BS 5503 pedestal type or BS 5504, corbel or wall

hung, and shall be heavy duty type of vitreous china. Corbel pans shall be washdown type P trap only with a hinged block open-front seat. A chair support shall be provided for mounting. Pedestal pans shall be washdown type 'P' or 'S' trap with a black plastic ring seat and secured with chromium plated screws. The height of either pan shall not exceed 405mm above finished floor.

271. 060 Urinal bowls and divisions shall be to BS 5520 and shall be heavy duty

vitreous china with concealed supports such that the lip of the bowl is not more than 610mm above finished floor level. The waste outlet shall be 32mm diameter.

271. 070 Flushing cisterns shall be to BS 1125 of ceramic ware and mounted such



that the underside is not less than 1905mm above finished floor level. Automatic flushing cisterns shall have a water control device to economise water usage.

271. 080 Flushing pipes shall be white enamelled steel, plastics or copper, self

finished, painted or chromium plated. 271. 090 Basins (ablution and hand) shall be to BS 1188 and BS 5506 and of heavy

duty vitreous china and mounted using fishplates, wall hangers, bolts or cast iron brackets. Central leg supports shall be provided where light wall construction or heavy usage of basins is anticipated. Waste outlets shall be 32mm with captive plug and overflow. Spray tap basins shall have one tap hole on the right hand side.

271. 100 Shower trays shall be to BS 6340 of glazed fireclay with anti-slip base and

waste outlet of 38mm diameter fitted with a strainer waste and overflow. 271. 110 Washing sinks shall be to BS 1206 of glazed fireclay, with a waste outlet of

38mm diameter, captive plug and overflow, and mounted on cast iron wall brackets finished in white nylon, vitreous enamel or other agreed finish. Where the wall is of light construction, stainless steel leg and strap supports shall be provided.

271. 120 Bucket sinks shall be to BS 1206, of glazed fireclay and fitted with bucket

grating of chromium plate brass or stainless steel with a hardwood pad and 38mm diameter waste outlet. Mountings shall be as for washing sinks.

271. 130 Drinking fountains shall be vitreous china provided with a 19mm or 32mm

waste outlet with chromium plated domed outlet grating and 13mm self-closing non-concussive lever or wheel action valve mounted with a cast iron supporting bracket finished in white porcelain enamel or nylon.

271. 140 All water fittings and materials for domestic use shall comply with the Water

Byelaws and be listed in the Water Byelaws Advisory Service (WBAS) Directory.

271. 150 Draw-off taps for sinks and basins shall be to BS 1010, BS 5388, BS 5412

as appropriate. They shall be chromium plated and marked blue for cold, red for hot. All draw-off taps shall have fitted in the supply pipe an in-line ball type isolating valve to facilitate maintenance of the draw-off tap.

271. 160 Thermostatic mixing valves shall be to BS 1415. 271. 170 Waste outlet bodies plugs and chains shall be to BS 3380. The bodies and



chains shall be chromium plated and the plugs plastic. 271. 180 Ball cocks for cisterns shall be to BS 1212. 271. 190 Gate valves on hot and cold water services, cold feeds and washout pipes

shall be of gun-metal to BS 5154 for sizes up to and including 54mm nominal bore, and flanged cast iron to BS 5163 for larger sizes. Flanges shall comply with BS 4504 PN 16.

271. 200 Stop valves shall be of gunmetal to BS 1010. 271. 210 Drain valves shall be of gunmetal and to BS 2879. 271. 220 Water storage cisterns shall be made from hot moulded glass reinforced

plastics, sectional steel suitably corrosion protected, galvanised mild steel to BS 417 Part 2, polyphone or olefin copolymer to BS 4213.

271. 230 Stainless steel sink units shall be to BS 1240 and pressed from 1.2mm

gauge stainless steel.

Pipes and Fittings 271. 240 Copper pipes shall be to BS 2871 (Part 1 to Table X) and shall have

capillary soldered, brazed or compression joints to BS 864. Lead free solder shall be used for potable water systems.

271. 250 Plastics pipes and fittings (including uPVC, abs, polypropylene,

polyethylene) for soil and waste drainage shall be, as appropriate, to BS 4514, BS 5254 or BS 5255 and shall have solvent welded or ring sealed pushfit joints.

271. 260 Centrifugally cast (spun) coated ductile iron pipe and fittings shall comply

with the relevant requirements of BS 416 medium grade bearing the British Standard Kite Mark, jointed with bolted couplings complying with BS 6087 all as the Timesave System or agreed equivalent.

The bolted coupling rubber gasket shall be specifically ordered incorporating inset conductors to provide electrical continuity along the full length of the pipe work systems.

Branch connection components shall consist of branch fittings or screwed boss fittings.

271. 270 Floor drainage gullies shall be of cast iron stainless steel (304 Grade) with



gratings of stainless steel, polypropylene or equal agreed material secured with stainless steel screws.

271. 280 Waste traps to sanitary fittings shall be of polypropylene, two-piece tubular

pattern to BS 3943.

Pipe Supports 271. 290 Supports to plastics and copper pipes shall be made using purpose made

nylon, plastic, copper or brass clips, brackets or hangers. Pipe hangers shall be to BS 3974.

Insulation

271. 300 Cold water services subject to condensation shall be insulated with a

minimum 19mm thickness of preformed split section non-degradable insulating material appropriate to the pipe size.

271. 310 Hot water services shall be insulated with a minimum 25mm thick insulation

similar to that above. 271. 320 All insulating material shall be to the fire requirements of BS 476 not less

than Class 'O' rating and shall have a low level of smoke generation. The materials shall be applied in strict accordance with the manufacturers recommendations and shall, on completion, have a smooth continuous, easily cleaned outer surface with all joints securely taped. Storage and Protection

271. 330 Glazed ceramic sanitary fittings shall be stored with either their

manufacturer's packaging or with the manufacturer's gummed paper edge protection intact. Care must be taken at all times to avoid chipping or cracking. Fixing accessories shall be separately packaged labelled and stored adjacent to the fittings.

271. 340 Stainless steel sinks, pipework, taps and all other valves or accessories

shall be stored with their manufacturer's packaging intact. 271. 350 Gummed paper and other edge protection shall be removed only when the

appliances are cleaned immediately before handover.

WORKMANSHIP

General



271. 360 The installation of internal sanitary drainage and water services shall be

carried out by, or under the supervision of, personnel registered with the Institute of Plumbing. The Contractor shall submit details to the Purchaser for information.

Fixing of Appliances

271. 370 Appliances shall be fixed with chromium plated steel or brass screws and

bedded as appropriate on 6:1 sand cement mortar.

Jointing and Pipework 271. 380 All joints in pipework shall be made in accordance with the pipework

manufacturer's instructions and the Contractor shall submit a statement to the Purchaser for agreement, detailing the joints for each type of pipe material to be used.

271. 390 Copper pipework under 42mm diameter bore shall be neatly bent in a

manner which preserves an even bore throughout and pipes shall be set either horizontally or vertically.

271. 400 Copper pipes over 67mm diameter shall be bronze welded using filler rods

and an oxyacetylene flame. 271. 410 Copper pipes buried in floor screeds and wall chases shall be protected

from contact with the plaster, concrete or mortar either by precoating with PVC or spirally wrapping in a mastic tape.

271. 420 Plastic pipes and copper pipes above 42mm diameter shall be routed using

straight pipes and standard bends. 271. 430 Screwed joints to metal fittings shall be made using ptfe tape. 271. 440 Connections between dissimilar pipe systems shall be by means of a

purpose designed transition piece agreed by both systems manufacturers. 271. 450 All pipework, jointing and support systems shall be constructed from

chemically and electrolytically compatible materials. Where incompatible materials may be in contact suitable means of insulation shall be provided to prevent damage to either surface.

271. 460 Hot and cold water service branches to ranges of sanitary fittings, or

branches to individual fittings, shall be provided with ball type isolating valves fitted as close as practicable to the fittings served.



271. 470 All pipework installations of conducting materials shall be cross-bonded and

earthed in the manner recommended in the current regulations of the Institute of Electrical Engineers.

271. 480 All bends on soil stacks shall be large radius bends. All changes of

direction and branch connections on suspended soil and waste pipe runs shall be made with 145o bends and branches, except where this is not practicable, in which case the fittings shall have the greatest angle possible below 145o.

271.485 All piped drainage systems shall be provided with traps of suitable size and

type immediately adjacent to the sanitary device being served.

Supports 271. 490 Pipework systems shall be supported on hangers or brackets at not less

than the intervals given below:

MATERIAL

SIZE IN MM

SPACINGS IN

METRES HORIZONTAL RUNS

VERTICAL RUNS

COPPER

10-15 20-30 32-40 42-50

1.2 1.4 1.7 1.8

1.2 1.4 1.7 1.8

PVC

32-38

50 75-100

150

0.5 0.9 0.9 1.0

1.2 1.2 1.8 1.8

IRON

All

1.8

2.4

271. 500 In all cases the pipework manufacturer's recommendations shall be applied

where these require closer spacing of fixings than those indicated above and on all flexibly jointed pipe systems at least one support shall be provided for each unit length.

271. 510 Brackets and hangers shall be securely fixed with non-corrodible screws

and fixings appropriate to the base material. 271. 520 All pipework systems shall be run and supported in a manner which

provides for thermal or other expansion and contraction and predictable building movement.

271. 530 All stacks shall be installed truly vertical, and horizontal pipework shall be CWSpec-SECT271-Rev4.doc 7/14 Detailed Civil Engineering Specification


true in alignment and uniform gradient. All stacks shall be supported by at least one pipe support bracket in a manner to support the vertical load and in any case the distance between pipe supports shall not exceed the distances specified.

271. 560 Provision shall be made in the fixing of branch pipes to the main vertical

stack to prevent shearing or deformation due to vertical movement of the main pipe.

271. 570 Horizontal and vertical runs of adjacent pipes shall be fixed in a manner

which allows sufficient space between the pipes or adjacent surfaces to carry out the installation, and subsequent painting and maintenance of the pipes without obstruction.

271. 580 Care shall be taken to ensure that the pipe axis is parallel with the axis of

the pipe ring or bracket and that drop rod supports are vertical. All supports shall be in alignment and shall not impose side strain on the pipework and shall provide uniform pipe gradient.

271. 590 Water service pipes passing through fire barriers shall be fitted in a manner

which maintains the barriers' fire rating and excludes transmission of smoke and flame across the barrier but which does not interfere with any thermal movement of the pipework. Penetrations through walls and floors in a visible position shall be provided with chromium plated or white plastic wall/floor plates.

271. 600 Additional supports shall be provided at branch connections and changes of

direction on suspended pipework providing a stable and secure pipework system capable of being rodded through without detriment to the system.

271. 610 Branch connections shall be supported independently and not used to help

in the support of it parent main. 271. 620 Overflows

Overflow and warning pipes discharging externally shall do so in a conspicuous position in an area where the discharge will not be disregarded. Where discharge internally is unavoidable this shall be positioned over a suitable floor drainage gully in a manner which will draw attention to the discharge without causing flooding or damage. The location of overflow and warning pipes shall be agreed by the Purchaser.

Vent Pipe Terminals



271.660 Vent pipes shall only pass through the roof with the agreement of the

Purchaser which will not be given unless there is no practical alternative. 271. 670 Purpose made weathering slate or manufactured weathering fittings shall

be provided to all vent pipe terminals through roof. 271. 680 Purpose made traditional lead soakers shall comprise BS 1178 No. 4 sheet

lead slate size 600 x 600 and upstand 170 high with leadburned seam and joint The upstand shall be a close tolerance fit to the pipe.

271. 700 PVC pipes shall be fitted with a PVC apron shrouding the lead upstand

terminating with PVC cowl and metal pipe shall be fitted with purpose made lead apron with top edge dressed into top of pipe and terminating with wire balloon grating.

271. 710 In the case of inverted roof construction the height of the upstand shall be

equal to the roof construction thickness above the waterproof membrane plus 150mm.

271. 720 Vent pipes shall terminate 300mm above the finished roof level.

Sealing Pipework Open Ends 271. 740 All pipework open ends or open sockets or open fittings shall be properly

sealed, plugged or capped during the progress of the works to prevent entry of building material and debris.

271. 750 Plastic, shaped hardwood or metal discs, plugs, caps or drain plugs will be

acceptable for this purpose. 271. 770 Rainwater outlets shall be temporarily plugged during the laying of

chippings. 271. 780 Loose chippings around outlets shall be swept clear prior to removing the

temporary plug.

System Access 271. 790 Access points shall be provided to facilitate rodding through, inspection and

testing of the entire pipework system. 271. 800 Access points shall be installed near the base of all stacks, at changes to

pipe direction, in the vicinity of or on all stack branches or grouped stack branches at each storey, on the upstream end of common branch waste



pipes, on the top of stub pipe upstand. 271. 810 Access points shall always be positioned above flood level of sanitary

appliances unless it is impracticable to do so, and they shall be oriented so as not to be obstructed by the structure or pipework, and such access points shall correctly relate to removable panels in order to facilitate ease of removal of the access plate, rodding through and replacement of the access plate.

271. 820 All in-line access doors shall be contoured to match the pipe bore. 271. 830 Metal or plastic rectangular or oval type access doors shall be fitted with

brass or other rust-proofed fixings bolts/screws and soft rubber gaskets. 271. 840 Iron pipe end access shall consist of screwed cap brass ferrule, lead

caulked into iron socket, or an iron blank cap secured with bolted coupling. 271. 850 Copper pipe end access shall comprise copper or copper alloy screwed cap

fitting. 271. 851 Plastics pipe end access shall consist of plastic screwed cap, fitting, all

complete with sealing washer.

QUALITY CONTROL

Submittals 271. 860 The Contractor shall submit full details for agreement including samples of

the following items which he proposes to use:

(a) ceramic sanitary ware

(b) pipe brackets and hangers.

Testing 271. 870 Testing for soundness (air test) shall be carried out in sections as the works

proceed to suit the progress of the building work. Pipes to be concealed shall be tested before being enclosed, and final testing shall be carried out at completion.

271. 880 The Contractor shall take remedial action in respect of any defects found

and shall re-test the section at fault until satisfactory before proceeding further to ensure soundness of the installation in readiness for the final tests at completion.



271. 890 All services shall be subjected to hydraulic test at a pressure 1.5 times the

maximum working pressure for not less than 30 minutes and shall be inspected under working conditions for flow and pressure., in accordance with BS 6700.

271. 900 Any defects revealed by the tests shall be made good and the tests

repeated until the results are satisfactory.

Sterilisation of Water System 271. 910 After completion of testing all debris shall be removed from the storage

cisterns and flushing cisterns and the whole system shall be thoroughly flushed out with clean water and drained. The system shall then be refilled with water into which is dispersed chlorine at a dilution of 50 parts per million. All taps and outlets on the system must be opened in sequence until chlorine is detected by comparator and then closed. After topping up the system with the chlorine solution it shall be allowed to stand for a period of at least 3 hours after which residual chlorine should be detectable at 0.2 mg/l by comparator. If chlorine cannot be detected the sterilisation procedure shall be repeated.

271. 920 After a successful conclusion to this procedure the system shall be drained

and thoroughly flushed before handing over, with the disinfecting water discharged to the agreement of the Purchaser.






BS 417 Specification for galvanised low carbon steel cisterns, cistern lids, tanks and cylinders.

BS 476 Fire Tests on Building Materials and structures. Part 7: Method for classification of the surface spread of flame of products. BS 864 Capillary and compression tube fittings of copper and copper

alloy. Part 2: Specification for capillary and compression fittings for copper tubes. BS 1010 Specification for draw-off taps and stop valves for water services

(screw drawn pattern). Part 2: Draw-off taps and above ground stop valves. BS 1125 Specification for WC flushing cisterns (including dual flush cisterns

and flush pipes). BS 1188 Specification for ceramic wash basins and pedestals. BS 1206 Specification for fireclay sinks: dimensions and workmanship. BS 1244 Metal Sinks for Domestic Purposes, Part 2: Specification for

stainless steel sink tops (excluding inset sinks). BS 1415 Mixing valves. Part 2: Specification for thermostatic mixing valves. BS 2871 Specification for copper and copper alloy tubes.

(Withdrawn) Replaced by BS EN 1057: 1996. Part 1: Copper tubes for water, gas and sanitation. BS 2879 Specification for Draining Taps (screw-down pattern). BS 3380 Specification for wastes (excluding skeleton sink wastes) and bath

overflows. BS 3402 Specification for quality of vitreous china sanitary appliances. BS 3943 Specification for plastics waste traps. BS 3974 Specification for pipe supports. BS 4213 Specification for cold water storage and feed and expansion

cisterns (polyphone or olefin copolymer) and cistern lids.

BS 4504 Flanges and bolting for pipes, valves and fittings, metric sizes. BS 4514 Specification for unplasticized PVC soil and ventilating pipes. BS 5154 Copper alloy globe, globe stop and check, check and gate valves. BS 5254 Specification for polypropylene waste pipe and fittings (external

diameter 34.6mm 45.0mm and 54.1mm). BS 5255 Plastic waste pipes and fittings.



BS 5412 Draw-off taps with metal bodies for water services. Part 1: Dimensional and design characteristics. (See also Part 2, Part 3,

Part 4 and Part 5). BS 5503 Specification for vitreous china washdown pans with horizontal

outlet. BS 5504 Specification for wall hung WC pans. BS 5506 Specification for wash basins. BS 5520 Specification for vitreous china bowl urinals (rimless type). BS 6340 Shower units. BS 6700 Specification for design, installation, testing, and maintenance of

services supplying water for domestic use within buildings and their curtilages.




CLAUSE REFERENCE


COMMENT

271.038 271.350 271.370 271.560 271.920

Details of Service Runs Details of plumbing personnel. Details of joints. Details of sanitary ware and pipe supports. Disposal of disinfecting water.



TECHNICAL SPECIFICATION WORK GROUP: WORK GROUP: 280: FINISHES SECTION NO: 281 TITLE: PLASTERING, RENDERING AND DRY LINING TABLE OF CONTENT SCOPE MATERIALS

General Cement Aggregates Water Lime Gypsum Plasters Bonding Agent Metalwork Accessories Gypsum Plasterboards Framing for Dry Lined Partitions Plasterboard and Dry Lining Jointing Materials

WORKMANSHIP

General Clean Working Conditions Preparation of Background Surfaces Plastering and Internal Rendering - General - Application of Plaster/Render External Rendering - General - Application of Render Plasterboard Dry Lining - General



TABLE OF CONTENT

- Fixing Wallboards - Joint and Angle Treatment - Defects and Damage to Finished Work - Plaster - Dry Lining

QUALITY CONTROL APPENDIX 1 BSI STANDARD AND OTHER REFERENCES APPENDIX 2 INFORMATION TO BE PROVIDED BY CONTRACTOR



SCOPE 281. 010 This Section defines:

(i) Plastering of internal walls.

(ii) Rendering of internal and external walls.

(iii) Erection of dry lining either as facing to internal walls or as facings to internal partitions.

(iv) Erection of plasterboard ceilings.

MATERIALS

General

281. 040 All premixed materials or materials in powder form shall be delivered to site

and stored on site in unbroken, dated containers bearing the manufacturer's product name.

Cement

281. 050 Cement shall be ordinary or rapid hardening Portland cement to BS 12 or

Portland blast furnace cement to BS 146.

Aggregates 281. 060 Sand for rendering shall be to BS1199 Table 1. It shall be from a clean and

uncontaminated source.

Water 281. 070 Mixing water shall be from an agreed clean and uncontaminated source of

potable quality and shall be tested in accordance with BS3148 if required. Lime

281. 080 Lime putty shall be either ready prepared to BS890 or made by mixing

hydrated lime powder to BS890 with water to thick cream consistency and leaving undisturbed for 16 hours.

281. 090 Lime and sand (coarse stuff) shall be either:



° ready mixed to BS 4721

° lime putty mixed with sand (the hydrated lime powder and sand to be mixed in the dry state before adding water then left for 16 hours).

Gypsum Plasters

281. 100 Premixed lightweight gypsum plaster shall be to BS 1191: Part 2. The type

of undercoat shall be compatible with the background to which it is to be applied.

281. 110 Retarded hemi-hydrate gypsum finish coat plaster shall be to BS1191: Part

1, Class B type 1.

Bonding Agent 281. 120 To be used to form a key when the background to receive the plaster is

particularly unfavourable (e.g. concrete surfaces cast against smooth shuttering).

281. 130 Bonding Agents shall be proprietary treatments as recommended by the

manufacturer. Polyvinyl acetate emulsion used for internal plastering with pre-mixed plasters shall be to BS5270.

281. 140 The agent shall be delivered in unopened cans bearing the maker's name

and be stored in dry frost-free conditions.

Metalwork Accessories 281. 150 Galvanised steel beads (corners, stops, architraves) with perforated angle

strip for use in internal plasterwork and dry lining shall be to BS6452: Part 1 with profiles appropriate to the application required.

281. 160 Expanded galvanised steel lathing shall be to BS 1369. 281. 161 Beads and lathing used externally in rendering shall be stainless steel. 281. 170 Staples, nails and fixing wire shall be galvanised steel to BS729. 281. 180 Galvanised steel clout nails for fixing beads, lathing and plasterboard shall

be to BS 1202: Part 1. The size and type shall be appropriate to the material to be fixed.



Gypsum Plasterboards 281. 190 Gypsum plasterboards for use as base boards and drylining wall-boards

shall be to BS 1230: Part 1, and of the following types:

° square or round edges baseboard ° fire resisting baseboard ° thermal baseboard with polystyrene layer to BS 3837

° vapour check baseboard with metallised polyester foil ° vapour check thermal baseboard with vapour resistant

membrane

The thickness, type and particular specification shall be shown on the Drawings.

Framing for Dry Lined Partitions

281. 200 Dry lined partitions shall be framed with proprietary systems based upon

galvanised mild steel channels to BS 2994 and BS 2989 or timber stud supports. The thickness of the channels or studs shall be sized in accordance with the manufacturer's instructions and the dimensions of the partitions. Plasterboard and Dry Lining Jointing Materials.



Plasterboard and Dry Lining Jointing Materials

281. 210 Joint fillers, finishes, tapes etc. shall be as recommended by the

manufacturers of the gypsum plasterboards WORKMANSHIP

General

281. 220 Handling and storage of materials shall be in accordance the

manufacturer's recommendations. Storage shall be in dry weatherproof conditions and with different materials kept separate.

281. 230 Cements, plasters, lime, filler materials shall be stored in dry conditions on

timber platforms. Plaster must be used within 2 months of the date on the bag; consignments shall be stored in a manner which allows them to be used in strict rotation, related to order of delivery. Bags shall not be punctured.

281. 240 Plasterboards shall be stacked flat in a dry building on a level surface

protected from rising damp. Dry lining boards shall be stacked with ivory faces together to avoid damage to the finished surface.

281. 250 Sand shall be stored on clean surfaces in such a manner as to allow

adequate drainage. It shall be stockpiled in a suitable manner to prevent contamination by other materials.

Clean Working Conditions

281. 260 Damage and soiling of the finished work shall be prevented during mixing,

transportation and application of plaster. 281. 270 All plaster and render shall be mixed with clean water on clean surfaces or

in clean containers. All surfaces shall be washed thoroughly after each mix. Mechanical mixers shall not be used.



Preparation of Background Surfaces

281. 280 The surfaces to be plastered or rendered shall be:

° free from local projections and concrete fins ° cleaned with detergent solutions to remove concrete release

agents, oil etc. and rinsed down with clean water ° free from paint spillages etc. which could affect adhesion of

plaster of render ° brushed down to remove dust and loose particles ° brushed down to remove any surface salts (the treatment

shall be repeated after 48 hours until the salts are removed) ° washed down with proprietary fungicide as necessary.

281. 290 The surfaces shall be inspected prior to the application of the plaster or

render to check that:

° surfaces are uncontaminated, sound and stable. ° surfaces are sufficiently true and even to accommodate the

specified thickness of the finish ° all openings, chases and built-in services have been

incorporated (corrodible metal surfaces shall be suitably protected)

° reasonably dry ° each surface shall be checked to ensure adequate adhesion

is provided, or to establish whether a proprietary bonding agent is required (or recommended by the block manufacturer).

281. 300 Fix all metal angle beads and stops with plaster dabs or nails as

appropriate. All metal work to be plumb, square and true to line. Cut ends to be protected with bitumen coating solution.

281. 310 Conduits buried in the undercoat shall be covered by jute scrim (90mm

wide) bedded in the finishing coat mix, pressed flat and pressed in. 281. 320 At junctions between dissimilar backgrounds which are to receive plaster,

fix plaster stops or steel lathing. 281. 330 At junctions between columns and panels of dissimilar backgrounds, a

separating layer of building paper shall be provided over the face of the column and steel lathing bridging over the column face shall be fixed to the panels at each side.



281. 340 Uneven backgrounds shall be dubbed out in thickness not greater than 10 mm in the same mix as the first coat. Each coat shall be cross-scratched immediately after the set, and allowed to dry out before the next coat is applied. Plastering and Internal Rendering.

General

281. 350 Admixtures shall not be used. 281. 360 Plaster shall not be used after initial set has taken place. Retempered

plaster or reconstituted mixes shall not be used. 281. 370 Mixing surfaces shall be cleaned whenever there is a change in material, or

a break in the work, and at the end of the day. 281. 380 Plaster shall not be applied to frozen backgrounds or in frosty conditions or

during extreme temperature or moisture which might affect the finished work.

281. 390 The use of mechanical application methods shall be agreed by the Purchaser. The work shall be carried out by trained operatives using suitable plaster as recommended by the manufacturers.

Application of Plaster/Render

281. 400 The undercoat shall be applied with a firm pressure and brought to a true

and level surface using a straight edge. Scratch the surface thoroughly to provide a mechanical key for the finishing coat.

281. 410 Each wall or ceiling surface shall be carried out in one continuous

operation. 281. 420 The finishing coat shall be carried out with a steel trowel to give a smooth,

blemish-free finish, unless otherwise instructed. 281. 430 Render to receive wall tiles shall be finished with a dry wood float as soon

as the wet sheen has disappeared. 281. 440 All arises shall be slightly rounded. 281. 450 Succeeding coats shall not be applied until undercoats are set. Cement-

based undercoats must be dry and cured with the drying shrinkage substantially complete.



281. 460 Cement rendering shall be kept damp by spraying or alternative methods

for at least 7 days after the initial set.

External Rendering

General

281. 470 Cold weather. Work shall not be carried out during inclement weather or frosty periods, or render applied to frozen backgrounds or when frost is expected within the next 24 hours. Each coat shall be left at least 24 hours before applying next coat.

281. 480 Hot weather. Each coat shall be prevented from drying out too rapidly;

spray with water as necessary. Application shall not be carried out in direct hot sun or drying winds.

281. 490 Wet weather. Finished work shall be protected as necessary to prevent

damage.

Application of Render. 281. 500 All workmanship shall be to BS 5262. 281. 510 Undercoats shall be applied with a trowel by laying on to give a rough, open

surface, or by throwing on and levelling with a straight edge. The surfaces shall be cross-scratched to give a key for hand-applied finishing coats.

281. 520 Apply all finishing coats, whether plain or textured, to a uniform thickness. 281. 530 Where a continuous finish is required, apply the render from top to bottom

to give a surface without joints. Day joints shall be planned to coincide with surface features, e.g. changes in direction, to minimise their visual impact.

281. 540 Textured or dry dashed finishes shall be applied while coating is plastic,

wetting the undercoat as necessary to maintain plasticity. 281. 550 Movement joints shall be formed through the full depth of render.

Plasterboard Dry Lining

General

281. 560 All wallboards shall be stored flat on a level surface, off the ground and



protected against the weather and rising damp. 281. 570 Wall-boards shall be carried on edge. They shall not be dragged over each

other. Broken boards shall not be used.

Fixing Wall-boards 281. 580 All dry lining wall-boards shall be fixed as recommended by the

manufacturer and shall be plumb, square and true to line. 281. 590 Edges of wall-boards and ceiling boards shall be centred on timber batten

or metal furring supports leaving a gap between ends of boards as recommended by the manufacturer.

281. 600 ‘Fixing’ nails for timber battens shall be at 150 mm centres and not less

than 13mm from the board edges. The nails shall not fracture the paper surface and depressions shall be filled with filler finished flush with the surface. Apply coat of joint finish.

281. 610 Fixing to metal firings shall be by plaster dabs at 450 mm centres and then

screwed at 300 mm centres, not less than 10 mm from the edge of the boards. Screw depressions shall be filled with filler finished flush with the surface. Apply coat of joint finish.

281. 620 Ceiling and soffit linings shall be fixed to support joists. End joints of boards

to be staggered. Paper-covered edges to be lightly butted with 3 mm gaps between cut edges.

Joint and Angle Treatment

281. 630 Apply a continuous thin coat of joint compound filler to joint tapers and

board edges and press on joint tape ensuring the surface is free from air bubbles. Finish flush with joint filler compound.

281. 640 The use of mechanical jointing techniques must be agreed by the

Purchaser and carried out in accordance with the manufacturer's recommendations.

281. 650 External angles shall be reinforced with metal angle beads bedded in

jointing compound with outer edges touching the plasterboard surface. Finish flush with two layers of jointing compound.

281. 660 Alternatively, subject to the agreement of the Purchaser, bed corner jointing

tape in jointing compound on each side of the angle. Finish flush with two



layers of jointing compound.

Defects and Damage to Finished Work

Plaster 281. 670 Make good, not only physical damage but the effects of blistering

efflorescence and flaking due to moisture penetration. Repairs to cracks caused by background movement should be delayed as long as possible.

Dry Lining

281. 680 Minor damage such as denting or scuffing of the finished surface shall be

lightly rubbed down and filled flush with joint filler in two applications. Minor damage resulting from heavier impact resulting in the fracture or disintegration of the core must be repaired by removing all loose material, the paper edge around the hole scored, cut back and sealed with PVA. The hole shall then be filled by two applications of joint filler.

281. 690 For more extensive damage, trim the damaged hole to form a neat

rectangular opening and cut a new piece of wallboard to fit the opening. In stud partition repairs the infill patch should be fixed to a piece of wallboard 100mm longer and 3mm narrower than the opening. This wall board shall be fixed to the back face of the broken board with joint filler. For wall-board lining defects, the patch shall be fixed to the wall with plaster dabs. When the patch adhesive has set, the joints shall be treated in a similar manner to cut edges during installation.

QUALITY CONTROL

281. 700 The Contractor shall submit to the Purchaser two copies of all certificates of

conformance for proprietary products used, and material test certificates to comply with this Specification.

281. 710 Sample panels of plaster work and rendering for each type of background

substrate shall be prepared for the Purchaser’s agreement and to act as a quality control reference.

281. 720 The Contractor shall notify the Purchaser when the background surface is

ready for plastering or rendering.



Appendix 1 BSI STANDARDS AND OTHER REFERENCES ° The British Standards referred to in Section 281 are listed below, together with any

other references specified therein. ° The latest editions shall be used, including all current amendments and additions. ° Any differences between their requirements and this Specification shall be

submitted to the Purchaser for his ruling.

BS12 Specification for ordinary and rapid hardening Portland Cement. BS146 Portland-blastfurnance cement.

BS729 Specification for hot dip galvanized coatings on iron and steel

articles. BS890 Specification for building limes. BS1191 Specification for gypsum building plaster. Part 1: Excluding premixed lightweight plasters. Part 2: Premixed lightweight plasters.

BS1199 Specification for building sands from natural sources. BS1200 BS1202 Specification for nails. BS1230 Gypsum plasterboard. Part 1: Specification for plasterboard excluding materials submitted to

secondary operations.

BS1369 Steel lathing for internal plastering and external rendering. BS2989 Specification for continuously hot-dip zinc coated and iron-zinc alloy

coated steel: wide strip, sheet/plate and slit wide strip. (Withdrawn) Replaced by BS EN 10143: 1993.

BS2994 Specification for cold rolled steel sections. BS3837 Expanded polystyrene boards. BS4022 Specification for prefabricated gypsum wallboard panels. BS4721 Specification for ready-mixed building mortars. BS5262 Code of Practice. External rendered finishes. BS5270 Specification for polyvinyl acetate (PVAC) emulsion bonding agents

for internal use with gypsum building plasters. BS5492 Code of Practice for internal plastering. BS6452 Beads for internal plastering and dry lining.




CLAUSE REFERENCE


COMMENT

281.390 281.640 281.700 281.710 281.720

Use of mechanical application methods. Use of mechanical jointing techniques. Material test certificates. Sample panels. Notifiction of background preparation.



TECHNICAL SPECIFICATION WORK GROUP: 280 : FINISHES SECTION NO: 282 TITLE: SUSPENDED CEILINGS TABLE OF CONTENTS SCOPE CONTRACTOR DESIGN MATERIALS

General Framing and Suspension System Ceiling Tiles

WORKMANSHIP

General Environmental Requirements Packaging, Storage and Protection Installation of Framework Edge Detail Ceiling Void Access Panels Fixing Tiles Painting Cavity Fire Barriers Tolerances

QUALITY CONTROL APPENDIX 1 BSI STANDARDS AND OTHER REFERENCES APPENDIX 2 INFORMATION TO BE PROVIDED BY CONTRACTOR



SCOPE 282. 010 This Section defines the requirements for materials and installation of

proprietary acoustic suspended ceiling systems including suspension systems and associated accessories.

CONTRACTOR DESIGN

282. 030 Detail drawings shall be submitted to the Purchaser for agreement. The

drawings shall show, but not necessarily be limited to, the following information:

° Reflected ceiling plan with direction of pattern. ° Setting out dimensions for installation and future maintenance with

full allowance made to accommodate light fittings, ventilation grilles, fire protection and detection points etc., location of hangers, primary and secondary support members, access facilities, any structural connections.

° Panel joint details. ° Changes in ceiling level and cavity barriers.

282. 040 The Contractor's design submission shall also include manufacturer's full

supporting technical literature, certificates of fire resistance rating and flame spread classification of testing organisation, certificate of sound absorption coefficients to BS 3638.

MATERIALS

General

282. 050 Suspended ceilings shall be of a proprietary system type to BS 8290. 282. 060 The fire resistance rating shall be 1 hour unless otherwise specified for

stability, integrity and insulation as determined in accordance with the requirements of BS 476.

282. 070 The flame spread classification shall be Class 'O', unless otherwise

specified, as determined by the large scale test conducted in accordance with the requirements of BS 476, Part 7. Framing and Suspension System



282. 080 Unless otherwise specified the suspension ceiling system shall be of the exposed grid type, and shall include all fixings such as rods, brackets, bracing, hangers, perimeters, connections and accessories designed to form an integrated and rigid framework in two horizontal directions.

282. 090 All members shall be of galvanized steel or other agreed corrosion resistant

metal. Exposed flanges and trims shall be shop finished to the appropriate colour agreed with the purchaser.

282. 100 Upper anchorage for hanger wire shall be power-driven eye-pin fasteners. 282. 110 Hanger wire shall be 12-gauge minimum, galvanised, soft annealed mild

steel. 282. 120 Hold-down clips, connectors and fasteners shall be standard types supplied

or recommended by the ceiling manufacturer. 282. 130 The main horizontal suspension members shall be of channel section, of a

size and gauge recommended by the ceiling manufacturer. Joints between members shall be achieved by channels back to back with an overlap of approximately 400mm and with a hanger support wire fixed at the mid-point of the junction. Metal tees for supporting the tiles shall be located immediately below the main horizontal support members.

282. 140 Perimeter edge support shall be of steel or aluminium angle. Angle size

shall be approximately 50mm (vertical edge) x 37mm (horizontal edge).

Ceiling Tiles 282. 150 Asbestos materials shall not be used in the manufacture of the ceiling tiles. 282. 160 Mineral fibre tiles face texture and size shall be shown on the Drawings.

Tile edges shall be rebated to allow a lay-in system where the bottom face of support members are exposed.

282. 170 Reinforced Calcium Silicate tiles size and type shall be shown on the

Drawings. 282. 180 Tiles in toilet and shower areas shall be resistant to moisture.

WORKMANSHIP

General



282. 190 Suspended ceiling systems shall be installed to BS 8290 and to the


Environmental Requirements 282. 200 Any work which will be concealed by suspended ceilings shall be

completed, tested, inspected and accepted before suspended ceiling work is started.

282. 210 Surfaces which will support the suspended ceilings, and those to which the

suspended ceilings abut, shall be inspected and accepted for completeness and adequacy to receive the ceilings before suspended ceiling work begins.

282. 220 Any work that could cause wetting of the materials shall be completed

before the ceilings are installed. The building should be weatherproof before erection commences.

282. 230 A uniform temperature above 13°C shall be maintained in the area where

materials are to be installed before, during and after installation.

Packaging, Storage and Protection 282. 240 Materials shall be delivered in original, unopened, protective packaging,

with manufacturer's labels clearly indicating product name, pattern, size, thickness and fire rating.

282. 250 Materials shall be stored in original protective packaging to prevent soiling,

physical damage or wetting. 282. 260 Cartons shall be stored in the installation area, opened at each end to

stabilize moisture content and temperature, for 48 hours prior to installation. Installation of Framework

282. 270 The grid pattern shall be as indicated on the Drawings and care shall be

taken to co-ordinate all joint locations with internal partitions and/or the raised access floor tiles and any other features, where instructed.

282. 280 Setting out shall be from the centre of the room. The centre of a tile or a tile

junction shall be located along the centre line of a room or principal wall, with cut tiles only at the edges. As far as possible cut tiles should be larger than half a tile.



282. 290 Hanger fixings shall be installed in the manner and positions shown on the

shop drawings but at not greater than 1200mm centres. Main suspension members shall be accurately located to maintain the grid and to be level.

282. 300 Main runners shall be connected end-to-end with manufacturer's standard

couplings and shall be accurately levelled. Cross runners shall be positively and rigidly connected to the main runners. Installation shall ensure that there is minimal torsional movement or displacement of joints and runners.

Edge Detail

282. 310 Tiles shall be cut in accordance with manufacturer's recommendations and

cut edges shall be located behind the perimeter edge supports to the ceiling.

282. 320 Fixings for edge support angles shall be in accordance with the details and

at locations shown on the shop drawings and shall be either:

(a) Fixed directly to softwood grounds approximately 50mm x 18mm i.e. with the face approximately 5mm proud of the face of a plaster finish. The 5mm gap shall be caulked using a one part polysulphide based sealant.

(b) Fixed directly to softwood grounds approximately 50mm x

50mm with the bottom face wrot and painted black.

The bottom flange of the angles shall be 10mm lower than the bottom face of the ground. Ceiling Void Access Panels

282. 330 Access panels shall be approximately 1200mm square and shall consist of

one or two hinged flaps. Suspension wires shall be provided at each of the four corners and the suspension system shall be suitably designed to be able to support a softwood frame and blockboard flaps faced with standard tiles. When closed the panel shall be flush with the remainder of the ceiling with only discreet push plates to indicate its presence.

Fixing Tiles 282. 340 Ceiling tiles shall be installed in the grid system after completion of

installation of the suspension, lighting fittings, ventilation grilles and fire



detection/protection systems. 282. 350 Tile fixings shall provide for full access except as otherwise specified. 282. 360 Mineral Fibre tiles shall be installed in the manner recommended by the

manufacturer, to provide a level surface free from any bowing or sagging and with accurately aligned joints.

282. 370 The Calcium Silicate tiles shall be screwed to the suspension system as

recommended by the manufacturer to provide a uniform appearance. 282. 380 Tiles in any room or space protected by an inert gas fire protection system

shall be secured to prevent lifting of the panel by the pressure differential generated during inert gas discharge. Means of access to the above-ceiling area shall be provided.

Painting

282. 390 Tiles shall be painted before installation in accordance with the finishing

schedule.

Cavity Fire Barriers 282. 400 Cavity Fire Barriers, shall be installed vertically in voids above ceilings at

not more than 20 metres spacing in any direction or as agreed with the local Fire Authority.

282. 410 They shall be fixed positively to the soffit of concrete floors by means of a

sheradised steel angle. The blanket shall be of sufficient depth to provide 50mm minimum horizontal seal to back of ceiling tiles. End laps to the blanket shall be 30mm minimum.

282. 420 Allowance shall be made to cut around ventilation ducts, pipes etc., within

the ceiling void with provision for a minimum of 50mm horizontal seal.

Tolerances 282. 430 Panel grid deflections shall conform to the requirements of BS 8290 282. 440 The finished suspended ceiling system shall be level within 1mm in 1m.



QUALITY CONTROL 282. 450 The Contractor shall obtain manufacturer's test certificates for the

Purchaser’s inspection before any on site work shall commence. 282. 460 The Contractor shall inspect the suspension system for adequacy of

fixings, tolerances and levels etc prior to the installation of the ceiling tiles.






BS 476 Fire Tests on building materials and structures. Part 7: Method for classification of the surface spread of flame of products. BS 3638 Method for measurement of sound absorption in a reverberation

room.

BS 8290 Suspended Ceilings. Part 1: Code of practice for design. Part 2: Specification for performance of components and assemblies. Part 3: Code of practice for installations and maintenance.




CLAUSE REFERENCE


COMMENT

282. 030 282. 040 282. 200 282.450 282.460

Contractor's detail Drawings. Manufacturer's literature. Notification of initial inspection. Test Certificates. Final inspection.



TECHNICAL SPECIFICATION WORK GROUP: 280 : FINISHES SECTION NO: 283 TITLE: WALL TILING TABLE OF CONTENTS SCOPE MATERIALS

General Tiles Bedding and Grouting Storage

WORKMANSHIP

General Preparation of Background Surfaces Fixing Tiles Cleaning and Protection

QUALITY CONTROL

General Inspection




SCOPE 283. 010 This Section defines the requirements for the supply and fixing of tiles for

internal and external use. 283. 020 The BSI Standards together with other references specified in this Section

are listed in Appendix 1.

MATERIALS

General 283. 030 Representative samples of the tiles shall be submitted to the Purchaser to

demonstrate quality, colour and surface finish. 283. 040 All tiles shall match the agreed samples and shall be obtained from a single

source. 283. 050 Fittings and accessories shall be obtained from the same tile manufacturer.

Tiles 283. 060 Glazed ceramic wall tiles for internal or external use shall be to BS 6431. 283. 070 The type, size, water absorption properties, surface finish, colour and

method of manufacture (extruded, dust pressed or cast) shall be shown on the Drawings.

283. 080 Tiles of the same batch numbers shall be used to avoid differences in

colour shades. 283. 090 Tiles for external use shall be frost resistant with a water absorption

capacity of 3% or less.

Bedding and Grouting 283. 100 Bedding adhesives shall be the following types:

° adhesive to BS 5980 ° cement based adhesive with Agreement certificate ° polymer modified cement type.

283. 110 The type of adhesive shall be as recommended by the adhesive manufacturer for its suitability for its intended application with full allowance



made for its location (internal or external), the likely exposure conditions and the substrate conditions when fixing the tiles.

283. 120 Grout for tiles shall be of the following types:

° cement based ° polymer modified cement based ° epoxy resin based.

283. 130 The grout selected shall be appropriate for the conditions to which it will be

subjected e.g. wet, sterile and hygienic areas. 283. 140 Proprietary pre-formed filling strips shall be used at movement joints which

shall be finished with a joint sealant. Joint sealants shall comply with Section 402.

Storage

283. 150 All tiles shall be stored in clean dry, frost free conditions in their original

cartons and separated from direct contact with the store room floor by a sheet of polythene.

283. 160 Adhesives and jointing materials shall be stored in similar conditions and as

recommended by the manufacturer. Different materials shall be stored separately from each other.

WORKMANSHIP

General

283. 170 Tiles shall be fixed by specialist workmen. 283. 180 Workmanship shall be to BS 5385 Parts 1, 2 and 4 as appropriate. 283. 190 All damaged tiles shall be rejected.



Preparation of Background Surfaces

283. 200 The surface to be tiled shall be:

° dust free and any surface contaminants cleaned off ° firmly bonded to its background ° plumb and true (+ 3 mm in 2 metres) ° adequately dried out (3 weeks minimum for cement sand render, 4

weeks for plaster and 6 weeks for concrete surfaces). 283. 210 Surfaces shall be primed prior to applying the adhesive when

recommended by the adhesive manufacturer.

Fixing Tiles 283. 220 Tiling adhesives shall be applied strictly in accordance with the

manufacturers instructions. 283. 230 Surplus adhesive shall be cleaned off the tiles as work proceeds and before

it sets. 283. 240 The thin bed notched trowel method is suitable for internal locations but

shall not be used where water penetration behind the tiles can occur. 283. 250 The thin bed/thick bed floating coat method is suitable for internal wet areas

and external locations. 283. 260 Cement and sand mortar can also be used for internal wet areas as well as

externally. This method requires the background to be wetted to prevent excessive water absorption from the mortar. Porous tiles may need to be soaked in clean water and allowed to drain.

283. 270 The finished tile face shall be plumb and true. The joints shall be vertical

and horizontal within 3 mm under a 2 metres straight edge. The width of joints shall be uniform.

283. 280 Movement joints shall be shown on the Drawings. The joint shall be allowed

to dry out before inserting filler and applying sealant in accordance with Section 402.

283. 290 Joints between tiles shall not be grouted up until the tiles are adequately

bonded to their background. The minimum period after tiling on porous



backgrounds shall be 24 hours and on impervious backgrounds 3 days.

Cleaning and Protection 283. 300 The surfaces of tiles shall be cleaned off and polished on completion. 283. 310 Washing down of the tiles with water shall not be carried out until the

bedding and grouting has fully set. In wet areas, e.g. showers, 14 days shall be allowed.

283. 320 External tiles shall be protected against inclement weather conditions until

the grouting has fully set.

QUALITY CONTROL

General 283. 330 The Contractor shall submit full manufacturers literature for tiles, adhesives

and all other proprietary products with recommendations for their suitability and instructions for their use.

283. 340 Sample reference panels of tiling shall be carried out when instructed by the

Purchaser.

Inspection 283. 350 The background surfaces to receive tiling shall be inspected to confirm their

suitability before the bedding of tiles commences.







BS 5385 Wall and floor tiling Part 1: Code of practice for internal ceramic wall tiling and mosaics in

normal conditions. Part 2: Code of practice for external ceramic wall tiling and mosaics. Part 4: Code of practice for ceramic tiling and mosaics in specific

conditions.

BS 5980 Specification for adhesives for use with ceramic tiles and mosaics. BS 6431 Ceramic floor and wall tiles.




CLAUSE REFERENCE


COMMENT

283. 030

Submission of samples

283. 330

Manufacturer's literature

283. 340

Sample panels

283. 350

Notification of background preparation prior to tiling



TECHNICAL SPECIFICATION WORK GROUP: 280 : FINISHES SECTION NO: 284 TITLE: SCREEDS AND FLOOR FINISHES TABLE OF CONTENTS SCOPE MATERIALS

General Floor Screeds and Heavy Duty Floor Finishes Solid Tiled Floor Finishes Plastic Tiles and Sheet Flooring Mastic Asphalt Floor Finishes

WORKMANSHIP

General

Sand Cement Dense Screeds, Concrete and Granolithic Toppings - Surface Preparation/Directly Bonded Construction - Surface Preparation/Monolithic Construction - Mixing of Dense Screeds/Toppings - Joints - Formwork - Laying - Finishing of Screeds/Toppings - Curing and Protection - Tolerances - Surface Hardeners - Solid Tiled Floor Finishes - General



TABLE OF CONTENTS

- Surface Preparation - Laying of Tiles - Cleaning and Protection

Plastic Tiles and Sheet Flooring - Surface Preparation - Laying

CARPET LAYING

- Protection Mastic Asphalt Floor Finishes - Surface Preparation - Laying - Curing and Protection

QUALITY CONTROL

General Testing Inspection




SCOPE 284. 010 This Section defines the following floor finishes:

(a) screeds (dense, lightweight, proprietary) (b) plastic tiles and sheet (c) solid tile flooring (d) mastic asphalt

284. 020 This Section does not cover:

(a) in-situ terrazzo floor finishes (b) wooden block type floor finishes

MATERIALS

General

284. 040 The Contractor shall be responsible for the selection of screeds and shall

submit samples and/or data sheets as instructed of all materials he proposes to use to the Purchaser for agreement. All manufactured materials shall be from agreed or BSI Registered Suppliers.

284. 050 Materials for each type of floor finish shall be obtained from a single

supplier

Floor Screeds and Heavy Duty Floor Finishes 284. 060 All concrete work associated with screeds which is not specifically covered

in Section 284 shall be in accordance with Section 201. 284. 070 Cement shall be ordinary Portland cement to BS 12 or Portland blast

furnace cement to BS 146. 284. 080 Coloured cements containing pigment to BS 1014 shall be used for

coloured toppings. Pigment shall not be added at the mixer. 284. 090 Fine aggregate shall be to BS 882 Table 5 (col M). 284. 100 Coarse aggregate shall be 10mm single-sized to BS 882 Table 4. 284. 110 For heavy duty concrete floors the aggregate impact value shall not exceed

25% when tested to BS 812.



284. 120 Coarse aggregate for granolithic screeds shall be 10mm single-sized granite chippings to BS 882, Table 4.

284. 130 Aggregates for use in lightweight 'No-Fines' screeds shall be either:

° expanded clay pellet aggregate to BS 3797 passing 20mm but retained on a 10mm test sieve to BS 410.

° pulverised sintered fuel ash pellet aggregate to BS 3797 and

passing 14mm but retained on a 10mm test sieve to BS 410. 284. 140 Proprietary dense screeds (modified sand-cement type) shall be supplied

and laid by agreed specialist firms. 284. 150 Proprietary lightweight screeds (aerated cement type with resinous air

entrainer) shall be supplied and laid by agreed specialist firms. 284. 160 Bonding compound agents shall be of agreed proprietary manufacture. 284. 170 Admixtures (eg calcium chloride and anhydrous calcium) shall not be used

unless agreed by the Purchaser. 284. 180 Surface hardeners shall be sodium silicate to BS 3984.

Solid Tiled Floor Finishes 284. 190 The classification type, colour, surface finish, mechanical and physical

qualities and any tile pattern shall be specified on the Drawings. 284. 200 All fittings and special tiles (eg cove skirtings, cappings, channels, stop

treads etc) shall be obtained from the same manufacturer as the floor tiles. 284. 210 Ceramic quarry tiles shall be to BS 6431. 284. 220 Concrete tiles shall be to BS 1197: Part 2. 284. 230 Cast stone tiles shall be to BS 1217. 284. 240 Glazed ceramic tiles (internal) shall be to BS 6431. 284. 245 Terazzo floor tiles shall be to BS 4131. 284. 250 Separating layer membranes shall be polythene sheet, not less than 500

gauge.



284. 260 Sand for bedding mortar shall be to BS 1200: Table 1.

Plastic Tiles and Sheet Flooring 284. 270 PVC tiles or sheeting shall be to BS 5085 or BS 3261 and shall be of a type

and colour specified in the room data sheets. The size and thickness shall be appropriate for the location.

284. 280 Sheeting shall be PVC flexible sheeting of a width to provide economy in

welding and satisfactory laying. All sheeting shall be capable of being welded to provide a watertight membrane, and shall be welded where it abuts PVC flexible skirting and in other areas instructed by the purchaser.

284. 290 Skirtings, where scheduled on room data sheets, shall be PVC flexible

sheeting, coved accordingly. They shall be capable of being welded at junctions along their length, at corners and to the sheet flooring.

Mastic Asphalt Floor Finishes

284. 300 Mastic asphalt grade shall be specified on the Drawings and shall be either:

(a) limestone aggregate asphalt to BS 6925

(b) natural rock aggregate asphalt to BS 6577

284. 310 Bitumen priming coats for metal and concrete surfaces shall be bitumen cut-back with a viscosity Redwood No. 2 of 25 secs maximum at 25°C and a maximum volatile solvent content of 60 per cent by weight.

284. 320 Isolating membranes for asphalt floors shall be either:

° resin-coated glass fibre tissue ° bitumenized sheathing felt to BS 747

284. 330 Rubbing sand for surface treatment shall be clean coarse sand from natural

deposits (passing 600 micron sieve and retained by 212 micron sieve to BS 410).



WORKMANSHIP

General

284. 340 All materials shall be stored in dry, weathertight locations in accordance

with the manufacturer's recommendations to prevent deterioration and damage. The general requirements in the Specification Section 201 Concrete Production shall apply.

284. 350 All screeds/toppings, mastic asphalt, tiles shall be laid by agreed

experienced or specialist personnel. 284. 360 Whenever practicable, flooring shall not be laid until the work of other

trades working in the same area has been completed. 284. 370 Flooring shall be protected adequately during subsequent building

operations. Damaged flooring shall be repaired or replaced as directed by the Purchaser.

Sand Cement Dense Screeds, Concrete and Granolithic Topping

Surface Preparation/Directly Bonded Construction

284. 380 Hardened smooth concrete surfaces shall be cleaned of all debris and

loose dirt and then mechanically roughened to remove laitance and expose but not loosen the coarse aggregate.

284. 390 When the concrete base is less than 100mm thick on precast concrete

units, and where mechanical scabbling may cause damage, the roughening of the surface shall be achieved by shot or grit blasting.

284. 400 The hardened roughened concrete surfaces shall be washed clean to

remove all adhering dirt and dust immediately prior to laying the screed. Any cracks or loose pockets shall be cut back to sound concrete and made good to the satisfaction of the Purchaser.

284. 410 The concrete surfaces shall be sprayed with water and maintained in a wet

condition for several hours prior to laying the screed to prevent suction. Surplus water shall be removed 30 minutes before the application of a proprietary bonding agent and the laying of the screed. Drainage holes in roof slabs shall be made good with cement/sand mortar 1:3.

Surface Preparation/Monolithic Construction



284. 420 Fresh concrete bases to receive monolithic toppings/floor or roof screeds

shall be brushed with a stiff broom while the concrete surface is still plastic. All laitance and dust shall be removed and the surface washed down prior to laying the topping/floor or roof screed.

Mixing Dense Screeds/Toppings

284. 430 Mix proportions shall be:

° cement sand screeds 1:4 cement/sand

° concrete toppings 1:1:3 cement/sand/coarse aggregate (10mm maximum size)

° granolithic toppings 1:1:3cement/sand/granite chippings

284. 440 The materials for dense screeds and toppings shall be gauged by weight

with allowance made for the moisture content of sand. 284. 450 Sufficient mixing water to ensure full compaction shall be used. The

excessive use of water shall be avoided. 284. 460 Forced action mechanical mixers shall be used. They shall be cleaned out

when there is a change in the mix, a break in the work and at the end of each day's work.

284. 470 The gauging of materials for lightweight screeds shall be by volume unless

otherwise instructed. 284. 480 Proprietary screeds/toppings shall be mixed strictly in accordance with the

manufacturer's instructions. 284. 490 In cold weather conditions:

° screeds/toppings shall not be mixed or laid when the ambient temperature is 3°C and falling



° mixing and laying can proceed when the temperature is 1°C

and rising provided the sand and water are heated. Frozen materials shall not be used.

° screeds/toppings shall not be laid on frozen or frost covered

surfaces 284. 500 In hot weather conditions ensure that:

° full compaction can be carried out avoiding the drying out of the mix and premature stiffening

° proper curing and full hydration takes place

° drying is controlled to minimise shrinkage

284. 510 In wet conditions protect the freshly laid surface from rain damage.

Joints 284. 520 Construction joints shall be formed in the screed topping to coincide with

joints in the structural concrete. Joints will be of a clean vertical butt type. One bay will be separated from another by a strip of building paper or coating of bitumen or other agreed suitable material to prevent bond between adjacent bays. The joints shall be compacted thoroughly at the edges.

284. 530 Movement joints in the base concrete shall be continued through the

screed/topping. 284. 540 The difference in level between the screed or paving finish on either side of

the joints shall not exceed 1mm.

Formwork 284. 550 The forms for the screeds or pavings shall be fixed on a firm foundation and

supported throughout their length so that they will not be disturbed by spreading and compaction. The forms shall be true to line within ± 3mm and level within the permitted tolerance on the floors.

Laying



284. 560 Lay in bays not greater than 15m2 in area with a length to breadth ratio not

exceeding 1.5. 284. 570 Separate unbonded cement/sand screeds, concrete and granolithic

toppings shall be laid in 2 layers (65mm minimum thickness) without bonding to the base concrete. The lower layer shall be thicker than the upper layer. The minimum thickness of the upper layer shall be 20mm and it shall be placed immediately following compaction of the lower layer.

284. 580 Thickness of separate bonded cement/sand screeds, concrete and

granolithic toppings shall be shown on the Drawings. The minimum thickness shall be 40mm.

° For thicknesses less than 50mm lay in one layer fully

bonded to the base. ° For thicknesses greater than 50mm lay in two layers, with

the lower layer thicker than the upper layer. The minimum thickness of the upper layer shall be 20mm and shall be placed immediately following compaction of the lower layer.

284. 590 Monolithic cement/sand screeds, concrete and granolithic toppings shall be

laid to the required thicknesses within 3 hours (or less in hot weather) of the base concrete being laid. Granolithic finishes shall not be less than 18mm nor greater than 35mm thickness and the edges of the finish shall be coincident with that of the structural base.

284. 600 'Lightweight' roof screeds shall be laid to a smooth even surface to receive

the topping. The minimum thickness laid shall be:

° 50mm for bonded clay pellet aggregate screeds

° 25mm for bonded fuel ash aggregate screeds 284. 610 'Proprietary' screeds shall be mixed and laid strictly in accordance with the

manufacturer's instructions.

Finishing of Screeds/Toppings 284. 620 Hand or power float to a smooth even surface as soon as the surface is



sufficiently hard. Re-trowel as necessary to obtain a suitable finish. Remove loose particles of laitance on completion.

The practice of 'dusting' of granolithic toppings shall not be allowed.

284. 630 Non-slip treatments, such as coarse chromite grains, shall be sprinkled on

the surface at a rate of not less than 1 kg/m2 and lightly trowelled in before final trowelling.

Curing and Protection

284. 640 Screed toppings shall be cured for at least seven days by the use of plastic

sheeting secured to frames which overlap the bays or an agreed liquid applied curing agent. Where plastic sheeting is used it shall be anchored to adjacent bays to promote curing.

284. 650 The floor shall not be opened to traffic until the curing is complete and it has

attained adequate strength. Vehicles shall not be permitted on the floor for at least 14 days. The Contractor shall take all possible precautions which include the use of scaffold barriers and signboards to ensure that the specified curing period and protection is provided.

284. 660 Artificial heating of areas where dense screeds/toppings have been laid

shall not be permitted for 4 to 6 weeks after laying, after which time the temperature shall be raised slowly.

Tolerances

284. 670 The screed surfaces shall be laid true to levels or falls to prevent ponding. 284. 680 Tolerances on the surface levels of floor screeds shall be ± 6mm, with a

maximum variation in the gap beneath a 3 metre straight edge of 5mm, and a maximum variation beneath a 1 metre straight edge of 2mm. The tolerance on screed level shall not be combined with the tolerance on structural floor level in such a way that the specified tolerance on screed thickness is exceeded.

Surface Hardeners 284. 690 Surface hardeners shall be applied to fully cured concrete surfaces after the

surface has been cleaned and any cracks or holes repaired.



284. 700 Sodium silicate solution shall be applied in two coats in accordance with the manufacturer's recommendations.

Solid Tiled Floor Finishes

General

284. 710 All workmanship shall be to BS 5385 284. 720 Each delivery of tiles shall be checked to ensure a match with the agreed

sample.

Surface Preparation 284. 730 Ensure that the base is free from any contamination, any looseness or

hollows. Base screeds shall be air dried for at least 3 weeks and concrete screeds for at least 6 weeks after curing.

Laying of Tiles

284. 740 Tiles shall be bedded either:

° in mortar on a separating layer ° in mortar bonded to the base ° with bonding adhesive

284. 750 No work shall be carried out when the temperature is 2°C or below, or when

temperatures of 2°C or less are expected during the drying period. 284. 760 Bedding mortar shall be cement/sand, 1:4 mix. It shall be of 'dry mix' with

just sufficient water to hold the mortar together. The mortar shall be machine mixed.

284. 770 Bedding mortar shall be laid to a depth not less than 15mm of more than

40mm. The mortar shall be thoroughly consolidated and screeded to the required level using screeding rules no more than 750-900mm apart and laid to levels and falls.

284. 780 The separating layer, when specified, shall be laid loose with minimum laps

of 100mm and overlaid by the cement/sand bedding mortar. 284. 790 To bond the bedding mortar to the base surface, a slurry of 1:1 cement:

clean fine sharp sand shall be brushed over the surface prior to the mortar being spread or alternatively a proprietary bonding agent shall be used.



284. 800 The depth of the mortar bed will be average 20mm and in no case less than 15mm or more than 40mm. The mortar shall be thoroughly consolidated by pounding to form a compact mass and screeded to the required level using screeding rules. Rules should be 750 to 900mm apart.

284. 810 In areas where chemical resistance is not required a grout/doping coat shall

be poured onto the bedding mortar to a uniform depth of 3mm and will consist of 1 : 1 Portland Cement and sand mixed with sufficient water to make it slightly runny. The mixture shall be laid with a trowel over an area not exceeding 2 square metres at a time.

284. 820 Alternatively, a layer of dry Portland cement shall be laid on top of the

compacted mortar bed. Tiles may only be laid after this cement has become wet with the moisture in the screed.

284. 830 Tiles shall be completely free from dust and dirt and shall be dipped in clear

water and excess water shaken off before laying. 284. 840 When bedding in adhesive the tiles shall be dry and the adhesive applied in

accordance with the manufacturer's instructions and recommended thickness. The tiles shall be pressed firmly and tamped into the adhesive.

284. 850 Tiles shall be laid to a straight joint and tapped lightly into position into the

grout before the bedding mortar has set. Care should be taken at this stage not to move the tiles about more than absolutely necessary. The tiles shall then be beaten down using a wooden beater to ensure that they are flat and level.

284. 860 Normal floor joints shall be never more than 4mm wide and never less than

3mm wide. Floor tiles in corporate identity toilet and other areas shall be laid with 6mm joints using grey grout.



284. 870 Where a sand/cement grout is required, the joints shall be filled with a grout

of 1 : 1 cement sand brushed over the tiles. After the joint mixture has sunk below the level of the tiles an application of 1 part of cement to 1 part of fine silver sand shall be made by rubbing over the tiling to fill up the joints. No water is required for this operation and dry clean rags should be used for cleaning and rubbing down. This process and cleaning shall be completed when the pointing material is still moist.

284. 880 Coved skirting shall be bedded, jointed and pointed in the same manner as

the tiles and with joints aligning with the floor tiling joints. 284. 890 Expansion joints will be made at all junctions, between floor tiles and

skirtings, walls, gullies and other floor finishes and at intervals not exceeding 4500mm centres in both directions, and directly over expansion joints in the structural concrete and supporting walls and beams in suspended floors.

284. 900 Expansion joints shall be 10mm wide taken down to the surface of the

damp proof membrane or concrete slab as appropriate. The joint filler shall be expanded neoprene strips, taken within 10mm of the final surface of the tiles and the final 10mm of the expansion joints filled with a polysulphide filler laid in accordance with the manufacturer's instructions.

284. 910 All tiled floors will be finished evenly and level. They shall be free from all

irregularities. All joints will be flush and free from voids and all other blemishes. The bottom of coved skirtings will be flush with the finished floor.

284. 915 Terrazzo tiles shall be ground and polished after laying in accordance with

BS 5385 Part 5.

Cleaning and Protection 284. 920 After laying, the floor shall be closed to traffic for a minimum period of 4

days and only light traffic shall be allowed for a further 10 days 284. 930 The finished floor shall be left free from mortar, grout and all other marks

and imperfections. Final cleaning shall not be done until all joints are set and shall be carried out in accordance with the manufacturer's recommendations.



Plastic Tiles and Sheet Flooring

Surface Preparation

284. 940 The floor shall be thoroughly cleaned and degreased with a fluid

recommended by the adhesive manufacturer. Any irregularities in the surface shall be made good with a filler supplied by the PVC tile or sheeting manufacturer.

284. 945 Floors to receive PVC sheet or tiles shall be levelled with a self levelling

smoothing compound ("latex"), mixed and laid in accordance with manufacturer's recommendations. Protein free compounds shall be used in food preparation areas.

Laying

284. 950 Before start of laying the flooring, the dryness/moisture in the base shall be

tested to BS 8203, and shall be the minimum stated in the code or the requirements of the adhesive and flooring manufacturers.

284. 960 The adhesives used shall be to BS 8203 and as recommended by the

tiling/sheeting manufacturer. 284. 970 Tiles shall be set out and laid with continuous in-line joints in accordance

with a setting out layout submitted to the Purchaser for agreement. Joints between the tiles shall be of the minimum width compatible with the efficient laying of the floor. Tiles shall be set out from the centre of the space/room unless agreed otherwise, so that:-

(a) Tiles along opposite edges are of equal size, and; (b) Edge tiles are more than 50% of full tile width

284. 980 All flooring shall be neatly cut and tight around the profile of any

obstructions rising above the floor surface. 284. 990 Skirtings shall be fitted true to line complete with all stop ends, internal and

external mitres. All joints shall be neatly welded. 284. 1000 The floor shall be finished complete, welded where specified and all PVC

skirtings and dividing strips fixed. After the adhesive has set the floor shall be washed clean. Layout of sheets shall be such that the number of seams is kept to a minimum. The Contractor shall obtain the Purchaser’s agreement to setting out of seams before commencing work. CARPET LAYING



284. 1001 Carpet laying shall be laid generally in accordance with N.B.S.

Specification M51 as amplified below.

(b) The carpet is supplied in 970mm widths and shall be edge sewn in accordance with the manufacturers recommendation, using machine sewing so far as practicable. The carpet shall be laid using carpet grippers of appropriate quality and type laid round the perimeter of the space/room. At openings and free edges, edging strips or agreed alternative shall be used. Cross seams will be permitted where necessary for practical purposes and subject to the agreement of the Purchaser.

Underlay shall be hair/jute of 56oz/m2 .

284. 1003 Contract carpet shall be of a quality suitable for the locations and use

indicated on Room Data Sheets. The Contractor shall provide carpet available in a range of colours for the Employer to select at the appropriate time.

284. 1004 Edging/cover strips shall be stainless steel with matt finish. 284. 1005 Coir door mats shall be 18mm thick, located in purpose made mat wells.

Protection 284. 1010 The Contractor is responsible for providing protection to all floor finishes by

such as thick cardboard, if appropriate, which shall be taped down to prevent damage. No vehicular traffic shall be permitted on the flooring.

The protective covering shall be removed and the floor washed clean and made ready for use just prior to handover. Mastic Asphalt Floor Finishes

Surface Preparation

284. 1020 Concrete surfaces shall be clean, free from contamination and dry. The

surface shall be primed with one even coat of cut back bitumen primer. 284. 1030 Where an isolating membrane is specified the concrete shall have a slightly

coarsened surface. 284. 1040 Isolating membranes shall be laid loose with 50mm laps.



284. 1050 Metal surfaces shall receive one coat of cut-back bitumen primer and allowed to dry.

Laying

284. 1060 Mastic asphalt shall not be laid at ambient temperatures below 10°C. 284. 1070 Mastic asphalt blocks shall be melted in mechanically agitated mixers to

maintain strict temperature control. Molten asphalt should not be heated above 230°C. The use of heating cauldrons shall only be permitted with the Purchaser’s agreement.

284. 1080 Dry limestone dust or other fine inert dust shall be used to prevent asphalt

sticking to buckets. The use of oil or ashes shall not be permitted. 284. 1090 Flooring asphalt shall be laid to the required thickness in one coat to

provide an even thickness and with a surface free from imperfections. 284. 1100 Blow holes shall be pierced and made good while the asphalt is still warm. 284. 1110 The asphalt shall be laid with joints staggered not less than 150mm. The

joints shall be clean and neat. Alternate bay construction shall be used when bays exceed 100m2.

284. 1120 Hot asphalt shall be applied to warm and clean edges of previous bays.

Any surplus shall be removed and the asphalt laid to form joints while edges are still warm.

284. 1130 A gap of 50mm shall be left between asphalt coats and abutting surfaces.

The gap shall be filled within 12 hours with flooring asphalt when cooling shrinkage has taken place.

284. 1140 Float the surface to a smooth finish. If a rubbing sand finish is specified,

remove surplus sand on completion. 284. 1150 Skirtings shall be formed in two coats (13mm total thickness) with a 25mm

radius coved fillet. 284. 1160 All channels and outlets shall be formed to ensure watertight joints.

Curing and Protection 284. 1170 On completion, remove all droppings, leave floor in a clean condition and

prevent other materials coming into contact with the asphalt. Maintain an



ambient temperature above 10°C for at least 3 days to allow conditioning of the floor.

284. 1180 The flooring shall not be used before it has cooled to the ambient air

temperature.

QUALITY CONTROL

General 284. 1190 The Contractor shall submit to the Purchaser two copies of Certificates

verifying that all materials comply with the Specification and the relevant British Standards including results of tests specified. Certificates for raw materials shall be provided for each consignment.

284. 1200 Two copies of all manufacturers technical literature and installation

recommendations shall be submitted to the Purchaser. 284. 1210 The Contractor shall obtain samples of each proprietary material to

demonstrate quality and colour etc as proposed for use in the Permanent Works.

284. 1220 The Contractor shall submit to the Purchaser proposals for laying, care and

maintenance of all screeds and floor finishes in accordance with the manufacturer's recommendations.

284. 1230 The Contractor shall retain records of all stages of the installation of

screeds and floor finishes. Dates of laying, testing carried out, environment conditions shall be noted for each area of floor finish.

Testing

284. 1240 Impact testing for suitability of screed for category of usage shall be carried

out on dense floor screeds laid on solid concrete floors not earlier than 14 days after laying the screed and before laying levelling screeds or finishes. Tests shall not be carried out on dense screeds laid on hollow pot or similar floors, toppings or lightweight screeds which could suffer damage.

284. 1250 The number and random locations of tests shall be agreed with the

Purchaser. The minimum number of tests shall be 4 per room area and not less than 4 per each 10 m2 floor area for areas designed for heavy wheeled traffic usage or 2 per each 10 m2 for light traffic usage.

A test shall be carried out in each doorway. Test results to be submitted to



the Purchaser. 284. 1260 The acceptable limits for indentation depths resulting from the tests shall be

in accordance with the recommendations of the manufacturer of the equipment. (BRE screed tester and depth gauge).

284. 1270 After curing, all screeded floor finishes shall be inspected for curling,

excessive cracking, material breakdown or hollowness. 284. 1280 In all cases appropriate remedial action shall be agreed with the Purchaser

in the event of non compliance. 284. 1290 Hardness and composition analysis tests for mastic asphalt samples from

site re-melting equipment shall be carried out to BS 5284 at the time of laying. Test results to be submitted to the Purchaser. Inspection

284. 1300 The inspection of surface preparation of all substrates shall be carried out

prior to laying screeds or floor finishes.







BS 12 Specification for ordinary and rapid hardening Portland Cement BS 146 Specification for Portland-blastfurnace cement BS 410 Specification for test sieves BS 747 Specification for roofing felts BS 812 Methods for Sampling and Testing of Mineral Aggregate,

Sands and Fillers BS 882 Aggregates from natural sources for concrete BS 1014 Specification for pigments for Portland cement and Portland cement

products BS 1197 Specification for concrete flooring tiles and fittings BS 1199 Specification for building sands from natural sources and 1200 BS 1217 Specification for cast stone BS 3261 Specification for unbacked flexible PVC flooring

(Withdrawn) Replaced by BS 649: 1997. BS 3797 Specification for lightweight aggregates for concrete BS 3984 Specification for sodium silicates BS 4131 Specification for Terrazo tiles BS 5085 Specification for backed flexible PVC flooring BS 5284 Methods: Sampling and testing mastic asphalt and pitchmastic used

in building. BS 5385 Code of practice for tile flooring and slab flooring BS 6431 Ceramic floor and wall tiles BS 6577 Specification for mastic asphalt for building (natural rock asphalt

aggregate) BS 6925 Specification for mastic asphalt for building and civil Engineering

(limestone aggregate) BS 8203 Code of practice for installation of sheet and tile flooring

CP 204 In-situ floor finishes




CLAUSE REFERENCE


COMMENT

284.040 284.1190 284.1200 284.1210 284.1220 284.1230 284.1250 284.1290 284.1300

Material samples. Material certificates. Material technical literature. Quality control samples. Method statement. Construction records. Impact testing results. Mastic asphalt test results. Inspection of surface preparation.



TECHNICAL SPECIFICATION WORK GROUP: 310 : WINDOWS, DOORS & SHUTTERS SECTION NO: 311 TITLE: WINDOWS AND DOORS TABLE OF CONTENTS SCOPE MATERIALS

General Doors and Windows Glazing Ironmongery Handling and Storage

WORKMANSHIP

General Installation Glazing

QUALITY CONTROL

General Inspection




SCOPE 311. 010 This Section defines the general requirements for the supply and

installation of standard door and window sets including hatchways, shutters, louvres and roof lights.

311. 030 This Section does not include specialist proprietary items including roller

shutter or sliding doors, etc.

MATERIALS

General 311. 040 Standard proprietary and purpose made doors, windows and shutters shall

be made by agreed manufacturers. 311. 050 Sample sections shall be submitted to the Purchaser to demonstrate the

standard of fabrication and finish to be provided. 311. 060 Types, duty and mode of operation, materials (timber, steel, upvc,

aluminium), dimensions, exposure classification and performance characteristics, protective finishes, glazing requirements, acoustic resistance, durability, level of insulation, fire resistance, locks and fittings, ironmongery shall be shown on the Drawings.

Special furniture including escutcheons, card holders and name plates shall be finished to match the remainder of the furniture unless otherwise specified.

311. 070 All mechanical fastenings shall be protected against corrosion. Metalwork,

nails, screws shall be galvanised as a minimum requirement. In exposed, corrosive or high humidity areas they shall receive other suitable protection such as plating.

311. 080 Lost headed nails to BS 1202 shall be used for decorative wood work to

allow for wood stopping. 311. 090 Brass or stainless steel screws only shall be used in hardwood, acidic wood

e.g. oak, or when clear finishes are specified. Screw cups shall be brass or stainless steel pressed socket pattern.



311. 100 The durability, maintenance and sound insulation requirements of windows

and rooflights shall comply with CP 153 Parts 2 & 3. The requirements for wind resistance, watertightness and air permeability shall be to BS 6375. Fire resistance shall be to BS 476 Part 8.

311. 110 Door and window sets etc when fabricated to site measurements shall allow

a 5mm perimeter clearance to the openings in the structure.

Doors and Windows 311. 120 External and internal wood door sets, leaves and frames shall be to BS

4787 and CP 151 Part 1. 311. 130 External wood door sets shall be of hardwood, internal doorsets shall be of

softwood unless otherwise specified. 311. 140 External opening doors and windows shall be fully weather stripped to

permit minimum air infiltration and maximum resistance to water penetration.

311. 150 Weather stripping shall be one of the following types:

° siliconised woven polypropylene pile ° extruded flexible pvc to BS 2571

unless otherwise specified.

311. 160 Aluminium alloy windows shall be to BS 4873. 311. 170 Steel windows, sills and doors shall be to BS 6510. 311. 180 Agreed intumescent seals shall be provided around fire doors. 311. 190 Veneered doors in pairs shall have matching veneers. 311. 200 All flush timber doors shall be flat and smooth, with lippings, glue bonded

and facings and be of fire check construction to BS 476. 311. 210 Solid core flush doors shall be made from:

° blockboard with hardwood lippings and edges ° or solid timber core strips butt jointed glued with grain

reversed and with 4mm plywood facings and hardwood lippings.



Glazing 311. 220 Factory glazed windows shall be to BS 6262.

The type and thickness of glazing shall satisfy any particular performance requirements and take fully into account the size of each panel with respect to safety considerations. Hermetically sealed double glazing units shall be to BS 5713.

311. 230 Glass for glazing shall be to BS 952 Part 1 311. 240 Glazing sealants and compounds shall be as recommended by the

manufacturers to provide the required hardness, be compatible with the contact surfaces and be coloured where specified to match the adjacent frame surround.

311. 250 Glazing accessories, beads, tape, setting blocks, channels, gaskets and

spacers shall be as recommended by the glazing manufacturers. 311. 260 Non combustible glazing channels shall be used for fire resistant doors. 311. 270 Setting blocks, distance pieces and location blocks in plasticised pvc shall

be to BS 2571. 311. 280 Linseed oil putty when used with soft wood frames shall be to BS 544. 311. 290 Cleaners, primers and sealers shall be as recommended by the sealant

manufacturers. 311. 300 Fixing screws shall be as recommended by the door and window

manufacturers. The fixing plugs shall be nylon or plastic correctly sized to suit the fixing screws.

Ironmongery

311. 305 Door furniture in general shall be selected from the "Hewi" range nylon

coated and coloured grey or ivory. The Contractor may use an alternative equivalent range subject to the Purchaser’s agreement.

311. 306 Locks shall be selected such that they are compatible to and may be suited

with locks in the Employers existing Buildings. 311. 310 The minimum requirement for hanging doors shall be as follows unless

otherwise specified:



° Internal non-fire doors up to 50 kg in weight or up to

2150mm x 850mm in size shall be hung on one pair of unwashered steel hinges (bright zinc plated) 100mm x 75m m each fixed to the door and frame by 8 steel countersunk screws.

° Internal fire doors up to 50 kg in weight or up to 2150mm x

850mm in size shall be hung on 1 pair of unwashered steel hinges (bright zinc plated) 100mm x 75mm and fixed to the door and frame by 8 steel countersunk screws.

° Internal doors, fire and non-fire which are heavier or larger

than described above and up to 2500mm x 1000mm in size shall be hung on 2 pairs of washered steel hinges (bright zinc plated) 100mm x 75mm each fixed in the door and frame by 8 steel countersunk screws.

° External doors up to 50 kg in weight and up to 2150 x

850mm in size shall be hung on 1 pair of 100mm x 75mm stainless steel hinges and fixed to the door and frame by 8 stainless steel countersunk screws.

° External doors heavier than above and up to 2500mm x

1000mm in size similar to the above but 2 pairs required.

311. 320 Internal doors which are required to open 180° shall be hung as follows:

° Non-fire doors up to 50 kg in weight and up to 2150mm x 850mm in size shall be hung on 1 pair of unwashered steel projecting hinges (bright zinc plated) 100mm x 100mm each fixed to door and frame by 8 steel countersunk screws.

° Fire doors as above - 1 pairs of hinges.

° Internal doors which are required to open 180° and are

heavier and/or larger than that described above and up to 2500mm x 1000mm in size shall be hung on 2 pairs of washered steel projecting hinges (bright zinc plated) 100mm x 100mm each fixed to door and frame by 8 countersunk screws.

External doors which are required to open 180° shall be hung as follows:



° Doors up to 50 kg in weight and up to 2150mm x 850mm in size shall be hung on 1 pair of S.S projecting hinges 100mm x 100mm each fixed to door and frame by 8 S.S countersunk screws.

° Doors heavier than above and up to 2500mm x 1000mm in

size, similar to the above but 2 pairs required.

Handling and Storage 311. 330 All materials shall be stored in clean dry conditions. 311. 340 Doors, windows, rooflights and fittings shall be stored in the manufacturers

protective packaging. Priming of woodwork shall not be considered as providing adequate protection.

311. 350 Timber door sets shall be maintained within specified moisture content

levels as necessary. 311. 360 Doors and windows shall be stored clear of the ground and stacked so that

they are not subject to distortion or damage. Door sets shall be stored flat. 311. 370 Glass units and sheets shall be handled with care to avoid breaking or

chipping and stored on edge in a near vertical position and protected against hard uneven bearing surfaces. No moisture shall be trapped between units or sheets.

311. 380 Glass shall not be allowed to come into contact with alkaline materials such

as cement or lime.

WORKMANSHIP

General 311. 390 The handling and unloading of doors, windows, rooflights etc shall avoid

damage and distortion. The units shall be kept in their protective packaging prior to installation.

311. 400 All doors and windows shall be numbered to ensure installation at the

correct locations. 311. 410 The installation of doors, windows, rooflights, glazing etc shall be carried

out by experienced personnel.



311. 420 Proprietary door sets, windows, rooflights etc shall be fixed in accordance with manufacturers instructions. Doors, windows etc supplied pre-hung shall be kept closed and secured during the fixing of the frames.

Installation

311. 430 The framework of windows, doors, rooflights etc shall be fixed to the

surrounding structure by positive mechanical anchors. 311. 440 The units shall be correctly positioned in relation to the openings, fixed

plumb and level with packings at fixing points to prevent distortion as the fixings are tightened.

311. 450 The gaps between the frames and the structure shall be filled with non

combustible material when fixing fire resisting door sets. 311. 460 Perimeter pointing with sealants shall be carried out in accordance with

Generic Specification Section 402. 311. 470 Timber exposed by site works shall be retreated with two liberal coats of

brush or spray applied preservative as used in the initial treatment or with a solution recommended by the preservative manufacturer.

311. 480 Purpose made wood door sets shall be tested at fabrication and erection

stages for moisture content of timber sections using an electrical moisture meter to the manufacturer's instruction. 5% of cross sections shall be tested and 90% of test results shall lie within the ranges specified in BS 1186 Part 1.

311. 490 The quality of workmanship in joinery shall be to BS 1186 Part 2. 311. 500 Doors shall be hung from the frames by hinges as specified and fixed with 8

no matching countersunk screws per hinge. 311. 510 Hinges shall generally be located 125mm from the top edge and 250mm

from the bottom edge. Other hinges when specified shall be equally spaced between the top and bottom hinges.

311. 520 All fire doors shall have a minimum of one pair of butt hinges. Clause

311.310 refers. 311. 530 Doors which are required to open 180° shall be hung on 100mm x 100mm

steel projecting hinges. Clause 311.320 refers. 311. 540 All door furniture shall be removed prior to carrying out any preparatory and



decorating work. 311. 550 All moving and closing parts of timber construction shall fit accurately with a

regular visible gap of 1.5mm.

Glazing 311. 560 Glazing workmanship shall comply generally with BS 6262. 311. 570 Glass with damaged edges or surface imperfections shall be discarded.

Glazed units with damaged edge tapes shall not be used. 311. 580 Glazing channels and surrounds which are to receive the glass shall be

cleaned and any coatings not firmly bonded to the substrate shall be removed.

311. 590 Primer and sealer shall be applied to dry, clean joint surfaces as instructed

by the sealant manufacturer. 311. 600 Patterned glass in external locations shall be fixed with the smoother face

outside. 311. 610 Glazing in timber surrounds shall be well bedded, back puttied and

sprigged, front puttied and neatly cleaned off to sight lines. 311. 620 Georgian wired glass shall be cut square and parallel with the direction of

the wires. Observation windows in doors shall be bedded in a soft packing or turned over wash leather or in neoprene gaskets as specified.

311. 630 Glazing in fire resisting doors shall be installed in accordance with the

manufacturers instructions.



QUALITY CONTROL

General

311. 640 The Contractor shall submit all manufacturers literature including full

instructions for installation and shop drawings as appropriate. 311. 650 Test certificates shall be provided to confirm the adequacy of all units to

satisfy performance requirements.

Inspection 311. 660 Openings in external walls shall be checked prior to installation of frames to

ensure that all preparatory work, fixings and damp proof membranes have been correctly installed.

311. 670 All units shall be checked for size, line and level, distortion. Hinged doors

and windows shall be checked for the correct hand and location. 311. 680 All opening units shall be checked for smooth swing and correct closure

with frame and locking mechanism. 311. 690 All furniture shall be checked and all keys labelled.






BS 476 Fire tests on building materials and structures.

BS 544 Specification for linseed oil putty for use in wooden frames. BS 952 Glass for glazing. Part 1: Classification.

BS 1186 Timber for and workmanship in joinery. BS 1202 Specification for nails. BS 2571 Specification for flexible PVC compounds. BS 4787 Internal and external wood door sets, door leaves and frames. BS 4873 Specification for aluminium alloy windows. BS 5713 Specification for hermetically sealed flat double glazing units. BS 6262 Code of practice for glazing in buildings. BS 6375 Performance of windows. BS 6510 Specification for steel windows, sills, window boards and doors.

CP 151 Doors and windows including frames and linings. Part 1: Wooden doors.

CP 153 Windows and rooflights. Part 2: Durability and maintenance. Part 3: Sound insulation.



APPENDIX 2 - INFORMATION TO BE PROVIDED BY TRACTOR

CLAUSE REFERENCE


COMMENT

311.050 311.640 311.650

Samples to be submitted. Manufacturer's literature. Test certificates.



TECHNICAL SPECIFICATION WORK GROUP: 310 : SHUTTER DOORS SECTION: 312 TITLE: SHUTTER DOORS TABLE OF CONTENTS SCOPE MATERIALS

General Finishes Delivery and Storage

WORKMANSHIP

Handling Erection and Installation

QUALITY CONTROL

Checking Commissioning Record Drawings




SCOPE 312. 010 This Section defines the supply, installation and commissioning of shutter

doors.

MATERIALS

General 312. 030 Shutter doors will be sliding folding type, motor operated from push-to-run

button stations with end of travel limit switches. Erection, installation and commissioning instructions will be prepared and supplied by the manufacturer.

312. 035 The door leaves shall be constructed absolutely resistant against torsion,

using stiffening frames torsion and appropriate steel sections.

Finishes 312. 040 Shutter doors are to be fabricated from mild steel galvanised by the

manufacturer.

Delivery and Storage 312. 050 The Contractor shall take delivery of the doors and associated components,

unload them from the delivery vehicle and store them in a dry covered store.

The doors shall be protected from the effects of damp and all moving parts and hinges be well greased. Large parts shall be laid on timber baulks.

WORKMANSHIP

Handling

312. 060 The doors shall be carefully handled and the contractor shall be fully

responsible for the doors and associated components upon delivery to site.



Erection and Installation

312. 070 Door frames shall be of galvanised mild steel fixed to masonry, concrete or

steelwork with steel anchors. The space between the wall and frame shall be entirely filled on all sides using cement mortar. Fixing on exposed concrete or fair-face masonry surfaces shall be effected by means of an appropriate construction which does not affect the uniform appearance of the exposed or fair-masonry surfaces. The connecting joints between the frame and all surfaces shall be sealed and finished.

312. 072 The doors shall be erected and installed in a workmanlike manner entirely

in accordance with the manufacturer’s instructions using personnel who are fully experienced in the erection and installation of shutter doors.

The alignment, verticality and level of the doors and components shall be within the manufacturer’s specified tolerances and all minimum clearances shall be maintained. All motors, drives, chains and pulleys shall be properly installed and power and control circuits connected as detailed in the manufacturers instructions.

Any on-site modifications or deviations from the manufacturer's recommendations shall be agreed by the Purchaser.

312. 075 The door when installed shall be operated entirely as intended. All safety

switches shall be fully tested. The doors shall be completely weathertight when in a closed position.

Upon completion of erection and installation all parts and components shall be thoroughly cleared of all grease, dust and other marks.

QUALITY CONTROL

Checking

312. 080 Immediately after delivery to site the doors shall be unpacked and all parts

and components checked against the inventory supplied by the manufacturer. The Contractor shall also check for damage, corrosion or other deterioration of parts or components.

The Contractor shall familiarise himself with the erection, installation and commissioning instructions and ensure that he fully understands the



procedures prior to the doors being required for erection. The Contractor shall allow sufficient time in his programme to obtain, if required, clarification from the manufacturer.

Commissioning

312. 100 After completion of installation and connection of mains power the operation

of each door shall be proven to the satisfaction of the Purchaser. The operation of all safety switches shall be checked by a suitable test to the agreement of the Purchaser.

Record Drawings

312. 110 Upon completion of installation and commissioning the Contractor shall

mark up a set of the Installation Drawings to show any modifications which have been made on site.




below.

The Contractor shall bring to the attention of the Purchaser any inconsistencies between the requirements of these Standards and this Specification Section.

None.




CLAUSE REFERENCE


COMMENT

312. 100 312. 110

Safety switch test method. Amended Installation drawings



TECHNICAL SPECIFICATION WORK GROUP : 330 : PAINTWORK SECTION NO : 331 TITLE: PAINTING OF BUILDINGS TABLE OF CONTENTS SCOPE MATERIALS

General Miscellaneous Preparatory Materials

WORKMANSHIP

General Colour/Finishes Unsuitable Site Conditions Surface Preparation

- General - Iron and Steelwork - Timber and Plywood - Galvanised Metalwork - Brickwork, Blockwork, Concrete, Plaster and Rendered Surfaces

Application of Paint

- General - Primers - Sealers - Undercoats - Finishing Coats

Methods of Application

- Roller Painting



TABLE OF CONTENTS

- Brush Painting - Spray Painting

QUALITY CONTROL





SCOPE 331. 010 This Section defines the requirements for the supply and site application of

paint including substrate surface preparation and related activities. 331. 020 This Section does not apply to structural steelwork, which shall be painted

in accordance with Section 211.

MATERIALS

General 331. 030 All painting work shall be carried out to BS 6150. 331. 040 All paint materials shall be branded and obtained from an agreed

manufacturer. Substitute materials will not be accepted. Preparatory materials shall be compatible with the paint system to be applied.

331. 050 All materials shall comply with the paint systems defined in the

Painting/Colour Finishes Schedules and shall be delivered to Site with labels on all containers bearing manufacturer's name, brand name, type of paint, stock number, batch number. They shall be supported by analyses of solids, storage instructions, thinning instructions, tinting instructions, drying and re-coat times, application instructions with recommended methods and any environmental restrictions.

331. 060 All paint materials shall be obtained from an agreed supplier. The

agreement of the Purchaser must be obtained before any change in supplier is implemented.

Miscellaneous Preparatory Materials

331. 070 Knotting shall be to BS 1336. 331. 080 White spirit shall be to BS 245 Type A. 331. 090 Linseed oil shall be to BS 6900. 331. 100 Stopping for woodwork shall be ready mixed emulsion polymer or oil based

type suitable for internal or external use as appropriate. 331. 110 Filler for plasterwork shall be of water mixed powder type. 331. 120 Stopping and filler for woodwork to receive clear finishes shall be ready



mixed and tinted to match timber.

WORKMANSHIP

General 331. 140 Containers without labels, or with defaced and illegible labels, shall be

removed permanently from the Works. 331. 150 Materials that have exceeded the recommended shelf life or that have been

subject to adverse conditions shall be removed permanently from the Works.

331. 160 Adequate ventilation and environmental conditions shall be ensured where

possible for all painting processes. Air demand respirators shall be used when adequate ventilation cannot be provided.

331. 170 Unavoidable splashes, etc., shall be cleaned up immediately, and the

surfaces splashed left in a clean state. An appropriate cleaner is to be used for the surface splashed. Damage resulting from the use of the wrong solvent shall be put right at the Contractor's expense.

331. 180 The Contractor shall clean up all work including windows, etc., on

completion and clear away all rubbish to the entire satisfaction of the Purchaser.

Colour/Finishes

331. 190 The Contractor shall carry out the painting of all items in accordance with

the Painting/Colour Finishes Schedules using the correct colours, methods of application and sequence of undercoating in all cases.

331. 200 Paint colours shall be selected from BS 4800. Sample areas of each

selected type shall be painted as a control for colour, texture and workmanship for each paint system.

331. 210 Each coat of paint shall have a distinguishing tint as recommended by the

paint manufacturer.



Unsuitable Site Conditions

331. 220 Paint shall not be applied when

(a) surfaces are affected by damp or frost

(b) substrates have not dried out

(c) the air temperature is below 4°C

(d) heat is likely to cause faults to develop

(e) air borne dust is likely to spoil wet paint

(f) condensation is likely to occur before paint is touch dry

(g) rain is likely to affect the paint.

Surface Preparation

General 331. 230 Items to be painted shall be thoroughly cleaned and prepared in

accordance with the Specification. 331. 240 All necessary precautions shall be taken to ensure completed finishes, plant

installations and other fixtures and fittings are protected. 331. 250 Door furniture shall be removed prior to painting and refixed on completion.

Iron and Steelwork 331. 270 Bare iron and secondary steelwork, handrailing, sheeting and pipes etc.

shall be thoroughly prepared by removing all dirt, rust and loose millscale to the satisfaction of the Purchaser.

331. 280 Preparation shall include the use of chipping hammers, scrapers,

mechanical wire brushes and carborundum grinding discs.

The use of mechanical chisels and other impact tools may exceptionally be ordered if in the opinion of the Purchaser their use is necessary.

331. 290 Tools shall be operated in such a manner that no sharp ridges or burrs are

left and no cuts made in the steel.



331. 300 Dust and other loose material shall be removed after cleaning. Oil and

grease shall be removed with white spirit. 331. 310 Surfaces exposed to an atmosphere polluted with chemicals, etc., shall be

thoroughly washed with fresh water and allowed to dry before priming. 331. 320 Surfaces inaccessible to manual cleaning, where steel scraping is

insufficient, hall be treated with chemical rust remover applied liberally. All surfaces and surrounding areas which become contaminated are to be thoroughly washed with fresh water. Priming shall be carried out as soon as practical and in any case the same day.

331. 330 Steelwork or ironwork primed before delivery and damaged in transit shall

have all damaged areas cleaned and patch primed immediately upon delivery. Areas damaged during erection shall be similarly dealt with.

331. 340 Priming coats shall be applied before any contamination or rusting occurs.

Timber and Plywood Surfaces 331. 350 Surfaces shall be thoroughly rubbed down to give a perfectly smooth finish

and cleaned to remove all dirt and dust then twice knotted and stopped before priming.

331. 360 After priming, defects such as open joints or nail holes shall be stopped with

hard stopping, and surface imperfections faced up. All such repairs shall be primed before undercoating is applied.

331. 370 Primed hardwood and softwood shall then be painted in accordance with

the Finishes Schedule. Surfaces shall be lightly rubbed down, cleaned and thoroughly dry before a further coat is applied.

331. 380 Hardwood containing an excess of natural oil shall be degreased with white

spirit immediately prior to priming. 331. 390 The moisture content of the substrate shall be checked to ensure that the

completed work will not be affected.

Galvanised Metal Work 331. 400 Surfaces shall be thoroughly cleaned and freed from dirt and all traces of

grease and oil removed with an agreed de-greasing solution applied in



accordance with the manufacturer's instructions. 331. 410 After cleaning, if so directed by the Purchaser, the Contractor shall treat the

surface to be painted with an agreed mordant solution. The mordant solution must be washed off the surface with copious supplies of cold water before any paint is applied. It is important that no trace of the mordant solution remains.

Brickwork, Blockwork, Concrete, Plaster and Rendered Surfaces

331. 420 All surfaces shall be cleaned down and all mortar and plaster splashes,

nibs, loose and flaking material shall be removed. 331. 430 All efflorescence surface salts shall be removed with a stiff brush and left

for 48 hours. If further efflorescence occurs the process shall be repeated. 331. 440 All holes, cracks and surface imperfections to be made good. 331. 450 Shutter release agents shall be removed by washing with a weak detergent

solution and rinsed with clean water. 331. 460 Adequate time shall be allowed for the primer to become thoroughly hard

and dry before the application on the undercoat.

Application of Paint

General 331. 470 Paint materials shall be handled, stored, mixed and applied in accordance

with manufacturer's recommendations. Any conflict between these recommendations and the Specification shall be clarified with the Purchaser before work starts.

331. 480 The methods of application of each type of paint shall be agreed by the

Purchaser before work starts. 331. 490 Paint shall be applied only to prepared, clean, sound and dry surfaces as

specified. 331. 500 A finished coat of one manufacturer shall not be applied to an undercoat of

another manufacturer. 331. 510 Paint shall be applied to the recommended minimum dry film thickness

(DFT) which shall be the absolute minimum coverage at any point of



measurement. Where DFT cannot be practically measured a coat shall be applied at the manufacturer's DFT equivalent spread rate with full allowance made for waste.

331. 520 Each coat of paint shall be thoroughly dry before the next coat is applied

and the surfaces of primers and undercoats shall be lightly rubbed down and dusted off.

331. 530 Coats shall be applied at proper intervals within the maximum and minimum

recommended drying periods to secure maximum adhesion. 331. 540 The Purchaser shall instruct the Contractor when to apply the final finishing

coat of paint. A considerable time delay may be required after completion of the underlying coats.

Primers

331. 550 Priming coats shall be applied generally by brush to give a coat of adequate

thickness with no misses and to suit the porosity of the surface. The primer shall be well worked into the surface, joints, angles and other places where future moisture is likely to collect and on surfaces that will become hidden from view and access.

Sealers

331. 560 Sealers and first coat P.V.A. shall be applied to suit the porosity of the

surface and/or seal in materials which are likely to adversely affected the subsequently applied painting system.

Undercoats

331. 570 Undercoats shall be applied evenly over the whole surface to give a solid

film, care being taken to avoid uneven thickness of paint at edges and angles.

Finishing Coats 331. 580 Finishing coats shall be applied evenly over the whole surface to give a

solid film, free from brush marks, sags, runs, orange peel effects or other defects.



331. 590 Excessive brushing out of aluminium paint shall be avoided.

Methods of Application

Roller Painting 331. 600 Roller painting shall be carried out with mohair or short pile sheepskin

rollers. It will not be allowed for:

a) Application of priming coats.

b) Work other than of a straightforward plain character.

Brush Painting 331. 610 Paint shall be applied so that the finished surface is free from avoidable

brush marks. 331. 620 All areas or parts shall be laid off correctly.

Spray Painting 331. 630 Spray painting will be permitted with agreed machines but in no case will it

be allowed in the application of the following:

a) Priming paints.

b) First coat of P.V.A. emulsion paint.

c) Where soiling of adjacent surfaces cannot be prevented.

d) Tar based paints and creosote. 331. 640 Perforated acoustic surfaces shall be sprayed at an angle of 30° to the

surface. 331. 650 Surfaces adjoining those being sprayed shall be carefully and closely

masked. 331. 660 The coating shall be even and adequate and the finish shall be free from

orange peel appearance, runs, sags, curtaining and other defects.

QUALITY CONTROL



General

331. 670 A complete description of painting methods and procedures shall be

submitted to the Purchaser including, but not limited to, the following:

a) Cleaning methods, materials and equipment, including positive methods of pollution control of solvents and blasting materials.

b) Paint application procedures, including paint manufacturer's

recommended methods of application and equipment types and sizes; recommended drying times, control methods for overspray, masking and protection of equipment and the environment; surface temperature control of items prior to and during the painting process; scaffolding; mixing procedures and quantities; any proposed deviations from the manufacturer's recommendations which shall be explained in detail.

c) Safety procedures, including storage methods, ventilation of

areas during painting, waste material disposal, personnel protection, equipment cleaning methods and fire prevention methods and procedures.

d) Equipment specifications and manufacturer's

recommendations for the use thereof.

e) Testing procedures to show conformance to the Specification.

f) Inspection procedures.

Application of paint coats shall not be carried out prior to receipt of this submission by the Purchaser.

Inspection and Testing 331. 680 The Purchaser shall be notified when:

a) The surface preparation for each room or area as agreed



with the Purchaser is started.

b) The painting of sample areas is to be carried out.

c) Surface preparation of areas which will become inaccessible has been started.

331. 690 Control records shall be retained by the Contractor for each location:

° Time of preparation of surfaces.

° Time of application of protective finishes.

° Measurements of paint film thickness or D.F.T.

° Moisture level readings of substrates.






BS 245 Specification for mineral solvents (white spirit and related hydrocarbon solvents) for paints and other purposes.

BS 1336 Specification for knotting. BS 4800 Specification for paint colours for building purposes. BS 5493 Code of practice for protective coating of iron and steel structures

against corrosion. BS 6150 Code of Practice for painting of buildings. BS 6900 Specification for raw, refined and boiled linseed oils for paints and

varnishes.




CLAUSE REFERENCE


COMMENT

331.670 331.680 331.690

Overall method statement. Notification of preparation of surfaces/sample areas/inaccessible areas. Control records.



TECHNICAL SPECIFICATION WORK GROUP: 400 : ANCILLARIES (CIVIL WORKS) SECTION NO: 401 TITLE: WATERPROOFING AND WATERSTOPS TABLE OF CONTENTS SCOPE MATERIALS WORKMANSHIP

Membranes Waterstops





installation of liquid applied and sheet waterproofing membranes and waterstops to concrete structures.

MATERIALS

401. 020 Proprietary waterproofing systems incorporated in the Works shall have a

current British Agrément Board Roads and Bridges Certificate and of a type agreed by the Purchaser.

401. 030 Liquid applied waterproofing shall be a water based bituminous latex

emulsion of a type to be agreed by the Purchaser or cut back bitumen complying with BS 3690 : Part 1 of viscosity grade 50 seconds plus suitable primer of such viscosity that it penetrates the concrete without forming a skin.

401. 040 Powder or slurry form waterproofing shall be a cementitious multipart

waterproofing system of a type to be agreed by the Purchaser. 401. 050 Sheet waterproofing membranes shall be one of the following:

(i) Cold-applied self adhesive bituminous or rubber bitumen sheeting of 1.5mm minimum thickness of bituminous compound with removable backing paper.

(ii) Waterproof building paper to BS 1521 of class B1F.

(iii) Impermeable plastic sheeting to BS 1763 with a minimum thickness

of 125 microns. 401. 060 Waterstops shall be purpose-made and manufactured from PVC or rubber

and supplied by a manufacturer agreed by the Purchaser. 401. 070 The Contractor shall submit drawings detailing the waterbar layout for the

structure indicating the joint positions and giving details of the jointing method.



WORKMANSHIP

Membranes 401. 080 All membranes shall be packaged, stored, handled, applied, protected and

cured in accordance with the manufacturer's instructions. 401. 090 Before application, surfaces shall be checked as being sound, free from

dirt and contamination, of smooth texture, dry (apart from powder or slurry membranes) and free from frost.

401. 100 Bituminous latex emulsion membranes shall be applied by brush or airless

spray using the number of coats specified by the specialist manufacturer and allowing an appropriate drying time between coats.

401. 110 Concrete surfaces to receive bitumen waterproofing shall be thoroughly

sealed with an evenly applied primer. The cut back bitumen shall be hot applied at a rate of spread per coat of 0.6 litre/m2. The first coat shall be allowed to dry before the second coat is applied.

401. 120 Commencement of application of waterproofing and subsequent coats shall

not occur without the Purchaser’s Agreement. 401. 130 Sheet membranes shall be suitably protected on external surfaces prior to

the commencement of backfilling.

Waterstops 401. 140 Waterstops shall be provided in continuous lengths. Where site jointing is

unavoidable it shall be carried out in accordance with the manufacturer's instructions using heat, sleeved or adhesive joints by suitably trained personnel.

401. 150 Waterstops shall be securely held in position using agreed securing

methods to avoid any damage to or distortion of the waterstops during concreting.

401. 160 The general requirements for inspection of waterstops prior to concreting

and the surface preparation of adjacent concrete after concreting are specified in Section 201.

401. 170 The caulking and sealing of movement joints which incorporate waterstops

is specified in Section 402.



QUALITY CONTROL 401. 180 The Contractor shall obtain manufacturer's material and test certificates as

appropriate for all waterproofing and waterstop materials. 401. 190 Only suitably trained personnel shall be allowed to apply waterproofing

membranes and make on site joints of waterstops.






BS 1521 Specification for waterproof building papers. BS 1763 Specification for thin PVC sheeting (calendered, flexible,

unsupported).




CLAUSE REFERENCE


COMMENT

401.070 401.110 401.120 401.130 401.180

Waterbar layout drawing. Notification of surface preparation. Notification of waterproofing. Notification of protection against backfill. Material/test certificates.



TECHNICAL SPECIFICATION WORK GROUP: 400 : ANCILLARIES (CIVIL WORKS) SECTION NO: 402 TITLE: CAULKING AND SEALANTS TABLE OF CONTENTS SCOPE MATERIALS

General Primer Back-Up Filler Sealants and Caulking Compounds

WORKMANSHIP

Joint Preparation Priming of Joints Mixing of Sealants/Caulking Compounds Application of Sealants





general use of sealants with respect to concrete construction, masonry, door and window frames.

It does not cover applications for waterproofing, damp-proofing, glazing work, sealants between cladding sheets, sealants for mechanical/electrical works, pressure retaining assemblies.

MATERIALS

General

402. 030 Materials shall be stored in a clean, dry, well ventilated area, raised above

ground level and protected from temperature extremes. Inflammable materials shall be stored in accordance with manufacturer's recommendations.

Primer

402. 040 The type of primer selected shall be compatible with the sealant and shall

be as recommended by the sealant manufacturer. It shall be quick drying and non-staining; it shall be delivered in unopened containers bearing the manufacturer's name, the product name and expiry date and any necessary warnings about flammability or health hazards.

Back-Up Filler

402. 050 Filler material shall not adhere to the caulking compound or sealant used

and shall be provided with a bond breaker as recommended by the manufacturer if the material used has no releasing property. Bond breakers shall be of aluminium foil, polyethylene or other agreed material.

402. 060 The joint filler shall be of the type specified below.

In all circumstances it shall be appropriate to the design function required and the environmental conditions to which it will be exposed.

402. 070 Type F1: Compressible non-extruding bitumen impregnated fibreboard

expansion joint fillers suitable for forming joints in in-situ concrete structures and between pre-cast concrete components. This filler shall not be used for expansion joints in fired clay brickwork (BS 5628 Part 3 refers).

402. 080 Type F2: Non absorbent closed cell semi-rigid polyethylene joint fillers.



402. 090 Type F3: Non absorbent closed cell readily compressible polyethylene joint

filler and back up strips. 402. 100 Type F4: Bitumen-free bonded granular cork expansion joint fillers. 402. 110 Type F5: Expanding polyurethane foam gap filler. 402. 120 Type F6: Filling for caulking movement joints in fire barrier walls or slabs

shall be with an agreed proprietary fire blanket. It shall be non-alkaline, shall be chemically stable and contain no corrosion promoting agents.

Sealants and Caulking Compounds

402. 130 All sealants and caulking compounds shall be waterproof and adherent to

the surface onto which they are to be applied. The materials shall be of a type suitable for the conditions of exposure in which they are to be placed. The sealants shall not slump or flow after application is complete during seasonal contraction and expansion of the joint up to +12.5% of the joint width (except where a lesser movement is specified). They shall not stain or discolour the adjacent surfaces and shall be formulated so that any toxic materials incorporated or generated during curing will not migrate to the surface where they could be extracted when the sealant has cured.

402. 140 Sealants and caulking compounds shall be of a type specified below. 402. 150 Type A: Hot-applied rubber/bitumen sealing compound which complies with

Type A1 (High extension) of BS 2499. It will be used for sealing the upper edges of vertical joints, e.g. those in floor and roof slabs where the sealed face will be horizontal or only slightly inclined.

402. 160 Type B: Hot-applied rubber/bitumen sealing compound which will

accommodate seasonal contraction and expansion of up to + 6% of the joint width and which complies with type A2 (Low extension) of BS 2499 shall be used for sealing the upper edges of vertical joints which are subject to little movement, and where the sealed face will be horizontal or only slightly inclined e.g. those in floor and roof slabs.

402. 170 Type C: Bituminous putty which will accommodate seasonal contraction

and expansion of up to +5% of the joint width it shall be used for sealing the exposed edges of vertical, horizontal, or inclined joints, e.g. those in walls and soffits of slabs.

402. 180 Type D: Cold-applied polysulphide based compound to BS 5212 shall be

used in positions as for type A but where resistance to dilute acids and



alkalis, oils and petrol is required. 402. 190 Type E: One-part polysulphide sealant to BS 5215 shall be used for window

and door frame surrounds, external walling and cladding. 402. 200 Type F: Two-part polysulphide based compound to BS 4254 shall be used

in positions as for type C but where resistance to dilute acids and alkalis, oils and petrol is required.

402. 210 Type G: Two-part component elastomeric sealant for use in type A

conditions but where maximum resistance to impact and abrasion is required.

402. 220 Type H: Multi-part, high performance, sealants with better characteristics for

high movement joints. 402. 230 Type I: Cold applied two part elastomeric cement mortar for use in damp

application conditions.

WORKMANSHIP 402. 240 Work shall be carried out by suitably trained personnel. The Purchaser may

require the Contractor to provide evidence in this respect.

Joint Preparation 402. 250 Joint surfaces shall be completely dry (apart from type I), clean and frost

free. Remove all dirt, dust laitance, friable and loose material by rigorous brushing. Any oil or grease must be removed by an agreed joint cleaner.

402. 260 Non-porous joint surfaces shall be cleaned mechanically or chemically,

achieving grease-free surface, suitable for adhesion of sealant.



402. 270 Porous joint surfaces such as brickwork, concrete or stonework shall be

cleaned by grinding, sand/water blast cleaning, mechanical abrading or combination of these methods to provide a sound base-surface (when dry) for sealant adhesion. In addition specifically:

(a) remove laitance by grinding or mechanical abrading;

(b) remove form oils by sand-water blast cleaning;

(c) remove loose particles already present or resulting from the

above treatment with oil-free compressed air.

Priming of Joints 402. 280 Substrate surfaces of joints shall be primed where necessary to ensure

sealant adhesion. Primers shall be applied strictly in accordance with manufacturer's instructions. Other surfaces shall be masked to prevent adhesion if the situation so requires.

Mixing of Sealants/Caulking Compounds

402. 290 All sealants and caulking compounds shall be mixed strictly in accordance

with the manufacturer's recommendations.

Application of Sealants 402. 300 Joints in concrete shall not be sealed until the concrete is at least 28 days

old. 402. 310 Sealants/caulking compounds shall not be applied to surfaces

contaminated by ice, frost and water. Any artificial means of heating to remove frost and ice shall not be used. The application temperatures required by manufacturers shall be observed.

402. 320 Joints shall be filled completely with sealant/caulking compound to exclude

all air and ensure firm adhesion of the material to the required joint surfaces. The sealant/caulking compound face shall be tooled to a slightly concave surface recessed behind adjacent structural surfaces except in the case of poured sealants.

402. 330 Width to depth ratio of caulks or seals shall be in accordance with



manufacturers instructions. Generally the depth of joints filled with caulking compound shall be half the joint width, with a minimum depth of 12mm.

402. 340 Joints of 18mm or less shall be provided with a bond breaker at the back or

bottom surface of the joint to allow the caulking or sealant to move freely under stress.

402. 350 Two-component or multi-component compound shall only be applied within

the permitted period recommended by the manufacturer. 402. 360 The Contractor shall notify the Purchaser when cavities of joints have been

prepared for filling and when the joints have been primed and the back up filler is in place.

402. 370 All sealed joints shall be protected until they reach their full performance

condition by:

(a) covering floor joints with boards;

(b) keeping traffic over slabs to a minimum;

(c) allowing sealants intended to resist hydraulic pressure or chemical attack to cure fully before being subject to operating conditions.

QUALITY CONTROL

402. 380 The Contractor shall submit all manufacturers' technical literature, including

application instructions, storage requirements, current test results on the materials supplied to confirm compliance with BS 3712, Health and Safety warnings, shelf life of materials.

402. 390 Sealants for use in contact with Potable Water shall not have any

deleterious effect on the water and shall have been tested and agreed to this effect by the Water Research Centre.

402. 400 Sample joint lengths shall be carried out to demonstrate to the Purchaser’s

satisfaction that the proposed method of working complies with the manufacturer's recommendations. Work should not proceed without the Purchaser’s agreement.



APPENDIX 1-BSI STANDARDS AND OTHER REFERENCES




BS 2499 Specification for hot applied joint sealants for concrete pavements. BS 3712 Building and Construction Sealants. Part 1: Method of test for homogeneity, relative density, extrudability,

penetration and slump. Part 2: Method of test for seepage staining, shrinkage, shelf life and

paintability. Part 3: Method of test for application life, skinning properties and tack-free

time. BS 4254 Specification for two-part polysulphide based sealants. BS 5212 Specification for cold-poured joint sealants for concrete pavements. BS 5215 Specification for one-part gun grade polysulphide based sealants. BS 5628 Code of Practice for Masonry. Part 3: Materials and components design and workmanship.




CLAUSE REFERENCE


COMMENT

402.240 402.380

Evidence of training of personnel. Manufacturer's technical details of materials to be used.



TECHNICAL SPECIFICATION WORK GROUP: 403 : ANCILLARIES (CIVIL WORKS) SECTION NO: 403 TITLE : PROPRIETARY ANCHOR SYSTEMS TABLE OF CONTENTS SCOPE CONTRACTOR DESIGN MATERIALS WORKMANSHIP QUALITY CONTROL TEMPORARY ANCHORS APPENDIX 1 BSI STANDARDS AND OTHER REFERENCES APPENDIX 2 INFORMATION TO BE PROVIDED BY CONTRACTOR



SCOPE 403. 010 This Section defines proprietary anchor systems used to fix items to

concrete, blockwork and brickwork.

CONTRACTOR DESIGN 403. 030 The Contractor shall design proprietary anchor systems, and shall submit to

the Purchaser calculations and drawings of his proposals. 403. 040 Anchor system design shall comply with the manufacturers

recommendations unless otherwise stated in this Specification. 403. 050 Loadings shall be as stated by the Purchaser where applicable.

MATERIALS 403. 060 Proprietary anchor systems include expansion bolts, reserve anchors and

similar devices, which shall be used in full compliance with manufacturers’ recommendations.

WORKMANSHIP

403. 090 Anchors shall be installed by suitably trained personnel. The Purchaser

may require the Contractor to provide evidence to his satisfaction in this respect.

403. 100 Installation of anchors shall be in accordance with the manufacturer’s

instructions. 403. 110 Drilling of holes to receive anchors shall only commence with the

agreement of the Purchaser. 403. 120 Holes shall be located to avoid reinforcement.

QUALITY CONTROL 403. 130 The manufacturers marking indicating the length of an anchor shall be

clearly visible after it has been installed. 403. 140 The Contractor shall make the necessary arrangements to test installed

anchors when instructed by the Purchaser.

TEMPORARY ANCHORS



403. 150 The Contractor may, if he so requires and consequent upon the agreement

of details by the Purchaser, use anchors to provide temporary support off permanent structures.

403. 160 All holes shall be made good to the requirements of Section 201 on removal

of the temporary anchors.






None.




CLAUSE REFERENCE


COMMENT

403.030 403.080 403.090 403.150

Calculations and drawings. Proprietary anchor details. Evidence of training. Temporary anchor details.



TECHNICAL SPECIFICATION WORK GROUP: 410 : ANCILLARIES (BUILDING WORKS) SECTION NO: 411 TITLE: COPINGS AND FLASHINGS TABLE OF CONTENTS SCOPE MATERIALS

General Storage Lead Aluminium

WORKMANSHIP

General Lead Aluminium

QUALITY CONTROL

General Inspection




SCOPE 411. 010 This Section describes the requirements for the installation of metalwork

coverings and flashings.

MATERIALS

General 411. 030 The Contractor shall submit samples of materials for use in the Permanent

Works to the Purchaser. 411. 040 The gauge thickness, type and relevant mechanical properties of materials

shall be compatible with the cladding system.

Storage 411. 050 Materials shall be stored in unbroken packaging clear of the ground in a

dry place. The surface and edges shall be protected against distortion and damage.

411. 060 Aluminium sheet and strip shall be prevented from contact with dissimilar

metals to prevent electrolytic action and corrosion.

Lead 411. 070 Milled lead sheet or strip for copings, rainwater outlets and gutters,

expansion joint covers, flashings and weatherings shall be to BS 1178.

Aluminium 411. 090 Aluminium sheet and strip for copings, cap flashings and expansion joint

covers, flashings and weatherings shall be to BS 1470.

WORKMANSHIP

General 411. 110 All work shall be carried out by skilled operatives using methods of

accepted practice. 411. 120 All base surfaces shall be clean, dry, smooth and free from projections



before the start of laying and fixing the covering materials. 411. 130 All preparatory work such as the formation of chases shall be carried out

prior to the fixing of the materials. 411. 140 Direct contact with dissimilar metals shall be avoided by the use of a heavy

coating of bituminous paint, isolating tape or felt as appropriate. Isolation shall be provided from copper lightning conductors.

Lead

411. 150 Flashings shall be fixed into accurately prepared chases in concrete or

masonry walls with lead wedges of a size and quantity adequate (maximum centres at 500mm) to securely hold the upper part of the metal. The groove shall then be pointed with 1:3 cement sand mortar.

411. 160 Lead flashing shall be finished 50mm clear of flat roof coverings with a

150mm minimum depth of flashing. Maximum end laps shall be 100mm, lap upstands shall be not less than 75mm.

411. 170 Continuous stepped flashings shall be formed at junctions between pitched

roofs and brickwork. The flashing shall be turned 25mm into chases, wedged at each step and pointed in mortar. The lap upstand shall be 100mm and the bottom edge tacked at 600mm centres.

411. 180 Wide sheets of lead fixed to concrete or masonry in areas of high wind

loading shall be dressed into dished hollows 75mm diameter x 37mm deep. The lead shall be screwed to plugs in the concrete using brass or stainless steel screws with suitably protected washers approx 37mm diameter. The hollow shall be filled with a lead solder using a suitable flux to ensure adhesion to the lead.

411. 190 Where lead burning is required, edges and faces of lead to be joined shall

be shaved clean and shall not be handled thereafter. Care shall be taken to ensure that the weld penetrates fully but does not burn through. The thickness of the lead burned seam shall be approximately one third thicker than the lead sheet being welded.

411. 200 Lead retaining clips and tacks shall be 50mm wide and cut from lead sheet

to match flashing. 411. 210 Copper clips shall be used in conditions of severe exposure and shall be

50mm wide and cut from 0.6mm thick sheet copper to BS 2870. Clips shall



be hot-dip coated with a high lead content solder in visible locations.

Aluminium 411. 220 Fixing of aluminium coverings shall comply with CP 143 Part 15. 411. 230 Aluminium coverings shall be cut cold, formed and bent to the specified

profiles in workshop conditions. 411. 240 Waterproof washers shall be used where fasteners penetrate flashings.

QUALITY CONTROL

General 411. 250 The Contractor shall submit shop drawings for all fabricated items showing

details and locations of joints, supports, fastenings etc with allowances for thermal expansion and contraction and structural movement.

Inspection

411. 260 Metalwork shall be examined to ensure that:

° it has been fabricated in accordance with the shop drawings

° there is no evidence of overstress of the sheet metal, breaks, wrinkles or distortions

° all joints will enable weathertight construction

411. 270 Prior to the installation of any metalwork the base surfaces shall be

examined to ensure that all surfaces are smooth, clean, dry and free from foreign matter and all provisions made to enable fixings to be made.






BS 1178 Specification for milled lead sheet for building purposes. BS 1470 Specification for wrought aluminium and aluminium alloys for

general engineering purposes: plate, sheet and strip. (Withdrawn) Replaced by BS EN 485 Parts 1-4, BS EN 515: 1993 and BS EN 573 Parts 1-4.

BS 2870 Specification for rolled copper and copper alloys: sheet, strip and foil.

CP 143 Codes of practice for sheet roof and wall coverings. Part 15: Aluminium Metric units.




CLAUSE REFERENCE


COMMENT

411.030 411.250

Samples of materials for use. Shop Drawings for fabricated items.



TECHNICAL SPECIFICATION WORK GROUP: 410 : ANCILLARIES (BUILDING WORKS) SECTION NO: 412 TITLE: LOUVRES TABLE OF CONTENTS SCOPE MATERIALS

General Louvre Type Sheet Metal Louvre Accessories Supporting Metalwork Filler Blocks Sealants Insulating Tape Insulation Fixings

CONTRACTOR DESIGN

General Design Life Responsibility for Design Detailed Design and Drawings Wind Loading Tolerances Weatherproofing Colour Surface Finish Climatic Variations Thermal Transmission Dissimilar Metals



TABLE OF CONTENTS WORKMANSHIP

Packaging, Handling, Storage and Protection Installation Works

QUALITY CONTROL

Tests on Louvres Fastener Tests




SCOPE 412. 010 This Section defines the requirements for the Louvres including all

necessary matching accessories, fixings and other items required to provide a complete, durable and weathertight installation.

MATERIALS

General

412. 030 All materials specified shall comply with the relevant British Standards listed

in Appendix 1. 412. 040 All materials shall be resistant to fungal attack, infestation, vermin and other

forms of biological attack. All materials shall be free of asbestos and other substances carrying a health risk.

Louvre Type

412. 050 Louvres are to be compatible with the wall cladding.

Sheet Metal Louvre Accessories 412. 060 Sheet metal louvre accessories shall be formed from the same material as

the louvres and shall be colour matched. The material thickness shall be appropriate to the particular application, but shall not be less than 0.9mm for aluminium sheets.

Support Metalwork

412. 070 Supporting metalwork for louvres shall be steel, fabricated, galvanised and

painted in accordance with the relevant sections of the Specification.

Filler Blocks 412. 080 Filler Blocks shall be manufactured from EPDM and shall be of closed cell

construction to ensure a weathertight seal.



Sealants

412. 090 Lap sealants shall be EPDM or elastomeric compound tape type sealants.

The sealants shall be soft enough not to interfere with the fit of the sheets and resilient enough to accommodate any variations in fit and thermal movements that may occur. Sealants shall not harden with age and shall be compatible with filler block materials.

Insulating Tape

412. 100 Tape for insulating dissimilar metals shall be self adhesive PVC. The

thickness shall not be less than 0.25mm.

Insulation 412. 110 Insulation material shall be mineral wool of 60kg/m3 density unless

otherwise specified.

Fixings 412. 120 Primary fixings shall be grade 316 stainless steel self tapping screws with

stainless steel/EPDM sealing washers. The particular type of fastener for a given application shall be selected in accordance with the fastener manufacturers recommendations, noting that hot rolled and cold formed steel substrates require different fastener designs.

412. 130 Secondary fixings shall be blind rivets with integral load spreading washers

and EPDM sealing washers. 412. 140 All fixings shall have integral or snap-on caps colour matched to the

material being fixed.



CONTRACTOR DESIGN

General

412. 150 Contractor designs shall comply with the relevant British Standards listed in

Appendix 1. Particular reference shall be made to BS 5427. 412. 160 All louvres shall have bird screens which shall comprise 6mm - 10mm

square opening mesh made of non-corrodible metal or plastic. 412. 170 The ventilation performance of finished louvres assemblies shall be equal to

or better than the requirements demanded by the ventilation system design. 412. 180 Positive provision shall be made within the construction of each louvre

assembly for draining louvres and louvre banks to the outside of buildings by means as such collection troughs or channels with outlet pipes.

Design Life

412. 190 The whole of the louvring and supports shall be designed to withstand

coastal environment conditions and local effects of cement and oil etc., and the flashings, closers, fascia fixings and all accessories shall be non-corrodible materials and be suitably protected against electrolytic action where appropriate and be generally in accordance with the specification for wall and roof cladding (Section No. 241).

Responsibility for Design

412. 200 The Contractor shall be responsible for the design of the cladding system,

which shall meet the requirements for design life listed in Section No. 241. 412. 210 The Contractor shall verify that the materials, profiles and finishes will

satisfy the performance requirements of the Specification. Should the Contractor wish to propose alternative materials then these shall be notified at the time of tender.

412. 220 The Contractor shall be responsible for developing the working details, but

shall not vary the intended architectural treatment without the agreement of the Purchaser.

412. 240 Louvring including framing, support steelwork and fixings within the



structural openings shall be designed to withstand the design loads.

Detailed Design and Drawings 412. 250 The Contractor shall prepare all necessary detailed design, general

arrangement and detailed drawings to enable fabrication and installation of the louvres to be carried out.

412. 260 The drawings shall show details and sizes for all louvres and accessories

and shall specify the type and location of all fasteners. 412. 270 The Contractor shall submit calculations and shop drawings to the

Purchaser for agreement. The calculations shall include stress and deflection checks for the louvre support structures and designs for all fasteners.

Wind Loading

412. 280 The louvres shall be designed to withstand the wind loadings derived from

the appropriate British Standards and Codes of Practice. Fixings shall be designed for a minimum wind suction loading of 5kN/m2 with a factor of safety of 2 against failure.

Tolerances

412. 290 The out of tolerance of the louvres and accessories shall not exceed 1/250

of the distance between fixings or width of flat surface.

Weatherproofing 412. 300 The louvre system shall be designed to be completely watertight.

Colour 412. 310 The same requirements shall apply to the louvres as for the decorative life

of the cladding system (Refer to Section 241).

Surface Finish 412. 320 The louvre coating is to have a smooth, flat finish to minimise retention of

dust, dirt etc. on the surface.

Climatic Variations



412. 330 Louvres shall be designed and detailed to take account of variations in

dimensions and shape due to changes in temperature and humidity without deterioration in performance. Coatings shall not suffer mechanical or chemical breakdown under extremes of temperature and humidity.

Thermal Transmission

412. 340 All louvres in external walls are to be aluminium and compatible with

cladding system with the inner leaf fully closeable to control heat loss during shutdown periods. Cold bridges, pattern staining, inside surface condensation and interstitial condensation shall be prevented in the design.

Dissimilar Metals

412. 360 The component parts of all joints and fastenings shall be selected to

prevent bi-metallic corrosion.

WORKMANSHIP

Packaging, Handling, Storage and Protection 412. 370 The Contractor shall comply with the manufacturer's recommendations for

packaging, handling, storage and protection of materials. Cladding sheets, linings and accessories shall be supplied in marked, fully enclosed cases with paper interleaves between sheets. Prior to erection, all materials shall be stored in their packages, off the ground and under cover.

412. 380 All materials shall be protected against mechanical or other damage and

contamination by dirt, oil or other contaminating matter. During erection and until handover measures shall be taken to avoid damage or soiling of materials. In particular, scaffolding shall be independent of the louvre with plastic buffers at the ends of the poles adjacent to the surface. During handling operations nylon slings or ropes shall be used. The use of clamps shall not be permitted.

412. 390 Damaged components shall not be used or repaired. Touching up with paint

will not be permitted.

Installation Works



412. 400 Prior to commencing installation, the Contractor shall inspect the framing to which the louvre is to be fixed to ensure that it has been erected correctly and within the tolerances specified. Any defects shall be corrected prior to the commencement of installation of the louvres.

412. 410 The installation work shall be carried out by experienced operatives with

due care, in an orderly manner and following the rules of good workmanship.

412. 420 The installation work shall be carried out in accordance with the shop

drawings and in accordance with a method statement to be provided by the Contractor for review by the Purchaser prior to commencement of the work.

412. 430 Holes for fasteners shall be drilled to the size recommended by the fastener

manufacturer. The use of punches for forming holes will not be permitted. 412. 440 All extraneous material, such as drilling swarf, metal off-cuts, insulation,

paper, sealants etc, shall be removed as the work progresses. All dirt and grease shall be removed from the surfaces of the cladding prior to hand-over.

QUALITY CONTROL

Tests on Louvres

412. 450 Tests to confirm the louvre performance under rain and wind shall be

carried out on a sample of each type of louvre to be incorporated in the Works. Tests shall be carried out in wind tunnel at appropriate air velocities and rainfall intensities; these are rain penetration tests and ventilation performance tests. Tests shall also be carried out to verify attenuation properties.

The Contractor shall provide verified results of all tests.

Fastener Tests

412. 460 The Contractor shall provide evidence of the strength of the proposed

fasteners. Particular attention shall be paid to the "fixing pull-through" mode of failure on thinner gauge materials. A minimum of six test results shall be provided for each application.






BS 729 Specification for hot dip galvanized coatings on iron and steel articles

BS 1091 Specification for pressed steel gutters, rainwater pipes, fittings and accessories.

BS 1449 Steel plate, sheet and strip BS 1470 Specification for wrought aluminium and aluminium alloys for

general engineering purposes: plate sheet and strip. (Withdrawn) Replaced by BS EN 485 Parts 1-4, BS EN 515: 1993 and BS EN 573 Parts 1-4.

BS 1494 Specification for fixing accessories for building purposes. Part 1: Fixings for sheet, roof and wall coverings.

BS 2989 Specification for continuously hot-dip zinc coated and iron-zinc alloy

coated steel: wide strip sheet/plate and slit wide strip. (Withdrawn) Replaced by BS EN 10143: 1993.

BS 4174 Specification for self tapping screws and metallic drive screws. BS 4255 Rubber used in preformed gaskets for weather exclusion from

buildings Part 1: Specification for non-cellular gaskets.

BS 4800 Specification for paint colours for building purposes BS 4868 Specification for profiled aluminium sheet for building. BS 4904 Specification for external cladding colours for building purposes. BS 5427 Code of practice for performance and loading criteria for profiled

sheeting in buildings. BS 6213 Guide to selection of constructional sealants. BS 6367 Code of practice for drainage of roofs and paved areas BS 6399 Loading for buildings. Part 1: Code of Practice for dead and imposed loads Part 3: Code of Practice for imposed roof loads. CP 3 Code of basic data for the design of buildings. Chapter V Loading Part 2: Wind Loads



CP 118 The structural use of aluminium CP 143 Code of practice for sheet roof and wall coverings Part 15: Aluminium: Metric units.




CLAUSE REFERENCE


COMMENT

412.230 412.270 412.420 412.450 412.460

Additional framing and trimming steelwork. Calculations and shop Drawings. Method statement. Louvre test results. Fastener test results.



TECHNICAL SPECIFICATION WORK GROUP : 400: ANCILLARIES (CIVIL WORKS) SECTION NO: 413 TITLE: PILING (GENERAL REQUIREMENTS) TABLE OF CONTENTS SCOPE GENERAL RELATED STANDARDS MATERIALS WORKMANSHIP QUALITY CONTROL APPENDIX 1 BRITISH STANDARDS AND OTHER REFERENCES APPENDIX 2 ENGINEERING DOCUMENTS APPENDIX 3 NOTIFICATION AND HOLD POINTS



SCOPE

413. 010 This Section defines the general requirements for materials, workmanship,

contractor design and quality control to be applied to the provision of all types of piles.

GENERAL

413. 021 The Contractor shall submit all relevant piling details to the Purchaser for

agreement at last two weeks prior to the commencement of piling operations. Such details shall include:

a) Pile type b) Pile design calculations c) Working loads d) Setting out drawing e) Proposed plant f) Proposals for pile tests.

413. 022 A copy of the Ground Investigation Report provided to the Contractor is for

information only. The Contractor shall carry out any further investigations and testing which he deems necessary to facilitate the design of the piling. The results of any such investigations shall be submitted to the Purchaser with the pile design calculations.

RELATED STANDARDS

413. 030 The BSI Standards together with other references specified in this Section

are listed in Appendix 1. 413. 031 All piling work shall be in accordance with 'Specification for Piling' produced

by The Institution of Civil Engineers. 413. 032 All references to British Standards are deemed to include equivalent

standards.



MATERIALS

413. 040 All materials shall comply with the 'Specification for Piling' by I.C.E.. 413. 041 The following shall apply:

(a) Cement shall be Ordinary Portland Cement complying with BS 12.

(b) Aggregates shall also comply with BS 882.

(c) Reinforcement shall comply with one of the following:

Hot rolled steel bars - BS 4449 Cold worked steel bars - BS 4461

(d) Concrete mix shall contain not less than 325kg of cement per cubic

metre and shall have a characteristic strength of not less than 40 N/mm2 at 28 days in accordance with BS 8110.

413. 050 Concrete mixes shall be designed mixes and shall comply with the

'Specification for Piling' by I.C.E. 413. 060 Any materials which have been rejected by the Purchaser for whatever

reason shall be removed promptly from the Site.

WORKMANSHIP 413. 070 All workmanship shall comply with the 'Specification for Piling', 1988 by

I.C.E.. 413. 071 Setting out shall be carried out from control stations identified on the

drawings. The Contractor shall be responsible for the setting out of all pile positions and maintaining temporary stations and offsets.

413. 072 The maximum permitted deviation of the pile centre from the centre point

shown on the agreed setting out drawing shall be 75mm in any direction at cut off level.



413. 073 Disposal of excavated material shall be carried out as necessary to facilitate

the works. Arisings, surplus concrete and steel including debris from trimming heads of working piles, anchor piles and caps shall be removed off-site by the Contractor.

413. 080 Safety precautions throughout the piling operations shall comply with the

Health and Safety at Work Act 1974 or any subsequent re-enactment thereof,

413. 081 The Contractor shall comply with the recommendations of BS 5228 : Part 4

for noise and vibration control of piling and associated operations unless otherwise authorised by the Purchaser.

QUALITY CONTROL

413. 090 The minimum requirement for the retention of records shall be to Table 1.1

of the 'Specification for Piling' by I.C.E.. 413. 100 All quality control for material procurement, testing of materials, pile testing,

on site and off site inspections etc. shall be in accordance with the 'Specification for Piling' by I.C.E..

413. 110 Pile testing shall be undertaken to validate the pile design and construction

methods proposed. At least one working compression pile and one working tension pile for each structure, at the discretion of the Purchaser, shall be subjected to a sustained load pile test in accordance with the ICE 'Specification for piling'. Results shall be presented in accordance with Clause 10.15 of the ICE 'Specification for Piling'.






The Contractor shall bring to the attention of the Purchaser any inconsistencies between the requirements of these Standards and this Specification.

'Specification for Piling' by The Institution of Civil Engineers (including all relevant standards referred to therein).

Health and Safety at Work Act 1974.

BS 12 - Specification for Portland cements.

BS 882 - Specification for aggregates from natural sources.

BS 1881 - Testing Concrete

BS 2789 - Specification for spheroidal graphite or nodular graphite cast

iron

BS 3100 - Specification for steel casting for general engineering purposes

BS 3148 - Methods of test for water for making concrete

BS 4360 - Specification for weldable structural steels

(Withdrawn) Replaced by BS 7613: 1994, BS 7668: 1994, BS EN 10029: 1991, Parts 1 to 3 of BS EN 10113: 1993, BS EN 10155: 1993 and BS EN 10210-1:1994.

BS 4449 - Specification for carbon steel bars for the reinforcement of

concrete

BS 5228: Part 4 Code of practise for noise and vibration control applicable to piling operations.

BS 8004 - Code of practice for foundations.

BS 8110 - Structural use of concrete




CLAUSE REFERENCE


COMMENT

413. 021 413. 090 413. 110

Design details Records. Pile testing to validate pile design and construction methods proposed.



APPENDIX 3 - NOTIFICATION AND HOLD POINTS

CLAUSE REFERENCE

NOTIFICATION POINTS

HOLD POINTS

413.100

As required by I.C.E. Specification for Piling'.

As required by I.C.E. Specification for Piling'.



TECHNICAL SPECIFICATION WORK GROUP: 050 : DRAINAGE SECTION NO: 052 TITLE: BUILDING DRAINAGE TABLE OF CONTENTS SCOPE CONTRACTOR DESIGN MATERIALS

Pipes and Joints Pipe Supports Gutters and Fittings Miscellaneous

WORKMANSHIP

Jointing General Pipe Supports and Fixings Gutters

QUALITY CONTROL

Testing and Inspection General Testing Air Tests Water Tests Performance Tests Discharge Tests



SCOPE 052. 010 This Section defines pipework installations above ground, internally and

externally for the conveyance of rainwater and waste water away from a building to a buried drainage system.

It does not include specific "plumbing trade" items which are part of a separate Section of this Specification.

CONTRACTOR DESIGN

052. 030 The design of installations shall be to BS 5572 and BS 6367. 052.035 The location, size and materials of any building drainage that will be left

exposed in the finished works shall be identified for agreement by the Purchaser.

MATERIALS

Pipes and Joints

052. 040 Steel prefabricated drainage stack units shall be to BS 3868. Galvanising

shall be to BS 729 and carried out after fabrication. 052. 050 Unplasticized PVC pipes and fittings for soil waste and rainwater shall be to

BS 4514 and shall have solvent welded or ring seal pushfit joints. 052. 060 Copper pipes shall be to BS 2871 : Part 1, Table X, and shall have capillary

soldered brazed or compression joints to BS 864. 052. 070 Cast iron pipes and fittings shall be sand cast or spun to BS 416 and have

"Timesaver" type joints to BS 6087 (two part cast iron clasp with rubber gasket and stainless steel nuts and bolts).

052. 080 Ductile iron pipes fittings and joints shall be to BS 4772 and shall have

either flanged joints or flexible spigot and socket joints. Where flanged pipes and fittings are required the flanges shall be PN16.

052. 090 UPVC rainwater systems shall be to BS 4576 Part 1.

Pipe Supports



052. 100 Support to pipes shall be made using purpose made nylon, plastic, copper, brass, iron or steel, brackets, clips, or hangers, of an appropriate diameter and of a type agreed by the Purchaser and secured to the base material (brick, concrete etc.) with expanding bolts, steel anchors or plastic plugs and screw fixings as appropriate.

052. 110 Adjustable pipe hangers shall be to BS 3974. 052. 120 Fixings to structural steelwork shall be by means of malleable iron girder

clamps of a standard heavy duty design. 052. 130 Ferrous pipe supports and fixings shall be hot-dipped galvanized to BS 729.

Any associated exposed cut threads or other minor exposed ferrous metal surfaces shall be coated with a zinc-rich primer.

052. 140 Insulating inserts shall be provided where necessary between the supports

and pipes of dissimilar metals to prevent electrolytic action. They shall be of elastomeric or cork composition and shaped to ensure retention within the pipe clip, which shall be of sufficient diameter to accommodate the extra thickness.

Gutters and Fittings

052. 150 Cast iron gutters, fittings and accessories shall be to BS 460. 052. 160 Pressed steel gutters, fixings and accessories shall be to BS 1091. 052. 170 UPVC gutters, fittings and accessories shall be to BS 4576. 052. 180 Brackets for gutters shall be of a type recommended by the manufacturer of

the gutter. 052. 190 Nuts and bolts shall be galvanized mild steel to BS 916. 052. 200 Metal washers shall be galvanized mild steel to BS 4320.

Miscellaneous 052. 210 Cast iron roof outlets and domical cages shall be to BS 416.



WORKMANSHIP

Jointing

052. 220 All joints in pipework shall be made in accordance with the pipework

manufacturer's instructions. 052. 230 Pipes which are required to be cut on site shall be checked for any ovality

and shall be cut clean and square using equipment appropriate to the material. Burrs shall be removed and any chamfers necessary for correct jointing shall be formed. The use of make-up pieces shorter than the pipe diameter is not permitted.

General

052. 240 All materials shall be stored in accordance with the manufacturer's

recommendations. 052. 250 Pipework shall be stored as follows:

(a) Under cover, clear of the ground.

(b) Pipe stacks shall be on level ground.

(c) Pipes shall not rest on their sockets.

(d) Pipe stacks shall be securely staked to prevent collapse. 052. 260 Elastomeric jointing rings shall be stored in protective containers or bags

until required for use. They shall not be exposed to sunlight 052. 270 All soil, drainage waste and rainwater pipes and gutters shall be laid to

adequate falls to ensure self cleansing velocities. The minimum gradient shall be 1 in 60.

052. 280 Pipes bridging building movement joints shall be installed with provision to

accommodate the maximum movement anticipated. 052. 290 Pipes passing through fire barriers, walls, slabs and beams shall be

installed in a manner which prevents the passage of smoke and flame across the fire barrier and which allows thermal movement of the pipes.

052. 300 Rodding access shall be provided at bends or branches and at the base of

all down pipes. Access doors shall be fitted as near as practicable to the top



of the pipe or fitting and never on the invert. 052. 310 Ventilation pipes passing through roofs shall be waterproofed and

terminated with a copper or plastic balloon grating. 052. 320 The junction between above ground pipes below ground pipes shall be by

means of a flexible joint. 052. 330 When mild steel pipework is specially fabricated the Contractor shall submit

a procedure detailing the jointing, installation and supports for the agreement of the Purchaser.

052. 340 All bends shall be to the largest practicable radius and branches shall be

swept in the direction of flow. Elbows shall not be used for drainage purposes.

052. 350 Pipes with integral sockets shall be fixed with the socket at the upper end

for vertical and inclined runs.

Pipe Supports and Fixings 052. 360 All pipe fixings shall be set straight and true. Suspension rods shall be

plumb. 052. 370 Guide brackets shall be used for intermediate supports between fixed

brackets for all vertical pipework. Pipe hangers may be used as intermediate supports for inclined runs of pipework.

052. 380 Pipe runs having integral sockets and mechanical ring seal joints to

accommodate expansion shall have fixed brackets to secure the pipe socket collars. Intermediate support to the pipe barrel shall be provided by means of guide brackets.

052. 390 Plain barrel pipes with double mechanical ring seal joint socket connectors

shall have brackets fixed on the pipe barrel at the highest point of each pipe. They shall be located 150mm from the socket, and intermediate support of the pipe barrel shall be by means of guide brackets.

052. 400 The positions of fixed brackets as anchor points and telescopic expansion

joints or other means of allowing thermal movement of pipework jointed with solvent cement joints shall be shown on the Drawings. Intermediate support of pipe work shall be by means of guide brackets.

Gutters



052. 410 Pressed steel gutters shall be jointed with agreed jointing compound and bolted together.

052. 420 UPVC gutters shall be jointed in accordance with the manufacturer's

instructions ensuring that the correct allowance is made for thermal movement.

QUALITY CONTROL

Testing and Inspection

General

052. 430 All gravity drain and ventilation pipes shall be subjected to both a visual

examination and test to ensure the soundness of the system and to verify its correct performance.

052. 440 The Contractor shall submit a statement to the Purchaser detailing his test

procedures. 052. 450 Soundness and performance tests shall be witnessed and the Contractor

shall notify the Purchaser of the times and places at which tests are to be carried out.

052. 460 Inspection and tests shall be made during the installation of the discharge

system as the work proceeds, to ensure that the pipework is properly secured and clear of obstructing debris and superfluous matter and that all work which is to be concealed is free from defects before it is finally enclosed.

Prefabricated units shall be tested at the works or place of fabrication, and inspected on delivery at the site.

052. 470 On completion, the discharge system shall be visually examined to ensure

that no cement droppings, rubble or other objects are left in the pipes and that no jointing material projects into the pipe bore. When this has been done, tests for soundness of the pipework and for performance shall be made. Testing



052. 480 All tests shall be fully recorded in a manner agreed with the Purchaser and copies of these records supplied.

Air Tests

052. 490 This test, to detect if all pipes and fittings are airtight shall normally be

completed in one operation. For large systems however the Contractor may, with the Purchaser's prior written agreement, test the systems in sections.

052. 500 The water seals of all sanitary appliances shall be fully charged and test

plugs or bags inserted into the open ends of the pipework to be tested. To ensure that there is a satisfactory air seal at the base of the stack, or at the lowest plug or bag in the stack, a small quantity of water sufficient to cover the plug or bag can be allowed to enter the system. One of the remaining testing plugs shall be fitted with a tee piece, and cocks on each branch, one branch being connected by means of a flexible tube to a manometer. Alternatively, a flexible tube from a tee piece fitted with cocks on its other two branches, can be passed through the water seal of a sanitary appliance. Any water trapped in this tube shall be removed and then a manometer can be connected to one of the branches as described above.

052. 510 Air shall be pumped into the system through the other branch of the tee

piece until a pressure equal to 38mm water gauge is obtained. The air inlet cock shall then be closed and pressure in the system shall remain constant for a period of not less than three minutes.

Water Tests

052. 520 The part of the system below the lowest sanitary appliance shall be tested

by inserting a test plug in the lower end of the pipe and filling the pipe with water up to the flood level of the lowest sanitary appliance, provided that the static head does not exceed 6 m.

052. 530 Long runs of above-ground pipework in the horizontal plane shall be

subjected to the water test. This shall be applied by inserting a test plug downstream of the section to be tested and filling the pipe with water up to the flood level of the lowest sanitary appliance upstream of the section under tests, provided that the static head does not exceed 6 m.

052. 540 Clean water shall be used and promptly removed upon completion of the

test.

Performance Tests



052. 550 Every trap shall retain not less than 25mm of seal when subjected to the appropriate discharge tests given below. Each test shall be repeated three times; the trap being recharged before each test and the maximum loss of seal in any one test, measured by a dip stick, shall be taken as the significant result.

052. 560 To test for the effect of self-siphonage the waste appliance shall be filled to

overflowing level and discharged in the normal way. WC pans shall be flushed. The seal remaining in the trap shall be measured when the discharge has finished.

052. 570 For ranges of appliances, appropriate combinations of appliances shall be

discharged, all traps shall be fully charged, waste appliances being filled to overflow level, and the seal remaining in each trap in the range measured when the discharge has ended. The worst conditions are likely to occur when the appliances at the top of the branch are discharged.

052. 580 To test the stability of trap seals when water flows down the stack, the

appropriate combinations of appliances shall be discharged simultaneously, with all traps fully charged. The seal remaining in the traps shall be measured when the discharge has ended.



Discharge Tests

Type of use

Number of appliances of each kind on the stack

Number of appliances to be discharged simultaneously 9 litres WC Wash Basin Kitchen Sink

Domestic

1 to 9 10 to 24 25 to 35 36 to 50 51 to 65

1 1 1 2 2

1 1 2 2 2

1 2 3 3 3

Commercial or Public

1 to 9 10 to 18 19 to 26 27 to 52 52 to 78 79 to 100

1 1 2 2 3 3

1 2 2 3 4 5



APPENDIX 1 BSI STANDARDS AND OTHER REFERENCES � The British Standards and other documents referred to in Section 052 are listed

below and shall be the current edition, including all amendments. � The Contractor shall bring to the attention of the Purchaser any inconsistencies


BS 416 Specification for cast iron spigot and socket soil waste and ventilating pipes (sand cast and spun) and fittings.

BS 460 Specification for cast iron rainwater goods. BS 729 Specification for hot dip galvanized coatings on iron and

steel articles. BS 864 Capillary and compression tube fittings of copper and copper

alloy. BS 916 Specification for black bolts, screws, and nuts hexagon and

square with BSW threads and partly machined bolts screws and nuts hexagon and square with BSW or BSF threads.

BS 1091 Specification for pressed steel gutters rainwater pipes fittings and accessories.

BS 2871 Specification for copper and copper alloy tubes. Part 1: Copper tubes for water gas and sanitation.

(Withdrawn) Replaced by BS EN 1057: 1996. BS 3868 Specification for prefabricated drainage stack units: galvanized

steel. BS 3974 Specification for pipe supports. Part 1: Pipe hangers and roller type supports. Part 2: Pipe clamps cages cantilevers and attachment to beams.

BS 4320 Specification for metal washers for general engineering purposes.

Metric series. BS 4514 Specification for unplasticized PVC soil and ventilating, pipes,

fittings and accessories. BS 4576 Specification for unplasticized PVC rainwater goods. BS 4772 Specification for ductile iron pipes and fittings.

(Withdrawn) Replaced by BS EN 545: 1995, BS EN 598: 1995 and BS EN 969: 1996.

BS 5572 Code of Practice for sanitary pipework. BS 6087 Specification for flexible joints for grey or ductile cast iron drainpipes

and fittings and for discharge and ventilating. BS 6367 Code of Practice for drainage of roofs and paved areas.




CLAUSE REFERENCE


COMMENT

052.330 052.440 052.480

Pipe support details. Details of test procedures. Records of tests.



CWSpec-SECTIO1E-Rev4.doc 1/2 Detailed Civil Engineering Specification

TECHNICAL SPECIFICATION TITLE: GENERAL REQUIREMENTS TABLE OF CONTENTS SCOPE STANDARDS ADDITIONAL REQUIREMENTS


CWSpec-SECTIO1E-Rev4.doc 2/2 Detailed Civil Engineering Specification

TECHNICAL SPECIFICATION TITLE: GENERAL REQUIREMENTS 1.1 SCOPE

This Specification covers the general requirements for design, performance, materials, workmanship, installation, testing and commissioning and packing and delivery for mechanical and electrical works for the Mechanical Handling Plant and Lifts.

The specifications for mechanical and electrical service systems in this Section are intended to indicate the minimum acceptable standards of materials and workmanship.

Notwithstanding the requirements set out herein, it shall be entirely the Contractor's responsibility to provide systems which, when completed, provide a comprehensive technically viable, safe and durable construction entirely in accordance with the requirements of the Scope of Works and the Specification.

1.2 STANDARDS

This Specification details the minimum outline requirements for the Lifts systems. 1.3 ADDITIONAL REQUIREMENTS

The requirements given to Section D, Clause 1.4 to Clause 1.13 inclusive, shall equally apply to this Section E.


CWSpec-SECTIO2G-Rev4.doc 1/14 Detailed Civil Engineering Specification

TECHNICAL SPECIFICATION TITLE: GENERAL SPECIFICATION FOR MATERIALS & WORKMANSHIP TABLE OF CONTENTS LIFTS

General Silence of Operation Hydraulic Lift Pumps Pump Motors Cylinders/Rams Valves Pipes, Hoses Suspension Pulleys Guides and Fixings Guide Shoes Buffers Creepage Lift Car Car and Landing Entrances Architraves Door Operators Locks Fascia Plate Controllers Controls Control Device Indicators Selectors Final Limits Car Top Control Station Car Safety Gear Data Plates Pit Light, Stop Push and Socket Outlet Shaft Lighting



TABLE OF CONTENTS

Motor Room Safety Labels Telephone/Intercom Unit Emergency Car Light and Alarm Bell Electromagnetic & Radio Interference Suppression Servicing Tools



TECHNICAL SPECIFICATION TITLE: GENERAL SPECIFICATION FOR MATERIALS AND WORKMANSHIP 2.1 LIFTS 2.1.1 General

The lift equipment shall comply with the requirements of the General and Particular sections of the Specification.

2.1.2 Silence of Operation

The systems as installed shall be quiet in operation under the conditions in which they will be called upon to operate, and shall be such that no noise or vibration is discernible outside plant rooms or similar place in which the equipment is housed. Noise levels in the machine rooms shall comply with the noise at Work Regulations 1989.

Noise shall not exceed NR40 within the building (excluding plant rooms) measured at 1.5m from wall/slabs of the lift shafts or plant or equipment rooms.

Anti-vibration mounts to be utilised where appropriate, based on technical advice from the manufacturers of the components.

2.1.3 Hydraulic Lift Pumps

The pump unit shall include the necessary motors, valves, oil tank, etc. and shall be self-contained in a structural steel frame suitably isolated from the building structure.

The total pump unit shall be accurately assembled and lined up so that correct alignment is available and maintained under all normal operating conditions.

The necessary oil filters will be provided on the inlet side of the pumps with suitable valves so that the filter can be cleaned or changed with a minimum loss of oil.

Suitable manual lowering devices shall be provided on the pump unit for emergency use, which shall be sealed in an agreed manner so that only authorised personnel can use it. It shall also include for a suitable hand pump to enable the lift to be raised in the event of power or other failure.



The hydraulic equipment shall be suitably bunded to contain spillage of oil.

2.1.4 Pump Motors

The pump motor shall be of the squirrel cage or slip ring type, as described in the General Specification, suitable for a minimum of 100 starts per hour and run with the minimum of noise and vibration, adequately protected by thermal overloads or other agreed means.

2.1.5 Cylinders/Rams

The cylinders and rams on a side ram installation shall be made of steel, accurately machined and assembled to ensure smooth and silent running. Suitable guiding is to be incorporated to ensure adequate fixing to the structure of the lift shaft and the ram head guided to carry the rope sheave, if provided.

A slack cable device must be incorporated which will close the lowering valve in the event of a descending lift car being obstructed in its movement.

2.1.6 Valves

All valves and other items of the hydraulic system shall be designed and arranged to give smooth starting, ride and stopping to ensure a completely satisfactory and safe installation. Oil flow valves shall be provided as necessary so that the oil may be cut off between the pump and the cylinder.

2.1.7 Pipes, Hoses

Hydraulic pipework shall be in Ai-Ni-Si-Brass alloy material to BS 2871 Part 2 CZ127 with compatible fittings and shall be isolated by rubber mountings or other suitable means from the building structure.

Flexible hoses shall be used where necessary and shall be of the armoured type to BS 4586 and installed in accordance with BS 5244.

2.1.8 Suspension

Suspension ropes shall not be less than 11mm dia and a minimum of four ropes each independent of the other shall be fitted.



All steel ropes will comply as necessary and be in accordance with BS 302 requirements. Details of the ropes fitted to the lift shall be shown on a brass plate, suitably inscribed and mounted on the crosshead of the car.

2.1.9 Pulleys

Pulleys and blocks shall comply with the requirements of BS 408.

All detector pulleys where applicable and as necessary to achieve the proper lead of the ropes from ram head and car are to be provided. Pulleys shall be of cast iron accurately machined and grooved for diameter of ropes used.

2.1.10 Guides and Fixings

The Contractor is to include for necessary steel guides for car and counterweight of "Tee" section, accurately machined with tongued and grooved joints and suitable fish plates, the guides and fish plates being machined where necessary to provide a smooth and even joint.

The Contractor shall also provide wrought iron or fabricated brackets for fixing to walls, concrete or steel beams, or steel separator beams with suitable full height screen where applicable and will provide for drilling separator beams for fixing the brackets where these are used, all in accordance with the required programme of works. Details of all fixing requirements to be submitted (sketch) with tender.

If, for reasons of design or building limitations, guide backing is require, the Contractor is to include for this as necessary.

Guides are to be mounted on base plates and adequately and firmly secured at the top and bottom.



2.1.11 Guide Shoes

Guide shoes of agreed design shall be provided and fixed to the top and bottom of the car frames.

The guide shoes shall have guide lubricators unless they incorporate liners of a type which do not require lubrication and the car guide shoes shall have adjustable spring loading.

2.1.12 Buffers

Buffers under the car shall also include all necessary supports and mountings including steel stools or columns to support the buffers at the correct height above the pit floor.

Spring buffers shall be of the helical coil type with a constant spring rate.

Timber buffers will not be acceptable.

2.1.13 Creepage

The necessary provision shall be made to automatically return the car at a slow speed to the correct floor level in the event of the lift car moving downwards when not in use due to oil leakage or other reasons. This automatic relevelling shall be carried out whenever the car has moved 25mm.

2.1.14 Lift Car

Each lift car shall be contained in a suitable steel frame constructed of structural steel members, rigidly assembled, with all necessary gussets and cleats.

The platform shall be rigidly constructed of fabricated structural steel sections, carrying an inner or floating frame, to which the car enclosure will be incorporated and will include means of isolation by sound-reducing and anti-vibration material between the main frame and sub-frame. It shall be so constructed that no suspension load of any description shall be transferred to the car enclosure.

The platform, car frame, doors, tracks, hangers, control equipment, indicators, load plates and wiring shall be included as necessary with suitable means of powered ventilation incorporated.

2.1.15 Car and Landing Entrances



Fire resistance of all landing entrances shall comply with the fire rating of the building structure. Sliding doors shall be of sheet steel construction, with suitable channel frames reinforced where necessary, of flush type construction, finished as called for in the specification. The bottom guides or gibs shall be continuous for fire rated entrance doors.

They shall be constructed to comply with the fire rating as called for and shall include necessary top and bottom tracks, the bottom tracks shall be machined from aluminium alloy cill plates and provided with stainless steel channel inserts, the sill plates arranged for final fixing by the builder.

2.1.16 Architraves

Architraves shall be manufactured of sheet steel or stainless steel as specified elsewhere, finished where necessary to suit the entrance sizes and be free from blemishes.

They shall be subject to the same fire rating as the landing doors.

2.1.17 Door Operators

The door operator shall be designed so that the movement of the doors shall be free from vibration, smooth in operation and with minimum noise.

The doors shall be provided with suitable electronic safety devices and the force exerted by the doors on an obstruction shall not exceed the force necessary to operate the safety device. It shall be possible to adjust the equipment so that minimum force is required, in accordance with the requirements of BS 5655, to re-open the doors.

Sequential door closing will be required with a reduced door closing period time following operation.

The door motor is to be provided with a suitable overload protection device.



2.1.18 Locks

The landing doors shall be provided with electrical and mechanical locks, operated by a retiring cam or similar device and the car door shall be electrically interlocked so that a lift cannot be moved unless all doors are closed and the landing doors locked.

It shall not be possible to open a landing door unless the lift is stopped (stopping) at that particular floor and in the case of centre opening doors, both panels shall be arranged to directly operate an electric interlock so that the lift is inoperative unless both doors are closed.

Suitable provision must be made at landings to release the lock and open the door irrespective of the position of the car. Preferred release in soffit or architrave.

This must be arranged by a special key of such a type and description so that only authorised personnel can operate the device. Necessary steps must be taken to ensure the release of the locks cannot be possible by use of wire, rod, screwdriver or other common tool or implement. Suitable covering must be provided to the release device.

2.1.19 Fascia Plate

Sheet fascia plates will be provided at each entrance between the underside of each track or cill and the top of the door frame below and suitable levelling aprons will be provide both on the car and below the lowest entrance.

2.1.20 Controllers

The controller panel, of non-hygroscopic material shall be rigidly fixed to a steel frame, mounted inside an adequately ventilated sheet steel case, arranged for floor or wall mounting. The case shall include doors at the front of rigid construction and removal panels at the rear and shall be fitted with efficient locks where necessary.

All the control equipment shall be enclosed in one or more cabinets and suitable rubber mats provided on the floor in front of the controllers where access is required.

Controllers will be of adjustable microprocessor or solid state type with suitable interlocking provided on contactors so that it is not possible for up/down contactors to operate simultaneously.



Any contactors shall be easily accessible and renewable with long break contacts incorporating self-cleaning action with arc shields.

Parts shall be easily accessible, marked and wired in accordance with the diagram provided and designed specifically for long life and ease of maintenance. All spare parts must be easily obtainable and stocked in the UK. The control system shall operate from a rectified supply of 110 volts d.c. Static switching equipment will be considered as suitable, providing the system has been used in similar circumstances for a period of two years and is fully operational and proven that full details are designed and submitted with the Tender.

The controller shall be designed to give the required operation as hereinafter specified and shall incorporate suitable switching arrangements so that the motor is shut off after the time involved in a complete round trip plus a suitable time margin.

The controller shall automatically limit the current to that necessary for the specified requirements and shall prevent damage to the electrical equipment from overload or excess current.

Protection shall be provided against phase failure and phase reversal.

The controller shall also be arranged to cut off the power supply, and bring the car to rest upon failure or operation of any of the electrical safety devices.

2.1.21 Controls

The car and landing push buttons shall be tactile and illuminated type to indicate registration of car calls. Landing buttons shall operate as DOOR OPEN buttons on lift equipped with power operated doors when the car is standing at the respective floor.

Audio status information shall be provided in addition to normal visual information.

After a pre-determined period, the car will automatically return to the designated floor when no calls registered in system.

Fireman's control shall be provided.



2.1.22 Control Device Indicators

All control devices, indicators and other similar items shall be contained in suitable boxes and all face plates shall be of satin stainless steel.

Push buttons in the car and on the landing shall not be mounted at a height in excess of 900mm above finished floor level and be inscribed with the appropriate international symbol. Suitable indication shall be arranged so that when the Fireman's control is operated, the passengers in the car are made aware of the fact that the lift is under Fireman's control.

If emergency power control is in operation similar indication to passengers shall be provided to inform passengers of the fact that the lift is under emergency power control.

Indicators shall be provided and fitted and shall be arranged so that the voltage rating of the lamps is at least 10% above the supply connected to the lamp.

2.1.23 Selectors

Selectors, where provided, will be controller mounted uni-selector, actuated by proximity switches, magnetic tape head or steel tape/multi-strand wire directly attached to the lift car and enclosed in a sheet metal, ventilated case and designed for long life and ease of maintenance.

2.1.24 Final Limits

Suitable automatic devices, arranged to bring the car to rest at terminal levels independently of the operating devices in the car shall be provided.

Final limit switches, in the lift shaft or motor room are to be provided, so arranged that they will positively stop the car and prevent normal operation should the car travel beyond the terminal stopping devices, without damage to the equipment or occupants.

2.1.25 Car Top Control Station

The car top control station shall be provided, to include an up and down push button and a constant pressure start button, all suitably shrouded to prevent accidental operation.



These buttons shall move the car at test speed not exceeding 0.5m/sec and all safety devices must be operative.

Additional limits to be provided, if necessary, to stop the car when approximately two metres from any fouling point or danger area at the top of the shaft, irrespective of any action on the part of the operator on top of the car. There shall also be a switch on the top of the car, which will remove the car buttons and the landing buttons from the circuit so that the car top control station has sole control of the lift and its movement.

In addition, there shall be DOOR OPEN AND DOOR CLOSE buttons which shall operate within the standard door open and close zones, a 15 amp switch plug, suitable for hand tools operating on a 110V supply and a lamp operated by a switch on the car roof.

Emergency light with alarm push to be incorporated within car top control station.

2.1.26 Car Safety Gear

A suitable safety gear to comply with the specification requirements shall be incorporated in the bottom members of the car frame, operated by means of an over-speed rope operated governor.

It shall incorporate a switch to cut off supply to the motor and apply the brake, at a pre-determined increase in speed above the rated speed of the lift. In the event of over-speeding continuing, the safety gear shall be tripped at a pre-determined speed and apply the safety gear.

The safety gear shall be released by raising the lift car and there shall be no damage to the lift car or car frame or passengers and no distortion by the application of the safety gear.

2.1.27 Data Plates In a conspicuous position in each lift car the duty load in kilograms and no. of

passengers will be engraved, final details of engraving and positioning to be agreed with the Purchaser.

Date of manufacture and reference number to be suitably engraved on brass plate and securely attached to the car sling crosshead members and not in the lift car.



A brass plate shall be fixed to oil reservoir tanks giving details of the oil and the amount required, together with a suitably visual oil level gauge, correctly marked and with a suitable drain cock.

2.1.28 Pit Light, Stop Push and Socket Outlet

A suitable light fitting and stop switch shall be fitted in the lift pit, in such a position that the light switch can be operated safely from the lowest floor entrance. A 13 amp socket outlet with RCD protection shall be fitted in the lift pit. Stop switches shall be operated safely from the pit and lowest floor entrance.

2.1.29 Shaft Lighting Shaft lighting shall be provided to BS 5655 min i.e. at 3000mm maximum

intervals and at most 0.5m from the highest and lowest points.

The shaft lighting shall be switched from the Motor Room with a switch adequately marked "shaft lighting".

2.1.30 Motor Room Safety

In the machine room, or where the main triple pole switch is concealed by other equipment, a stop switch shall be provided adjacent to the lift machine as protection for the maintenance engineers. The additional switch shall be provided when the position of the lift machines, in relation to the main switch makes it necessary to meet the requirement of "moving machinery" in BS 7671.

"Emergency Release" instructions and "Electric Shock" notice shall to be provided in the motor room. A ‘Danger’ notice shall be affixed to motor room which will be provided with adequate locking device.

A rubber safety mat shall be provided on the floor in front of each control panel.

2.1.31 Labels Labels shall be supplied and fixed to each cable, consisting of white background

TRAFFOLYTE rigid sheet with 6mm letters engraved and coloured to suit each service in compliance with the relevant regulations. Labels shall be fixed by screws or bolts (adhesive is not acceptable) and arranged to indicate type of service i.e. Electrical, Mechanical, etc.



Size and number of cores Type of Conductor Cable Reference No. as shown on distribution diagram

Travelling cables are shall be multi-cored vulcanised rubber insulated, with braided fire resistant covering, specially designed for use on lifts.

2.1.32 Telephone/Intercom Unit A suitable telephone box and wiring to a junction box in internal motor room shall

be provided. The cable shall be 6 pair to British Telecom standard.

The face plate shall be stainless steel, inscribed with international symbol and preferably mounted below the car push box.

2.1.33 Emergency Car Light and Alarm Bell

An emergency alarm bell shall be fitted, at an agreed position, with a suitable push in the lift car, which will indicate by light signal in the car that the bell is operating.

It shall be battery operated, shall include the necessary battery chargers to ensure the battery is charged automatically and when two or more lifts are in a group, a suitable electric indicator shall also be provided and fixed in an agreed position, to indicate which lift is operating the alarm bell.

Facilities shall be provided to enable a remote alarm bell to be installed. The alarm shall be linked to the condition monitoring system.

An emergency light shall be included in each car. The power supply for this will be from a battery pack and be automatically rechargeable and capable of feeding at least one lamp for three hours in the case of interruption to normal supplies. The lighting shall come on automatically upon failure of normal lighting.

2.1.34 Electromagnetic & Radio Interference Suppression Interference suppression to BS 800 and BS 613 shall be incorporated.

Suppression components shall not be used in circuits where failure might cause an unsafe condition.



2.1.35 Servicing

The Tenderer shall specify the costs for providing a 15 year fully comprehensive maintenance contract. The Contract shall be payable annually and shall be only adjustable in accordance with NALM published indices.

2.1.36 Tools

The Contractor shall provide and fix in the plant motor room a rack for the storage of the following tools which shall also be provided unless integrally designed.

1. Manual winding wheels

2. Brake release levers

3. Lock release keys

4. Any other tools for use in emergency

5. Framed and glazed wiring diagram shall also be provided and fixed.

It should be noted that the equipment will not be handed over or accepted until the tools and wiring diagrams are fixed.


TECHNICAL SPECIFICATION TITLE: SCHEDULES TABLE OF CONTENTS LIFTS

General Main Characteristics Hoistway Power Supply Headroom Internal Lift Car Arrangement Car and Landing Entrances

CWSpec-SECTIO3S-Rev4.doc 1/4 Detailed Civil Engineering Specification


TECHNICAL SPECIFICATION TITLE: SCHEDULES The Contractor shall complete the Schedules with details of the plant and equipment. He shall also submit full manufacturers' literature. 3.1 Lifts a) General

Location :

Quantity of Lifts :

Lift Type :

Product Reference : b) Main Characteristics

Load :

Speed :

Travel :

Serving :

Floor level designation :

Drive system :

Control system :

Machine room location :



c) Hoistway

Clear lift well dimensions :

Landing door finish :

Façade type :

Lift well luminaires :

Lift well Illuminance : d) Power Supply : e) Headroom : mm

f) Internal Lift Car Arrangement

Internal dimensions :

Car type and finishes : Car Luminaires :

Car Illuminance :

Car façade :

Opening arrangement :

Car door panels :

Ceiling type :

Car flooring :

Additional car features :



g) Car and Landing Entrances

Clear opening :

Door configuration :

Door operator type :



CWSpec-SECTIO4-Rev4.doc 1/21 Detailed Civil Engineering Specification

TECHNICAL SPECIFICATION TITLE: PARTICULAR REQUIREMENTS FOR THE ELECTRICAL SERVICES TABLE OF CONTENTS SCOPE STANDARDS ADDITIONAL REQUIREMENTS CLOSED CIRCUIT TELEVISION (CCTV)

General Standards Scope of Works Operational Considerations Cameras Camera Locations Transmission Control Centre

PUBLIC ADDRESS SYSTE

General Speaker Circuits Inputs to System Battery Standby Cabling

FIRE ALARM SYSTEMS

General Audibility of Fire Alarm Systems Manual Call Points Control Static Fire Appliances



TABLE OF CONTENTS FIRE AND SMOKE BARRIERS GENERAL POWER

General Foul Water Pumping Station

INTERIOR LIGHTING EMERGENCY AND ESCAPE LIGHTING FINAL CONNECTIONS (GENERAL)

Flexible Cables Small Single Phase Equipment Final Connections Large Single Phase and Three Phase Equipment - Final Connections

TELEPHONE AND DATA SYSTEMS DUCTING AND DRAWPITS LIGHTNING PROTECTION EARTHING

Electrical Installation Bonding Other Service Bonding Supplementary Bonding of Extraneous Metalwork Protective Conductor Sizing and Termination Main Earth Connection Safety Safety Electrical Warning Notices

STANDARD MOUNTING HEIGHTS



TABLE OF CONTENTS LABELLING ROLLER SHUTTER DOORS OR SLIDING FOLDING



TECHNICAL SPECIFICATION TITLE: PARTICULAR REQUIREMENTS FOR THE ELECTRICAL SERVICES 4.1 SCOPE

This section sets out the particular requirements for the electrical services including the electrical building services, exterior lighting, security, CCTV, PA Systems, fire detection systems and telephones.

4.2 STANDARDS

This Specification details the minimum outline requirements for the Electrical systems.

4.3 ADDITIONAL REQUIREMENTS

The requirements given in Section D Clause 1.4 to Clause 1.13 inclusive shall equally apply to this.

4.4 CLOSED CIRCUIT TELEVISION (CCTV) 4.4.1 General

Except as otherwise specified or agreed, all the equipment comprising the CCTV system shall be suitable for continuous service under the onerous conditions expected on site and shall be effectively protected against damage and the weather conditions found on site.

Except as otherwise prescribed or agreed, all apparatus and components therefore which are included in the system shall be of tried and proved design and construction.

As round-the-clock surveillance is required, the equipment shall meet this Specification from full sunlight down to the levels of artificial lighting ("Low light system", illumination range 105 to 4 lux).

The installation shall be designed, installed and commissioned by a specialist company experienced in CCTV systems.



4.4.2 Standards

All component parts of the installation shall comply with the latest relevant British Standards Specifications and EC Directives and shall be manufactured to strict systems of limits.

The system shall conform to the National Approved Council for Security Systems Code of Practice for Planning, Installation and Maintenance of Close Circuit Television Systems.

4.4.3 Scope of Works

The system shall comprise the provision of a complete CCTV system which shall include, but not be limited to:

· Cameras, masts and supplementary lighting

· Power supplies

· Communication links

· Control centre(s), control console(s) and all equipment

· Civil and builder's work

· Brackets, fixing etc. to buildings/structures

· Testing and commissioning

· Provision of full operation and maintenance procedures and record

drawings

· Training

The system shall be sized to allow for the addition of at least 6 further cameras and monitors in the future.



4.4.4 Operational Considerations

Automation of the following functions will be provided:

· Video switching · Selection of camera preposition

· Monitoring equipment

· Lighting control

These functions shall be controlled from:

· Timed events

· Manual intervention.

Irrespective of the degree of automation, the operator should be able to take manual control of the system.

Automation of picture selection shall take the following into consideration:

· Allocation of the monitors that display the pictures from these cameras. On

screen display of the camera identification is required, preferably in conjunction with a mimic diagram of the installation.

· Which pictures are to be recorded in real time.

The following response times shall be kept to a minimum:

· Camera pre-positioning where pre-sets are used on the zoom lens control

and pan and tilt head control.

· Operator's response time where intervention is required.

To minimise response times, cameras,, monitors, video recorders etc. shall be kept powered up at all operational times.



4.4.5 Cameras

General

All cameras shall be Colour CCD cameras with a horizontal resolution of at least 400 lines and with the appropriate sensitivity to provide optimum quality pictures in the lighting conditions for the site.

All cameras shall be capable of reading car registrations at 100m.

All cameras shall have a pan/tilt and zoom and shall operate at a voltage of 12/24 Vdc.

External cameras shall be complete with wipe facilities and heaters.

Camera Mounting Selection of a camera housing and mast, which must be finished to the colour advised by the Purchaser shall be suitable for the environmental conditions, including:

· Exposed maritime

· Lightning protection

· Vandal resistance

· Internal temperature rise

Support steelwork shall be protected to Table 3 Part 9 of BS 5493.

The camera mounting arrangement shall allow for the separation of video signal earth and housing metal work.

Brackets shall adequately provide for:

· The maximum weight of the equipment with sufficient rigidity for the camera

equipment and other devices. Rigidity shall be sufficient to maintain clear images with the narrowest field of view, i.e. full zoom and must include the rigidity of the camera mount.

· Future access and safe working.

· Moving cameras having sufficient clearing space from adjacent objects.



Camera Functions

The manual panning, tilting and zooming rates of cameras with zoom lenses shall be operator controlled with maximum and minimum speeds and proportional control suitable for the applications. The lenses must be of appropriate aperture and range of focal lengths to suit the camera sensor, the fields of view and the range of lighting levels. They must be fully motorised and have auto-iris functions but with manual override provision.

The recommendations for pan and tile units shall take fully into account:

· Environmental capabilities

· Platform loading

· Torque figures in relation to unbalanced platform loading and wind load

· Pan and tilt unit backlash on both axes

· Speed and range of movement of pan and tilt.

4.4.6 Camera Locations

Camera locations to be agreed with the Employer. 4.4.7 Transmission

Video transmission, together with control data shall be in real time and without perceptible degradation using either:

a) Fibre Optic

b) Coaxial Cable

c) A combination of systems. In view of the ongoing site development, an ability to easily reroute/redirect transmission paths will be a distinct advantage and should be feature of the Tender.



4.4.8 Control Centre

Full control of the system shall be provided from the Control Room and Gate House Building, together with video multi-plexing and recording in real time with camera number, data and time generation in S-VHS format with full screen selection.

The equipment complement shall include a large-sized monitor (25" colour) with a six-way splitter displaying the pictures of the cameras with a 14" colour spot monitor. All pictures would be recorded at all times, recording being in time-lapse mode or long play mode except during alerts.

Provision shall be provided for the connection of repeat monitors.

4.5 PUBLIC ADDRESS SYSTEM 4.5.1 General

The Public Address System will be interfaced with the Fire Alarm to also act as a Voice Evacuation system. When designing this system the Contractor must take into consideration the relevant parts of BS 5839, Part 1. Regarding power supplies, monitoring, alternate alarm communication circuits and audibility BS 7443 ̀ Sound Systems for Emergency Purposes' must also be considered as regards ̀ SPEECH INTELLIGIBILITY' rather than audibility. In other respects the system shall comply with the requirements of BS 6259 Type 3.

The system shall be modular in construction to allow for the addition of future facilities and shall be controlled from the Control Room by means of a PC based system with necessary software. The PC and software shall be provided as part of these works.

4.5.2 Speaker Circuits

The Contractor is responsible for the design and provision of a loudspeaker distribution system to give good sound reproduction throughout the complex.



4.5.3 Inputs to System

All paging via the PA system will be done using a telephone interface from the PABX system enabling all authorised extensions access to the Broadcast System, or a microphone situated in the Control Room. The order of priority on the inputs shall be as follows:-

1 Fireman's Priority Microphone located adjacent to Fire alarm panel. 2 Fire Evacuate Message 3 Fire Alert Message 4 Pre-set Message 1 5 Pre-set Message 2 6 Pre-set Message 3 7 Pre-set Message 4 8 Pre-set Message 5 9 Pre-set Message 6 10 Pre-set Message 7 11 Pre-set Message 8 12 Pre-set Message 9 13 Pre-set Message 10 14 Telephone Paging All controls for the Public Address system should be located in the Control Room. All equipment should be modular and based round the 19 inch rack mounting system.

All preset messages shall be capable of being recorded locally in the Control Room and shall be capable of being re-recorded each time a message needs to be changed without the need to be reprogrammed and taken from site.

4.5.4 Battery Standby

The Contractor is to calculate loading and size of battery units necessary to comply with BS 5839 Part 1 requirements. Sealed standby batteries are required.

4.5.5 Cabling

All loudspeaker cables shall be Fire Resistant in accordance with BS 6207 Part 1 and should be arranged so that every alternate speaker within a particular zone is fed via a separate supervised amplifier circuit. Care should also be taken to arrange that the priority inputs are also suitably protected from the effects of fire.



4.6 FIRE ALARM SYSTEMS 4.6.1 General

The Contractor shall provide an automatic detection fire alarm system (but not be limited to these systems) in accordance with the requirements of BS 5839, level of protection Type L2.

The specialist Contractor shall be a LPCB certified company.

The Contractor shall provide a master fire alarm controller which is interfaced with the Public Address system via a P.C. which shall be housed in the Control Room.

4.6.2 Audibility of Fire Alarm Systems

All fire alarm audible warnings are to be transmitted by recorded/live voice messages over the PA system.

The warning voice message will only be broadcast in the area covered by the system in which the fire has occurred.

4.6.3 Manual Call Points

Manual call points shall be located on all exit routes and in particular on floor landings of staircases and at exits to the open air. In general, they should be sited so that no person need travel more than 30m in order to activate the alarm.

4.6.4 Control

The fire alarm systems shall be linked to all mechanical services to allow control of the systems as deemed necessary by the Fire Officer. The security and access control system shall also be integrated to enable all electromagnetic door locks to de-energise on a fire alarm signal.

4.6.5 Static Fire Appliances

The Contractor shall be responsible for providing all necessary static fire appliances.



4.7 FIRE AND SMOKE BARRIERS

The Contractor shall make adequate provision for fire and smoke barriers in and around trunking, conduits, cables etc. which pass through any floor, ceiling, wall, partition etc. which is a fire barrier, in full accordance with the IEE Wiring Regulations 16th Edition.

The Contractor shall ensure that this work is carried out to the requirements of the IEE Wiring Regulations 16th Edition and that the integrity of any such fire barrier is properly maintained where pierced by a service installed under this Contract.

4.8 GENERAL POWER 4.8.1 General

The general power requirements are as shown in the room data sheets and shall include the following:

a) Switched Socket outlets and fused connections - all buildings and walkways.

b) Hand dryers, Sanitary Towel and shaver supplies.

c) Lifts

d) Mechanical services electrical requirements, including plant, electrically

operated doors, windows, pumps and other fixed equipment.

e) All other ancillary electrical systems, PA, Fire Alarms and telephones.

Socket outlets, switches shall be of robust metal clad manufacture within the building. White dado trunking shall be used.

All electrical accessories are to be of a robust type. All socket outlets in outdoor or semi outdoor areas shall be weatherproof and RCD protected.

4.8.2 Foul Water Pumping Station

The Contractor shall provide a suitable rated supply for the foul water pumping station designed and constructed within this Contract.

4.9 INTERIOR LIGHTING



The general lighting requirements are as shown in the room data sheets and shall include the following:-

a) Metal halide pendant type luminaires with prismatic bell shaped skirt in the

high-bay areas.

b) Surface/recessed mounted fluorescent luminaires complete with prismatic diffusers in all general areas, including staff toilets, corridors etc.

c) Surface/recessed mounted fluorescent luminaires complete with low

brightness diffusers in all offices.

d) Corrosion resistant and vandal/vapour proof fluorescent luminaires in plant rooms.

e) Lighting to entrance canopy to be recessed compact fluorescent

downlighters.

Lighting levels shall be as detailed on the room data sheets and as the CIBSE Guide for Interior Lighting.

In all areas where there are false ceilings or suspended lighting, the luminaires shall be recessed with plug connectors and flexible connections to the conduit fixed to the soffit above. The connectors shall be located no more than 300mm from the suspended ceiling.

The installation shall be carried out as a flush conduit system wherever practicable with surface conduit in areas such as barrel vault ceilings.

Where conduits are run surface mounted they shall be hidden wherever possible behind structural steelwork etc. All area lighting shall be switched from a central position in each room. Where multiple luminaires are installed in a room, they shall be grouped to provide lighting control e.g. luminaires near windows in offices separately switched to internal luminaires. Full 2 way and intermediate switching shall be provided at all access points.

All luminaires shall be of robust construction with fluorescent luminaires being as `Thorn' or agreed similar with T8 tubes and high frequency low loss control gear.

4.10 EMERGENCY AND ESCAPE LIGHTING



The emergency lighting shall be designed in accordance with BS 5266. The emergency lighting shall generally be provided by means of self-contained non-maintained battery-invertor packs utilising the general lighting where practicable.

The battery/invertor packs shall be contained in the fittings or in a housing next to the appropriate fittings.

All battery/invertor packs shall have a minimum emergency duration of 3 hours.

All escape routes and exits shall be lit by means of illuminated maintained self-contained luminaires. Exit doors shall be provided with emergency luminaires internally and externally. External luminaires shall be IP65 rated polycarbonate vandal/weatherproof fittings.

The emergency lighting scheme should include adequate facilities for testing and recording the system condition. A suitable means of testing alternate emergency luminaires shall be provided to avoid the risk of having all luminaries discharged while the building is occupied.

For areas illuminated by low-voltage downlighters or high - bay lighting additional emergency luminaires shall be utilised to achieve the requirements of BS 5266, as appropriate.

4.11 FINAL CONNECTIONS (GENERAL)

This Section details the requirement for flexible cables and standard methods of final connection to luminaires and equipment in frequent use. In some instances variations in the construction or application of a luminaire or item of equipment will require a non-standard method of final connection.

4.11.1 Flexible Cables

All flexible cables used for final connections to fixed or portable equipment other than detailed below shall be 300/500 volt grade to BS 6500, PVC insulated and white circular PVC sheathed with conductors of HC tinned copper wires.

All flexible cables used for luminaires or for final connections to any fixed or portable equipment which:



i) contains any form of heating element

ii) is fixed to any pipework or appliance which is fed with, or forms part of a

distribution system for hot water or other heated fluid

iii) forms part of any combustion appliance or chimney

shall be 300/500 volt grade, to BS 6500 silicone rubber insulated and white circular glass braided sheathed with conductors of HC tinned copper wires.

4.11.2 Small Single Phase Equipment Final Connections

For the purpose of this Clause small single phase equipment is defined as any non-portable item operating at 240 volts or less, single phase, with a current rating not exceeding 13 amps, but excluding fixed luminaires.

Where the item is wall mounted on a concealed wiring system and a back entry can be made to it, then a flush mounted box shall be fitted and the item mounted to conceal the box. Where the item contains any form of heating element or is fed with any hot fluid, the fixed wiring shall terminate at a fixed connector block mounted in the box and a heat resisting final connection will make a back entry to the item. Where a heat resisting final connection is not required, the fixed wiring shall make a back entry and terminate at the item terminal block.

Where the item is wall mounted on a concealed wiring system and a back entry cannot be made to it then the fixed wiring shall terminate at a box which shall be fixed immediately adjacent to the item and the final connection made in flexible cable or flexible conduit. Where the item is wall mounted on a surface wiring system and the item has suitable provision for the direct entry of the wiring medium then, other than where a heat resisting final connection is required, a direct entry shall be made. Where a heat resisting final connection is required then the "fixed to flexible" final connection shall be made all as described above.

Where local control is required for isolation purposes to comply with the IEE Regulations 16th Edition an isolator unit shall be mounted adjacent to the item.

4.11.3 Large Single Phase and Three Phase Equipment - Final Connections

At all fixed single and three phase industrial equipment the circuit wiring shall



terminate in an isolator adjacent to the equipment from which the supply is to be taken to the equipment via any starters or other control devices.

4.14 TELEPHONE AND DATA SYSTEMS

Not referred to here. 4.15 DUCTING AND DRAWPITS

The Contractor shall install three separate duct systems with drawpits. One system shall be for power distribution and power control cables and the second for communication systems including PA, Security, Fire Alarm, CCTV etc. ("Comms") and the third for the external telephone system provider.

The ducting is generally to be PVC-u in accordance with BS3506 Class `O'. Size and colours as follows:-

BT 100mm dia Grey

Comms 100mm dia Orange

Power 150mm dia Black.

The dimensions and number of ducts and the dimensions of draw pits shall finally be decided by the Contractor subject to the agreement of the Purchaser and in particular the final design shall ensure that recommended minimum bending radii for cables are taken into account. All draw pits shall have heavy duty covers which shall be single, two, three or four piece to facilitate removal using only a proprietary cover lifter. At least two proprietary cover lifters shall be provided as part of this contract.

All ducts upturns into buildings shall be sealed with flexible, waterproof, fire resistant sealant after installation of cables.



4.16 LIGHTNING PROTECTION

The lightning protection system shall comply with the requirements of the latest edition of BS 6651 and the General Electrical Specification where this is more onerous. Where buildings are steel framed and the frame constitutes a good electrical conductor, the vertical steel frames may be used as down conductors appropriately jointed to the air and earth terminations.

The resistance to earth of high mast lighting columns shall be measured. If this measurement exceeds 10 ohms then an earth electrode termination shall be installed for each unit according to BS 6651 to achieve a resistance not exceeding 10 ohms..

Transient overvoltage protection shall be provided on all power, communications, and aerial connections as required by Appendix C of BS 6651 for an installation with a consequential loss rating of 3.

4.17 EARTHING

The Contractor is to earth the whole installation in accordance with BS 7671 (IEE Wiring Regulations 16th Edition), BS 7430 (Earthing) and also with the earthing requirements of the General Electrical Specification.

Where lightning protection is provided for a building/structure, the lightning protection system shall be bonded to the main earth terminal of the building/structure along with all other services as required by BS 7671.

The LV switchgear panel earth bar shall be bonded by a suitably sized protective conductor to the substation LV earth bar in the switchroom. All other items of electrical equipment including the mobile diesel generator set shall be bonded to the LV earth bar by suitably sized protective conductors.

4.17.1 Electrical Installation Bonding

All metalwork, other than current carrying conductors, which forms part of or provides mechanical protection for the electrical installation including all appliances and equipment, shall be bonded to the main earth terminal of the switch panel from which it is fed by circuit protective conductors.



The circuit protective conductor shall be a copper conductor or may be in a whole or in part any metal trunking; metal conduit excluding flexible conduit; cable sheath and/or armouring of any cable, armoured flexible cords or cables; or the integral earth conductor of any multicore cable provided that its cross-sectional area complies with the requirements of the IEE Regulations 16th Edition.

4.17.2 Other Service Bonding

All exposed structural steelwork, lifts, ventilation ducting, central heating and water services systems shall be bonded by means of a main bonding conductor to the main earth terminal.

No part of any other service, nor any bonding termination at such services shall be used to form part of the earth fault path of any circuit protective conductor.

Before commencing earth bonding between any other service and any part of the electrical installation, the Contractor shall ensure that the protective/bonding conductor is properly connected to earth and the other services will not be the sole earth fault path.

The Contractor shall prove the continuity of all existing services. The Purchaser shall be invited to witness these tests. All areas which fail to give satisfactory test results shall be specifically brought to the attention of the Purchaser.

4.17.3 Supplementary Bonding of Extraneous Metalwork

All extraneous metalwork as defined in the IEE Regulations 16th Edition and which is specified to be bonded therein shall be bonded to the electrical installation circuit protective conductor. The fixing screws of conduit saddles, cable clips, accessories or items of equipment shall not be relied upon as the sole means of bonding to any structural steelwork or other metal required to be bonded.

4.17.4 Protective Conductor Sizing and Termination

All protective conductors shall be sized strictly in accordance with the IEE Regulations 16th Edition unless a conductor of lower impedance is specified elsewhere.

Where a protective conductor takes the form of a cable it shall have a copper conductor insulated with green/yellow PVC insulation.



All protective cable conductors shall be terminated using compression lugs where bolted connections are required.

For the purpose of this clause, short lengths of protective conductor which are copper tape and which are wholly fixed to the exterior of an individual switchpanel or other item of equipment need not be insulated.

4.17.5 Main Earth Connection

The copper earth rods for the main earth shall be steel cored copper rods of not less than 12mm diameter and 3m lengths and shall be fitted with a disposable head for driving into the ground.

Earth rods shall be spaced apart at a distance at least equal to their length and no rod shall be set closer than 3m to the foundations of any building. Every earth rod shall be provided with an earthenware or concrete inspection trap with removable cover which shall be installed flush with the finished ground level, the trap cover shall be inscribed ̀ ELECTRICAL EARTH'. All earth lead connections to earth rods shall be made by means of clamps as provided for the purpose by the earth rod manufacturer.

4.17.6 Safety

A reliable method of earth protection must be provided to any section of the installation before that section has mains voltage applied to it.

4.17.7 Safety Electrical Warning Notices

A permanent warning notice shall be attached to or fixed adjacent to the point where an earth conductor connects to an earth electrode or where a bonding conductor connects to an extraneous conductive part. The label shall be durably marked `SAFETY ELECTRICAL CONNECTION - DO NOT REMOVE' as per the IEE Regulations 16th Edition.



4.18 STANDARD MOUNTING HEIGHTS

The standard mounting height of the underside of the faceplates of accessories and other fitments above finished floor level shall be as listed below:

Light Switches 1300mm

Socket Outlets (Wall mounted) 400mm

Isolators and Starters 1300mm

Radio and TV Sockets 400mm

Wall Light Fittings 2200mm

Light Boxes 2000mm

Thermostats 1700mm

Fire Alarm Pushes 1300mm

Panic Buttons 1300mm

Wall Mounted Telephones 1350mm

Dado Trunking 1000mm

Socket outlets above benches shall be 200mm above the worktop.

4.19 LABELLING

The Contractor shall supply and fix warning labels to all removable covers on equipment including lighting switches and other accessories, main switchgear and distribution boards, junction boxes, control or other equipment at which a potential greater than 250 volts exists. These labels shall bear the word "DANGER" together with the value of the voltage present, e.g. `DANGER 415 VOLTS'. If items of apparatus in which voltages do not exceed 240V can be reached simultaneously by a person and the potential between them exceeds 240V, then each must carry a warning notice stating the highest voltage that exists between the two, e.g. 'DANGER 415 VOLTS BETWEEN APPARATUS'.

Where a control panel or other items of equipment contains secondary circuits



which are not isolated by the primary means of isolation provided for the item then a warning label shall be fitted to that item.

The label shall give warning that a secondary circuit is not isolated by the primary isolator. It shall also specify the circuit(s) which are not isolated (e.g. contactor coil circuit(s)) and where such circuits can be isolated.

Every junction box, switch fuse, fuseway or other item of equipment associated with, or controlling the supply to a fire alarm system shall be fitted with a label bearing the words `FIRE ALARM` together with any information which may be required.

The above labels shall be ivorine or traffolyte with the information engraved on them in 6mm high red capital lettering on a white background. The labels shall be fixed by screws or rivets.

Switchgear, distribution boards and other similar controls are to be labelled to indicate function. Labels shall be ivorine or traffolyte with information engraved on them in 6mm high red capital lettering on a white background. The labels shall be fixed by screws or rivets. Labels fixed by adhesive are not acceptable.

Danger notices shall be fixed to the external doors of all switchrooms and to all distribution and switch boards.

4.20 ROLLER SHUTTER DOORS OR SLIDING FOLDING

The Contractor shall provide suitably sized roller shutter or sliding folding doors as indicated on the plans generally in accordance with IEC 730-2012.

The doors shall be operated by local up/down pushbuttons mounted in a recessed module discretely positioned adjacent to the roller shutters. An isolator shall be provided above the suspended ceiling for local isolation of each shutter. The roller shutters shall be equipped with an override mechanical device to enable the shutters to be raised and lowered on power or motor failure. The colour and finish of doors shall be agreed with the Purchaser prior to orders being placed.


TECHNICAL SPECIFICATION TITLE: GENERAL REQUIREMENTS TABLE OF CONTENTS SCOPE STANDARDS

General Codes and Regulations Compliance with British Standards Design Standards of equipment and components Materials and Workmanship

DEFINITIONS ENVIRONMENTAL CONDITIONS RADIO INTERFERENCE SUPPRESSION FIRE PRECAUTIONS CONTRACTOR'S SUBMISSIONS

General Working Drawings Current Drawings

RECORD DOCUMENTS

General Record Drawings Operating and Maintenance Manuals

COMMISSIONING

CWSpec-SECTION1-Rev4.doc 1/16 Detailed Civil Engineering Specification


TABLE OF CONTENTS TESTING

General Tests and Inspection at Manufacturer's Works On Site Testing Earthing Tests Test Results

TRAINING SPARES



TECHNICAL SPECIFICATION TITLE: GENERAL REQUIREMENTS 1.1 SCOPE

This part specifies the minimum design, performance, materials, workmanship, testing and commissioning requirements for the heating, ventilating, water and electrical building services and the external and internal mechanical and electrical infrastructure and systems.

1.2 STANDARDS 1.2.1 General Codes and Regulations

All design, materials, workmanship, testing and commissioning shall be in accordance with the appropriate standards which shall include but not necessarily be limited to:

- The Recommendations of the Chartered Institution of Building Services

Engineers (CIBSE Guides) & Codes.

Volume A - Design Data

Volume B - Installation and Equipment Data

Volume C - Reference Data

Volume D - Transportation Systems in Buildings

- British Standard Specification and Codes of Practice

- BS 7671 IEE Requirements for Electrical Installations (The IEE Wiring Regulations 16th Edition), with Amendments

- Electricity at Work Regulations

- Electricity Supply Act, 1988

- The Factories Act

- The Building Regulations - The Health and Safety at Work Act



- Local Authority Bye Laws

- Water Authority Byelaws

- Fire Officers Committee Regulations

- Requirements of the local Fire Prevention Officer

- The supply of Machinery (Safety) Regulations 1992 (S.I.1992/3073) as amended (S.I. 1994/2063)

- Gas Safety Regulations

1.2.2 Compliance with British Standards

Equipment and the installation shall conform with the requirements of all relevant British and European Standards and Codes of Practice and Statutory Regulations and including but not necessarily limited to the following:

BS 7671 Requirements for Electrical Installations (The IEE Wiring

Regulations 16th Edition)

BS 31 Steel conduit and fittings

BS 4568 Steel conduit and fittings

BS 731 Flexible steel conduit

BS 4607 Non-metallic conduits and fittings for electrical installations

BS 6004 PVC Insulated Cables

BS 6007 Rubber insulated cables

BS 6346 PVC insulated cables

BS6469 Electric cables BS 6500 Insulated flexible cords and cables

BS 6207 Mineral insulated copper sheathed cables

BS 5486 Low voltage switchgear and control gear

BS5489 Road lighting



BS 8206 Lighting for buildings

BS 4533 Luminaires

BS 5266 Emergency Lighting

BS 5499 Fire safety

BS 5839 Fire detection and alarm systems for buildings BS 5588: Part 3 Fire precautions in the design and construction of buildings.

Code of Practice for office buildings.

ISO 8201 Acoustics - Audible evacuation signal ISO 8253 Acoustics - method of conducting speech audiometric tests.

BS 4737 Intruder Alarms

IEC 839 Alarm Systems

BS 6651 Lightning Protection

BS 7430 Earthing

BS 88 Cartridge Fuses

BS 5655 Lifts and service lifts

BS 5304 Code of Practice for safety of machinery

BS 302 Stranded wire ropes BS 6977 Specification for insulated flexible cables for lifts and other

flexible connections

BS 5810 Code of Practice for access for the disabled buildings

BS 759 Valves, gauges and other safety fittings

BS 853 Calorifiers and Storage Vessels for central heating and hot water supply

BS 143 Malleable cast iron pipe fittings



BS 864 Capillary and compression tube fittings of copper

and copper alloy

BS 1387 Steel tubes

BS 1740 Wrought steel pipe fittings

BS 3602 Steel pipes and tubes for pressure purposes

BS 4508 Thermally insulated underground pipelines

BS 8207 Energy efficiency in buildings

BS 727/BS 800 Radio interference suppression

Reference to British, European and other National or International Standards shall be deemed to mean the latest edition of the standard with amendments current at the time

1.2.3 Design

This Specification details the minimum outline requirements for electrical & mechanical systems within the civil engineering and building works scope.

The Contractor shall be responsible for:-

a) All aspects of design, application and proving of the equipment in

accordance with the requirements of the Specification and the Drawings. b) Liaison between suppliers to ensure complete compatibility of all equipment

at both component and system interface levels.

c) Overall systems engineering and co-ordination to ensure that all equipment, software, components and systems together form a consistent, rational and fully integrated system.

d) The supply, installation and termination and testing of all components, cabling, cabling systems and wiring of all components which may be necessary to achieve the correct and specified function and to provide a safe and reliable installation, whether or not such components are specifically called for in the Specification.

1.2.4 Standards of equipment and components



The equipment and components shall be designed and constructed;

a) to be suitable for the heavy duty conditions, such that with proper

maintenance and operation, a minimum working life of 15 years is expected without replacement or reinstatement of any major assembly or a substantial proportion of component elements;

b) such that routine and occasional maintenance throughout its life shall be a

practical minimum, compatible with the preservation of maximum reliability;

c) to withstand the electrical, mechanical, thermal and atmospheric stresses to which it may be subjected under operational conditions, without deterioration or failure with due consideration given to the environment in which it is to be installed;

d) to high standards of manufacture, reliability, accuracy and repeatability of

performance.

Components and equipment shall be standardised throughout the Works so that wherever more than one item is supplied, all such items shall be identical.

The Contractor shall notify the Purchaser in writing of any proposed change in design, manufacture, manufacturing methods or materials from those included or implied once agreement by the Purchaser has been given. The Purchaser recognises the importance of including the latest principles and design in the final design of any plant, but it is necessary that he should be fully aware of the details of construction of the plant as finally installed and of the reasons for any change from that offered.



Where there are not full details in the Specification or associated drawings regarding the exact location or method of installation of measuring equipment, sensors or other size mounted equipment, the Contractor shall submit details of his proposed installation to the Purchaser for agreement before starting any installation work.

1.2.5 Materials and Workmanship

Requirements for standards of materials and workmanship relevant to particular types of work, installation or equipment are specified herein.

The specifications for mechanical and electrical service systems in this Part are intended to indicate the minimum acceptable standards of materials and workmanship.

Notwithstanding the requirements set out herein, it shall be entirely the Contractor's responsibility to provide mechanical and electrical services systems which, when completed, provide a comprehensive technically viable, safe and durable construction entirely in accordance with the requirements laid down.

1.3 DEFINITIONS

‘Plant’ shall mean machinery, apparatus, materials, articles and things of all kinds incorporated in the Works.

The term ‘provide’ and its derivatives shall mean the complete design, manufacture, delivery, installation, testing and commissioning of the Works, inclusive of such ancillary service as inspection and witnessed testing at the places of manufacture, workshop and site painting, handling on site, site trials and of all such other services as are noted in the Specification or reasonably necessary for the safe, reliable and efficient completion of the Contract.

1.4 ENVIRONMENTAL CONDITIONS

All plant shall remain operational, within specification, over the ranges

Ambient Temperature -20° to +35°C Relative Humidity 10% to 95% (non condensing)

Variations in the power supply to the works of:

±10% of nominal voltage and ±2.5% of nominal frequency

shall not effect the system operation.



1.5 RADIO INTERFERENCE SUPPRESSION

Apparatus, such as thyristor controls, contactor starters, contactors, luminaire chokes, etc. shall be fitted with means for suppressing interference frequencies.

The standards of interference suppression required shall be in accordance with BS 800.

Details of the equipment and methods to be used in determining the level of radio interference shall be as specified in BS 727.

1.6 FIRE PRECAUTIONS

All plant, apparatus, connection, wiring etc. shall be so designed and arranged to minimise the risk of fire and any damage resulting from fire.

1.7 CONTRACTOR'S SUBMISSIONS 1.7.1 General

The Contractor shall submit Construction Information to the Purchaser for review in accordance with the specification. Submissions of Construction Information shall include manufacturer’s drawings and specifications for all major items of plant, including electrical equipment, switch panels, control panels. The information shall include all details of performance, electrical connections, wiring diagrams.

Submissions in respect of major manufactured plant items are to be made at least 28 days before the date when the Contractor plans to place a firm order for supply of the item.

1.7.2 Working Drawings

The Contractor shall submit Services Schematics, Design Basis Statements, Calculations and detailed Working Drawings in accordance with the Specification. The drawings shall show clearly the installation and details of all concealed sections. They shall identify all pieces of equipment and give capacities and duties.

The Drawings shall comprise in principle but not be restricted to the following:-

a) General arrangement drawings of all services at a scale of 1:50 (including

pipework, conduit and trunking drawings).

b) Sub-stations, Plant Rooms, Switchrooms, Motor Rooms at a scale of 1:20 in plan and elevation/section.



c) Core areas and riser shaft co-ordinated services at a scale of 1:20 in plan and elevation/section.

d) Schedules of all equipment, fully referenced and cross referenced with the

drawings.

e) Schematic drawings of all services, clearly identifying the type of components, size and manufacturer, cross references with the drawings.

f) Dimensioned details of pits, drawpit chambers, etc.

g) Routes and dimensioned sections of all ducting and pipework.

h) Exterior services including water supplies, CCTV, lighting, and security

systems etc. at a scale of 1:500. 1.7.3 Current Drawings

During the progress of the Works, the Contractor shall keep a set of drawings kept up to date showing any alterations which have been made to the scheme and to the position of all services as actually installed. These drawings shall be kept, updated daily, and be accessible to the Purchaser and Purchaser’s appointed Representative.

1.8 RECORD DOCUMENTS 1.8.1 General

Copies of record documents including record drawings and operating and maintenance instructions and manuals shall be provided to the Purchaser in accordance with the Specification.

1.8.2 Record Drawings The Contractor shall prepare all record drawings, necessary drawings and

diagrams of the "as-fitted" works as may be required for record and for care, maintenance, repair, and other purposes, and these shall include:

a) Arrangement drawings of each complete installation to a scale of not less

than 1:50.

b) Outline dimensioned drawings of each of the principal items of plant. Each shall carry or be accompanied by a schedule of fittings, instruments and components which shall include the maker's names, reference numbers, ratings and full particulars of all the component parts.



c) Sectional drawings of each of the major items of plant with the parts named

and numbered to facilitate maintenance and overhaul. d) Detailed electrical, piping and operational schematic diagrams.

e) Schedules, diagrams, and route sections for cable, ducts and other services

installations.

f) Cable and pipe route plan of the site and of each of the principal installations showing sections through the cable groups and service ducts so that each cable etc., in a group or trench may be readily identified. This information shall preferably be shown on a number of large scale drawings which shall be correlated by means of a small scale master plan.

g) Diagrams and all relevant operational particulars in respect of electrical and

hydraulic circuits and equipment. 1.8.3 Operating and Maintenance Manuals

The Contractor shall submit 2 copies of the Operation and Maintenance Manuals for all of the mechanical and electrical services for review by the Purchaser not less than 4 weeks before final testing and commissioning. The Contractor shall prepare comprehensive maintenance and operation manuals and shall obtain from the manufacturers of all equipment supplied under his contract and equipment supplied by others, all the instruction manuals necessary for the correct maintenance and operation of that equipment. The manuals shall include a complete diagram of all internal and external mechanical, electrical and other services connections with a parts list identifying all components.

The Manuals shall be comprehensive and prepared in accordance with the requirements of BS 4899 and as a minimum include the following:-

i) Full description of each system.

ii) Method of manual and automatic operation.

iii) Procedures in case of faults

iv) Emergency procedures

v) Recommended maintenance requirements with details of lubricants etc.



vi) Schedule of spares vii) Full technical data including drawings of plant and circuit diagrams

viii) Test certificates

Once the manuals have been agreed the Contractor shall provide 6 bound copies as described in the Specification.

1.9 COMMISSIONING

Prior to the commencement of any commissioning works, the Contractor shall submit a schedule of commissioning works with a fully detailed method statement for review by the Purchaser.

All commissioning shall be undertaken in accordance with CIBSE codes, BS 7671, the requirements of the General and Particular Specifications and any special requirements of the manufacturer of the systems supplied.

The Purchaser will indicate which commissioning tests he wishes to witness and the Contractor shall agree dates for these with the Purchaser. Any commissioning tests which fail shall be repeated until satisfactory results as determined by the Purchaser are achieved. When it is not possible at the particular time of commissioning and testing for full load conditions to be obtained or simulated, the Contractor shall repeat such operations at such future time with full load when the simulation can be achieved. Any repeat text shall be carried out at no extra cost to the Contract. Where portions of the work are commissioned and tested separately, the Contractor shall, upon final completion, demonstrate to the Purchaser that all the several portions are capable of proper simultaneous operation in accordance with the requirements of the Contract.

In cases where the overall building programme is such that the Contractor will need to return, for the purpose of testing, regulation, adjustment or remedial work, to portions of the buildings, which by the time, may be in occupation by the Employer, the Contractor shall be deemed to have allowed in his Tender accordingly and shall take all necessary precautions against damage when working in such areas.

1.10 TESTING 1.10.1 General

Upon completion of installation on site each item of plant shall be tested for compliance with this Specification and in accordance with the relevant specification



or code issued by the British Standards Institution. In the absence of such a specification or code these tests shall be performed in a manner subject to the agreement of the Purchaser.

The Contractor shall give fourteen working days notice to the Purchaser when the plant is ready for tests.

The Contractor shall provide all labour, materials, stores and apparatus necessary for tests and inspections.

1.10.2 Tests and Inspection at Manufacturer's Works

Prior to despatch all plant mechanical and electrical shall be tested at the manufacturer's works in the presence of the Purchaser or his appointed representative to determine its performance characteristics and for the purpose of determining if it complies with the specification or codes issued by the British Standards Institution. In the absence of such a specification or code, these tests shall be performed in a manner subject to the agreement of the Purchaser.

The Contractor shall give fourteen working days notice to the Purchaser when plant is ready for test at the manufacturer's works. In the event of testing and/or inspection being carried out at a sub-contractor's works, the Contractor's representative shall accompany the Purchaser or his appointed representative on each visit.

Electric motors shall be tested separately in accordance with BS 5000 and certified test certificates provided in triplicate.

Pumping plant shall be subjected to witness tests in accordance with BS 5316 Part 1, 1976, Class 'C' tests.



Electrical panels shall be subjected to the following witnessed tests, at the Manufacturer's Works, prior to despatch to site:

(a) A thorough visual inspection, with all covers both in place and removed.

(b) Operational tests on all control and auxiliary circuits, with switches, lamps,

etc, being connected as necessary to represent equipment mounted remotely from the switchboard.

(c) Phase continuity tests.

(d) Flash test (2.5 kV applied between phases and between phases and earth

for a period of 1 minute).

(e) Insulation tests at 500V between phases and between phases and earth.

If it is necessary to provide simulated controls in order to perform a test at the manufacturer's works, the Contractor shall provide such controls as part of the Works. The design of the controls shall be subject to prior agreement by the Purchaser.

1.10.3 On Site Testing

Tests required shall be carried out by the Contractor and witnessed by the Purchaser. The Contractor shall give reasonable notice to the Purchaser of all tests so that the Purchaser can make arrangements for witnessing.

Testing as called for in the IEE Wiring Regulations 16th Edition shall be completed in the sequence stated in the Regulations as follows:

a) Continuity of protective conductors b) Continuity of ring final circuit conductors c) Insulation resistance of phase and neutral conductors

d) Polarity checks throughout the installation

e) Earth fault loop impedance check

f) Earth electrode resistance check

g) Operation of residual current operated devises.



The Contractor shall submit to the Purchaser a Method Statement detailing his programme for on site testing, which shall take into account that completed stages of work may be handed over to the Employer and become operational before all later stages of the work are ready for testing.

The Contractor shall rectify any faults or defective work revealed by the tests and shall retest the work, as many times as are necessary, at his own expense.

Where further tests are required to be undertaken on areas of work already handed over to the Employer, these tests shall be undertaken at times agreed with the Purchaser and Employer before commencing any works.

The Contractor shall supply all instruments, apparatus, materials and labour for testing. Any retesting shall not be an extra charge to the Contract.

All instruments used for testing of the installation shall be fully calibrated and have current calibration certificates, which shall be made available for inspection by the Purchaser on request.

1.10.4 Earthing Tests

Resistance tests shall be made between the general mass of earth and the earth electrode(s) and/or substation earth system.

An earth loop test shall be carried out between each phase of the supply and the installation main earth point in accordance with the IEE Regulations 16th Edition, BS 7671.

1.10.5 Test Results

Three copies of all test certificates, log sheets, performance curves, etc, relating to the tests at manufacturer's works shall be sent to the Purchaser at the conclusion of each test. No item shall be despatched to site before the Purchaser has in writing agreed such certificates, etc.

In addition to the above tests, test certificates shall be provided as required by the Purchaser, to prove compliance of components and assemblies with the relevant British Standards.

All necessary test equipment shall be provided. For the purpose of testing, each switchboard/motor control centre shall be fully assembled, both electrically and mechanically, into one composite unit. It shall not be acceptable to test the



switchboards in sections.

The Contractor shall hand to the Purchaser a copy of the results of all on-site tests, the originals shall be included within the Maintenance Manuals.

1.11 TRAINING

The Contractor shall submit a training programme with his Tender which shall allow for the training of the Employer's staff so that they may operate and maintain the Plant in a competent manner in accordance with the Health and Safety at Work Act, the Electricity at Work Act and other relevant statutory requirements.

A full training programme with details of syllabus shall be submitted for agreement to the Purchaser and shall be implemented one month before handover of any section of the Works. The Purchaser’s decision as to the adequacy of the training shall be final.

1.12 SPARES

Spares shall be supplied in one or more compartmented boxes solidly constructed in planed timber and having a hinged lockable lid with stay, carrying handles and a permanent label to be agreed with the Purchaser.



TECHNICAL SPECIFICATION TITLE: GENERAL SPECIFICATION FOR MATERIALS AND WORKMANSHIP TABLE OF CONTENTS MECHANICAL (H&V) AND ELECTRICAL WORK PLANT AND MATERIALS

General Design Installation Painting and Protection



TECHNICAL SPECIFICATION TITLE: GENERAL SPECIFICATION FOR MATERIALS AND WORKMANSHIP 2.1 MECHANICAL (H&V) AND ELECTRICAL WORKS

Materials and workmanship for building services (mechanical and electrical) and external services shall be in accordance with the following specifications or as otherwise detailed in the Specification.

Standard Specification (M&E) No.1 - Electrical Installations

Standard Specification (M&E) No.3 - Mechanical Installations

Standard Specification (M&E) No.100 - Ventilation Installations

The above specifications are prepared by Department of the Environment, Transport and Regions, Directorate of M&E Engineering Services and distributed by the HMSO.

Where the term ‘SO’ is used in the above specifications, this shall mean the Purchaser.

Where there is any conflict between the requirements of this Specification and the, general specifications for materials and workmanship referenced above, the requirements of this Specification shall apply.

The above specification of mechanical and electrical service systems are intended to indicate the minimum acceptable standards of materials and workmanship and shall not override the specification given in the Particular Specification which follows.

Any Local Authority requirements shall supersede the requirements of the above specifications unless otherwise directed by the Purchaser.

2.2 PLANT AND MATERIALS 2.2.1 General Design

All component parts of the Plant shall be manufactured to allow complete interchangeability of similar parts. The general design of the Plant and particularly that of contacts and other wearing parts shall be governed by the need for long periods of operational service without frequent maintenance and attention being necessary.



All equipment and plant shall be suitably arranged to enable safe access for operation and maintenance.

Except as otherwise prescribed or agreed, all apparatus and components thereof which comprise the Works shall be of tried and proved design and construction.

Holding-down bolts and fixings for securing the plant to structural steelwork or the like shall be of the clamp pattern such as do not require the steelwork to be drilled.

Small fixing screws and other small parts shall be of non-ferrous metal and shall engage in white-metal, plastic or equal agreed non-corrodible plugs.

All details, except as otherwise specifically agreed, shall be hot dipped galvanised.

The Mechanical & Electrical equipment and all components thereof shall be rated for continuous service at the specified duties under the prevailing atmospheric and operational conditions on site.

The Mechanical & Electrical Equipment shall be of such material or shall have such surface protection, painting and finish as will afford satisfactory protection against atmospheric corrosion under the prevailing conditions and under those transient conditions which may occur from time to time, without frequent maintenance painting or other treatment being necessary.

The electrical installation shall comply with the requirements of the General Electrical Specification.

Anti-vibration mounts to be utilised where appropriate, based on technical advice

from the manufacturers of the components. 2.2.2 Installation

i) The Mechanical and Electrical Components shall be installed in accordance with the manufacturer's recommendations.

ii) Before starting to install the equipment, the Contractor shall satisfy himself

that all constructional details provided for the accommodation or fixing of the equipment are correct according to the Drawings.

iii) The equipment shall be set true and level on the as-constructed surface.

2.2.3 Painting and Protection



With the exception of bright machined surfaces, the Contractor shall apply to all steelwork and machinery two coats of paint of agreed quality and colour at Works and touch up on site all damage to the paint finish. Prior to despatch from Works, all bright surfaces and decorative finishes shall be adequately protected against subsequent deterioration or damage.

The Contractor shall ensure adequate protection for all materials against deterioration or damage on site and removal of this protection will not relieve the Contractor of his responsibilities for protection.



TECHNICAL SPECIFICATION TITLE: PARTICULAR REQUIREMENTS FOR MECHANICAL SERVICES TABLE OF CONTENTS GENERAL EXTERNAL DESIGN PARAMETERS FOR HEATING AND VENTILATION SYSTEMS DESIGN CONSIDERATIONS

Internal Design Temperatures Heating Mechanical Ventilation Domestic Water Services Automatic Controls

SITE WATER MAIN FIRE HYDRANTS FIRE ENGINEERING SYSTEMS

General Scope



TECHNICAL SPECIFICATION TITLE: PARTICULAR REQUIREMENTS FOR THE MECHANICAL SERVICES 3.1 GENERAL

The particular requirements for the mechanical building services which include but are not limited to central heating, mechanical ventilation, domestic hot and cold water, connection to site water mains, fuel oil storage and distribution, fire fighting and fire prevention are considered below and should be read in conjunction with the General Specification and Drawings

3.2 EXTERNAL DESIGN PARAMETERS FOR HEATING AND VENTILATION

SYSTEMS

For all buildings, the winter external conditions for the design of heating and ventilation systems shall be taken as - 4°C DB 100% RH.

3.3 DESIGN CONSIDERATIONS

The design considerations provided herein for the various buildings are to be taken as a guide only as the Contractor shall be fully responsible for the complete design, installation and commissioning of all of the mechanical building services. The requirements shall be read in conjunction with Mechanical and Electrical Room Data Sheets appended to the Scope of Works.

3.3.1 Internal Design Temperatures

The winter minimum and summer maximum internal design temperatures are given in the Room Data Sheets.

3.3.2 Heating

Steel panel radiators shall be installed in all rooms, corridors, stairways, etc. to be heated and which are naturally ventilated.

Steel panel radiators sized to offset the fabric losses only, shall be installed in all rooms, corridors, etc. which are plenum ventilated by air at a constant discharge temperature but which does not also offset the fabric losses. Low level, floor supported convector style radiators shall be installed below full height perimeter glazing.



All radiator circuits shall be designed for a weather compensated LPHW system with a 3 port mixing valve.

3.3.3 Mechanical Ventilation

All ventilation plant and equipment must be suitable for a marine environment with adequate protection against corrosion.

Plenum supply and/or extract ventilation systems shall be provided as specified on the Room Data Sheets. This shall generally include the following areas:-

Toilets Lift motor rooms and lift shafts Internal rooms and corridors Stores, cleaners and lobbies Entrance Hall Communications

The toilet areas shall be provided with minimum 10 air changes per hour extract using twin fan units with autochangeover upon duty fan failure plus plenum supply air at 80% maximum of the extract rate.

Internal stores shall be provided with mechanical extract ventilation equivalent to 2 air changes per hour and Cleaners rooms equivalent to 4 air changes per hour. To provide make up air to these rooms, the doors shall be undercut by a minimum of 20mm from finished floor (with an allowance for any carpets in adjacent areas).

Internal offices, etc, shall be provided with mechanical supply and extract ventilation equivalent to 10 litre/sec per person subject to a minimum air change rate of 4 per hour.

Rooms, corridors, etc, with external opening windows shall be designed for natural ventilation unless the opening window area is insufficient for natural ventilation, when mechanical ventilation shall be provided. Other than in toilet areas, for economy of operation, all ducted supply and extract ventilation systems shall be arranged for a modulated fresh air/recirculation air mix with motorised dampers.

The control of the fresh air/recirculation air mix shall be by temperature detectors in the supply and extract ducts to vary the fresh air quantity to obtain free 'cooling' or 'heating' subject to the minimum fresh air requirement due to the occupancy.

The winter design shall be based on a fresh air supply equivalent to 10 litre/sec per person for the maximum occupancy. However, the design supply air volume with



recirculation into the individual spaces must be sufficient to provide good air distribution and space temperature over the whole of the area served and may be in excess of the design fresh air volume.

The Contractor shall allow for gloss painting the exposed ventilation ductwork and supplying the grilles and diffusers factory-finished to an agreed colour. All exposed ductwork shall be agreed with the Purchaser.

Air handling units shall include a blank section for the possible future addition of a DX cooling coil with eliminator plates.

Lift and escalator motor rooms shall be provided with mechanical ventilation to the manufacturer's requirements.

Lift shaft ventilation shall be provided in accordance with BS 5655 Part 6, ducted to outside the building.

3.3.4 Domestic Water Services

The BS 2871 Part 1 Table X copper domestic water services shall be designed in accordance with BS 6700 to serve all draw-offs in the building. Isolation valves and drain cocks shall be provided at all water entry points to the building and servicing ball type valves are to be fitted to the hot and cold water connections to each sanitary fitting.

Domestic hot water shall be supplied at 65°C maximum from copper storage calorifiers with a pumped secondary circulation.

The hot water supply to the hand basins shall be reduced in temperature from the 65°C storage temperature to 43°C max. via local or group blending valves.

Mains cold water is to be run to supply all water storage cisterns, drinking water points, vending machines, kitchens, mess sinks, wash down hose points, etc.

Automatic flushing cisterns shall be fitted with an automatic economy valve to shut off the cisterns during periods when the toilets are not being used.

The domestic water installation shall comply with the relevant clauses of the current Model Water Byelaws.

In addition to branch isolating valves on stopcocks, servicing valves shall be installed on the water connections local to each sanitary fitting.

3.3.5 Automatic Controls



Wall or floor mounted control panels are to be provided in the plant room to contain all selector switches, motor starters, relays, automatic temperature controls, etc. to suit the plant being controlled. The panel shall be fitted with a Caradon-Trend (or equal) BMS controller complete with front of panel display unit.

Each panel is to incorporate a panel alarm integrator to send a volt free signal hard wired to the Control Room to give indication that a fault is present on the particular panel.

3.4 SITE WATER MAIN

The Contractor shall arrange to provide the water supply for the site including a new water meter with valved bypass for Fire Brigade use.

The new MDPE main shall be laid in accordance with the pipe manufacturers recommendations, the National Joint Utilities Group publication 'Recommended Positioning of Utilities' Mains and Plant for New Works', and any particular requirements of the Water Company.

The Contractor shall undertake all trenching, back filling, resurfacing and the formation of any valve boxes associated with the new water main.

In addition to the isolating stopcock and draincock located at the water main entry within the buildings, a stopcock in a valve box shall be installed external to the buildings.

3.5 FIRE HYDRANTS

The Contractor shall supply and install new fire hydrants each connected to a 100mm bore branch pipe off the site new water main.

The Contractor shall form hydrant access chambers with heavy duty grade covers to meet the requirements of the Fire Service.

3.6 FIRE ENGINEERING SYSTEMS 3.6.1 General

This section describes the requirements for the design and installation of Fire Engineering Systems. The Contractor shall ensure the integration of the fire



engineering systems with other building services such as fire/smoke detection systems, HVAC systems and condition monitoring systems. The Contractor shall ensure that fire engineering systems comply with the requirements of the local Fire Prevention Officer.

The design and installation of all Fire Engineering Systems shall be undertaken by a specialist company qualified to undertake this class of work.

3.6.2 Scope

The Contractor shall supply and install all Fire Engineering Systems specifically required by the Local Fire Prevention Officer, these may include such systems as:-

- Smoke control/clearance within the occupied areas including roof located

powered ventilators, low level controlled air inlets, high level fire zone separation screening, etc.

- Smoke control/clearance within the Entrance Hall and to include

mechanical smoke extract low level air inlet louvres and zone control, etc.

- Smoke control using powered roof ventilators at the head of internal Fire Escape/Exit Routes.

- Static fire appliances, extinguishers, fire blankets, etc. as may be necessary

in Plant Rooms, Electrical Rooms, Kitchens and other designated areas. - Firemans control panel with isolation/control over air handling and heating

plant etc., and interfacing with the fire alarm system.

- Fire only or motorised smoke/fire dampers (with damper control panel) in air distribution ducts where passing through fire zone walls or floors.

- Status monitoring of fire systems using volt free contacts in control panels

and interfacing with the condition monitoring system.
